Service Information
Document Title: Function Group: Information Type: Date:
Hub reduction, installing 463 Service Information 26/01/2022
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A40E Volvo
Hub reduction, installing
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A40E Volvo
The method applies for installing the hub reduction on all axles.
Op nbr 463-046
Total procedure time (hr): 3.50
Tools:
9993844 Regulator
88830175 Pump
11666051 Pressure gauge
11668014 Lifting equipment
11668007 Standard Jack Single
11668007 Standard Jack Single
11668010 Wheel forklift
88830129 Installation tool
E-tool, E-2517, shut-off valve
E-tool, E-2518, adapter
11054368 Adapter
931206 Plug
This operation also includes required tools and times for applicable parts of the following operations:
Wear indicator, adjusting
Hub, pressure testing
Drive axle oil, changing
Brake system, bleeding
Wheel, installation
Brake cooling oil, changing
1. Change the O-ring on the hub end.
Lube the O-ring with vaseline, or similar, after installation.
NOTE!
Make sure that the O-ring is located at the bottom of the bevel. This is especially important by the slot for the wear
indicator.
Figure 1
2. Change the O-ring on the ring gear.
Lube the O-ring with vaseline, or similar, after installation.
Figure 2
3. Check that the wear indicator is fitted correctly. It should be fitted under the air bleeder nipple.
Figure 3
NOTE!
Installation of face seals demands thorough instructions for both cleanliness and installation. Therefore, read carefully what
applies for installation of these before starting the job, see Maintenance
NOTE!
The face seals are replaced in pairs, i.e. replace the seal ring and O-ring on both drive shaft and in the axle housing.
4. Clean the retainer with Bycotest C10 or equivalent.
Figure 4
5. Clean the new face seal's contact faces and 88830129 Installation tool with Bycotest C10 or equivalent, according to
special instructions, see Maintenance.
NOTE!
Use clean gloves for all handling of slide rings and associated O-rings. Any remains of oil or grease will cause the
seal to lose its function.
Figure 5
6. Install 88830129 Installation tool–C with the flange between the O–ring and slide ring's flange.
Figure 6
.
1. 88830129 Installation tool–C
2. Slide ring
3. O–ring
7. Install 88830129 Installation tool–B over installation tool C.
Figure 7
1. O–ring
2. 88830129 Installation tool–C
3. 88830129 Installation tool–B
8. Press in the face seal in the retainer on the axle housing.
NOTE!
The O-ring may not be twisted after installation.
NOTE!
After installation, the slide ring's sealing face shall be parallel, within 0.5 mm (0.020 in), of the retainer's edge.
Figure 8
1. 88830129 Installation tool–B
2. 88830129 Installation tool–C
3. Face seal (slide ring seal)
Figure 9
1. Holder
2. O–ring
3. Face seal's (slide ring) sealing surface
4. The retainer's edge and the sealing face shall be parallel after installation
9. Secure the half shaft in a vice with protection for the jaws to protect the splines.
Weight: approx. 30 kg (66 lbs)
Figure 10
10. Remove all loose parts from the half shaft. Check the half shaft and intermediate ring for damage and wear, change
if needed.
11. Clean the half shaft from oil and dirt with Bycotest C10 or equivalent.
Figure 11
12. Clean the new O-ring that is to be installed farthest out on the half shaft and 88830129 Installation tool–C with
Bycotest C10 or equivalent, according to special instructions, see Maintenance
NOTE!
Use clean gloves for all handling of slide rings and associated O-rings. Any remains of oil or grease will cause the
seal to lose its function.
Figure 12
1. 88830129 Installation tool–C
2. O–ring
13. Install 88830129 Installation tool–C around the half shaft with the flange facing up so that it rests on the half shaft's
edge.
Figure 13
1. 88830129 Installation tool–C
14. Install the O-ring over the installation tool.
NOTE!
The O-ring may not be twisted after installation.
1. O–ring
2. 88830129 Installation tool–C
15. Clean the intermediate ring with Bycotest C10 or equivalent, according to special instructions, Maintenance.
Figure 14
16. Press down the intermediate ring over the O-ring.
1. Intermediate ring
2. O–ring
3. 88830129 Installation tool–C
17. Remove the seal installing tool.
18. Clean the contact faces on the new face seal with Bycotest C10 or equivalent, according to special instructions, see
Maintenance.
Figure 15
19. Install 88830129 Installation tool–C with the flange between the O–ring and slide ring's flange.
Figure 16
1. 88830129 Installation tool–C
2. Slide ring
3. O–ring
20. Install 88830129 Installation tool–B over installation tool C.
Figure 17
1. O–ring
2. 88830129 Installation tool–C
3. 88830129 Installation tool–B
21. Press down the face seal in the intermediate ring using the installation tools.
NOTE!
The O-ring may not be twisted after installation.
1. 88830129 Installation tool–B
2. 88830129 Installation tool–C
3. O–ring
4. Intermediate ring
5. Slide ring
NOTE!
After installation, the slide ring's sealing face shall be parallel, within 0.5 mm (0.020 in), of the intermediate ring's
edge.
1. O–ring
2. Intermediate ring
3. O-ring,
4. Face seal's (slide ring) sealing surface
5. The intermediate ring's edge and the sealing
face shall be parallel after installation
22. Remove the installation tools.
23. Slide the half shaft carefully into the axle housing until it enters the dog-clutch collar. Make sure that the half shaft
is slid in horizontally and does not come into contact with the face seal, which may change position in case of
contact.
Figure 18
NOTE!
The following steps should be performed in sequence, without interruption:
24. Clean the face seals' sealing surfaces, both the axle housing's and the half shaft's face seal with alcohol, Bycotest
C10 or equivalent, according to special instructions, see Maintenance.
Figure 19
25. Smear a thin film with the axle's oil, see Recommended lubricants, on the slide rings' sealing surfaces immediately
before the seals are pushed together.
NOTE!
No oil may come into contact with the O-rings.
Figure 20
26. Slide in the half shaft so that the sealing surfaces on the slide rings make contact with each other in parallel.
NOTE!
Avoid pulling out the half shaft when the face slide rings have made contact with each other. The O-ring may be
damaged or move out of position, in that case the face seals must be cleaned again and new oil must be smeared
on around the contact surfaces.
Figure 21
27. Install the hub.
NOTE!
Make sure that the marking on the hub end and axle end line up opposite each other.
Weight, hub reduction: approx. 415 kg (914.9 lbs) — 455 kg (1003 lbs)
Weight, drive shaft: approx. 30 kg (66.1 lb)
28. Install four bolts evenly spaced around the circle and tighten.
Install the remaining bolts.
Tighten the bolts crosswise.
Tightening torque, see: Axles, tightening torques
Figure 22
29. Remove 11668014 Lifting equipment
30. The air bleeder nipple is available in two versions. The older version seals with silicone and the newer with a rubber
seal. For the older version, clean the connection in the axle housing from old silicone and apply new silicone on the
breather nipple before installing, as shown in the figure. The newer version breather nipple seals with a rubber seal;
check the seal, change it if needed
Figure 23
1. Older version, seal with silicone
2. Newer version, seal with rubber seal
31. NOTE!
Install the air bleeder nipple, without sealing with silicone at this time. The air bleeder nipple is sealed after
performing pressure check of the hubs.
Tightening torque, see: Axles, tightening torques
Figure 24
32. The brake oil connection is available in two versions. The older version seals with silicone and the newer with a
rubber seal. For the older version, remove any remains of silicone and oil from the threaded hole in the axle
housing and apply new silicone, RTV 5242, on the oil connection before installing, as shown in the figure. For the
newer version, check the seal, change it if needed.
Figure 25
1. Older version, seal with silicone
2. Newer version, seal with rubber seal
33. Install and tighten the brake oil connection.
Tightening torque, see: Axles, tightening torques
Figure 26
Adjusting wear indicator and pressure testing of brake
34. For adjusting wear indicator and pressure testing of brake, see Wear indicator, adjusting.
NOTE!
Only adjust the wear indicator when new brake discs have been installed.
Figure 27
Pressure check of hub
35. For pressure testing of hub, see Hub, pressure testing
Figure 28
36. Remove the plugs from the brake cooling oil hoses and brake oil line, and on the connections fore these.
Install the brake cooling oil hoses and the brake oil line on the hub.
Figure 29
1. Brake oil line
2. Brake cooling oil hose, incoming oil
3. Brake cooling oil hose, outgoing oil
37. Remove the breather nipple and seal with silicone if the newer version of nipple is used. Install the breather nipple.
Tightening torque, see: Axles, tightening torques
38. Fill oil in the axle. See appropriate parts of Drive axle oil, changing.
39. Bleed the brake oil system, see Brake system, bleeding.
40. Install the wheel, see Wheel, installation
41. Bleed the brake cooling oil system by starting the machine and running it for a time.
42. If required, refill brake cooling oil in the tank. See appropriate parts of Brake cooling oil, changing.
43. Restore the machine from service position.
