LIT-002-00 – HEAVY DUTY SERVICE MANUAL 22,500-27,500 LBS. AXLE CAPACITY – DEXTER

SEOCONTENT-STARTOPERATION MAINTENANCE
SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACITY
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Table of Contents
Introduction ………………………………………………………. 3
Important Safety Notice …………………………………………….. 3
lnstallation ………………………………………………………………. 3
General Welding Recommendations ………………………… 4
Axle Beam RepairWelding ………………………………………….. 4
Preheating Recommendations ……………………………………. 4
Affects of Welding on Axle Beam Material …………………….. 4
Welding Guide …………………………………………………………. 4
Stress of Axle Beams ………………………………………………… 4
Spring Seat Placement and Location …………………………… 5
Weld Placement Recommendation for Welding Spring Seats
to Round Axles …………………………………………………………. 5
Wheel Bearings ………………………………………………….. 7
Grease Lubrication ……………………………………………………. 7
Oil Lubrication ………………………………………………………….. 7
Adjustment ……………………………………………………………… 7
Recommended Wheel Bearing
Lubrication Specifications ………………………………………….. 7
Grease: …………………………………………………………….. 7
Approved Grease Sources: …………………………………… 7
Oil: …………………………………………………………………… 8
Approved Oil Sources: …………………………………………. 8
Brake Adjustment Procedure …………………………………. 9
Brake Assembly/Disassembly ……………………………… 10
16½” x 7″ Brakes …………………………………………………… 10
Disassembly ……………………………………………………. 10
Reassembly ……………………………………………………. 10
12¼” x 7½” Brakes – P Style ……………………………………. 10
Disassembly …………………………………………………….. 10
Reassembly ……………………………………………………. 11
12¼” x 7½” Brakes – PQ Style ………………………………….. 11
Disassembly …………………………………………………….. 11
Reassembly …………………………………………………….. 11
Heavy Duty Suspension System (HOSS) ………………….. 13
Installation …………………………………………………………….. 13
Alignment ……………………………………………………………… 13
Measuring ……………………………………………………………… 13
Adjusting ……………………………………………………………….. 14
Precautions ……………………………………………………………. 14
Additional Suspension Maintenance Check …………………. 14
Suspension Torque Requirements ………………………………. 14
Torque Values for Bolts ……………………………………………. 14
HEAVY DUTY SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACllY ,~- DEXTER
Maintenance ……………………………………………………. 15
Brake Component Lubrication ………………………………….. 15
For camshaft roller journals ………………………………… 15
For anchor pins ………………………………………………… 15
For manual slack adjusters …………………………………. 15
For automatic slack adjusters ……………………………… 15
Frequency of Service ………………………………………………. 15
Suggested Preventative Maintenance …………………………. 15
Every 1,000 Miles ……………………………………………. 15
Every 12,000 Miles ………………………………………….. 15
Every 25,000 to 30,000 Miles …………………………… 15
Every 100,000 Miles, Once a Year,
or at Brake Reline ……………………………………………… 15
Fastener Specifications ……………………………………… 16
Replacement Parts/Kits …………………………………….. 17
Brake Shoe Hardware Kits ………………………………………… 17
Brake Block Kits ……………………………………………………… 17
Camshaft Repair Kits ……………………………………………….. 17
Shoe & Block Assemblies …………………………………………. 17
Warranty …………………………………………………………. 18
Axle Identification …………………………………………….. 19
Service Record …………………………………………………. 20
Notes ……………………………………………………………… 22
Dexter Video Gallery …………………………………………… 24
Introduction
This manual is designed to provide information for you to
understand, use, maintain, and service your trailer running
gear system. Your axles are manufactured by Dexter Axle.
Since 1960, Dexter’s experience in the design, testing,
and manufacturing of trailer axles has resulted in the most
complete product line in the industry. The Dexter running
gear system consists of axles, suspensions, and braking
systems which are engineered to provide you the finest
towing and stopping performance available today.
Two Dexter philosophies are at work to provide you the best
product available and have enabled us to maintain our
position of leadership. First, we operate on the theory that
“there is always a better way” for a product to operate, to
be manufactured, and/ or to be serviced. We are constantly
striving to find that better way.
Secondly, we maintain wall-to-wall production control so
that all the major components of your running gear system
are manufactured in Dexter facilities under our strict quality
control standards. These manufactured components include
axle beams, hubs, drums, spindles, and braking systems, as
well as the components used in the attachment of the axle
to the chassis. Dexter has the most complete, state-of-theart
manufacturing facilities which enable us to provide you,
the trailer owner, with the finest product possible.
Visit us online at www.dexteraxle.com.
Important Safety Notice
Appropriate service methods and repair procedures are
essential for the safe, reliable operation of all running gear
as well as the personal safety of the individual doing the
work. This manual provides general directions for performing
service and repair work with tested, effective techniques.
Following these guidelines will help assure reliability.
There are numerous variations in procedures, techniques,
tools, parts for servicing axles, as well as in the skill of the
individual doing the work. This manual cannot possibly
anticipate all such variations and provide advice or cautions
as to each. Anyone who departs from the instructions
provided in this manual must first establish that they neither
compromise their personal safety nor the vehicle integrity by
their choice of methods, tools, or parts.
Refer to your vehicle manufacturer’s owners manual for
additional procedures, techniques, and warnings prior to
performing any maintenance or repairs.
HEAVY DUTY SERVICE MANUAL
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&CAUTION
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This is the safety alert symbol. It is used to alert you to
potential injury hazards. Obey all safety messages that follow
this symbol to avoid possible injury or death.
Installation
To assure safe operation and maximum durability of parts
such as brake linings and tires, it is necessary to position
and install the axle properly. It is recommended that the
axle assembly be installed so that camshafts rotate in the
same direction as the wheels. Installation in which the
camshaft rotation is opposite that of wheel rotation could
cause noisy brakes, chatter, and wheel “hop”. With this
thought in mind, the axle should be ordered with placement
of air chamber and slack adjuster assemblies that will
ensure the correct directional rotation of the camshafts
when the axle is installed.
It is the responsibility of the axle installer to adjust the
brakes properly. The recommended adjustment procedure is
covered in the section pertaining to brakes.
Responsibility for proper axle alignment lies with the axle
installer. The axle must be installed so that it will be parallel
to the drive axle(s) of the tractor. This will allow good vehicle
control when cornering, longer tire wear, and it will eliminate
dog tracking. Alignment can be determined by measuring
from the center of the trailer king pin to the center of each
end of the axles. The difference should not vary by more
than 1/16″. In the case of multiple axles, the axles must
also be in line with each other. The difference between the
centers of one axle and the centers of the other axle must
not vary more than 1/a”.
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General Welding Recommendations HEAVY DUTY SERVICE MANUAL
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Dexter tubular axles are made of high strength steel for
better fatigue life and superior welding qualities. The round
tubular axles provide a uniform section modulus no matter
how the beam is rotated.
Brake spiders are positioned and welded to exacting
specification requirements at our factory. Ring welding the
spider directly to the axle beam provides a higher strength
and more reliable brake attachment over bolt-on versions.
In welding suspension component parts to a Dexter trailer
axle, extreme care must be exercised to obtain correct
location and ensure the spring seat load bearing surfaces
are parallel to each other.
Axle Beam Repair Welding
In the interest of safety and preserving the service life of
trailer axle assemblies, Dexter recommends that trailer axle
beams NOT be repair welded. Repair welding can detract
from the structural integrity of an engineered component,
particularly on heat-treated parts where the benefit of the
processing may be nullified by the welding. Therefore, a new
replacement beam should be installed as soon as possible.
Preheating Recommendations
Absolutely no welding should be done on axles that are
below 50°F. Before welding on suspension components
or any other part onto the axle, the area (within 3″) of the
attachment point should be warmed slowly to between
500-600°F. Immediately after checking the temperature
with an appropriate temperature sensitive crayon, the
part(s) should be tack welded in place. Recheck the
temperature and if below 475°F, reheat to 500-600°F and
complete welding per welding instructions.
Affects of Welding on
Axle Beam Material
All welds made on the beam create, in effect, an extremely
localized heat-treatment of the metal. The heat generated
during the welding process can cause the material in the
HAZ (heat affected zone) to become hardened or brittle.
This effect can impart an undesirable characteristic to
the normally ductile structure. This small hardened area
becomes the weakest part of the beam and therefore is
the area most susceptible to failure. The axle beam is
no stronger than its weakest section. As evident from the
sketch on the next page, the welds should be horizontal
and as near as possible to the front and rear horizontal
center line of the axle beam. Always avoid welds that are
circumferential in nature below the horizontal center line.
Welding Guide
Dexter supplies axles to customers in all stages of assembly
from the beam with spindles only, to the complete axle
assemblies. In the final analysis and with few exceptions,
we have little or no control over later assembly of
incomplete units by the trailer fabricator and, therefore,
we can not be responsible for warranty on improperly
processed components.
Stress of Axle Beams
The main loaded stresses on a beam are expressed as
three primary stress zones. The compression stress zone
(top side), the tension stress zone (bottom side), and the
neutral stress zone (front and rear horizontal center line
commonly referred to as the neutral axis).
Vertical —~
Centerline
Neutral
Axis
COMPRESSION SIDE
Horizontal
Centerline
TENSION SIDE
The above is a graphic representation of the degrees of
stress in the wall of the tube when the beam is under load.
The length of the arrows “X” represents the amount of stress
at a given point. From this illustration, it is evident that the
two opposite stresses diminish as the horizontal center line
of the beam is approached.
In addition, the torsional stress imparted by braking action
of the wheels is taken into consideration in rating the axle
capacity. An allowance of both stresses bending (beam
load) and torsional are factored into the calculations to
provide an acceptable design factor. The stresses are
reapplied and reversed many times during normal axle
beam life. For this reason, the beam material must have
certain properties such as impact strength, that permit it to
absorb shock, to flex, and then to resume its original and
normal “as manufactured” condition.
When welding, it is necessary to avoid the high stress areas
on the tube top side (compression zone) and tube bottom
side (tension zone). All welds should be made as close to
the horizontal center line as possible. When the axle tube is
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General Welding Recommendations HEAVY DUTY SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACllY ,~- DEXTER
To assure welds are within
approved neutral axis
zone quadrants
Maximum rotation of
camshaft position is
+6′ up to -6′ down
from o· neutral axis,
Forward
Axle Centers
MOST COMMOM FOR
OVER-THE-HIGHWAY
OPERATIONS,
subjected to the heat from welding and then rapid cooling,
the material adjacent to the weld loses it’s desirable ductile
properties and becomes brittle. If this condition exists in the
high stress areas under maximum load conditions, the life
of the axle will be greatly reduced and premature fatigue
failure can occur. Recommended locations for the welds are
shown below.
Spring Seat Placement and Location
One of the most critical and important phases of vehicle
fabrication is the placement, location, and attachment of
spring seats on the axle.
“Overhang” is defined as axle track minus spring center
dimension divided by two:
T-S.C.
2
The maximum spring center is calculated such that
recommended inside of tire or drum clearance to vehicle
frame is achieved.
Permanent deformation and/or premature failure of the axle
may result if the spring centers are too narrow.
Weld Placement Recommendation for
Welding Spring Seats to Round Axles
Note: If spring seat and related U-bolt clamp parts are
different than shown, refer or consult with suspension
manufacturer for weld recommendations.
Do not
weld in
this area
3.00″
4.00″
Do not
weld in
this area
TOP
BOTTOM
The welding rods should conform to AWS (American Welding
Society), grade E-7O18 (Oven-Dried) or comparable.
Recommended rod size is o/32″ at voltage and amperage
recommended by the electrode manufacturer. For maximum
strength, a three-pass weld should be used. The arc should
not be broken at the end of each pass and the corners should
be wrapped. The electrode should be backed up to fill in the
crater at the end of each pass. If the arc is broken between
passes, thoroughly clean the weld between each pass.
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General Welding Recommendations
Process Electrode
Shielded metal-arc welding of A.W.S.* E70XX
carbon and low alloy steels.
Gas metal-arc welding of carbon A.W.S. * ER70S-X
and low alloy steels.
Submerged arc welding of mild A.W.S.* F-72-XXXXX
and low alloy steels.
• American Welding Society
CAUTION
Do not bring axles in from non-heated storage and weld while
cold. Do not “test the arc” on the axle beam.
Fillets up to ½” can be used. Maximum gap .030 inch.
The attachments should fit-up as close to the beam as
possible to avoid excessive welding. Electrical grounding to
the axle for welding purposes, should be done on one of the
attachments such as the air chamber bracket, cam support,
or brake spider. Connections should be clean and tight.
Loose or dirty connections will cause arcing at that point
during welding. These small arced areas can create the
potential for failure in highly stressed structures. Therefore,
grounding should never be done directly on the axle tube.
Never attach the ground to an area that would allow the
ground path to pass through the spindles, bearings, hub, or
wheel components.
CAUTION
To provide optimum suspension-to-tube welds, preheating is
recommended. Preheating will minimize loss of the ductile
properties in the weld area by slowing the rate of cooling,
thus reducing the formation of an untempered martensitic
grain structure adjacent to the weld. Martensite, a brittle
grain structure, is formed by the rapid cooling of the metal
surrounding the weld area. Preheat the suspension seat weld
area to 500-600° F prior to welding. Preheated temperature
should be verified with a temperature sensitive crayon or
appropriate means.
The above welding recommendation pertains to all Dexter
Axle Company axle beams. Unapproved variation from the
procedures listed will void the axle warranty and could
result in an unsafe weld.
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Wheel Bearings
Periodic inspection and regular replacement of lubricant is
important to obtain maximum bearing life. Always inspect
bearings for damage prior to installation. When installing
wheel bearings, it is important to ensure both the inside of
the wheel hub cavity, bearings and grease cap are clean. It
is also recommended that seals be replaced when wheel
hubs have been removed for service. EXTREME CARE
SHOULD BETAKEN WHEN REINSTALLING WHEEL HUBS
TO PREVENT DAMAGE TO THE SEALS. DO NOT CONTACT
RUBBER SEALING LIP WITH THE SPINDLE THREADS.
Grease Lubrication
Grease should be replaced every 12,000 miles or 12
months. Prior to repacking bearings, all old grease should
be removed from the wheel hub cavity and bearings.
Bearings should be packed by machine. If machine is
unavailable, packing by hand method is acceptable. The
method to pack bearing cones is as follows:
1. Place a quantity of grease onto
the palm of your hand.
2. Press a section of the widest
end of bearing into the outer
edge of the grease pile closest
to the thumb, forcing grease
into the interior of the bearing
between two adjacent rollers.
3. Repeat this while rotating the bearing from roller to
roller.
4. Continue this process until you have the entire
bearing completely filled with grease.
5. Before reinstalling, apply a light coat of grease onto
the bearing cup mating surface.
Oil Lubrication
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rotating the hub to ensure proper seating of the
bearings, cups and seal in the wheel hub.
&CAUTION
You must follow the maintenance procedures to prevent
damage to important structural components. Damage to
certain structural components such as wheel bearings can
cause the wheel end to come off of the axle. Loss of a wheel
end while the trailer is moving can cause you to lose control
and lead to an accident, which can result in serious injury or
death.
2. Loosen the inner spindle nut to remove preload
torque.
3. Hand tighten the inner adjustment nut, then back off
¼turn,% turn maximum.
4. Install lock ring (lock ring must engage pin on inner
spindle nut. Nut to engage nearest pin hole).
5. Install tab washer and outer locknut. Torque outer
spindle nut to 250-300 Ft. Lbs. Bend 3 tabs over
outer nut flats to secure.
6. This procedure should assure an end-play of .001″ to
.010″ which must be present in the adjusted wheel
bearing assembly.
Recommended Wheel Bearing
Lubrication Specifications
Grease:
Thickener Type Lithium Complex
Dropping Point 215°C (419°F) Minimum
Consistency NLGI No. 2
Additives EP, Corrosion & Oxidation Inhibitors
Viscosity Index 80 Minimum
Oil should be changed at least once a year, or 100,000 Approved Grease Sources:
miles, or whenever the seals or brakes are replaced. Oil
level should be inspected every 1,000 miles. Always allow
a few minutes, after adding oil or after vehicle operation, for
the oil to settle when establishing the required oil level.
Adjustment
1. After properly installing the bearings and seals
according to the manufacturer’s recommendations,
tighten the inner spindle nut to 100 Ft. Lbs. while
76 Lubricants Company
Citgo Petroleum Corp.
Exxon Company, USA
Kendall Motor Oil
(Div. of Witco Corp.)
76 Multiplex EP
76 Multiplex RED
Lithoplex MP #2
Lithoplex CM #2
Ronex, MP
Kendall Super Blu L427
Grease
2019.01 I 1
Wheel Bearings
Mobil Oil Company Mobil Grease HP
Mobilith AW 2
Mobil I Synthetic Grease
Mystik Oil Company Inc. Mystik JT-6 Hi-Temp Grease
Red Lithium Complex EP No. 2
Mystik SX-6 Synthetic Blend
Extreme
Range, Low Temp Blue Lithium
Complex
Oil Center Research Liquid-0-Ring No, 167L
of Oklahoma
Pennzoil-Quaker State Synthetic Red Grease
Company
Shell Gadus S3 V220C
Gadus S5 V220
Rotella Heavy Duty Lithium
Complex#2
Royal Mfg. Company Royal 98 Multi-Lube EP #2
Lithium Complex
Chevron Texaco Chevron Ulti-Plex Grease EP
NLGI2
Texaco Starplex Moly MPGM 2
Chem Arrow Corp. Arrow 78981-1
Valvoline Valvoline Multi-Purpose GM
(Div. of Ashland Inc.)
Great Plains Lubricants Lithium Complex EP Grease
NLGl2
Oil:
I SAE 90, SAE SOW-90, SAE 75W-90
Approved Oil Sources:
Ashland Oil Valvoline Dura Blend
Valvoline Power Lube
CITGO Petroleum Co. CITGO Premium Gear Oil MP
Mystik JT-7
Mystik Power Lube
Conoco Universal Gear Lubricant SOW-
90
Exxon Company USA Gear Oil GX 80W-90
Industrial Oils Unlimited Super MP Gear Oil SOW-90
Kendall Refining Co. Kendall NS-MP Hypoid Gear
Lube
Lubriplate Division / Lubriplate APG 90
Fiske Brothers Refining
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MFA Oil Company Multi-Purpose Gear Oil SOW-
90
Mobil Oil Corporation Mobilube SHC
Mobil 1 Synthetic Gear Lube
Phillips 66 Petroleum Superior Multi-Purpose Gear
Oil
Philguard Gear Oil
Philsyn Gear Oil
Pennzoil Products Co. Gear Plus 80W-90 GL-5
Gear Plus Super 75W-90
Gear Plus Super EW 80W-90
Multi-Purpose 4092 Gear Lube
Oil Center Research Liquid-0-Ring 750 GX
Sun Refining and Sonoco Ultra
Marketing Company Sonoco Dura Gear
Shell Oil Company SpiraxA
Spirax G
Spirax HD
Spirax S
Texaco Oil Company Multigear EP
Multigear SS
Troco Division / Multigear Select Gear Oil
Royal Manufacturing
Union Oil Company Unocal MP Gear Lube
76 Triton Syn Lube EP
2019.01 I s
Brake Adjustment Procedure
1. Grease cam bracket and spider fittings.
CAUTION
Care must be exercised to prevent grease from coming in
contact with brake linings which could result in reduced
braking performance.
2. Adjust the slack adjuster until the brake lining comes
into contact with the brake drum.
A. For green brakes*, there should be a slight amount
of wheel drag at initial adjustment to compensate
for any lining irregularities (high spot, etc.)
B. For burnished or broken-in brakes, back off the
slack adjuster to achieve .030″ clearance between
drum and shoes.
3. Apply brakes using normal truck operating pressure
(average line pressure should be 90 psi.).
&CAUTION
USE OF AIR PRESSURE IN EXCESS OF 130 PSI COULD
RESULTIN FAILURE OFTHE AIR CHAMBER OR SPRING BRAKE
CHAMBER AND RESULT IN INJURY.
A. Check the amount of push rod travel. Maximum
should not exceed 2″ for Type 30 chambers and
1 ¾” for Type 24 chambers.
1) Optimum push rod travel on a green brake*
should be under 2″.
2) Optimum push rod travel on a burnished or
broken-in brake should be under 1 ¾”.
B. With air pressure applied to brakes, check
for lining to drum contact. The contact should
approach 100%. Use a .010″ feeler gauge if in
doubt. It should not fit between the lining and
drum during brake application.
C. Check to ensure the lining is inside the drum
during application. More than .06″ hanging out of
the drum is not recommended.
4. Release air pressure from the brakes and confirm that
all brakes release to the normal relaxed position.
*Note: A “green brake” is an unground, unburnished
brake. Normal manufacturing tolerances dictate that
there is a break-in period required after which the
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lining will seat into a perfect concentric situation.
During this break-in period, the user must be aware
that additional brake adjustments will be mandatory
to achieve optimum braking performance.
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Brake Assembly/Disassembly
Although Dexter Axle supplies non-asbestos
brake linings as standard equipment, asbestos
linings may still be found on axles in service.
&CAUTION
POTENTIAL ASBESTOS DUST HAZARD!
Some older brake linings may contain asbestos dust, which has
been linked to serious or fatal illnesses. Certain precautions
need to be taken when servicing brakes:
1. Avoid creating or breathing dust.
2. Avoid machining, filing or grinding the brake linings.
3. Do not use compressed air or dry brushing for cleaning
(dust can be removed with a damp brush).
16½ 11 x 711 Brakes
Disassembly
1. Block and secure trailer on adequate capacity jack
stands. Follow trailer manufacturers recommendations
for lifting and supporting the unit. Check that the
wheel and drum rotate freely.
2. Release brake and back off slack adjuster.
3. Remove wheel equipment.
4. Remove slack adjuster lock ring and slack adjuster.
5. Remove brake drum (if outboard mount). Remove hub
and drum assembly (if inboard mount).
6. Disengage the roller retainers from the rollers.
7. Press down on the bottom brake shoe and remove
the lower cam roller. Lift the top shoe and take out
the top cam roller.
8. Lift out the shoe retractor spring, which is now free of
tension.
9. Swing the lower shoe back approximately 180°
to relieve the tension on the shoe keeper springs.
Remove the springs and slip the shoes off the anchor
pins.
10. Remove camshaft lock ring, spacer washer(s) and
camshaft.
11. After removing the shoes, completely inspect all brake
components, servicing as necessary.
Reassembly
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1. Install new anchor pin bushings, camshaft bushing
and camshaft seals into the spider.
2. Install cam roller, retainer clip and retractor spring
retainers onto the brake shoes.
3. Install Ya” thick camshaft washer onto the camshaft.
4. Install the cam shaft into the spider. Install spacer
washer and lock ring retainer on camshaft before
sliding the camshaft through the camshaft support
bracket. Install the slack adjuster, washer and lock
ring retainer.
5. Install the brake keeper springs onto the shoes. Install
shoes onto the spider by placing shoes in place on
the anchor pins, then “wrap” the two shoes into place
about the spider.
6. Install the shoe retractor spring onto the shoes.
7. Connect slack adjuster to brake chamber push rod.
8. Reinstall wheel equipment per manufacturers
instructions.
9. Adjust brakes as outlined in brake adjustment
procedures.
Note: Always use new springs when servicing brakes.
Always use Dexter shoes when replacing shoes.
12¼ 11 x 7½ 11 Brakes -P Style
Disassembly
1. Block and secure trailer on adequate capacity jack
stands. Follow trailer manufacturers recommendations
for lifting and supporting the unit. Check that the
wheel and drum rotate freely.
2. Release brake and back off slack adjuster.
3. Remove wheel equipment.
4. Remove slack adjuster lock ring and slack adjuster.
5. Remove hub and drum assembly.
6. Remove anchor pin anti-rotation bolt (if applicable).
7. Remove anchor pin retainers and washers.
8. Remove anchor pins and brake shoes.
9. Remove brake return springs.
10. Remove camshaft lock ring, spacer washers(s) and
2019.01 I 10
Brake Assembly/Disassembly
cam shaft.
11. Remove roller pin retainers.
12. Remove roller pins, rollers from shoes.
13. Remove camshaft bushings and seals from spider.
14. After removing the shoes, completely inspect all brake
components, servicing as necessary.
Reassembly
1. Install new camshaft bushing and camshaft seals into
the spider.
2. Install cam roller assemblies onto the brake shoes.
3. Install “D” shaped camshaft washer onto the
camshaft.
4. Install the camshaft into the spider. Install spacer
washer and lock ring retainer on camshaft before
sliding the camshaft through the camshaft support
bracket. Install the slack adjuster, washer and lock
ring retainer.
5. Install shoes, anchor pins and spacers onto spider.
Install anchor lock rings.
6. Install retractor spring.
7. Tighten anchor pin anti-rotation screw (if applicable).
8. Connect slack adjuster to brake chamber push rod.
9. Reinstall wheel equipment per manufacturers
instructions.
10. Adjust brakes as outlined in brake adjustment
procedures.
Note: Always use new springs when servicing brakes.
Always use Dexter shoes when replacing shoes.
12¼ 11 x 71h II Brakes – PQ Style
Disassembly
1. Block and secure trailer on adequate capacity jack
stands. Follow trailer manufacturers recommendations
for lifting and supporting the unit. Check that the
wheel and drum rotate freely.
2. Release brake and back off slack adjuster.
3. Remove wheel equipment.
4. Lift top shoe upward to disengage the shoe webs
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from the anchor pin. Remove anchor pin.
5. Repeat procedure 4 for the bottom shoe.
6. Remove brake keeper springs.
,~- DEXTER
7. Unwrap bottom shoe by pivoting the shoe on the
camshaft head and twisting the shoe 90° under the
spindle. Remove shoe assemblies from spider.
8. Remove slack adjuster lock ring, disconnect slack
clevis, and then remove slack adjuster.
9. Remove camshaft lock ring, spacer washer(s) and
camshaft.
10. Completely inspect all brake components, servicing
as necessary.
Reassembly
1. Install new camshaft bushing. Ream bushing to
1.505/1.515 if required. Install camshaft seals into
the spider.
2. Lubricate roller bore with anti-seize and install new
cam roller assemblies onto the brake shoes.
Note: The head of roller pin should face the camshaft
“D” washer once shoes are installed on spider.
3. Install “D” shaped camshaft washer onto the
camshaft.
4. Install the camshaft into the spider. Install 005-075-
00 washer and lock ring retainer on the camshaft
before sliding the camshaft through the camshaft
support bracket.
5. Install the slack adjuster and 005-134-00 washer
and 069-078-00 lock ring retainer for 28 spline
camshafts or 005-075-00 washer and 069-020-00
lock ring retainer for 10 spline camshafts.
6. Lubricate anchor pin notches with anti-seize lubricant.
7. Install “W” shaped retractor spring retainer pin
into the 0.50″ diameter shoe web holes near the
camshaft roller end of the shoe.
8. Install retractor spring between shoes. Place top shoe
onto spider as in service. Pivot bottom shoe on the
camshaft head and twist the shoe 90° under the
spindle, properly placing shoe on the spider as in
service.
2019.01 I 11
Brake Assembly/Disassembly
9. Install two (2) keeper springs on the anchor end of
the shoes.
10. Lubricate anchor pin bores and shoe anchor pins with
anti-seize lubricant.
11. Repeat procedure 10 for the bottom shoe.
12. Lift top shoe upwards to clear anchor pin hole. Install
anchor pin.
13. Connect slack adjuster to brake chamber push rod.
14. Lubricate cam bushings and slack adjuster.
15. Reinstall wheel equipment per manufacturers
instructions.
16. Adjust brakes as outlined in brake adjustment
procedures.
Note: Always use new springs when servicing brakes.
Always use Dexter shoes when replacing shoes.
HEAVY DUTY SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACllY ,~- DEXTER
2019.01 I 12
Heavy Duty Suspension System (HOSS) HEAVY DUTY SERVICE MANUAL /1:J®
22,500-27,500 LBS. AXLE CAPACllY DEXTER
Installation
Responsibility for proper axle alignment lies with the axle
installer. The axle must be installed so that it will be parallel
to the drive axle(s) of the tractor. This will allow good vehicle
control when cornering, longer tire wear, and it will eliminate
dog tracking. Alignment can be determined by measuring
from the center of the trailer king pin to the center of each
end of the axles. The difference should not vary by more
than ½s”. In the case of multiple axles, the axles must
also be in line with each other. The difference between the
centers of one axle and end centers of the other axle must
not vary more than 1/s”.
it CAUTION
Safety glasses should be worn at all times when assembling or
dlsassembllng axles and their components.
Dexter tubular axles are made of high strength steel for
better fatigue life and superior welding qualities. The round
tubular axles provide a uniform section modulus no matter
how the beam is rotated.
Brake spiders are positioned and welded to specific
requirements at our factory. Welding the spider directly to
the axle beam provides a higher strength and more reliable
brake attachment over bolt-on versions.
In welding suspension components to a Dexter trailer
axle, extreme care must be exercised to obtain correct
location and ensure the spring seat load bearing surfaces
are parallel to each other. Any welding of additional
attachments to the axle should be approved by Dexter’s
engineering department.
Alignment
For safe and efficient trailer operation, to prevent excessive
tire wear off-tracking and hard pulling, it is recommended
Before taking axle alignment measurements, make sure the
trailer is unloaded and free the suspension of any binds by
pushing the trailer backwards and then pulling the trailer
forward. While pulling the trailer forward on a level floor, apply
the brakes and release. This will ensure that an adjustable
undercarriage is in its rearmost lock position. The trailer MUST
be level from side to side as well as from front to rear.
Note: Neither service nor parking brakes should be applied
during the measurement procedure.
Ensure the king pin or coupler is at the correct height.
Use axle end extenders (or remove outer wheels and any
obstructions) to achieve a straight line for measuring from
king pin to the axle ends or axle centers.
Proper tools for axle alignment inspection are:
Spring loaded kingpin extender with level or plumbob.
Axle end extenders.
50 foot steel tape.
Optional; adjustable tram.
A means to measure axle center to axle center.
Optional; Extra adjustable track arm (rod) clamp bolts
if required.
Adjustable Track
Arm(Rod)
Adjust Clamp Bolt/ Nut
Tighten to 150 Ft. Lbs.
Figure 1
that after a short break-in period you have a qualified trailer Measuring
mechanic check the alignment. See Figure 2.
To align a four (4) spring suspension, the track arms need
to be adjusted. There is one adjustable track arm (rod) on
each axle; typically on the road (left) side.
Loosen the clamp nuts at each end of the adjusting bolt so
the adjusting rod can rotate (see Figure 1). Align front axle
with the king pin or coupler and adjust rear axle parallel
to the front axle. Be sure to secure the clamps on the
adjustable track arm after alignment (see Figure 1).
1. Lateral Centerline (E). Determine lateral centerline
of trailer body and axles by measuring distance E
between trailer and axle centerlines first, and correct
so that distance E is ¼” or less for each axle.
2. Thrust Angle (A, B). Measure distances A (curbside)
then B (roadside) from the king pin or coupler to the
front of the axle extension or axle centers. These must
2019.01 I 13
Heavy Duty Suspension System {HOSS) HEAVY DUTY SERVICE MANUAL
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be equal to within 0.1 degree or 1/s” of each other {A
= B ± 1/s”). Ensure the lateral tension {pulling force)
applied to the measuring tape is the same for both A
and B measurements. Use a tensioning device scale
or optical {laser) to ensure accuracy.
3. Scrub Angle (C, D). Measure distances C {curbside)
then D {roadside) between axles, measuring from
front of axle extension to front of axle extension, or
axle center to center. Adjust the rear axle so it aligns
to the front axle. These also must be equal to within
¼s” of each other {C = D ± ¼s”). This measurement
should be as close to zero as possible. The smaller
the offset, the lower the rolling resistance and the
better the fuel economy.
A
–.-.-.-.-.-.-.———————— -L-
-…………..-…………..-…………..-…………..~
B
Figure 2
Additional Suspension
Maintenance Check
Track arms should be checked for clearance. If slack is found,
it should be repaired immediately since this indicates that
there is wear in the rubber bushing or track arm parts. Check
the adjustable track arm clamps for proper torque. Loose
clamps will cause wear on the adjusting threads and the
suspension cannot be kept in alignment. On leaf spring type
suspensions, have the trailer checked for axle alignment after
two to three thousand miles.
Check leaf springs for broken leaves. Replace broken
leaves immediately to prevent the other leaves from being
overloaded. On taper leaf springs, be sure the plastic liner
is serviceable and on top of the spring. The liners between
leaves should be in place and serviceable.
Suspension Torque Requirements
CAUTION
Before torquing equalizer bolts, level equalizers parallel to
main frame members. After lnltlal break-In period (up to 1,000
mlles) and at least every 4 months thereafter; all bolts and
nuts should be checked to ensure recommended torque Is
being maintained.
Adjusting Torque Values for Bolts
1. Loosen the adjustable track rod clamp bolts {Figure (With Clean Dry Threads)
1) and turn the center rod to adjust as necessary per
above.
2. After adjusting, tighten the adjustable track rod
clamp nuts {Figure 1) to proper torque. Recheck
measurements and readjust as needed.
Precautions
1. Always measure to the front axle ends for accurate
alignment.
2. Avoid measuring to rims, suspension brackets, hub
cap, vent holes, brake drums, etc. This can result in
improper alignment. For accurate measurements, use
axle extenders.
3. Always align any succeeding axles with the front axle,
not to the kingpin or coupler.
DescrlpUon
11/a-7 UNC Nut
Oiled
Dry
1-8 UNC Nut; Dry
Spring Keeper Nut
5/a-18 UNF; Dry
Track Rod Clamp Nut
%-11 UNC; Dry
U-Bolt 3/4-10 UNC Nut; Dry
Torque
R. Lbs.
615
815
350
50
150
200
2019.01 I 14
Maintenance
Brake Component Lubrication
A schedule for the periodic lubrication of brake components
should be established by the operator on the basis of past
experience and severity of operation.
For camshaft roller journals
Lubricate with high temperature anti-seize grease.
For anchor pins
Lubricate with high temperature anti-seize grease.
For manual slack adjusters
Lubricate with NLGI Grade 2.
For automatic slack adjusters
Lubricate with ASA manufacturers’ recommended lubricant.
Anchor Pins and
Roller Journals
Lubricate wtth high temperature
anti-seize grease
For Automatic Slack Adjusters
Lubricate with ASA manufacturers’
recommended lubricant
Spider and
Support Bushings
Lubricate with NLGI Grade 2
Frequency of Service
Camshaft roller journals, anchor pins, slack adjusters every
25,000 to 30,000 miles or every six months depending
on severity of service. For off-highway use, service every 4
months depending on severity of service.
Note: Reline shoes or replace with new shoe and lining
assemblies when the linings are grease saturated.
HEAVY DUTY SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACllY ,~- DEXTER
Suggested Preventative Maintenance
Every 1,000 Miles
Check oil level in wheel hub and inspect wheel for leaks.
Every 12,000 Miles
Check brake adjustment. Repack wheel bearings (grease
application).
Every 25,000 to 30,000 Miles
Check lining wear and estimate reline time. Inspect
camshaft, camshaft spider bushing, and camshaft support
bracket bushing for any signs of wear.
Lubricate brake actuating components.
Every 100,000 Miles, Once a Year,
or at Brake Reline
Replace wheel bearing lubricating oil (if applicable).
Check brake air chambers and slack adjusters. Inspect
brake rollers, roller shafts, anchor pins and bushings, and
replace if necessary.
2019.01 I 15
Fastener Specifications
Size&
Part Name Model Thread Grade Torque
Spindle Nut
lnner(lg) D2L_ 25/a-16 5
Refer to Bearing
D2M
Adj. Section
– 250-300 Ft. Lbs.
Outer (sm) D2H 25/a-16 5
Grease Zerk
Cam Bushing ¼-28 UNF 2 5-15 In. Lbs.
Spider 1/a-27 NPT 2 5-8 Ft. Lbs.
Cam Brackets All Models ¼-20 2 3-4 Ft. Lbs.
Air Chamber
Hex Nut
Mounting All Models 5/a-11 5
85-95 Ft Lbs.
Nuts
Locknut
120-140 Ft. Lbs.
Anchor Pin 12¼” Dia.
Clamp Bolt Air Brakes
7/is-20 5 60-70 Ft. Lbs.
Dust Shield
16½” Dia.
Mounting
Air Brakes w/ 5/is-18 5 10-15 Ft. Lbs.
Tapped Spiders
Hub Cap All Models 5/ia-18 5 10-15 Ft. Lbs.
Drum
Mounting
12¼” Dia. 5/a-18 5 160-180 Ft. Lbs.
Screw
Backnut
16½” Dia. ¾-16 5 175-200 Ft. Lbs.
Wheel Nut
Inner 10 on 11¼ ¾-16 5 or 8 (steel)
or 8 (aluminum) 450-500 Ft. Lbs.
Outer 10 on 8¾ 1¼-16 5 450-500 Ft. Lbs.
10 on 285.75 22mm x 1.5 10.9 450-500 Ft. Lbs.
Flange Nuts or
8 on 275mm
Rim Mounting
Demountable
¾-10
Refer to Manf.
Rim Type
5
Recommend.
HEAVY DUTY SERVICE MANUAL
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2019.01 I 16
Replacement Parts/Kits
Brake Shoe Hardware Kits
Brake Size Air (one brake)
12¼” X 7½” P Style K71-098-00
12¼” x 7½” PQ Style K71-460-00
16½” X 7″ Q Style K71-136-00
Brake Block Kits
Brake Size Air (one brake)
12¼” x 7½” P and PQ Style K71-133-00
16½” x 7″ Q Style K71-138-00
Camshaft Repair Kits
Brake Size Air (one brake)
12¼” x 7½” P and PQ Style K71-101-00
16½” x 7″ Q Style K71-135-00
Shoe & Block Assemblies
Brake Size Part Number
12¼” x 7½” P Style 040-175-01
12¼” x 7½” PQ Style 040-320-01
16½” x 7″ Q Style 040-180-00
HEAVY DUTY SERVICE MANUAL
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2019.01 I 11
Warranty
Dexter Axle Limited Warranty
What Products Are Covered
All Dexter Axle Company (“Dexter”) trailer axles, suspensions, and brake
control systems manufactured on or after September 1, 2016, excluding
Dexter 6000 series Manufactured Housing Axles. Additional exclusions
include the following brands: UFP by Dexter, AL-KO (IAC), Titan Brakes
and Actuators by Dexter, and BrakeRite by Dexter products, which are
covered under separate warranties.
Limited 1 Year Warranty
As specified in Dexter’s current publication “Operation Maintenance
Service Manual”, grease and oil seals FOR ALL PRODUCTS have a one
(1) year limited warranty to the original purchaser from the date of first
sale of the trailer incorporating such components. Except as to grease
and oil seals, the following four other warranties are available.
Limited 2 Year Warranty
Dexter warrants to the original purchaser that its electric/hydraulic
brake actuators shall be free from defects in material and workmanship
for a period of two (2) years from the date of first sale of the trailer
incorporating such components.
Limited 5 Year Warranty
Dexter warrants to the original purchaser that its axles, suspension
systems and Genuine Replacement Parts shall be free from defects in
material and workmanship for a period of five (5) years. The warranty
period shall begin from the date of the original purchase of the trailer
and/or Genuine Replacement Parts.
Limited 7 Year Warranty
Dexter warrants to the original purchaser that its Predator Series•
electric brake controllers shall be free from defects in material and
workmanship for a period of seven (7) years from the date of purchase.
Limited 10 Year Warranty
Dexter warrants to the original purchaser that the suspension
components of its Torflex• axles shall be free from defects in material
and workmanship for a period of ten (10) years from the date of first
sale of the trailer incorporating such suspension components.
Exclusive Remedy
Dexter will, at its option, repair or replace the affected components of
any defective axle, repair or replace the entire defective axle, or refund
the lesser of the original purchase price and the then-current list price
of the axle or components. In all cases, a reasonable time period must
be allowed for warranty repairs to be completed. Allowance will only be
made for installation costs specifically approved by Dexter.
What You Must Do
In order to make a claim under these warranties:
1. You must be the original purchaser of the trailer in which the
sprung suspension axles orTorflex• axles or components were
originally installed.
2. You must promptly notify Dexter after detection of any defect, but in
any case within the applicable warranty period of such defect, and
provide us with the axle or applicable component serial number
and any substantiation of such defect which may include, but is not
limited to, the return of part(s) that we may reasonable request.
3. The axles, suspensions and components must have been installed
and maintained in accordance with good industry practice and
any specific Dexter recommendations, including those specified
in Dexter’s current publication “Operation Maintenance Service
Manual”.
Exclusions
HEAVY DUTY SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACllY
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These warranties do not extend to and do not cover defects caused by:
1. The connecting of brake wiring to the trailer wiring or trailer wiring to
the towing vehicle wiring.
2. The attachment of the running gear to the frame.
3. Parts not supplied by Dexter.
4. Any damage whatsoever caused by or related to any alteration of
the axle including welding supplemental brackets to the axle.
5. Use of an axle on a unit other than the unit to which it was
originally mounted.
6. Normal wear and tear.
7. Improper alignment.
8. Improper installation.
9. Unreasonable use (including failure to provide reasonable and
necessary maintenance as specified in Dexter’s current publication
“Operation Maintenance Service Manual including required
maintenance after “Prolonged Storage”).
10. Improper torque values and torqueing of wheel nuts. (The proper
torqueing procedure and torque values are contained in Dexter’s
current publication “Operation Maintenance Service Manual”).
11. Cosmetic finish or corrosion.
Limitations
1. In all cases, Dexter reserves the right to fully satisfy its
obligations under the Limited Warranties by refunding the lesser
of the original purchase price and the then-current list price of
the defective axle ( or, if the axle has been discontinued, of the
most nearly comparable current product).
2. Dexter reserves the right to furnish a substitute of replacement
component or product in the event an axle or any component of the
axle is discontinued or is otherwise unavailable.
3. These warranties are nontransferable.
General
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL
OTHER WARRANTIES EXCEPT THAT OFTITLE, WHETHER WRITTEN,
ORAL OR IMPLIED, IN FACT OR IN LAW (INCLUDING ANY WARRANTY
AGAINST INFRINGEMENT OR OF MERCHANTABILITY OR RTNESS FOR
A PARTICULAR PURPOSE).
These warranties give you specific legal rights, and you may also have
other rights which vary from state to state.
DEXTER HEREBY EXCLUDES INCIDENTAL AND CONSEQUENTIAL
DAMAGES, INCLUDING LOSS OFTIME, INCONVENIENCE, LOSS
OF USE, TOWING FEES, TELEPHONE CALLS, COST OF MEALS
OR LODGING, FOR ANY BREACH OF ANY EXPRESS OR IMPLIED
WARRANTY.
Some states do not allow limitations on how long an implied warranty
lasts, or the exclusion or limitation if incidental or consequential
damages, so the above exclusion or limitation may not apply to you.
Inquiries regarding these warranties should be sent to:
Dexter Axle Company
P.O. Box 250
Elkhart, IN 46515
Note: Current publication “Operation Maintenance Service Manual” can be
found at www.dexteraxle.com.
2019.01 I 1s
Axle Identification
In the unlikely event that you should require service
assistance from Dexter, please have the lot (serial) number
of the axle available when you call.
On all axles produced after April 2001, this nine digit
number can be found near the center on the rear side of
the axle beam. Look for the words DEXTER AXLE and the lot
number will be located directly under the name. For easier
identification, rubbing a piece of chalk over the number may
help bring out the engraving.
Recreational Vehicle axles that have been certified for use in
Canada will also bear the letters CSA.
HEAVY DUTY SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACllY
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2019.01 I 19
Service Record
Date Service Performed
HEAVY DUTY SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACllY
Mileage
1::,·
DEXTER
2019.01 I 20
Service Record
Date Service Performed
HEAVY DUTY SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACllY
Mileage
1::,·
DEXTER
2019.01 I 21
Notes HEAVY DUTY SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACllY ,~- DEXTER
2019.01 I 22
Notes HEAVY DUTY SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACllY ,~- DEXTER
2019.01 I 23
Dexter Video Gallery HEAVY DUTY SERVICE MANUAL
22,500-27,500 LBS. AXLE CAPACllY
l:J®
DEXTER
In keeping with our continual commitment to industry safety and the development of innovative products, please feel
free to view our ongoing video gallery at www.dexteraxle.com/resources/videos or scan the following QR codes. We are
confident these videos will help educate and promote the Dexter product line that you, as our customer, are investing in.
II!) .i. •I!) .. . ,: II I!) ,: . II 1!1~- . 11 I!) ..
Bearing EL H Actuator Electric Brakes E-Z FLEX!. TORFLEX!
Maintenance Installation Suspension Suspension Axles
IJ ~1 l!llfil!I I!) . I!)~ I• ml II I!) I•
E-Z LUBE! Genuine Brakes Genuine Leaf Spring Sway Control
System Replacement Parts Axles
II l!l~~l!I – l!l!t~l!I II II’:” I!) . • I!)~ • I!) ..
Manual Bleed Medium Duty Nev-R-Adjust! Power Bleed Removable
Hydraulic Disc Axles Brakes Hydraulic Disc Spindle
2019.01 I 24
Genuine Dexter axles and components are available nationwide from our
plant locations listed below or through our network of distributors.
Check our website for the distributor nearest you.
Dexter • Plant 12
301 West Pearl Street
Fremont, Indiana 46737
Phone: 260-495-5100
Fax: 260-495-1701
Dexter • Plant 24
135 Sunshine Lane
San Marcos, California 92069
Phone: 760-744-1610
Fax: 760-744-1616
Dexter – Plant 52
5885 51 Street SE
Calgary, Alberta T2C 3V2
Phone: 587-323-8411
Fax: 58 7-327-0129
Dexter – Headquarters
2900 Industrial Parkway East ■ Elkhart, Indiana 46516
Phone: 574-295-7888 ■ Fax: 574-295-8666
www.dexteraxle.com
Dexter – Plant 13 Dexter • Plant 15 Dexter – Plant 21
500 South 7th Street 500 Southeast 27th Street 199 Perimeter Road
Albion, Indiana 46701 El Reno, Oklahoma 73036 Monticello, Georgia 31064
Phone: 260-636-2195 Phone: 405-262-6700 Phone: 706-468-6495
Fax: 260-636-3030 Fax: 405-262-9089 Fax: 706-468-2966
Dexter • Plant 25 Dexter • Plant 27 Dexter • Plant 39
1041 Baxter Lane 1845 South 300 West 902 South Division Street
Winchester, Tennessee 37398 Salt Lake City, UT 84115 Bristol, Indiana 46507
Phone: 931-967-5101 Phone: 801-486-4916 Phone: 574-848-4491
Fax: 877-457-9861 Fax: 801-486-1711 Fax: 574-848-4825
www.ventline.com
Dexter – Plant 61 Dexter – Plant 62
21611 Protecta Drive 301 North Kennedy Street
Bkhart, IN 46516 Shawnee, Oklahoma 74801
Phone: 574-294-6651 Phone: 405-273-9315
Fax: 574-295-6626 Fax: 405-273-1054
Dexter – Plant 23
5600 Bucknell Drive SW
Atlanta, Georgia 30336
Phone: 404-4 77-6899
Fax: 4 70-443-1 715
Dexter • Plant 51
34 7 King Street West
Ingersoll, Ontario N5C 2K9
Phone: 226-242-5291
Fax: 226-444-04 7 4
www.ingersollaxles.com
NO PART OF THIS MANUAL MAY BE REPRODUCED WITHOUT DEXTER’S PERMISSION. ALL PART NUMBERS,
DIMENSIONS AND SPECIFICATIONS IN THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE.
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G L O B A L