User manual AXLETECH MM5.3 MAINTENANCE MANUAL

[. . . ] 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. [. . . ] · 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. · Both surfaces of all thrust washers. · Trunnion ends of the spider cross or differential pinion shaft. pinions. Thread must be without damage and clean so that accurate adjustment and correct torque values can be applied to fasteners and parts. · Clean and repair the threads of fasteners and holes. Use a die or tap of the correct size or a fine file for this purpose. ! CAUTION · Refer to "Torque Table" in Section 4, when tightening all fasteners. · Teeth, splines and thrust surface of differential · Teeth, bore and thrust surface of differential Welding Repair The carrier box assembly housing material is Not suitable for welding repair. Do not attempt to repair weld this carrier box assembly. Figure 3. 5 Removing Dri-Loc Fasteners If it is difficult to remove fasteners from components, the strength of Dri-Loc, adhesive or Loctite 277 can be decreased by heating. Refer to the following procedure. Do not exceed 177° C (350° F) maximum. Heating must be done slowly to prevent thermal stresses in the other components. 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. Repeat Step 1 until you remove the fastener. Page 11 ! CAUTION Section 3 Prepare Parts for Assembly Installing Fasteners With Pre-Applied Adhesive, AxleTech Liquid Adhesive, Loctite Liquid Adhesive or Equivalent Installing New Fasteners With Pre-Applied Adhesive Patches 1. Clean the oil and dirt from threaded holes. Use a wire brush. Apply Liquid Gasket Material Take care when you use adhesives, thread locking compounds or any sealants to avoid serious personal injury. Follow the manufacturer's instructions to prevent irritations to the eyes and skin. Take care when you use silicone gasket materials to avoid serious personal injury. Follow the manufacturer's instructions to prevent irritation to the eyes and skin. AxleTech recommends the following liquid gasket materials: ! WARNING Do not apply adhesives or sealant on new fasteners with pre-applied adhesive patches or inside closed threaded holes. If other adhesives or sealants are used, the new adhesive will not function correctly. [. . . ] Severe operating or prolonged use of corrosive materials may require more frequent intervals. Oil Level Check and Adjust: NOTE: Separate fill and drain plugs are located on the carrier box assembly. Correct procedure to check oil level in the carrier box assembly: 1. Place blocks in front and back of the rear axle wheels to keep the vehicle from moving. Remove the plug from the carrier box housing assembly. [. . . ]