Rear Axle Support

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine, remove the key, and allow the machine to cool.

   

   Figure 1

4. Remove the hood from its hinges.

   Note: Retain all removed parts for later installation.

5. Rotate the battery-disconnect switch to the OFF position (Figure 2).

   

   Figure 2

   1. Battery-disconnect switch (OFF position)
   2. Battery-disconnect switch (ON position)

6. Raise the rear of the machine and support it with jack stands. Refer to Operator’s Manual for the correct procedure.

This step will create space around the rear axle prior to removing it.

1. Remove the rear wheels (Figure 3).

   

   Figure 3

   1. Rear wheel

2. Remove any parts located between the engine and the rear of the machine so that the rear axle support is exposed (Figure 4):

   • Cooling assembly

   • Batteries

   • Air filter

   • Alternator

   • Electrical subsystems

   • Hydraulic hoses

   Remove as many parts as needed so that there is enough space to remove the rear axle support in step Removing the Existing Rear Axle Support.

   Note: Retain all removed parts for later installation.

   Note: To ease assembly, label any hydraulic hoses to indicate their correct locations. Put caps and plugs on all fittings and hoses to prevent contamination.

   

   Figure 4

   1. Rear axle support

3. Remove any parts that are still attached to the axle support.

4. Disconnect any hydraulic hoses attached to the steering cylinders and the rear wheel motors (Figure 5). Repeat on the other side for each.

   

   Figure 5

   1. Hydraulic hose
   2. Steering cylinder
   3. Rear wheel motor

1. Remove the locknut and the thrust washer that secures the pivot shaft to the frame as shown in Figure 6.

   

   Figure 6

   1. Locknut
   2. Thrust washer

2. Support the rear axle to prevent it from falling.

   Caution

   The rear axle assembly weighs approximately 136 kg (300 lb). Use an appropriate lifting device to safely lift the rear axle assembly.

3. Pull the pivot shaft from the frame and the rear axle. Carefully lower the entire rear axle assembly and remove it from under the machine. Locate and retrieve the 2 thrust washers from between the machine frame and rear axle (Figure 7).

   

   Figure 7

   1. Rear axle assembly
   2. Rear axle
   3. Thrust washer
   4. Pivot shaft

This step describes how to remove the existing axle support and prepare the frame for the next step.

1. Grind down the weld located between the axle support and the corner support as shown in (Figure 8). Repeat on the other side.

   

   Figure 8

   1. Grind down this weld. Repeat on the other side.

2. Using a ruler and a drawing tool, draw a line angled 90° from the base of the axle support in both directions (Figure 9). Repeat on the other side.

   

   Figure 9

   1. 90° angle

3. Use a reciprocating saw to cut straight through the metal along the markings (Figure 10). If required, use a sander to ensure that the cuts are flush to the edge.

   

   Figure 10

Remove any paint from the indicated areas to ensure a continuous weld in step Welding the Replacement Rear Axle Support. Repeat on the other side for each (Figure 11).

Figure 11

1. Remove paint from these areas

Parts needed for this procedure:

1. Put the replacement axle support into position. Using clamps and metal support plates, secure it as shown in Figure 12. Ensure that the axle support is flush to the existing frame and that there aren’t any gaps.

   

   Figure 12

   1. Replacement rear axle support
   2. Clamp

2. Insert the spacer axle between the axle supports to ensure that they are the correct distance apart (Figure 13). Adjust the position of the replacement axle support accordingly.

   

   Figure 13

   1. Axle supports
   2. Spacer axle
   3. Pivot shaft

3. Insert the pivot shaft through the spacer axle (Figure 13). If the pivot shaft does not rotate freely adjust the position of the replacement axle support. Sand the edges of the frame as required.

4. After the axle support is in the correct position, remove the pivot shaft and the spacer axle.

5. Apply tack welds to the outside, underside, and where the corner support touches the axle support in order to hold it in place (Figure 14). Repeat on the other side.

   

   Figure 14

   1. Apply tack welds to these locations

6. Remove the clamps and the metal plates holding the axle support in place.

1. Weld the axle support to the frame in the areas shown in (Figure 15). Repeat on the other side.

   

   Figure 15

   1. Apply welds to these areas

2. Remove any weld splatter and ensure that all surfaces are clean.

3. Spray paint the newly welded areas.