SPICER. AXLE
Contents
1. SPICER AXLE MAINTENANCE MANUAL INDEPENDENT FRONT SUSPENSION SPICER AXLE DIVISION DANA CORPORATION FORT WAYNE INDIANA INDEX Page LUBRICATION a 5 3 IDENTIFICATION OF SERVICE TOOLS 4 IDENTIFICATION OF AXLE ASSEMBLY COMPONENTS 5 AXLE IDENTIFICATION a ee So ee ee Se 6 DISASSEMBLY OF WHEEL ENDS lt a oe eee 7 SERVICING DIFFERENTIAL YOKE SHAFT BEARING 13 LUBRICATING UNIT BEARING 15 CARRIER SECTION asa Cassa cere es eae 19 IMPORTANT SAFETY NOTICE Proper service and repair is important to the safe reliable operation of all motor vehicles or driving axles whether they be front or rear The service procedures recommended and described in this service manual are effective methods for performing service operations Some of these service operations require the use of tools specially designed for the purpose The special tool should be used when and as recommended It is impossible to know evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way Accordingly anyone who uses a se2. 0 002 0 001 0 0 002 0 003 0 002 0 003 0 004 0 004 Figure 69 1020 69 Pinion setting chart in thousandths of an inch k New Pinion Marking Old Pinion 15 10 20 18 13 10 08 05 03 0 8 18 4 15 13 10 08 05 03 5 15 13 10 08 eee 3 08 05 03 03 Figure 70 1020 70 Pinion setting chart metric Use these charts as a guideline to set pinion position Figure 71 View of master pinion block pinion height block scooter gage cross arbor and arbor discs NOTE Be sure that all carrier bores are free from all nicks dirt or any other contamination Figure 71 102074 24 Figure 74 Place pinion height block on top of master pinion block and against arbor as shown Tool D 115 1 Pinion Height Block Figure 72 1020 72 Place the master pinion block into the inner pinion bearing bore of the carrier as shown Tool D 139 Master Pinion Block Figure 75 1020 75 Place scooter gage on pinion height block Apply light pressure with fingers at the back side of the scooter gage Make sure the scooter gage is flat on the pinion height block then set the indicator at zero 0 Tool D 115 Scooter Gage Figure 73 1020 73 Place arbor discs and arbor into the cross bores of the carrier as shown Tools D 115 3 Arbor D 115 4 Arbor Discs Figure 76 Slide scooter gage towards the arbo
3. Shims are available in thicknesses of 003 005 010 and 030 mm 08 13 25 and 76 of measuring and adjusting backlash If the original shim stacks are lost or cannot be ac curately determined it is recommended that the shim stacks be found by using the procedures described in this manual NOTE It is recommended that whenever bearings are removed they are replaced with new ones regardless of mileage SS Figure 61 1020 93 Place a few shop towels over the vise to prevent the ring gear teeth from being nicked Remove the ring gear screws NOTE It is recommended that whenever the ring gear screws are removed they are replaced with new ones regardless of mileage Figure 62 1020 62 Tap the ring gear with a rawhide or heavy duty plastic hammer to free it from the case Remove the case and ring gear from the vise 21 Figure 59 _ 1020 59 Turn the nose of carrier down Remove the outer pinion bearing cup as shown Caution Do not nick the carrier bore Tools D 147 Remover C 4171 Handle C 4291 Extension 1020 60 Figure 60 Remove the differential bearings with a puller as shown Wire the shims bearing cup and cone together and identify from which side of the dif ferential case they were removed ring gear side or opposite side If any of the shims are bent or mutilated they should be replaced with new ones at the time of assembly New shims are availabl
4. de C 4053 Tor 3281 Hol C Tools Nem t to 200 220 lbs ft 271 298 1111011 nu Torque p 1020 88 Figure 88 Op oe S OG gs E Daa O 5 2 Bu O fo u8 2 g 2 of 350 Ga E ae 0 Tee Oem S AD o 5 Qag o Bot Hav orc 5 Dass ov ae Ba we 3 Aes ester SA 1020 94 Figure 94 Assemble the pinion mate shaft Make sure the lock pin hole in the shaft lines exactly with the lock pin hole in the case Assemble the lock pin Peen some metal of the case over the pin to lock it in place Figure 92 1020 92 Rotate the pinion mate gears and side gears until the pinion mates turn to the windows of the case Remove the pinion mate gears and spherical washers Lift the side gears and thrust washers out of the case Inspect all the parts including the machined surfaces of the case If excessive wear is visible on all the parts it is suggested that the com plete differential assembly is replaced If any one of the gears need replaced then both gears are to be replaced as a set Figure 95 1020 95 Be sure flange face of the differential case is free of nicks or burrs Assemble ring gear to differential case using new ring gear screws Draw up screws alternately and evenly Torque screws to 45 60 lbs ft 61 81 Nem Tool C 3952 A Torque Wrench 30 1020
5. following the part number Refer to the lubrication section of this manual for lubricant requirements involving limited slip differentials All Spicer Model 44 Independent Front Suspen sion axles are identified with a manufacturing date and complete part number which are stamped on the left hand support arm in an area between the fill plug and wheel end b X XXXXX XXXXXX X MANUFACTURING DATE AXLE IDENTIFICATION TAG Figure 4 1020 4 NOTE In the event there are two build dates the latter will be the date in which the brake components were assembled The number stamped next to the manufacturing date is the complete axle assembly part number It is recommended that when referring to the axle obtain the complete part number and build date To do this it may be necessary to wipe or scrape off the dirt etc from the support arm DISASSEMBLY OF WHEEL ENDS Follow the Vehicle Manufacturer s recommenda tions for the removal of the tire and rim brake caliper and hub lock assembly NOTE If it is necessary to replace brake components refer to vehicle service manual Figure 5 1020 5 Remove the outer lock nut lock nut washer and j the inner wheel bearing adjusting nut Figure 7 page Tool C 4170 A Wheel Bearing Lock Nut Ad Remove grease seal and inner bearing cone justing Wrench Discard seal and replace with new one at time of assembly Tool D 131 Slide Hammer sae Be Figure 6 1020 6 F
6. plate Gradual ly tighten the screws until they draw the adapters tight to the bearing Tools D 127 2 Flange Plate D 127 3 Adapters D 127 4 Forcing Plate SP 3020 Washers WP 5026 Screws Tighten the screws of the tool alternately and evenly until the bearing cone is removed from the yoke shaft Be careful not to mar or nick the ma chined surfaces of the yoke shaft Put the installing ring on the yoke shaft and place in the press as shown Use a small flat washer be tween the forcing screw and the yoke shaft to pro tect each one from damage during the installation of the unit bearing Tighten the forcing screw until bearing is com pletely seated against the shoulder of the yoke shaft To make sure the bearing is seated use a 0016 038mm feeler gage between the bearing seat and bearing If the feeler gage will enter then continue to force the bearing further onto the yoke shaft until the feeler gage does not enter Tools DD 914 P Press DD 914 9 Adapter Ring D 127 1 Installing Ring Bearing amp Small Flat Washer 8 CAUTION CE Extra care must be taken during installation of Figure 36 1020 36 the retainer ring onto the axle shaft The press To install the retainer ring on the yoke shaft fit of the retainer ring is greater than the press follow the procedures as described in Figure 35 Use fit of the bearing Caution must be used to pre a 0015 038mm feeler page between the unit vent crushing
7. recommended that the hypoid gear lubricant be drained daily and internal parts be inspected for water damage and or contamination Clean examine and if necessary replace damaged parts prior to assembling and refilling with the specified hypoid lubricant NOTE It is recommended that whenever bearings are removed they are to be replaced with new ones regardless of mileage 1020 2 Figure 2 The following is a detailed list of all special tools required to service the Spicer Model 44 Independent Front Suspension Axle Assembly Description Supporting Fixture Vise Adapter Supporting Fixture Installer Inner Pinion Bearing Cup Remover Inner Pinion Bearing Cup Installer Outer Pinion Bearing Cup Remover Outer Pinion Bearing Cup Handle Universal Extension Universal Remover amp Installer Front Axle Ball Joint Adapter Ball Joint Removing Sleeve Ball Joint Removing Item No Tool No D 245 D 246 D 145 D 148 D 144 D 147 C 4171 C 4291 D 150 1 D 150 2 D 150 3 14 15 16 17 18 19 20 21 23 924 Description Spreader Spreader Adapters Press Adapter Ring Adapter Set Rear Pinion Bearing Cone Adapter Set Differential Bearing Cones Adapter Plug Differen tial Hub Scooter Gauge D 115 2 Scooter Block and D 106 5 Dial Indi cator Pinion Height Block Arbor Arbor Discs Master Pinion Block Master Dif
8. the bearing bearing and retainer ring to be sure that the retainer ring is seated At least one point should exist where the feeler gage cannot enter between the bearing and the retainer ring If the feeler gage can enter completely around the circumference the retainer ring must be forced further onto the yoke shaft LUBRICATING THE UNIT BEARING WITH GREASE Figure 37 1020 37 Figure 38 1020 38 Push seal and retainer plate away from the unit Fill the cavity with a good quality number 2 E P bearing to allow a cavity between the seal and extreme pressure lithium base wheel bearing bearing grease 15 Figure 1 1020341 Reassemble the slip yoke and journal cross to the stub shaft Install the shaft assembly into the car rier Torque the retainer plate screws to 30 40 Lbs Ft 41 54 Nem Install right hand shaft assembly into the slip yoke giving special attention to the spline If the slip yoke has a wide tooth space in the spline make sure that it is aligned with the wide tooth on the axle shaft spline Tool C 3952 A Torque Wrench NOTE Prior to installing the right hand shaft assembly into the slip yoke lubricate the splines with a good extreme pressure grease satisfying N L G I grade 1 or 2 specifications For lubrication after assembly refer to vehicle service manual Figure 42 Assemble new needle bearing into spindle Tools D 122 Installer C 4171 Handle 16 Figure 39 After cavity i
9. 93 Figure 93 Place the differential case in a vise Apply a good quality grease to the new side gear thrust washers and to the hub and thrust face of the new side gears and assemble into the case Lubricate the new pi nion mate gears and spherical washer Hold the side gears in place with one hand and assemble the pi nion mate gears and spherical washers with the other hand Rotate the side gears and pinion mate gears until the holes of the washers and pinion mate gears line up exactly with the holes in the case DIFFERENTIAL ore ee Figure 98 1020 98 Place the differential case onto step plate Assemble the required amount of shims to the ring gear side hub as determined in Figure 97 Place the bearing cone on the hub of the differential case Use the bearing installer to seat the bearing cone The step plate is used to prevent possible damage to the hub and bearings while assembling bearing cones Tools C 4487 1 Step Plate D 156 Installer C 4171 Handle Assemble the remaining shims of the total shim pack as determined in Figure 65 Add an additional 010 25 mm to the remaining shims Assemble the opposite side differential bearing cone as shown EXAMPLE In Figure 65 a total of 077 1 96 mm was recorded In Figure 97 a totalof 059 1 50 mm was recorded This leaves a balance of 018 46 mm for op posite side ring gear and adds up to 077 1 96 mm which was obtained at the start
10. A P I Service Classification GL 5 IMPORTANT As special equipment limited slip differentials are provided in many vehicles The freedom from chatter is a function of the lubricant used and cannot be covered in the above specification In some applications a special limited slip differential lubricant may be required If required these special lubricants are normally available through equipment manufacturer WHEEL BEARING LUBRICATION Wheel bearings are lubricated by packing the bearing with grease It is recommended that a number 2 consistency lithium base 12 hydroxy stearate grease containing an E P additive be used NOTE We suggest that wheel bearing lubricants selected for use with disc brake applications in addition to the E P properties expressed in this Manual should be compatible with elevated temperatures i e high temperature lubricant For specified wheel bearing lubricant refer to vehicle Service Manual SUBMERSION OR DEEP WATER FORDING If the vehicle is exposed to water deep enough to cover the hubs of the front axle it is recommended that the wheel ends be disassembled and inspected for water damage and or contamination daily Clean examine and if necessary replace damaged parts prior to relubricating and assembling the wheel end components Pay particular attention to the bearings In the event the gear carrier housing should become submerged in water particularly if over the breathers it is
11. To compensate for preload and backlash add 010 25 mm to the opposite side The shim pack totals for this example are as follows Ring gear side 059 1 50 mm Opposite side original balance of 018 46mm plus 010 25 mm gives 028 71 mm INSTALLATION OF Figure 96 1020 96 Install master differential bearings onto case Remove all nicks burrs dirt etc from hubs to allow master bearings to rotate freely Place differential assembly into the carrier Set up dial indicator as shown Force the differen tial assembly away from the pinion gear until it is completely seated against the cross bore face of the carrier With force still applied to the differential case place tip of dial indicator on a flat machined surface of the differential case if available or on the head of a ring gear screw and set the indicator at zero 0 Tools D 128 Dial Indicator D 135 Master Bearings 1020 97 Figure 97 Force ring gear to mesh with pinion gear Rock ring gear slightly to make sure the gear teeth are meshed Repeat this procedure several times until the same reading is obtained each time Be sure the indicator reads zero 0 each time the ring gear is brought back against the cross bore face of the car rier This reading will be the necessary amount of shims between the differential case and differential bearing on the ring gear side Remove the dial in dicator and the differential cas
12. asured individually and then added together to obtain the shim stack total To change the pinion position shims are available in thicknesses of 003 005 and 010 mm 08 13 and 25 If a new gear set is used notice the plus minus or zero 0 etching on both the old and new pinion and adjust the thickness of the new shim pack to compensate for the difference between these two pinion etchings The chart in Figures 68 and 69 is helpful for determining this change For example If the old pinion is etched 2 m 5 and the new pinion is etched 2 m 5 then add 004 10mm to the original shim stack thickness in order to install the new pinion at proper position 1020 67 Figure 67 View of ring and pinion etched with metric iden tification Ring gears and pinions are supplied in matched numbers on both pinion and sets only Matchin ring gear are etched for verification If a new gear set is being used verify the numbers on each pinion and ring gear before proceeding with assembly mm 08 13 25 16 mm 08 13 25 oo 2 625 in 66 68 mm 1020 68 23 in 003 005 O10 030 Pinion Prelead in Pinion Position 0 Shims 005 010 Front and Rear Model 44 x Centerline of Ring Gear Pinion Oil Baffle Pinion Oil Stinger Figure 68 New Pinion Marking Oid Pinion Marking SE ES 0 002 0 001
13. bly End Yoke and Dust Shield 13 Washer 14 Pinion Nut 15 Left Hand Support Arm 16 Fill Plug 17 Axle Identification Tag 18 Cover Screws 19 Differential Case 20 Ring Gear Screws 21 Differential Bearing Preload and Backlash Shims 92 Differential Bearing Cup and Cone 23 Differential Bearing Cap 24 Differential Bearing Cap Screw 25 Differential Cross Shaft 26 Differential Side Gear Thrust Washer 27 Differential Side Gear 28 Differential Pinion Mate 29 Differential Pinion Mate Thrust Washer 30 Roll Pin 31 Right Hand Support Arm 32 Cotter Key AXLE IDENTIFICATION In this figure the axle is identified with 1 8 3 17mm high stamped characters For example The manufacturing date or build date of the axle is interpreted as follows The first number is the month second number is the day of the month the third number is year the letter is the shift and the last number is the line that built the axle The next number is the part number The digits reading from left to right is the basic number for identifying the particular axle assembly The digit following the dash will identify ratio differential and end yoke options used in the assembly The axle identification tag is required by the vehicle manufacturer and pro vides their corresponding identification of the axle to the Dana Spicer part number If the axle is equip ped with limited slip differential the axle identifica tion tag will have the letters LS
14. d 3 m 8 we would want to add 003 08mm more shims to the shim stack than would be re quired if the pinion were etched to zero 0 Figure 77 1020 77 Front and rear carrier sections may vary in the in ner pinion bearing bore depth because of the need for either a pinion baffle or a pinion slinger or both The application of an axle assembly in a particular vehicle determines whether these two items are re quired If a baffle or slinger is removed then they should be replaced with a new one during assembly A baffle or slinger when installed properly kelp control the position of the pinion in relation to the centerline oF the ring gear Therefore these items if used must be measured and used as a part of the in ner pinion bearing shim stack 1020 78 Figure 78 Figure 3 1020 83 Insert the pinion into the carrier Assemble the outer pinion bearing cone slinger and end yoke onto the pinion spline Do not assem ble the oil seal and pinion bearing preload shims at this time Use the yoke installer as shown to draw the end yoke onto the pinion spline Tools W 162 Installer C 3281 Holder Figure 84 1020 83 Assemble the washer and pinion nut Torque the nut until it requires 10 lbs in 1 1 Nem to rotate the pinion Rotate the pinion several revolutions before checking the pinion position This is done to seat the bearings and assure a more accurate reading NOTE The reason fo
15. e from carrier Remove master bearings from differential case 1020 101 Figure 101 Install the bearing caps and screws Make sure the letters or numbers stamped on the caps corres pond in both position and direction with the letters or numbers stamped into the carrier Torque the bearing cap screws to 80 90 Lbs ft 108 122 Nem Tool C 3952 A Torque Wrench Figure 102 Check ring gear and pinion backlash in three equally spaced points with a dial indicator as shown Backlash tolerance is 005 13mm to 009 28mm and cannot vary more than 003 08mm between points checked High backlash is corrected by moving shims from the opposite side of the differential case to the ring gear side thus moving the ring gear closer to the pinion Low backlash is corrected by moving shims from the ring gear side of the differential case to the op posite side thus moving the ring gear away from the pinion 1020 102 CAUTION Before applying new silicone rubber sealer make sure the carrier face and unitized support arm is clean and free of all foreign matter such as dirt oil and old silicone rubber sealant 32 Figure 99 1020 99 Install spreader and indicator to carrier as shown DO NOT SPREAD CARRIER OVER 015 38 mm Tools D 113 Spreader D 227 Spreader Adapters D 128 Dial Indicator Set Remove indicator Figure 100 Assemble differential bearing cups to differential bearing c
16. e in thicknesses of 003 005 010 and 030 mm 08 13 25 and 76 Tools DD 914 P Press DD 914 9 Adapter Ring C 293 18 Adapter Set C 293 3 Adapter Plug If the original shim stack or equivalent replace ment for each side is available the shim stack may be used as a starting point to assemble the differen tial case Assemble the shim stack and new bearings on the same side which they were taken from and install the differential case into the carrier as de scribed later in this manual Follow the procedures Figure 65 1020 65 Force the differential assembly as far as it will go in the opposite direction Repeat these steps until the same reading is obtained Record the reading of the indicator This amount in shims will be included in the final assembly shim stacks to establish differential bearing preload and ring gear backlash After making sure the readings are correct remove the dial indicator and differential assembly from the carrier 1020 66 View of ring and pinion etched with inch iden tification 22 1020 63 Install the master differential bearings onto the case Remove all nicks burrs dirt etc from hubs to allow the master bearings to rotate freely Tool D 135 Master Bearings Figure 64 102064 Assemble differential case into carrier less pinion Mount a dial indicator with a magnetic base on the flange face as shown Force the differential as
17. ferential Bearing Item No Tool No D 113 D 227 DD 914 P DD 914 9 C 293 39 C 293 18 C 293 3 D 115 D 115 1 D 115 3 D 115 4 D 139 D 135 aoRWN op 8 9 10 11 12 13 Description Screws Puller Slide Hammer Wrench Flange or Yoke Installer Inner Axle Shaft Seal Torque Wrench 300 Ft Lb Torque Wrench 150 Ft Lb Torque Wrench 50 In Lb Installer Pinion Oil Seal Installer Differential Side Bearings Item No Tool No 42 SP 5026 43 D 131 44 C 3281 45 D 249 A 46 C 4053 47 C 3952 A 48 D 193 49 W 147 D 50 D 156 Pinion Setting Gauge and Master Differential Bearing Kit D 115 44 40 Degree Steer Front Ball Joint Removing and Installing Kit D 150 Axle Shaft Bearing Removing and Installing NOTE Kit D 127 Torque Wrenches C 4053 C 3952 A and D 193 are optional and can be purchased separately 1020 3 Description Sleeve Ball Joint Installing Dial Indicator Set Installer Inner Pinion Bearing Cone Wrench Wheel Bearing Adjusting Nut Installer Front Brake Hub Grease Seal Installer Front Brake Hub Outer Bearing Cup Remover Front Brake Hub Outer Bearing Cup Installer Front Spindle Needle Bearing Installer Front Brake Hub Inner Bearing Cup Remover Front Brake Hub Inner Bearing Cup Installer Flange or Yoke Remover Flange or Yoke Installing Ring Bearing Flange Plate Axle Ada
18. hout notice or obligation in specifications descriptions and illustrations and to discontinue models or revise designs Questions regarding this manual should be directed to Spicer Axle Division Dana Corporation P O Box 1209 Fort Wayne Indiana 46801 Attention Engineering Technical Service Dept BULLETIN 5324
19. igure 8 1020 8 Remove hub and rotor assembly Outer wheel Remove outer wheel bearing cup bearing cone will slide out as rotor is removed Tools D 259 Bearing Cup Remover C 4171 Han dle Figure 11 102011 Assemble inner wheel bearing cup Tools D 154 Installer C 4171 Handle Distribute a sufficient amount of grease inside the hub between the bearing cups Pack inner bearing cone full with the specified grease Wipe the excess grease around the rollers Assemble inner wheel bearing cone into cup Figure 9 1020 39 Remove inner wheel bearing cup Tools D 260 Bearing Cup Remover C 4171 Han dle NOTE The bearing bores must be free of nicks and burrs Clean grease and dirt from hub and bearing bores with a standard metal cleaning solvent Figure 12 1020 12 Assemble new grease seal Apply a small amount of grease around lip of seal Tools D 155 Seal Installer C 4171 Handle 1020 10 Figure 10 Assemble outer wheel bearing cup Tools D 140 Installer C 4171 Handle Figure 15 1020 15 Place spindle in a vise Do not locate on bearing diameters or threads Remove the oil seal Remove the axle shaft needle bearing as shown in Figure 15 Tool D 131 Slide Hammer If the tie rod has not been removed do so at this time following vehicle manufacturer s recommenda tions Remove shaft and joint assemblies Plastic slinger will come out with left hand assembly Right hand assembly will se
20. ing diameters Clean the yoke shaft and carefully remove all nicks or burrs Figure 35 1020 35 Position the press in a vise Assemble a new re tainer plate and a new oil seal onto the yoke shaft The oil seal lip should be coated with the proper hypoid lubricant Slide a new unit bearing onto the shaft The proper direction to install the unit bear ing is to have the large radius on the inner race towards the yoke end of the shaft NOTE The unit bearing is a complete pre assembled bearing assembly consisting of cup cup rib ring cone rollers and cage The cup and rib ring are bonded together to facilitate handling and installation When the bearing is serviced the cup will usually separate from the rib ring Should separation occur care should be taken so as not to damage the cone rollers and cage Should damage occur to these parts the bear ing assembly must be replaced with a new one 14 1020 33 Figure 33 After drilling the ring use a chisel positioned across the hole and strike sharply to break the ring Discard and replace with a new one at time of assembly 1020 34 Figure 34 Push retainer plate and seal towards the yoke end of the axle shaft Install the flange plate in a vise Position the yoke shaft through the forcing plate and install the adapters between the forcing plate and the unit bearing Slide the screws through the washer and forcing plate then start them into the flange
21. on according to Figure 83 to 84 Tools D 115 3 Arbor D 115 4 Arbor Discs D 115 1 Pinion Height Block D 115 2 Scooter Gage When the pinion position is within the acceptable tolerance of 002 05mm of the pinion etch remove the pinion nut washer end yoke slinger outer pinion bearing cone and the pinion Lubricate the inner and outer bearings by applying a small amount of the specified lube on the rollers of the bearing cone Model 44 axles which use a pinion oil baffle re uire the pinion be installed into the carrier before the preload shims are assembled onto the pinion In sert the pinion into the carrier and hold in place Assemble the preload shims which are equal in thickness to the stack height of the original preload shims removed during disassembly onto the pinion 29 a iss 3 S Q 2 S i n 0 3 f l 0 he S ge n ne 0 E po D Q O 2 ted slip differential is used refer to the 1111 1121 193 Torque Wrench D Tool Remove the pinion mate shaft with a drift as Figure 91 shown ln increase To i gs ion should read 20 40 lbs ase preload add 1n to decre 9 in ims h pound torque wrench as shown ith new bear an inc remove sh 89 torque of p 5 Nem w ing ing ims 4 reload h Us rotat 2 3 P s 1020 91 1020 89 igure F e Wrench er
22. ones Install differential assembly into carrier Use a rawhide or heavy duty plastic hammer to seat differential assembly into cross bore of carrier Care should be taken to avoid nicking the teeth of the ring gear or pinion during assembly Remove spreader 1020 100 1020 104 Figure 104 Mount the carrier to the unitized Support arm be ing careful not to smear the silicone rubber sealant material Torque the cover screws to 30 40 lbs ft 41 54 Nem Torque the 2 left hand support arm to carrier side tab screws Early models used 375 16 screws while later models used 500 13 screws 375 16 screws torque 30 40 Lbs ft 41 54 Nem 500 13 screws torque 85 100 Lbs ft 115 136 Nem Allow one hour cure time before filling the unit with the proper hypoid lubricant When the carrier assembly is rebuilt to specifica tions refer to the vehicle manufacturer s recommen dations for the proper installation procedure into the vehicle Tool C 3952 A Torque Wrench 33 Figure 103 The mating surfaces of the left hand unitized sup port arm and the carrier should be free of dirt oil etc Apply the sealer to the carrier face as shown The sealer bead is to be 1 8 3 18mm to 1 4 6 35 mm wide and should not pass through or out side of the holes Sealant material must meet specification of INE GE303 Al9 B37 E16 E36 Z1 Z2 and Z3 sealant 1020 103 NOTE Use of cleaning solvent
23. ooth PATTERN INTERPRETATION RING GEAR DRIVE SIDE COA D E IM Backlash correct Thinner pinion position updated S Updated Backlash correct Thicker pinion position Aon 8777 dated Pinion position shim correct Decrease back lash 0 5 2 0G fe Pinion position shim correct Increase back lash PATTERN MOVEMENTS SUMMARIZED 1 Decreasing backlash moves the ring gear closer to the pinion Drive pattern convex side of gear moves slightly lower and toward the toe Coast pattern concave side of gear moves lower and toward the toe 2 Increasing backlash moves the ring gear away from the pinion Drive pattern moves slightly higher and toward the heel Coast pattern moves higher and towards the heel 3 Thicker pinion position shim with the backlash constant moves the pinion closer to the ring gear Drive pattern moves deeper on the tooth flank contact and slightly toward the toe Coast pattern moves deeper on the tooth and toward the heel 4 Thinner pinion position shim with the backlash constant moves the pinion further from the ring gear Drive pattern moves toward the top of the tooth face contact and toward the heel Coast pattern moves toward the top of the tooth and slightly toward the toe 4 81 3500 WE SUPPORT VOLUNTARY MECHANIC CERTIFICATION THROUGH National Institute for Dana Corporation Spicer Axle Division reserves the right to make changes from time to time wit
24. parate at the slip yoke 1020 13 Figure 13 Remove spindle nuts NOTE If the nuts are of the torque prevailing design they are to be replaced with new ones Figure 16 E Remove cotter key from top socket Loosen both the top and bottom nuts Remove the top nut 1020 14 Figure 14 Remove spindle Tap lightly with a rawhide or heavy duty plastic hammer to break the spindle loose from the knuckle Remove disc brake splash shield Figure 17 _ 1020 17 Using a rawhide or heavy duty plastic hammer hit sharply on the top stud to free the knuckle from the tube yoke After knuckle is free from the yoke remove the bottom nut Figure 19 1020 19 Place knuckle in vise as shown If bottom ball socket is equipped with a snap ring remove as shown NOTE Discard bottom nut The nut on the bottom socket is of the torque prevailing design and is not to be reused NOTE Bottom ball socket must be removed first Figure 18 1020 18 Remove camber bushing as shown If the camber bushing cannot be removed by hand use a Pitman arm puller or similar tool RAA Figure 20 1020 20 Assemble ball socket tools as shown Turn forcing screw and push out bottom socket Discard ball socket Tools D 150 1 Ball Joint Remover amp Installer D 150 2 Sleeve D 150 3 Sleeve Ball Joint Removing 10 Figure 3 1029 23 Upper ball socket has a cotter key hole in the stud end Assemble socket into kn
25. pters Removal Forcing Plate Washers Arrangement of components Item No Tool No D 150 4 D 128 W 262 C 4170 A D 155 D 140 D 259 D 122 D 154 D 260 W 162 D C 452 D 127 1 D 127 2 D 127 3 D 127 4 SP 3020 O5 26 27 28 29 30 31 32 33 34 35 36 937 309 40 4 Figure 3 ITEM DESCRIPTION 33 Slotted Nut 34 Camber Adjuster 35 Locknut 36 Upper Socket Assembly 37 Lower Socket Assembly 38 Snap Ring 39 Steering Knuckle 40 Brake Splash Shield 41 Bearing Retaining Ring 42 Unit Bearing 43 Oil Seal 44 Retainer Plate 45 Shaft Assembly and Slip Yoke Assembly 45 A Outer Shaft and Joint Assembly 46 Retainer Plate Screws 47 Dust Shield 48 Oil Seal 49 Wheel Bearing Spindle Spacer 50 Grease Seal Spindle 51 Needle Bearing Spindle 52 Spindle 53 Nut Spindle Retaining 54 Grease Seal Hub 55 Inner Wheel Bearing Cone and Cup 56 Hub and Rotor 57 Outer Wheel Bearing Cone and Cup 58 Wheel Bearing Adjusting Nut Inner 59 Wheel Bearing Nut Lock Washer 60 Wheel Bearing Adjusting Nut Outer 61 Hub Lok Assembly 62 Stop Bolt Steering 63 Nut Stop Bolt DESCRIPTION 1 Carrier 9 Drive Gear and Drive Pinion Assembly 3 Slinger Oil Drive Pinion 4 Inner Pinion Bearing Cup and Cone 5 Pinion Position Shims 6 Oil Seal 7 Dust Slinger 8 Pinion Bearing Preload Shims 9 Outer Pinion Bearing Cup and Cone 10 Pinion Oil Seal Slinger Outer 11 Pinion Oil Seal 12 End Yoke Assem
26. quality grease to the lip of the seal and position the seal on the Installer as shown Tool D 249 A Installer Inner Axle Shaft Seal Figure 28 1020 28 Remove the inner axle shaft seal from the housing as shown Pry seal out and discard CAUTION When removing a seal be careful so as to avoid Figure 30 1020 30 nicking or gouging the housing Slide the seal into the carrier seal bore Make sure the seal is centered and is straight with the seal Tools Screwdriver or similar tool bore Use a rawhide or heavy duty plastic hammer Plastic mallet as shown to completely seat the seal in the bore SERVICING DIFFERENTIAL YOKE SHAFT BEARING NOTE To remove axle shaft assemblies follow procedures as illustrated in Figures 5 through 15 Figure 32 1020 32 420 34 Place the shaft in a vise Drill a inch 6 4mm hole in the outside of the retainer ring to a depth ap Remove retainer plate slip yoke and stub shaft proximately the thickness of the ring Do not drill assembly Remove slip yoke and journal cross from all the way through the ring The drill could damage stub shaft the axle shaft Figure 31 13 CAUTION Do not heat or cut the bearing cone assembly with a torch Damage to the yoke shaft will result Remove seal and retainer plate and discard Replace the seal and retainer plate with new ones at the time of assembly Inspect the machined surfaces of the yoke shaft particularly the seal and bear
27. que Wrench NOTE In the event that knuckles are received with the sockets and snap ring assembled to the knuckle along with new top and bottom nuts and cotter key follow procedures as illustrated in figures 24 through 27 for assembly For steering angle setting refer to vehicle service manual Figure 24 1020 24 Assemble knuckle and socket assembly to yoke as shown Slide camber bushing into place on stud of top ball socket Be sure lugs on yoke engage the slots in camber bushing Assemble new torque revailing nut on bottom socket and torque to 20 30 bs Ft 27 41 Nem Place a tool such as a socket or similar object on top of the bushing and strike with a plastic or rawhide mallet to seat the bushing Make sure the tool rests on the bushing and has enough height to prevent striking the ball joint stud NOTE _Install camber bushing on top ball joint stud with the arrow pointing outboard for positive camber Install bushing with the ar row pointing inboard for negative camber Zero camber bushings will not have arrows and may be rotated in either position as long as the lugs on yoke engage the slots in the bushing For proper camber setting refer to vehicle ser vice manual 1020 25 Figure 25 NOTE It is recommended that all oil or grease seals be replaced with new ones whenever the axle is disassembled Figure 29 1020 29 Apply a light coat of hypoid lubricant or a good
28. r As the in dicator moves over the top of the arbor the dial will move in a clockwise direction across the face of the indicator When the indicator is at the top center of the arbor the dial will stop traveling in a clockwise direction If the dial starts to move in a counter clockwise direction this means that you have pass ed the top center position on the arbor Record only the reading when the indicator is at top center on the arbor and the dial has stopped moving clockwise E E on the indicator face This reading indicates the Figure 74 1020 74 thickness of the shim stack that is required to in 25 Figure 78 Measure each shim baffle and slinger separately with a micrometer and add together to get the total shim stack thickness Figure 79 1020 79 Place the baffle and then the required amount of shims in the inner pinion bearing bore Drive the inner pinion bearing cup into the carrier with tools as shown Tools D 145 Installer C 4171 Handle 1020 80 Figure 80 Assemble the outer pinion bearing cup into carrier as shown Tools D 144 Installer C 4171 Handle stall a pinion that is etched with a zero 0 at a zero 0 position If the pinion being installed has a plus or a minus etching then an adjustment of this shim stack is For example If a pinion is etched 3 m 8 then this pinion would require 003 08 mm less shims than a pinion etched zero 0 If a pinion is etche
29. r Adapters D 128 Indicator Set 1020 57 Figure 57 Pull out the pinion oil seal with the puller as shown Discard the seal and replace with a new seal at time of assembly Remove the outer pinion bear ing cone and outer pinion oil slinger Tool D 131 Slide Hammer 1020 58 Figure 58 Remove the inner pinion bearing cup with tools as shown Tools D 148 Remover C 4171 Handle NOTE Shims are located between the inner bearing cup and carrier bore which may also include an oil baffle If shims and baffle are bent or nick ed they should be replaced at time of assembly Measure each shim individually and wire the shim stack together If the stack has to be replaced replace with the same thickness 20 1020 55 Figure 55 Remove the end yoke or flange with the tools as shown If the yoke or flange shows wear in the area of the seal contact it should be replaced Tools C 452 Yoke Remover C 3281 Holding Wrench 1020 56 Figure 56 Remove pinion by tapping with a rawhide or heavy duty plastic hammer Catch the pinion with our hand to prevent it from falling to the floor and eing damaged _ NOTE On the spline end of the pinion there are pinion bearing preload shims These shims may stick to the outer bearing and then fall to the floor Be sure to collect all these shims and keep them together since they will be used later in assembly If shims are mutilated replace with new ones
30. r not assembling the pinion oil seal and preload shims at this time is due to the possibility of having to adjust pinion bear ing preload or pinion position It would be necessary to again remove the oil seal and as mentioned whenever seals are removed they are to be replaced with new ones 1020 81 Figure 81 Remove the inner pinion bearing cone as shown Tools DD 914 P Press DD 914 9 Adapter Ring C 293 39 Adapter Set Figure 82 1020 82 If an inner pinion slinger is used assemble the slinger and then the inner pinion bearing cone onto the pinion Drive the bearing on the shaft until it is completely seated Tool W 262 Installer Install the outer pinion bearing cone outer slinger and end yoke onto the pinion Use the yoke installer as shown in Figure 83 Assemble a washer and pin ion nut and torque the pinion nut to 200 220 lbs ft 271 298 Nem Using an inch pound torque wrench as shown in Figure 84 measure the preload on the pinion bearings The rotating torque of the pinion should read 20 40 lbs in 2 3 4 5 Nem with new bearings To increase preload remove shims to decrease preload add shims Remove the pinion nut washer and end yoke as shown in Figures 54 and 55 Figure 86 1020 86 Apply a light coat of hypoid lubricant to the lip of the pinion oil seal and assemble into the housing Tools W 147 D Seal Installer C 4171 Handle 1020 87 Figure 87 Assemble
31. rvice procedure or tool which is not recommended must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service methods he selects Should an axle assembly require component parts replacement it is recommended that Original Equip ment replacement parts be used They may be obtained through your local service dealer or other original equipment manufacturer parts supplier The use of non original equipment replacement parts is not recom mended as their use may cause unit failure and or affect vehicle safety NOTE Throughout this manual reference is made to certain tool numbers whenever special tools are re quired These numbers are numbers of Miller Special Tools 32615 Park Lane Garden City Michigan 48135 They are used herein for customer convenience only Dana makes no warranty or representation to these tools 2 Litho in U S A LUBRICATION It is not our intent to recommend any particular brand or make of lubricant for the Spicer hypoid axles However a S A E 90 weight multipurpose gear lubricant meeting Mil Spec L 2105 B or 80W 90 multipur pose gear lubricant meeting Mil Spec L 2105 C and suitable for A P I Service Classification GL 5 is sug gested as a minimum requirement COLD WEATHER OPERATION If the vehicle is operated below 0 F 18 C it is advisable to use S A E 80 multipurpose gear lubricant meeting Mil Spec L 2105 B and suitable for
32. s full of grease wrap some tape com pletely around the rib ring and seal to enclose the cavity 5 1020 39 ay Figure 40 Pull the seal towards the bearing until it contacts the rib ring This will force the grease between the rollers and the cup 1020 40 NOTE If the grease is not apparent on the small end of the rollers repeat the same steps until the grease is evident between the small end of the roller and cup Remove the tape Figure 43 1020 43 Assemble grease seal into spindle The lip of the seal is to be directed away from the spindle E Figure 46 1020 46 Assemble the plastic slinger onto the left hand shaft and joint assembly 5 000 127mm from the inboard spline end This slinger protects the inner axle seal installed in Figures 29 and 30 from stones etc Place a mark on the shaft at the slinger position for checking purposes after shaft assembly has been installed Figure 44 1020 44 Some front axles are equipped with a V seal which is assembled to the axle shaft stone shield as shown If seal is worn remove and replace with a new one Figure 47 1020 47 Install the left hand shaft and joint assembly Assemble new plastic spacer disc brake splash shield and V seal if required as shown in Figure 44 Assemble spindle assembly Check the plastic slinger for proper position as described in Figure 46 and correct if necessary Figure 45 1020 45 NOTE Pack
33. s may prevent the silicone rubber sealant from adhering to the carrier face and unitized support arm resulting in leaks of axle lubricant SPICER RING GEAR amp PINION TOOTH PATTERN INTERPRETATION When setting the pinion position many of the service manuals required a final pinion position check by using gauges that verified the dimension from the center line of the differential carrier center line of ring gear to the face of the pinion button Thig s ba ign i u alane Wggea ifyigg 3 0 t ee stalfish of fie 0 17 tom m t e pinn ggfr Theffinal will be Ausige thd G 5 0 ACT PA RN METHOD as described in this bulletin RING GEAR AND PINION TOOTH CONTACT PATTERN TOP LA This 6 see public 05 20 Q2 room The TOE of the gear tooth is the portion of the tooth surface at the end towards the center The HEEL of the gear tooth is the portion of the tooth surface at the outer end The TOP LAND of a gear tooth is the surface of the top of the tooth Every gear has a characteristic pattern The illustrations show typical patterns only and explains how patterns shift as gear location is changed When making pinion position changes shims should be changed in the range of 002 inch 05 mm to 004 inch 10 mm until correct pattern has been obtained When a change in backlash is required backlash shims should be changed in the range of 1 1 2 times the amount of backlash required
34. sembly as far as possible in the direction towards the indicator With force still applied set indicator at zero 0 Tool D 128 Indicator NOTE Indicator D 128 should be adjusted to provide for a minimum of 200 5 08 mm travel Figure 68 The distance from the centerline of the ring gear to the button end of the pinion for the Model 44 axle is 2 625 inches 66 68 mm On the button end of each pinion there is etched a plus number a minus number or a zero 0 which indicates the best running position for each particular gear set The position of the pinion is con trolled by the amount of shims between the inner pinion bearing cup and the carrier bearing bore For example if a pinion is etched 3 m 8 this pinion would require 003 08mm less shims than a pinion etched 0 This means that by remov ing shims the mounting distance of the pinion is increased to 2 628 66 75mm which is just what a 3 m 8 indicates Or if a pinion is etched 3 m 8 we would want to add 003 08mm more shims than would be required by a pinion that is etched 0 By adding 003 08mm shims the mounting distance of the pinion is decreased to 2 622 66 60mm which is just what a 3 m 8 etching indicates If the old ring gear and pinion set is to be reused measure the old shim stack and build a new shim stack to this same dimension It is recommended that each shim be me
35. tallation of the wheel ends and shaft assemblies Refer to the vehicle service manual for removal and installation of the uni tized support arm Loosen the carrier screws holding the carrier assembly to the left hand unitized support arm and allow the lube to drain out Carefully remove the carrier screws and remove the carrier from the unitized sup port arm Drain all the lube from the carrier assembly AS Figure 53 1020 53 Pry the differential case from the carrier with two pry bars Use caution to avoid damage to any machined surfaces Tag the bearing cups to indicate from which side they were removed Remove spreader Se 1020 54 Figure 54 Turn nose of carrier up Hold end yoke or flange with a tool similar to the one shown and remove the pinion nut and washer Tool C 3281 Holding Wrench 19 ESS Figure 51 EEN 1020 51 Mount the carrier in a fixture as shown Note the matched numbers or letters stamped on the bearing caps and the carrier When assembled the number or letter on the caps must agree in both the horizontal and vertical position with the number or letter stamped on the carrier Remove the bearing caps Tools D 245 Supporting Fixture D 246 Vise Adapter ay es Figure 52 1020 52 Mount the spreader to the carrier Use a dial in dicator as shown DO NOT SPREAD THE CAR RIER OVER 010 25mm Remove the dial in dicator set Tools D 113 Spreader D 227 Spreade
36. the end yoke washer and a new pinion nut Tools W 162 Installer C 3281 Holder 1020 85 Figure 85 Place the arbor discs and arbor into the cross bore of the carrier Place the pinion height block on the button end of the pinion et the dial indicator of the scooter gage at zero 0 Slide the scooter gage towards the arbor As discussed in Figure 76 the in dicator will show the greatest clockwise reading when it is at the top center of arbor This reading in dicates the position of the pinion An indicator reading within 002 05mm of the etching on the pinion is considered acceptable If the inion position is not within plus or minus 002 05 mm of the etching on the button of the pinion refer to the pinion setting chart in Figures 69 or 70 as a guide to how much change in the shim stack is needed to position the pinion properly For example If the etch on the button of the pin ion is 2 m 5 and the indicator reading is 003 08mm the pinion is installed too close to the centerline of the differential crossbore It is not within the acceptable tolerance of 002 005 mm of the pinicn etch Referring to the chart in Figures 69 or 70 in order to move from a position of 3 8 to the correct position of 2 5 we need to remove 005 18mm of shims from the shim stack Follow the recommended procedures for removing the shim stack and make this change Reinstall the pini
37. the thrust face area of the shaft and seal full Be sure the chamfer side of the thrust washer of grease Also fill the seal area of the spindle with is toward the joint end of the axle shaft joint grease 17 Figure 0 1020 50 To adjust wheel bearing end play torque inner ad justing nut to 50 Lbs Ft 68 Nem to seat the bear ings Rotate the hub then back off the inner ad justing nut one fourth turn maximum Assemble the lockwasher by turning inner locknut to nearest hole in lockwasher Assemble outer locknut and tor que to 160 Lbs Ft 203 Nem Min Refer to vehicle EE specifications for wheel bearing end play Tools C 4170 Wheel Bearing Wrench C 3952 A Torque Wrench To assemble the hub lock assemblies refer to vehi cle manufacturer s recommendations Figure 48 1020 48 Assemble new nuts Torque nuts to 20 30 lbs ft 27 41 Nem Tool C 3952 A Torque Wrench NOTE To service hub and rotor assembly refer to Figures 7 through 12 Figure 49 1020 39 Assemble hub and rotor onto spindle Pack outer wheel bearing with specified grease wipe excess grease around the rollers CARRIER SECTION NOTE If it becomes necessary to service any parts inside the carrier it is suggested that the entire left hand unitized support arm and carrier assembly be removed from the vehicle and held in a large heavy duty vise or stand Refer to appropriate section of the service manual for removal and ins
38. to bring the gears into specification For example if the backlash needed to be changed by 004 inch 10 mm the shim pack should be changed by 006 inch 15 mm as a starting point The actual amount of backlash change obtained will vary depending upon the ratio and gear size High backlash is corrected by moving the ring gear closer to the pinion Low backlash is corrected by moving the ring gear away from the pinion These corrections are made by switching shims from one side of the differential case to the other LENGTHWISE BEARING 45717 dated NOTE When making changes note that two variables are involved Example If you have the back lash set correctly to specifications and you change the pinion position shim you may have to readjust the backlash to the correct specification before checking the pattern Refer to pattern interpretation WARNING Gear teeth may have sharp edges When handling gears use care to avoid personal injury i STEPS 1 Paint ring gear teeth with a marking compound to both the drive and coast side 2 Rotate ring gear one complete revolution in both directions while load is being applied with a large screwdriver or similar tool between the carrier casting and differential case flange 2307 01 The dri E shuld befc d he kooti The coast pattern should De c ia ered on the too but may be slightly toward the toe There should be some clearance between the pattern and the top of the t
39. uckle Make sure this area is free from dirt etc and that socket is straight Assemble tools as shown Turn forcin screw and push socket into knuckle as far as it wi go Tools D 150 1 Ball Joint Installer amp Remover D 150 2 Sleeve D 150 4 Installing Sleeve 11 Figure 21 1020 21 Assemble ball socket tools as shown Turn forcing screw and push out top socket Discard ball socket Tools D 150 1 Ball Joint Remover amp Installer D 150 2 Sleeve D 150 3 Sleeve Ball Joint Removing 1020 22 Figure 22 Lower ball socket does not have a cotter key hole in the stud end Assemble bottom socket into the knuckle Make sure this area is free from dirt etc and that the socket is straight Assemble tools as shown Turn forcing screw and push socket into knuckle as far as it will go Tools D 150 1 Ball Joint Remover amp Installer D 150 2 Sleeve D 150 4 Installing Sleeve If required assemble snap ring on bottom socket Figure 5 Assemble top nut on top socket Tighten nut until it pulls the stud of the bottom socket into the tapered hole of the yoke Torque top nut to 100 Lbs Ft 135 Nem After nut has been torqued tighten nut until castellation aligns with cotter key hole Tool C 3952 A Torque Wrench Figure 26 1020 26 Assemble cotter key NOTE Do not loosen top nut to install cotter key Figure 27 1020 27 Torque bottom nut to 90 110 Lbs Ft 122 149 Nem Tool C 3952 A Tor
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