Mack Gu

46102-2 Rear Drive Axle Housing, Replacement
You must read and understand the precautions and guidelines in Service Information, Function Group 70, General
Safety Practices, Frame, Springs, Shocks and Wheels before performing this procedure. If you are not properly
trained and certified in this procedure, ask your supervisor for training before you perform it.
Danger
Do not attempt to repair or service this vehicle without sufficient training, the correct service literature, and the
proper tools. Failure to follow this could make the vehicle unsafe and lead to serious personal injury or death.
Danger
Before working on a vehicle, set the parking brake, place the shift lever in Neutral, and chock the front wheels.
Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death.
1
Secure the vehicle for service by parking it on a level surface, applying the parking brake, and chocking the front
wheels.
2
Disconnect all cables from the negative (ground) battery terminals to prevent personal injury from electrical shock and
prevent damage to electrical components.
3
Drain the gear oil from the axle housing into a suitable container.
4

Chassis ID Path
4/Repair/GU, RADD-TR1, DC-T6AWF/Rear Drive Axle Housing, Replacement
Model Identity
GU 131782472
Publishing Date ID/Operation No.
Wednesday, August 7, 2013 46102-2
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Copyright Volvo Group North America
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
IMPACT 3.0 Saturday, February 15, 2014
Caution
The weight of the axle housing is evenly distributed. not
Using safe lifting methods, lift and support both the vehicle frame and the axle housing to be replaced. Position a
suitable jack under the axle housing so it can be safely removed from under the vehicle when it is uninstalled.
5
Release the parking brake.
6
Back off the brake slack adjuster on both sides of the axle so that the brake drums can be removed.
7
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1. Caging Bolt (nut and washer not shown)
Cage the brake air chambers on both sides of the axle.
8
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1. Air Hose Connector
Disconnect the two air hoses from the brake chamber. Do this on both sides of the axle housing.
Note: Note the position of the hoses for correct reconnection later.
9
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1.
2.
Lock Nut
Axle Shaft
Drain the fluid from the hubs into a suitable container. Remove the fasteners securing the axle shaft and remove the
axle shaft from the axle housing. Do this on both sides of the axle housing.
10
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Position a wheel dolly under the tires and carefully remove the hub along with the wheels and tires as an assembly.
Place the hub nuts and outer wheel bearings in a clean, safe location to avoid contamination. Do this on both sides of
the axle housing.
11
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1.
2.
3.
4.
5.
Upper Brake Shoe
Lower Brake Shoe
Roller
Return/Retractor Spring (pins shown)
Anchor Spring
Remove the brake shoes and related brake components from the end axle housing. Do this on both sides of the axle
housing.
12
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1.
2.
3.
4.
5.
6.
7.
8.
Shock Absorber
Upper Bushing Washer
Upper Rubber Bushing
Middle Bushing Washer
Rubber Bushing
Lower Bushing Washer
Spacer
Lock Nut
Remove the fasteners securing the lower end of the shock absorber to the shock mount on the lower axle plate. Do this
on both sides of the axle housing.
13
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1.
2.
3.
Bolt
Lock Nut
Upper End of Shock Absorber
Remove the fastener securing the upper end of the shock absorber to the frame-mounted bracket. Do this on both
sides of the axle housing.
14
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1.
2.
3.
4.
5.
Bolt
Upper Bracket
Spacer
Lower Bracket
Lock Nut
Remove the fasteners attaching the spring plate. Do this on both sides of the axle housing.
15
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1. Bolt
Remove the four fasteners that attach the rubber spring block and the S-cam support bracket to the upper axle
mounting plate. Do this on both sides of the axle housing.
16
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1.
2.
3.
S-Cam Support Bracket
Bolt
Lock Nut
Remove the fasteners attaching the lower end of the S-cam support bracket to the attachment ear of the S-cam tube,
and remove the bracket. Do this on both sides of the axle housing.
17
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1. Hollow Rubber Spring Block
Using an assistant and an air lift tool, raise the frame to move the end of the leaf springs off the rubber spring block.
Remove the hollow rubber spring block off the upper axle plate. Do this on both sides of the axle housing.
18
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1. Lock Nut
Remove the fasteners securing the brake anchorage to the end of the axle housing. Do this on both sides of the axle
housing.
19
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1. Brake Anchorage
Remove the brake anchorage assembly (including dust shield, brake anchorage, S-cam tube, slack adjuster, brake
chamber, wheel speed sensor/wiring) as a unit from the end of the axle housing. Do this on both sides of the axle
housing. Clip cable ties as needed and route the wheel speed sensor wiring (if applicable) out of the way.
20
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1. Centering Set Screw
Loosen the two upper axle mounting plate set screws (one located at each side of the upper axle mounting plate). Do
this on both sides of the axle housing.
21
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1. Bolt
Remove the four fasteners securing the upper axle mounting plate to the bottom axle mounting plate, and remove the
upper axle mounting plate from the axle housing. Do this on both sides of the axle housing.
22
Disconnect the air line to the differential lock mechanism, and remove any sensor wiring, if applicable. Clip plastic tie
wraps as needed.
23
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1. V-Stay Apex Dust Cap
Remove the dust cap from apex of the V-stay torque rod attached to the top of the differential carrier housing.
24
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1.
2.
Small C-Clip
Retainer
Remove the V-stay retainer and C-clips from the V-stay torque rod apex.
25
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1.
2.
V-Stay Apex Pivot Bolt (M20)
Washer
Remove the M20 V-stay torque rod apex pivot bolt and washer.
26
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1. Bolt
Remove the fasteners securing the two ends of the V-stay torque rod to the two anchorage brackets.
27
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1.
2.
Set Screw
M27 Removal Fastener
22 / 54
1. Ratchet
Caution
Use only hand tools to turn the M27 removal fastener to pull off the V-stay torque rod and to prevent damage to
the differential housing.
To avoid cross threading, carefully install an M20 x 25mm, 1.5 thread pitch set screw into the V-stay attachment hole in
the carrier housing. Turn the set screw 13 to 16 full turns. Then, with the set screw in place, install the M27 removal
fastener in the V-stay apex pivot and turn it to remove the V-stay torque rod from the differential carrier housing.
28
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Caution
The V-stay torque rod is heavy, so use assistance to remove it from the vehicle.
Cut any plastic tie straps as needed and carefully remove the V-stay torque rod off the vehicle. Inspect the threads in
the bolt hole in top of the differential carrier housing for damage. Use a chase tap to clean the threads of old
threadlocking compound and debris.
29
Remove the drive shaft(s) from the differential carrier.
30
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1.
2.
Bolt
Lock Nut
Note: Before removal of the lower torque rods, note the orientation of the arrows on the rod and the placement of the
snap ring for proper reinstallation of the torque rods.
Caution
The axle housing is heavy and the weight is not distributed evenly. Before removing the lower torque rods,
make sure the jack being used can safely support the axle housing.
Caution
The lower torque rods are heavy, so take care when lowering it from the vehicle.
Note: It may be necessary to loosen the torque rods on both sides of the suspension for easier removal of the torque
rod.
Remove each lower torque rod connected to the differential housing to be replaced by removing the fasteners securing
25 / 54
1.
the ends to the lower axle mounting plate and bogie bracket.
31
Centering Set Screw
Loosen the two centering set screws on the lower axle mounting plates on both sides of the differential housing.
32
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1.
2.
3.
4.
Lock Nut
Washer
Long Bolt
Short Bolt
Caution
The lower axle mounting plate is heavy, so take care when lowering it from the vehicle.
Remove the fasteners securing the lower axle mounting plate to the axle housing and remove the lower mounting plate
from the axle housing.
33
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Caution
Be careful not to damage components during removal.
With assistance, lift the vehicle frame enough to move the axle housing from under the vehicle. Move the axle housing
to a safe location so that components can be safely removed and reused on the replacement differential housing.
34
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1.
1.
2.
3.
4.
5.
6.
7.
Prepare the replacement axle housing for installation by securing it and cleaning all mounting surfaces in preparation
for installing reused components.
35
Differential Carrier
Transfer reused components from the old differential carrier to the replacement differential carrier. As the components
are removed before reinstallation, inspect them, checking for wear and damage. Replace any components as needed:
Remove the differential carrier side cover.
Remove the fasteners securing the differential carrier to the axle housing.
Install a suitable lifting device and, with assistance, lift the carrier from the axle housing.
Clean the carrier surface that mates with the replacement axle housing.
With assistance, position the differential carrier into the replacement axle housing.
Install the carrier fasteners and torque to
207 19 Nm (153 14 ft-lb).
Install the differential carrier side cover and torque the fasteners to 41 4 Nm (30 3 ft-lb).
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36
Caution
Be careful not to damage components during installation.
With assistance, position the replacement differential carrier/axle housing assembly under the vehicle so it is directly
below the installation location.
37
Caution
Be careful not to damage components.
With assistance, lower the vehicle frame.
38
30 / 54
1.
2.
3.
4.
Lock Nut
Washer
Long Bolt
Short Bolt
Position the lower axle mounting plate onto the bottom of the differential housing and install the fasteners hand tight.
Do this on both sides of the axle housing.
39
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Position the upper axle mounting plate onto the top of the differential housing; note the position of the arrow on top of
the plate and orient the plate appropriately. Install the two set screws into the bracket and tighten them by hand to
center the upper plate onto the axle housing. Do this on both sides of the axle housing.
Note: The front set screws must be installed so they extend into the machined boss on the front of the axle.
40
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1. Bolt
Install the four fasteners used to secure the upper plate to the lower plate hand tight in an X pattern. Do this on both
Note: Initially hand tighten the bolts 2-3 turns to prevent cross threading.
41
While checking to make sure the upper plate is contacting the top of the axle at both the front and rear surfaces, torque
the upper axle top plate set screws to
34 5 Nm (25 4 ft-lb). Do this on both sides of the axle housing.
42
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Install the two set screws into the lower axle plate and tighten them by hand to center the lower plate to the axle
housing. Do this on both sides of the axle housing.
Note: The forward set screws must extend into the recess on the front side of the axle housing.
43
Torque the lower axle seat plate set screws to
44
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1. Fasteners to torque
Tighten the fasteners securing the lower axle plate to the differential housing using an X pattern and torque to
45
Torque the four fasteners securing the upper axle top plate to the lower plate using an X pattern each in two stages
time. For the first stage, torque to 75 Nm (55 ft-lb). For the second stage, torque to 175 30 Nm (130 22 ft-lb). Do this
on both sides of the axle housing.
46
35 / 54
1.
2.
1.
Bolt
Lock Nut
36 / 54
1.
2.
3.
4.
1.
Anti-Rotation Clamp
Snap Ring
Arrow visible from bottom; oriented to of chassis. outside
Arrow visible from bottom; oriented to of chassis. not inside
Note: Before installing the lower torque rods, note the orientation of the arrows on the rod and the placement of the
snap ring for proper reinstallation of the lower torque rods. See the illustration showing the bottom view of the lower
torque rods.
Caution
The lower torque rods are heavy. so take care when positioning them onto the vehicle.
Install each of the lower torque rods by positioning it between the bogie bracket and the lower axle plate and installing
the fasteners. Tighten the bolts and nuts and torque to
47
Tighten any other torque rod fasteners that may have been loosened during the torque rod removal steps to make
removal easier.
48
Lock Nut
37 / 54
Position the brake anchorage as an assembly (including dust shield, brake anchorage, S-cam tube, slack adjuster,
brake chamber, wheel speed sensor/wiring) onto the end of the axle housing and hand start the fasteners by hand to
avoid cross threading. Do this on both sides of the axle housing.
49
Tighten and torque the brake anchorage assembly fasteners to 271 27 Nm (200 20 ft-lb). Do this on both sides of
the axle housing.
50
Install the drive shaft(s) to the differential carrier. Tighten and torque the fasteners to 166 10 Nm (122.5 7.5 ft-lb).
51
Caution
The V-stay torque rod is heavy, so use assistance if needed to position the torque rod.
Note: Start all V-stay torque rod fasteners by hand to avoid thread damage.
Note: Make sure the mating surfaces of the V-stay pivot and the top of the differential carrier are clean and free of
debris.
38 / 54
1.
Using assistance, position the V-stay torque rod in place in the vehicle, with the pivot stud in position on the differential
carrier housing. Install the fasteners by hand at the V-stay frame anchorage mounting brackets first. Then, use a jack
under the front of the axle housing to aid in installing the pivot bolt.
52
Bolt
Tighten and torque the V-stay torque rod fasteners at the two V-stay frame anchorage mounting brackets to
175 30 Nm (129 22 ft-lb).
53
39 / 54
1.
2.
V-Stay Apex Pivot Bolt (M20)
Washer
At the V-stay apex joint, tighten the M20 pivot ball bolt attaching the V-stay torque rod to the differential carrier and
torque to 542 +14/-20 Nm (400 +10/-15 ft-lb).
54
40 / 54
1.
2.
Small C-Clip
Retainer
Install the retainer so that the hex portion captures the head of the M20 pivot ball bolt. This may take several attempts.
If the first attempt does not allow the retainer to fit over the bolt hex head, rotate the retainer clockwise to the next
position of the 7-sided feature. Repeat if needed until all seven points have been tried or the retainer fits. If no position
captures the bolt head, turn the retainer over and repeat the process. When the bolt hex head is captured, install the
snap ring to hold the retainer in place.
Note: Brush a liberal amount of lithium grease (XHP 222) onto all internal parts of the V-stay apex joint after assembly.
55
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1. V-Stay Apex Dust Cap
Install the dust cap onto the V-stay apex joint by placing it into position and briskly striking the top with the hand until it
seats.
56
Reconnect the air line to the differential lock mechanism, and reinstall any sensor wiring, if applicable. Use plastic tie
wraps as needed to secure the wiring in place.
57
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1. Hollow Rubber Spring Block
Position the rubber spring block onto the top of the upper axle plate. Do this on both sides of the axle housing.
58
43 / 54
1.
2.
3.
S-Cam Support Bracket
Bolt
Lock Nut
Position the S-cam support bracket so that it is on top of the bottom flange of the rubber spring block and on the
attachment ear of the S-cam tube. Install the fasteners securing the S-cam bracket to the S-cam tube but do not torque
at this point. Do this on both sides of the axle housing.
59
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1. Bolt
Install the four fasteners securing the S-cam bracket and the rubber spring block to the top of the upper axle plate. Do
this on both sides of the axle housing.
60
Tighten the four fasteners securing the rubber spring block and S-cam bracket to the top of the upper axle plate and
torque to 175 30 Nm (129 22 ft-lb). Then, tighten the nut securing the lower end of the S-cam bracket to the S-cam
tube and torque to 48 8 Nm (35 6 ft-lb). Do this on both sides of the axle housing.
61
45 / 54
1. Spring Plate
Lower the springs slowly onto the top of the rubber spring blocks. Make sure the rubber spring plates are in the proper
position between the upper and lower spring leafs on both sides of the axle housing.
62
46 / 54
1.
2.
3.
4.
5.
Bolt
Upper Bracket
Spacer
Lower Bracket
Lock Nut
Install the spring plate fasteners (bolts, nuts, spacers and brackets) to attach the spring plates to the upper and lower
springs. Tighten the spring plate fasteners and torque to
63
47 / 54
1.
2.
3.
Bolt
Lock Nut
Upper End of Shock Absorber
Install the fasteners securing the upper end of the shock absorber to the frame-mounted bracket and torque to 140 25
Nm (103 18 ft-lb). Do this on both sides of the axle housing.
64
48 / 54
1.
2.
3.
4.
5.
6.
7.
8.
Shock Absorber
Upper Bushing Washer
Rubber Bushing
Middle Bushing Washer
Rubber Bushing
Lower Bushing Washer
Spacer
Lock Nut
Install the fasteners securing the lower end of the shock absorber to the shock mount on the lower axle plate. Torque
the nut to
65
49 / 54
1.
2.
3.
4.
5.
Upper Brake Shoe
Lower Brake Shoe
Roller
Return/Retractor Spring (pins shown)
Anchor Spring
Install the brake shoes and related brake components onto the axle housing. Do this on both sides of the axle housing.
Note: The installation of new brake springs is recommended.
66
Remove the old seal from the axle hub. Check the bearings for wear or damage and replace if needed. Install a
replacement seal onto the hub along with a small amount of approved lubricant. Do this on both sides of the axle
housing.
67
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Use the wheel dolly and carefully reinstall the axle hub along with the wheels and tires as an assembly. Reinstall the
outer wheel bearings and the hub nuts. Check the wheel bearing end play and, if applicable, torque the axle nut to
Note: Bend the lock washer to prevent the axle nut from loosening.
68
51 / 54
1.
2.
Lock Nut
Axle Shaft
Install the axle shaft along with a new gasket. Tighten the fasteners to 203 21 Nm (150 12 ft-lb). Do this on both
69
Fill the differential housing to the proper level with approved gear lubricant. If applicable, check the fluid level in the
differential carrier housing and the power divider.
70
52 / 54
1. Air Hose Connector
Reinstall the two air hoses onto the brake chamber. Do this on both sides of the axle housing.
71
Reconnect all cables to the negative (ground) battery terminals.
72
Start the vehicle and allow the brake air system to get to the normal operating pressure.
Note: Make sure the parking brake is released.
73
53 / 54
1. Caging Bolt (nut and washer not shown)
Uncage the brake air chamber by removing the caging bolt.
74
Adjust all brakes to specification.
75
Set the parking brake.
76
Remove the jack stands from under the frame and remove the wheel chocks.
77
Perform a rear alignment check and adjust if needed.
Note: An alignment performed on an alignment machine is the preferred method.
54 / 54

Mack Gu

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46102-2 Rear Drive Axle Housing, Replacement

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