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spicer tandem drive axles pro-40 single reduction and single

1. 9 Forward rear axle wheel differential lock air shift cylinder part of axle assembly 10 Wheel differential lock in dicator switch part of axle assembly 11 Indicator light of audible signal 12 Fuse or circuit breaker 13 Power supply 14 66468 Quick release valve optional located on frame rail and within 10 feet of tubing from control valve Theory of Operation Wheel Differential Lock The Dana Wheel Differential Lock is an optional feature for e Shift Cylinder Assembly Operates a shift fork and Dana Axles In operation it positively locks the wheel differen push rod assembly Le to provide improved traction under adverse road condi e Shift Fork and Push Rod Assembly Engages and ions l disengages the differential lock curvic clutch assembly The differential lock is driver controlled through an electric e Curvic Clutch Assembly Consists of a sliding clutch switch or air valve mounted in the cab The locking mecha splined to a axle shaft and a fixed clutch which is nism is air operated to engage a mechanical clutch and lock splined to the differential case hub the wheel differential It is spring operated to disengage the lock and permit the wheel differential to function normally The differential lock also includes a selector switch electric which senses clutch engagement and sends an electrical sig The wheel differential lock consists of three
2. Midway thru thickness of nut Note Use of a torque multiplier is recommended A IMPORTANT If you can t get the correct torque on yoke nut try torquing the nut with the truck wheels on the ground and with the axle shafts installed 12 Install axle shafts and axle stud nuts If used also install lock washers and taper dowels 13 Connect inter axle driveline Make sure driveline is properly phased Lubricate U joints 14 Add axle lubricant Fill to bottom of filler hole IMPORTANT 96 When axle has been disassembled or housing axle shafts or wheel equipment replaced check axle assembly for proper differential actions before operating vehicle Wheels must rotate freely and independently 15 Road test vehicle to bring axle lubricant up to tem perature Recheck joints drain and fill plugs for leak age Retighten as necessary Forward Assembly Measure and Adjust Note Use bearing cup driver to insure seating of snap ring after installation with snap ring pliers See illustration for steps 1 4 1 eooo D Assemble cover assembly to axle housing Position dial indicator at yoke end of output shaft Push in on output shaft and zero the dial indicator Using a pry bar move output shaft axially and mea sure record end play Correct end play for a new assembly is 0 001 to 0 015 The maximum end play for a used assembly is no more than 0 015 If end play is incorr
3. 1 Part number 4 Matching gear set number 7 Indicates genuine Dana Spicer parts 2 Number of ring gear teeth 5 Number of pinion teeth 8 Heat Code 3 Manufacturing numbers 6 Date code General Information General Information The description and specifications contained in this service Any reference to brand name in this publication is made publication are current at the time of printing simply as an example of the types of tools and materials recommended for use and should not be considered an Dana Spicer Corporation reserves the right to discontinue endorsement Equivalents if available may be used or to modify its models and or procedures and to change specifications at any time without notice Important Notice This symbol is used throughout this WARNING Failure to follow indicated manual to call attention to procedures procedures creates a high risk of personal where carelessness or failure to follow injury to the servicing technician specific instructions may result in personal injury and or component CAUTION Failure to follow indicated damage procedures may cause component damage or malfunction Departure from the instructions choice of tools materials and recommended IMPORTANT Highly recommended parts mentioned in this publication procedures for proper service of this unit may jeopardize the personal safety of the service technician or vehicle NOTE Additional service information not op
4. 36 Adjust Pinion Bearing Preload 37 Trial Buildup 37 Final Buildup ennen 38 Install Drive Pinion Assembly 41 Wheel Differential Forward Parts Exploded View 42 Disassemble Overhaul and Assemble Wheel Differential Forward 43 Disassemble Wheel Differential 43 Overhaul amp Assemble Wheel Differential 44 Measure and Adjust Carrier Assembly 46 Adjust Backlash and Preload 46 Change Backlash Setting 47 Measure Ring Gear Runout 47 Measure Ring Gear Total 47 Adjust Ring amp Pinion Tooth Contact Pattern 48 Adjust Contact Pattern 48 Adjust Pinion Position 49 Adjust Ring Gear Position Backlash 49 Wheel Differential Lock Forward Parts Exploded View 50 Install and Adjust Wheel Differential Lock 51 Install and Adjust Ring Gear Thrust Bolt 52 Housing amp Output Shaft Assembly Forward Parts Exploded VieW ccccccccccsescssscseeeeseeeees 53 Disassemble Output Shaft Assembly 54 Overhaul amp Assemble Output Shaft Assembly 55 Measure and Adjust 57 Replace Seal 57 Guidelines for Reusing Yoke nn 58 Table of Contents Differential Carrier Rear 0 0 00naneneeeeeieeneeennne 59 Towing Parts Exploded Vie
5. 4 7 Input torque 4 Rear axle torque is transmitted from the output shaft side 2 Lockout disengaged gear through the output shaft inter axle driveline drive 3 Forward axle torque is transmitted from the helical side pinion ring gear wheel differential and axle shafts gear through the pinion helical gear drive pinion ring gear 5 Input torque power flow from the vehicle driveline is wheel differential and axle shafts transmitted to the input shaft and the inter axle differential spider The differential distributes torque equally to both axles 86 Theory of Operation With Lockout Engaged Inter Axle Differential is Not Operating Lockout should only be engaged when both axles are rotat ing at the same speed Operation should be limited to low traction situations and should be disengaged when normal traction returns Failure to do so will result in poor handling and damage to the axle components Wd ko A E A P9 CAA 1 Input torque 2 Lockout engaged 3 Forward axle torque is transmitted from the helical side gear through the pinion helical gear drive pinion ring gear wheel differential and axle shafts Note Varied road surface conditions can result in unequal torque distribution between the two axle assemblies A CAUTION Prolonged operation with the lockout engaged can dam age axle and driveline components 4
6. e Adjust used gear sets to display the same contact pattern observed before disassembly A correct pat tern is up off the toe and centers evenly along the face width between the top land and root Otherwise 1 Face width the length and shape of the pattern are highly vari 2 Tooth depth able and is considered acceptable as long as it does 3 Heel not run off the tooth at any point 4 Top land 5 Root 6 Toe TIR 3 Identify if new or used gearing gt 4 Check tooth contact pattern new or used gearing New Gearing Correct Pattern e Paint six ring gear teeth 180 apart and roll the gear to obtain a contact pattern The correct pattern is 1 Pattern along the face width could be longer slightly below center on the ring gear tooth with lengthwise contact up off the toe The length of the pattern in an unloaded condition is approximately one half 1 2 to two thirds 2 3 of the ring gear tooth in most models and ratios e _ The pattern could vary in length and should cover half 1 2 of the tooth or more face width The pat tern should be evenly centered between tooth top land and root and should be up off the tooth toe a Adjust Ring Gear Position Backlash If the ring gear pattern shows incorrect face width contact change backlash by adjusting the ring gear If the pattern is too close to the edge of the tooth toe move the ring gear away from the pinion to increase backlash 75 Wheel Different
7. In Vehicle Note See page 20 for out of vehicle Note Parts inspection and cleaning procedures are important and should be adhered to Cleanliness in your work area is important as dirt is an abrasive and will cause prema ture wear of the otherwise serviceable parts A CAUTION During installation of power divider components the inter axle differential input shaft assembly or IAD shift system parts may fall from the carrier if not careful Use caution to prevent injury or damage 1 Make sure dowel pins are installed in carrier 2 Install output side gear bearing cup if removed Press bearing cup in carrier Use a press and an appropriate sleeve Make certain bearing cup is evenly and firmly seated If a press is not available use a sleeve or a bearing driver tool and a hammer to install the cup 1 Lubricate o rings 2 Bearing cup 3 Lubricate o rings 4 Install the output side gear if removed 5 Install the IAD assembly to the output side gear If reusing the IAD assembly install in the same direc tion as removed Note For lube pump models see page 23 6 Out of the vehicle on a bench install lockout slid ing clutch onto the input shaft tai 7 Install thrust washer Forward Assembly 8 Install helical side gear and snap ring 11 Install plastic trough in power divider cover 12 Install power divider cover to carrier Use Dana approved RTV compound on the
8. Note Gasket compound will harden in 20 minutes Install power divider as quickly as possible to avoid future leaks 24 Forward Assembly Lube Pump Disassembly For output side gear and or pump replacement follow the procedure below 1 Remove the output side gear bearing cone if required 1 Press 2 Press Tool 2 Remove pump locking dowel pin from the hole in the output side gear hub 3 Lube Pump Installation Use these instructions with the carrier assembly in or out of the vehicle If the unit does not have a pump go to the Power Divider Assembly section Note Keep work area clean Dirt is an abrasive and will cause premature wear of the otherwise serviceable parts Note For non pump models see page 17 for output side gear seal manifold installation Note Only service the power divider if the differential carrier is secured in a stand or while the axle is still attached to the housing CAUTION A CAUTION CAUTION During installation of power divider cover the inter axle differential IAD input shaft assembly or IAD shift sys tem parts may fall from the carrier if not careful Use caution to prevent injury or damage 1 Install the pump into the output side gear so that the pump shaft is facing toward the teeth end of the side gear 2 Install the pump locking dowel pin into the hole in the output side gear hub Make sure the pin is lined up with the machined slot in the
9. Pinion 26 Inner pinion bearing cone 27 Pinion bearing spacer 28 Inner pinion bearing cup 29 Pinion cage shim 30 Pinion cage 31 Outer pinion bearing cup 32 Outer pinion bearing cone 33 Helical gear 34 Pinion roll pin 35 Pinion nut Parts Identification Wheel Differential Lock Assembly Parts Exploded View 16 oQ y O 1 Fixed curvic clutch gear 7 Push rod 13 Plastic washer 2 Snap ring 8 Piston driver 14 Piston cover 3 Curvic clutch gear 9 Set screw 15 Cap screw flange head 4 Spring pin 10 Piston 16 Cap screw manual engagement 5 Shift fork 11 O ring 17 Gasket 6 Compression spring 12 Switch 93 Parts Exploded View 94 1 Pinion Nut 2 End Yoke and Slinger 3 Oil Seal 4 Outer Pinion Bearing Cone 5 Outer Pinion Bearing Cup 6 Pinion Spacer 7 Inner Pinion Bearing Cup 8 Inner Pinion Bearing Cone 9 Drive Pinion 10 Carrier Housing 11 Diff Case Dowels 12 Ring Gear 13 Ring Gear Bolts 14 Flange Half Bearing Cone 15 Flange Half Bearing Cup Parts Identification 16 Flange Half Bearing Adjuster 17 Side Pinion Thrust Washer 18 Side Pinion 19 Side Gear 20 A B Differential Shaft 21 Pin 22 Capscrew 23 Flat Washer 24 Flange Half Cap 25 Plain Half Cap 26 Cotter Pin 27 Side Gear Thrust Washer 28 Plain Half Diff Case 29 Plain Ha
10. Qa p gt N 77 3 Ex lt Forward Assembly Wheel Differential Forward Parts Exploded View le AA 11 Flange Half LH 19 18 4 9 ST KS x 1 Ring gear 11 Nut 2 Cap screw 12 Diff bearing adjuster plain half 3 Flat washer 13 Bearing cup plain half 4 Diff carrier bearing caps 14 Bearing cone plain half 5 Cotter pin 15 Diff case RH plain half 6 Diff case LH flange half 16 Side gear thrust washer 7 Bearing cone flange half 17 Side gear 8 Bearing cup flange half 18 Diff spider 9 Diff bearing adjuster flange half 19 Side pinion 10 Bolt 20 Side pinion thrust 42 Forward Assembly Disassemble Overhaul and Assemble Wheel Differential Forward Disassemble Wheel Differential A IMPORTANT During following procedure place differential assembly on malleable surface to prevent damage when ring gear falls off its mounting position 4 Lift out spider side pinions and thrust washers 1 Remove nuts and bolts fastening ring gear to differ ential cases allowing gear to fall free If gear does not fall tap outer diameter with soft mallet to loosen 5 Remove remaining side gear and thrust washer 6 Remove bearing cones from case halves using suit able puller ont a n 7 Remove bearing cone from plain case half in two steps a Mount puller vertically to split bearing This action wil
11. Spicer Tandem Drive Axles lt pana gt SPICER Drivetrain Products Service Manual PRO 40 Single Reduction amp Single Reduction with Wheel Differential Lock AXSM0058 September 2013 D40 145D R40 145S D40 145X Table of Contents Introduction Model Listing 1 Model Information c cccccccscsccsecsecsecsecsecsecseeeeeees 1 Model Identification 2 Part Identification ccccccccscscsecsecsscsecsesseeeeseeeees 2 Ring Gear and Pinion s s s 3 General Information 4 Important Notice 4 Inspection Failure Analysis 5 How to Diagnose a Failure seeeeeeeeeeee 5 Prepare the Parts for Inspection 6 Find the Cause of the Failure 6 Correct the Cause of the Problem 6 Inspect Axle Housing rnnnennnnenenn 7 Inspect Components 7 Inspect Primary Gearing cccccceecsseecsseeeteeseteeseees 8 Check Input Shaft End play Forward Axle Adjust 8 Output Shaft End play Forward Axle Adjust 8 Tandem Axle Assemblies 00505111111111111 9 Differential Carrier Assembly Forward 10 Disassemble Carrier Assembly Forward Standard Differentials 0 ccccccscseseeseeseeseeees 10 Diff Lock Models 10 Engage via Air Pressure 10 Engage Manually ceccccccseeeeteeeeeeeteeeeeeees 10 Install
12. T gt a a Pp N 77 3 lt 3 Check ring gear tooth contact pattern Paint ring gear teeth and check tooth contact pattern Correct tooth patterns Checking and adjusting procedures are on pages 61 62 4 Install bearing adjuster cotter pins 47 Forward Assembly Adjust Ring and Pinion Tooth Contact Pattern 1 Face width 2 Tooth Depth 3 Heel 4 Top land 5 Root 6 Toe Note Rear axle gearing is shown in the following instructions Correct tooth contact patterns and adjustments are the same for forward and rear axles 1 Identify if new or used gearing 2 Check tooth contact pattern new or used gearing New Gearing Correct Pattern Paint six ring gear teeth 180 apart with marking compound and roll the gear to obtain a contact pattern The correct pat tern is slightly below center on the ring gear tooth with length wise contact up off the toe The length of the pattern in an unloaded condition is approximately one half to two thirds of the ring gear tooth in most models and ratios The pattern could vary in length and should cover 1 2 tooth or more face width The pattern should be evenly centered between tooth top land and root and should be up off the tooth toe 48 Used Gearing Correct Pattern Used gearing will not usually display the square even contact pattern found in new gear sets The gear will normally have a pocket at the heal end of the
13. Ask more questions when examining the interior of the carrier Does the lubricant meet the manufacturer specifications regarding quality quantity and viscos ity As soon as you have located the failed part take time to analyze the data Find the Cause of the Failure Here begins the real challenge to determine the exact cause of the failure Keep in mind that there is no benefit to replacing a failed part without determining the cause of the failure For example after examining a failed part and finding that the fail ure is caused by a lack of lubrication you must determine if there was an external leak Obviously if there is an external leak just replacing the failed gear is not going to correct the situation Another important consideration is to determine the specific type of failure which can be a valuable indicator for the cause of failure The following pages show different types of failures and possible causes Use this as a guide in determining types of failures and in correcting problems Correct the Cause of the Problem Once the cause of the problem has been determined refer to the appropriate service manual to perform the repairs Clean 10 Wash steel parts with ground or polished surfaces in solvent There are many suitable commercial sol vents available Kerosene and diesel fuel are accept able A WARNING Gasoline is not an acceptable solvent because of its extreme combustibility It is unsafe in the
14. Yoke 3 puller tool Remove seal Use care when removing the old seal to prevent damage to the housing seal bore Inspect the seal bore area for any damage nicks gouges corrosion Carefully remove any slight damage with a crocus cloth Clean the bore area to remove any loose debris A CAUTION Do not use any silicone or permatex type bore sealant with this seal 5 Remove the new seal from its package and install with the proper driver Service kit 217414 D Input Use driver 126917 only D Output Use insert 128706 with driver 126917 R Pinion Use driver 126917 only 97 T gt a a Pp N 77 3 lt Forward Assembly A CAUTION Due to the resiliency of the plastic driver hammer rebound may occur when the seal is seated Keep clear of the ham mer rebound path 6 Handle the seal by its outside diameter avoiding any contact with the seal lips During installation use the proper driver to make sure that the seal is mounted properly 7 Use a rubber mallet to drive the seal tool in until the flange bottoms on the housing cover bore face The flange will locate the seal at the proper depth 58 Guidelines for Reusing Yoke A CAUTION Do not use the yoke if it has any damage on the seal surface nicks or scratches The surface of the yoke and the lips of the seal form a critical interface which retains the axle s lubricant while sealing the axle from outside co
15. gears should achieve proper contact with the same shims removed from the axle at disassembly If the pattern is too close to the edge of the tooth toe move the ring gear away from the pinion to increase backlash Note Check ring gear backlash after each shim change and adjust if necessary to maintain the 0 006 to 0 018 specifications If the pattern is too close to the top land of the gear tooth remove pinion shims Move pinion toward the ring gear ge 3 Loosen the bearing adjuster on the teeth side of the ring gear several notches 4 Loosen the opposite adjuster one notch 5 Return to adjuster on teeth side of ring gear and If the pattern is too close to the root of the gear tooth add tighten adjuster until it contacts the bearing cup pinion shims Move pinion away from the ring gear 6 Continue tightening the same adjuster 2 or 3 notches and recheck backlash If the pattern is concentrated at the heel too far up the tooth move the ring gear toward the pinion to decrease backlash T gt a Qa D gt 7 77 3 lt 7 Loosen the bearing adjuster on the teeth side of the ring gear several notches 8 Tighten the opposite adjuster one notch 9 Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup 10 Continue tightening the same adjuster 2 or 3 notches and recheck backlash 49 Forward Assembly Wheel Diff
16. A IMPORTANT Do not allow pinion to drop on hard surface If gear set is to be reused keep pinion bearing cage shim pack intact for use in reassembly If the original shims can not be reused record the number and size of shims in the pack 33 Forward Assembly Front Axle Pinion Assembly Forward Parts Exploded View 1 Pinion pilot bearing 2 Pinion 3 Pinion bearing cone inner 4 Pinion bearing spacer 8 Cap screw 9 Pinion bearing cup outer 10 Pinion bearing cone outer 11 Pinion helical gear 5 Pinion bearing cup inner 12 Roll pin 6 Shim 7 Pinion bearing cage 13 Slotted pinion nut Before 3 01 95 two spacers were used instead of the one shown 34 Forward Assembly Disassemble and Overhaul Drive Pinion The following procedures cover both forward and rear differ 9 Remove pilot bearing from pinion using a split type ential drive carrier disassembly puller Use two procedure steps to remove each bearing 3 Remove the pinion nut roll pin a Mount puller vertically to separate the bearing This action will force puller halves under bearing 5 Remove the helical gear with the proper puller tool and start moving bearing off pinion 4 Loosen and remove the pinion nut 6 Press pinion out of bearing cage and bearing cone 1 Press ram b Mount puller horizontally to press pinion out of 7 Remove bearing cups with proper puller tool bearing 8 Remov
17. IMPORTANT In order to maintain the differential bearing preload you will need to turn the flange half bearing adjuster the same amount in the same direction If you need more backlash reverse this procedure 1 Install carrier bearing caps and torque carrier cap bolts to 330 360 ft Ibs 447 488 Nem 2 Recheck backlash If the bearing adjusters were not in straight or fully seated the backlash will change a Used Gearing Reset to backlash recorded before disassembly b New Gearing Backlash should be between 0 008 and 0 018 0 15 0 46 mm 3 Check ring gear tooth contact pattern Paint ring gear teeth and check tooth contact pattern Correct tooth patterns see Adjust Tooth Contact Pattern 4 Install bearing adjuster cotter pins 74 Measure Ring Gear Runout Measure Ring Gear Total 1 Measure ring gear total radial runout Indicator reading should not exceed 0 010 0 25 mm 2 Measure ring gear total backface runout Indicator reading should not exceed 0 010 0 25 mm Wheel Differential Adjust Ring and Pinion Tooth Contact Pattern Used Gearing Correct Pattern e Used gearing will not usually display the square even contact pattern found in new gear sets The gear will normally have a pocket at the heal end of the gear tooth The more use a gear has had the more the line becomes the dominant characteristic of the pattern 3 a T
18. bolt 126219 12 M16 X 1 5 24 mm 215 255 292 346 Wheel diff case cap screw 10 9 M14 X2 16 mm12 pt 114 140 155 190 Carrier Carrier to housing cap screw 12 9 M16 X 2 24mm 230 270 312 366 Carrier to housing nut 12M 16X 1 5 24mm 199 244 270 331 Differential bearing cap screw 12 9 M20 X 2 5 30 mm 350 428 475 580 Thrust bolt jam nut 4 M24 X 2 36 mm 148 181 201 245 Housing Axle cover cap screw 12 9 M12 X 1 75 18 mm 85 103 115 140 500 20 11 16 55 71 75 96 Axle shaft to wheel hub nuts 625 18 15 16 170 190 230 258 750 16 11 8 285 345 386 468 Breather fitting u tube design 375 18 750 Hex 20 26 27 35 Magnetic plug fill NPSF 1X 11 5 13 16 40 60 54 81 Oil drain plug NPTF 150 14 1 2 Drive 40 60 54 81 Temperature sender plug 40 60 54 81 Note Fasteners using self locking thread patches may be reused if not damaged but should be secured by a few drops of Loctite 277 on threaded surface Reused fasteners should be wiped clean of excess oil special cleaning not required Torque nut to 840 Ib ft 1140 Nem then continue tightening to align nut slot with nearest hole in pinion shank Correct torque values are extremely important to assure long Dana life and dependable performance Under tightening of parts is just as harmful as over tightening Exact compliance with recommended torque values will assure the best results The data includes class and torque tightening values 96 Torque Chart Rear Carrier P
19. fork head and compression 13 When adjustment is complete torque fasteners to spring in carrier 28 35 Ib ft 8 47 Nem 4 Install new o ring on piston 14 Install selector switch in cylinder cover Torque 5 Lubricate piston and o ring with silicone grease and Ce tee een install piston assembly in cylinder Position piston 15 Check selector switch operation Check switch elec with small diameter hub toward closed end of cylin trically with an ohmmeter or continuity tester Switch der should close show continuity when clutches are 6 Screw piston driver on push rod engaged and should open no continuity when Clutches are disengaged 7 Tighten piston driver until shift fork clutch is approx imately 0 030 of an inch from the fixed clutch 030 7 8 Push down by hand on the piston driver both clutches must be completely engaged 9 Install set screw in piston driver torque to 12 15 Ib ft 16 20 Nem A CAUTION On 3 90 ratio models only a washer P N 210288 must be used between the piston driver and piston Failure to install the washer will cause engagement and disengagement problems in the differential lock 10 Trial fit install piston cover assembly Hand tighten Cap Screws 51 T gt a Qa D gt 7 77 3 lt Forward Assembly Install and Adjust Ring Gear Thrust Bolt 1 Thread thrust screw into the carrier until firm contact with the back
20. if the gear set is to be replaced If gear set is to be reused check tooth contact pattern and ring gear backlash before disassembling differential carrier When checking backlash a yoke or helical gear must be installed and torqued to get an accurate reading Best results are obtained when established wear patterns are maintained in used gearing 1 Mount differential carrier in repair stand Note For easier disassembly loosen but do not remove pin ion self locking nut Forward axle pinion is equipped with slotted nut remove roll pin with a pin punch then loosen nut 2 If reusing gear set also punch mark bearing adjust ers for reference during assembly 1 Punch marks 32 3 Remove cap screws flat washers and bearing caps Back off bearing adjusters and remove adjusters and bearing cups 4 Using a chain hoist lift ring gear and differential assembly out of carrier Forward Assembly Disassemble Pinion Assembly 1 Remove pinion bearing cage cap screws Remove pinion and cage assembly from carrier Remove shim pack Note For easier disassembly loosen but do not remove pin ion self locking nut Forward axle pinion is equipped with slotted nut remove roll pin with a pin punch then loosen nut 2 Remove pinion bearing cage cap screws Remove pinion and cage assembly from carrier Remove shim pack T gt o a Pp N 77 3 lt
21. is incorrect determine shim pack changes as follows Add shims to increase end play 0 003 to 0 007 0 001 0 001 0 002 to 0 006 Desired end play New Parts Measured end play Step 3 Add shims to provide desired end play Remove shim to decrease end play 0 015 0 015 0 003 to 0 007 0 012 to 0 008 Measured end play Step 3 Desired end play New Parts Remove shims to provide desired end play Check Output Shaft End play Forward Axle See illustration for steps 1 3 1 Position dial indicator at yoke end of output shaft 2 Push in on output shaft and zero the dial indicator 3 Using a pry bar move input shaft axially and mea sure record end play Adjustment Correct end play for a new assembly is 0 001 to 0 005 The maximum end play for a used assembly is no more than 0 005 If end play is incorrect contact Dana Tandem Axle Tandem Axle Assemblies 9 a 2 x Carrier fasteners Carrier assembly Front axle assembly Rear axle assembly Inter axle differential lockout HAA amp ND Forward Assembly Differential Carrier Assembly Forward Disassemble Carrier Forward Note The removal of the forward carrier does not require dis connecting of the inter axle driveline and removal of the output shaft yoke assembly as most other Dana tan dems require Standard Differentials 1 Block the vehicle Drain axle lubricant Disconnect
22. lubricant until level with the bottom of the hole b If wheel ends were removed follow instructions in wheel end servicing page 40 Correct lube level at bottom of filler hole Always use the filler hole as the final reference If lube is level with the bottom of the hole the axle is properly filled 80 Note Lube fill capacities see chart are basic guidelines and will vary based on the angle the axle is installed in a par ticular chassis Torque fill plug to 40 60 Ibs ft 54 82 Nem TIP The axle can be filled through the axle housing breather hole Fill until lube level is even with the bottom of filler hole in axle housing rear cover 1 With axle on level surface fill housing with oil to bottom of plug 2 Temperature sensor mounting hole on 3 wi ro Wheel End Seal Wheel End Seal Parts Exploded View 1 Installation tool 2 Seal 3 Rear hub 81 Wheel End Seal Disassemble and Overhaul Wheel End Seal Install Wheel End Seal 1 Before installation lubricate the following with the Never work under a vehicle supported by only a jack same lubricant used in the axle sump Always support vehicle with stands Block the wheels and e Inner bearing make sure the vehicle will not roll before releasing the brakes e Wheel seal follow the directions provided by the seal supplier 2 Place seal on installation tool A IMPORTANT 3 Drive seal with installation
23. multiplier is recommended If difficulty is experienced in achieving correct torque torque the nut with the truck wheels on the ground and with the axle shaft installed A IMPORTANT Follow the instructions specified by the thread adhesive manufacture when applying thread adhesive compound 29 T gt 9 a Pp N 77 3 lt Carrier Assembly Forward Parts Exploded View 1 Piston engagement bolt 2 Cap screw 3 Switch 4 Washer 5 O ring 6 Piston 7 Setscrew 8 Piston driver 9 Push rod 10 Clutch fork 11 Spring 12 Sliding clutch 13 Pin 14 Piston cover 30 Forward Assembly Forward Assembly Disassemble Carrier Assembly Note For models having the wheel differential lock option or a carrier thrust bolt follow the steps below These parts must be removed first before further removal of the wheel differential can take place Disassemble Wheel Differential Models with Wheel Differential Lock 1 For ease of servicing mount differential carrier in stand with differential lock facing up Note To overhaul and reassemble the wheel differential the shift fork and clutch assembly must be removed from carrier See instructions below 2 Remove shift cylinder mounting screws then lift shift cylinder piston and o ring assembly off carrier and end of push rod 1 Shift cylinder 3 To disassemble shift cyl
24. nuts Note Flange half differential cases were redesigned starting with production axles built in January 1997 New style ring gear bolts are also required with the new style flange case the torque specification for this bolt is dif ferent than the old 126219 bolt See chart Bolt No Torque Specs 129686 180 220 Ib ft Nem 224 298 126219 215 255 Ib ft Nem 292 346 Note Reference Dana Bulletin ABIB 9701 for more details 9 Lower assembled differential assembly in to the car rier using a hoist and a strap Be careful not to dam age the differential bearings lowering the assembly 10 Install the bearing cup and bearing adjuster to the flange half side first 11 Install the bearing cup and bearing adjuster to the plain half side Use a long screwdriver or bar to lift the differential up while installing the cup and bear ing adjuster 45 T gt a Qa D gt 7 77 3 lt Forward Assembly Measure and Adjust Carrier Assembly Adjust Backlash and Preload 3 Tighten the plain half adjuster two lug notches Start with the notch at the top count two notches coun terclockwise on the adjuster turn the adjuster so that the notch is facing straight up You now have a two notch preload ANS EN 1 Flange half 2 Plain half 1 Turn the flange half bearing adjuster in until the ring gear contacts the pinion zero backlash than back the adjuster out tw
25. pinion and its bearings If the pinion is rotated under these conditions for any period of time bearings will overheat resulting in axle damage or failure If this is impossible to lift the drive wheels remove all axle shafts to prevent gear rotation and cap the wheel hubs to prevent loss of lubricant and a possible road hazard See the following section Proper Vehicle Towing with Wheel Differential Lock for removal procedure D D er 2 a Ke 85 Theory of Operation Power Divider Operation Power Flow and Torque Distribution In operation the power divider accepts torque from the The inter axle differential compensates for minor variations vehicle driveline and distributes it equally to the two axles in speed between the two axles the same way the wheel differential works between the two wheels of a single drive This assembly is of the two gear design consisting of an axle This unit also acts as a central point in distribution of input shaft inter axle differential output shaft and two con torque to the two axles stant mesh helical gears The power divider also includes a driver controlled air operated lockout When lockout is engaged it mechanically prevents inter axle differentiation for better performance under poor traction conditions With Lockout Engaged Inter Axle Differential is Operating PR p b 005
26. pump body 1 Machined Slot 2 Pin 25 T gt a Qa D gt 7 77 3 lt Forward Assembly Lube Manifold Disassembly Lube Manifold Installation 1 Disconnect the hose from the lube manifold 1 Install the manifold assembly into the output side gear bore in the carrier Make sure the barbed nipple So REMOVE MIE men Toll Asono BY prying ou is lined up with the opening in the carrier casting around the inner diameter IMPORTANT A IMPORTANT IMPORTANT Once removed the seal manifold assembly can not be reused This component should always be replaced with new Use the same removal procedure for the output side gear seal removal on the non pump models 1 Barbed Nipple 2 Install the hose clamp on the hose push the hose onto the barbed fitting and slide the clamp over the barbed nipple Note Seals are not sold separately from the manifold 3 Route the suction end of the hose through the holes in the carrier casting to the bottom of the carrier 1 Barbed Nipple 4 Fully press the manifold assembly into position Note Use care when pressing the manifold assembly to avoid damaging the seals and barbed nipple Do not over press plastic 26 Forward Assembly Note For non pump manifold installation it is important to line up the oil inlet path hole in the manifold with the oil path opening in the carrier manifold casting gt A 1 M
27. removing the input shaft bearing cone While pressing on new oil retainer make sure not to over press and or press with the retainer at an angle If the retainer is bent or distorted it may rub on the input cage or not seal properly to the v ring Forward Assembly 25 Press input bearing cone on input shaft 27 Press bearing cup in input bearing cover 28 Install new oil v ring on input bearing cage cover 2 as P T 4 W in Ay 1 Bearing cup press 2 V ring a 5 ch o 29 If bushing removal is needed the bushings must exit from the thrust washer side of the helical gear Qa 1 Press 4 Input shaft bearing cone gt 2 Plate 5 Oil retainer a 3 Drive Sleeve 6 Input shaft 1 Tap out bronze bushings oa 26 If input shaft bearing cup needs replacement use 30 Install bronze bushing in helical side gear Bushings either of the following recommended practices must be installed from thrust washer side of gear See illustration for dimensional tolerances e Weld a bead around the cup when the weld cools the cup will fall out e Drill a 1 4 size hole through the bearing cover to the back side of the cup and use a punch to remove the bearing cup 1 32 1 Press 2 Sleeve 3 1st bronze bushing press to shoulder 4 Shoulder 5 Sleeve 6 Second bronze bushing recess 1 32 17 Forward Assembly Install Power Divider to Carrier Assembly
28. repeat equipment failures by developing good failure analysis practices Knowing how to diagnose the cause of a premature failure is one of the prerequisites of a good heavy equipment technician How to Diagnose a Failure The following five steps are an effective approach to good failure diagnostics 1 Document the problem 2 Make a preliminary investigation 3 Prepare the parts for inspection 4 Find the cause of the failure 5 Correct the cause of the problem Document the Problem Here are some guidelines for starting to learn about a failure including questions to ask 1 Talk to the operator of the truck 2 Look at the service records 3 Find out when the truck was last serviced 4 Ask In what type of service is the truck being used 5 Ask Has this particular failure occurred before 6 Ask How was the truck working prior to the failure You need to be a good listener Sometimes insignificant or unrelated symptoms can point to the cause of the failure 7 Ask Was the vehicle operating at normal temperatures 8 Ask Were the gauges showing normal ranges of operation 9 Ask Was there any unusual noise or vibration After listening review the previous repair and maintenance records If there is more than one driver talk to all of them and compare their observations for consistency with the service and maintenance records Verify the chassis Vehicle Identification Number VIN number from the vehi
29. splined to differential case 9 Sliding clutch splined to axle shaft 90 Differential Lock Engagement Indicator Differential lock engagement is detected by a switch electric mounted on the differential carrier An actuator mounted in the piston cover operates the switch When the shift fork moves to engage the differential lock the push rod actuator moves away from the switch allows the switch to close and send an electrical signal to turn on a cab mounted indicator light or an audible signal When the shift fork moves to disengage the differential lock the compression spring also moves the push rod actuator to contact the switch The switch is opened and turns off the cab mounted indicator light or the audible signal 2 wr u ta Uo SHAS 17 a N Differential Lock Disengaged 1 Spring is decompressed 2 Shift fork 3 Push rod 4 Selector switch 5 Piston 6 Shift cylinder 7 Air pressure applied disengages clutches 8 Fixed clutch splined to differential case 9 Sliding clutch splined to axle shaft Power Divider Forward Parts Exploded View Parts Identification 1 Output shaft nut 2 Output yoke 3 Output seal 4 Output shaft bearing snap ring 5 Outer bearing cup 6 Outer bearing cone 7 Inner bearing cone 8 Inner bearing cup 9 Output shaft 10 Se
30. tool onto hub Wheel end seals can be easily damaged during handling Leave the seal in its package until installation to prevent damage or contamination 1 Remove outer bearing and wheel 2 Remove oil seal 3 Remove inner bearing 4 Remove old wear sleeve 2 piece design only with a ball peen hammer and discard A IMPORTANT Do not cut through the old wear sleeve Damage to the housing may result 5 Inspect spindle journal and hub bore for scratches or burrs Recondition with an emery cloth as required Note Deep gouges can be repaired by filling gouge with hard ening gasket cement and smoothing with emery cloth 6 Clean hub cavity and bearing bores before reassem bly Be sure to remove contaminants from all recesses and corners 7 Clean bearings thoroughly with solvent and examine for damage Replace damaged or worn bearings A IMPORTANT Always use the seal installation tool specified by the seal manufacturer Using an improper tool can distort or damage the seal and cause premature seal failure 82 Wheel End Seal Verify Wheel End play Procedure Adjust End play with Wheel Hub Verify that end play meets specification using a dial indicator An indicator with 0 001 0 03 mm resolution is required Wheel end play is the free movement of the tire and wheel assembly along the spindle axis 5 g2 m 2 a D Correct end play is 0 001 0 005 0 025 0 125 mm 4 Attach a dial indicat
31. 0 005 0 025 0 127 mm range disassemble and inspect the components If parts are found to be defective replace the defective parts reassemble and repeat wheel bearing adjust ment procedure Verify end play with a dial indicator 83 Wheel End Seal Lubricate Wheel End Wheel End with Oil Fill Hole Before operating the axle the wheel hub cavities and bear ings must be lubricated to prevent failure When wheel ends are serviced follow Dana s wheel end lubri Pont Yel s cation procedure before operating the axle CH CA Dana axles may be equipped with either of two wheel end KE designs 2 bas e Wheel ends with an oil fill hole e Wheel ends without an oil fill hole Wheel Ends with an Oil Fill Hole 7 Rotate the wheel end hub until the oil fill hole is up Be Remove the oink pug Wheel End without Oil Fill Hole 9 Pour 1 2 pint of axle sump lubricant into each hub through the wheel end fill hole 10 Install oil fill plug and tighten to specified torque EE t oot 1 Wheel end oil fill hole 2 Proper lubricant level 3 Lubricant flow from sump 84 Proper Vehicle Towing Proper Vehicle Towing Without Wheel Differential Lock Lift the drive wheels completely off of the ground or damage will occur A WARNING Do not lift the front wheels non drive wheels This alters the oil s position in the drive axle draining it away from the drive
32. Components Inspect all steel parts for Notches visible steps or grooves created by wear Pitting or cracking along gear contact lines Scuffing deformation or discolorations These are signs of excessive heat in the axle and are usually related to low lubrication levels or improper lubrica tion practices In addition inspect the following for damage Differential gearing Bearings for loose fit on drive pinion pilot bearing and differential bearings All fasteners for rounded heads bends cracks or damaged threads Inspect machined surf aces of cast or malleable parts They must be free of nicks burrs cracks scoring and wear Look for elongation of drilled holes wear on sur faces machined for bearing fits and nicks or burrs in mating surfaces Inspect Primary Gearing Before reusing a primary gear set inspect teeth for signs of excessive wear Check tooth contact pattern for evidence of incorrect adjustment Check Input Shaft End play Forward Axle Note Before disassembling the power divider measure and record input shaft end play See illustration for steps 1 3 1 Position dial indicator at yoke end of input shaft 2 Push in on input shaft and zero the dial indicator 3 Using a pry bar move input shaft axially and mea sure record end play Adjustment Correct end play for a new assembly is 0 003 to 0 007 The maximum end play for a used assembly is no more than 0 014 If end play
33. Differential Carrier Forward 11 Inter Axle Lockout Types Forward Parts Exploded View 12 Disassemble Lockout 13 External Type Lockout cccesscceseeeteesees 13 Integral Type Lockout ccccceseseeetssseteeseees 13 Install Lockout rintin 13 External Type Lockout eenenn 13 Integral Type Lockout uneeenennn 13 Power Divider Forward Parts Exploded View s seseseneneesesesnsnsnsnnnnsnsesnsne 14 Disassemble Assemble amp Overhaul LUE RSR a 15 Install Power Divider to Carrier Assembly IN VONIGIO RSR 18 Disassemble Assemble amp Overhaul Out of Vehicle 20 Install Power Divider to Carrier Assembly Out of Vehicle 23 Lube Pump DISASSOIMDIY ur aua anne 25 Installation sr a aa aa ns 25 Lube Manifold Disassembly cccccccseeccseeessseecsscsesecseeessseesseerees 26 Installation 26 Measure and Adjust Input Shaft End Play 28 Carrier Assembly Forward Parts Exploded View 30 Disassemble Carrier Assembly 31 Disassemble Wheel Differential Models w Wheel Differential Lock 31 Models with Ring Gear Thrust Bolt 31 Disassemble Wheel Differential 32 Disassemble Pinion Assembly 33 Front Axle Pinion Assembly Forward Parts Exploded View 34 Disassemble and Overhaul Drive Pinion 35 Replace Pinion Bearing Cage Cups
34. Lubrication Information The ability of a drive axle to deliver quiet trouble free operation over a period of years is largely dependent upon the use of good quality gear lubrication in the correct quantity The most satisfactory results can be obtained by following the directions contained in this manual The following lubrication instructions represent the most current recommendations from Dana Approved Lubricants General Gear lubrications acceptable under military specifi cation MILSPEC MIL L 2105D Lubricating Oils Gear Multipurpose are approved for use in Spicer Drive Axles The MIL L 2105D specification defines performance and viscosity requirements for multigrade oils It supersedes both MIL L 2105B MIL L 2105C and cold weather specification MIL L 10324A This specification applies to both petroleum based and synthetic based gear lubricants if they appear on the most current Qualified Products List QPL 2105 for MIL L 2105D Note The use of separate oil additives and or friction modifiers are not approved in Spicer Drive Axles Synthetic based Synthetic based gear lubricants exhibit superior thermal and oxidation stability and generally degrade at a lower rate when compared to petroleum based lubricants The performance characteristics of these lubricants include extended change intervals improved fuel economy better extreme temperature operation reduced wear and cleaner component appearance The family
35. Metric Tons Metric Tons Nut Torque 840 Ibs ft 575 703 Ibs ft 1 140 Nem 780 953 Nem Torque nut to 840 Ibs ft 1 140 Nem then continue tighten ing nut to align nut slot to nearest hole in pinion shank Vise Method a if the yoke and nut are used mount the assem bly in a vise clamping yoke firmly 1 Vise 39 T gt 9 Qa D gt 7 77 3 lt Forward Assembly Press Method a Ifa press is used position a sleeve or spacer so that load is applied directly to the back face of the outer bearing cone CTI u Z 1 Press 6 Measure Pinion Bearing Preload Use a spring scale 9 Stake pilot bearing using staking tool This is essen to test the assembly rolling torque To use the spring tial to retain the bearing scale wrap flexible wire around the bearing cage attach the scale and pull Preload is correct when Read only the torque value after the bearing cage starts to rotate 7 Adjust Pinion Bearing Preload If necessary adjust pinion bearing preload Disassemble the pinion bear ing cage as recommended in this manual and change the pinion bearing spacer A thicker spacer will decrease preload A thinner spacer will increase preload gt torque required to rotate the pinion bearing cage is from 5 13 lbs This specification is translated into Stake Pattern lbs in readings in the previous chart CAUTION IMPORTANT Use th
36. Rear axle torque is transmitted from the output shaft side gear through the output shaft inter axle driveline drive pinion ring gear wheel differential and axle shafts 5 Input torque power flow from the vehicle driveline is transmitted directly to the helical side gear and the output shaft A positive drive is provided to both axles for maximum traction under adverse road conditions 87 5 lt r D 9 en Theory of Operation Operate Wheel Differential Assembly The Dana wheel differential lock is driver controlled and oper ated by a carrier mounted air actuated shift unit In operation it positively locks the wheel differential to provide improved traction under adverse road conditions Control Systems for Differential Lock Two systems may be used to control the differential lock operation Transmission Low Range Interlock Control System The wheel differential is locked manually with the transmis sion in Low Range It is unlocked by the driver or unlocked when the transmission is shifted out of Low Range Note The interlock system is preferred for vehicles equipped with an air shifted Low Range transmission It is designed to ensure the differential lock is not left engaged and to prevent accidental engagement when transmission is in high range Direct Driver controlled System Direct Driver controlled System The driver manually locks and unlocks the wheel d
37. al manifold assembly 11 Sump screen 12 Seal manifold feed tube 13 Output side gear bearing cup 14 Output side gear bearing cone 15 Pump locking Pin 16 Output side gear 17 Pump 18 Snapping ring 19 Inter axle differential 20 Helical side gear 21 Sliding clutch 22 Shift fork assembly 23 Spring 24 Input shaft 25 Input shaft oil retainer 26 Input shaft bearing cone 27 Power divider cover 28 Lube trough 29 Cap screw 30 Input bearing cup 31 Input cage shim 32 Input cage V ring 33 Input cage 34 Cap screw 35 Oil Seal 36 Input yoke 37 Input nut 91 UOHEIIUSp Sed Front Drive Axle Parts Exploded View Parts Identification 1 Flange half bearing adjuster 2 Flange half bearing cup 3 Flange half bearing cone 4 Flange half carrier cap 5 Flange half differential case 6 Nut 7 Ring gear 8 Side gear thrust washer 9 Side gear 10 Wheel differential spider 11 Side pinion 12 Side pinion thrust washer 92 26 27 28 29 13 Carrier cap bolt 14 Lock washer 15 Plain half carrier cap 16 Side gear 17 Side gear thrust washer 18 Plain half differential case 19 Plain half bearing cone 20 Plain half bearing cup 21 Plain half bearing adjuster 22 D head carrier or front carrier 23 Dowel 24 Pinion pilot bearing 31 32 33 34 35 25
38. anifold Oil Inlet Hole T gt o a Pp N 77 3 zZ lt 27 Forward Assembly Measure and Adjust Input Shaft End Play Note After power divider overhaul and installation on carrier check and adjust input shaft end play The correct end play when new parts are used in overhaul is 0 003 to 0 007 with reused parts the maximum is 0 014 28 1 Remove input shaft nut Remove input bearing cover cap screws Remove bearing cover and shim pack if installed 2 Reinstall bearing cover without shims Hold in posi tion with hand pressure and measure clearance between power divider cover and bearing cover using a feeler gauge 3 The bearing cover clearance measured in Step 2 plus 0 005 will equal shim pack thickness required for desired end play rebuild with new parts Add 0 015 to shim pack for rebuild with used parts 4 Install shim pack and bearing cover Install cap screws Torque screws to 114 140 lb ft 155 190 Nem Make sure shims are flat with no kinks or bends 1 Push in and zero indicator read and record 2 Pry down 5 Install yoke using installation tool and nut Tighten nut snugly Tap end of input shaft lightly to seat bear ings 6 Check input shaft end play with dial indicator posi tioned at yoke end of input shaft Move input shaft axially and measure end play If end play is correct seal shim pack with Dana approved RTV compound to prevent lube lea
39. arts Identification Location Thread Size Class Grade Torque Specification Pinion End Nut M36 x 1 5 10 9 625 1040 Ibs ft 848 1410 Nem Ring Gear to Diff Case Cap Screw M20 x 1 5 10 9 435 465 lbs ft 589 630 Nem Carrier Cap Screw M20 x 2 10 9 330 360 Ibs ft 447 488 Nem Fill Plug 1x 1 11 5 40 60 Ibs ft 54 81 Nem Carrier to Housing Cap Screw M14x2 10 9 142 158 lbs ft 193 214 Nem Parking Brake Cap Screws M16 x 1 5 10 9 180 220 lbs ft 244 298 Nem 97 y o 77 D O D r 98 Copyright Dana Limited 2013 Dana hereby grants their customers vendors or distributors permission to freely copy reproduce and or distribute this document in printed format It may be copied only in its entirety without any changes or modifications THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON AUTOMOTIVE ALL COPIES SERVICE EXCELLENCE National Institute for Note Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed Although every attempt has been made to ensure the accuracy of information contained within Dana makes no representation about the completeness correctness or accuracy and assumes no responsibility for any errors or omissions Features and functionality may vary depending on selected options Al
40. arts may 5 fall from the carrier if not careful Use caution to prevent injury or damage Install helical side gear 1 Make sure dowel pins are installed in carrier 2 Output side gear bearing cup If removed press bearing cup in carrier Use a press and an appropri ate sleeve Make certain bearing cup is evenly and firmly seated If a press is not available use a sleeve or a bearing driver tool and a hammer to install the cup 3 Lubricate o rings 6 4 Install the output side gear using one of the follow ing instructions non pump models or lube pump models Ajquiassy puemio4 7 Install compression spring shift fork push rod and lockout sliding clutch Non pump Models a Install output side gear b Install the IAD assembly to the output side gear If reusing the IAD assembly install the same direction as removed 8 Install input shaft assembly 23 Forward Assembly Note The input shaft snap ring is not used in this buildup 12 Install input cage cap screws and tighten until snug 13 Measure and adjust input shaft end play see page 28 9 Install plastic oil trough in power divider cover 14 Torque input cage cap screws to 114 140 Ib ft 10 Install power divider cover to carrier Use Dana 155 190 Nem approved RTV compound on the carrier mating sur 15 Install NEW input seal see page 71 face Torque cap screws to 114 140 Ib ft 155 190 p u Nem 16 Reinstall input yoke
41. ation use axle shafts with unequal lengths Axle shafts may also be location spe cific with various wheel equipment Do not misplace axle shafts from their intended location Identify left and right shafts for reference during reassembly TIP If necessary loosen dowels by holding a brass drift in the center of the shaft head and striking drift a sharp blow with a hammer A CAUTION Do not strike the shaft head with a steel hammer Do not use chisels or wedges to loosen shaft or dowels 9 Remove carrier cap screws nuts and lock washers 10 Remove differential carrier assembly Forward Assembly Install Differential Carrier Forward 6 Connect main driveline making sure all yokes are in I phase Lubricate U joints IMPORTANT 7 Note Before installing carrier assembly inspect and thor oughly clean interior of axle housing using an appropri ate solvent and clean rag Connect differential lockout air line 1 Apply Dana approved RTV compound on axle hous ing mating surface as shown in the illustration Com pletely remove all old gasket material prior to applying new material Compound will set in 20 min utes Install carrier before compound sets or reapply 1 Apply silicone gasket in this pattern 2 Common stud locations T gt o Qa D N 77 3 Ex lt TIP To assist in installing complete differential carrier use two pieces of threaded rod M16 X 1 5 threaded into carri
42. carrier mating sur face Torque cap screws to 114 140 lb ft 155 190 Nem Note Gasket compound will harden in 20 minutes Install power divider quickly as possible to avoid future leaks 9 13 Install input cage shim and input cage assembly Ajquiassy puemio4 14 Install input cage cap screws and tighten until snug 15 Measure and adjust input shaft end play see page 28 A CAUTION 16 Torque input cage cap screws to 114 140 Ib ft 155 190 Nem During installation of power divider components a part 17 Install NEW input seal may fall from the carrier Use caution to prevent injury or damage 18 Reinstall input yoke Forward Assembly Disassemble Assemble and Overhaul Power Divider Out of Vehicle The power divider cover comes off as a unit followed by the 8 Remove shift fork compression spring and shift rod input shaft and then the helical side gear The power divider can be replaced with the axle assembly both in or out of the chassis and with the differential carrier assembled to the axle housing A CAUTION During removal of power divider cover the inter axle differ ential IAD input shaft assembly or IAD shift system parts may fall from the carrier if not careful Use caution to pre vent injury or damage 1 Disconnect the main driveline 9 Remove input shaft and helical thrust washer from the carrier Disconnect the lockout air line Remove input yoke Remove
43. cer size used Select a spacer 0 001 larger for use in the final pinion bearing cage assembly The larger spacer compensates for slight growth in the bearings which occurs when they are pressed on the pinion shank Do not assume that all assemblies will retain proper pre load once bearings are pressed on pinion shank FINAL PRELOAD TEST MUST BE MADE IN EVERY CASE 38 Final Buildup Note During pinion bearing installation locate each part in same position that was used in trial buildup preload test 1 Press inner bearing cone on pinion A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cone 2 Install preselected bearing spacer Forward Assembly 3 Install bearing cage on drive pinion 4 Press outer bearing cone on pinion A IMPORTANT To prevent bearing damage spin cage while pressing outer bearing on 5 Apply clamp load to the pinion bearing cage assem bly Either install the yoke or helical gear and torque the pinion nut to specifications or use the press to simulate nut torque see chart at right Specifications for Pinion Bearing Final Buildup Preload Test Torque to Rotate Bearing Cage w o pinion seal 18 42 Ibs in 2 0 4 7 Nem Forward Axles Rear Axles Spring Scale 5 13 Ibs 2 5 6 0 kgs Reading Press Loads 17 19 Tons 14 15 Tons 15 4 17 2 12 7 13 6
44. cle identification plate as well as the mileage and hours on the vehicle Make a Preliminary Investigation These steps consist of external inspections and observations that will be valuable when combined with the results of the parts examination 1 Look for leaks cracks or other damage that can point to the cause of the failure 2 Make note of obvious leaks around plugs and seals A missing fill or drain plug would be an obvious cause for concern 3 Look for cracks in the carrier housing harder to see but sometimes visible 4 Does the general mechanical condition of the vehicle indicate proper maintenance or are there signs of neglect 5 Are the tires in good condition and do the sizes match 6 If equipped with a torque limiting device is it working properly During the preliminary investigation write down anything out of the ordinary for later reference Items that appear insignificant now may take on more importance when the subassemblies are torn down Prepare the Parts for Inspection After the preliminary investigation locate the failure and pre pare the part for examination In carrier failure analysis it may be necessary to disassemble the unit 7 When disassembling subassemblies and parts do not clean the parts immediately since cleaning may destroy some of the evidence 8 When tearing down the drive axle do it in the recom mended manner Minimize any further damage to the unit 9
45. cover to power divider while aligning piston with push rod Make 11 Remove shift cylinder body or cast iron cover o ring sure shoulder washer or gasket is in place and piston 4 For stamped steel style lockouts attach mounting bracket to cylinder body and secure cap screws 5 Tighten cap screws to 28 35 Ib ft 38 47 Nem Do not remove push rod Removal of push rod will result in shift fork and compression spring falling into power divider 6 Connect differential lockout air line unit If this occurs disassembly of the power divider 7 Cycle the lockout unit to insure there are no leaks assembly will be necessary and system shifts freely 12 Remove shoulder washer in cylindrical design lock outs Cast iron cover lockout designs do not use a shoulder washer 1 Assemble o rings onto piston and piston cover Apply silicone grease to o rings Integral Type Lockout Note Cylindrical design lockout and cast iron cover lockout are interchangeable only as complete assemblies 2 Gently push piston and o ring assembly into lockout J cylinder recess Make sure piston is pushed all the 2 Integral Type Lockout way in D 1 With axle installed in vehicle place differential lock 3 Install piston cover and o ring assembly Start by selector valve in the disengaged or unlocked posi hand tightening clockwise 8 tion z 3 FR CAUTION 2 Disconnect differential lockout air line A 3 Remove piston cover and o r
46. d Yoke 3 Slinger 4 Oil Seal 5 Outer Pinion Bearing Cone 6 Outer Pinion Bearing Cup 62 7 Pinion Spacer 8 Inner Pinion Bearing Cup 9 Inner Pinion Bearing 10 Drive Pinion 11 Carrier Rear Assembly Pinion Disassembly 1 Remove yoke nut 2 Remove yoke using a yoke puller service tool 1 Yoke puller 3 Remove oil seal 4 Place carrier in a press with threaded end of pinion face up 5 Place a wood block under pinion to avoid damage to gear teeth Onl l 1 Press 2 Outer bearing 3 Inner bearing 4 Wood block 5 Drive pinion 6 Bearing preload spacer 6 Press pinion through outer bearing and out of carrier casting 7 Remove bearing preload spacer and save for use in reassembly 8 Remove inner bearing cone from pinion using a split type puller Use two procedure steps to remove each bearing a Mount puller vertically to separate the bearing This action will force puller halves under bearing and start moving bearing off pinion b Mount puller horizontally to press pinion out of bear ing 1 Press 9 If bearings are to be replaced remove bearing cups from carrier casting at this time Pinion removal complete 63 JJ D z an 3 lt Rear Assembly Pinion Installation Final Buildup Note Do not install oil seal in carrier until bearing preload is correctly adjusted 1 Press inner bearing con
47. e bearing spacer from pinion T gt 9 Qa Pp N 77 3 zZ lt 35 Forward Assembly 10 Remove inner bearing cone from pinion using a Replace Pinion Bearing Cage Cups split type puller Use two procedure steps to remove each bearing a Mount puller vertically to separate the bearing This action will force puller halves under bearing and start moving bearing off pinion 1 Cup outer 2 Bearing cage 3 Cup inner b Mount puller horizontally to press pinion out of 1 Remove cups bearing 2 Clean and inspect bearing cages for damage nicks and burrs 1 Press ram 2 Sleeve must apply pressure to back face of outer bearing cone 3 Install inner and outer pinion bearing cups Use a press and an appropriate drive sleeve Make certain bearing cup is evenly and firmly seated 1 Press 36 Forward Assembly 4 Seat cups securely to shoulder Check clearance Adjust Pinion Bearing Preload between cup and bearing cage Must be less than 0 001 Trial Buildup 1 Assemble pinion bearing cage bearings spacer and spacer washer without drive pinion or oil seal Cen ter bearing spacer between two bearing cones Lubricate bearing cups and cones 1 Bearing 2 Cup 3 Spacer 4 Cage 5 Cup 6 Bearing Note When new gear set or pinion bearings are used select nominal size spacer from the specification chart If origi
48. e correctly sized spacer Do not use shim stock or grind spacers These practices can lead to loss of bearing preload and gear or bearing failure 8 Press pilot bearing on pinion IMPORTANT To prevent bearing damage use suitable sleeve that only contacts the inner race of bearing cone 40 Forward Assembly Install Drive Pinion Assembly 1 Place shim pack on carrier making sure holes are properly aligned Make sure shims are flat with no kinks or bends 3 If dummy yoke was used remove nut and yoke Install helical gear on pinion Install M42 X 1 5 nut and torque to 840 1 020 Ib ft 1 140 1 383 Nem Note If gear set is to be reused install same quantity and size of shims removed during disassembly When installing a new gear set use nominal shim pack indicated Nominal Shim Pack Axle in mm Rear 0 023 0 584 2 Install drive pinion assembly Install bearing cage cap screws and lock washers Torque cap screws to 114 140 lb ft 155 190 Nem Note Use a dummy yoke if available in place of helical gear This will result in easier disassembly and reassembly during carrier adjustments Note Do not install cotter roll until carrier adjustments are completed A IMPORTANT Torque to 840 Ibs ft 1 140 Nem then continue tightening nut to align slot with the nearest hole in pinion shank Install roll pin 1 Roll pin 2 Slotted nut 41 T o
49. e on pinion A IMPORTANT IMPORTANT To prevent bearing damage use suitable sleeve that only con tacts inner race of bearing cone 2 Install preselected bearing spacer 64 Press inner and outer bearing cups into the carrier until seated Use a feeler gage 0 0015 0 038 mm approximately to make sure that bearing cups are fully seated in bearing bores Apply lubricant to both cup and cone Place carrier housing in press with the pinion sup ported by wood block 6 x 6 x 6 152 x 152 x 152 mm so the inner pinion bearing is mated to the cone 1 Press 2 Outer pinion bearing 3 Wood block 4 Drive pinion 5 Bearing preload spacer Press outer bearing onto pinion until completely seated Rotate carrier during seating process Use torque multiplier and torque pinion nut to 710 1040 Ibs ft 848 1410 Nem Rear Assembly 7 Measure torque to rotate the pinion with an inch 11 Use a rubber mallet to drive the seal tool in until the pound torque wrench Torque measurements should flange bottoms on the housing cover bore face The be taken every fourth 4th revolution and should flange will locate the seal at the proper depth read between 34 42 in lbs of bearing preload JJ DQ a a D lt Note If bearing preload does not fall within allowed limits preload can be increased by using a thinner spacer and decreased by using a thicker space
50. earings are assembled with both bearing cones back to back Use a press and a sleeve to install one bearing at a time A CAUTION To prevent bearing damage use a suitable sleeve that only contacts the bearing race 2 Apply pressure until the inner bearing cone touches the shoulder of the output shaft 3 Apply pressure until the back of the outer bearing cone touches the back of the inner bearing Note Axle housings with welded on covers procured through service will include the inner bearing cup as part of the service axle housing assembly Go to Step 6 if the inner cup has already been installed 4 Lightly coat the output bore of the axle housing cover with a 9 5 38 wide application of Loctite 680 where the bore contacts the inner bearing cup Do not apply Loctite outside of this area to the bearing rollers or outboard of the inner cup bore Improper application of the Loctite could lock the rollers or cause excessive pre load A CAUTION Add loctite adhesive to the inner bearing surface of the housing and NOT to the bearing race itself If added to the race excessive adhesive could get on the surface of the outer bearing race journal during installation and cure the outer cap in place with excessive pre load 5 Using a sleeve and driver hammer install the inner bearing cup 6 Put the output shaft and bearing assembly into the axle housing assembly 7 Using a sleeve and driver hammer install the out
51. ect contact Dana 5 Install oil seal Follow seal replacement procedures on page 72 of this manual Install yoke Install yoke nut One of the following options may be utilized i Install a new nut with the pre applied thread adhesive compound Tighten the nut to the specified torque 680 832 Ibs ft 920 1130 Nem j If a new nut with pre applied thread adhesive compound is unavailable apply Loctite 277 or 271 available in 0 5 ml tube Dana P N 129293 to the nut along two threads for at least two flats 120 of the nut midway through the thickness See illustration Tighten the nut to the specified torque 680 832 lbs ft 920 1130 Nem Replace Seal Dana strongly recommends using seal drivers when installing new seals Use the proper driver to make sure that the seal is square an d installed to the proper depth A CAUTION Oil seals can be easily damaged prior to installation Use care when handling the new seal to prevent damage or con tamination Leave the seal in its package until installation On new yokes leave the protector on the yoke until it is installed on the shaft to prevent damage or contamination 1 Inspect axle end play at the yoke see page 10 Ser vice if beyond specified limit Remove the old yoke using appropriate tool A yoke puller tool may be made from the center section of most gear puller tools or may be purchased from your local tool distributor 1
52. er bearing cup into the housing assembly over the out put shaft bearing cone 8 Using snap ring pliers install the snap ring that fas tens the outer bearing cup into the welded on cover assembly 9 Check the end play of the output shaft New assem blies should measure 0 001 to 0 015 Note Use the bearing cup driver to insure seating of snap ring after installation with snap ring pliers LL gt 1 Press 2 Plate 3 Sleeve 4 Press bearing on second 1 Snap ring 2 Bearing cup 3 Output shaft assembly 4 Inner bearing cup 5 Rear cover assembly 10 Install output yoke gt 3 Q 4 5 Press bearing on first 6 Output shaft 7 Plate 55 T gt a a Pp N 77 3 lt Forward Assembly 11 Install yoke nut using one of the following options g Install a new nut with the pre applied thread adhesive compound Tighten the nut to the specified torque 680 832 lbs ft 920 1 130 Nem h If anew nut with pre applied thread adhesive compound is unavailable apply Loctite 277 or 271 available in 0 5 ml tube Dana P N 129293 to the nut along two threads for at least two flats 120 of the nut midway through the thickness Tighten the nut to the specified torque 680 832 Ib ft 530 1 130 Nem A IMPORTANT Follow the instructions specified by the thread adhesive manufacturer when applying thread adhesive compound
53. er cap screw holes Rod should be approximately 6 long Use these to pilot the carrier into the housing 2 Install carrier to housing lock washers cap screws and nuts Torque to proper specification Torque to 230 270 Ib ft 312 366 Nem 3 After 11 02 98 axle housing covers are welded in place If you have a bolt on cover install rear hous ing cover output shaft assembly see page 53 Torque all fasteners to proper specifications Torque to 85 103 Ib ft 115 140 Nem Install inter axle driveline making sure yokes are in phase 4 Install axle shafts and axle stud nuts if used also install lock washers and tapered dowels 5 Add axle lubricant Fill to bottom of filler hole 11 Forward Assembly Inter Axle Lockout Types Forward Parts Exploded View 1 2 3 en 4 2X PRE 5 vA 6 1 Compression spring 4 Piston 2 Shift fork 5 O ring 3 O ring 6 Piston Cover Air operated to engage the lockout and spring released to disengage the lockout Forward Assembly Disassemble Lockout Install Lockout External Type Lockout External Type Lockout 8 With axle installed in vehicle place differential lock 1 Assemble o rings onto piston Apply silicone grease selector valve in the disengaged or unlocked posi to o ring tion 2 Install piston and o ring assembly into cylinder body 9 Disconnect differential lockout air line or cast iron cover 10 Remove cap screws 3 Attach shift cylinder body or cast iron
54. erator covered in the service procedures TIP Helpful removal and installation procedures to aid in the service of this unit Refer to the OEM vehicle specifications Always use genuine Dana Spicer replacement parts Inspection Failure Analysis Failure analysis is the process of determining the original cause of a component failure in order to keep it from happening again Too often when a failed component is replaced without determining its cause there will be a recurring failure If a carrier housing is opened revealing a ring gear with a broken tooth it is not enough to settle on the broken tooth as the cause of the carrier failure Other parts of the carrier must be examined For a thorough understanding of the failure and possible insight into related problems the technician needs to observe the overall condition of the vehicle No one benefits when a failed component goes on the junk pile with the cause unknown Nothing is more disturbing to a customer than a repeat failure Systematically analyzing a failure to prevent a repeat occurrence assures quality service by avoiding unnecessary downtime and further expense to the customer The true cause of a failure can be better determined by knowing what to look for determining how a piece of the equipment was running and learning about previous problems In the case of a rebuilt rear axle mismatched gears may have been installed The more successful shops prevent
55. erential Lock Forward Parts Exploded View 1 Piston engagement bolt 8 Piston driver 2 Cap screw 9 Push rod 3 Switch 10 Clutch fork 4 Washer 11 Spring 5 0 ring 12 Sliding clutch 6 Piston 13 Pin 7 Setscrew 14 Piston cover 50 Forward Assembly Install and Adjust Wheel Differential Lock Note With differential carrier completely assembled and adjusted install differential lock as follows 11 Screw in manual engagement screw by hand approximately 1 inch or until snug fit light resis tance pressure is felt both clutches must be com 1 Install fixed curvic clutch on splined hub of flanged pletely engaged differential case then install snap ring 12 Remove manual engagement screw clutches must completely disengaged Repeat above procedure if clutches not completely disengaged 2 If shift fork and sliding curvic clutch are disassem bled engage fork with clutch hub and install spring pin in the long leg of the fork See illustration for fork mounting position on clutch Note Fork adjustment is correct when curvic clutch teeth are fully engaged with the fork free when moved by hand When air pressure is released or the manual bolt is removed the shift assembly should disengage freely 3 Position compression spring shift fork and clutch assembly in shift opening of the carrier Align pilot hole of shift fork with pilot hole of carrier Install pushrod engaging shift
56. face of the ring gear is made 2 Loosen the thrust screw 1 4 turn to obtain the cor rect adjustment of 0 020 50mm clearance between gear face and screw Tighten jam nut hold ing thrust screw stationary with a wrench torque jam nut 150 190 Ibs ft 203 258 Nem 3 Recheck to assure minimum clearance during full rotation of ring gear 1 D head carrier or front carrier 2 Thrust bolt 3 Thrust bolt jam nut 52 Forward Assembly Housing and Output Shaft Assembly Forward Parts Exploded View 1 Output shaft nut 2 Output yoke 3 Output seal 4 Snap ring 5 Outer bearing cup 6 Outer bearing cone 7 Inner bearing cone 8 Inner bearing cup 9 Output shaft 10 Fill Plug 11 Jam nut 12 Locking ring 13 Spindle nut 14 Axle housing 15 Breather 16 Breather hose 17 Carriage cap screw 18 Lock washer 19 Nut 20 Lock washer 21 Stud 22 Drain plug 23 Axle shaft 53 T gt 9 Qa Pp N 77 3 lt Forward Assembly Disassemble Output Shaft Assembly Note For forward axle rear covers that are removable the out put shaft may be removed when the cover is in or out of the axle assembly 1 Disconnect the inter axle driveline at the forward axle rear cover position 2 Remove yoke nut shoulder nut 3 Remove yoke from output shaft using appropriate tool 1 Yoke puller tool TIP A yoke pul
57. gear tooth The more use a gear has had the more the line becomes the dominant char acteristic of the pattern Adjust used gear sets to display the same contact pattern observed before disassembly A correct pattern is up off the toe and centers evenly along the face width between the top land and root Otherwise the length and shape of the pattern are highly variable and is considered acceptable as long as it does not run off the tooth at any point 1 Pattern along the face width could be longer Adjust Contact Pattern If necessary adjust the contact pattern by moving the ring gear and drive pinion e Ring gear position controls the backlash This adjustment moves the contact pattern along the face width of the gear tooth e Pinion position is determined by the size of the pin ion bearing cage shim pack It controls contact on the tooth depth of the gear tooth These adjustments are interrelated As a result they must be considered together even though the pattern is altered by two distinct operations When making adjustments first adjust the pinion then the backlash Continue this sequence until the pattern is satisfactory Forward Assembly Adjust Pinion Position Adjust Ring Gear Position Backlash If the gear pattern shows incorrect tooth depth contact If the gear pattern shows incorrect face width contact change change drive pinion position by altering the shim pack Used backlash by adjusting the ring gear
58. haft Align Pin Holes Fit End Into Slot 70 19 Install the locking pins to both sides of the differen tial case 20 Install outer side gear Note No thrust washer is used at this location 21 Lower the ring gear onto the case assembly aligning the locking dowels Wheel Differential 22 Install and hand tighten all new ring gear cap screws 23 The interface of the ring gear to differential case is a press fit Put the assembly in a press with the ring gear facing upward Make certain that the ring gear is flush and square to the differential case before pressing Press until ring gear bottoms out on the case A IMPORTANT IMPORTANT DO NOT use the cap screws to draw the ring gear into place Only use a press 24 Press new ring gear bearing cone A IMPORTANT IMPORTANT When pressing differential case bearing cones note that the bearing is beyond flush with the top of the case The cone must be fully seated To prevent bearing damage use suitable sleeve that only contacts the inner race of the cone A used bearing race would be a suitable tool This tool should have a slit cut if the ID is the same as the bearing boss OD 25 Tighten and torque ring gear cap screws in an alter nating pattern 435 465 lbs ft 589 630 Nem 71 a F en z 72 Wheel Differential 26 Install differential case assembly into carrier Be careful not to damage t
59. he differential bearings lower ing the assembly 27 Lubricate the differential bearings and install bearing cups and differential bearing adjusters Wheel Differential Measure and Adjust Carrier Assembly Adjust Backlash and Preload 1 Turn the flange half bearing adjuster in until the ring gear contacts the pinion zero backlash then back the adjuster out two 2 notches from the adjuster lugs 1 Flange half 2 Plain half 2 Tighten the plain half adjuster until the bearing cup just starts to turn this is a zero bearing preload 3 Tighten the plain half adjuster two lug notches Start with the notch at the top count two notches coun terclockwise on the adjuster turn the adjuster so that the notch is facing straight up You now have a two notch preload NS EN 1 Lugs 2 One notch 4 Use a rubber mallet to make certain that both bear ing adjusters are fully seated 5 Measure backlash Make sure it is within specifica tion of 0 008 0 018 0 15 0 46 mm TIP To give yourself room to adjust contact pattern set it between 0 012 0 014 0 30 0 36 mm 73 3 D T Wheel Differential Change Backlash Setting If you have too much backlash the ring gear needs to move Closer to the pinion Back off the plain half adjuster counting the number of notches you back it off each notch equals about 0 003 0 08 mm of backlash A IMPORTANT
60. housings axle shafts and wheel equipment Model Listing Tandem Axles Load Capacity D40 145 40 000 Lbs 18 144 kg Model Information D40 145 X Options D Dual Drive Forward Axle D Wheel Differential Lock with Inter Axle Differential forward unit only R Dual Drive Rear Axle H Heavy Wall Housing P Lube Pump GAW Rating x 1000 Ibs S SelectTrack X Without Inter Axle Gear Type 1 Standard Single Reduction Design Level Head Assembly Series a S O 5 Introduction Model Identification Drive Axle 3 CUST PART NO SPEC O 2 i MADE IN MODEL PART NO Spicer SERIAL NO RATIO Rear Carrier 1 Country of origin 2 Axle model identification 3 Specification number assigned to the axle built by Dana Spicer Identifies all component parts of the axle including special OEM requirements such as yokes or flanges Part Identification Axle Housing Forward Carrier 4 OEM part number assigned to the axle build 5 Carrier assembly serial number assigned by the manufacturing plant 6 Axle gear ratio 7 Carrier assembly production or service part number Axle Shaft 1 ID Tag 2 Axle shaft part number Introduction Ring Gear and Pinion Note Ring gear and drive pinion are matched parts and must be replaced in sets Forward Axle Rear Axle a i x
61. ial ring gear away from the pinion to increase backlash 1 Loosen the bearing adjuster on the teeth side of the ring gear several notches 2 Loosen the opposite adjuster one notch 3 Return to adjuster on teeth side of the ring gear and tighten adjuster until it contacts the bearing cup 4 Continue tightening the same adjuster two 2 or three 3 notches and recheck backlash If the pattern is concentrated at the heel too far up the tooth move the ring gear toward the pinion to decrease backlash 5 Loosen the bearing adjuster on the teeth side of the ring gear several notches 6 Tighten the opposite adjuster one notch 7 Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup 8 Continue tightening the same adjuster two 2 or three 3 notches and recheck backlash 76 Service Kit 217414 Location 126917 New Welded D Housing Cover Lube Quantity Difference 0 zero Standout of Output Shaft Yoke Length increased by 6mm 25 this should not have any significant impact on inter axle driveline length or drive line angles 126917 126917 128706 Interchangeability of Parts Across reference chart of OLD axle housing to NEW axle housings with welded on covers will be published in a sepa rate bulletin The bolt on D Housing covers will remain avail able for service 77 Lubrication General
62. ifferential using a cab mounted electric switch or air valve The follow ing description assumes the system includes a cab mounted electric switch and a solenoid valve as shown in the illustra tion An air valve may be substituted for these components Operation is as follows 1 With control switch in the unlock position the wheel differential functions normally 2 When the control switch is placed in the lock position the air supply solenoid valve opens and air pressure activates the shift cylinder The shift fork is moved to engage the curvic clutches which in turn lock the wheel differential 3 When the control switch is placed in the unlock position air pressure supply to the shift cylinder is shut off and air pressure is released from the cylin der A compression spring moves the shift fork to disengage the curvic clutch and unlock the wheel differential 1 Cab mounted control valve plunger in valve open 2 Dry air supply tank 80 120 PSI 3 Preferably equal in length 4 Power supply 5 Fuse or circuit breaker 6 Indicator light or audible signal 7 Wheel differential lock indicator switch part of axle assembly 8 Rear axle wheel differential lock air shift cylinder part of axle assembly 88 J
63. inder for inspection first remove or back off actuator switch The piston and o ring assembly can be removed by inserting a pen cil size tool through the cylinder air port 4 Grasp push rod end and pull it out of the shift fork spring and carrier Note When the push rod is disengaged from the shift fork the fork and sliding curvic clutch assembly can be removed from carrier Note Do not disassemble shift fork from the sliding curvic clutch unless parts replacement is necessary To disas semble use pin punch to remove spring pin from long leg of fork The fork can now be disengaged from the clutch 5 Remove the snap ring then lift fixed curvic clutch off differential case hub spline Further disassembly of carrier is the same for axles without differential lock Models with Ring Gear Thrust Bolt Note If the carrier model has a ring gear thrust bolt installed it must be backed away from the ring gear before you can remove the wheel differential 1 Back off thrust bolt jam nut 2 Back out thrust bolt from the carrier until the end of the bolt is flush with the inside of the carrier casting This will allow enough clearance between the ring gear and the carrier pilot web 1 D head carrier or front carrier 2 Thrust bolt 3 Thrust bolt jam nut 31 T gt a a Pp N 77 3 lt Forward Assembly Disassemble Wheel Differential All Standard Models Note Omit this step
64. ing Do not to strip threads or use excessive force damage to 4 Remove piston and o ring assembly with pliers part may occur Note To remove shift fork and push rod parts the power 4 Tighten piston cover to 25 35 lb ft 35 47 Nem divider must be removed See power divider section 5 Connect differential lockout air line 6 Cycle the lockout unit to make sure there are no leaks and the system shifts freely 13 Power Divider Forward Parts Exploded View Forward Assembly 1 Output shaft nut 2 Output yoke 3 Output seal 4 Output shaft bearing snap ring 5 Outer bearing cup 6 Outer bearing cone 7 Inner bearing cone 8 Inner bearing cup 9 Output shaft 10 Seal manifold assembly 11 Sump screen 12 Seal manifold feed tube 13 Output side gear bearing cup 14 Output side gear bearing cone 15 Pump locking Pin 16 Output side gear 17 Pump 18 Snapping ring 19 Inter axle differential 20 Helical side gear 21 Sliding clutch 22 Shift fork assembly 23 Spring 24 Input shaft 25 Input shaft oil retainer 26 Input shaft bearing cone 27 Power divider cover 28 Lube trough 29 Cap screw 30 Input bearing cup 31 Input cage shim 32 Input cage V ring 33 Input cage 34 Cap screw 35 Oil Seal 36 Input yoke 37 Input nut Forward Assembly Disassemble Assemble and Overha
65. input seal Position a drain pan under the power divider unit Remove PDU cap screws NOS or D Remove power divider cover 20 Forward Assembly 11 Remove the IAD assembly from the output side gear 16 Press new oil retainer on input shaft A CAUTION It is not recommended to reuse the oil retainer due to possi ble damage that may occur while removing the input shaft bearing cone While pressing on new oil retainer make sure not to over press and or press with the retainer at an angle If the retainer is bent or distorted it may rub on the input cage or not seal properly to the v ring 17 Press input bearing cone on input shaft 12 Remove the output side gear 1 Note Remove lube pump if you have one IT 2 wi f C Ne ul 4 a 13 Inspect output side gear o rings for nicks and cuts Orn Ay 3 Replace if necessary D a 14 Install new bearing cup ED 5 gt 15 Remove input shaft bearing cone and oil retainer if D necessary 1 Press 4 Input shaft bearing cone 2 Plate 5 Oil retainer 3 Drive sleeve 6 Input shaft 1 Press 2 Bearing 3 Oil retainer 4 Input shaft 21 Forward Assembly 18 If input shaft bearing cup needs replacement use either of the following recommended practices e Weld a bead around the cup when the weld cools the cup will fall out e Drill a 1 4 size hole through the bearing cover to the back side of the cup and use a pu
66. kage Then torque input shaft nut 7 If end play is incorrect change shim pack size as fol lows Add shims to increase end play Desired end play New Parts 0 003 to 0 007 Measured end play Step 6 0 001 0 001 Add shims to provide desired end play 0 002 to 0 006 Disassemble shim to decreased end play Measured end play Step 6 0 015 0 015 Desired end play New Parts 0 003 to 0 007 Remove shims to provide desired end 0 012 to 0 008 play Forward Assembly 8 To add or remove shims remove input shaft nut and yoke Remove cap screws lock washers and bearing cover Add or remove shims as required 9 Install bearing cover and cap screws Seal shim pack with Dana approved RTV compound to prevent lube leakage then torque input shaft cap screws 150 165 lb ft 204 224 Nem 10 Install yoke 11 Install yoke nut One of the following options may be used a Install a new nut with the pre applied thread adhesive compound Tighten the nut to the specified torque 840 1020 lb ft 1148 1383 Nem b Ifa new nut with pre applied thread adhesive compound is unavailable apply Loctite 277 or 271 available in 0 5 ml tube Dana P N 129293 to the nut along two threads for at least two flats 120 of the nut midway through the thickness Tighten the nut to the specified torque 840 1020 lb ft 1148 1383 Nem IN Se a Midway thru thickness of nut Note Use of a torque
67. l other trademarks are property of their respective owners Dana Commercial Vehicle Products Group 3939 Technology Dri ne ne DANA SPICER Drivetrain Products www dana com All applications must be approved by the Application Engineering Department Specifications and or design are subject to change without notice or obligation Printed in USA AXSM 0058 09 13
68. l start moving bearing off case 2 Punch mark differential cases for correct location during reassembly Remove cap screws and lift off plain differential case half T gt a Qa Pp N 77 3 lt b 1 Punch marks 3 Lift out side gear and thrust washer TON A FLIAENS Del 8 Remove bearing cone from flanged case half using suitable puller 43 Forward Assembly Overhaul and Assemble Wheel Differential 3 A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts the inner race of the cone A used bearing race would be a suitable tool This tool should have a slit cut if the ID is the same as the flange OD 1 44 2 Press new flange half bearing cones on differential case halves Press new plain half bearing cones on differential case halves 6 Place thrust washer and side gear in flanged differ ential case Lubricate all differential parts Assemble side pinion and thrust washers on spider Place this assembly in flanged differential case Rotate gears and check for proper mesh ER D 20 Forward Assembly 7 Align punch marks and install plain case half Install cap screws and tighten to 114 140 lb ft 155 190 Nem Check differential for free rotation by turning side gear hub 1 Punch marks 8 Install ring gear Secure with bolts and
69. ler tool may be made from the center section of most gear puller tools or may be pur chased from your tool distributor 4 Remove oil seal 5 Remove snap ring 6 Remove output shaft and outer bearing cup as an assembly M 1 Snap ring 2 Outer bearing cup 3 Output shaft assembly 4 Inner bearing cup 5 Rear cover assembly 54 TIP It may be helpful to loosely reinstall the yoke and shoulder nut giving the technician more of an area to grip when removing the output shaft 7 Remove the inner bearing cup from rear cover assembly This may be removed from inside the axle housing when the carrier is removed or by removal of the forward axle rear cover 8 Remove both inner and outer bearing from output shaft 1 Press 9 Remove output shaft inner bearing cup Note Components such as the inter axle driveline yoke oil seal and output shaft assembly should have been removed according to normal service procedures Removing the differential assembly from the axle hous ing is not necessary but would ease the removal pro cess of the inner bearing cup from the cover bore e Using a bearing puller tool remove the inner bearing cup f Visually inspect the inner machined bore sur face of the welded on cover for nicks and burrs Repair if necessary Forward Assembly Overhaul and Assemble Output Shaft Assembly Note Lubricate the parts with gear lube during assembly 1 The output shaft b
70. les 400 000 Km 60 000 miles 96 500 Km 75W 140 or 3 years or 1 year Mineral MIL L 2105E J02360 75W 75W 90 120 000 miles 193 000 Km 60 000 miles 96 500 Km Base API GL 5 Gear Oil 75W 140 80W or 1 year or 1 year MIL PRF 2105E 90 85W 140 Axles using LMS wheel end system Axles using adjustable wheel bearing system rm a ir Q 79 Lubrication Change Lube Drain Drain when the lube is at normal operating temperature 150 200 F It will run freely and minimize the time neces sary to fully drain the axle this insures the axle is flushed Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container Note Dispose of all used lubricants properly by following dis posal methods approved for mineral or synthetic based oils After initial oil change inspect drain plug for large quantities of metal particles These are signs of damage or extreme wear in the axle Clean the drain plug and replace it after the lube has drained completely Inspect breather for clogging or cor rosion Clean or replace as necessary Fill Front Axle a With vehicle on level ground remove the filler hole plug from the axle housing cover and fill the axle with approved lubricant until level with the bottom of the hole Rear Axle a Remove the filler hole plug from the axle housing cover and fill the axle with the approved
71. lf Bearing Cone 30 Plain Half Bearing Cup 31 Plain Half Bearing Adjuster 32 Pipe Plug Parts Identification Housing and Output Shaft Assembly Parts Exploded View 1 Output shaft nut 2 Output yoke 3 Output seal 4 Snap ring 5 Outer bearing cup 6 Outer bearing cone 7 Inner bearing cone 8 Inner bearing cup 9 Output shaft 10 Axle housing 11 Breather hose 12 Breather 13 Lock washer 14 Carriage cap screw 15 Nut 16 Lock washer 18 17 Stud 18 Drain plug 19 Spindle nut 20 Locking ring 21 Jam nut 22 Axle shaft 23 Fill plug 95 y EJ a D O D r Fastener Torque Specifications Forward Carrier Parts Identification Power Divider Class Size Tool Ibs ft Nem Diff lock cover to carrier 8 8 M10 X 1 5 13 mm 28 35 38 47 Diff lock switch 8 8 M12X 1 5 10 12 14 16 IAD lock cover cap screw 8 8 M10 X 1 5 13 mm 28 35 38 47 Input bearing cage cap screw 10 9 M14 X2 21mm 114 140 155 190 Input shaft nut M42 X 1 5 55 mm 840 1020 1140 1383 Power divider cover cap screw 10 9 M14 X2 21 mm 114 140 155 190 Diff and Gearing Front pinion helical nut Grade 8 M42 X 1 5 65 mm 840 1020 1140 1383 Output shaft nut M39 X 1 5 55 mm 680 832 920 1130 Rear pinion nut 8 8 M36 X 1 5 55 mm 575 703 780 953 Ring gear nut with
72. loded VieW ccccccscccsescesscsseeeseeeees 92 Seals Wheel Differential Lock Assembly Service Kit 217414 77 Parts Exploded View 93 General Lubrication Information 78 Parts Exploded View 94 Approved Lubricants ccccccscscsecsecsecseeseeees 78 Housing and Output Shaft Assembly Recommendations for Visc Ambient Temp 78 Parts Exploded View 95 Lube Change Intervals ccccccssecsscseeeeseesees 79 Fastener Torque Specifications 96 Change LUDO nian 80 Torque Chart Rear Carrier 97 Drain 80 ENS NN tenant 80 Wheel Ends Wheel End Seal Parts Exploded View 81 Disassemble amp Overhaul Wheel End Seal 82 Install Wheel End Seal 82 Verify Wheel End play Procedure 10101512 83 Adjust End play w Tire amp Wheel Assem 83 Adjust End play with Wheel Hub 83 Readjust Wheel End play Procedure 83 Lubricate Wheel End 84 Wheel Ends with an Oil Fill Hole 84 Introduction Introduction Dana Spicer Corporation Commercial Vehicle Division presents this publication to aid in maintenance and overhaul of Dana Spicer single drive axles Instructions contained cover the models listed Their design is common with differences in load capacity Capacity variations are achieved by combining basic differential carrier assemblies with different axle
73. main driveline Disconnect differential lockout air line oe N Disconnect lead wires to the selector switch and air line at shift cylinder 6 Remove axle shafts Diff Lock Models For removal of the locking wheel differential carrier assembly the differential lock must be engaged and held in the engaged position This can be accomplished by one of two methods either engage via air pressure or engage manually Engage via Air Pressure a Using an auxiliary air line apply 80 120 PSI air pressure to shift cylinder air port to engage clutch 1 Connect 80 120 PSI air line to cylinder port Engage Manually a Install a 0 250 18 NPTF bolt over 1 5 long in the cylinder air port to manually engage the clutches GM models require a M12 X 1 5 X 38mm bolt Note Hand tighten the bolt over torquing may cause damage to the shift unit To facilitate hand tightening coat bolt threads with axle lube 1 Hand tighten with socket 2 M12 x 1 5 x 38mm bolt GM only 0 250 18 NPTF all models except GM Note With either method the axle shaft may have to be rotated to permit the clutch to become engaged A WARNING Do not lie under carrier after fasteners are removed Use transmission jack to support differential carrier assembly prior to loosening fasteners 7 To remove axle shaft remove axle stud nuts If used remove lock washers and taper dowels 8 Remove axle shafts Note All models in this public
74. major assemblies nal to a cab mounted indicator light or an audible signal device i u u m ey amp S lt D 9 o a 3 1 Curvic clutch assembly 1a Sliding clutch 1b Fixed clutch 2 Shift fork and push rod assembly 2a Shift fork 2b Pushrod 3 Shift cylinder assembly 3a Piston driver 3b Selector switch 89 Theory of Operation Differential Lock Engaged Air pressure applied to the shift cylinder moves the piston push rod shift fork and the sliding curvic clutch engages the fixed curvic clutch The sliding clutch is splined to the axle shaft The fixed clutch is splined to the differential case hub Engaging the two Clutches locks the wheel differential thus preventing wheel differential action Differential Lock Disengaged When air pressure at the shift cylinder is released a compres sion spring mounted on the push rod moves the push rod shift fork and sliding clutch as an assembly The sliding clutch moves out of engagement with the fixed clutch The wheel dif ferential is unlocked and operates normally NZ 7 J eh 8 9 Differential Lock Engaged 1 Spring is compressed 2 Shift fork 3 Push rod 4 Selector switch 5 Piston 6 Shift cylinder 7 Air pressure applied engages clutches 8 Fixed clutch
75. nal parts are used use spacer removed during disas sembly T gt 9 Qa Pp N 77 3 lt 2 With the bearings well lubricated place the assembly in the press Position sleeve so that load is applied directly to the back face of the outer bearing cone 1 1 Press ram 2 Sleeve must apply pressure to back face of outer bearing cone 3 Spring scale 37 Forward Assembly 3 Rotate pinion cage while applying press load see chart below to the assembly and check rolling torque Wrap soft wire around the bearing cage attach spring scale and pull Preload is correct when torque required to rotate the pinion bearing cage is from 5 13 Ibs 2 5 6 0 kg Specifications for Pinion Bearing Trial Buildup Preload Test Torque to Rotate Bearing Cage w o pinion seal 18 42 in Ibs 2 0 4 7 Nem Forward Axles Rear Axles Spring Scale 5 13 Ibs 2 5 6 0 kg Reading Press Loads 17 19 Tons 14 15 Tons 15 4 17 2 12 7 13 6 Metric Tons Metric Tons Nominal Bearing 0 496 in 0 638 in Thickness Spacer 12 60 mm 16 21 mm A CAUTION Read only the torque value after the bearing cage starts to rotate 4 If necessary adjust pinion bearing preload by chang ing the pinion bearing spacer A thicker spacer will decrease preload A thinner spacer will increase pre load IMPORTANT Once correct bearing preload has been established note the spa
76. nch to remove the bearing cup 19 Press bearing cup in input bearing cover 20 Install new oil v ring on input bearing cage cover 1 Bearing cup press 2 V ring 22 21 If bushing removal is needed the bushings must exit from the thrust washer side of the helical gear 1 Tap out bronze bushings 22 Install bronze bushing in helical side gear Bushings must be installed from thrust washer side of gear See illustration for dimensional tolerances 1 Press 2 Sleeve 3 1st bronze bushing press to shoulder 4 Shoulder 5 Sleeve 6 Second bronze bushing recess 1 32 Forward Assembly Install Power Divider to Carrier Assembly Out of Vehicle Note Parts inspection and cleaning procedures are important Lube Pump Models and should be adhered to Cleanliness in your work area is important as dirt is an abrasive and will cause prema ture wear of the otherwise serviceable parts a Install output side gear pump assembly into carrier The lube pump mounting holes are oriented in such a way that it can be installed only in one position Note It is assumed that the different carrier is secured in a b Lube pump coupling Line up the drive couplings stand tangs with the pump and IAD notches The spacing of the tangs are the same one side to the other If reusing the IAD assembly install the same direction as it was removed During installation of power divider components p
77. ntaminants The condition of the yoke hub s surface is a very important factor in determining seal life Carefully inspect the seal surface area of the yoke hub for signs of wear and damage Do not reuse the yoke if there is noticeable wear such as heavy grooving beyond normal pol ishing from the seal lips Note Do not rework the yoke with abrasives such as emery paper or crocus cloth Clean the surface of the yoke as necessary using chemical cleaners Remove all trace of the chemicals from the yoke after cleaning A CAUTION Do not use wear sleeves Wear sleeves increase the yoke hub surface diameter and cause premature seal wear and repeat seal failure Rear Assembly Differential Carrier Assembly Rear N J D a 77 amp 3 lt 1 Carrier fastener 2 Carrier assembly Rear Assembly 59 Differential Carrier Rear Parts Exploded View 60 1 Pinion Nut 2 End Yoke and Slinger 3 Oil Seal 4 Outer Pinion Bearing Cone 5 Outer Pinion Bearing Cup 6 Pinion Spacer 7 Inner Pinion Bearing Cup 8 Inner Pinion Bearing Cone 9 Drive Pinion 10 Carrier Housing 11 Diff Case Dowels 12 Ring Gear 13 Ring Gear Bolts 14 Flange Half Bearing Cone 15 Flange Half Bearing Cup 16 Flange Half Bearing Adjuster 17 Side Pinion Thrust Washer Rear Assembly 18 Side Pinion 19 Side Gear 20A Differential Shaft 20B Differential Shaft 21 Pin 22 Cap
78. o notches of the adjuster lugs 1 Flange half 4 Use o a a certain that both bear 2 Plain half ing adjusters are fully seated 5 Measure backlash Make sure it is within specifica 2 Tighten the plain half adjuster until the bearing cup tion of 0 006 0 018 just starts to turn this is a zero bearing preload TIP To give yourself room to adjust contact pattern set it between 0 010 0 012 46 Forward Assembly Change Backlash Setting Measure Ring Gear Runout If you have too much backlash the ring gear needs to move Measure Ring Gear Total Closer to the pinion Back off the plain half adjuster count the 1 Measure ring gear total radial run out Indicator number of notches you back it off each notch equals about reading should not exceed 0 010 0 003 of backlash A IMPORTANT In order to maintain the differential bearing preload you will need to turn the flange half bearing adjuster the same amount in the same direction If you need more backlash reverse this procedure 1 Install carrier bearings caps and torque carrier cap bolts to 350 428 Ibs ft 475 580 Nem 2 Recheck backlash if the bearing adjusters were not in straight or fully seated the backlash will change c Used Gearing Reset to backlash recorded 2 Measure ring gear total back face run out Indicator before disassembly reading should not exceed 0 010 d New Gearing Backlash should be between 0 006 and 0 018
79. of Spicer gear lubricants represents a premium quality synthetic lube which fully meets or exceeds the requirements of MIL L 2105D These products available in both 75W 90 and 80 W 140 have demonstrated superior performance in comparison to others qualified under the MILSPEC as demonstrated by extensive laboratory and field testing For a complete list of Spicer approved synthetic lubricants contact your local Dana representative See back cover of this manual for appropriate phone number Makeup Lube Maximum amount of non synthetic makeup lube is 10 78 Recommendations for Viscosity Ambient Temperature The following chart lists the various SAE grades covered by MIL L 2105D and the associated ambient temperature range from each Those SAE grades shown with an asterisk are available in the Spicer family of synthetic gear lubricants The lowest ambient temperatures covered by this chart are 40 F and 40 C Lubrication recommendations for those applications which consistently operate below this temperature range must be obtained through Dana by contacting your local Dana representative Grade Ambient Temperature Range 75W 40 F to 15 F 40 C to 26 C 75W 80 40 F to 80 F 40 C to 21 C 75W 90 40 F to 100 F 40 C to 38 C 75W 140 40 F and above 40 C and above 80W 90 15 F to 100 F 26 C to 38 C 80W 140 15 F and above 26 C and above 85W 140 10 F and abo
80. or with its magnetic base to the hub or brake drum as shown below 5 Adjust the dial indicator so that its plunger or pointer is against the end of the spindle with its line of action approximately parallel to the axis of the spindle 6 Grasp the wheel assembly at the 3 o clock and 9 With indicator mounted at bottom o clock positions Push the wheel assembly in and Push Pull at sides of drum out while oscillating it to seat the bearings Read bearing end play as the total indicator movement CAUTION Readjust Wheel End play Procedure Excessive End play lf end play is greater than 0 005 127 mm remove the outer nut and pull the lock washer away from the inner nut but not off the spindle Tighten the Adjust End play with Tire and Wheel Assembly inner nut to the next alignment hole of the dowel type washer if used Reassemble the washer and re torque the outer nut Verify end play with a dial indicator If end play is not within specification readjustment is required Insufficient End play If end play is not present remove the outer nut and pull the lock washer away from the inner nut but not off the spindle Loosen the inner nut to the next adjustment hole of the dowel type washer if used Reassem ble the washer and re torque the outer nut Verify end play with a dial indicator Fine Tuning the End play If after performing the readjust ment procedures end play is still not within the 0 001
81. r 12 Install end yoke Always measure each spacer before assembly to ensure correct thickness Note Dana Spicer recommends that new torque prevailing nuts be used 8 Repeat process until torque to rotate is between 34 42 in lbs After proper preload is achieved remove 13 Use torque multiplier and torque pinion nut to 710 yoke and install new seal with proper service tool 1040 Ibs ft 848 1410 Nem 1 Seal Driver A CAUTION 2 Oil Seal 3 Pinion Cage CAUTION Do not use any silicone or permatex type bore sealant with this seal 9 Remove the new seal from its package and install with the proper driver R Pinion Use drive 126917 only A WARNING WARNING Due to the resiliency of the plastic driver hammer rebound may occur when the seal is seated Keep clear of the hammer rebound path 10 Handle the seal by its outside diameter avoiding any contact with the seal lips During installation use the proper driver to make sure that the seal is mounted properly 65 Wheel Differential Assembly Parts Exploded View Diff Case Bearing Adjuster Diff Bearing Cup Diff Case Bearing Cone Differential Case Side Gear Thrust Washer Side Gear Differential Shaft 8 Side Pinion NOUA UNS 66 Wheel Differential 9 Side Pinion Thrust Washer 10 Pin 11 Ring Gear 12 Ring Gear Bolt 13 Ring Gear Bearing Cone 14 Ring Gear Bearing Cup 15 Ring Gear Bearing Adjuste
82. r 16 Locating Dowels Wheel Differential Disassemble Overhaul and Assemble Wheel Differential Disassemble Wheel Differential A CAUTION A IMPORTANT CAUTION IMPORTANT The differential case and gears will fall after separation Sup Do not press on the wheel differential shaft to free the ring port the case so that it will not cause damage to the differen gear from the case Pressing on the wheel differential shaft tial or bodily injury may cause it to bend and or fatigue 3 Remove the outer side gear 1 Remove cap screws fastening ring gear to differen tial case 4 Remove the differential shaft locking pins by turning the differential case opening facing down Use a hammer to lightly tap on the side of the case to free the locking pins 2 The ring gear to differential case interface is a press fit Place the assembly in a press with the case fac ing downward Support the assembly on either side of the ring gear Thread a cap screw back into one of the case holes by hand Press down on the head of the cap screw you may need to press in more than one position to free the ring gear from the case 67 a F en z Wheel Differential 5 The locking pins are slip fit and should fall from the 9 Remove bearing cones from ring gear and differen case easily tial case in two steps a Mount puller vertically to split bearing This action will start moving the bearing off ca
83. screw 23 Flat Washer 24 Flange Half Cap 25 Plain Half Cap 26 Cotter Pin 27 Side Gear Thrust Washer 28 Plain Half Diff Case 29 Plain Half Bearing Cone 30 Plain Half Bearing Cup 31 Plain Half Bearing Adjuster 32 Pipe Plug Rear Assembly Install Differential Carrier Rear A IMPORTANT IMPORTANT Before installing carrier assembly inspect and thoroughly Clean interior of axle housing using an appropriate solvent and Clean rag 1 Apply Dana Spicer approved RTV compound on axle housing mating surface as shown in the illustration Completely remove all old gasket material prior to applying new material Compound will set in 20 min utes Install carrier before compound sets or reapply 1 Apply RTV gasket in this pattern Note To assist in installing complete differential carrier use two pieces of threaded rod M14 X 2 threaded into car rier cap screw holes Rod should be approximately 4 102 mm long Use these to pilot the carrier into the housing 2 Install carrier to housing lock washers and cap screws Torque to proper specification Torque to 142 158 Ib ft 193 214 Nem 3 Install axle shafts and axle stud nuts 4 Add axle lubricant Fill to bottom of filler hole in carrier 5 Connect main driveline and lubricate joints 61 JJ D 9 a a D 3 lt Rear Assembly Drive Pinion Rear Axle Pinion Assembly Parts Exploded View 1 Pinion Nut 2 En
84. se and gear 6 Remove the half shafts first and then remove their side pinions and thrust washers b Mount puller horizontally to remove cone Half Differential Shaft 7 Remove the full shaft side pinions and thrust washers LE 8 68 Wheel Differential Assemble Wheel Differential 10 Press new bearing cone on the differential case 11 Place thrust washer on the side gear Lubricate both sides of the thrust washer before installing ID 12 Install the side gear and thrust washer in the differ ential case 13 Start the full differential shaft into the shaft bores in the case that does not have a locking pin hole Side Pinion and Thrust Full Differential Shaft Locking Pin Holes 14 Install a side pinion and thrust washer and push the shaft through the side pinion Side Pinion and Thrust Washer 15 Install the side pinion and thrust washer to the other side of the full shaft 69 3 D T Wheel Differential 16 Install a side pinion and thrust washer on the half shaft side Side Pinion and Thrust Washer 17 Install the half shaft so that the pin is facing upward and push it in until it stops Half Differential Shaft Pin Hole Facing Upward 18 The end of the half shaft should fit into the slot of the full shaft at the same time as the hole in the case lines up with the hole in the half s
85. ul Power Divider In Vehicle The power divider cover comes off as a unit followed by the input shaft and then the helical side gear The power divider can be replaced with the axle assembly both in or out of the chassis and with the differential carrier assembled to the axle housing A CAUTION During removal of power divider cover the inter axle differ ential IAD input shaft assembly or IAD shift system parts may fall from the carrier if not careful Use caution to pre vent injury or damage 7 Disconnect the main driveline 8 Disconnect the lockout air line 9 Remove input yoke 10 Remove input seal 11 Position a drain pan under the power divider unit 12 Remove PDU cap screws 13 Remove power divider cover 14 Remove shift fork compression spring and shift rod T o Qa D N 77 3 Ex lt Forward Assembly 17 Remove helical side gear and snap ring Note Remove lube pump if you have one See page 30 N 1 Inspect output side gear o rings for nicks and cuts 18 Remove thrust washer Replace if necessary 1 Press 2 Bearing 3 Oil retainer 4 Input shaft 22 Install new bearing cup 23 Remove input shaft bearing cone and oil retainer if necessary 24 Press new oil retainer on input shaft 20 Remove the output side gear CAUTION It is not recommended to reuse the oil retainer due to possi ble damage that may occur while
86. ve 12 C and above Available in the Spicer family of synthetic gear lubricants Lubrication Lube Change Intervals This product combines the latest manufacturing and part Severe Service Lubrication Change Intervals Severe service washing technology When filled with a Spicer approved applications are those where the vehicle consistently synthetic lubricant at the factory the initial drain is not operates at or near its maximum GCW or GVW ratings dusty required or wet environments or consistent operation on grades greater than 8 For these applications the ON OFF HIGHWAY Change the lubricant within the first 5 000 miles of operation portion of the chart should be used Typical applications when not using a Spicer approved synthetic lubricant are construction logging mining and refuse removal in either a new axle or after a carrier head replacement Base subsequent lubricant changes on a combination of Note Clean metallic particles from the magnetic filler plug the following chart and user assessment of the application and drain plugs Clean or replace the breather yearly to and operating environment avoid lube contamination due to water ingestion Synthetic or Lubricant SAE Change Interval for Line Haul Change Interval for Vocational Mineral Synthetic SHAES 256 SAE 75W 90 500 000 miles 800 000 Km 120 000 miles 193 000 Km or 5 years or 1year Synthetic SHAES 256 SAE 75W 90 250 000 mi
87. w 60 Proper Vehicle TOWINg 85 Install Differential Carrier Rear 61 Without Wheel Differential Lock 2 85 Drive Pinion re 62 Rear Axle Pinion Assembly Theory of Operation Parts Exploded VIEW nennen 62 Power Divider Operation 86 Pinion Disassembly 63 With Lockout Engaged cssccsssecsecseecseesseesseeneens 86 Pinion Installation e 64 With Lockout Engaged sssssiiiieessseeeeiiiireesseererrrieen 87 Final Buildup 22 225452 rat ne mnnmnnt 64 Operate Wheel Differential Assembly 88 Control Systems for Differential Lock 88 Wheel Differential Assembly Transmission Low Range Interlock Control System 88 Parts Exploded View 66 Direct Driver controlled System 88 Disassemble Overhaul amp Assem Wheel Diff 67 Wheel Differential LOCK 89 Assemble Wheel Differential 73 Lock Engaged 90 Measure and Adjust Carrier Assembly 73 Lock Disengaged En 90 Adjust Backlash and Preload 74 Differential Lock Engagement Indicator 90 Change Backlash Setting e 74 Measure Ring Gear RUNOUt eeeen 74 Parts Identification Measure Ring Gear Total 74 Power Divider Adjust Contact Pattern 75 Parts Exploded View 91 Adjust Ring Gear Position Backlash 75 Front Drive Axle Parts Exp
88. workshop environment 11 Wash castings or other rough parts in solvent or clean in hot solution tanks using mild alkali solu tions Note If a hot solution tank is used make sure parts are heated thoroughly before rinsing 12 Rinse thoroughly to remove all traces of the cleaning solution 13 Dry parts immediately with clean rags 14 Oil parts e If parts are to be reused immediately Lightly oil e If parts are to be stored Coat with oil wrap in corrosion resistant paper and store in a clean dry place Inspect Axle Housing Axle housing inspection and repairs are limited to the follow ing checks or repairs e Visually inspect axle housing for cracks nicks and burrs on machined surfaces e Check carrier bolt holes and studs for foreign mate rial e Replace damaged fasteners Look for loose studs or cross threaded holes A CAUTION Any damage which affects the alignment or structural integ rity of the housing requires housing replacement Do not re pair by bending or straightening This process can affect the material s properties and cause it to fail completely under load e Check all seals and gaskets Note Replace conventional gaskets with silicone rubber gas ket compound included in many repair kits The com pound provides a more effective seal against lube seepage and is easier to remove from mating surfaces when replacing parts 1 Axle housing 2 Machined surface Inspect

spicer tandem drive axles pro-40 single reduction and single

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