User manual AXLETECH MM5.3-144 CARRIER BOX ASSEMBLY A4 3200E 2033 292

[. . . ] Carrier Box Assembly Ensemble de carter de nej-de-pont Maintenance Manual MM5. 3 Manuel de maintenance MM5. 3 Issued 6-04 Edité Mai 04 Models / Mòdeles A4 3200E 2033 293 A4 3200E 2033 292 Service Notes Before You Begin This manual provides instructions for AxleTech International's Carrier Box Assembly. Read and understand all instructions and procedures before you begin to service components. Read and observe all Caution and Warning safety alerts that precede instructions or procedures you will perform. These alerts help to avoid damage to components, serious personal injury, or both. [. . . ] If the compressed air does not pass through the breather after cleaning, replace the breather. Install the breather in the carrier box housing. Clean Parts with a Rough Finish · Parts with a rough finish can be cleaned with cleaning solvent or in a hot solution tank with a weak alkaline solution. · Parts must remain in hot solution tanks until completely cleaned and heated. · Parts must be washed with water until the alkaline solution is removed. Clean The Carrier Box Housing · The carrier box assembly can be steam cleaned on the outside to remove dirt, grease or external contamination. · Before the carrier box assembly is steam cleaned, close or put a cover over the breather on top of the carrier box assembly NOTE: Do not direct steam cleaning spray directly at the carrier input or output yokes & seal assemblies during the initial cleaning as could attempt to push external dirt into the carrier box assembly components. Page 9 Section 3 Prepare Parts for Assembly Tapered Roller Bearings Inspect the cup, cone, rollers and cage of all tapered roller bearings in the assembly. If any of the following conditions exist, replace the bearing: · The centers of the large diameter end of the rollers are worn level with or below the surface. · The centers of the large diameter end of the rollers are worn to a sharp edge. Figure 3. 1 · The centers of the large diameter end of the rollers are worn to a sharp edge. · Damage on rollers and on surfaces of the cup and cone inner race that touch the rollers. Figure 3. 3 WORN RADIUS WEAR MARKS WORN SURFACE · A visible roller groove is worn in the cup or cone inner race surfaces. You can see the groove at the small or large diameter ends of both parts. Figure 3. 4 ETCHING AND PITTING · A visible roller groove in the cup or cone inner race surfaces. The groove can be seen at the small or large diameter end of both parts. Figure 3. 2 CRACK WEAR GROOVES · Deep cracks or breaks in the cup, cone inner race or roller surfaces. Page 10 Section 3 Prepare Parts for Assembly Pinions and Gears Spiral bevel pinion and gear are machined in a matched set. When a pinion or ring gear of a set needs to be replaced, both the gear and pinion must be replaced at the same time. Verify the condition of the bearing cone seats and spline on the pinion shaft. Output Shafts Inspect output shafts for wear and cracks on the shaft body or in the splines. These shafts may be serviced individually as required. ! CAUTION Repair or Replace Parts Replace the worn or damaged parts of an carrier box assembly. The following are some examples to check for repair and possible replacement: · Replace any fastener if corners of the head are worn. Main Differential Assembly Always replace thrust washers, differential side gears and pinion gears in full matched sets. A higher stress on original parts and early failure of the entire assembly will result if a new part is used in combination with parts that are older or worn. · Replace oil seals or grease seals at the time of carrier box repair. ! CAUTION · Clean parts and apply new liquid gasket material where required when the carrier box is assembled. Use a fine file, India stone, emery cloth or crocus cloth for this purpose. · Remove nicks, marks and burrs from parts having · Inside surfaces of both case halves. [. . . ] · If the oil level is below the bottom of the fill plug: Add the specified oil according to the following procedure: Fill the carrier box assembly with the specified oil through the fill plug hole. Wait a few minutes to allow the oil to flow through the entire carrier box assembly. NOTE: Too low an oil level could cause component damage as proper lubrication may not be available to protect against component damage. Install and tighten the fill plug to the correct torque specification. Breather Cover the breather when steam cleaning the carrier box housing to prevent water from entering the carrier box and contaminating the oil. [. . . ]