SRT95 Off-Highway Truck

Rear Axle Assembly

Part 1 Structure and Installation

Part 2 Parts Presentation
Part 3 Maintenance
Part 1 Structure and Installation
Rear axle assembly installation
The rear axle connects the rear wheels to the chassis through A-frame, link and the
rear suspension .
Frame
Link
Rear suspension

Rear axle assembly A-frame

Power train of rear axle

Power train : Bevel gear → Driven gear→ Differential →Axle shaft → Planetary
→ Rear hub → Wheel

Bevel gear

Planetary Rear hub Axle shaft Differential Driven gear

 1.1 Structure
The rear axle assembly at the end of power transmission system, it will drive shaft torque
transmitted by the main reducer and differential increased and changed direction, torque
increase through the half shaft to the both sides of the planetary, torque after increases
again and delivered to the wheels, to ensure that the vehicle performance.
Vehicle carry and transfer force through the housing and wheel.
Main reducer and
Rear brake assembly differential assembly

Planetary Rear hub Axle shaft Rear axle housing

assembly assembly
1.2 Rear Axle Assembly Installation

Connect with frame

Connect with rear driveline

Connect with rim and tire Connect with frame

Connect with rear suspension

1.3 Lubrication Point
A-frame lubrication Link lubrication

Rear axle housing filler

Planetary filler
Part 2 Parts Presentation
2.1 Rear Axle Housing Assembly

Bearing Link Bearing

A-frame

Oscillation stop

Spindle
Breather

Rear axle housing

 When in installation,protection coordination of two spindle on the surface,not a bump
and scraches and other defects.
 When in installation,protection the surface on rear axle housing and main reducer and
differential assembly. not a bump and scraches and other defects.
 Rear axle housing assembly fastener torque should be checked regularly.

Table of tightening torques for rear axle housing assembly

Tightening torque
Bolt size Connect parts
(N.m)
Connect the A-frame with the rear axle
M42×160 GB5782 10.9 3640
housing
Connect the Oscillation stop with the rear axle
M24×65 GB70.1 10.9 935
housing

M24×160 GB32.1 The fixed bearing type A-frame 935

M12×25 GB5783 10.9 To fix the shaft 114

2.2 Main Reducer and Differential Assembly

2.2.1 Function ：

（ 1 ） Multiply torque delivered by the driveline

and change the torque direction.

（ 2 ） Transmit torque to the axle shafts.

（ 3 ） Allow the drive wheels to rotate at different

speeds.

2.2.2 Key parameters:

（ 1 ） Reduction ratio （ 2.16 ： 1 ）

（ 2 ） Ground clearance: 780mm

 2.2.3 Main reducer and differential assembly configuration

Oil seal Yoke

Bearing seat
Bearing
Driven spiral bevel gear
Drive spiral bevel gear

Main reducer housing Bearing

Planetary bevel gear

Adjusting nut
Left differential housing
Bearing

Axle shaft bevel gear

Right differential housing Bearing
2.2.4 Assembly and adjustment ：
(1) Adjust the backlash in circular tooth.
Determine the required shim pack thickness so as to give the proper gauging distance
within 0.08 mm(0.003 in) etched on pinion gear tail shaft as follows.

Checking shim requirements

using inside micrometer
(2) Backlash ： Check the backlash between Driving gear and Ring gear,
The clearance value is 0.41~0.56mm(0.016-0.022 in).
(3) Map of the gear tooth pattern is obtained.

Checking ring gear backlash Proper tooth contact

(4) Adjustment

Ring gear

Pinion side

Ring gear side

Pinion
Pinion side

Correct Movement for adjustment

Ring gear side
Main reducer and differential assembly structure

1- Axle shaft bevel gear washer

1 8
2-Planetary bevel gear

3-Spider
7
2
4- Right differential housing
6
5-Bearing 3

6-Bearing
4
7- Axle shaft bevel gear 5

8- Left differential housing

2.2.5 Lubrication ：

Main reducer housing and bearing seat are corresponding inlet and outlet ， to ensure the
full lubrication.

inlet outlet inlet outlet

 Assembly animation
2.2.6 Troubleshooting
Trou Trouble
NO. Cause Picture Troubleshooting
ble part

　
Drive spiral Replace the damaged
1 Broken gear teeth
bevel gear gear

Noise
2 Bearing Bearing worn 　 Replace bearing

Axle shaft bevel gear Replace axle shaft

3 Differential 　
damaged bevel gear and washer
 Trouble
NO. Trouble Cause Picture Troubleshooting
part

4 Noise Differential Washer worn 　 Replace washer

Oil seals
5 Oil seals Oil seals worn 　 Replace oil seals
worn
2.3 Planetary

Structure

Ring gear Ring gear

Pinion pin
Pinion pin

Planet pinion Sun gear

Axle shaft
Sun gear

Ring gear carrier

Planetary
carrier
Planet pinion

Planetary carrier
Planetary (Exploded Magnetic plug/washer
view) Cover
Cover
Ring gear Bolt
Sun Gear Planetary carrier
O-Ring Sun gear
Planetary carrier
Thrust washer
Ring gear Roller
O-Ring
Ring gear carrier

Thrust plate
Bearing spacer
Pinion pin
Planet pinion
Thrust spacer

Pin retainer/Bolt/Lockwire
Nut
Thrust spacer
Planet pinion
Pinion pin
Bearing spacer
Thrust plate
2.3.2 Axle Shaft Description

Axle Shaft is a solid axle which transfer power between Differential and Planetary, one
side is connected with Cone Gear from Differential by its spline ,other side is connected
with the Sun Gear from Planetary.
It is a full floating axle shaft. Such a structure makes the spline of axle shaft just receive
and transfer torque ,avoid bearing any bending moment and opposite force. Torque comes
from Cone Gear through axle shaft to Planetary.
2.3.3 Familiar troubleshooting of Planetary

 High temperature ：
1.Insufficient or incorrect lubricant;
Troubleshooting ： Check oil level and replace if required.
2.Pinion bearings seized
Troubleshooting ： Replace the bearing.
 Noise ：
1.Insufficient or incorrect lubricant;
Troubleshooting ： Check oil level, add if low.
2.Gear teeth in Planetary chipped;
Troubleshooting ： Replace gear.
Note:
When replace the Ring Gear Carrier, must be readjust the bearings gap of Rear Wheel.
2.3.4 Lubrication and maintenance

①. When the dipstick line of Planetary is horizontal below the center line. Add oil
through the hole for plug until the oil overflow. （ SAE 80W/90 ） Gear Oil ）
②.Replace the lubricant only after the first 150 hours ;
Sampling oil and contrast with standard every 150 hours ;
Replace the lubricant second time at 1200 hours;
Afterwards sampling oil and contrast with standard every 150 hours;
Replace lubricant third time at 3000 hours;
Later sampling oil and contrast with standard every 150 hours ;
Replace lubricant fourthly at 6000 hours.

Plug
Part 3 Rear Axle Maintenance and Service

3.1 Lubrication
1. Lubricant ： SAE GL-5 80W/90 Heavy load vehicle gear oil.
2. Oiling position and oil level ： Add oil through the hole on rear axle housing for
differential until the oil overflow; Add oil through the plug hole on cover for planetary until
the oil overflow.
3. Service Capacities ：
Planetaries (total) : 57L
Differential : 61L

Note: The 'oil-level' markings on the planetary

cover are horizontal, before add oil.
3.2 Check and Maintenance

1. Remove dirt, oil, grease usually, Check and clean the breather every 250 hours , keep it
unhampered. Tighten the plug or bolt in time, if found any part was loose.
2. Check all parts usually ,if find any leakages, loosened and damaged, repair and eliminate
it in time. Check liquid level , refill as required .
3. Replace the lubricant only after the first 150 hours; every 1500 hours thereafter.
4. Observe all parts in bearings everyday to inspects if there is anywhere without lubricating,
examine and repair if required.
3.3 Cautions ：
1. Should be replaced in pairs.

No. Should be replaced with partner-parts Picture

1
Bearing cap and Differential housing

2 Bearing cone and bearing cup

3 Thrust washer

4 Drive and Driven spiral bevel gear

5 Right and Left differential housing

 6 Axle shaft bevel gear and
Planetary bevel gear

2. Identify bearing caps and main reducer housing to aid in assembly.

3. At servicing work ， clean all parts which has sealant formerly in a suitable solvent, dry
and daubed with the thickness of 1mm sealant.
4. Clean all bolts, after dry and daubed with anaerobic adhesive, screw down with the
standard moment.
5. Must replace all gaskets ,such as O-ring and oil seals ,if they are disassembled.
6. When thrust washer in differential was frayed and dowel pin will be bare ,replace the
thrust washer.
7. If parts are not to be assembled immediately , treat them with a good rust preventative
with suitable material to prevent corrosion.
Thanks!