AXLE INSTALLATION AND MAINTENANCE MANUAL

972.547.6020 • 800.445.0736 • FAX: 972.542.0097

725 E. UNIVERSITY ST. McKINNEY, TEXAS 75069
www.WatsonSuspensions.com
Table of Contents

WC Axle Application Guide 2

WC Axle Part Numbering Guide 3
Model WCN 4
Model WCP 10
Brake Lining Certification 16
Air Chamber Spacing 17
Axle Options 18
Model WCN Brake Part Number X-Reference 12.25” 19
Model WCN Brake Part Number X-Reference 16.5” 20
Model WCP Brake Part Number X-Reference 16.5” 21
Axle Lubrication 22
Fastener Torque Specifications 23
Self-Adjust and Manual Brake Adjuster Removal, Installation and maintenance 24
Wheel Bearing Adjustment Procedures 31
Recommendations For Wheel End Lubrication 35
WC Weld Procedure 43

REV 3-5-2010
WCL6H14A
Watson & Chalin Axle Application Guide
Bearing Capacity
Axle Bearings
(lbs/Kg)*
WCN Outer Cup HM212010
Outer cone HM212049
25000/11350
Inner cup HM218210
Inner cone HM218248
WCP Outer Cup HM518410
Outer cone HM518445
26000/11800
Inner cup HM518410
Inner cone HM518445

Recommendations:
1- Follow the Watson & Chalin “Normal Service” Capacity chart to select an axle for applications
running a majority of time on highway travel with “SPRING SUSPENSION” installed on it.
2- When the applications involves running a significant amount of off-road miles, or on exceptionally
rough roads - select the next heavier tube wall than was identified on the applicable Watson & Chalin
Capacity chart.
3- When installing the axle on air suspensions or high torsion single pivot suspensions -select the tube
wall axle than was identified on Watson & Chalin “AIR RIDE SUSPENSION” Capacity chart.
Minimum wall thickness to be used on an air ride suspension is 0.58”
Watson & Chalin Axle Part Numbering Guide

Prefix Spindle type Wall Thickness Brake Size Axle type Track Width Numbering
WC N 5 67 ST 715 -XXX

N Spindle or
N* D22 3 10mm 27 12.25 x 7.5 ST Straight 715 71.5”
P Propar type 4 0.5 67 16.5 x 7 6D 6” Drop 730 73.0”
F FF Spindle 5 0.58 54 15 x 4 9D 9” Drop 775 77.5”
A26/K30
K Spindle 6 0.75 87 18 x 7 6I 6” Inverted Drop 955 95.5”
A A45 Spindle S Solid 9I 9” Inverted Drop 120 120”
By 1/8 increments

WCN167ST775-001
WCP167ST715-002 SAMPLE AXLE
WCP167ST715-003 NUMBERS
WCN127ST120-004
 Model: WCN
Bearing Group: Inner: HM218248, Outer: HM 212049

Outside Diameter: 5” - Straight Tube

Tube wall Max. Capacity –Mechanical susp’n* Max. Capacity – Air susp’n*
0.58” 25,000 lbs (normal service) 22,500 lbs (normal service)
0.75” 27,000 lbs (Normal service) 25,000 lbs (normal service)

*See capacity charts for details

Track lengths
71.5” (standard)
77.5” (standard)
Other tracks also available (38” to 108”)

Brakes (Refer to: Brake Lining Certification List)

16 ½ x 7” quick change, Q, FMSI-4515E
16½ x 7” quick change, Q+, FMSI-4707
16 ½ x 8 5/8” quick change GP, FMSI-4551
12 ¼ x 7 ½” quick change DA, FMSI-4692

ABS
Bracket is standard - in the SAE recommended position.

Tire Inflation
Spindle preparation is standard - fits PSI, Tiremax and Airgo hardware

Hub and Drum Assemblies

All standard North American “N” type products will assemble to the WCN spindle.

Parts X- Reference
See “Reference Information” section
 WCN 5” O.D.

BRGS: HM218248 = HM212049

AIR RIDE
W&C AXLE CAPACITY RATING
SPRING SUSPENSION SUSPENSION
NORMAL SERVICE (See Notes)
TUBE WALL TUBE WALL

THIS IS NOT A CERTIFICATION ( FOR INFORMATION ONLY) 0.58” 0.75” 0.58” 0.75”
AXLE AXLE AXLE AXLE
BEAM BEAM BEAM BEAM
SPRING MOMENT CAPACITY CAPACITY CAPACITY CAPACITY
SPINDLE TRACK SEATS ARM GAWR. GAWR. GAWR. GAWR.
TYPE (INCHES) (INCHES) (INCHES) (lbs.) (lbs.) (lbs.) (lbs.)
WCN 71.5 38 16.75 25,000 27,000 25,000 25,000
WCN 71.5 37 17.25 24,320 27,000 24,320 25,000
WCN 71.5 36 17.75 23,640 27,000 23,640 25,000
WCN 71.5 35 18.25 22,990 26,800 22,990 25,000
WCN 71.5 34 18.75 22,380 26,100 22,380 24,870
WCN 71.5 33 19.25 21,800 25,400 21,800 24,230
WCN 71.5 32 19.75 21,240 24,700 21,240 23,610
WCN 71.5 31 20.25 20,720 24,100 20,720 23,030
WCN 71.5 30 20.75 20,220 23,500 20,220 22,480
WCN 71.5 29 21.25 19,740 23,000 19,740 21,950
WCN 71.5 28 21.75 19,290 21,440

WCN 77.5 44 16.75 25,000 27,000 25,000 25,000

WCN 77.5 43 17.25 24,320 27,000 24,320 25,000
WCN 77.5 42 17.75 23,640 27,000 23,640 25,000
WCN 77.5 41 18.25 22,990 26,800 22,990 25,000
WCN 77.5 40 18.75 22,380 26,100 22,380 24,870
WCN 77.5 39 19.25 21,800 25,400 21,800 24,230
WCN 77.5 38 19.75 21,240 24,700 21,240 23,610
WCN 77.5 37 20.25 20,720 24,100 20,720 23,030
WCN 77.5 36 20.75 20,220 23,500 20,220 22,480
WCN 77.5 35 21.25 19,740 23,000 19,740 21,950
WCN 77.5 34 21.75 19,290 21,440
NOTES:
1. Ratings are for spring or air suspensions used in normal service.
2. High torsion single point spring suspensions are considered same as air suspensions.
3. For off-road use, find the rating above, then use the next heavier wall.
4. Special applications: call Watson & Chalin for technical assistance
 WCN6D
6” DROP CENTER AXLE BEARINGS: HM218248 + HM212049
WATSON & CHALIN CAPACITY Air Ride SUSPENSION
RATING for AIR RIDE SUSPENSIONS TUBE WALL
THIS IS NOT A CERTIFICATION
( FOR INFORMATION ONLY) 0.58” 0.75
MOMEN
SPRING T ARM AXLE BEAM AXLE BEAM
SPINDLE TRACK SEATS (INCHE CAPACITY CAPACITY
TYPE (INCHES) (INCHES) S) GAWR. (lbs.) GAWR. (lbs.)
WCN 71.5 38 16.75 22,500 25,000
WCN 71.5 37 17.25 21,850 24,320
WCN 71.5 36 17.75 21,230 23,640
WCN 71.5 35 18.25 20,650 22,990
WCN 71.5 34 18.75 20,100 22,380
WCN 71.5 33 19.25 19,580 21,800
WCN 71.5 32 19.75 19,080 21,240
WCN 71.5 31 20.25 18,610 20,720
WCN 71.5 30 20.75 18,160 20,220
WCN 71.5 29 21.25 17,730 19,740

WCN 77.5 44 16.75 22,500 25,000

WCN 77.5 43 17.25 21,850 24,320
WCN 77.5 42 17.75 21,230 23,640
WCN 77.5 41 18.25 20,650 22,990
WCN 77.5 40 18.75 20,100 22,380
WCN 77.5 39 19.25 19,580 21,800
WCN 77.5 38 19.75 19,080 21,240
WCN 77.5 37 20.25 18,610 20,720
WCN 77.5 36 20.75 18,160 20,220
WCN 77.5 35 21.25 17,730 19,740

NOTES:
1. Ratings are for air suspensions used in normal service.
2. For off-road use, find the rating above, then use the next heavier wall.
3. Special applications: call Watson & Chalin for technical assistance
 Model: WCP
Bearing Group: Inner: HM518445, Outer: HM518445

Outside Diameter: 5” – Straight Tube

Tube wall Max. Capacity –Mechanical susp’n* Max. Capacity – Air susp’n*
0.58” 25,000 lbs (normal service) 22,500 lbs (normal service)
0.75” 27,000 lbs (Normal service) 25,000 lbs (normal service)
* See capacity charts for details

Outside Diameter: 5 ¾” Straight Tube

Tube wall Max. Capacity –Mechanical susp’n* Max. Capacity – Air susp’n*
0.39” 25,000 lbs (normal service) 25,000 lbs (normal service)

Track lengths
71.5” (standard)
77.5” (standard)
Other tracks also available (38” to 108”)

Brakes (Refer to: Brake Lining Certification List)

16 ½ x 7” quick change, Q, FMSI4515E
16 ½ x 7” quick change, Q+, FMSI4707
16 ½ x 8 5/8” quick change GP, FMS
I4551 12 ¼ x 7 ½” quick change DA, FMSI4692

ABS
Bracket is standard in the SAE position
Tire Inflation
Spindle preparation is standard fits PSI, Tiremax and Airgo hardware
Hub and Drum Assemblies
All standard North American “P” type products will assemble to the WCP spindle.
Parts XReference
See “Reference Information” section
 WCP 5” O.D.
BRGS (2) HM518445

AXLE CAPACITY RATING TUBE WALL

NORMAL SERVICE (See Notes) Spring Suspension Air Ride Suspension
THIS IS NOT A CERTIFICATION ( FOR INFORMATION ONLY)
0.58 “ 0.75 “ 0.58 “ 0.75 “
SPRING MOMENT AXLE BEAM AXLE BEAM AXLE BEAM AXLE BEAM
SPINDLE TRACK
SEATS ARM CAPACITY CAPACITY CAPACITY CAPACITY
TYPE (INCHES)
(INCHES) (INCHES) GAWR. (lbs.) GAWR. (lbs.) GAWR. (lbs.) GAWR. (lbs.)
WCFP” “ 71.5 38 16.75 25,000 27,000 25,000 25,000
37 17.25 24,320 27,000 24,320 25,000
36 17.75 23,640 27,000 23,640 25,000
35 18.25 22,990 26,800 22,990 25,000
34 18.75 22,380 26,100 22,380 24,,870
33 19.25 21,800 25,400 21,800 24,230
32 19.75 21,240 24,700 21,240 23,610
31 20.25 20,720 24,100 20,720 23,030
30 20.75 20,220 23,500 20,220 22,480
29 21.25 19,740 23,000 19,740 21,950

WCFP” “ 77.5 44 16.75 25,000 27,000 25,000 25,000

43 17.25 24,320 27,000 24,320 25,000
42 17.75 23,640 27,000 23,640 25,000
41 18.25 22,990 26,800 22,990 25,000
40 18.75 22,380 26,100 22,380 24,870
39 19.25 21,800 25,400 21,800 24,230
38 19.75 21,240 24,700 21,240 23,610
37 20.25 20,720 24,100 20,720 23,030
36 20.75 18,160 23,500 18,160 22,480
35 21.25 17,730 19,740 17,730 21,950

WCFP” “ 84 “ 50.5 16.75 22,500 25,000

49.5 17.25 24,320 27,000
48.5 17.75 23,640 27,000 Call Call
47.5 18.25 22,990 26,800 Watson & Watson &
46.5 18.75 22,380 26,100
45.5 19.25 21,800 25,400 Chalin for Chalin for
44.5 19.75 21,240 24,700 technical technical
43.5 20.25 20,720 24,100
42.5 20.75 20,220 23500
assistance. assistance.
41.5 21.25 19,740 23000

NOTES:
1. Ratings are for spring or air suspensions used in normal service.
2. High torsion single point spring suspensions are considered same as air suspensions.
3. For off-road use, find the rating above, and then use the next heavier wall.
 Model: WCPX676D
Bearing Group
Inner: HM518445
Outer: HM518445
Outside Diameter: 5” Drop Center & Camel Back Tube: 6” drop.
(8” and 9” drops also available)

Tube wall Maximum capacity*

0.58” (X=’s 5) 22,500 lbs (normal service)
0.75” (X=’s 6) 25,000 lbs (normal service)
*See capacity charts for details

Track lengths
71.5” (standard)
77.5” (standard)
Other tracks available – please consult Watson & Chalin Sales and Technical support.
Brakes
16 ½ x 7” quick change, FMSI4515
16 ½ x 7” quick change, GP+ (Q+), FMSI4707

ABS
Bracket is standard in the SAE position

Tire Inflation
Spindle preparation for PSI, Tiremax and Airgo is standard.

Cam position
Ahead of axle
Behind the axle

Cam Length
See specific model drawing

Hub and Drum Assemblies

All standard North American “P” type products will assemble to spindle.
Parts XReference
See “Reference Information” section
 Brake Lining Certifications on Watson & Chalin Axles
Tire
Spring Auto-Slack
Lining Brake size Loaded Country /
Manufacturer FMSI # Brake Size Arm Length Rating (lbs) Certification
Marerial (inches) Radius Continent
(inches²) (inches)
(inches)
PL133 Fuwa 16.5 x 7 4515E 20.6 30-30 5.5 20,000 USA,Canada FMVSS121/CMVSS121
PL133 Fuwa 16.5 x 7 4515E N/R (1) Type-30 6 12 tonnes (2) Australia ADR Schedule-4, SARN#35665
MB21 Carlisle 16.5 x 7 4515E 20.6 30-30 5.5 20,000 USA,Canada FMVSS121/CMVSS121
PL244 Fuwa 16.5 x 7 4515E 20.6 30-30 5.5 23,000 USA,Canada FMVSS121/CMVSS121
PL133XT Fuwa 16.5 x 7 4707 20.6 30-30 5.5 20,000 USA,Canada FMVSS121/CMVSS121
PL244 Fuwa 16.5 x 7+(3) 4707 20.6 30-30 5.5 23,000 USA,Canada FMVSS121/CMVSS121*

PL244 Fuwa 12.25 x 7.5 4692 15 30-30 6 20,000 USA,Canada FMVSS121/CMVSS121

Notes:
1- N/R = Not required for this certification
2- Metric tonnes.
3- 16.5 x 7 is Q+ REV. 2 - 09.28.2009
 Air Chamber Spacing
(Inches)
AC

BRAKE SIZE TRACK CL WCN WCP

12.25 x 7.5” 65 20.75 8.3
12.25 x 7.5” 71.5 20.75 14.8 N/A
12.25 x 7.5” 71.5 21.13 14 N/A
12.25 x 7.5” 71.5 23.38 9.5 N/A
12.25 x 7.5” 71.5 23.75 8.8 N/A
12.25 x 7.5” 77.5 20.75 20.8 N/A
12.25 x 7.5” 77.5 21.13 20 N/A
12.25 x 7.5” 77.5 23.38 15.5 N/A
12.25 x 7.5” 77.5 23.75 14.8 N/A
16 ½ x 7” 71.5 17.52 22.1 22.1
16 ½ x 7” 71.5 20.63 15.9 15.9
16 ½ x 7” 71.5 21.38 14.4 14.4
16 ½ x 7” 71.5 23.75 9.7 9.7
16 ½ x 7” 71.5 24.13 8.9 8.9
16 ½ x 7” 77.5 17.52 28.1 28.1
16 ½ x 7” 77.5 20.63 21.9 21.9
16 ½ x 7” 77.5 21.38 20.4 20.4
16 ½ x 7” 77.5 23.75 15.7 15.7
16 ½ x 7” 77.5 24.13 14.9 14.9
16 ½ x 8 5/8” 71.5 17.52 22.1 22.1
16 ½ x 8 5/8” 71.5 20.63 15.9 15.9
16 ½ x 8 5/8” 71.5 21.38 14.4 14.4
16 ½ x 8 5/8” 71.5 23.75 9.7 9.7
16 ½ x 8 5/8” 71.5 24.13 8.9 8.9
16 ½ x 8 5/8” 77.5 17.52 28.1 28.1
16 ½ x 8 5/8” 77.5 20.63 21.9 21.9
16 ½ x 8 5/8” 77.5 21.38 20.4 20.4
16 ½ x 8 5/8” 77.5 23.75 15.7 15.7
16 ½ x 8 5/8” 77.5 24.13 14.9 14.9
Notes: 16.5 x 8 5/8” is a centerline brake -same spider position as 16.5 x 7”
Type 2424 = 7.5” O.D.
Type 3030 = 8.31” O.D.
 Axle Options

ABS Sensors Installed:

Slack Adjusters:
Wabco Haldex
Haldex Bendix
Bendix Watson & Chalin - BTC
Other

Bearings:
Seals:
Watson & Chalin standard Watson & Chalin standard
Timken SKF C/R
Stemco Stemco
Others Others

Hub Cap:
Dust Shield
Watson & Chalin Standard 16.5”
Stemco 12.25”
Others

Air Chambers and Spring Brakes

Watson & Chalin – BTC
Others

10 spline camshafts: (28 spline

standard)

Camshaft Enclosures

Notes:
Total axle price varies according to the options.
“Watson & Chalin Standard” is usually the best priced option.
New options can be added upon request when quantities/price/availability are suitable.
 WCN Axle
12.25" Brake Part Number X-Reference

WCN Spindle: Threads 2 5/8"-16 UNS 2A

Fuwa FN
Hendrickson HN
Meritor TN, TQ
Spicer (Dana) D22, K22
IMT F22

Bearings: HM212049 Outer

HM218248 Inner

Brake shoes: 12 1/4" X 7 1/2" 0.715: Standard

FMSI 4692
Fuwa DA
Meritor Q
Spicer Fast Change
IMT TIME

Camshafts: Standard Lining: GP Std 1 1/2" Cam Bushing, 28 splines

Manufacturer Fuwa IMT Meritor Euclid
20 3/4" Left C11-0401-527L 202129-206-LH R607247 E-9753
20 3/4" Right C11-0401-527R 202129-206-RH R607248 E-9754
21 1/8" Left C11-0401-537L N/A N/A N/A
21 1/8" Right C11-0401-537R N/A N/A N/A
23 3/8" Left C11-0401-595L 202129-233-LH R607253 E-9759
23 3/8" Right C11-0401-595R 202129-233-RH R607254 E-9760
23 3/4" Left C11-0401-603L N/A N/A E-10925
23 3/4" Right C11-0401-603R N/A N/A E-10926
Repair Kit: N/A 2028 R615014 E-2469

Fuwa / NEW Fuwa / OLD IMT Meritor Euclid

Spider Bushing C13-0201 3305-0038 405129 N/A E-759/807
Spider Seal C14-0201 3957-0038 408101 1205M1105 E-1416
Cam bushing C20-0201 3302-0038 N/A A2-3105-G-1151 E-1318AHD

Hub Seals Stemco C/R Out-Runner Timken

6" 0D x 4 5/8" ID 320-2110 seal 46303 Pro 859 WB116GST
315-1504 ring 46305 Classic NLGI#2 Grease

Hub Cap Bolts: (6) 5/16" NC Bolts on 5 1/2" BCD

Notes: 1- Rollers, anchor pins, springs, snap rings, etc. are all industry standard.
2- Above supplied for information only. Please measure parts before installing.
3- N/A = Not available

Options: Many options are available - Consult Watson & Chalin Customer Service.
 WCN Axle
16.5" Brake Part Number X-Reference

WCN Spindle: Threads 2 5/8"-16 UNS 2A

Fuwa FN
Hendrickson HN
Meritor TN, TQ
Spicer (Dana) D22, K22
IMT F22
Bearings: HM212049 Outer
HM218248 Inner

Brake shoes: 16 1/2" X 7" 0.75: Standard 0.88" Thick

FMSI 4515E 4707
Fuwa GP GP+
Meritor Q Q+
Spicer Fast Change XL
IMT TIME SL

Camshafts: GP & GP+, 1 5/8" Cam Head Journal, 28 Spline

Manufacturer Fuwa / NEW Fuwa / OLD Spicer/Dana Meritor Euclid
17 1/2" Left C11-0301-445L N/A M16WKL25-175 R607227 E-9731
17 1/2" Right C11-0301-445R N/A M16WKR25-175 R607228 E-9732
20 5/8" Left C11-0301-524-L 3304-0621L M16WKL25-205 R607229 E9733
20 5/8" Right C11-0301-524R 3304-0621R M16WKR25-205 R607230 E9734
21 3/8" Left C11-0301-543-L N/A M16WKL25-213 N/A N/A
21 3/8" Right C11-0301-543R N/A M16WKR25-213 N/A N/A
23 3/4" Left C11-0301-604-L N/A M16WKL25-236 R607231 E-9735
23 3/4" Right C11-0301-604R N/A M16WKR25-236 R607232 E-9736
24 1/8" Left C11-0301-613-L 3304-0622L M16WKL25-242 R607277 E-10909
24 1/8" Right C11-0301-613-R 3304-0622R M16WKR25-242 R607278 E-10910
Repair Kit: N/A N/A 8132803 R615019 E-9790A

Fuwa / NEW Fuwa / OLD Spicer/Dana Meritor Euclid

Spider Bushing C13-0302 3306-0011 M16HD106 R627034 E-9789
Spider Seal C14-0300 3307-0011 M16HH103 R627015 E-3991
Cam bushing C20-0201 3302-0038 N/A A2-3105-G-1151 E-1318AHD

Hub Seals Stemco C/R Out-Runner Timken

6" 0D x 4 5/8" ID 320-2110 seal 46303 Pro 859 WB116GST
315-1504 ring 46305 Classic NLGI#2 Grease

Hub Cap Bolts: (6) 5/16" NC Bolts on 5 1/2" BCD

Notes: 1- Rollers, anchor pins, springs, snap rings, etc. are all industry standard.
2- Above supplied for information only. Please measure parts before installing.
3- N/A = Not available
Options: Many options are available - Consult Watson & Chalin Customer Service.
 WCP Axle
16.5" Brake Part Number X-Reference
WCP Spindle: Threads 3.48"-12 UN-2A
Fuwa FP
Hendrickson HP
Meritor TP
Spicer (Dana) P22
IMT F24

Bearings: HM518445 Outer

HM518445 Inner

Brake shoes: 16 1/2" X 7" Standard Thick

FMSI 4515 4707
Fuwa GP GP+
Meritor Q Q+
Spicer Fast Change XL
IMT TIME SL

Camshafts: GP & GP+, 1 5/8" Cam Head Journal, 28 Spline

Manufacturer Fuwa / NEW Fuwa / OLD Spicer/Dana Meritor Euclid
17 1/2" Left C11-0301-445L N/A M16WKL25-175 R607227 E-9731
17 1/2" Right C11-0301-445R N/A M16WKR25-175 R607228 E-9732
20 5/8" Left C11-0301-524-L 3304-0621L M16WKL25-205 R607229 E9733
20 5/8" Right C11-0301-524R 3304-0621R M16WKR25-205 R607230 E9734
21 3/8" Left C11-0301-543-L N/A M16WKL25-213 N/A N/A
21 3/8" Right C11-0301-543R N/A M16WKR25-213 N/A N/A
23 3/4" Left C11-0301-604-L N/A M16WKL25-236 R607231 E-9735
23 3/4" Right C11-0301-604R N/A M16WKR25-236 R607232 E-9736
24 1/8" Left C11-0301-613-L 3304-0622L M16WKL25-242 R607277 E-10909
24 1/8" Right C11-0301-613-R 3304-0622R M16WKR25-242 R607278 E-10910
Repair Kit: N/A N/A 8132803 R615019 E-9790A

Fuwa / NEW Fuwa / OLD Spicer/Dana Meritor Euclid

Spider Bushing C13-0302 3306-0011 M16HD106 R627034 E-9789
Spider Seal C14-0300 3307-0011 M16HH103 R627015 E-3991
Cam bushing C20-0201 3302-0038 N/A A2-3105-G-1151 E-1318AHD

Hub Seals Stemco C/R Out-Runner Timken

6" 0D x 4 5/8" ID 320-2110 seal 46303 Pro 859 WB116GST
315-1504 ring 46305 Classic NLGI#2 Grease

Hub Cap Bolts: (6) 5/16" NC Bolts on 5 1/2" BCD

Notes: 1- Rollers, anchor pins, springs, snap rings, etc. are all industry standard.
2- Above supplied for information only. Please measure parts before installing.
3- N/A = Not available
Options: Many options are available - Consult Watson & Chalin Customer Service.
 AXLE LUBRICATION
Oil and grease suggested change intervals:

Varying loads and driving conditions will affect the service interval requirements. This chart is a generally accepted guide.
Always work in a clean area and clean all parts with proper solvents before use. Never refill the hub with used oil.
Contaminated lubricants can quickly destroy the entire assembly.

TIME or DISTANCE OIL GREASE BRAKES COMPONENTS

1,000 miles 1,600 km Check the oil level and replace
the oil if it is contaminated.
Check for leaks. Replace oil and
seal if hub has been removed.
See the "Add" and "Full" rings
on the hub cap
12,000 miles 19,200 km Check brake adjustment
30,000 miles 48,00 km or Heavy Duty Use (On/Off Road) Heavy Duty Use Check wear in the linings,
six months Change the oil (On/Off the cams, and the spider
Road) Grease the bushings. Grease the
bearings brake actuating
100,00 miles 160,000km Normal Use Normal Use
or every year Change the oil Grease the bearings
Varies Consult the semi-fluid synthetic grease Manufactrurer for recommendations.
Also replace this grease if the hub is removed.

CAUTION: Do not mix lubricants types.

Lubricants:

The following GREASE properties are recommended

Soap type - Lithium Complex or Equivalent
Dropping point - 446ºF (230ºC) Minimum
Consistency - NLGI No. 2 or No.1
Additives - Corrosion & Oxidation Inhibitors, EP optional
Base Oil - Solvent Refined Petroleum oil

The following Oil properties are recommended

Gear Oil API GL-5 Performance level

SAE 90 Normal Duty

SAE 75W, SAE 80W Extreme cold environment
SAE 140 Extreme hot environment
 FASTENER TORQUE SPECIFICATIONS
Description Thread Grade Torque
Cam bracket bolts: 3/8” 5 40 ft-lbs, 55Nm
10mm 8.8 40 ft-lbs, 55Nm

Hub Cap 5/16”-18UNC 5 15 ft-lbs, 28Nm

Dust Shield 5/16” – 18UNC 5 15 ft-lbs, 28Nm

Air Chambers
Type 9, 12, 16 7/16”- 14UNC N/A 30-40 ft-lbs, 40-55Nm
Type 20, 24, 30 5/8”- 11UNC N/A 100-115 ft-lbs, 135-155Nm

Spindle nuts; see “Wheel Bearing Adjustment Procedures” TMC RP618

 Recommended Practice

RP 609B VMRS 013-001, 013-002

SELF-ADJUSTING AND MANUAL BRAKE ADJUSTER

REMOVAL, INSTALLATION AND MAINTENANCE
PREFACE with a clevis and the spline end is installed on the
The following Recommended Practice is subject to brake camshaft. Primarily, the brake adjuster is a
the Disclaimer at the front of TMC’s Recommended lever that converts the linear force of the air chamber
Maintenance Practices Manual. Users are urged to push rod into a torque which turns the brake cam-
read the Disclaimer before considering adoption of shaft and applies the brakes.
any portion of this Recommended Practice.
Two types of brake adjusters are in use: manual type
PURPOSE AND SCOPE brake adjusters, which periodically require a manual
The purpose of this Recommended Practice (RP) is adjustment; and self-adjusting brake adjusters, which
to provide information regarding the removal, instal- automatically adjust during normal service braking
lation, operation, maintenance, and selection of applications. All brake adjusters use the worm and
heavy-duty vehicle manual and self-adjusting brake gear principle and fundamentally differ only in their
adjusters. torque limit specification.

INTRODUCTION NOTE: Manual and self-adjusting brake adjusters

In an S-cam type foundation brake, the final link are for brake adjustment and will not compensate for
between the pneumatic system and the foundation normal wear characteristics and maintenance re-
brake is the brake adjuster. The arm of the brake quirements associated with foundation brakes.
adjuster is fastened to the push rod of the chamber

BALL INDENT TYPE SLACK ADJUSTER POSITIVE LOCK TYPE SLACK ADJUSTER

BODY
LOCK SCREW

LOCKING
COLLAR

WORM
SHAFT
ADJUSTING ADJUSTING
HEX HEX

WORM
GEAR

Fig. 1: Manual Brake Adjusters

© 2002—TMC/ATA
Issued 3/80
RP 609B — 1
Revised 3/2002
MANUAL BRAKE ADJUSTERS • Type, width, number, and diameter of splines.
Manual brake adjusters contain four basic compo- • Clevis pin diameter (do not drive out bushing
nents: the body, worm gear, worm shaft, and locking to accommodate a larger clevis pin).
screw or collar. See Fig. 1. • Brake chamber push rod size (5/8" or 1/2").
• If offset configuration, determine the offset
The worm shaft of a brake adjuster incorporates an dimension (right or left side).
external adjusting hex. Turning the adjusting hex
rotates the worm shaft which turns the worm gear BRAKE ADJUSTER REMOVAL AND
and brake cam shaft, thus spreading the brake shoes INSTALLATION
and reducing drum-to-lining clearance.
: To avoid possible injury, proper precau-
Light to medium gross axle weight rating (GAWR) tions must be taken to prevent automatic actuation of
vehicles utilize either a spring-loaded locking sleeve the brake chambers while removing or installing
or a lock ball indent adjustment lock to prevent the slack adjusters. Always block the wheels or me-
worm shaft from backing off. chanically secure the vehicle. Spring brakes must be
mechanically caged. All brakes should be released.
Higher torque-rated brake adjusters use the lock ball
or plunger and worm shaft indent principle adjust- A. Manual Brake Adjuster Removal—
ment lock. The lock ball or plunger must engage the 1. Remove the brake chamber push rod clevis
worm shaft indent after the adjustment is completed. pin.
An audible metallic click can be heard when engage- 2. Remove the retaining mechanism from the
ment is made. end of the brake camshaft.
3. Rotate the adjusting hex to back the brake
SELF ADJUSTING BRAKE ADJUSTERS adjuster out of the clevis.
While self-adjusting brake adjuster designs vary in 4. Remove the brake adjuster from the spline
the manner in which they are installed and operate, end of the brake cam shaft.
all are designed to automatically maintain a prede-
termined drum-to-lining clearance or brake chamber B. Manual Brake Adjuster Installation—
stroke. Some self-adjusting brake adjusters adjust 1. Install the brake adjuster on the cam shaft so
upon the brake application stroke, others adjust the adjustment hex and grease fitting (if so
upon release. Self-adjusting brake adjusters should equipped) are accessible for servicing.
not have to be manually adjusted while in service. 2. Align the brake adjuster arm with center of the
However, manual adjustments can be made tempo- push rod clevis. Install the clevis pin and
rarily to get a vehicle to a maintenance facility for secure it with a new cotter pin.
inspection and repair, if necessary. 3. Check to be sure the angle formed by the
brake adjuster arm and the brake chamber
! CAUTION Self-adjusting brake adjusters do not push rod is greater than 90° when the brake
eliminate or reduce the need for periodic inspection adjuster is in the released position.
and maintenance of the adjuster components and 4. Install the brake adjuster retaining mecha-
attaching hardware. Self-adjusting brake adjusters nism on the end of the brake cam shaft, being
should never be operated as a manual adjuster, if the sure to shim it to less than 0.060 inch of end
self-adjusting function is not operating properly. play.
5. Tighten the jam nut on the push-rod-to-clevis
BRAKE ADJUSTER REPLACEMENT attachment (1/2 - 20 300-400 in. Ibs. 5/8 - 18
When replacing a brake adjuster, it is recommended 400 in. Ibs.).
that the replacement be of the same size as the 6. After installation, make certain there is ad-
original equipment. All self-adjusting brake adjusters equate clearance in both the fully applied and
on a vehicle should be made by the same manufac- fully released positions. Check to ensure that
turer. To identify the proper replacement, the follow- all brake adjusters rotate freely and without
ing slack adjuster key dimensional checks are rec- binding.
ommended. 7. Adjust the brakes by following the procedure
• Arm length (center of spline to center of arm in the section entitled BRAKE ADJUSTMENT
hole to be used). PROCEDURE.

© 2002—TMC/ATA
RP 609B — 2
 Fig. 2: Self-Adjusting Brake Adjuster Types

C. Self-Adjusting Brake Adjuster Removal— D. Self-Adjusting Brake Adjuster Installation—

1. Remove the clevis and link pins and the an- 1. Ensure that the brake chamber is installed in
chor bracket nut or pawl, if necessary (see the bracket holes appropriate for the self-
Fig. 2). adjusting brake adjuster arm length.
a.Style A—Remove the clevis and link pins. 2. Clean the camshaft splines.
b.Style B—Remove the retaining ring quick 3. Coat the camshaft splines and the end of the
connect yoke. brake chamber push rod with an anti-seize
c. Style C—Remove the pawl, clevis, and type product.
link pins. 4. Install either a quick connect nut or threaded
d.Style D—Remove the clevis pin and clevis on the brake chamber push rod per the
anchor bracket nuts. manufacturer’s recommendations. Some
manufacturers offer both quick connect and
2. Remove the retaining mechanism from the threaded clevises.
end of the brake cam shaft. 5. Install the self-adjusting brake adjuster on the
3. Rotate the adjusting mechanism to back the camshaft.
self-adjusting brake adjuster out of the clevis, 6. Install the self-adjusting brake adjuster retain-
if necessary. ing mechanism on the end of the brake cam
4. Remove the self-adjusting brake adjuster from shaft, being sure to shim it to less than 0.060
the spline end of the brake cam shaft. inch of end play.
7A. Rotate the adjusting mechanism to either
NOTE: If a manual brake adjuster is being install a clevis and link pin or to connect the
removed to be replaced with a self-adjusting clevis with a quick connect nut (see Fig. 2,
brake adjuster, the manual or threaded clevis Styles A, B, and C).
must be removed from the brake chamber 7B. For Style D, install the anchor bracket loosely
push rod (with Style D self-adjusting brake and then rotate the adjusting mechanism to
adjuster, the existing clevis is used and addi- install the clevis pin.
tional anchor bracket hardware is required). 8A. Using the correct gauge or template, (see
Leave the jam nut on the push rod. Fig. 2, Styles A, B, and C) check for the proper
mounting angle. Adjust the clevis for the cor-
rect angle, if necessary.

© 2002—TMC/ATA
RP 609B — 3
spring pressure is relieved from the clevis. Work the Style C). The pawl must be installed properly
adjusting nut 1/4 turn back and forth while watching and tightened to 15 - 20 ft-lbs after backing off
for cam rotation. If you have 1/8 to 1/4 turn of play the adjuster.
without the cam rotating, the manual brake should be 2. Apply the brakes several times and observe
replaced. Repeat this procedure every 1/4 turn of the whether the adjustment mechanism is rotat-
adjusting nut to check the whole gear set. ing in the direction needed to reduce brake
chamber pushrod stroke. If the adjusting
Self-Adjusting Brake Adjuster Failure Analysis— mechanism does not rotate, the brake ad-
If the power stroke is at or more than the maximum juster should be replaced.
stroke, measure free stroke and check/inspect the 3. Check back-off torque by rotating the adjust-
adjuster components and attaching hardware to ing hex as follows (see Fig. 2):
determine if the slack adjuster is operational. • Style A: Minimum 15 ft-lbs counter clock-
wise (CCW)
FREE STROKE MEASUREMENT • Style B: Minimum 15 ft-lbs CCW
Free stroke is the amount of brake arm movement • Style C: Less than 45 in-lbs CCW (pawl
required to move the brake shoes against the drum. removed)
To measure free stroke, perform the following: • Style D: Minimum 15 ft-lbs CCW
1. With the brakes released, measure from the
brake chamber face to the center of the clevis Consult the manufacturer for more information.
pin.
2. With a lever, pry the brake adjuster arm until PREVENTIVE MAINTENANCE
the brake shoes contact the drum and mea- Every month, 8,000 miles, or 300 operating hours,
sure the brake adjuster movement check brake chamber push rod travel;chamber stroke
(see Fig. 6). should be in compliance with the maximum allow-
3. The difference between the brake released able adjusted strokes indicated in Table 1, without
and applied measurements is the free stroke. the brakes dragging or the pushrod binding. Adjust
The free stroke should be 3/8" - 5/8". If the free manual slacks if necessary. Due to different operat-
stroke is in the correct range, the out of spec ing conditions, adjustments may be necessary at
stroke is due to a foundation brake problem. earlier intervals.
Check for missing or worn components,
cracked brake drums, or improper lining-to- Every 6 months, 50,000 miles, or 1,800 operating
drum contact. If the free stroke is greater than hours, lubricate all brake adjusters and clevis pins
recommended, a self-adjusting brake adjuster with manufacturer’s recommended lubricant. Check
function test should be performed. for worn clevises, clevis pins, clevis pin bushings,
and worn or broken control arm/attaching brackets.
SELF-ADJUSTING BRAKE ADJUSTER Failure to replace worn, broken, or disconnected
FUNCTION TEST components will increase chamber stroke. Lubrica-
1. Remove the pawl, then rotate the adjusting tion and inspection may be necessary at earlier,
mechanism at least one complete turn as if intervals due to different operating conditions.
backing off the brake adjustment (see Fig. 2,

© 2002—TMC/ATA
RP 609B — 7
 Recommended Practice
RP 618 VMRS 018

WHEEL BEARING ADJUSTMENT PROCEDURES

PREFACE adjusting the wheel bearings. Failure to do this
The following Recommended Practice is subject to may result in improper wheel bearing adjust-
the Disclaimer at the front of TMC’s Recommended ment.
Maintenance Practices Manual. Users are urged to
read the Disclaimer before considering adoption of REFERENCES
any portion of this Recommended Practice.
TMC RP 622,Wheel Seal and Bearing Removal,
Installation and Maintenance.
OBJECTIVE
The goal of this Recommended Procedure is to
PROCEDURES
achieve a verifiable wheel bearing end play of
Step 1: Lubricate the bearing with clean axle lubri-
0.001" to 0.005" (0.025 mm to 0.127 mm).
cant of the same type used in the axle sump or hub
assembly.
SCOPE
The following service procedures apply to steer,
IMPORTANT
drive, and trailer axle assemblies using conven-
(a) In oil bath systems that rely on differential
tional double nut or single nut systems. Follow
these service procedures carefully to prevent pre- fill to provide lubricant to the wheel seals,
mature wheel end component failure and increase do not pack bearings with grease before
seal and bearing life. installation. Grease will temporarily re-
strict or prevent the proper circulation of
ABS (anti-lock braking systems) and traction con- axle lubricant and may contribute to wheel
trol systems with wheel end sensing require precise seal failure.
bearing adjustment to function properly.
(b) Never use an impact wrench to adjust
This Recommended Practice details proper service wheel bearings.
procedures for D-type, bendable-type, and dowel-
type spindle nut washers. Step 2: After the wheel hub and bearings are as-
sembled on the spindle or axle tube, torque the
NOTE: For single nut self-locking systems, consult inner (adjusting) nut to 200 lbf• ft (271 N•m) while
manufacturers’ instructions. rotating the wheel hub assembly. Refer to Table 1
at the end of this Recommended Practice.
If you have a system that differs from what is
indicated in this procedure, consult the vehicle Step 3: Back off the inner (adjusting) nut one full
manufacturer’s recommended procedure. turn. Rotate the wheel.

WARNING: Never work under a unit supported Step 4: Re-torque the inner (adjusting) nut to 50
by only a jack. Always support the vehicle with lbf• ft (68 N•m) while rotating the wheel hub assem-
stands. Block the wheels and make sure the unit bly. Refer to Table 1 at the end of this Recom-
will not roll before releasing brakes. mended Practice.

CAUTION: If your axle is equipped with spoke Step 5: Back off the inner (adjusting) nut. Refer to
wheels and the rim clamps have been disas- Table 1 at the end of this Recommended Practice
sembled to remove the tire and rim assembly, for the proper back-off amount.
the tire and rim assembly must be reinstalled
and the rim clamps properly torqued BEFORE Step 6: Install the locking washer.

©2003—TMC/ATA Issued 3/93

RP 618-1
If dowel pin and washer (or washer tang and nut flat) (d) Grasp the wheel assembly at the 3 o’clock and
are not aligned, remove the washer, turn it over and 9 o’clock positions. Push the wheel assembly in and
reinstall. If required, loosen the inner (adjusting) nut out while oscillating it to seat the bearings. Read
just enough for alignment. bearing end play as the total indicator movement.

IMPORTANT NOTE: If end play is not within specification,

Never tighten the inner (adjusting) nut for readjustment is required.
alignment at this point of the procedure. This
may pre-load the bearing and cause premature Step 9: RE-ADJUSTMENT PROCEDURE
failure.
Excessive End Play
Step 7: Install and torque the outer (jam) nut. Refer If end play is too loose, remove the outer (jam) nut
to Table 1 at the end of this Recommended Practice and pull the washer away from the inner (adjusting)
for proper torque values. nut, but not off the spindle. Tighten the inner (adjust-
ing) nut to the next alignment hole of the washer.
NOTE: This adjustment allows the wheel to Reassemble the washer and re-torque the outer
rotate freely with 0.001" to 0.005" (0.025 mm to (jam) nut. Refer to Table 1 for torque values. Verify
0.0127 mm) end play. end play with a dial indicator.

Step 8: Verify end play with a dial indicator. Wheel Insufficient End Play
end play is the free movement of the tire and wheel If end play is not present, remove the outer (jam) nut
assembly along the spindle axis. and pull the washer away from the inner (adjusting)
nut, but not off the spindle. Loosen the inner (adjust-
(a) Make sure the brake drum-to-hub fasteners are ing) nut to the next alignment hole of the washer.
tightened to the manufacturers’ specifications. Reassemble the washer and re-torque the outer
(jam) nut. Refer to Table 1 for torque values. Verify
(b) Attach a dial indicator with its magnetic base to end play with a dial indicator.
the hub or brake drum.
FINE TUNING THE ADJUSTMENT
(c) Adjust the dial indicator so that its plunger or If, after performing the readjustment procedures,
pointer is against the end of the spindle with its line end play is 0.004" - 0.005" (0.102 mm - 0.127 mm)
of action approximately parallel to the axis of the range, repeat the appropriate procedures, remov-
spindle. See Fig. 1. ing the washer from the spindle, tighten or loosen

With indicator mounted at bottom

With indicatorat
push/pull mounted at bottom
sides of drum
push/pull at sides of drum

(a) with tire assembly (b) without tire assembly

Fig. 1: Dial Indicator Set-Up

©2003—TMC/ATA
RP 618-2
the inner adjusting nut the equivalent of 1/2 of an the inner and outer nut. Bend the tangs over the
alignment hole of the washer, or reversing the closest flap perpendicular to the tang. See Fig.
alignment washer, and reinstalling it onto the spindle. 2.
Reassemble and re-torque the outer (jam) nut.
Refer to Table 1 for torque values. Verify end play CAUTION: Before operating the unit, the wheel
with a dial indicator. hub cavities and bearings must be lubricated to
prevent failure. For final wheel end assembly
NOTE: Bendable-type washer lock only: Secure refer to TMC RP 622.
nuts by bending one wheel nut washer tang over

SINGLE NUT ADJUSTMENT TANG-TYPE LOCK ADJUSTING NUT SPINDLE WASHER-TYPE

ADJUSTING NUT
Bend tangs Wheel bearing
perpandicular adjusting nut
Adjusting
nut to closest (inner)
Nut flat
lock

Dowel pin
Wheel bearing
Outer adjusting Spindle washer
Cotter
“D” Washer nut nut (inner) Outer nut
pin

“D” Type “Tang” Type “Dowel” Type

Fig. 2: Adjusting Nut Identification and Installation

©2003—TMC/ATA
RP 618-3
 TABLE 1

WHEEL BEARING ADJUSTMENT PROCEDURE

STEP 1: Lubricate the wheel bearing with clean axle lubricant of the same type used in the axle sump or hub assembly.
Note: Never use an impact wrench when tightening or loosening lug nuts or bolts during the procedure.

INITIAL INITIAL FINAL BACK OFF JAM NUT TORQUE ACCEPTABLE

ADJUSTING BACK OFF ADJUSTING AXLE THREADS FINAL NUT TORQUE END PLAY
NUT NUT TYPE PER INCH BACK OFF SIZE SPECIFICATIONS
TORQUE TORQUE
STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8

12 1/6 Turn *
Install Cotter Pin to Lock
Axle Nut in Position
18 1/4 Turn *
Steer
(Front)
Non-Drive
14 200-300 lb•ft 0.001"-0.005"
Less Than
1/2 Turn 2-5/8" (271-407 N•m) (.025-.127 mm)
200 lb•ft One 50 lb•ft (66.7 mm)
18
(271 N•m) Full (68 N•m)
While While
Turn Dowel
Rotating Rotating 300-400 lb•ft As Measured
12 Type
Wheel Wheels (407-542 N•m) Per Procedure
Washer
Drive 1/4 Turn With Dial
Tang Type 200-275 lb•ft Indicator
16 (271-373 N•m)
Washer **

12 300-400 lb•ft
2-5/8"
Trailer 1/4 Turn (66.7 mm) (407-542 N•m)
and over
16

* If dowel pin and washer (or washer tang and nut flat) are not aligned, remove the washer, turn it over, and reinstall. If
required, loosen the inner (adjusting) nut just enough for alignment.
** Bendable type washer lock only: Secure nuts by bending one wheel nut washer tang over the inner and outer nut. Bend
the tangs over the closest flat perpendicular to the tang.

©2003—TMC/ATA
RP 618-4
35
 Recommended Practice

RP 631A VMRS 018

RECOMMENDATIONS FOR WHEEL END LUBRICATION

PREFACE
The following Recommended Practice is subject Hub
to the Disclaimer at the front of TMC’s Recom-
mended Maintenance Practices Manual. Users Outboard Seal
are urged to read the Disclaimer before consid- Bearing
ering adoption of any portion of this Recom-
mended Practice. Adjusting Nut

PURPOSE AND SCOPE Inboard

The purpose of this Recommended Practice is to Hubcap Bearing
offer equipment users recommendations and
operational considerations for selecting lubri-
cants for use in wheel end applications. Lubricant
Cavity
Wheels
This Recommended Practice applies to Class 3-
8 trucks, buses, tractors, and trailers designed Fig. 1: Non-Drive Wheel End
for on-highway applications.

This Recommended Practice applies to only “tradi- Other relevant TMC Recommended Practices
tionally” equipped axles and hubs. This Recom- include:
mended Practice defines “traditionally” equipped • RP 624, Lubricant Fundamentals.
axles and hubs as wheel ends equipped with two • RP 709, Hubcap Standardization — Bolted-
single row, widespread, tapered roller bearing as- On Type.
semblies which are manually adjusted.

This Recommended Practice addresses

two categories of wheel ends: driven and
non-driven. Non-driven wheel ends include
Brake
steer, dolly, trailer, pusher and tag axles.
Drum
(See Figures 1 and 2).
Hub
The lubricant used in the wheel ends can be Outboard
either petroleum-based or synthetic- Bearing Seal
based oils or greases.
Adjusting Nuts
REFERENCE Drive Axle
For additional information on wheel bearing Shaft
adjustment, installation and maintenance,
refer to TMC: Gasket Spindle
• RP 618, Wheel Bearing Adjustment
Procedures . Oil Cavity
Inboard
• RP 622, Wheel Seal and Bearing Bearing
Removal, Installation, and Mainte-
Wheels
nance.
Fig. 2: Drive Axle Wheel End

©2003—TMC/ATA Issued 3/96

RP 631A—1
Revised 11/1999
Fleet managers should also reference original equip-
ment manufacturer (OEM) maintenance and service
manuals as appropriate.

NON-DRIVEN AXLE LUBRICANT

CONSIDERATIONS
Non-driven wheel ends can be lubricated effectively
with either oil or grease, depending on the fleet
application. Both lubricating substances use oil as
the lubricating medium. (Refer to RP 624, Lubricant Fill to
Fundamentals for details.) oil level line

A. Non-Driven Oil-Lubricated Wheel Ends

Inspection and Preparation

Clean and inspect the wheel end components includ-
ing all bearings, hubcaps, hub and bearing cups, Fig. 3: Lubrication Fill Oil (Static)
axle spindle, and fasteners, removing all contami-
nants and lubricant residue. Replace seal, hubcap Hubcap Considerations: Oil
gasket, and all questionable parts. For detailed pro- Select the proper vented, bolt-on or threaded hubcap
cedures, refer to TMC RP 622. for the application and follow hubcap suppliers’ in-
structions for proper attachment to the wheel hub. Fill
Component Lubrication wheel end assembly through the fill port with the
Pre-lubricate the inner and outer wheel bearing same oil. Allow time for the oil to seep through the
cones with clean lubricant of the same type used in outer bearing and fill the hub cavity. Continue to add
the hub assembly. oil until the oil reaches the oil fill line as indicated on
the hubcap. (See Figure 3.)
! CAUTION : Failure to lubricate bearing correctly,
and maintain proper lubrication, may result in bear- NOTE: For hubcaps with side fill plugs, do not allow
ing damage. For additional information refer to TMC the oil to go past the centerline or vent hole.
RP 618 and RP 622.
! CAUTION : Overfilling or under filling a wheel hub
! CAUTION : In oil bath systems, do not pack bear- with lubricant may result in premature component
ings with grease before installation. Grease will failure.
temporarily restrict or prevent the proper circulation
of lubricant and may contribute to wheel seal failure. Install center fill or side fill plug. Torque side fill plug
to hubcap manufacturer’s specifications. Clean-up
Hub Fill Procedures: Oil any over spills that would give the appearance of a
Install the wheel seals as documented in RP 622. leaking hubcap.
Apply lubricant to the bearing journals and bearing
cones. Use the same lubricant that will be used to B. Non-Driven Grease-Lubricated Wheel Ends
lubricate the system. This will help inhibit fretting
corrosion and make assembly easier. Use lifting NOTE: Semi-fluid greases are NLGI 000 and 00.
equipment to align the hub assembly with the spindle NLGI 0 is a soft grease. All three grades listed above
taking care not to damage the seal and spindle are treated as semi-fluid greases in this RP. Hard
threads. While the hub is supported/suspended, fill greases are defined as NLGI 1, 2, and 3 consisten-
the hub cavity with clean oil and push the hub into cies in this RP.
position, or push the hub into position and then fill the
hub cavity. Inspection and Preparation
Clean and inspect the wheel end components includ-
Install the outer bearing, and adjusting nut systems. ing all bearings, hubcaps, hub and bearing cups,
Adjust wheel bearings using TMC RP 618 or OEM axle spindle, and fasteners, removing all contami-
Maintenance Manual. Verify end play (0.001" to nants and lubricant residue. Replace seal, hubcap
0.005") with a dial indicator.

©2003—TMC/ATA
RP 631A—2
 : If grease packing is done by hand,
appropriate protection — such as gloves and cloth-
ing — should be worn to minimize skin contact with
the grease.
Mandatory
Grease Area
! CAUTION : Overfilling or under filling a wheel hub
with lubricant may result in premature component
failure.

Hub Fill Procedures: Semi-fluid Grease

If tires are not mounted, install the hub on the spindle.
Fig. 4: Packing of Bearing Cone Take care to not damage the seal. Use lifting equip-
ment to align the hub assembly with the spindle
gasket, and all questionable parts. For detailed pro- taking care to not damage the seal and spindle
cedures, refer to TMC RP 622. threads and push the hub assembly into position.
NOTE: If retrofitting an oil or grease system with a With the hub supported, before installing the outer
semi-fluid grease, be sure to note the need for bearing cone, begin filling from the bottom of the hub
special cleaning instructions, fill procedures and cavity. Top-off by placing the pump nozzle above the
equipment (i.e., vented hubcap). spindle, and continue pumping grease into the hub
cavity. (See Figure 5.)
Component Lubrication
Pack the inner and outer wheel bearing cones full
with grease. Work the grease into the bearing in the
direction of the arrow shown in Figure 4 by machine
or hand such that the grease goes under the bearing
cage toward the cone rib and roller ends.
Cup Small Inside
Diameter
For corrosion prevention, place a light film of grease CONE
on all metal components, including the hubcap. Wipe
off the excess grease. Install the wheel seals as ROLLER

described in TMC RP 622.

CUP
CAGE
CUPS

! CAUTION : Failure to lubricate bearing correctly

and maintain proper lubrication may result in bearing
Fig. 5B: Tapered Bearing Nomenclature
damage. For detailed procedures, refer to TMC RP
618 and RP 622.

Apply Grease Around

Adjusting Nut

Fig 5A: Lubrication Fill

Fig. 5: Semi-Fluid Grease Top Off Procedure Semi-Fluid Grease (No. 00)

©2003—TMC/ATA
RP 631A—3
 Maintenance Manual. Verify end play (0.001" to
0.005") with a dial indicator. Before installing the
hubcap, apply a coating of grease around the wheel
bearing adjustment nut(s).

Hubcap Considerations: Semi-fluid Grease

Use an appropriate tamper-proof, vented hubcap.
These hubcaps prevent gear oils from being acci-
dentally added to grease-filled wheel ends.

NOTE: Because of the hubcap’s special venting

capability and the properties of the semi-fluid grease,
do not fill the hubcap with grease.

Fig. 5C: Using Template to Hold Lubricant NOTE: If a metal hub cap is used, it is necessary to
coat the interior surfaces with a film of grease. Use
The grease fill amount should be to a 3 o’clock and special care not to cover the vent with grease.
9 o’clock level. This represents 50 percent hub cavity
fill. (See Figures 5A and 5B.) Hub Fill Procedures: Hard Grease
Before installing the hub, pack grease into the hub
NOTE: A template may be used to hold the lubricant cavity. Fill the circumference of the hub cavity using
in place while filling the hub cavity. (See Figures 5 the bearing races as the proper level guide. (See
and 5C.) Figure 6.)

Use lifting equipment to align the hub assembly with

! CAUTION : Make sure that there are no air-pock-
the spindle taking care to not damage the seal and
ets trapped under the grease. If pumping equipment
spindle threads. Push the hub assembly into position.
is used, ensure the pump does not aerate the grease.
Aeration of the grease may result in underfilling.
Install the outer bearing, washers and adjusting nuts.
Adjust wheel bearings per TMC’s RP 618 or OEM
Install the outer bearing, washers and adjusting nuts.
Maintenance Manual. Verify end play (0.001" to
Adjust wheel bearings per TMC’s RP 618 or per OEM

Fig. 6: Lubrication Fill Greases (Nos. 1,2, & 3)

©2003—TMC/ATA
RP 631A—4
0.005") with a dial indicator. Apply a coating of Install the outer bearing, washers and adjusting nuts.
grease around the adjusting nut(s). Adjust wheel bearings per TMC’s RP 618 or OEM
Maintenance Manual. Verify end play (0.001" to
Hubcap Considerations: Hard Grease 0.005") with a dial indicator.
Use an appropriate tamper-proof, hubcap. These
hubcaps prevent gear oils from being accidentally Install the flanged drive axle shaft with a new axle
being added to grease-filled wheel ends. Follow the flange gasket. Torque flange nuts to axle
recommendation of the seal supplier to determine if manufacturer’s specification. Clean-up any over spills
the hubcap should be vented or non-vented. that would give the appearance of a leaking system.

NOTE: If a metal hub cap is used, it is necessary to Oil is supplied directly to the wheel ends at assembly
coat the interior surfaces with a film of grease. Use and through the axle tube during operation. To
special care not to cover the vent with grease. achieve final fill level, each end of the drive axle must
be raised a minimum of eight inches for one minute
DRIVEN AXLE LUBRICANT WHEEL END to move the lubricant into the opposite wheel end.
CONSIDERATIONS Recheck the main sump for the proper oil level and
top off the lubricant level, if required. The oil fill level
NOTE: In this Recommended Practice, all driven is always to the bottom of the fill plug or hole in the
axles are oil lubricated. axle reservoir.

Inspection and Preparation ! CAUTION : Do not pack the drive axle wheel
If the wheel end is disassembled, clean and inspect bearings with grease when the wheel ends will be
the wheel end components including all bearings, lubricated with oil from the axle differential. (See RP
axle shafts, hub and bearing cups, axle, and fasten- 622 and RP 618.)
ers, removing all contaminants and lubricant resi-
due. Replace seal, axle flange gasket, and all ques- NOTE: Always check the axle breather to be sure it
tionable parts. For detail procedures, refer to TMC is operating properly and completely free of dirt and
RP 622. debris.

Component Lubrication MAINTENANCE AND INSPECTION

Pre-lubricate the inner and outer wheel bearing REQUIREMENTS
cones with clean lubricant of the same type used in The following inspection criteria are intended for
the axle reservoir. units whose vocation is strictly on-highway use only.
The inspection criteria are not intended for unitized
! CAUTION : Failure to lubricate bearing correctly or pre-set wheel ends, refer to systems manufacturer
and maintain proper lubrication may result in bearing for inspection and service recommendations.
damage. For additional information refer to TMC RP
618 and RP 622. These recommendations depend on the proper as-
sembly of the system, including the proper lubricant
! CAUTION : In oil bath systems, do not pack bear- fill level.
ings with grease before installation. Grease will
temporarily restrict or prevent the proper circulation A. OIL LUBRICATED WHEEL ENDS
of lubricant and may contribute to wheel seal failure. INSPECTION CRITERIA

Hub Fill Procedures: Oil Level 1—Simple Inspection (Pre-Trip/In-Service)

Install the wheel seals, as documented in RP 622. Fill Walk around vehicle and check wheel-ends for obvi-
hub cavity with oil. Use lifting equipment to align the ous signs of lubricant leakage, such as hubcap
hub assembly with the spindle taking care to not gasket and wheel seal areas, oil soaked brake lin-
damage the seal and spindle threads. Push the hub ings. Check for broken or missing components. Any
assembly into position. seepage is reason for further inspection and appro-
priate action.
While the hub is supported, fill the hub cavity with
clean oil and push into position or push into position Take appropriate action if leaks or oil soaked brake
and then fill the hub cavity. linings are noted.

©2003—TMC/ATA
RP 631A—5
NOTE FOR DRIVERS: After making an en route stop, reason for further inspection and appropriate action.
walk around the unit and feel the hubs. If there is any
significant differences in temperatures or excessive Raise the vehicle and check for smooth rolling of
temperature, contact your maintenance department. wheels. Check for signs of excessive end play in the
When feeling hubs for temperature, seasonal influ- wheel-end. This does not include removal of the hub
ences should be taken into consideration. cap.

If wheel-ends are equipped with a sight glass on the NOTE: Leaking grease may not spread over the hub
hubcaps, check to ensure the oil is at the proper fill and brake components as with hubs filled with oil.
level. When inspecting for grease leaks the inspection
must be done very carefully with the aid of a bright
NOTE: Oil residue may be present at the vent area. beam of light from a flashlight or droplight.
This is an indicator that the system is venting properly.
This should not be construed as system leakage. NOTE: Some grease seals will purge very small
amounts of grease in normal operation.
Level 2—100,000 miles or Annual Inspection:
For non-driven axles check lubricant level and con- If there is seepage around the hubcap flange area,
dition. If lubricant is contaminated replace old lubri- take appropriate action to eliminate seepage as
cant with the same type lubricant. If lubricant condi- directed by your maintenance instructions.
tion is good and level is low, fill to the proper level.
Check for any signs of leakage at the seal or hubcap If leakage in the seal area is found, remove the wheel
gasket areas. Check for oil soaked brake linings. end and replace the hubcap gasket, seal and lubri-
cant. Inspect the spindle and bearings for damage
For driven axles, check for any signs of leakage at and replace if needed. Anything abnormal requires
the seal or axle flange gasket areas. Also check for Level 3 Inspection.
leaks at hub fill hole if so equipped. Check for oil
soaked brake linings. ! CAUTION : A clogged vent can damage the wheel
seal allowing internal pressure build up in the wheel
Take appropriate action if leaks or oil soaked brake end.
linings are noted.
Level 3—Lube Level Inspection
B. GREASE LUBRICATED WHEEL ENDS (Per OEM Recommendation)
INSPECTION CRITERIA When using grease in a wheel-end the only method
to accurately check the lubricant level is by pulling
Level 1—Simple Inspection (Pre-Trip/In-Service) the outer bearing. If using a hard grease, there is no
Walk around vehicle and check wheel-ends for obvi- need for a Level 3 Inspection.
ous signs of lubricant leakage, such as hubcap
gasket and wheel seal areas, grease soaked brake
! CAUTION : Failure to remove the outer bearing
linings. Check for broken or missing components.
may provide a false lubricant level reading.
Any seepage is reason for further inspection and
appropriate action.
To verify proper lube level the following procedures
need to be performed.
NOTE FOR DRIVERS: After making an en route stop,
1. Before performing any maintenance on the
walk around the unit and feel the hubs. If there is any
vehicle take appropriate action to ensure the
significant differences in temperatures or excessive
vehicle is safely secured.
temperature contact the maintenance department.
2. Remove hubcap, hubcap gasket and inspect
When feeling hubs for temperature, seasonal influ-
hubcap for adequate venting capabilities.
ences should be taken into consideration.
3. Verify wheel-bearing end play for conform-
ance to RP 618.
Level 2—Detailed External Inspection
4. Record end play measurements.
(Conducted at PM or at least annually)
Check wheel-ends for obvious signs of lubricant
leakage, such as hubcap gasket and wheel seal ! CAUTION : Apply the parking brake, if axle is
areas, grease soaked brake linings. Any seepage is equipped. This will ensure that the wheel/hub

©2003—TMC/ATA
RP 631A—6
 assembly is supported and held steady during Lube change intervals as determined by the manu-
removal of the spindle nut and outer bearing. facturer dictate when Level 4 service is performed.
This will eliminate the possibility of spindle, bear-
ing or seal damage due to the cocking or slipping NOTE: Manufacturer is defined as the final assem-
of the wheel-hub assembly. bler of the product or the particular system supplier.

! CAUTION : Care should be taken so the When reassembling industry standard wheel-ends,
wheel-end assembly is properly supported. assemble per RP 622 and RP 618. Seals and gas-
kets must be replaced.
5. Remove adjusting nuts.
6. Remove outer bearing. Failed Component Analysis
7. While maintaining proper support to the wheel- Save prematurely failed parts and lube samples for
end or hub, visually check lube level. In a analysis. The lubricant sample collected should be at
semi-fluid grease system, if the lubricant flows least four ounces. A similarly sized new lubricant
out of the hub cavity, the hub cavity should be sample (not previously used) is also required. This
refilled to the 3 o’clock and 9 o’clock level. This will aid in supplier assisted detection and prevention
represents 50 percent hub cavity fill. (See of premature failures. The components’ history of
Figures 5 and 5A.) usage should also be provided (i.e., vehicle’s voca-
tion, mileage, maintenance records, and history of
In a semi-fluid grease system, if the grease inspection and repair/replacement of components
doesn’t flow, inspect lubricant condition in the such as seals, seal wear rings, lubricant, bearings,
hub cavity. Go to Level 4 Inspection if abnormal etc.).
conditions are noted. If no abnormal conditions
are noted, add grease until it flows out of the hub OPERATIONAL CONSIDERATIONS FOR
cavity. LUBRICANTS
Service interval ranges from 100,000 miles to five
NOTE: If changing grease types or brands, years in over-the-road service, depending on axle
contact your lubricant supplier to insure compat- type, manufacturer recommendations, and lubricant
ibility. performance. Mineral oil based lubricants have lower
initial costs than synthetics lubricants, but need to be
8. Clean bearing and inspect for wear and changed more frequently in some equipment. When
damage. When reassembling industry stan- choosing a lubricant, the fleet needs to consider:
dard wheel-ends, assemble per RP 618. • the manufacturer’s recommendation for the
axle make and model in service.
NOTE: Manufacturer is defined as the final as- • the fleet savings associated with extended
sembler of the product or the particular system service intervals.
supplier. • the total cost of the lubricant.

Level 4—Wheel-end Disassembly Inspection NOTE: Because seal performance may vary when
(Complete System Tear-down) switching lubricants, consult your seal supplier for
If any abnormal conditions are found during inspection compatibility concerns.
Levels 1, 2, or 3, remove wheel-end for inspection.

©2003—TMC/ATA
RP 631A—7
11621.SLDDRW 4/28/2009 8:36 AM

REV. DESCRIPTION ECN DATE BY NOTES:

A NEW DRAWING - 03/01/95 RON WELD PROCEDURE 1. AXLE SEATS TO BE CLAMPED SECURELY IN THE PROPER POSITION WITH
ARMS PARALLEL AND SQUARED IF ASSEMBLED.
B
C
CORRECTED NOTE 4
ADDED DANA & MERITOR SPECS
3042
3042
12/03/03
12/09/03
JFF
JFF
FOR 1/2 ROUND ARM/SEAT 2. THE WELDING RODS SHOULD CONFORM TO AWS GRADE E-7018 (OVEN-DRIED)
OR COMPARABLE. USE COMPARABLE WIRE IS USING MIG WELDER.
D ADDED SUDISA NOTE 4 3042 12/10/03 JFF TO AXLE ONLY DO NOT
WELD IN
3.
4.
AXLE TUBE AND AXLE SEATS MUST BE CLEANED.
DO NOT WELD AXLES WHEN AXLES ARE COLD. NORMAL PREHEAT
3.00
E
F
CHANGED NOTE 4 & 6
CHANGED NOTE 4 BACK
C-5073
C-5305
12/26/07
04/03/08
EFR
EFR
FOR OTHERS SEE PAGE 2 TOP
THIS AREA! RECOMMENDATIONS ARE BETWEEN 100 AND 300 DEGREES F. CONSULT
AXLE MANUFACTURER IF NECESSARY.
G INTO SOLIDWORKS AND UPDATED C-6299 4/22/2009 TEG E --IMT REQUIRES 60-200 F PRIOR TO WELDING.
--DANA REQUIRES AXLE AND MATING BRACKETS MUST BE 60 F PRIOR TO WELDING.
F --MERITOR REQUIRES AXLE TUBE AND HARDWARE BEING WELDED TO AXLE TO BE
2.00 MAX
MINIMUM OF 60 F PRIOR TO WELDING.
ACCEPTABLE D --SUDISA REQUIRES AXLE TUBE AND HARDWARE BEING WELDED TO AXLE TO BE
WELD AREA MINIMUM OF 60 F PRIOR TO WELDING.
1.50 MAX IF OTHER MANUFACTURER'S AXLE IS USED, CONSULT THEM PRIOR TO WELDING,
FOR PREHEAT SPECIFICATIONS.
5. APPLY WELDS IN THE SIZES AND SEQUENCE SHOWN IN FIRGURE 1, AND 3.
APPLY WELDS IN AREAS SHOWN IN FIGURE 4. THE ELECTRODE SHOULD BE
BACKED UP TO FILL IN THE FILLET CRATER AT THE END OF EACH PASS.
BOTTOM E THE CORNERS SHOULD BE WRAPPED. CLEAN THE WELD BETWEEN EACH PASS.
4.00 DO NOT 6. SEQUENCE 1 SHOULD BE PERFORMED ON BOTH AXLE SEATS PRIOR TO
WELD IN CONTINUING WITH PASSES 2 AND 3. THE SEQUENCE SHOULD BE PASS #1
THIS AREA! ON BOTH AXLE SEATS, THEN PASS 2 AND 3 ON EACH SEAT IN SERIES.
FIGURE2

3 PASS 3 PASS
2 PASS 2 PASS
FIGURE 3 1 PASS
1.00 1 PASS
CL AXLE CL AXLE
1.00

SEE FIGURE 2
FOR MAX
CL

START FIGURE 1 START

WELD PROCEDURE
FOR 1/2 ROUND ARM/SEAT
TO AXLE ONLY
FOR OTHERS SEE PAGE 2
DO NOT "TEST THE ARC" ON THE AXLE BEAM WELD PROCEDURE
FOR 1/2 ROUND ARM/SEAT
.38 .50
TO AXLE ONLY
.38 .38 .50 FOR OTHERS SEE PAGE 2
DEPTS TOLERANCES DESCRIPTION:
AFFECTED (EXCEPT AS NOTED) AXLE SEAT WELDING SPECS
DECIMAL PREVIOUS ASSY: SHEET:

- .06 - 1 OF 2
SUSPENSION MODEL: SCALE:
FRACTIONAL
FIRST PASS SECOND PASS THIRD PASS - 1/16 - 1:1
FIGURE 3 NOTE: PARENTHESIS ( ) DENOTES
WEIGHT: ANGULAR DATE: DRAWN BY: SIZE: DRAWING NO:

REFERENCE DIMENSION - 1 03/01/95 RON B 11621

11621.SLDDRW 4/28/2009 8:36 AM

WELD PROCEDURE FOR MONO PIVOT BUSHING TYPE ARMS Welding Procedures
Preparation
REFER TO ES006 FOR ALIGNMENT TO AXLE Warning ! Clean welds between passes and incorporate tacks
into the first pass on the tacked side. Fill weld craters and
1. The surface must be free of paint, water, avoid undercuts and cold laps over welds.
and other contaminants where welding is to occur. Welds should not be started or stopped at the end of the weld pass.
2. Suspension parts must be at least 60°F. * Normal They should stopped and started away from the ends as shown in Figure 7.
recommendations is to preheat Do not wrap the corners of the axle seat while welding.
100-300 degrees F.
1. Three passes are required on each area where the axle is welded to the arms.
* Note: Some axle manufacturers recommend preheating Figure 6 shows the size of the weld of each pass.
the axle before it is welded. Consult the axle 2. Start welding in the sequence shown in Figure 7 at the rear side where the axle
manufacturer for recommended guidelines on and seat meet . Make all first pass welds at all areas before proceeding to the
welding to the axle. second pass.
3. Welding needs to be done in a flat horizontal position. 3. Figure 7 also shows the length of weld for both overslung and underslung models.

Welding Axle to Suspension

Weld Specifications
WELD PROCEDURE FOR COMMON:

Caution ! The welding procedures must be followed carefully

to avoid damage to the axle and suspension which could
cause an accident and or serious personal injury.

TA250/300 TOP MOUNT

TA250/300 UNDERSLUNG

AL2300
DESCRIPTION:
AXLE SEAT WELDING PROCEDURE

SHEET: 2 OF 2
DATE: SCALE: DRAWN BY: SIZE: DRAWING NO:

04/22/09 1:8 tgreaves B 11621