Challenger Terra Gator 3244 Chassis. Manual - part 96

Repairing or Replacing Parts

Replace worn or damaged parts of an axle assembly.

The following are some examples to check for repair

and possible replacement:
• Replace any fastener if corners of the head are

worn.

• Replace washers if damaged.
• Replace oil seals or grease seals at the time of axle

repair.

• Clean parts and apply new liquid gasket material

where required when the axle is assembled.

• Remove nicks, marks and burrs from parts having

machined or ground surfaces including axle shaft

splines. Use a fine file, India stone, emery cloth or

crocus cloth for this purpose.

CAUTION

Threads must be without damage and clean so
that accurate adjustment and correct torque 
values can be applied to fasteners and parts.
• Clean and repair threads of fasteners and holes.

Use a thread die or tap of the correct size or a fine

file for this purpose.

• Tighten all fasteners to correct torque values.

Removing Dri-Loc Fasteners

If it is difficult to remove fasteners from components,

the strength of Dri-Loc, adhesive or medium and high

strength thread-locking compound can be decreased

by heating. Refer to the following procedure.

CAUTION

Do not exceed 177° C (350° F) maximum. Heating
must be done slowly to prevent thermal stresses
in the other components.
1.  Heat the fastener for three to five seconds only.

Try to loosen the fastener with a wrench. Do not

use an impact wrench to loosen the fastener or hit

the fastener with a hammer. 

2.  Repeat Step 1 until you remove the fastener.

!

!

Preparing Surfaces, Threaded
Holes and Fasteners for Later
Assembly.

1.  Clean the oil and dirt from threaded holes. Use a

wire brush.

2.  Remove all the old gasket material from both 

surfaces.

3.  Clean the surfaces where silicone gasket 

material will be applied. Remove all the oil, 

grease, dirt and moisture without damaging the 

mating surfaces.

4.  Dry both surfaces.

Flush Lube from the Axle

The entire rigid mount axle housing assembly shares the

same oil. Lubricant contamination of the wheel end or

housing bowl can spread to all areas of the axle. Flush

the lubricant from the entire axle housing before you

assemble the axle.
1. Reminder note that there are (3) magnetic plugs in an

axle assembly , (1) in the carrier bowl bottom and (1)

each in the axle housing flange bottom. These must

be removed and cleaned of any metallic debris before

axle reassembly.  

2. The oil fill plug located in back of axle housing bowl is

non-magnetic. This plug can also be removed during

axle cleaning.

3. For axles that have internal wet brake option: there

are (2) wet brake inspection plugs that are located (1)

in each axle housing flange. These plugs are also

non- magnetic.

4. Clean any debris from behind internal flange in 

housing bowl area.

5. Verify all contaminants in housing leg areas have

been removed.

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Section 3

Prepare Parts for Assembly

Page 24

Axle Assembly

General comments to be applied to the Axle

Assembly Procedures and Recommendations:

1. Clean and dry all surfaces to which sealant or

adhesive will be applied.

2. Clean and dry all threads of capscrews or holes to

which thread locker will be applied.

3. Apply thread locker to capscrew threads in through

holes, and into tapped holes when blind holes.

4. All fastener torques and recommended thread 

locker types are located in a table listed in the

“Torque Table” in section 6 in this manual by thread

size and location.

5. Torquing of all capscrews is to be done in a 

crossing pattern for even clamping.

6. Taper bearing cones and cups must be from the

same bearing vendor. Do Not mix cups and cones

in mating assemblies or same axle wheel ends.

7. Needle bearings must be from the same bearing

vendor, if being replaced from disassembly, and

not mixed in re-assembly. Variations in different

bearing vendors can adversely impact needle 

bearing life.

8. After pressing a bearing cone/cup into an assembly,

use a 0.025mm (0.001”) feeler gauge to verify

assembly is properly installed against bearing

cone/cup shoulder.

9. Mating surfaces between 2 components must be

free of “positive” indentations (with material above

surface). Minor “negative” indentations are 

permitted.  

10. Functional critical surfaces must be free from

defects:

Friction faces on the wet brake /Hydraulic differ-

ential lock stationary discs and reaction plates.

Piston bores of the wet brake and Hydraulic 

differential lock components.

Seal races or seat, O-Ring sealing surfaces.

Planet pinion bore, planet pinion shaft.

11. Use of the correct assembly tools are recom-

mended to assure a quality rework on these axle

components. A listing of the recommended

assembly tools is indicated in the “Special Tools”

section and are available upon request. Use of

incorrect assembly tools may cause damage to

component being installed and other components

associated with component being assembled.

12. All friction discs must be pre-soaked for at least

12 hours in axle oil after rotating wheel end prior

to vehicle use.

13. Following the final axle assembly, there are 4 axle

tests that should be performed to help assure a

quality re-assembly. (Information on each of these

tests are located in the assembly section as the

axle group is assembled or in the carrier manual

5.4 for the carrier test if done separately prior axle

re-installation).

a. Carrier Hydraulic Differential Functional and

Leak Test (if HDL differential equipped).

b. Wet Disc Brake Functional and Leak test.

(if equipped).

c. Axle Air Leak Test.

d. Axle Spin Test. 

NOTE:

Refer to AxleTech manual 5.4 to follow  

the differential carrier assembly recommended 

procedures.

AXLETECH

STF SPEC

DESCRIPTION

APPROVED COMPOUND

WHERE USED
Diff. case bearing cup

STF 02-452 Retaining compound, anaerobic Loctite 680

Wheel bearing spacer

Planetary ring gear shim

STF 02-435

Sealant, anaerobic flexible

Loctite 518

Pinion cage shim pack
Diff. case bearing cup

STF 02-458 Retaining compound, anaerobic Loctite 635

Wheel bearing spacer

Planetary ring gear shim

Loctite 5699

Input yoke spline

Permatex 82194

HDL inlet port

STF 02-437

Sealant, RTV non-corrosive

Three Bond 1216

Ring gear thrust screw

Three Bond 1216E

Housing, carrier face

Housing, trunnion adapter face

Thread Locker’s, Adhesives, Sealants

AxleTech STF specs for organic materials are called out across the text. Use table below to identify 

approved compounds.

Section 4
Assembly

Page 25

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

WARNING

Use straps to lift axle housing into safe axle work-
stand with lifting straps. Care should be taken to
secure the axle housing so personal injury or com-
ponent damage does not occur.

WARNING

Take care when using lifting devices. When 
you use a lifting strap, inspect the strap for 
damage before you use it. Do not use a lifting
strap to shock load or drop load a component.
Serious personal injury and damage to 
components can result.
1. Using lifting straps ,safely lift the clean axle housing

and place in axle stand with carrier bowl opening fac-

ing forward to assemble brake tubing components if

axle has the central actuation wet brake option. If the

axle is without central actuation wet brakes, skip to

“Install Carrier into Axle Housing Assembly”

section.

If the axle being assembled has the wet disc brake 

central actuation port option, follow the recommended

assembly procedure. Should the axle being assembled

not have a central actuation wet disc brake option, skip

to the next section. Figure 4.1.

!

!

1. If the central actuation hydraulic inlet port was previ-

ously removed from the axle housing, apply high

strength thread-locker to M22 threads of hydraulic

inlet port and insert into the top or front of the axle

housing near the carrier area. 

NOTE:

The internal hydraulic tee-fitting (see page 5)

may be used to install the hydraulic inlet port by applying

oil to the tee threads and screwing the tee fitting into the

flange side of the port using it to turn in the hydraulic

inlet port until hydraulic port is fully installed. Refer to

“Torque Table” in section 6.
NOTE:

It is recommended that before removing the

hydraulic tee-fitting or special tool to wait at least 15 

minutes to allow the thread locker to become effective. 
2. Apply oil on the thread of the tee-fitting, if using it as a

temporary tool. 

3. The tool should be removed from the inlet port once

the port is installed, after waiting a minimum of 

15 minutes. 

4. Before installing the hydraulic tee-fitting into the axle

housing, back off the jam nut against the shoulder

and install the tee-fitting into the inlet port inside the

carrier bowl by hand tightening and then slowly

loosen tee to align with direction of both hydraulic

brake tubes.

NOTE:

These brake tubes will only fit correctly installed

into the correct side of the axle housing. If previously

marked during disassembly, this would assist in re-

assembly in correct positions.
5. Insert both the brake tubes and fittings at the same

time from each of the axle flange ends to optimize the

fit into the axle housing. 

NOTE:

The brake tubes have threaded hydraulic nuts

on each end.
6. Hand -tighten each brake tube assembly to the

hydraulic tee. 

7. Hand tighten each brake tube assembly on the banjo

fittings aligning with the ports in the axle housing. 

NOTE:

Care should be taken to not exceed the 

recommended torque value and over stress the other

connections in the tubing assemblies.

Figure 4.1

Section 4

Assembly

HYDRAULIC
INLET PORT
WET DISC
BRAKE

HYDRAULIC
TEE FITTING
(AS TOOL)

Page 26

8. Tighten the M12 banjo fittings by holding the banjo

stationary while using a wrench to tighten its bolt per

“Torque Table” in section 6.

9. Tighten the tee-fitting to inlet port nut, refer to “Torque

Table” in section 6.

10. Tighten the banjo-fitting to hydraulic brake tube nuts

(11/16”), per “Torque Table” in section 6.

11. Install any internally mounted brake tube clips over

the tube.

Install Carrier into Axle Housing
Assembly

1.Using the lifting straps, lift the axle housing assembly

and rotate the axle housing to have the carrier bowl

opening facing upwards and safely secure the axle

housing so no personal injury or component damage

can occur.

WARNING

When you apply some silicone gasket materials, a
small amount of acid vapor is present. To prevent
serious personal injury, ensure that the work area
is well-ventilated. Read the manufacturer’s
instructions before using a silicone gasket 
material, then carefully follow the instructions.
If a silicone gasket material gets into your eyes,
follow the manufacturer’s emergency procedures.
Have your eyes checked by a physician as 
soon as possible.
• Apply  3.0 mm (0.12 inch) bead of sealant STF 02-437

to the axle housing where the carrier assembly will be

assembled. Figure 4.2.

!

CAUTION

Take care when using lifting devices. When 
you use a lifting strap, inspect the strap for 
damage before you use it. Do not use a lifting
strap to shock load or drop load a component.
Serious personal injury and damage to 
components can result.
• Using the lifting straps to safely lift the carrier assembly

and install into the axle housing. Figure 4.3.

2. Apply high strength thread locker to each of the 

capscrew threads and install the M16 hex head 

carrier to axle housing capscrews and hardened

washers and tighten per “Torque Table” in 

section 6.

!

Figure 4.2

Figure 4.3

Section 4
Assembly