【ENGLISH】the Repair Manual of ST16-HC16 Drive Axle

STR-HC/ST16.
01
STR-HC/ST16.01
The Repair Manual of

STR-HC/ST16 Drive Axle
SINOTRUK No. 777 Hua'ao Road Jinan,
INTERNATIONAL Shandong Province, China, 250101
AFTER SALES SERVICE DEPARTMENT STR-HC/ST16.01
1st Edition -English-
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1st Edition
STR-HC/ST16.01
STR-HC/ST16 Drive Axle (Drum Brake)
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PREFACE
This manual provides assistance in performing repairs correctly on vehicles and units and
reflects the known technical situation appertaining at the copy deadline.
This publication assumes that persons who use it possess the requisite technical
knowledge in repairing vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do
not always correspond to the unit to be repaired or its peripherals.
The repair jobs are divided up into sections and subsections. Each subsection starts with
a page of jobs to do in advance. The jobs to do in advance contain a summary of the main
prerequisites for the repair section in question. The detailed description of work can follow
the jobs to do in advance. Only the tightening torques for screw/bolt connections which
deviate from the standard are indicated in the repair sections.
Important instructions concerning technical safety and the safety of personnel are
specifically highlighted, as indicated below.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed exactly
in order to avoid exposing people to risk.
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed exactly
in order to avoid serious or irreparable damage to property.
NOTE
An explanatory note which is useful for understanding the working or
operating procedure to be performed.
Comply with general safety regulations when performing any repair work.
We reserve the right to make modifications in the course of further development.
Best wishes from
SINOTRUK INTERNATIONAL.
PRINTER'S IMPRINT
Reprinting, copying or translation, even of extracts, is not allowed without the written
approval of SINOTRUK. All rights under the copyright law are strictly reserved by
SINOTRUK. If any changes or modifications are made without the written approval of
SINOTRUK then SINOTRUK shall not be liable for any material defects attributable to the
unauthorized changes or modifications. SINOTRUK is not liable for any damage
attributable to unauthorized changes or modifications.
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CONTENT
1. STR-HC/ST16 Drive Axle ................................................................................................ 5
1.1. Structure and Principle of STR-HC/ST16 Drive Axle ....................................... 5
1.1.1. Final Drive............................................................................................................ 6

1.1.2．Differential ....................................................................................................... 12
1.1.3. Half Axle and Axle Housing .......................................................................... 20
1.2. STR-HC/ST16 Drive Axle Assembly Process .................................................. 21
1.2.1. Sub-assembly Process .................................................................................. 21
1.2.2. Axle Assembly Process ................................................................................. 26
2. Maintenance of STR-HC/ST16 Drive Axle ................................................................ 36
2.1. Routine Maintenance ............................................................................................. 36

2.2．Correct Use of Differential Lock........................................................................ 36
2.2.1. Inter-wheel Differential Lock......................................................................... 36
2.2.2. Inter-axle Differential Lock ............................................................................ 36
2.3 .Code and Identification of Main Parts ............................................................... 37
2.3.1. Cross Shaft........................................................................................................ 37
2.3.2. Half Axle Gear................................................................................................... 37
2.3.3. Planet Gear........................................................................................................ 38
2.3.4. Planet Gear Bushing....................................................................................... 38
2.3.5. Bevel Gear Pair ................................................................................................ 39
2.3.6. Hub Oil Seal ...................................................................................................... 40
2.3.7. Rear Brake Drum ............................................................................................. 40
2.3.8. Rear Hub ............................................................................................................ 40
3. Troubleshooting ............................................................................................................. 42
3.1. Oil Leakage............................................................................................................... 42
3.1.1. Wheel Oil Leakage........................................................................................... 42
3.1.2. Leakage of Final Drive.................................................................................... 48
3.1.3. Oil Leakage of Axle Assembly ..................................................................... 49
3.2. Abnormal Sound and Heating ............................................................................. 50
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3.2.1. Wheel Abnormal Sound and Heating ......................................................... 50
3.2.2. Abnormal Sound and Heating of Final Drive............................................ 54
3.3. Common Differential Fault ................................................................................... 57
3.3.1. Common Differential Lock Mis-operation ................................................. 57
3.3.2. Common Differential Fault ............................................................................ 58
3.3.3. Note in Differential Lock Operation ............................................................ 59
3.3.4. Inspection Method of Differential Lock ..................................................... 59
3.4. Brake Failure ............................................................................................................ 59
3.4.1. Lack of Braking Force .................................................................................... 59
3.4.2. Braking Drag ..................................................................................................... 60
3.4.3. Abnormal Brake Sound.................................................................................. 60
3.5. Other Common Faults ........................................................................................... 61
3.5.1. Drive Axle not Driving .................................................................................... 61
3.5.2. Rear Wheel Deflection .................................................................................... 61
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1. STR-HC/ST16 Drive Axle

1.1. Structure and Principle of STR-HC/ST16 Drive Axle
STR-HC/ST16 Drive Axle is composed of final drive, differential, half axle and axle
housing. Its functions are shown as followings: ①To transfer engine torques from
universal driving devices to driven wheels through final drive, differential and half axle so
as to realize reducing speed and increasing torque. ② To change the direction of torque
transmission through cone gear pairs of final drive. ③ To achieve the differential effect of
wheels at two sides through differential so as to guarantee inner and outer wheels
steering with different speeds. In Figure 1-1, STR-HC/ST16 Drive Axle is composed of
final drive, differential, half axle and axle housing.
Final drive is one of major components in automotive transmission to reduce speed and
increase torque. When a transmission is not set with any overdrive gearing, the
transmission ratio of final drive shall be the minimum transmission ratio of driven system.
It can also be called as main transmission ratio. Differential is used to solve relevant
issues such as different rotation speeds of driven wheels at two sides in motor steering
and different speeds of multi-axis drive axle. Half axle is used to pass driving forces
reliably. Axle housing is an installation foundation piece of main components for
transmission and drive system.
In heavy duty truck, all drive axles are at the rear and called together as Rear Axle. Most
drive axles manufactured in SINOTRUK are double drive axles, and a few are single rear
ones. Normally, the front one of double drive axle is called as middle axle, and the rear
one as rear axle. Drive axles in SINOTRUK may be divided into two series such as STR
and HW according to their structural features.
Figure 1 Composition of Drive Axle

1 – Clutch; 2 - Transmission; 3 – Universal Joint; 4 – Drive Axle; 5 – Differential; 6 – Half Axle
7 – Final Drive; 8 – Transmission Shaft
STR series drive axle is one of products with the largest output in SINOTRUK. It is an axle
being suitable to China's national conditions through ten years of digestion, absorption
and improvement depending on introducing Austria Steyr Technology. Its feature is to add
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wheel reducer gears at central single-stage final drive. Therefore, the transmission of STR
series drive axle shall have double reductions and can also be called as double-stage
reduction axle. See Figure 1-2.
Figure 1-2 STR Series Tandem Drive Axle
As same as all drive axles, STR series drive axle is also composed of final drive,
differential, half axle and axle housing.
1.1.1. Final Drive
1. Central Final Drive
For rear final drive of STR series drive axle, see Figure 1-3.
Figure 1-3 Appearance
In Figure 1-4, the end flange of Flange 2 is connected with transmission shaft. There are
internal splines in its bore to fit with splines at the handle of Driving Bevel Gear 7 so as to
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transfer engine power from universal drive shaft to Driving Bevel Gear 7. Driving Bevel
Gear 7 can rotate around its axis under the support of two tapered roller bearings 4 and 6.
Driving Bevel Gear 7 and Driven Bevel Gear 9 can be a pair of mutually meshing bevel
gears. Their axes are perpendicular. Through their meshing, they can rotate the rotary
direction of above engine power with 90°and then transfer to Differential 15 installed
firmly with driven bevel gear. At the same time, any meshing between driving and driven
bevel gears can also reduce the power speed and increase its torque. Under the support
of Bearing 13 at two ends, Differential 15 may rotate around its axis to distribute engine
torque after speed reduction, torque increasing and commutation of driving and driven
bevel gears into two half axles.
Figure 1-4 Structure of Final Driver
1 – Flange Nut .2 – Flange .3 – O il Seal seat and oil seal assy. 4, 6, 13 – Tapered Roller Bearings 5 – Bearing
Block 7 – Driving Bevel Gear 8 – Final Drive Housing 9– Driven Bevel Gear 10 – Adjusting Nut 11 –
Round Nut 12 – Fixed Mesh Cover 14 – Seal Ring 15 – Differential Assembly
To guarantee proper meshing, the relevant position between driving and driven bevel
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gears may be adjustable. There is a group of adjustable washers (not marked in Figure1-4)
between counter-faces of Bearing block 5 and Final drive housing 8. That increasing and
reducing different thickness of washers make Driving Bevel Gear 7 and Bearing Block 5
move up and down together so as to adjust relevant positions of driving and driven bevel
gears in vertical direction. At the outside of Tapered Roller Bearing 13 at two ends of final
drive, there is one Adjusting Nut 10 respectively. That screwing in and out the nut may
make Differential Assembly 15 fastening with Driven Bevel Gear 9 move axially. The
adjustment in two above sections may adjust the mesh position of driving and driven bevel
gears to an appropriate state.
Before adjusting the above meshing state, smear red pigments (mixture of red lead
powder and oil) at tooth surface of driven bevel gear firstly, then use hands to make
driving bevel gear with reciprocating rotation. Therefore, there will be red blots at two
operating surfaces of driven bevel gear tooth. If any blot at forward and reverse operating
surfaces of driven bevel gear is at the middle of tooth height but inclined to little end as
well as is more than 60% of tooth width, it means the proper meshing. For proper meshing
blot, see Figure 1-5.
Figure 1-5 Proper Meshing Blot of Driven Bevel Gear
The final drive housing of final drive assembly is opposite to the surface of axle housing.
Then, all including Axle Housing, Final Drive Housing 8, Bearing Block 5 and Oil Seal
Block together with Oil Seal Assembly 3, Flange2 and Flange Nut 1 will surround into an
enclosed space. In the space, there is a large amount of lubricating oil to lubricate moving
parts such as bearing and gear. In assembly, there shall be oil-resistant silicone sealant
between contact surfaces of final drive housing and axle housing, between contact
surfaces of final drive housing and oil seal block, between contact surfaces of oil seal
block and bearing block and between flange nut and flange to seal the lubricating oil
reliably in the space. That between oil seal block and flange shall be installed with oil seals
respectively for dust prevention and sealing oil so as to make flange rotate around its axis
under the support of bearing but also guarantee lubricating oil not penetrating from the
clearance between flange and oil seal block.
2. Tandem Final Drive
Tandem final drive is used normally for the middle axle of tandem drive axle. It may divide
engine power from universal driving device into two sections. One is to drive middle axle,
and the other is to lead towards rear axle.
For tandem final drive of STR series drive axle, see Figure 1-6. Engine torque will pass
through transmission shaft and Flange 4 to Differential Case (front) 1 of inter-axle
differential through spline input. Inter-axle differential will distribute the above torque to
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two Half Axles 13 and 16. Tandem Axle 32 will transfer the torque of front half axle gear to
Output Flange 29 of middle axle and lead it to rear axle with one transmission shaft.
Hollow Shaft 20 uses spline to drive Driving Cylinder Gear 19 to rotate and transfer the
power of Rear Half Axle Gear 16 to Driving Bevel Gear 35 through the mesh of Driving
and Driven Cylinder Gear 19 and 38. It can transfer the power to Inter-axle Differential 34
of middle axle after realizing speed reduction, torque increasing and commutation through
the meshing of Driving and Driven Bevel Gears 35 and 33. The rest contents are same as
that of rear axle (central) final drive.
Figure 1-6 STR Series Tandem Final Drive (Middle Axle Final Drive)
1 – Differential Case (front) 2,31 – Flange Nut 3, 30 – Cotter Pin 4, 29 – Flange 5, 27, 41 – Bearing Block
6, 18, 21, 28 – Deep Groove Ball Bearing 7 – Locking Ring 8 – Lock Pin 9 – Shifting Fork 10 – Pin 11 –
Pressure Switch 12 – Half Axle Gear (Front) Washer 13 – Front Half Axle Gear 14 – Planet Gear Gasket 15 –
Inter-axle Planet Gear 16 – Rear Half Axle Gear 17 – Differential Case (rear) 19 – Driving Cylinder Gear 20 –
Hollow Axle 22 – Axial Spring Collar 23 – Round Nut 24 – Axle Housing 25 – Half Axle 26 – Sliding Mesh
Sleeve 32 – Tandem Axle 33 – Driven Bevel Gear 34 – Inter-axle Differential 35 – Driving Bevel Gear 36 –
Final Drive Housing 37 – Cylindrical Roller Bearing 38 – Driven Cylinder Gear 39 – Axle Box 40 – Spacer
Bush 42 – Tapered Roller Bearing 43 – Bearing Outer Ring Pressure Plate 44 – Axle Box Cover 45 – Half
Axle Gear (Rear) Washer 46 – Cross Shaft
3. Wheel Reducer
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Wheel reducer is another type of final drive. The total reduction ratio of STR series drive
axle equals to the product of reduction ratios of central final drive and wheel reducer. The
reduction ratios of STR series drive axle shall have series such as 3.93, 4.42, 4.8, 5.73,
6.72, 9.49 and 10.89.
For end view of STR series wheel-side planetary reducer mechanism, see Figure 1-7. In
Figure 1-7, Internal Gear Ring 1 is stationary, and Sun Gear 3 in the middle is a driving
part to fit with half axle through spline in its inner bore. Half axle drives Sun Gear 3 to
rotate after receiving engine torque transferred through clutch, transmission, universal shaft,
final drive and differential. There are five Planet Gears 2 meshing together with sun gear
and internal gear ring among them. When Sun Gear 3 is rotating, any Planet Gear
meshing with it can only rotate around its own axis but also revolute around sun gear
because internal gear ring is stationary. The above revolution speed is the output one of
planetary reducer mechanism. Now, the transmission ratio of wheel reducer is as following:
i = number of internal gear ring/sun gear +1. Obviously, i＞1. This shows that the wheel
reducer mechanism is decelerated, and this means the output speed (revolution speed of
planet gear) is less than the input speed (sun gear speed).
Figure 1-7 Planetary Wheel Reducer

1 – Internal Gear Ring 2 – Planet Gear 3 - Sun Gear
For the structure of STR series drive axle wheel reducer, see Figure 1-8. Half Axle 17
passes through Axle Housing 16 to transfer engine power with deceleration, torque
increasing and commutation through central final drive to wheel reducer. Sun Gear 29 will
fit with Half Axle 17 through spline and limit its axial position through Sun Gear Gasket 28.
Half axle is floating in axle housing. To avoid any factor such as centrifugal force because
of steering to pull half axle away externally and effect on the operation of gear in wheel
reducer, there shall be a lifting pin that its head is a sphere at the middle of End Cover 30
to press its half axle end face so as to limit it shifting. There are 5 Planet Gears 3 to mesh
with sun gear around it. Two ends of every Planet Gear are installed with a Planet Gear
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Gasket 32 to reduce any friction between planetary and relevant parts and improve the
lubricating condition of the part. The central hole of Planet Gear is installed with Planet
Axle 31. There are two Needle Roller Bearings 4 between Planet Gear and planet axle to
guarantee both with relative rotation smoothly. That between needle roller bearings can be
separated with Gasket 33. Both ends of every planet axle shall pass through
corresponding position holes of Planet Carrier 5 and Wheel Reducer Housing 1
respectively. Both planet carrier and wheel reducer housing are fastened together with
bolts. At the outside of five planet gears, Internal Gear Ring 2 meshing with planet gears
will fit with Gear Bracket 8 through spline and can be stuck in the slot of internal gear ring
with spring collar to fasten them together firmly. Gear Bracket 8 shall be fit with Axle
Housing 16 through spline. Axle housing may be connected with frame through
suspension system, and they are stationary relatively. Therefore, Gear Bracket 8 and
Internal Gear Ring 2 are stationary in the above parts. The shaft of gear bracket is
installed with Tapered Roller Bearing 22. It may support Rear Hub 21 together with
Tapered Roller Bearing 18 installed at axle housing so as to make rear hub rotate around
its axis. Three parts including Rear Hub 21, Wheel Reducer Housing 1 and Brake Drum 11
can be fastened together with Wheel Bolt 9 and Wheel Nut 10.
Figure 1-8 STR Series Wheel Reducer Mechanism

1 – Wheel Reducer Housing; 2 – Internal Gear Ring; 3 – Planet Gear; 4 – Needle Roller Bearing; 5 – Planet Carrier;
6 – O il Baffle Disc; 7 – Hole Spring Collar; 8 – Gear Bracket; 9 – Wheel Bolt; 10 – Wheel Nut; 11 – Brake Drum; 12
– Splash Cover; 13, 14, 23 – Axel Seal; 15 – Bearing Spacer; 16 – Axle Housing;17 – Half Axle; 18, 22 – Tapered
Roller Bearing;19 – Brake Shoe; 20 – O-Seal Ring; 21 – Rear Hub;24 – Round Nut; 25 – Adjustable Gasket;26 – Pilot
Pin; 27, 34 – Screw Plug; 28 – Sun Gear Gasket;29 - Sun Gear; 30 – End Cover; 31 – Planet Axle;32 – Planet Gear
Gasket; 33 – Gasket;
When Sun Gear 29 is driven by Half Axle 17 to rotate, Planet Gear 3 will mesh with Sun
Gear and Internal Gear Ring 2 to make Planet Gear rotating about Planet Axle 31 but also
revolute around sun gear so as to drive planet axle to revolute together with it. Planet axle
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is connected with Planet Carrier 5 and Wheel Reducer Housing 1 to make 1 rotating with
Rear Hub 21 fastened on it. Wheel Bolt 9 at rear hub is connected with hub so as to make
wheels having the power from engine.
That adjusting gasket thickness through Round Nut 24 can make axial position
fine-adjustment of gear bracket at axle housing so as to adjust the preload of two Bearings
18 and 22.
Wheel reducer is a relatively closed place and the oil level of lubricating oil is about at the
position of half axle centerline. In a space enclosed by End Cover 30, Wheel Reducer
Hosing 1, Rear Hub 21, Spacing Ring 15, Axle Housing 16, Axle Seal Ring 13, 14, 23 and
Half Axle, that between end cover and wheel reducer housing as well as between spacing
ring and axle housing may be smeared with sealant. That between wheel reducer housing
and rear hub may be sealed with O-Ring 20, that between spacing ring and rear hub may
be sealed with shaft seal and that between half axle and axle housing may be sealed with
shaft seal. Then, there is not any connection with outside except air vent under inner bore
of Gear Bracket 8. The air vent is higher than the level of lubricating oil not to make any
lubricating oil in wheel reducer into axle housing so as to meet the requirements that the
necessary oil level of wheel reducer shall be more than that in the middle of axle housing.
When the temperature of oil in wheel reducer is risen caused by the operation of gear and
bearing, both air and lubricating oil in wheel reducer shall be expanded at the same time.
High pressure air will be exhausted to the middle of axle housing from the above vent and
connected with the atmosphere through air vent at the upper of axle housing. There shall
be one screw plug 27 and 34 respectively at end cover and wheel reducer housing.
Through corresponding holes of these screw plugs, lubricating oil may be filled into and
discharged out of wheel reducer. At the same time, the hole of Screw Plug 27 can also be
an oil level observation hole. In oil injection, it shall be rotated to the position that is at the
same level with centerline. That filling with lubricating oil to the hole and beginning to
overflow means there has been enough oil already.
Following with continuously deepening understanding with STR series drive axle and
market competition intensification, SINOTRUK is always committed to improving the
quality of products. To improve the reliability of seal between wheel reducer housing and
rear hub, SINOTRUK changes one O-ring 20 in original STR structure into 2. To improve
lubrication conditions of central final drive and reduce oil temperature of wheel reducer,
SINOTRUK cancelled Axle Seal 23 in some axle types, and increase the oil level at the
middle section of axle housing same as that in wheel reducer. To improve the carrying
capacity of axle and reduce the failure rate of hub bearings (Tapered Roller Bearings 18
and 22), SINOTRUK unified these two bearings as 32222 Width series. To improve the
lock reliability of axle nut (Round Nut 24), SINOTRUK changed it as dual-nut locking
structure.
1.1.2．Differential
In the process of automobile driving, there are two states such as rolling and sliding for
relative motion of wheel and road. Between them, the sliding can also be divided into two
kinds such as turn and slip sliding. Provided that the movement speed of wheel center
relating to road in wheel plane is U, the wheel rotation angular velocity is ω, and the pure
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wheel rolling radius is rr ; If U = rr  , the movement of wheel to road is pure rolling; if

ω≠0, that is pure sliding turn when U=0; If U≠0, that is pure slip sliding when ω=0.
When an automobile turns in traveling, the curve distances of both inside and outside
wheel centers at the same time are different obviously, that means that the distance of
outside wheel is more than that of inside wheel. If both sides of wheels are fixed on the
same rigid shaft, the angular velocity of both wheels is same. Now, the outside wheel must
slip sliding while rolling, and the inside one must slip turning while rolling. Similarly, when
an automobile is driving straightly at uneven road, the actual curve distances of two side
wheels are different. Even if the road is very straight, the rolling radius of every tire is
different actually because of tire manufacturing size error, different wear degree, different
bearing loads, or different air charging pressures. Therefore, so long as the angular
velocity of every wheel is equal, there must be any wheel sliding on road. Any wheel
sliding on road can not only accelerate tire wear, increase automobile power consumption,
but also lead to the consequences such as deterioration of steering and braking
performance even broken axle.
Therefore, there shall not be any wheel slip as much as possible under normal driving
conditions. To this end, every wheel (especially driven wheel) may be guaranteed with
different angular velocities to rotate in structure.
If any driven gear of final drive may drive both sides of wheels at the same time through
one whole rigid axis, the angular velocity of two wheels can only be equal then. To enable
both sides of wheels rotating with different angular velocities necessarily and ensure
wheels under a pure rolling state, the whole axis driving both sides of wheels must be
disconnected (that shall be half axle). The device that can make both side wheels at the
same axle rotating with different angular velocities is called as differential. The kind of
differential can also be called as inter-wheel differential.
For multi-axis drive automobile, that among every drive axle is connected through a
driving shaft. If any driving wheel of every axle is rotating with same angular velocity, there
will be similar situation as the above wheels without differential. To make every drive axle
having different input angular velocities to eliminate any slip of every axle driving wheel,
there may be set with inter-axle differential among every drive axle.
When there is any larger difference of attached conditions among left/right or front/rear
driving wheel and road, any simple gear differential cannot guarantee that automobile get
enough traction force. Any driving wheel with poor adhesive conditions will slip with high
speed but automobile cannot move forward (see below). Therefore, any automobile with
the above situation shall be equipped with anti-slip differential.
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Figure 1-9 Exploded view of Symmetric Bevel Gear Differential

1 – Differential Case (left); 2 – Half Axle Gear Thrust Washer; 3 – Half Axle Gear; 4 – Planet Gear; 5 –
Differential Case (right); 6 – Bolt; 7 – Spherical Gasket of Planet Gear; 8 – Planet Gear Shaft (cross shaft)
Symmetric bevel gear differential is used widely in automobile. For its structure, see
Figure 1-9.
Symmetrical inter-bevel gear differential is composed of planetary cone gear, planet gear
shaft (cross shaft), cone half axle gear and differential case. In Figure 1-10, differential
case is composed of Left Case 1 and Right Case 5 fixed with bolts. Driven gear of final
drive shall be fixed at the flange of Left Differential Case 1 with rivets or bolts. In fitting,
four axle journals of cross Planet Gear Shaft 8 are embedded in holes formed by
corresponding groove at two half faces of differential case. The subdivision surface of
differential case will pass through the centerline of every journal in planet gear shaft.
Every journal cover is floated with a Straight Bevel Planet Gear 4. All of them can mesh
with two Straight Bevel Half Axle Gears 3. Any journal of half axle gear will be supported at
corresponding left and right block holes of differential case as well as connected with half
axle through spline. The power may be output to driven wheels from driven gears of final
drive through differential case, cross shaft, planet gear, half axle gear and half axle. When
two side wheels are rotating with same speed, planet gear will rotate around half axle axis,
and this is revolution. If both side wheel resistances are different, planet gear will rotate
around its own axis (this is called as rotation) while having the above revolution movement.
Now, two half axle gears will drive two side wheels to rotate with different speeds.
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Figure 1-10 Symmetric Bevel Gear Differential Manufactured in SINOTRUK

1 – Differential Case (left); 2 – Adjustable Gasket; 3 – Half Axle Gear; 4 – Planet Gear; 5 – Differential Case (right); 6
– Bolt;7 – Planet Gear Gasket; 8 – Planet Gear Shaft (cross shaft);9 – Bush; 10 – Bush Retaining Ring
Differential of STR series drive axle manufactured in SINOTRUK is improved basing on

the structure of original STR differential structure, and its structure is same basically as
the above. SINOTRUK increases the cross-shaft diameter to improve its strength as well
as add Bush 9 and Bush Retaining Ring 10 between Planet Gear 4 and Cross Shaft 8 so
as to reduce any friction with cross shaft in planet wheel rotation, improve any lubrication
between them, and improve the life of entire differential assembly.
1. Principle of Speed Difference
The movement relationship of every element in differential may be illustrated in Figure

1-11. Symmetric bevel gear differential is a kind of planet gear mechanism. Differential
Case 3 is fixed and connected with Driven Gear 6 of final drive, and then it is an driving
0 , Planet Gear Shaft 5 is fixed and connected with

link. Provided its angular velocity is
Differential Case 3 to form a planet carrier. Both Half Axle Gears 1 and 2 are driven links,
and their angular velocities are 1 and 2 respectively. Point A and B are mesh points
between Planet Gear 4 with Half Axle Gear 1 and 2 respectively. The center point of
planet gear is C. All distances from Point A, B, and C to differential rotation axis are r.
When planet gear is only revolving around differential rotation axis with planet carrier
together, all circumferential speeds of Point A, B, and C at the same radius are equal (see
Figure 1-11b). Their value is

0 r . Then, 0 = 1 = 2 ; this means that differential does
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not act on differential effect. But the angular velocity of half axle equals to that of
Differential Case 3.
Figure 1-11 Principle of Speed Difference

1, 2 – Half Axle Gear; 3 – Differential Case; 4 – Planet Gear; 5 – Planet Gear Shaft; 6 – Driven Gear of Final Drive
When Planet Gear 4 rotates around its own Axis 5 with angular velocity ω4 besides its
1r = 0 r + 4 r4 , and that of

revolution, the circumferential speed of Mesh Point 4 is
2 r = 0 r − 4 r4 .
Mesh Point B is
1r + 2 r = (0 r + 4 r4 ) + (0 r − 4 r4 )

Then,
1 + 2 = 20
That is to say:
If angular velocity is expressed with revolution per minute n, then,
n1 + n2 = 2n0
This is the motion characteristics equation of symmetric bevel gear differential of two half
axle gears with same diameter. It shows that the speed sum of left and right side half axle
gear is two times of differential case speed but has no relationship with planet gear speed.
Therefore under steering or other driving situation, any automobile can depend on planet
gears to rotate with corresponding speeds so as to make two side driven wheels rolling
but not slipping with different speeds on road.
From the above motion characteristics equation, the followings can also be obtained:
①When the speed of any side half axle gear is 0, that of the other side half axle gear will
be two times of differential case speed. ② When the speed of differential case is 0 (for
example, use a central brake to brake any driving axle), one side half axle gear will rotate
reversely with same speed if the other side half axle gear is rotating under other external
torque.
2. Torque Distribution of Symmetric Bevel Gear Differential
M 0 from final drive will be transferred to half axle gear through differential
The torque
case, planet gear shaft and planet gear. Planet gear is equivalent to a equal armed lever,
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but the radius of two half axle gears is same too. Therefore, when planet gear does not
rotate, it may always distribute Torque M0 evenly to left and right half axle gears. That
1
M1 = M 2 = M0
means 2 .
Figure 1-12 Differential Torque Distribution
When two half axle gears are rotating to the same direction with different speeds, provided
the speed n1 of Left Half Axle is more than that of Right Half Axle n2, planet gear shall
rotate around Planet Gear Shaft Journal 5 according to the direction of Solid Arrow n4 in
Figure 1-12. Now, there will be some frictions between planet gear hole and planet gear
shaft journal as well as gear back and differential case. The direction of Friction Torque Mr
for planet gear is opposed to that of its Speed n4. See dotted arrow in Figure 1-12. The
friction torque make planet gear with two Circumferential Forces F1 and F2 that are same
in value but opposite direction to effect additionally on left and right half axle gear. F1 may
decrease Torque M1 of left half axle that is rotating fast, but F2 will increase Torque M2 of
right half axle that is rotating slowly. Therefore, when there is any speed difference with
1 1
M1 = (M 0 − M r ) M 2 = (M 0 + M r )
left and right driven wheel, then 2 , 2 . The torque
difference of left and right wheels equals to Internal Friction Torque M r of differential.
To balance internal friction torque of differential as well as torque distribution
characteristics, use a locking factor K often to express as following.
M 2 − M1 M r
K= =
M0 M0
The ratio of internal differential friction torque and its input torque (torque on differential
case) is defined as Differential Locking Factor K. The torque ratio of fast and slow half
M2
axles is
M1 Kb
and can be defined as torque ratio expressed in as
M 2 1+ K
Kb = =
following:
M1 1− K .
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The internal friction torque of symmetric bevel gear differential used widely at present is
very small. Its locking factor K is K=0.05～0.15, and the torque ratio Kb is 1.1~1.4. It may
be thought that the torque is always with equal distribution basically whatever the speeds
of left and right driving wheels are equal. This distribution proportion is satisfied for
automobile driving straight or turning on good road.
That an automobile drives on bad road will effect on its carrying capacity seriously. For
example, when one driven wheel of automobile contacts with mud or snow/ice road
surface, it will slip and turn on site. But it will be stationary at good road surface. This is
because the adhesion between one wheel and road surface at mud road is very small.
The road surface can only effect with very small reaction torque on half axle. Although the
adhesion between the other wheel and good road surface is very large, any torque
distributed to the wheel can only be equal to a very small one transferred to driven wheel
with slip turning because symmetric bevel gear differential has a characteristic to
distribute torque evenly. This will lead the total traction not overcome any driving
resistance, and automobile cannot move forward. This problem can be solved only with
anti-slip differential.
For STR series mandatory locking type symmetric bevel gear differential manufactured in
SINOTRUK, see Figure 1-13. When one side wheel is at a road surface with little
adhesion, driver may switch on differential rocker in cab to make Sliding Mesh Sleeve 13
with face tooth to close to Fixed Mesh Cover 11 and mesh with its face tooth. There are
splines in inner hole of Sliding Mesh Sleeve 13. They can fit with that of Half Axle 15 at
corresponding positions. The spline of inner hole in fixed mesh cover shall be fit with that
on Differential Case 1. When face gear of Sliding Mesh Sleeve 13 is embedded into the
tooth of Fixed Mesh Sleeve 11, it may make Half Axle 15 compulsorily to rotate with
Differential Case 1 synchronously. As mentioned, cross shaft is in cross holes of two
Differential Cases 1 and 5 and rotates together with differential cases. Now, Half Axle 15
and Half Axle Gear 3 at one side shall rotate with differential cases synchronously. Then,
Planet Gear 4 covered at cross shaft cannot rotate around cross shaft, and there will not
be any speed difference with left and right half axle gears. That is to say, differential does
not work now, and left and right half axles are interlocked as a whole to rotate together.
Thus, when any driven wheel at one side slips without any tension, the whole torque from
final drive will be distributed to the driven wheel at the other side so as to make automobile
drive normally.
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Figure 1-13 STR Series Mandatory Locking Differential Manufactured in SINOTRUK

1 – Differential Case (left); 2 – Adjustable Gasket; 3 – Half Axle Gear; 4 – Planet Gear; 5 – Differential Case (right); 6
– Bolt; 7 – Planet Gear Gasket; 8 – Planet Gear Shaft (cross shaft); 9 – Bush; 10 – Bush Retaining Ring; 11 – Fixed
Mesh Cover; 12 – Round Nut; 13 – Sliding Mesh Sleeve; 14 - Lock Washer
When an automobile leaves bad road, differential lock must be picked in time. Any
operation of differential lock shall be conducted in parking. And if it is too early or late to
pick down differential lock, that means there shall be rigid connection with left and right
wheels on good road, there will be mentioned things and a series of problems without any
differential.
The operating principle of inter-axle differential and lock is same as that of inter-wheel
differential. Their structure is same largely. For the structure of STR series drive axle
inter-axle differential, see Figure 1-14. Input shaft shall be integrated with front case of
inter-axle differential and rotate under the drive of Flange 4. Female spline of two Half Axle
Gear 13 and 16 are fit with male spline of Tandem Axle 32 and Hollow Shaft 20
respectively so as to lead power to final drive at middle and rear axles respectively.
Differential principle is same as that of inter-wheel differential, and here will not be
repeated. Ten Locking Pins 8 fixed at Locking Ring 7 in inter-axle differential lock may
pass through Differential Case (front) 1. For its position not needing any differential lock,
see Figure 1-14. When there is a locking inter-axle differential, locking ring will drive
locking pin to move backward till pass into corresponding position holes of Half Axle Gear
(front) Gasket 12 and Front Half Axle Gear 13 under any stir of Fork 9. Then, Differential
Case (front) 1 will rotate synchronously with Front Half Axle Gear 13. Now, differential
does not work as any differential role.
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Figure 1-14 Axle Box and Inter-Axle Differential

1 – Differential Housing (front); 2 – Flange Nut; 3, 30 – Cotter Pin; 4 – Flange; 5, 41 – Bearing Block; 6, 18, 21 –
Deep Groove Ball Bearing; 7 – Locking Ring; 8 – Lock Pin; 9 – Shifting Fork; 10 – Pin; 11 – Pressure Switch; 12 –
Half Axle Gear (Front) Washer; 13 – Front Half Axle Gear; 14 – Planetary Gear Gasket; 15 – Inter-axle Planet Gear;
16 – Rear Half Axle Gear; 17 – Differential Housing (rear); 19 – Driving Cylinder Gear; 20 – Hollow Axle; 22 – Axial
Spring Collar; 23 – Round Nut; 35 – Driving Bevel Gear; 37 – Cylindrical Roller Bearing; 38 – Driven Cylinder Gear;
39 – Axle Box; 40 – Spacer Bush; 42 – Tapered Roller Bearing; 43 – Bearing Outer Ring Pressure Plate; 44 – Axle
Box Cover; 45 – Half Axle Gear (Rear) Washer; 46 – Cross Shaft;
Figure 1-15 Half Axle of STR Series Drive Axle
1.1.3. Half Axle and Axle Housing
1. Half Axle
For half axle of STR series drive axle, see Figure 1-15. The left diagram shows a half axle
at the side of differential lock. The half axle is a solid one for transferring power between
differential and driven wheel. Its inner end is connected with half axle gear of differential,
and its outer end is connected with wheel reducer. They may transfer engine torque from
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engine to differential through drive shaft and final drive and lead to wheel reducer.
2. Axle Housing
The function of drive axle housing is to support and protect final drive, differential and half
axle to make axial relative position of left and right driven wheels being stationary as well
as support frame and every assembly on it together with driven axle. When driving, an
automobile can bear road surface reaction force and torque from wheels and transfer to
frame through suspension. For any housing of STR series drive axle, see Figure 1-16.
Figure 1-16 Three-Section STR Series Drive Axle Housing
1.2. STR-HC/ST16 Drive Axle Assembly Process

1.2.1. Sub-assembly Process
Before assembling entire Steyr rear axle, carry out subassembly processes of differential,
wheel reducer and final drive.
1. Sub-assembly Differential
(1) Oil differential cavity (2) Put into adjustable gaskets
(3) Put half axle gear (4) Put cross shaft planet gear
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(5) Detection clearance shall be (6) Smear thread glue

controlled between 0.6mm and 1mm
(7) Preload according to symmetry (8) Install differential locking pin and
principle remove it freely
2. Subassembly Wheel Reducer
(1) Make good match identification (2) Remove planet carrier bolts
(3) Sub-assemble wheel reducer (4) Smear thread glue
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(5) Planet carrier is installed with oil retaining disk;

Install planet carrier according to original positions
Tighten it according to symmetry principle, Torque: 113~137Nm;
3. Sub-assembly Final Drive
(1) Assemble driven bevel gear at (2) Install locking pieces and bearing
differential
(3) Install bearing outer ring (4) Install driving wheel bearing
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(5) Assemble bearing (6) Drip thread lock glue in final

block assembly drive housing connection thread hole
Preload shall be controlled in 1~2Nm Plain shall be smeared with oil-resistant sealant
(7) Use pneumatic wrench to preload symmetrically.

Firstly, preload two bolts symmetrically and then other bolts.
(8) Assembly of two bearing outer rings is finished. Differential shall not be inclined. Adjust
adjustable nuts slightly to adjust bearing pretension.
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(9) Use B16 pneumatic wrench to tighten (10) Any adjustable gear side clearance
nuts for preloading. shall be controlled in 0.25~0.45mm.
(11) Adjust strictly according to mesh area (12) Bush cap nut torque shall be
requirements controlled in 210~260Nm
(13) Install locking plate and control torque

in 21~25Nm
(14) Install fixed mesh cover to guarantee
the torque in 200~240Nm
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(15) Use screwdriver to turn locking piece and locking edge over firstly,
then tap it gently to guarantee locking effect.
1.2.2. Axle Assembly Process
1. Introduction of STR Series Middle and Rear Axles

SINTOTRUK has introduced Steyr series middle and rear drive axles from Europe,
combined China actual conditions, depended on market feedbacks, made many times of
technological improvements and formed two series products (such as normal STR and
Steyr HOWO) with several hundreds of types that are in dominant position in China
market.
Main features of Styre series middle and rear drive axles are to decelerate main reduction
spiral bevel gear and wheel planet reducer as well as have inter-wheel and inter-axle
differential locks.
Because wheel reducer has double reduction, the primary bevel gear pair is smaller, and
the whole vehicle ground clearance is large with good steering ability. Axle housing
section size designs have been enhanced to improve actual carrying capacities. Materials
are selected as steel sheet welding, cast iron and cast steel axle housing. Rated single
axle loads include two kinds such as 13,000kg and 16,000kg.
Originally, Styre series middle and rear drive axles are introduced with 13-ton and
1,800mm drive axle. Now, SINOTRUK has developed and improved them continuously to
meet the requirements of various vehicles.
2. Improvement of STR Series Middle and Rear Axles
1) Successful research and development of SHW axle can coordinate HW vehicle axle
configurations and develop STR-HC/ST16 Drive Axle with 1850mm track. (Axle housing
has been lengthened), the size of spring center distance has been lengthened with 60mm.
2) Depending on successful research and development of ST16 axle, SINOTRUK has
developed 16-ton STR-HC/ST16 Drive Axle to adapt to large tonnage vehicle axle
configurations. (Axle cross section has been enlarged), and dimensions have been
widened and thickened.
3) Successful research and development of cast axle housing. HC16 heavy duty cast
drive axle is a heavy duty drive axle that SINOTRUK has absorbed and drawn upon
design concepts of international heavy truck cast drive axle fully, adopt advanced design
methods and sophisticated manufacturing technologies with careful development and
production. The axle has stronger carrying capacity with deflection resistance and
reduced the leakage rate of whole axle greatly. Through strict bench tests and road test
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verification, the product performances have been close to the international advanced
level.
The material of cast axle housing is unique. Experimental evidences proved that it can not
only have many good features of normal cast such as good castability, vibration, low notch
sensitivity, and higher impact toughness but also have excellent mechanical properties
that are comparable with steel. It can make axle housing adapting poor working conditions
such as large load and strong shock.
It has advanced three-section structure design of overall cast axle housing with higher
rigid and strength as well as stronger carrying capabilities.
3. Assembly Process of STR Series Middle and Rear Axles
1) Procedure 1: Axle housing assembly positioning as well as installation of upper and
lower arch clamp assembly
Operation Note:
At ventilation plug thread, smear 5699 to tighten it.
After smear 5699 around hexagon bolts at the junction surface of arch fixture clamp
assembly and axle housing, use cross recessed countersunk head screws to fasten them.
Procedure 1: Axle housing assembly positioning as well as installation of upper and lower
arch clamp assembly
2) Procedure 2: Installation of brake bottom plate assembly and half axle oil seal
Operation Note:
① Brake bottom plates for ST16 and non-ST16 axle housings shall not be mixed to install.
② Smear 242 thread locking adhesives at bolts and threads.
③ Heighten axle housing of oil level holes. Do not install any half axle oil seal.
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Procedure 2: Installation of brake backplane assembly and half axle oil seal
3) Procedure 3: Installation of differential joystick and shift fork
Operation note: After set O-ring at joystick assembly, smear lubricating grease evenly at
O-ring. In assembling, do not damage O-ring.
Procedure 3: Installation of differential joystick and shift fork

4) Procedure 4: Installation of camshaft, camshaft bracket and brake adjusting arm
Operation note: Pay attention to any difference of left and right camshaft. Do not bump
camshaft. Handle them with care. Clamp ring must be clamped into camshaft slot.
Procedure 4: Installation of camshaft, camshaft bracket and brake adjusting arm

5) Procedure 5: Installation of brake shoe assembly
Operation note: ① Rotate brake clearance adjustment arm, and roller shall be turned
freely.
② Smear “Loctite 767 Anti-seize compound” at contact surface of wheel and brake shoe.
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Procedure 5: Installation of brake shoe assembly

6) Procedure 6: Installation of spacing ring assembly and wheel hub bearings
Operation note: Installation of spacing ring. Install it at axle housing head with big bore
chamfer facing inward. Then, heat bearing inner ring to 100℃, and install it at axle head.
Do not heat bearings more than 100℃.
There shall not be any clearance among spacing ring, bearing inner ring and punch
installation.
Procedure 6: Installation of spacing ring assembly and wheel hub bearings

7) Procedure 7: Installation of rear hub, gear bracket and gear
Operation Note:
① Use a punch to install bearing inner ring in the end.
②The rotational resistance torque of hub shall be controlled in the range of 10±3Nm. Use
hands to rotate the assembly with soft feeling but no jamming.
③ Knock rear hub at designated site (rough hub surface between wheel bolts) to vibrate
bearing clearances. Before assembling hub assembly, use cotton to clean the surface of
spacing ring. Smear lubricating grease evenly at hub oil seal. There shall not any grease
at external end face.
④ Use a punch in oil seal assembly. Do not knock it directly. There shall be a clearance
between two disc oil seal surfaces. Do not reverse any oil seal position.
⑤ Tighten axle nuts, and tightening torque is 300-400Nm.
⑥ Pay attention to axle nut turning direction. The direction of right nut is clockwise and left
nut is opposite (anticlockwise).
⑦ After assembling, use locking pieces to lock axle nuts and identify them.
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Procedure 7: Installation of rear hub, gear bracket and gear

8) Procedure 8: Installation of wheel reducer assembly
Operation Note:
① Set large seal ring in hub seal groove, and smear lubricating grease evenly at the
arrangement position of wheel reducer housing cavity. Use tools to press wheel reducer
housing at proper position. Then, install two countersunk head screws to fasten. Before
assembling wheel reducer housing, be careful to remove any bump burr.
② Pay attention to the position of hub vent hole. The position of wheel reducer housing
vent hole shall be opposite to it.
③ Countersunk head screw which connecting wheel reducer with hub must be installed in
the end.
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Wheel Vent Hole
Procedure 8: Installation of wheel reducer assembly

9) Procedure 9: Installation of rear brake drum
Operation Note:
① Use a filler gauge to measure the clearance difference between two shoes and brake
drum at the same side. It is required not be more than 0.5mm. If there is any over
difference, replace brake shoe assembly.
② Countersunk head screws shall be installed in the end.
③ Vent holes of brake hub and wheel side shall be opposite.
④ There is an interlinked tank at the edge of brake hub.
Procedure 9: Installation of rear brake drum

10) Procedure 10: Installation of half axle and sun gear
Operation Note:
① Insert half axle into sliding mesh sleeve of inter-wheel differential. Do not install it in the
end. Before assembling, inspect whether there is any bump with half axle and sun gear as
well as repair it.
② Half axle may be divided into left and right ones. Single spline is for right half axle, dual
spline is for left half axle. The length of SHW half axle is 25mm longer than that of STR
half axle.
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Single Spline
Duel Spline
Procedure 10: Installation of half axle and sun gear

11) Procedure 11: Installation of final drive
Operation Note:
① The tightening torque of nut is 96～78Nm. Glue smeared on the surface shall be
continuous without any break. Clear excess sealants around bowl plug.
② Insert left and right half axle from two ends of axle housing into spline holes of
inter-wheel differential gear to the end.
Procedure 11: Installation of final drive

12) Procedure 12: Installation of wheel end cover; riveting nameplate.
Operation Note:
①Clean any matching surface of end cover and wheel reducer housing, smear
oil-resistant silicone sealant. Glue strip shall be continuous without any break.
② Use bolts to twist end cover tightly. Bolt torque shall be 41~51Nm.
③ Rivet and fasten nameplate at designated position. The depth of rivet hole shall be
4~4.5mm.
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Procedure 12: Installation of wheel end cover; riveting nameplate.

13) Procedure 13: Installation of tandem shaft, bearing block assembly and flange
assembly
Operation Note:
① Smear lubricating grease at the lip of bearing block preinstalled with seal. The twisting
torque of flange nut shall be 750~950Nm.
② Install cotter pin to lock effectively.
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Procedure 13: Installation of tandem shaft, bearing block assembly and flange assembly
14) Procedure 14: Assembly commissioning
Operation Note:
① Tightening torque of wheel oil filling and discharging screw plug shall be 20~35Nm.
In commissioning process, the temperature of axle housing, wheel side and bearing block
housing of driving bevel gear shall not be 70℃ more than ambient temperature. There
shall not be any leakage at anywhere of assembly.
③ Replace commissioning oil one time every 1000 vehicles.
④ Technical specifications of axle assembly inspected in test shall include as followings.
1. Brake; 2. Differential (inter-wheel and inter-axle); 3. Differential lock (inter-wheel and
inter-axle); 4. Reduction ratio; 5. Whether there is any leakage; 6. Moving parts shall
rotate flexibly.
Procedure 14: Assembly commissioning

15) Installation of bracket
Operation Note:
① Tightening torque of spring slide bolt shall be 450~600Nm.
Tightening torque of air chamber bracket bolt (four bolts at four corners) shall be
450~600Nm. That of two middle bolts shall be 450-540 Nm.
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Procedure 15 Installation of bracket

The above includes assembly processes and key attention points of STR and SHW
middle and rear axles. As the maximum amount of heavy duty automobile in China, axles
are also very diverse in their changes. Under basic structure and transfer mode are same,
users may determine which kind the maintained axle is to avoid selecting mistake parts
depending on different tread, different loads and different suspension modes.
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2. Maintenance of STR-HC/ST16 Drive Axle
2.1. Routine Maintenance

1. Loading shall not be more than regulations in specification. Especially in uneven road
surface, do not drive very fast, or do not brake excessively.
2. Inspect oil level of final drive and wheel reducer periodically. Add oil when it is
inadequate. After driving 2,000~4,000 km, carry out mandatory maintenance, replace
gear oil. After mandatory maintenance, replace gear oil every 10, 000 km for every
vehicle.
3. Inspect any operation of differential lock periodically. If it does not operate well,
inspect reasons and repair it timely.
4. Use inter-axle and inter-wheel differentials correctly.
5. Pay attention to fill with adequate oil for middle axle. After filling oil, vehicle shall be
driven for 5 km. Then stop it to inspect its oil level again so as to ensure oil level of middle
axle box and inter-axle differential. If oil level is low, fill oil again.
6. Inspect the temperature of drive axle and wheel reducer (not more 70 than ambient
temperature) and the connection of every component (drive shaft and flange connecting
bolt, wheel bolt, and bolt at joint of final drive and axle housing) periodically in vehicle
driving. Inspect again every driving 2, 000 km.
7. Clean vent hole periodically to ensure good ventilation. Inspect oil charging/discharging
plug of wheel reducer, final drive and axle housing periodically. When there is any
looseness, carry out tightening it again. Pay attention not dismantling repeatedly to
prevent from damaging oil plug thread.
8. Inject lubricating grease to clearance adjusting arm when driving every 2, 000 km.
2.2．Correct Use of Differential Lock
2.2.1. Inter-wheel Differential Lock
The function of inter-wheel differential lock is to make left and right wheels with automatic
differential when turning so as to avoid tire wear and mechanical damage. Automobile will
slide when single wheel is in smooth or muddy road. When automobile cannot be driven
out, carry out linking inter-wheel differential lock together. Now, left and right half axles
become a rigid connection shaft, and it will be easy to drive automobile out of failure
surface. After driving out automobile, remove differential lock immediately. Otherwise, it
will cause serious tire wear and damage differential.
2.2.2. Inter-axle Differential Lock
Tandem drive axle is installed with inter-wheel and inter-axle differential locks that can
drive easily out of failure surface. Their purpose is to drive vehicles out of bad road when
meeting any muddy and smooth road.
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Dashboard in cab is installed with two differential lock switches. One is inter-wheel
differential lock switch, the other is inter-axle differential lock switch. When automobile is
driven into a muddy road but some certain axle single wheel is slipping, driver shall
engage clutch and press inter-wheel differential lock switch. When indicator is ON, both
middle and rear axle inter-wheel differential locks are linked at the same time. When
clutch pedal is loosened, left and right wheels of one axle will slip and idle at the same
time, but the other axle will not run, automobile cannot be driven out. Now, driver shall
engage clutch and press inter-wheel differential lock switch, driver shall put gearshift lever
in neutral position and loosen clutch to drive automobile out of failure surface when
indicator is ON. After driving automobile out of failure surface, remove differential lock
immediately.
2.3 .Code and Identification of Main Parts

2.3.1. Cross Shaft
Figure No. Name Identification Manufacturer Remark
AZ9231320150 Cross Shaft 72300 KC.23.72300 Inter-wheel Differential
Figure 1-1 Cross Shaft
2.3.2. Half Axle Gear
WG921320151 Half Axle Gear 0AB09 33.12.0AB09 Inter-wheel Differential

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Manufacturer Code
Figure 1-2 Half Axle Gear
2.3.3. Planet Gear
WG9231320152 Planet Gear 0AB09 33.12.0AB09 Inter-wheel Differential

Manufacturer Code
Figure 1-3 Planet Gear
2.3.4. Planet Gear Bushing
WG9231320159 Planet Gear Bushing 0AH10 33.02.0AH10 Inter-wheel Differential
WG9231320159 Planet Gear Bushing 0AH11 33.04.0AH11 Inter-wheel Differential
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Manufacturer Code
Figure 1-4 Planet Gear Bushing
2.3.5. Bevel Gear Pair
WG9231320912 Bevel Gear Pair 00175 23.01.00175 29/21 rear axle

WG9231320912 Bevel Gear Pair 0AB09 33.12.0AB09 29/21 rear axle
Manufacturer Code
Figure 1-5 Bevel Gear Pair
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2.3.6. Hub Oil Seal
Figure 1-6 Hub O il Seal
2.3.7. Rear Brake Drum
Figure No. Name Identification Manufacturer
WG9112340006 Rear Brake drum 0AD03 37.01.0AD03

WG9112340006 Rear Brake drum 0AF03 37.07.0AF03
WG9112340006 Rear Brake drum 0AF06 42.13.0AF06
Manufacturer Code
Figure 1-7 Rear Brake Drum
2.3.8. Rear Hub
Figure No. Name Manufacturer

WG9112340009 Rear Hub 37.07.0AF02
WG9112340009 Rear Hub 37.07.0AF03
WG9112340009 Rear Hub 42.13.0AF06
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Manufacturer Code
Figure 1-8 Rear Hu
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3. Troubleshooting
3.1. Oil Leakage
Figure 2-1 Sectional Drawing of Wheel Reducer
3.1.1. Wheel Oil Leakage
1. Any leakage caused by casting defect of wheel end cover (pore, sand hole and slag
hole), flat warp, crack and sealant failure among wheel reducer housing
(1) Treatment method: Replace wheel side end cap or re-smear sealant for assembly.
Figure 2-2 Schematic Diagram of Smearing Sealant on Wheel Side End Cap
(2) Maintenance points: Remove remnant tape of end cap and wheel reducer housing,
clean joints, smear 5699 sealant at the surface of end cap. Adhesive tape shall be
continuous without any break around round hole at end cap.
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2. Leakage caused by looseness or damage of fixing bolt at wheel end cap and oil
charging/discharging screw plug assembly.
(1) Treatment method: Tighten or replace fixing bolts on wheel end cap and oil
charging/discharging screw plug assembly.
(2) Maintenance point: Tighten fixing bolts at wheel end cap firmly, and detect bolt
tightening torque (41~51Nm).
3. Leakage caused by incorrect installation of O-ring in wheel side, loose matching and
O-ring damage
Figure 2-3 “Personal Emergency Link” Repair of O-ring Leakage
(1) Discrimination: Wet and dry conditions between two O-rings, whether there is any
deformation, distortion, injury or flexibility loss with O-ring.
(2) Treatment method: Replace or re-install O-ring.
Figure 2-4 “Personal Emergency Link” Repair of O-ring Leakage
(3) Maintenance points: Inspect whether any burr has been removed from groove; remove
processing residues such as debris, dirt and foreign particles; O-ring flash shall be
inclined about 45° to axle housing center; do not twist or scratch; smear lubricating grease
in 0~5cm near to large end in wheel cavity in assembly; do not extrude O-ring excessively;
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prevent from excessive tensile to avoid any elastic fatigue. When air temperature is less
than 10℃, re-install O-ring into hub seal groove after O-ring has been heated in hot water
(heating time shall not be more than 3 minutes, temperature shall not be more than 80℃).
4. Hub oil seal failure such as deformation, lip injury, spring relaxation and rubber aging.
Figure 2-5 Seal Structure Drawing
(1) Discrimination: Oil stain at seal end is radial. Use finger to touch oil seal lip tip gently
and judge whether it feels even or sharp, whether lip is perfect, whether there is any crack
or eccentric wear (under normal conditions, lip tip shall be sharp, even and smooth, lip
shall be perfect without any defect); use a magnifying glass to observe whether there is
any defect such as impurities, bubbles, sulfur marks, lack of sealant, embossing defect
and crack with lip.
(2) Maintenance points: Remove remnant tape of end cap and wheel reducer housing,
clean joints, smear 5699 sealant at the surface of end cap. Adhesive tape shall be
continuous without any break around round hole at end cap.
(3) Pseudo leakage: Too much butter will cause pseudo leakage at early driving. Carry out
discriminating through inspecting dust dry and wet conditions of leakage section. This
does not need any maintenance.
Figure 2-6 Parallel Installation of O il Seal and End Face
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(4) Treatment method: Replace oil seal.
(5) Maintenance points: Take proper protection measures to avoid seal scratching, inspect
whether oil seal spring is lost or installed properly, whether force areas are reasonable.
Before installation, smear proper lubricating grease evenly at seal lip.
Figure 2-7 Use Shim Plate for Hammer to Assemble
(6) Error seal assembly method (for example):
Figure 2-8 Inner Diameter of Pressing Tool is Too Small
Figure 2-9 Seal is Inclined Too Much When Entering into Hole
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Figure 2-10 Do not Use Hammer to Assemble without Shim Plate
5. All including incorrect installation of spacing ring assembly, surface defect or very poor
surface roughness will cause poor hub seal to leak.
(1) Treatment method: Install spacing ring assembly correctly or replace it and oil seal.
(2) Maintenance point: Inspect whether there is any surface defect (scratch or longitudinal
groove caused by machining); use cotton clothes to clean spacing ring and axle head joint;
smear proper lubricating grease of axle housing axle head joint before installation; carry
out assembling spacing ring after heating it to 60~100℃.
6. All including hub casting defect (pores, sand hole and slag hole), crack, too loose hub,
inner and outer shifting with hub seal can lead to leakage.
Figure 2-11 Leakage of Hub Sand Hole
(1) Treatment method: Replace hub or oil seal, adjust hub bearing preload, and tighten
axle head nuts firmly.
(2) Maintenance point: Before assembling, smear proper lubricating grease evenly at hub
seal lip. Knock hub rough surface to vibrate bearing clearance, and then use hands to
rotate hub assembly till feel soft without clamp. Ensure hub rotation resistance torque in
10±3Nm (if resistance torque is over little, there will be axial displacement to make axle
head nut fall off. If resistance torque is too large, bearing will be burnt to death).
7. Wheel reducer housing casting defect (pores, sand hole and slag hole) and external
1st Edition 46
STR-HC/ST16.01
reasons cause crack and then there will be leakage.
(1) Treatment method: Repair or replace wheel assembly.
(2) Maintenance point: Dual assembly (press and install planet carrier to wheel reducer
housing according to dual identifications). Pay attention to making the direction of planet
wheel gasket oil tank (external side toward reducer housing, and internal side toward
planet carrier). Convex of needle roller bearing cage shall be toward 99012340077
Washer.
Figure 2-12 Leakage of Hub Sand Hole
8. Other reasons such as axle housing crack and three-section axle housing head run-out
Figure 2-13 Three-section Casting Axle Housing Head Run-out
Figure 2-14 Three-section Casting Axle Housing Head Run-out
(1) Discriminate whether tire runs out outward (thee-section type) and observe whether
1st Edition 47
STR-HC/ST16.01
there is any run out of axle head root.
(2) Treatment method: Replace axle housing.
3.1.2. Leakage of Final Drive
Figure 2-15 Sectional Drawing of Rear Final Drive Figure 2-16 Sectional Drawing of Middle Axle Final Drive
1. Oil discharging screw plug is loose or damaged and there is leakage without poor seal.
(1) Treatment method: Tighten or replace screw plug assembly.
2. That bolt connection among every contact surface (such as interface of final drive and
axle housing) is loose or sealant failure will cause oil leakage.
(1) Treatment method: Inspect and tighten loose connection, smear sealant and
reassemble.
(2) Maintenance point: Remove residual colloid of axle housing disc area and final drive
disc area. Clean joint surface. Smear Loctite 5699 sealant evenly around joint, bowl block
and pin hole. Adhesive tape is continuous. There is not any break around screw hole. Its
diameter shall be about 3mm. Bolt tightening torque of final drive is 78~96 Nm. Tighten
final drive disc bolts periodically.
Figure 2-17 Schematic Diagram of Axle Housing Disc Smearing Sealant
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STR-HC/ST16.01
3. Final Drive Housing Casting Defect (Pores, Sand Hole and Slag Hole) and Crack
Cause Oil Leakage
(1) Treatment method: Repair or replace reducer housing assembly.
(2) Maintenance point: Ensure parts clean without any burr or scratch. Others are same as
maintenance points on contact surface of final drive and axle housing.
Figure 2-18 O il Leakage of Final Drive Housing (Sand Hole under Nameplate)
4. Failure of Final Drive Oil Seal Causes Oil Leakage
(1) Treatment method: Dismantle to inspect and replace flange seal.
For maintenance points of final drive seal failure mode and assembly, refer to hub seal.
5. All including flange spline wear, flange wear rear concentricity too poor, bad interface of
seal and flange can cause oil leakage. Flange loosening cause oil leakage such as cotter
pin off and nut looseness.
(1) Treatment method: Replace damaged parts. Tighten flange nuts and lock them.
(2) Maintenance point: Tighten flange nut, and ensure the torque is 750~950Nm. Press
front flange and smear lubricating oil at oil seal joint.
6. All including too poor dynamic balance of transmission shaft, loose connection bolts of
transmission shaft and final drive flange and over much vibration of final drive flange will
damage oil seal block and oil seal so as to cause oil leakage.
(1) Treatment method: Maintain or replace transmission shaft, flange, oil seal and oil seal
block. Tighten and connect them.
7. Other reasons such as poor road condition and overload, loose even broken double
axle thrust rod bolt, rear overhang dislocation and over much horizontal vibration may
cause final drive with oil leakage.
(1) Treatment method: Inspect, maintain or replace damaged parts.
3.1.3. Oil Leakage of Axle Assembly
1. That oil charging/discharging screw plug of axle housing assembly is loose or damaged
will cause oil leakage.
(1) Treatment method: Tighten or replace screw plug assembly.
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2. That poor seal between O-ring and housing of inter-axle/inter-wheel differential lock
rocker will cause oil leakage.
(1) Treatment method: Dismantle to inspect and replace O-ring.
3. That tandem axle seal ring failure (For failure mode, refer to hub oil seal) or damaged
bearing block will cause oil leakage.
(1) Treatment method: Dismantle to inspect and replace seal ring and bearing block.
4. That loose or damaged middle axle output flange and poor joint with oil seal will cause
oil leakage.
(1) Treatment method: Overhaul, tighten and lock flange or replace flange.
5. That over poor dynamic balance of transmission shaft or loose bolts with flange
connection cause flange vibrating over much and damage bearing, bearing block and oil
seal so as to cause oil leakage.
(1) Treatment method: Maintain or replace transmission shaft, flange, oil seal and oil seal
block. Tighten and connect them.
6. That axle housing crack, casting defect and weld porosity will cause oil leakage.
Figure 2-19 Longitudinal Joint Crack of Punching Axle Housing
(1) Treatment method: Repair or replace axle housing assembly.
(2) Maintenance point: Remove welding slag from welding axle housing to make groove.
7. That dual-axle limit plate and limit clearance becoming large, broken thrust rod bolt,
bent or damaged thrust rod, over much left-right swing of rear suspension will damage
bearing and oil seal at tandem axle or form oil leakage.
(1) Treatment method: Maintain, replace oil seal, seal block and others.
3.2. Abnormal Sound and Heating

3.2.1. Wheel Abnormal Sound and Heating
1. That wheel bolt is loose and broken will cause abnormal sound. .
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Discrimination: Abnormal sound comes from wheel parts.

(1) Discrimination: Abnormal sound comes from wheel parts.
(2) Treatment method: Replace wheel bolts.
Figure 2-20 Broken Wheel Bolt

(3) Maintenance point: At bolt threads, smear anti-bite agent 767. Fasten tires for two
times (do not meet the requirements of fastening torque only one time) at least according
to the principle of diagonal fastening. Tightening torque: M=550~600Nm. Wipe lubricating
grease and oil clean on bolts and nuts.
(4) Illustration on wheel bolt and nut: After tire nuts are tightened firmly, that among thread
has a self-locking feature (thread helix angle is less than equivalent friction angle among
thread). In bolt coupling, helix angle is some certain value. Equivalent friction angle shall
be changed following with friction conditions among threads. After oil smearing, equivalent
friction angle among thread will be reduced, and self-locking performance of bolt coupling
will become poor. That smearing lubricating grease at tire bolts and nuts or dipping them
into lubricating oil will make nuts being loosened even tire run away.
2. That there is oil lack or poor oil quality in wheel reducer will generate abnormal sound and
heating.
(1) Discrimination: Detect whether wheel side temperature is 70℃ more than ambient
temperature in driving.
(2) Treatment method: Fill or replace oil according to relevant regulations. Inspect oil level
frequently in use. In maintenance, inspect the quality of gear oil. If oil quality is poor,
please replace it.
(3) Maintenance point: In oil changing, clean the inner of axle housing clearly, and then fill
new oil in proper quantity.
Half axle at right side of middle axle and left side of rear axle shall be installed with sliding
mesh sleeve of inter-wheel differential lock. When being taken, a half axle at the side can
only be extracted out in 140mm. otherwise, sliding mesh sleeve of differential lock will fall
down to hinder any extraction of final drive assembly. In normal repair, if half axle is
extracted when vehicle is maintained but axle is not discomposed, remember lock
differential lock firstly. Use iron wire fix differential lock rocker arm at the position of joint to
prevent mesh sleeve fall out, and then extract out half axle. Otherwise, half axle cannot be
installed under sliding mesh cover is fell out.
3. That sun gear/half axle spline wear and clearance become larger will cause abnormal sound.
When there is no clearance between half axle and end cap, end cap will be heated.
(1) Discrimination: Abnormal sound is from wheel section. There is abnormal sound at the
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rear of vehicle. The higher the speed is, and the heavy the sound is. When vehicle is
driven or slipped with low speed, sound becomes small and even till disappears.
(2) Treatment method: Replace sun gear or half axle.
4. Both clearance and wear between wheel planet gear and internal gear ring are increased.
(1) Discrimination: Same as the above.
(2) Treatment method: Replace planet gear or internal gear ring.
(3) Maintenance point: Dual assembly of planet carrier and wheel reducer housing.
Direction of planet wheel gasket oil tank (external side toward reducer housing, and
internal side toward planet carrier). Convex of needle roller bearing cage shall be toward
washer.
Figure 2-21 Tooth Wear of Internal Gear Ring

5. When preload of hub bearing is too much (less) or bearing is damaged, there will be
abnormal sound and heating with wheel side
(1) Discrimination: Bearing wear - there is any sound with drive axle in driving. Following
with speed improvement, the sound will be reduced or disappear in slipping. Bearing fall
apart – there is any sudden abnormal sound in driving. Insufficient bearing lubrication –
there will be very minor thermal discoloration following with scratch at larger end of roller.
Figure 2-22 Deformation of Bearing Retainer

(2) Treatment method: Adjust hub bearing preload, or replace bearing.
(3) Maintenance: Use cotton yarn to clean the joint between bearing inner ring and shaft
head. Smear lubricating grease evenly. Heat bearing inner ring to ensure the temperature
of bearing is 60~100℃. After being cleaned and dried as well as stored into storehouse,
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all bearings must be smeared with lubricating oil or antiseptic and packed with protective
paper. Bearing shall be put in dry area and packed with original package so as to reduce
the possibility of static corrosion before installation.
6. That meshing too tight (loose) between every gear in wheel-side planet gear train or
damaged gear will generate abnormal sound and heating.
temperature in driving and whether there is any debris or impurity in gear oil.
(2) Treatment method: Replace and adjust parts.
(3) Maintenance point: Dual assembly of planet carrier and wheel reducer housing.
Direction of planet wheel gasket oil tank (external side toward reducer housing, and
internal side toward planet carrier). Convex of needle roller bearing cage shall be toward
washer.
Figure 2-23 That Impurities in Wheel Reducer Causes Abnormal Wear of Sun Gear
7. Serious wear of wheel side such as planet gear shaft, gasket wear and tear will cause
abnormal sound and heating.
temperature in driving and whether there is any debris or impurity in wheel-side gear oil.
(2) Treatment method: Replace wheel side or damaged parts.
8. All including drive axle housing deformation, interfere of half axle and axle housing or wheel
side movement can cause abnormal sound and heating.
(1) Discrimination: After drive axle has been deformed, there will be very large sound, and
too for tire. There is any gear meshing friction sound in wheel side reducer as well as
eccentric wear for tire.
(2) Treatment method: Replace axle housing and avoid any overload traffic.
Figure 2-24 Axle Housing Deformation Causing Eccentric T ire Wear
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3.2.2. Abnormal Sound and Heating of Final Drive

1. That there is oil lack or poor oil quality in final drive will generate abnormal sound and
heating.
(1) Discrimination: In driving, there is continuous sound with middle and rear axles, and
axle housing is heated seriously.
(2) Treatment method: Replace gear oil.
2. That too large (small) driving and driven bevel gear meshing clearance or improper
adjustment of mating surface will cause abnormal sound and heating.
(1) Discrimination:
Too much meshing clearance: In automobile driving, when there is any instant conversion
speed or instable speed, there will be any rhythm and heavy crash sound in axle. When
speed is stable relatively, sound will be reduced or disappear.
Too small meshing clearance: In automobile driving, there is a kind of continuous gear
meshing sound in axle. Sound frequency will be increased following with speed is larger.
After accelerator is switched off, sound will be reduced.
Improper adjustment of meshing trace: Same as too small meshing clearance.
(2) Treatment method: Adjust tooth and meshing clearance of bevel gear pair correctly.
(3) Maintenance: Adjust gear backlash through replace adjustable gasket as well as screw
in and out differential bearing adjusting nuts. Dial indicator header points to external side
at large end of driven bevel gear tooth surface. Header is pressed about 1mm. under
guaranteeing that driving bevel gear is not rotating, turn driven bevel gear, and the reading
of dial indicator shall be controlled between 0.25mm and 0.45mm. If it is out of range,
adjusting nuts at two ends shall be adjusted tightly or loosely in symmetry. The length of
nut screwing in at one side shall be same as that of nut screwing out at the other side.
When repairing and dismantling driving and driven bevel gears, keep adjustable gaskets
in good condition. In any reassembly, restore original gaskets necessarily.
(4) Adjust meshing area of driving and driven bevel gear: Smear fixture of red lead powder
and oil at the side of driven gear tooth. Replace adjustable gaskets and tighten adjusting
nuts at two ends of differential according to meshing trace display. The tightening torque
of tile cover is 210~260Nm.
(5) Correct meshing trace: The height of meshing trace shall not be 50% more than tooth
height. The length of meshing area shall be 1/2 to 2/3 of whole tooth length. Concave
meshing area may be allowed in the middle of tooth.
Figure 2-25 Correct Meshing Trace of Bevel Gear
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STR-HC/ST16.01
(6) For meshing trace and adjustment method, see the following drawing.
Correct meshing trace:

1. The height of meshing trace shall not be 50% more than tooth height.
2. The length of meshing area shall be 1/2~2/3 of whole tooth length.
3. Convex meshing area may be at the middle of tooth.
Error meshing trace – Gear scrapped:
1. Positive (negative) side is deflected to the large end, and negative (positive)
side is deflected to the small end.
2. Positive (negative) side is deflect to tooth top, and negative (positive) side
is deflected to tooth root.
图 1A 图 2A 图 3A
正确的啮合痕迹: 图图2A2A 图图3A3A 图图4A4A

图图1A1A
图合痕
1A 图 2A 图 3A 图 3A 图 3A 图 4A
50 图
1.啮%图 1A迹高度 A 于齿高的
图不1小
图 1A 图 3A 图图3 图
A4A 4A图 4A
图 1A 2A 图 2A
图 2A 图 2A
图 1A Figure 1A 图 2FAigure 2A Fi 图
gure3A3 A Figure 4A图 4A
确
正的确啮
的合啮痕
合迹痕:迹: 2.啮合区长度占全齿长度的 1/2 至 2/3
啮
1痕迹:
.合
啮痕合迹痕高迹度高不度小不于小齿于高齿的高 5的0%50%
的啮合痕迹:
3.凹面啮合区允许在齿中部
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.痕
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度长度占
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拧松被动齿轮端的调整螺母拧紧被动齿轮端的调整螺母增加垫片
区中面长
部啮度合区占允全许齿在长齿中度部的 1/2 至
2/3 的
区
合区
中允
部允许许在在齿
齿中中部
错误的啮合痕
拧迹 -齿
松被动轮报端
齿轮废的:调整螺母拧紧拧被
紧动
被齿动轮轮图
齿端的
端调的1整
B螺
调整母
螺图减少
2B 图 3B
拧松被动齿轮端的调整螺母母增加
增垫加片
垫的片厚
的度厚度减垫少片
垫的片厚
的度厚度
啮合区允许在齿中部
错的
误误啮的合啮痕合迹痕-迹齿-轮
齿报轮废报1.:废正: (反)面偏大端,反图(图正
1B1)B面偏小端图图4B4B
拧松被动齿轮端的调整螺母
拧松被动齿轮端的调整螺母
拧紧被动齿轮
拧紧被动齿轮
母
端的调整螺母
图端的图 2B
2B调整螺增加垫图片的图3B厚度3B
增加垫片的厚度减少垫片的厚度
正
1iven
.(正反()反面 )偏
r 面大
偏端大,端反,(反正(2)正 c rew off adju stin g nu t of dri ve n拧紧
拧松被动齿轮端的调整螺母 ge a 被动齿 ten轮adj
端usti
的调整螺ng n ut o 母
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et 垫hic片 ne的 s 厚度
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的啮合痕迹-齿轮报废: 松)面被偏动齿轮,端反的( 调正整 ) 面螺偏母齿根拧紧被动齿调整螺母 et t增加垫片的厚度
废: 拧松被动齿轮端的调整螺图母 1B 拧紧被动齿轮端的图调 2B整螺母图 3B 图 4减B 少垫片的厚度
合痕迹-齿轮报废:
正
2.(正反()反面)偏面齿偏顶齿,顶反,(反正()正面)偏面图偏根
齿齿1B根图 1BFigure 1B 图 2B Fig 图 ure 22BB 图增加垫3B F图igu3re片的
B3B
厚度图Fig4u减图Bre 少 44BB垫片的厚度
痕
(反迹)面 -齿偏轮大报端,废反:(正)面偏小端拧od紧
正面废)偏:大偏端小
面 ,反端(正)面偏小端拧松被图动1B齿轮 Fig 端ure的 26调 Ad整 jus 螺
tme母 nt Meth图 2ofB被Bev动 el 齿
Me 轮 shi 端ng T的 rac调e 增加垫片的厚图度4B
减少
图
整
图螺3 母图 4B
(反大 )面偏齿顶 ,反 (正偏)面偏齿根
1B B 图 2B 图 3B 垫
偏
正合
端 ,反 (正 )面小 3 端
. Fig ht tooth of driving/driven bevel gear and driving/driven cylinder drive generates
面偏痕偏迹
齿顶
))面偏小端
面齿-根
,反齿轮报废:
(正)面偏齿根
图 1B 图 2B 图 3B
偏齿顶,反(正)面偏齿a 根 bnormal sound and heating
)面
正偏偏
)面大齿
端根,反(正)面
(1)偏D 小
isc端
rimination: There is metal crushing sound in driving.
)面偏齿顶,反(正)面偏齿根
Figure 2-27 Fight Tooth of Bevel Gear
(2) Treatment method: Replace bevel gear pair or adjust meshing area.
1st Edition 55
STR-HC/ST16.01
Figure 2-28 Fight Tooth of Driving/Driven Cylinder Gear

(3) Normal abnormal sound: There is not any abnormal sound in normal automobile
driving. Once it is decelerated with oil withdraw, there will be a Buzz noise. This is
normally generated because of teeth back strain or pitting corrosion of bevel gear. This
kind of light sound will not relate to overall situation, and automobile can be driven
normally. But when it is serious, dismantle and replace it.
4. Improper bearing preload adjustment, oil lack or other reasons can cause bearing burnt and
part scattering so as to lead to abnormal sound and heating.
(1) Discrimination: In drive axle, there is a very messy and crash sound. The faster the
automobile, the larger the noise is. And it sounds in acceleration and deceleration. When
there is any sudden abnormal sound in driving, this means bearing is scattered.
(2) Treatment method: Replace bearing or adjust bearing preloading device.
5. When there is too much tooth clearance of differential planet gear, both half axle gear and
half axle spline can be worn to cause abnormal sound.
(1) Discrimination: When automobile is driven in bent road, there will be a sound from
drive axle. In straight line driving, the sound is reduced or disappears.
(2) Treatment method: Dismantle to inspect and replace differential or any damaged part.
(3) Maintenance point: When discomposing differential, mark at two differential half cases
to carry out dual assembling various gaskets.
Figure 2-29 Fight Tooth of Differential Half Axle Gear

After being dismantled together with lock pins, it shall be stored and original assembling
positions shall be marked. Inspect part appearance quality. Check whether it is cleaned,
1st Edition 56
STR-HC/ST16.01
whether there is any bump injury. Smear some butter or oil at cross shaft, and set bush
retaining ring, planet gear bushing, planet gear and spherical washer. Planet gear inner
hole and sphere shall be smeared with lubricating grease to guarantee axial clearances
between planet gear and spherical washer. When 0.6mm feeler gauge is inserted into its
clearance, and planet gear shall rotate freely. When 1mm feeler gauge is inserted into its
clearance, turn planet gear to rotate only one circle but the gear will be clamped. Use
hands to turn half axle gear installed in differential. Do not rotate too tightly, there shall not
be any obvious clearance. Tightening torque of differential connecting bolt shall be
106~130Nm.
6. All including hollow shaft, input shaft section of inter-axle differential and cross shaft are
fractured.
Fig.2-30 Fractured Input Terminal of Inter-axle Differential

(1) Discrimination: There is a sudden sound in driving. Transmission shaft can be rotated
but automobile cannot be driven.
(2) Treatment method: Replace hollow shaft, differential housing or cross shaft.
(3) Maintenance point: Same as the above.
3.3. Common Differential Fault

When automobile is in muddy, one wheel is idling. When inter-wheel differential lock is
linked, any load of whole vehicle will be concentrated into a drive axle. Over much load
will damage and break final drive gear teeth. When automobile is driving in uneven rod,
the rolling distance of middle and rear axle wheels are not consistent. When inter-axle
differential fails, there is not any more differential rotation causing tire sliding. Additional
load of final drive gear will be increased, and gear teeth will be fatigued and fractured.
3.3.1. Common Differential Lock Mis-operation

1. After inter-axle and inter-wheel differential locks are locked, turning steering wheel will
damage differential. After differential lock is locked, differential will not act on any
sub-speed differential role. Turning steering wheel in force will damage differential easily.
2. Differential lock switch is damaged. After differential lock is connected and automobile
is out of bad road, disconnect differential lock switch. Because of electric appliance or
rocker switch failure, differential lock is not removed. Turning steering wheel will damage
differential easily.
3. When vehicle is under non-stop state, differential shall be connected. When vehicle is in
running, differential shall be connected. Because of much torque, differential will be
1st Edition 57
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damaged easily.
3.3.2. Common Differential Fault

1. Any improper operation will damage differential possibly.
(1) Treatment method: Driver shall operate differential according to operation instruction.
2. Low oil level and poor oil quality cause poor lubrication especially poor differential
splash lubrication will damage differential.
(1) Treatment method: Inspect oil level frequently in use. In maintenance, inspect the
quality of gear oil. If oil quality is poor, please replace it.
(2) Treatment method: Inspect lubricating oil quantity and quality. Fill or replace oil
according to the regulations.
3. All including of grinding round loss of cross shaft journal and grinding of planet gear
gasket will cause planet gear not rotating or realizing any non-differential function.
(1) Discrimination: Refer to any operation of differential, and inspect it.
(2) Treatment method: Replace gear, gasket and cross shaft.
4. All including grinding loss and ablation between half axle gear and differential housing
as well as planet gear and cross shaft will cause differential without any differential
function.
Fig. 2-31 Grinding Injury of Cross Shaft and Planet Gear

(1)Treatment method: Replace damaged parts such as half axle gear, planet gear or
differential housing.
5. All including input shaft section of inter-axle differential and cross shaft are fractured.
(1) Discrimination: There is a sudden sound in driving. Transmission shaft can be rotated
but automobile cannot be driven.
(2) Treatment method: Replace hollow shaft, differential housing or cross shaft.
6. All including loose mesh sleeve locking nut of inter-wheel differential lock, slide
meshing sleeve movement intervention, incorrect or loose fork bending plate will cause
linking/disconnecting differential lock difficultly.
(1) Treatment method: Look for interference causes and carry out maintaining.
7. Mis-operation will cause differential lock pin being fractured. All including movement
interference of inter-axle differential lock ring or pin, force movement block and slide
meshing sleeve or differential lock ring as well as operating cylinder failure will cause
linking/disconnecting differential lock difficultly.
(1) Treatment method: Look for interference causes and carry out maintaining.
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3.3.3. Note in Differential Lock Operation

1. When linking inter-axle or inter-wheel differential locks, disconnect clutch firstly. When
vehicle is under a stop state (equivalent to walking speed in driving), operate through
rocker switch. After linking it, the indicator shall be ON.
2. Use inter-wheel differential lock, and vehicle can only be driven in straight line. Do not
turn it. Because differential has bee locked firmly, it cannot function any sub-speed
differential. Any turn will damage gear teeth.
3. If inter-wheel differential lock has been disconnected, the indicator is still ON and
vehicle cannot be turned, stop vehicle to find any reason. Till after inter-wheel differential
locks can be removed, vehicle can be turned to drive.
4. After passing bad roads, remove inter-axle differential lock but indicator is still ON. Find
any reason and remove inter-axle differential lock. If inter-axle differential lock is not
removed, automobile running resistance is large, speed cannot be improved, and oil
consumption will be increased.
5. To ensure vehicle having good passing performance, carry out inspecting any operation
of inter-axle and inter-wheel differential locks periodically.
3.3.4. Inspection Method of Differential Lock

Park vehicle at flat and wide place, lift one side of drive axle wheels (8×4, 6×4, lift middle
and rear axles, 4×2 lift rear axle). Loosen manual brake valve and transmission is at the
neutral position. Use hands to turn and lift one side of wheels that shall rotate freely. If
they can not rotate, it indicates that differential lock is under the state of lock.
1. Under all including rocker switch, indicator, line and air route are normal, switch on the
power, the indicator shall be OFF. Otherwise, it indicates that differential lock is under the
state of lock. Carry out inspecting and eliminate it.
2. Start engine to make its air pressure to 0.7MPa. Press rocker and link front, middle and
rear inter-wheel differential locks respectively. Turn any wheel lifted at one side. If not, it
indicates that it is under the state of lock. Otherwise, differential lock is not linked. Inspect
reasons and eliminate them.
3. Start engine to make air pressure to 0.7MPa. Link inter-axle differential lock, rotate any
wheel lifted at one side. Middle and rear drive wheels can rotate with the same speed. It
indicates that inter-axle differential locks are under the state of lock.
4. After rocker has pressed, indicator shall be ON. If it is not ON as well as inter-axle and
inter-wheel differential locks have been locked, inspect circuit failures.
3.4. Brake Failure

3.4.1. Lack of Braking Force
1. Deformed brake air chamber thrust rod, improper stroke adjustment, insufficient brake air
pressure of air capacity, air pipeline leakage, incorrect adjustment of general brake valve or other
brake valves, or damaged parts.
(1) Treatment method: Repair and adjust brake air chamber thrust rod travel, inspect pneumatic
pipeline and every air valve, and replace damaged brake valve.
2. Inner surface cracking of brake drum, friction aging, cracking, falling and oil stain as well as
poor joint between brake friction piece and brake drum
(1) Treatment method: Clear oil stain or replace friction piece, brake drum; correct the fitting
1st Edition 59
STR-HC/ST16.01
position of friction piece; and bore brake drum.

3. Brake clearance adjusting arm failure
(1) Adjust or replace brake clearance adjusting arm.
Figure 2-32 Brake Profile
Figure 2-33 O il Stain of Friction Piece
3.4.2. Braking Drag

1. All including camshaft catching, return spring softening and fracture, slow brake release can
cause brake drag.
(1) Treatment method: Repair or replace camshaft and return spring.
(2) Maintenance point: Inspect whether brake shoes are in pair in assembly. Smear anti-catching
agent at the joint among brake shoe assembly, roller and supporting kin.
2. Poor relay valve exhaust, leakage of manual brake valve and its pipeline, too long or deformed
stroke of thrust rod in brake air chamber and blocked return
(1) Treatment method: Repair or replace relay valve, manual brake valve, pipeline and brake air
chamber.
3.4.3. Abnormal Brake Sound

1. Worn friction piece will make bolt protruding, friction piece surface becomes hardened or
deteriorated.
(1) Treatment method: Repair and replace friction piece.
1st Edition 60
STR-HC/ST16.01
2. Deformed brake shoe, uneven compression of brake drum, not tight contact between brake
shoe and friction piece, and loose fixing pin of brake shoe
(1) Treatment method: Replace brake shoe, tighten connecting bolts of friction piece, and fasten
screws of fixing pin.
3. Uneven and out-of-round inner surface wear of brake drum, loose hub bearing in wear possibly
with brake noise
(1) Treatment method: Replace brake drum and hub bearing.
3.5. Other Common Faults

3.5.1. Drive Axle not Driving
1. That inter-axle differential input end and cross shaft are broken will cause not driving.
(1) Treatment method: Replace differential housing or cross shaft.
2. All including broken tandem shaft and hollow shaft as well as fractured half axle can cause not
driving.
(1) Treatment method: Repair and replace parts such as tandem shaft or hollow shaft.
3.5.2. Rear Wheel Deflection

1. Differential cannot function to cause real wheel deflection.
(1) Treatment method: Repair or replace differential.
2. All including deformed hub, loose hub bearing can cause any wave-type wear of tire crown.
(1) Treatment method: Replace bearing, hub or rim.
3. Rear spring limit plate of dual axle falls off, rear spring has no limit horizontally, and rear wheels
swinging in deflection.
(1)Treatment method: Install rear spring limit plate as well as adjust plate spring clearances till to
be proper.
4. All including too move axle housing bend and damaged thrust rod block will cause axle
dislocation and deflection.
(1) Treatment method: Replace axle housing and thrust rod block.
1st Edition 61

【ENGLISH】the Repair Manual of ST16-HC16 Drive Axle

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STR-HC/ST16.

The Repair Manual of

SINOTRUK No. 777 Hua'ao Road Jinan,

INTERNATIONAL Shandong Province, China, 250101

AFTER SALES SERVICE DEPARTMENT STR-HC/ST16.01

1st Edition -English-

STR-HC/ST16 Drive Axle (Drum Brake)

We reserve the right to make modifications in the course of further development.

Best wishes from

1.1. Structure and Principle of STR-HC/ST16 Drive Axle ....................................... 5

1.1.1. Final Drive............................................................................................................ 6

1.1.3. Half Axle and Axle Housing .......................................................................... 20

1.2. STR-HC/ST16 Drive Axle Assembly Process .................................................. 21

1.2.1. Sub-assembly Process .................................................................................. 21

1.2.2. Axle Assembly Process ................................................................................. 26

2. Maintenance of STR-HC/ST16 Drive Axle ................................................................ 36

2.1. Routine Maintenance ............................................................................................. 36

2.2.1. Inter-wheel Differential Lock......................................................................... 36

2.2.2. Inter-axle Differential Lock ............................................................................ 36

2.3 .Code and Identification of Main Parts ............................................................... 37

2.3.1. Cross Shaft........................................................................................................ 37

2.3.2. Half Axle Gear................................................................................................... 37

2.3.3. Planet Gear........................................................................................................ 38

2.3.4. Planet Gear Bushing....................................................................................... 38

2.3.5. Bevel Gear Pair ................................................................................................ 39

2.3.6. Hub Oil Seal ...................................................................................................... 40

2.3.7. Rear Brake Drum ............................................................................................. 40

2.3.8. Rear Hub ............................................................................................................ 40

3.1. Oil Leakage............................................................................................................... 42

3.1.1. Wheel Oil Leakage........................................................................................... 42

3.1.2. Leakage of Final Drive.................................................................................... 48

3.1.3. Oil Leakage of Axle Assembly ..................................................................... 49

3.2. Abnormal Sound and Heating ............................................................................. 50

3.2.1. Wheel Abnormal Sound and Heating ......................................................... 50

3.2.2. Abnormal Sound and Heating of Final Drive............................................ 54

3.3. Common Differential Fault ................................................................................... 57

3.3.1. Common Differential Lock Mis-operation ................................................. 57

3.3.2. Common Differential Fault ............................................................................ 58

3.3.3. Note in Differential Lock Operation ............................................................ 59

3.3.4. Inspection Method of Differential Lock ..................................................... 59

3.4. Brake Failure ............................................................................................................ 59

3.4.1. Lack of Braking Force .................................................................................... 59

3.4.2. Braking Drag ..................................................................................................... 60

3.4.3. Abnormal Brake Sound.................................................................................. 60

3.5. Other Common Faults ........................................................................................... 61

3.5.1. Drive Axle not Driving .................................................................................... 61

3.5.2. Rear Wheel Deflection .................................................................................... 61

1. STR-HC/ST16 Drive Axle

Figure 1 Composition of Drive Axle

Figure 1-2 STR Series Tandem Drive Axle

1.1.1. Final Drive

1. Central Final Drive

Figure 1-3 Appearance

Figure 1-4 Structure of Final Driver

Figure 1-5 Proper Meshing Blot of Driven Bevel Gear

2. Tandem Final Drive

Figure 1-7 Planetary Wheel Reducer

Figure 1-8 STR Series Wheel Reducer Mechanism

wheel rolling radius is rr ; If U = rr  , the movement of wheel to road is pure rolling; if

Figure 1-9 Exploded view of Symmetric Bevel Gear Differential