SkyTrak 8042 Service Manual - Manual (Page 283)

Axles, Drive Shafts, Wheels and Tires
5.10 Model 8042, 10042, 10054 Legacy Rev. 10/03
d. Axle Inspection, Internal Service and Repair
Detailed axle service instructions (covering the axle,
differential, brakes and wheel-end safety, repair,
disassembly, reassembly, adjustment and
troubleshooting information) are provided in the ZF Axle
Repair Manuals. (Refer to Section 5.3.8, “ZF Axle Repair
Manuals.”)
The axle should be checked, serviced and repaired only
by experienced service technicians who are aware of all
safety instructions and particular component features.
e. Axle Installation
The front and rear axle assemblies differ in that the front
axle assembly is equipped with a parking brake
mechanism and limited-slip feature; the rear axle has
neither. The steps below outline a typical axle installation
procedure, suitable for either the front or the rear axle
assembly.
1. Before proceeding, ensure that the vehicle will
remain in place during axle installation. Block the
front and rear of both tires on the axle that is already
installed on the vehicle.
2. If applicable, raise the vehicle using a suitable jack
or hoist. Place suitable supports beneath the frame
and lower the vehicle onto the supports, allowing
enough room for axle installation. Ensure that the
vehicle will remain in place during axle installation.
3. Using a suitable jack, hoist or overhead crane and
sling, remove the axle (2-Front or 3-Rear) from its
support or holding stand. Balance the axle and
prevent it from tipping, turning or falling while
positioning it beneath the vehicle. DO NOT raise or
otherwise disturb the vehicle while installing the axle.
Keep the axle supported and balanced on the jack,
hoist or overhead crane and sling throughout the
installation procedure.
4. Position the axle (2-Front or 3-Rear) under the
frame, and align the pivot pin bearings with the holes
in the frame.
5. Coat the axle pivot pin (4) with a light film of clean
engine or hydraulic oil; DO NOT use an anti-seize
compound.
Note: ALWAYS replace elastic locknuts with new elastic
locknuts to help ensure proper fastening.
6. Install the axle pivot pin (4) and shims (5). Add or
remove shims until a maximum gap of 0.6" (1.5 mm)
is obtained. Balance the number and thickness of
shims equally on both sides. Secure the pivot pin
with one capscrew (5) and a new locknut (6).
Note: If new frame sway (front) or stabilizer (rear)
cylinder bearings (8) have been installed in the axles or
vehicle frame, the fracture (1) in the bearing race must
be positioned at the 9 o’clock position as shown below.
7. Move the cylinder (9-Front or 10-Rear) into position
on the axle cylinder anchor (11). Insert a cylinder-
mount pin (12) through the cylinder and cylinder
anchor. Secure the cylinder-mount pin (12) with one
capscrew (13) and a new locknut (14).
8. Apply multi-purpose grease through the self-tapping
lube fitting (15) to lubricate the self-align bearing (8)
and the cylinder-mount pin (12).
9. Install the drive shaft assemblies (16 and 17). (Refer
to Section 5.4.7, “Drive Shaft Installation.”)
MM5530
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