Service Manual

Rev. A
4WD Rear Axle
Unit S/N 80001 - 99999
Reelmaster 5200-D/5400-D 4WD Rear AxlePage 9 - 9
(Unit Serial No. 80001 - 99999)
Removal
1. Remove rear axle drive shaft (see Drive Shaft in this
section of this manual).
2. Drain rear axle lubricant (see Changing Rear Axle
Lubricant in this section of this manual).
3. Thoroughly clean the steering cylinder hydraulic
hose connections. Disconnect the hydraulic hoses from
the steering cylinder. Put caps or plugs on all the fittings
and hoses to prevent contamination.
Note: To ease reassembly, tag each of the hoses to
show their correct position on the steering cylinder.
4. Remove steering cylinder (see Chapter 7−Brakes
and Steering in this manual).
5. Remove the cotter pins and slotted hex nuts from the
tie rod ball joints. Use a ball joint fork and remove the ball
joints from the steering arms.
6. Loosen the rear wheel lug bolts.
7. Remove the capscrew securing the end of the axle
pivot pin to the chassis (Fig. 10).
8. Block the front wheels and jack up the frame (just
ahead of the rear wheels) until the rear tire is about 1 in.
(25 mm) above the floor. Support the machine with jack
stands to prevent it from falling.
9. Remove rear wheels and wheel spacers.
10.Support the rear axle from underneath and remove
the axle pivot pin. This will release the rear axle and
washer(s) from the frame, allowing the axle to be low-
ered and removed.
Note: Several washers may have been installed be-
tween the axle pivot tube and frame during manufac-
ture. Make sure the same thickness and quantity of
washers are installed in the same location during reas-
sembly.
11.Wipe the rear axle pivot pin and pivot bushings with
a rag to remove dirt and grease. Inspect the pin and
bushings for wear or damage. Replace components as
necessary.
Installation
1. Apply a thin coat of grease to the inside of the rear
axle pivot bushings and move the rear axle assembly
into position under machine frame.
2. Install washer(s) and axle pivot pin. Use medium
strength Loctite thread locker on the capscrew and se-
cure the axle pivot pin in place (Fig. 10).
1. Install the tie rod ball joints. Tighten ball joint hex nuts
and install new cotter pins.
2. Install steering cylinder (see Chapter 7−Brakes and
Steering in this manual).
3. Install rear wheel spacers, rear wheels, and lug
bolts.
4. Remove the jackstands and lower the machine to the
floor.
5. Tighten rear wheel lug bolts to 30 to 35 ft-lbs. (41 to
47 Nm).
6. Lubricate the rear axle pivot bushings through the
grease fitting on axle assembly.
7. Fill rear axle with lubricant (see Changing Rear Axle
Lubricant in this section of this manual).
8. Install rear axle drive shaft (see Drive Shaft in this
section of this manual).
9. Install the hydraulic hoses to the steering cylinder.
10.Check steering cylinder hydraulic connections for
leaks.