Front Axle Shaft Replacement and Repair

TM 9-2320-363-34-1 · Chapter 5 — Front Axle Maintenance

This task covers:     a. Removal b. Disassembly c. Cleaning    d. Inspection     e. Repair
                      f. Assembly g. Installation

Applicable Configuration:                        References:

All except M915A2
                                                 TM 9-2320-363-20
Tools and Special Equipment:
                                                 Equipment Condition:
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N05                      Reference              Condition Description

Materials/Parts:                                 TM 9-2320-363-20       Axle Oil Drained

Ring, Seal            P/N 2034370                TM 9-2320-363-20       Front Slack Adjuster and
                                                                        S-Cam Removed
Washer, Lock (2)
                                                 General Safety Instructions:
Grease, Automotive
and Artillery (GAA)   Appendix B, Item 26
                                                                    WARNING
Oil, Lubricating                                   Adhesives, solvents, and sealant compounds
Gear                  Appendix B, Item 37          can burn easily, can give off harmful vapors,
                                                   and are harmful to skin and clothing. To avoid
Adhesive-Sealant,                                  injury or death, keep away from open fire and
Silicone              Appendix B, Item 3           use in well-ventilated area. If adhesive,
                                                   solvent, or sealant compound gets on skin or
Loctite 242           Appendix B, Item 33          clothing, wash immediately with soap and
                                                   water.

l Procedure is the same for both right and left axle shafts and cage ring assemblies. Right side is shown.

l Perform steps 1 thru 3 for M917A1 and M917A1 w/MCS.

1. DISCONNECT CTIS TUBE (1) FROM ADAPTER (2) AND REMOVE ADAPTER FROM MANIFOLD BLOCK (3).

2. REMOVE TWO SCREWS (4), LOCK WASHERS (5), MANIFOLD BLOCK (3) AND SEAL RING (6) FROM SKEIN (7). DISCARD LOCK WASHERS AND SEAL RING.

3. DISCONNECT CTIS VENT TUBE (8) FROM ELBOW (9) AND REMOVE ELBOW FROM SKEIN (7).

4. MATCHMARK AXLE SKEIN (7), BRAKE SPIDER (IO), AND BALL SOCKET (11).

5. REMOVE 10 CAPSCREWS (12) FROM AXLE SKEIN (7), BRAKE SPIDER (10), AND BALL SOCKET (11).

MATCHMARKS

6. REMOVE AXLE SKEIN (7) AND BRAKE SPIDER (10) FROM AXLE SHAFT ASSEMBLY (13).

7. REMOVE BRAKE SPIDER (10) FROM AXLE SKEIN (7).

8. REMOVE AXLE SHAFT ASSEMBLY (13) FROM BALL SOCKET (11).

Before splitting cage ring, mark axle shafts and cage ring halves to ONE MATCHMARK ensure correct assembly. Axle shaft yoke trunnion must be replaced in same cage ring holes.

1. MATCHMARK BOTH HALVES OF CAGE RING (1).

TWO MATCHMARKS

2. REMOVE EIGHT SOCKET HEAD SCREWS (2) FROM TWO CAGE RING HALVES (1).

3. REMOVE TWO CAGE RING HALVES (1) FROM TWO SHAFTS (3 AND 4).

Use general cleaning methods to clean all parts (page 2-30).

1. INSPECT ALL PARTS FOR WEAR OR DAMAGE.

2. INSTALL EIGHT SOCKET HEAD SCREWS (2) IN TWO CAGE RING HALVES (1) AND TIGHTEN SCREWS TO 30 LB-FT (41 N.m).

3. MEASURE INSIDE DIAMETER OF SHAFT HOLES IN TWO CAGE RING HALVES (1) AND OUTSIDE DIAMETER OF YOKES ON TWO SHAFTS (3 AND 4). IF DIFFERENCE IS MORE THAN 0.20 IN. (5.08 mm), REPLACE TWO CAGE RING HALVES (1) AND TWO SHAFTS (3 AND 4).

4. REMOVE EIGHT SOCKET HEAD SCREWS (2) FROM TWO CAGE RING HALVES (1).

Use general repair methods to repair damaged parts (page 2-33).

1. APPLY LIGHT COAT OF GREASE TO FOUR TRUNNIONS (1) AND TWO CAGE RING HALVES (2).

2. ALINE MATCHMARKS AND INSTALL TWO CAGE RING HALVES (2) ON TWO SHAFTS (3 AND 4).

3. INSTALL EIGHT SOCKET HEAD SCREWS (5). DO NOT TIGHTEN SCREWS.

4. MOVE TWO SHAFTS (3 AND 4) TO CHECK FOR FREE SIDE-TO-SIDE MOVEMENT INSIDE TWO CAGE RING HALVES (2).

5. TIGHTEN EIGHT SOCKET HEAD SCREWS (5) TO 95 LB-FT (129 N.m).

1. TURN BALL SOCKET (1) TO STRAIGHT-AHEAD POSITION.

2. APPLY THIN COAT OF OIL TO POLlSHED SURFACES OF AXLE SHAFT ASSEMBLY (2).

3. PACK CAGE RING (3) WITH GREASE.

4. iNSTALL AXLE SHAFT ASSEMBLY (2) IN BALL SOCKET (1) LONG END FIRST.

5. FILL BALL SOCKET (1) AND CAGE RING (3) WITH GREASE.

MATCHMARKS

Adhesives, solvents, and sealant compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealant compound gets on skin or clothing, wash immediately with soap and water.

6. APPLY THIN COAT OF SILICONE ADHESIVE-SEALANT TO BOTH SIDES OF BRAKE SPIDER (4) AND AXLE SKEIN (5).

7. ALINE MATCHMARKS ON BRAKE SPIDER (4) WITH MATCHMARKS ON AXLE SKEIN (5).

8. INSTALL BRAKE SPIDER (4) AND AXLE SKEIN (5) OVER AXLE SHAFT ASSEMBLY (2).

9. ALINE MATCHMARKS ON BRAKE SPIDER (4) AND AXLE SKEIN (5) WITH MATCHMARKS ON BALL SOCKET (1).

10. APPLY SILICONE ADHESIVE-SEALANT TO UNDERSIDE OF HEADS OF IO CAPSCREWS (6) AND APPLY LOCTITE 242 TO THREADS OF CAPSCREWS.

11. INSTALL 10 CAPSCREWS (6) AND TIGHTEN TO 185-190 LB-FT (251-257 N.m).

12. APPLY THIN COAT OF GREASE TO BEARING AND SEAL SURFACES OF AXLE SKEIN (5).

13. INSTALL ELBOW (7) TO SKEIN (5) AND CONNECT CTIS VENT TUBE (8).

14. INSTALL NEW SEAL RING (9) AND MANIFOLD BLOCK (10) TO SKEIN (5) WITH TWO NEW LOCK WASHERS (11) AND SCREWS (12).

15. INSTALL ADAPTER (13) TO MANIFOLD BLOCK (10) AND CONNECT CTIS TUBE (14).

Install front slack adjuster and S-cam (TM 9-2320-363-20). Fill axle with oil (TM 9-2320-363-20).