Challenger Terra Gator 3244 Chassis. Manual - part 94

Page 15

9. Remove both the inner and outer bearing cones,

planetary hub assembly, and TRS toric ring metal

face seal half from the spindle. Wrap the inner and

outer bearing cones to prevent contamination and set

aside for later cleaning, inspection and re-assembly.

CAUTION

Care should be taken to store the (2) halves of the
face seal to protect them from damage and saved
for reassembly later when required.
10. Remove the loose TRS face seal from the spin-

dle. Please use the face seal tool as shown in the

special tools section during later reassembly. If

removed, store the (2) face seal halves together

and wrapped in a manner to prevent contamina-

tion or damage to the metal seal surfaces.

11. If required, use a suitable bearing cup puller to

remove both the cups from the planetary hub

assembly. Wrap both the bearing cups to prevent 

contamination. If bearing cups are not to be

removed, please proceed to the next step.

12. Remove the inner bearing spacer from the 

spindle only if required. This spacer has had

Loctite 680 or equivalent applied at original 

production assembly and should not be removed

unless damaged.

WARNING

Observe all warnings and cautions provided by
the press manufacturer to avoid damage to 
components and serious personal injury.

NOTE:

Should the planetary spider and gearsets

need to be disassembled, please go to the specific

section for disassembly required.
13. Remove the planetary ring gear and O-ring from

the spindle flange, if required, separate the ring

gear and O-ring from the spindle.Set aside these

components for later inspection and reassembly.

Figure 2.15.

!

!

Disassembly of the Planetary Spider
Assembly

1. Place the planetary spider assembly safely in a

vertical position with the planetary gears facing

upwards. Figure 2.16.

NOTE:

Using a grease pencil, mark each planet 

pinion shaft/planetary pinion gear with same number

to identify which pinion shaft and gear were originally

pre-assembled together for later re-assembly. 
2. Mark each planet pinion shaft and its planetary pin-

ion gear with matching numbers.

3. Remove the snap ring from the groove near end 

of each planetary pinion shaft.

4. Remove the inner washer from each planetary 

pinion shaft. During removal, mark the washer 

with the pinion shaft number to retain with same

original planetary shaft/gear assembly or place in

numbered plastic bags.

NOTE:

The (33) needle rollers/planetary gear 

assembly should also be placed in separate bags as

removed from each planetary pinion /shaft assembly

and marked to keep the rollers with the same planet

gear/shaft for later inspection and re-assembly.
5. Carefully lift the planet pinion gear, full complement

of needle rollers, and outer thrust washer as an

assembly. It may be easier to slide a thin shim

stock under the thrust washer or planetary pinion

gear as it is lifted to capture all the loose needle

rollers. The needle rollers should be retained or

replaced, if required, as a set for each planetary

pinion and pinion shaft.

6. Using the grease pencil, label the outer washer

with the same number as marked for the planetary

gear/needle roller assembly.

NOTE:

Repeat above for each planet gear to be

removed.

Section 2

Removal & Disassembly

Figure 2.15

O-RING

RING GEAR

SPINDLE

Figure 2.16

SNAP RING

INNER THRUST
WASHER

PLANETARY
PINION GEAR

ROLLERS

OUTER THRUST
WASHER

PLANETARY
PINION SHAFT

PLANETARY SPIDER

Page 16

Do Not Remove the Planetary Pinion
Shafts from the Planet Spider

NOTE:

The planetary pinion shafts are not 

serviceable items. Be careful not to bump or 

damage the pinion shafts. 

CAUTION

The planetary pinion shafts are not serviceable
items and must not be pressed out of the 
planetary spider shaft.
The planetary pinion shafts are precisely "fixture

located" in the spider by a heavy press fit. Removal

and reassembly of the pinion shafts can change the

precision pinion shaft locations relative to each other.

Disassembly of the Wet Brake Assembly

If the axle being serviced has a wet disc brake, use

the following recommended service procedure.

Figure 2.17.

Set aside each component as removed

for later inspection and reassembly in the correct

order with mating surfaces together. Should the axle

being serviced be less wet brake, move to the 

next section Disassembly of the Axle Shaft, Snap

Ring, Sun Gear Assembly.

NOTE:

Number or stack in order of removal the 

friction discs and stationary plates as a reference 

during later reassembly.

1. The backing plate may now be removed by sliding

the backing plate off the dowels located in the axle

housing flange.

2. Friction disc can be removed by sliding off the sun

gear teeth.

3. The brake stationary plate can be removed by 

sliding along the axle housing dowels.

!

NOTE:

Capscrews in spring housing had a medium

strength thread locker applied at original production

assembly. 
NOTE:

These capscrews also compress the brake

return springs on the spring dowels within the brake

assembly. Figure 2.18.
4. Loosen the (2) M8 spring housing to axle housing

capscrews and washers that retain the wet brake

piston assembly.

5. Remove the axle shaft, sun gear, snap ring, and

thrust washer assembly from the axle housing. The

thrust washer may come out with the axle shaft

assembly or may stay within the spring housing.

Should the thrust washer stay within the spring

housing, remove separately after the axle shaft is

removed.

6. Remove the spring housing capscrews, washers

and return springs from the spring dowels with the

spring housing from the axle.

7. Remove the wet brake piston and (2) D-Rings

attached.

8. Remove the (2) D-Rings from the wet brake piston

for later inspection and reassembly. 

NOTE:

Dowels might have a light press into the axle

housing. If being removed, care should be taken not

to damage the dowels to be reused in later reassembly.
9. Remove the (2) wet brake spring dowels from axle

housing, only if required. 

CAUTION

Follow recommended glue manufacturers 
recommendations for safe usage and to avoid
potential irritation to skin, eyes, etc.

!

Figure 2.17

STATIONARY
PLATE

FRICTION DISC

BACKING PLATE

DOWEL

Figure 2.18

SPRING DOWEL

SPRING

THRUST
WASHER

SUN GEAR

M8 CAPSCREWS AND WASHERS

SPRING HOUSING

AXLE SHAFT

PISTON

D-RING SEALS

SNAP RING

Section 2
Removal & Disassembly

Page 17

10. Remove the shim that is glued onto the axle

housing flange face, only if required, by using a 

suitable glue dissolving agent. Removal of this

shim is only required, if the removal of any of the

(6) dowels fixed into the axle housing flange is

required. During removal, the shim could be

destroyed, so replacement with a new shim is 

recommended. Figure 2.19.

11. Remove the (6) dowels from the half rounds in the

axle housing flange, only if required. If being

removed, care should be taken not to damage 

the dowels to be reused in later reassembly.

Disassembly of the Axle Shaft, Snap
Ring, Sun Gear Assembly

To complete disassembly of the axle shaft, sun gear,

snap ring sub assembly, use the following 

recommended procedure. Figure 2.18.
1. Remove the axle shaft, sun gear, snap ring and

thrust washer assembly from the axle housing, if

not already removed. (Axle being serviced is less

wet disc brake).The thrust washer may stay within

the spring housing when the axle shaft is removed.

Should the thrust washer stay within the spring

housing, remove the thrust washer 

separately after the axle shaft is removed. 

2. Remove the snap ring retaining the sun gear on

the axle shaft. 

3. Remove the sun gear from the axle shaft.
4. Remove the thrust washer from the axle shaft.
With the axle shafts removed, the carrier assembly

removal, as well as servicing the internal hydraulic

brake tubing assemblies if equipped with the wet

brake option, is now possible. 
NOTE:

For recommended carrier removal procedure,

the AxleTech carrier maintenance manual 5.4 should

be used for recommended disassembly, inspection,

and reassembly procedures. 

Disassembly of Wet Brake Actuation
Tubing Assembly

If the axle being serviced has a wet disc brake with

central actuation, then there will be internal wet brake

actuation tubing assemblies in the axle housing

assembly. These tubing assemblies will be accessible

for service when the carrier assembly, axle shaft and

planetary wheel ends are removed. “The following

service procedure is recommended to disassemble

the brake tubing assemblies, if required.
1. Loosen both the (2) M14 hydraulic nuts fitted to the

tee near the carrier bowl of the axle housing.

2. Loosen the hydraulic nut in the axle housing flange

ends that retains the opposite end of each tube

assembly. Mark tubing for later reassembly in 

same locations.

3. The complete hydraulic tube assembly can now be

removed separately from the axle housing from

each of the housing flange ends.

4. The hydraulic tee can now be unscrewed from the

axle housing carrier bowl area.

NOTE:

This inlet port had high strength thread locker

applied at original production assembly.
5. The M22 hydraulic inlet port can be removed, 

only if required, from the axle housing. 

Figure 2.19

SHIM

DOWEL

Section 2

Removal & Disassembly

Page 18

NOTE:

For the axle equipped with the wet brakes,

there are O-ring oil fill/drain plugs. The lower (3) plugs

are magnetic plugs. These plugs must be removed

and cleaned.

WARNING

To prevent serious eye injury, always wear safe eye
protection when you perform vehicle maintenance
or service.

Solvent cleaners can be flammable, poisonous
and cause burns. Examples of solvent cleaners
are carbon tetrachloride, and emulsion-type and
petroleum-base cleaners. Read the manufacturer’s
instructions before using a solvent cleaner, then
carefully follow the instructions. Also follow the
procedures below.

• Wear safe eye protection.

• Wear clothing that protects your skin.

• Work in a well-ventilated area.

• Do not use gasoline, or solvents that contain

gasoline. Gasoline can explode.

• You must use hot solution tanks or alkaline

solutions correctly. Read the manufacturer’s
instructions before using hot solution tanks and
alkaline solutions. Then carefully follow the
instructions.

• Remove gasket material from parts. Take care

not to damage ground surfaces.

• Do NOT clean ground or polished parts in a hot

solution tank, water, steam or alkaline solution.

Take care when you use Loctite

®

adhesive to avoid

serious personal injury. Read the 
manufacturer’s instructions before using this
product. Follow the instructions carefully to 
prevent irritation to the eyes and skin.

Clean Rough Parts

1. Clean rough parts with the same method as 

cleaning ground and polished parts.

2. Rough parts can be cleaned in hot solution tanks

with a weak or diluted alkaline solution.

3. Parts must remain in hot solution tanks until 

heated and completely cleaned.

4. Parts must be washed with water until all traces 

of the alkaline solution are removed.

!

Clean Ground and Polished Parts

1. Use a cleaning solvent to clean ground or polished

parts or surfaces. Kerosene or diesel fuel oil can

be used for this purpose. Do not use gasoline.

2. Use a tool with a flat blade if required, to remove

sealant material from parts. Be careful not to 

damage polished or surfaces.

CAUTION

Do not use hot solution tanks or water and 
alkaline solutions to clean ground or polished
parts. Damage to parts can result.
3. Do not clean ground or polished parts with water or

steam. Do not immerse ground or polished parts in

a hot solution tank or use strong alkaline solutions

for cleaning, or the smooth sealing surface may 

be damaged.

Cleaning the Axle Housing
Assembly

NOTE:

Refer to manual 5.4 to Clean and Inspect the

Carrier. Follow all recommended procedures and

comments with all Warnings and Cautions noted.
• An axle housing may be steam cleaned on the 

outside to remove dirt. If cleaning only outside of

housing, cover over all openings in the axle 

assembly. Examples of openings are breathers

(unless breathers are remote mounted).

• The axle housing may be steam cleaned internally

when all components and plugs are removed. Cover

over all openings in the axle assembly. Examples of

openings are breathers (unless breathers are

remote mounted).

• The axle housing should be inspected for any signs

of housing cracks or other wear damage. All thread-

ed holes should be reviewed to assure threads are

not damaged for re-assembly. Threaded holes may

be repaired by thread metric taps, if possible.

• Remove all metallic particles from all the magnetic

drain plugs.

• After cleaning, check behind the internal flange in

carrier area for contaminants. Also, check housing

arms for contaminants. Remove any contaminants

prior to reassembling.

Dry Parts After Cleaning

1. Parts must be dried immediately after cleaning 

and washing.

2. Dry the parts using soft, clean paper or cloth rags.

!

Section 3
Prepare Parts for Assembly