Challenger Terra Gator 3244 Chassis. Manual - part 90

Planetary Drive Axles

Pont Double Reduction

Maintenance Manual 9L

Issued 9-06

Manuel de maintenance 9L

Edité Septembre 06

Models/Módeles

PRC2715

PRC2725

PRC2726

PROC2715

PROC2725

Before You Begin

This maintenance manual describes the correct 

service and repair procedures for all AxleTech 

planetary axle models listed on front cover. The 

information contained in this manual was current at

time of printing and is subject to change without

notice or liability.
You must follow your company procedures when you

service or repair equipment or components. You

must understand all procedures and instructions

before you begin to work on a unit. Some procedures

require the use of special tools for safe and correct

service. Failure to use special tools when required

can cause serious personal injury to service person-

nel, as well as damage equipment and components.
AxleTech International uses the following notations 

to warn the user of possible safety problems and to

provide information that will prevent damage to

equipment and components.

Safety Alerts, Torque Symbol 
and Notes

Service Notes

WARNING

A Warning alerts you to an

instruction or procedure that

you must follow exactly to

avoid serious personal

injury.

CAUTION

A Caution alerts you to 

an instruction or procedure

that you must follow 

exactly to avoid damage 

to components.
The torque symbol alerts

you to tighten fasteners to 

a specified torque value.

NOTE: 

A Note provides information

or suggestions that help 

you correctly service a 

component.

!

!

The instructions contained in this Field Maintenance

Manual are intended for use by skilled and 

experienced mechanics knowledgeable in the 

installation, repair and replacement of the AxleTech

product described herein. Installation, maintenance

and replacement of such products require a high

degree of skill and experience. The consequences 

of improper installation, maintenance or replacement

(including the use of inferior or substandard 

components) are grave and can result in product 

failure and resulting loss of control of the vehicle,

possible injury to or death of persons and/or possible

future or additional axle damage. AxleTech does not

authorize anyone other than highly skilled and 

experienced individuals to attempt to utilize the

instructions contained in this Manual for the 

installation, maintenance or replacement of the 

product described herein, and AxleTech shall have

no liability of any kind for damages arising out of 

(or in connection with) any other use of the 

information contained in this Manual.

Additional Publications

For AxleTech service manuals, please contact:

1-877-877-9717 and 248-816-5401 or visit our 

website at www.axletech.com.

How To Order

Order items from AxleTech International.
Phone orders are also accepted by calling AxleTech

International’s Customer Service Center at 

877-547-3907 or send a fax to 866-547-3987.

Exploded Views

Axle Housing Assembly With Forced Cooling Option.....................................................................................1

Axle Housing Assembly – Heavy Housing Using Recessed Carrier Mounting ..............................................2

Axle Housing With Trunnion Option................................................................................................................3

Heavy Axle Housing With Central Actuation Service Brake – Top Inlet Port..................................................4

Heavy Axle Housing With Central Actuation Service Brake – Front Inlet Port ...............................................5

Planetary Wheel End Components.................................................................................................................6

W3H Shaft Speed Wet Disc Service Brake ....................................................................................................7

Two Friction Disc Brake.............................................................................................................................7

Single Friction Disc Brake .........................................................................................................................7

Rigid Mount Axle – No Brake..........................................................................................................................8

Rigid Mount Axle – with Service Brake And Parking Brake............................................................................8

Trunnion Mount Axle – No Brake....................................................................................................................8

Trunnion Mount Axle – with Service Brake .....................................................................................................8

Section 1: Introduction

Description ......................................................................................................................................................9

Identification ....................................................................................................................................................9

Section 2: Removal & Disassembly

Removal and Disassembly from the Vehicle ................................................................................................10

Disassembly of the Trunnion Assemblies......................................................................................................11

Disassembly of the Axle Housing Bowl Side Trunnion Assembly ...........................................................11

Disassembly of the Carrier Input Trunnion Assembly .............................................................................12

Axle Disassembly Procedure ........................................................................................................................12

Wheel End Disassembly Procedure........................................................................................................12

Disassembly of the Planetary Spider Assembly......................................................................................15

Do Not Remove the Planetary Pinion Shafts from the Planet Spider.....................................................16

Disassembly of the Wet Brake Assembly................................................................................................16

Disassembly of the Axle Shaft, Snap Ring, Sun Gear Assembly............................................................17

Disassembly of Wet Brake Actuation Tubing Assembly..........................................................................17

Section 3: Prepare Parts for Assembly

Clean Rough Parts........................................................................................................................................18

Clean Ground and Polished Parts ................................................................................................................18

Clean the Axle Housing Assembly ................................................................................................................18

Dry Parts After Cleaning ...............................................................................................................................18

Prevent Corrosion on Cleaned Parts ............................................................................................................19

Inspect Parts .................................................................................................................................................19

Tapered Bearing ......................................................................................................................................19

Planetary Wheel End Gearing ......................................................................................................................20

Needle Roller Bearings .................................................................................................................................20

Planetary Wheel End Thrust Washers..........................................................................................................20

Planetary Spider Shaft ..................................................................................................................................21

Wheel End Spindle........................................................................................................................................21

Driver.............................................................................................................................................................21

Planetary Nut Lock System...........................................................................................................................21

Planetary Assembly O-Rings ........................................................................................................................21

Axle Shafts ....................................................................................................................................................21

Axle Housing .................................................................................................................................................21

Axle Trunnion Components...........................................................................................................................21

Wet Brake Assembly Components ...............................................................................................................21

Repairing or Replacing Parts ........................................................................................................................23

Removing Dri-Loc Fasteners ........................................................................................................................23

Preparing Surfaces, Threaded Holes and Fasteners For Later Assembly ...................................................23

Flush Lube from the Axle ..............................................................................................................................23

Table of Contents

Section 4: Assembly

Axle Assembly...............................................................................................................................................24

Assembly of the Axle Housing Components with Central Actuation Wet Disc Brake Feature Option .........25

Install Carrier into Axle Housing Assembly ...................................................................................................26

Axle Housing Plugs Assembled ....................................................................................................................27

Axle Without Wet Disc Brake Assembly........................................................................................................27

Axle Shaft, Thrust Washer, Snap Ring, Sun Gear Assembly .......................................................................28

Wet Brake Assembly in the Axle Housing.....................................................................................................28

Axle Shaft, Thrust Washer, Snap Ring, Sun Gear Assembly .......................................................................29

Install the Wet Brake Disc Components into the Axle Housing ....................................................................29

Wet Disc Brake Actuation and Functional Test .............................................................................................30

Spindle and Planetary Ring Gear Sub-Assembly .........................................................................................30

Wheel Hub, Inner Bearing Spacer, Wheel Bearings, Seal, and Spindle Sub-Assembly..............................31

Toric Ring Face Seal into Hub and into Spindle ...........................................................................................32

Check for Correct Installation of the TRS Toric Ring Seal ......................................................................34

Wheel Hub to Spindle Assembly...................................................................................................................35

Planetary Spider Sub-Assembly ...................................................................................................................36

Re-Use Components...............................................................................................................................36

New Components....................................................................................................................................36

Planetary Spider Assembly, Spindle & Planetary Ring Gear Assembly, and Wheel Hub Assembly ............37

Install the Planetary Wheel End Assembly On the Axle Housing.................................................................38

Axle Air Leak Test..........................................................................................................................................39

Axle Spin Test ...............................................................................................................................................39

Hydraulic Differential Lock (HDL) Actuation Function and Leak Test ...........................................................40

Installation of the Trunnion Feature Option...................................................................................................40

Trunnion Adapter...........................................................................................................................................41

Re-Installation into Vehicle............................................................................................................................43

Section 5: Lubrication

Breather.........................................................................................................................................................44

Seals .............................................................................................................................................................44

Oil Level ........................................................................................................................................................44

Approved Oil Listings ....................................................................................................................................44

Approved Grease ..........................................................................................................................................44

Lubrication Specification ...............................................................................................................................45

Table C (Lubricant Cross Reference (Viscosity) and Temperature Chart)....................................................45

Brake Actuation Fluid ....................................................................................................................................45

Section 6: Torque

Torque Table..................................................................................................................................................46

Section 7: Special Tools

How to Make a Yoke Bar ..............................................................................................................................47

Table of Contents