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1. 6 7 Differential Lock Engaged 1 Spring is compressed 2 Shift fork 3 Piston and rod 4 Selector switch 5 Air pressure applied engages clutches 6 Fixed clutch splined to differential case 7 Sliding clutch splined to axle shaft and engaged with fixed clutch 82 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 J Differential Lock Disengaged 1 Spring is decompressed 2 Shift fork 3 Piston and rod 4 Selector switch 5 Air pressure applied disengages clutches 6 Fixed clutch splined to differential case 7 Sliding clutch splined to axle shaft Parts Identification Power Divider Parts Exploded View 1 Output shaft nut 2 Output yoke 3 Output seal 4 Output s
2. 1 Press 28 Drive Pinion A IMPORTANT C To install the outer bearing cup place the carrier in a press with the top of the carrier facing up Use the correctly sized spacer Do not use shim stock or grind D Place the cup in the bore use a sleeve or bearing driver spacers These practices can lead to loss of bearing preload tool to press the cup until it is fully seated Use a feeler and gear or bearing failure gage to make sure the cup is fully seated To prevent bearing damage use suitable sleeve that only contacts the inner race of bearing cone Use a press sleeve to install the inner bearing cone and pilot bearing if used onto the pinion Apply pressure until the bottom of the cone touches the shoulder of the pinion Apply lubricant to the cone of the bearing m Note If a press is not available use a sleeve or bearing driver and a hammer to install the cups 3 If removed install the inner and outer bearing cups into the carrier A To install the inner bearing cup place the carrier in a press with the bottom of the carrier facing up B Place the cup in the bore use a sleeve or bearing driver tool to press the cup until it is fully seated Use a feeler gage to make sure the cup is fully seated g lt Si 29 Drive Pinion 4 For Forward Carriers Install the helical with the larger boss 6 Install the pinion spacer side facing down in the carrier Align the helic
3. 3 Using a 3 4 wrench l e Rotate the fitting at least 1 2 turn until nipple points to rear N 5 e El e E D 5 D 65 Ss Ve wi Wheel End Seal Parts Exploded View 1 Installation tool 2 Seal 3 Rear hub 66 Wheel End Seal Remove and Overhaul Wheel End Seal WARNING Never work under a vehicle supported by only a jack Always support vehicle with stands Block the wheels and make sure the vehicle will not roll before releasing the brakes IMPORTANT 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 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 hardening gasket cement and smoothing with emery cloth 6 Clean hub cavity and bearing bores before reassembly 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 IMPORTANT Always use the seal install
4. Push rod 11 Switch 8 O ring Wheel Differential Lock Install and Adjust Wheel Differential Lock Note With differential carrier completely assembled and adjusted install differential lock as follows 1 If shift fork and sliding clutch are disassembled engage fork with the clutch hub and install spring pin in the fork leg See illustration below for fork mounting position on clutch 2 Position compression spring shift fork and clutch in shift opening of the carrier Align pilot hole of shift fork with the pilot hole of carrier 3 Install pushrod through shift fork compression spring and carrier pilot hole 4 Lubricate piston and o ring with silicone grease Install shift piston assembly into cylinder Position piston with small diameter hub toward closed end of cylinder 5 Install piston cover o ring 6 Install piston cover and torque to 50 75 Ibs ft 68 102 Nem 7 Install selector switch and torque to 10 12 Ibs ft 14 16 Nem 8 Check selector switch operation Check switch electrically with an ohmmeter Switch should be closed when clutches are engaged and open when disengaged 55 2 bi gt 74 x Output Shaft Assembly amp Rear Cover Housing and Output Shaft Assembly Parts Exploded View 1 Ge G 56 1 Output shaft nut 8 Inner bearing cup 15 Breather hose 2 Output yoke 9 Output shaft 16 Carr
5. Pinion nut 4 Pinion shim 0 o et 2 D E D y 85 Parts Identification Differential Carrier Assembly Parts Exploded View 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 Pinion Shim 8 Inner Pinion Bearing Cup 9 Inner Pinion Bearing Cone 10 Drive Pinion 11 Carrier Housing 86 12 Diff Case Dowels 13 Ring Gear 14 Ring Gear Bolts 15 Flange Half Bearing Cone 16 Flange Half Bearing Cup 17 Flange Half Bearing Adjuster 18 Side Pinion Thrust Washer 19 Side Pinion 20 Side Gear 21A B Differential Shaft 22 Pin 23 Capscrew 24 Flat Washer 25 Flange Half Cap 26 Plain Half Pedestal 27 Cotter Pin 28 Side Gear Thrust Washer 29 Plain Half Diff Case 30 Plain Half Bearing Cone 31 Plain Half Bearing Cup 32 Plain Half Bearing Adjuster Parts Identification Wheel Differential Lock Parts Exploded View 1 Fixed curvic clutch gear 5 Spring pin 9 Piston cover 2 Snap ring 6 Shift fork 10 Switch 3 Curvic clutch gear 7 Push rod 11 Plastic washer 4 Compression spring 8 O ring 5 5 A pm 1 O D 87 Parts Identification Housing and Output Shaft Assembly Parts Exploded View 1 ge 88 1 0utput shaft nut 8 Inner bearing cup 15 Breather hos
6. Power Divider Operation Power Flow and Torque Distribution 77 78 Operate Wheel Differential Assembly 79 Control Systems for Differential Lock 79 Direct Driver Controlled System 80 Wheel Differential Lock 81 Differential Lock t sbs 82 Parts Identification 83 88 Power Divider Parts Exploded 83 Forward Axle Pinion Assembly Parts Exploded View 84 Rear Axle Pinion Assembly Parts Exploded View u u 85 Wheel Differential Parts Exploded View 86 Wheel Differential Lock Parts Exploded View 87 Housing and Output Shaft Assembly Parts Exploded View 88 Fastener Torque Specifications 89 General Information Introduction Dana Commercial Vehicle Systems Division presents this publication Model Information to aid in maintenance and overhaul of Spicer tandem drive axles p The following models are included in this publication Instructions contained cover the models listed Their design is similar with primarily differences in load capacity Capacity variations are achieved by combining basic differential carrier assemblies with different axle housings axle shafts and wheel equipment D40 155 D40 156 The
7. bearing and cause premature failure E Go to step 12 B Install the Tang type lock washer on the spindle C Install the outer nut on the spindle and tighten to 250 Ibs ft 339 Nem D Verify endplay E After verifying endplay secure the outer nut by bending 180 apart two opposing tangs of the locking washer over the outer nut 12 Install the following New gasket at axle shaft flange Axle shaft Axle flange nuts and tighten to specified torque 13 Lubricate axle wheel ends 69 Wheel End Seal Verify Wheel Endplay Procedure Verify that endplay meets specification using a dial indicator An indicator with 0 001 0 03 mm resolution is required Wheel endplay is the free movement of the tire and wheel assembly along the spindle axis Correct endplay is 0 001 0 005 0 025mm 0 125 mm Attach a dial indicator with its magnetic base to the hub or brake drum as shown below D 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 Grasp the wheel assembly at the 3 o clock and 9 o clock positions Push the wheel assembly in and out while oscillating it to seat the bearings Read bearing endplay as the total indicator movement 70 CAUTION If endplay is not within specification readjustment is required Readjust Wheel Endplay Procedure Excessive Endpl
8. 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 80 9 Forward rear axle wheel differential lock air shift cylinder part of axle assembly 10 Wheel differential lock indicator 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 Spicer Wheel Differential Lock is an optional feature for The wheel differential lock consists of three major assemblies Spicer Axles In operation it positively locks the wheel differential to provide improved traction under adverse road conditions e Shift Cylinder Assembly Operates a shift fork and push rod assembly The differential lock is driver controlled through an electric switch or air valve mounted in the cab The locking mechanism is air operated to engage a mechanical clutch and lock the wheel differential It is spring operated to disengage the lock and permit the wheel e Curvic Clu
9. 5 Carrier assembly serial number assigned by the manufacturing plant 6 Axle gear ratio 7 Carrier assembly production or service part number Axle Shaft 2 Axle shaft part number General Information Ring Gear and Pinion Note Ring gear and drive pinion are matched parts and must be replaced in sets 5 3 D 1 Part number 2 Number of ring gear teeth 3 Manufacturing numbers 4 Matching gear set number 5 Number of pinion teeth 6 Date code 7 Indicates genuine Spicer parts 8 Heat code 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 fail
10. Power Divider nr 12 22 Power Divider Parts Exploded 12 Power Divider Disassembly Forward Carrier Assembly seen 13 14 Pump Disassembly Lube Manifold Disassembhy 16 Manifold Assembly 17 INTE 18 Power Divider Assembly 19 22 Carrier El UE 23 24 Carrier Disassembly Forward Carrier Assembly ere 23 24 Drive Pinion Pinion Removal Forward Axle Pinion Assembly Parts Exploded VIGW t tes 27 Rear Axle Pinion Assembly Parts Exploded neg 27 Drive Pinion Overhaul and Assembly Forward and Rear Carrier Assembly 28 34 Wheel Differential ss 35 40 Wheel Differential Parts Exploded View 35 Disassemble Overhaul and Assemble Wheel Differential 36 40 Forward Carrier inner Forward Carrier Assembly Measure Ring Gear Runout Rear Wheel Differential Parts Exploded View Rear Carrier Aesembiy a Adjust Tooth Contact Position Wheel Differential Lock Wheel Differential Lock Parts Exploded 54 Install and Adjust Wheel Differential 1 55 Output Shaft Assembly amp Rear Cover 56 61 Housing and Output Shaft Assem
11. bearing cup and adjuster 41 42 Forward Carter 6 Again with a screw driver lift the differential case so plain half 8 We can now set a rough backlash With the plain half bearing cup can be installed adjuster loose turn the flange half adjust so that the ring gear is moving in the direction of the pinion gear Keep adjusting the flange half bearing adjuster until the ring gear contacts the pinion gear 9 Now back the flange half adjuster off three notches of the bearing adjuster 7 Now install the plain half bearing adjuster Make sure the adjuster is square to the bearing cup Forward Carter 10 Now turn the plain half adjuster inward until you feel 12 With a dead blow hammer seat each of the bearing adjusters resistance on the adjuster Continue to rotate the adjuster until the bearing cup just starts to rotate stop This is your zero bearing preload setting 11 Tighten the bearing adjust two additional notches to create the proper bearing preload nu 5 E Le D 43 A4 Forward Carter 14 Place the tip of the indicator to the drive side heel of a ring 17 Start by backing off the bearing adjuster on the side that the gear tooth gear set needs to move Example To increase the backlash n back off the flange half adjuster first To decrease the amount 15 Record the actual backlash Remember this is a rough lash of backlash back off the plain h
12. determined refer to the appropriate service manual to perform the repairs Inspection Clean 1 Wash steel parts with ground or polished surfaces in solvent There are many suitable commercial solvents available Kerosene and diesel fuel are acceptable A WARNING Gasoline is not an acceptable solvent because of its extreme combustibility It is unsafe in the workshop environment 2 Wash castings or other rough parts in solvent or clean in hot solution tanks using mild alkali solutions Note If a hot solution tank is used make sure parts are heated thoroughly before rinsing 3 Rinse thoroughly to remove all traces of the cleaning solution 4 Dry parts immediately with clean rags 5 Oil parts e f parts are to be reused immediately Lightly oil e f 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 following checks or repairs Visually inspect axle housing for cracks nicks and burrs on machined surfaces Check carrier bolt holes and studs for foreign material Replace damaged fasteners Look for loose studs or cross threaded holes CAUTION Any damage which affects the alignment or structural integrity of the housing requires housing replacement Do not repair by bending or straightening This process can affect the material s properties and cause it to fail com
13. instructions Correct tooth contact patterns and adjustments are the same for forward and rear axles 1 Face width 2 Tooth depth 3 Heel 4 Top land 5 Root 6 Toe 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 pattern is 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 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 52 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 gear tooth The more use a gear has had the more the line becomes the dominant characteristic 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 do
14. two additional notches to create the so that the ring gear is moving in the direction of the pinion proper bearing preload gear Keep adjusting the flange half adjuster until the ring gear contacts the pinion gear 7 Now back the flange half adjuster off three notches 10 With a dead blow hammer seat the flange half bearing 8 Now turn the plain half adjuster inward until you feel resistance adjusters on the adjuster This is your zero bearing preload setting Rear Carrier 11 Mount the base of a dial indicator to the flange of the carrier 13 Record the actual backlash Remember this is a rough lash 14 Now we can make our final backlash adjustments The backlash specification for this axle model is 0 008 0 018 We want to set the backlash at 0 012 0 013 for new gearing If the backlash has to increase in size the ring gearing must move away from the pinion Each notch in the adjuster equals 0 003 0 004 of backlash 12 Place the tip of the indicator to the drive side heel of a ring gear tooth Le D 49 Rear Carrier 15 Start by backing off the bearing adjuster on the side that the 17 Snug the bolts down with an impact gun gear set needs to move Example To increase the backlash back off the flange half adjuster first To decrease the amount of backlash back off the plain half bearing adjuster first 18 The backlash must be remeasured at thi
15. 0 miles 96 500 Km 75W 140 or 3 years or 1 year Mineral Base MIL L 2105E J02360 75W 75W 90 120 000 miles 193 000 Km 60 000 miles 96 500 Km API GL 5 Gear Oil 75W 140 80W 90 or 1 year or 1 year MIL PRF 2105E 85W 140 Axles using LMS wheel end system Axles using adjustable wheel bearing system For additional lubrication information see TCMT 0021 74 Lubrication Change Lube Drain Drain when the lube is at normal operating temperature 150 200 F It will run freely and minimize the time necessary 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 disposal 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 corrosion 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 lubricant until l
16. 4 Using a sleeve and driver hammer install the inner bearing cup 5 Put the output shaft and bearing assembly into the axle housing assembly 6 Using a sleeve and driver hammer install the outer bearing cup into the housing assembly over the output shaft bearing cone 7 Using snap ring pliers install the snap ring that fastens the outer bearing cup into the welded on cover assembly 8 Check the endplay of the output shaft New assemblies should measure 0 001 0 045 0 03 mm 1 143 mm Note Use the bearing cup driver to insure seating of snap ring after installation with snap ring pliers eee lt SS 3 UN 8 Je e 1 Press 2 Plate 3 Sleeve 4 Press Bearing on Second 5 Press Bearing on First 6 Output Shaft 7 Plate 59 go e bi Agugesg yeys yndjng 60 1 Snap Ring 2 Bearing Cup 3 Output Shaft Assembly 4 Inner Bearing Cup 5 Rear Cover Assembly 6 Output Seal Output Shaft Assembly amp Rear Cover 9 Install the output seal 10 Install output yoke Note Use of a torque multiplier is recommended TIP 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 11 Install axle shafts and axle stud nuts If used also install lock washers and taper dowels 12 Connect inter axle driveline Make sure driveline is pro
17. 8 Output Shaft Assembly amp 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 housing is not necessary but would ease the removal process of the inner bearing cup from the cover bore A Using a bearing puller tool remove the inner bearing B Visually inspect the inner machined bore surface of the welded on cover for nicks and burrs Repair if necessary Output Shaft Assembly amp Rear Cover Overhaul and Assemble Output Shaft Assembly Note Lubricate the parts with gear lube during assembly 1 The output shaft bearings are assembled with both bearing cones back to back Use a press and a sleeve to install one bearing at a time 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
18. Spicer Tandem Drive Axles lt pana gt SPICER Drivetrain Products Service Manual AXSM0049 D40 155 Series D40 156 Series September 2014 General Information General Information The description and specifications contained in this service publication are current at the time of printing Dana reserves the right to discontinue or to modify its models and or procedures and to change specifications at anytime without notice Any reference to brand names in this publication is made simply as an example of the types of tools and materials recommended for use and should not be considered an endorsement Equivalents if available may be used 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 on injury and or Geng CAUTION Failure to follow indicated damage procedures may cause component damage or malfunction IMPORTANT Highly recommended procedures Departure from the instructions choice for proper service of this unit of tools materials and recommended ep S parts mentioned in this publication may Note Additional service information not jeopardize the personal safety of the covered in the service procedures service technician or vehicle operator Tip Helpful removal and installati
19. al gear pressed free from the bearings the pinion will not be damaged 2 ain bs MN IMPORTANT The bearing spacer will be reused or used as a starting point 1 Carrier Assembly when resetting the pinion bearing preload Do not discard 2 Press this part 3 Pinion 4 Wood Block 6 Use the proper pressing tool to press the end of the pinion until free from the pinion bearings WY MIN lt 5 1 Press 27 Drive Pinion Drive Pinion Overhaul and Assembly Forward and Rear Carrier Assembly The preload of the bearings on the drive pinion is adjusted by a B Mount the puller horizontally to press the bearing from spacer between the inner and outer bearing cones and the helical the pinion gear The preload is adjusted by changing the thickness of the spacer A thicker spacer will decrease the preload a thinner spacer 1 will increase the bearing preload The following procedure covers both the forward and rear axle carrier overhaul and assembly Note See carrier disassembly for instructions on pinion and yoke removal 1 Remove the inner pinion bearing cone from the pinion using a split type puller Use two procedure steps to remove each bearing A Mount the puller vertically to separate the bearing from the pinion This action will force the puller halves behind the bearing race and start moving the bearing from the pinion
20. al gear between the inner and outer bearing cups Note If you are using the same drive pinion use the same spacer that was originally installed in the assembly If the drive pinion is to be replaced the original spacer will be used as the starting point of adjustment 1 Large Long Boss 5 Place the pinion on a 6 x 6 x 6 block of wood and lower the carrier over the pinion 30 Drive Pinion 7 Install the outer bearing cone 10 Place a press sleeve over the top of the outer bearing cone E S Use the press to apply 10 tons of force It is important to 8 The bearing must now be driven onto the pinion with a bearing rotate the carrier slightly to make sure that the rollers of the driver far enough to keep the pinion assembly in place while bearing are properly seated the assembly is loaded into the press 9 Align a 6 x 6 x 6 wood block under the drive pinion then lower the carrier and pinion assembly into a press so that it is supported by the block 2 lt 5 31 32 Drive Pinion 11 With 10 tons of force on the press you should be able to feel 13 Run the nut down with an impact gun The pinion should still a small amount of drag as you rotate the carrier If the carrier have the same slight drag that was obtained in the press turns with no drag at all the pinion spacer thickness should be decreased by using a thinner spacer If the carrier is hard
21. alf bearing adjuster first 16 Now we can make our final backlash adjustments The backlash specification for this axle model is 0 008 0 018 We want to set the backlash at 0 012 0 013 for new gearing If the backlash has to increase in size the ring gearing must move away from the pinion Each notch in the adjuster equals 0 003 0 004 of backlash IMPORTANT Note Remember we just set our bearing preload at two notches When you back off one of the adjusters you must tighten the opposite adjuster the same number of notches Forward Carter 18 With the backlash set at 0 012 0 013 install the flange Measure Ring Gear Runout half and plain half bearing cups Measure Ring Gear Total 1 Measure ring gear total radial runout Indicator reading should not exceed 0 010 25 mm nu i 5 a Le D D 2 Measure ring gear total backface runout Indicator reading should not exceed 0 010 25 mm 20 The backlash must be remeasured at this time If the backlash did not remain at 0 012 0 013 the cups should be removed and the backlash must be readjusted This process must be repeated until the specified backlash is achieved with the bearing cups installed and torqued to Dana specifications 45 Rear Carrier Differential Carrier Assembly Parts Exploded View 1 Pinion Nut 2 End Yoke and Slinger 3 Oil Seal 4 Outer Pinion Bearing Con
22. and record 1 Position dial indicator at yoke end of output shaft input shaft endplay p pay 2 Push in on output shaft and zero the dial indicator 1 Position dial indicator at yoke end of input shaft S 3 Using a pry bar move output shaft axially and 2 Push in on input shaft and zero the dial indicator measure record endplay 3 Using a pry bar move input shaft axially and measure record endplay Adjustment Adjustment Correct endplay for a new assembly is 0 001 0 045 The Correct endplay for a new assembly is 0 003 0 007 See the maximum endplay for a used assembly is no more than 0 045 Input Shaft Endplay procedure in the Power Divider Assembly If endplay is incorrect contact Dana section for proper endplay adjustment procedure Differential Carrier Assembly Differential Carrier Assembly Parts 1 Carrier fasteners 2 Carrier assembly 3 Forward axle assembly 4 Rear axle assembly Differential Carrier Assembly Remove Differential Carrier Forward and Rear Note The removal of the forward carrier does not require disconnecting of the inter axle driveline and removal of the output shaft yoke assembly as most other Spicer tandems require Standard Differentials 1 Block the vehicle 2 Drain axle lubricant 3 Rear Only Disconnect inter axle driveline 4 Front Only Disconnect main driveline 5 Front Only Disconnect differential lockout air line 6 Disconnect l
23. atches 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 contaminants 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 polishing 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 63 Seal Replace Service Kit Location Location Housing Breather Housing Breather Spicer has an axle breather that consists of a fitting hose and clamp 4 Insert hose onto fitting long end down assembly This breather design has improved resistance to water ingestion clogging caused by dirt ice or snow buildup around the base of the breather See installation instructions below all views from rear 1 Install fitting in breather hole ZT 2 Tighten fitting finger tight N 5 Push hose firmly against fitting Rotate hose to point down CH E B CON Y
24. ation tool specified by the seal manufacturer Using an improper tool can distort or damage the seal and cause premature seal failure Install Wheel End Seal 1 Before installation lubricate the following with the same lubricant used in the axle sump e Inner bearing Wheel seal follow the directions provided by the seal supplier 2 Place seal on installation tool 3 Drive seal with installation tool onto hub 67 m m 2 2 gt Wheel End Seal Adjust Wheel Bearing WARNING Do not mix spindle nuts and lock washers from different systems Mixing spindle nuts and lock washers can cause wheel separation Note The lock washer for a four piece tang dowel type wheel nut system is thinner than the lock washer for a three piece tang type wheel nut system and is not designed to bear against the inner nut 1 Inspect the spindle and nut threads for corrosion and clean thoroughly or replace as required Note Proper assembly and adjustment is not possible if the spindle or nut threads are corroded 2 Inspect the tang type washer if used Replace the washer if the tangs are broken cracked or damaged 3 Install the hub and drum on the spindle with care to prevent damage or distortion to the wheel seal CAUTION A wheel dolly is recommended during installation to make sure that the wheel seal is not damaged by the weight of the hub and drum Never support the hub on the spindle with
25. ay lIf 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 inner nut to the next alignment hole of the dowel type washer if used Reassemble the washer and re torque the outer nut Verify endplay with a dial indicator Insufficient Endplay lIf endplay 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 Reassemble the washer and re torque the outer nut Verify endplay with a dial indicator Fine Tuning the Endplay lf after performing the readjustment procedures endplay is still not within the 0 001 0 005 0 025 mm 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 adjustment procedure Verify endplay with a dial indicator Wheel End Seal Lubricate Wheel End Lj CAUTION Wheel Ends with an Oil Fill Hole 8 m Before operating the axle the wheel hub cavities and bearings 1 Rotate the wheel end hub until the oil fill hole is up i t failure must be lubricated to prevent failure 2 Remove the oil fill plug o When wheel ends are serviced follow Spicer s wheel end lubrication D 3 Pour 1 2 pint of axle sump lubricant into each hub procedure before operating t
26. bility 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 specification 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 of Spicer gear lubricants represents a pr
27. bly Parts Exploded dE 56 Remove Output Shaft Assembly 57 58 Overhaul and Assemble Output Shaft Assembly 59 60 OS mirer dc RR TERRE QS aa EAR 61 Seal Replace iainta 62 64 IEN E RE 62 Guidelines for Reusing YOKE 63 Sr EM 64 New Welded D Housing 64 Housing Breather nn 65 Wheel End S al u icri rente detenta 66 72 Wheel End Seal Parts Exploded 66 Remove and Overhaul Wheel End Seal 67 Install Wheel End Seal 67 Adjust Wheel Bearing AA 68 69 Verify Wheel Endplay 70 Readjust Wheel Endplay Procedure 70 Lubricate Wheel End Wheel Ends with an Oil Fill 71 Wheel Ends Without Oil Fill Hole 72 General Lubrication Information Lubrication sciences Approved Lubricants Recommendations for Viscosity Ambient US nl 73 Lube Change Intervals 74 Change Lube UCI EE 75 SUE 75 Towing GUI LE 76 Proper Vehicle Towing enn 76 Theory of Operation ss 71 82
28. cage 34 Input seal 35 Input yoke 36 Input nut 37 Piston 36 O ring 39 Piston cover 40 Pinion cover Power Divider Power Divider Disassembly Forward Carrier Assembly Use these instructions with the carrier assembly in or out of 7 Remove the power divider cover assembly Use the tabs the vehicle provided to free the cover from the carrier assembly 1 Disconnect the main driveline 2 Disconnect the lockout airline 3 Drain the axle lubricant into a clean oil pan 4 Remove the input yoke nut and yoke 5 To de stake the nut use a chisel or drift with a round tip The flange of the nut must be pushed far enough outward so that the staked area will not interfere with the input shaft threads when the nut is removed See diagrams below CAUTION Failure to de stake the pinion nut will result in damage to the drive pinion threads when removed The pinion nut should never be reused always replace with new WY Eeer 8 Remove the input shaft sliding clutch shift fork and spring as 2 E an assembly 1 Round Tipped Chisel 2 Machined Slot In Pinion 3 Nuts Staking Flange y s 1 6 Remove the input seal Note Do not reuse the seals after disassembly 13 9 Remove the thrust washer and helical side gear 10 Remove the inter axle differential assembly Power Divider Pump Disassembly For output side gear and or pump r
29. cate the failure and prepare the part for examination In carrier failure analysis it may be necessary to disassemble the unit e When disassembling subassemblies and parts do not clean the parts immediately since cleaning may destroy some of the evidence e When tearing down the drive axle do it in the recommended manner Minimize any further damage to the unit Ask more questions when examining the interior of the carrier Does the lubricant meet the manufacturer specifications regarding quality quantity and viscosity 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 failure 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 to correct problems Correct the Cause of the Problem Once the cause of the problem has been
30. constant 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 Wm Wan W D KO EE i lt h i GS D 1 Input torque 4 Rear axle torque is transmitted from the output shaft side gear 2 Lockout disengaged through the output shaft inter axle driveline drive pinion ring 3 Forward axle torque is transmitted from the helical side gear gear wheel differential and axle shafts through the pinion helical gear drive pinion ring gear wheel 5 Input torque power flow from the vehicle driveline is transmitted differential and axle shafts to the input shaft and the inter axle differential spider The differential distributes torque equally to both axles 77 Theory of Operation With Lockout Engaged Inter Axle Differential is Not Operating Note Varied road surface conditions can result in unequal torque distribution between the two axle assemblies Lockout should only be engaged when both axles are rotating at the same speed Operation should be limited to low traction situations and should be disengaged when normal traction returns Failure to do A CAUTION so will result in po
31. e 2 0ulput yoke 9 Output shaft 16 Carrier capscrew 3 Output seal 10 Spindle nut Outer 17 Nut 4 Snap ring 11 Locking ring 18 Washer 5 Outer bearing cup 12 Spindle nut Inner 19 Stud 6 Outer bearing cone 13 Axle housing 20 Axle shaft 7 Inner bearing cone 14 Breather Fastener Torque Specifications Fastener Torque Specifications Location Lbs Ft Power Divider Input Cover Bolts 340 27 IAD Shift Cylinder Cap 85 15 Wheel Differential amp Gear Ring Gear to Diff Case Bolts 860 13 Forward Axle Pinion Nut 1254 41 Er a D 2 ki 7 bi e D bi Rear Axle Pinion Nut M48 x 1 5 925 30 1254 41 Carrier Cap Bolts long amp short 915 60 Carrier to Housing Bolts 420 27 Carrier to Housing Nuts 420 27 Wheel Diff Lock Switch 169 33 Wheel Diff Shift Cylinder Cap 85 15 Breather 375 18 NPTF 20 25 27 35 Temperature Sending Plug SE 89 Notes 90 Notes 91 For spec ing or service assistance call 1 877 777 5360 or visit our website at dana com Dana Commercial Vehicle Products Group 3939 Technology Dri rut AOR EE Dana SPICER dana com Application Policy Capacity ratings features and specifications vary depending upon the
32. e 5 Outer Pinion Bearing Cup 6 Pinion Spacer 7 Pinion Shim 8 Inner Pinion Bearing Cup 9 Inner Pinion Bearing Cone 10 Drive Pinion 11 Carrier Housing 46 12 Diff Case Dowels 13 Ring Gear 14 Ring Gear Bolts 15 Flange Half Bearing Cone 16 Flange Half Bearing Cup 17 Flange Half Bearing Adjuster 18 Side Pinion Thrust Washer 19 Side Pinion 20 Side Gear 21A B Differential Shaft 22 Pin 23 Capscrew 24 Flat Washer 25 Flange Half Cap 26 Plain Half Pedestal 27 Cotter Pin 28 Side Gear Thrust Washer 29 Plain Half Diff Case 30 Plain Half Bearing Cone 31 Plain Half Bearing Cup 32 Plain Half Bearing Adjuster Rear Carrier Rear Carrier Assembly 1 Using a chain hoist and the proper lift tool lift the ring gear and wheel differential assembly from the carrier 4 Install the pedestal washers and bolts and snug with an impact gun 5 With a screw driver lift the differential case so the flange half bearing cup and bearing adjuster can be installed 2 Apply a thin coat of oil to both wheel differential bearings 3 Starting on the plain half side install the bearing cup and bearing adjuster into the plain half carrier pedestal so that the adjuster has two threads exposed outside of the pedestal 191129 1094 47 48 Rear Carrier 6 We can now set a rough backlash Turn the flange half adjust 9 Tighten the bearing adjust
33. e in the Spicer family of synthetic gear lubricants 73 uolje911qn7 Lubrication Lube Change Intervals This product combines the latest manufacturing and part washing Severe Service Lubrication Change Intervals Severe service technology When filled with a Spicer approved synthetic applications are those where the vehicle consistently operates at or lubricant at the factory the initial drain is not required near its maximum GCW or GVW ratings dusty or wet environments EA I or consistent operation on grades greater than 8 For these Change the lubricant within the first 5 000 miles of operation applications the ON OFF HIGHWAY portion of the chart should be when not using a Spicer approved synthetic lubricant in either Typical applications are construction logging mining and a new axle or after a carrier head replacement Base subsequent refuse removal lubricant changes on a combination of the following chart and user assessment of the application and operating environment Note Clean metallic particles from the magnetic filler plug and drain plugs Clean or replace the breather yearly to avoid lube contamination due to water ingestion Synthetic or Lubricant 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 5 years or 1 year Synthetic SHAES 256 SAE 75W 90 250 000 miles 400 000 Km 60 00
34. e piston and o ring assembly with pliers Note In order to remove the shift fork and push rod parts first remove the power divider cover See the Power Divider section Assembly 1 Assemble the o ring onto the piston Apply silicone grease to the o ring 2 Gently push the piston o ring assembly into the lock out cylinder bore Make sure the piston assembly is pushed in all the way 3 Install the piston cover Tighten by hand and then torque from 50 75 Ibs ft 68 102 Nem 4 Connect the differential lock air line 5 Cycle the lockout to make sure there are no leaks and the system is operating properly 11 Power Divider Power Divider Parts Exploded View 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 11 Clamp 12 Seal manifold feed tube 13 Sump screen 14 Output side gear bearing cup 12 15 Output side gear bearing cone 16 Pin 17 Output side gear 18 Pump 19 Inter axle differential 20 Helical side gear 21 Thrust washer 22 Lockout sliding clutch 23 Shift fork spring 24 Shift fork assembly 25 V ring 26 Input shaft 27 Input shaft 28 Input shaft bearing cone 29 Carrier housing 30 Input cover shims 31 Input cover 32 Input cover capscrew 33 Bearing cup and
35. e shift fork from the sliding clutch unless parts are to be replaced To disassemble use a pin punch to 1 For ease of service mount differential carrier in head stand remove spring pin from the fork leg The sliding clutch can now with the differential lock facing up be removed from the fork 5 Remove the shift fork spring EI gt 7 77 bi 3 lt Note Omit this step if the ring gear is to be replaced If the ring gear is to be reused check the tooth contact pattern and ring gear backlash before disassembling the carrier assembly When checking the backlash a yoke or helical gear must be installed and torqued to the proper specification to get an accurate reading Best results are obtained when tooth contact patterns are maintained in used gearing 23 Carrier Assembly 6 Mount the differential carrier in a head stand with the wheel 8 Using a long flat blade screwdriver on a pry bar back off one of differential facing upward the wheel diff bearing adjusters and remove 9 Using a chain hoist and the proper lift tool lift the ring gear and wheel differential assembly from the carrier Note For easier disassembly loosen but do not remove the pinion nut 7 Remove the carrier differential bearing cap capscrews flat washers and bearing caps 24 Drive Pinion Forward Axle Pinion Assembly Parts Exploded View 9 1 Pinion 4 Pinion shim 7 Pinion bea
36. ead wires to the selector switch and air line at shift cylinder 7 Remove axle shafts WARNING Do not lie under carrier after fasteners are removed Use transmission jack to support differential carrier assembly prior to loosening fasteners 8 To remove axle shaft remove axle stud nuts If used remove lock washers and taper dowels 9 Remove axle shafts Note All models in this publication use axle shafts with unequal lengths Axle shafts may also be location specific 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 with a sharp blow with a hammer CAUTION Do not strike the shaft head with a steel hammer Do not use chisels or wedges to loosen shaft or dowels 10 Remove carrier capscrews nuts and lock washers 11 Remove differential carrier assembly gt 7 77 1 3 lt UE ETTI Differential Carrier Assembly Install Differential Carrier Forward and Rear IMPORTANT Tip To assist in installing complete differential carrier use two z pieces of threaded rod M16 X 1 5 threaded into carrier Before installing carrier assembly inspect and thoroughly capscrew holes Rod should be approximately 6 long clean interior of axle housing using an appropriate solv
37. emium 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 For additional lubrication information see TCMT 0021 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 Ambient Temperature Range 75W 40 F to 15 F 40 C to 26 C 75W 90 40 to 100 F 40 C to 38 C 75W 80 40 F to 80 F 40 C to 21 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 above 12 C and above Availabl
38. ent Use these to pilot the carrier into the housing and clean rag 2 Install carrier to housing lock washers capscrews and nuts 1 Apply Spicer approved RTV compound on axle housing mating Torque to proper specification See Torque Chart on page 89 surface as shown in the illustration Completely remove all old gasket material prior to applying new material Compound 3 Install axle shafts and axle stud nuts If used also install will set in 5 minutes Install carrier before compound sets or lock washers and tapered dowels reapply FRE 4 Add axle lubricant Fill to bottom of filler hole 1 5 Rear Only Connect inter axle driveline making sure all Ne 2X7 yokes are in phase Lubricate u joints ae v os gt NA 6 Front Only Connect main driveline making sure all yokes v are in phase Lubricate u joints LA o 7 Front Only Connect differential lockout air line D D GC kel D er A er XA e PL Qu er 1 Apply silicone gasket in this pattern 10 Inter Axle Lockout IAD Differential Lock Disassembly Inter Axle Lockout Integral Shift Cylinder with Welded Push Rod Assembly 1 Compression spring 2 Shift fork assembly 3 Piston 4 O ring 5 Piston cover Disassembly 1 With the axle installed in vehicle place differential lock selector valve in the disengaged or unlocked position 2 Disconnect the differential lockout air line 3 Remove the piston cover 4 Remove th
39. eplacement follow the procedure below 1 Remove the output side gear bearing cone if required 3 Remove pump from the output side gear y D s 1 4 Remove the output side gear bearing cup from the carrier with the proper bearing puller tool 1 Press 2 Press Tool 2 Remove pump locking dowel pin from the hole in the output side gear hub 15 Power Divider Lube Manifold Disassembly 1 Disconnect the hose from the lube manifold 2 Remove the manifold assembly by prying it out around the inner diameter IMPORTANT Once removed the seal manifold assembly cannot 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 Note Seals are not sold separately from the manifold 1 Barbed Nipple 16 Power Divider Manifold Assembly 1 Install the manifold assembly into the output side gear bore in the carrier Make sure the barbed nipple is lined up with the opening in the carrier casting 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 1 Manifold Oil Inlet Hole 5 Attach the suction screen to the end of the hose y D s 1 1 Barbed Nipple 2 Install the hose clamp on the hose push the ho
40. er flange of the cover pee 34 20 Install the cover making sure that the cover is parallel to the carrier opening 21 Use a dead blow mallet to seat the cover Wheel Differential Differential Carrier Assembly Parts Exploded View 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 Pinion Shim 8 Inner Pinion Bearing Cup 9 Inner Pinion Bearing Cone 10 Drive Pinion 11 Carrier Housing 12 Diff Case Dowels 13 Ring Gear 14 Ring Gear Bolts 15 Flange Half Bearing Cone 16 Flange Half Bearing Cup 17 Flange Half Bearing Adjuster 18 Side Pinion Thrust Washer 19 Side Pinion 20 Side Gear 21A B Differential Shaft 22 Pin 23 Capscrew 24 Flat Washer 25 Flange Half Cap 26 Plain Half Pedestal 27 Cotter Pin 28 Side Gear Thrust Washer 29 Plain Half Diff Case 30 Plain Half Bearing Cone 31 Plain Half Bearing Cup 32 Plain Half Bearing Adjuster 35 LI i h 2 Wheel Differential Disassemble Overhaul and Assemble Wheel Differential Disassemble Wheel Differential IMPORTANT Do not press on the wheel differential shaft to free the ring gear 2 The ring gear to differential case interface is a press fit from the case Pressing on the wheel differential shaft may Place the assembly in a press with the case facing d
41. es not run off the tooth at any point 1 Pattern along the face width could be longer Ring Gear Adjust Ring Gear Position Backlash If the gear pattern shows incorrect face width contact change If the pattern is concentrated at the heel too far up the tooth backlash by adjusting the ring gear move the ring gear toward the pinion to decrease backlash If the pattern is too close to the edge of the tooth toe move the ring gear away from the pinion to increase backlash 99 Y 1 Loosen the bearing adjuster on the teeth side of the ring gear several notches Z 2 Tighten the opposite adjuster one notch A 3 Return to adjuster on teeth side of ring gear and tighten D adjuster until it contacts the bearing cup j E f 4 Continue tightening the same adjuster 2 or 3 notches pA lt Z and recheck 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 ring gear and tighten adjuster until it contacts the bearing cup 4 Continue tightening the same adjuster 2 or 3 notches and recheck backlash ec DO 53 Wheel Differential Lock Wheel Differential Lock Parts Exploded View 1 Fixed curvic clutch gear 2 Snap ring 3 Curvic clutch gear 4 Compression spring 54 5 Spring pin 9 Piston cover 6 Shift fork 10 Plastic washer 7
42. evel 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 Note Lube fill capacities see chart are basic guidelines and will vary based on the angle the axle is installed in a particular 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 Axle Lube Quantity Axle Model D40 155 Axle Location Axle Awe Quantity Pints Axle Model D40 156 Axle Location Axle Angle Quantity Pints forwerg fe 75 rm e KI E Towing Guide Proper Vehicle Towing Without Wheel Differential Lock Lift the drive wheels completely off of the ground or damage will occur 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 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 it is impossible to lift the drive
43. ge or D Input Insert contamination Leave the seal in its package until installation D Output Driver On new yokes leave the protector on the yoke until it is R Pinion Driver installed on the shaft to prevent damage or contamination R Pinion Insert 1 Inspect axle endplay at the yoke see page 10 Service if beyond specified limit A WARNING 2 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 too distributor Due to the resiliency of the plastic driver hammer rebound may occur when the seal is seated Keep clear of the hammer 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 1 Yoke Puller Tool 3 Remove seal Use care when removing the old seal to prevent damage to the housing seal bore 4 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 62 Seal Replace Guidelines for Reusing Yoke A CAUTION Do not use the yoke if it has any damage on the seal surface nicks or scr
44. haft 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 11 Clamp 12 Seal manifold feed tube 13 Sump screen 14 Output side gear bearing cup 15 Output side gear bearing cone 16 Pin 17 Output side gear 18 Pump 19 Inter axle differential 20 Helical side gear 21 Thrust washer 22 Lockout sliding clutch 23 Shift fork spring 24 Shift fork assembly 25 V ring 26 Input shaft 27 Input shaft 28 Input shaft bearing cone 29 Carrier housing 30 Input cover shims 31 Input cover 32 Input cover capscrew 33 Bearing cup and cage 34 Input seal 35 Input yoke 36 Input nut 37 Piston 36 O ring 39 Piston cover 40 Pinion cover 83 vi et 1 O D Parts Identification Forward Axle Pinion Assembly Parts Exploded View 9 1 Pinion 4 Pinion shim 7 Pinion bearing cup outer 2 Pinion bearing cone inner 5 Pinion helical gear 8 Pinion bearing cone outer 3 Pinion bearing cup inner 6 Pinion bearing spacer 9 Pinion nut 84 Parts Identification Rear Axle Pinion Assembly Parts Exploded View 9 10 KE e 1 Pinion 5 Pinion bearing spacer 8 Oil seal 2 Pinion bearing cone inner 6 Pinion bearing cup outer 9 Yoke 3 Pinion bearing cup inner 7 Pinion bearing cone outer 10
45. he axle he wheelend fil hole ith either of t heel end designs PIGEN AE Dray S her or tag wheetend 4 Install oil fill plug and tighten to specified torque e Wheel ends with an oil fill hole e Wheel ends without an oil fill hole UU TE 1 Wheel End Oil Fill Hole 2 Proper Lubricant Level 3 Lubricant Flow from Sump 71 Wheel End Seal Wheel Ends Without Oil Fill Hole 1 With axle level and wheel ends assembled add lubricant 4 Raise the left side of the axle 6 or more Hold axle in this through filler hole in axle housing cover until fluid is level position for one minute with the bottom of filler hole Lower the left side 2 Raise the right side of the axle 6 or more Hold axle in this position for one minute 6 With axle on a level surface add lubricant through housing cover oil filler hole until fluid is level with the bottom of the 3 Lower the right side hole Note Axles without wheel end fill holes will require approximately 2 5 additional pints of lubricant to bring the lube level even with the bottom of fill hole 1 With axle on level surface fill housing with oil to bottom of plug 2 Temperature sensor mounting hole 3 Oil will run into wheel end 4 will run into wheel end 5 Tilt housing side to side 1 minute per side 6 Recheck oil level in axle 72 Lubrication General Lubrication Information The a
46. ial assembly from rotating during the torquing process Torque ring gear bolts to 635 ft lbs 10 ft lbs 860 13Nem A 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 14 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 40 Forward Carter Forward Carrier Assembly 1 Using a chain hoist and the proper lift tool lift the ring gear 3 Starting on the flange half side install the bearing cup by and wheel differential assembly from the carrier using a long screw driver to lift the case assembly to make alignment easier QG Cup Ne 4 Now install the bearing adjuster It s important to make sure the adjuster is installed squarely to the bearing cup nu 5 c D _ 2 Apply a thin coat of oil to both wheel differential bearings 5 Back the bearing adjuster off one full turn to allow movement when installing the plain half
47. ier capscrew 3 Output seal 10 Spindle nut Outer 17 Nut 4 Snap ring 11 Locking ring 18 Washer 5 Outer bearing cup 12 Spindle nut Inner 19 Stud 6 Outer bearing cone 13 Axle housing 20 Axle shaft 7 Inner bearing cone 14 Breather Output Shaft Assembly amp Rear Cover Remove Output Shaft Assembly Note For forward axle rear covers that are removable the output 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 puller tool may be made from the center section of most gear puller tools or may be purchased from your tool distributor 4 Remove oil seal 5 Remove snap ring 6 Remove output shaft and outer bearing cup as an assembly 1 Snap Ring 2 Outer Bearing Cup 3 Output Shaft Assembly 4 Inner Bearing Cup 5 Rear Cover Assembly 6 Output Seal 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 57 go e bi yeys dun 5
48. just the inner bearing and seal This can damage the seal and cause premature failure 4 Completely fill the hub cavity between the inner and outer bearing races with the same lubricant used in the axle sump 5 Before installation lubricate the outer bearing with the same lubricant used in the axle sump Note Lubricate only with clean axle lubricant of the same type used in the axle sump Do not pack the bearings with grease before installation Grease will prevent the proper circulation of axle lubricant and may cause wheel seal failure 6 Install the outer bearing on the spindle 7 Install the inner nut on the spindle Tighten the inner nut to 200 Ibs ft 271 Nem while rotating the wheel hub 68 CAUTION Never use an impact wrench to adjust wheel bearings A torque wrench is required to assure that the nuts are properly tightened 8 Back off the inner nut one full turn Rotate the wheel hub 9 Retighten the inner nut to 50 Ibs ft 68 Nem while rotating the wheel hub 10 Back off the inner nut exactly 1 4 turn Note This adjustment procedure allows the wheel to rotate freely with 0 001 0 005 0 025 mm 0 127 mm endplay 11 Install the correct lock washer for the wheel nut system being used Three piece Dowel type Lock Washer System 1 2 1 Inner Nut 2 Dowel Pin 3 Dowel type Lock Washer 4 Outer Nut A Install the Dowel type lock washer on the spindle Note If the dowel
49. model and type of service Application approvals must be obtained from Dana contact your representative for application approval We reserve the right to change or modify our product specifications configurations or dimensions at any time without notice Drivetrain Products Printed in USA AXSM0049 09 14
50. on procedures to aid in the service of this unit Always use genuine Spicer replacement parts Table of Contents Table of Contents Wheel Differential Assembly Assembly page 23 f ae Inter Axle Lockout page 11 WE Housing f Breather End Seal page 65 page 66 Output Shaft Lubrication iN Assembly amp age 73 Rear Cover J page 56 D e bi Le Table of Contents General Information 1 3 ig 1 Model Identification Parts Identification nien three Ring Gear and Pinon 3 MnS PECON 4 7 Failure UE 4 5 Prepare the Parts for Inspection 5 Inspection a ceive oem tee e it re adie 6 Endplay Procedure sss 7 Check Input Shaft Endplay Forward 7 Check Output Shaft Endplay Forward Axle 7 Differential Carrier Assembly 8 10 Differential Carrier Assembly 8 Remove Differential Carrier Forward and Rear 9 Install Differential Carrier Forward and Rear 10 Inter Axle Lockout sienne 11 IAD Differential Lock Disassembly 11 Inter Axle Lockout essen 11
51. or handling and damage to the axle components Prolonged operation with the lockout engaged can damage axle and driveline components La ba 4 1 Input torque 4 Rear axle torque is transmitted from the output shaft side gear 2 Lockout disengaged through the output shaft inter axle driveline drive pinion ring 3 Forward axle torque is transmitted from the helical side gear gear Wheel diferential alae through the pinion helical gear drive pinion ring gear wheel 5 Input torque power flow from the vehicle driveline is transmitted differential and axle shafts 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 78 Theory of Operation Operate Wheel Differential Assembly The Spicer wheel differential lock is driver controlled and operated 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 transmission in Low Range It is unlocked by the driver or unlocked when the transmission is shifted out of Low Range No
52. ownward cause it to bend Support the assembly on either side of the ring gear Thread a capscrew back into one of the case holes by hand Press down 1 Remove capscrews fastening the ring gear to differential case on the head of the capscrew you will need to press in more than one position to free the ring gear from the case CAUTION The differential case and gears will fall after separation Support the case so that it will not cause damage to the differential or bodily injury 3 Remove the outer side gear 36 Wheel Differential 4 The locking pins are a slip fit and should be easily removed 7 Remove the full shaft side pinions and thrust washers from the differential case LI i h 5 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 6 Remove the two half shafts first and then remove their side pinions and thrust washers Hal 1 Shaft 37 38 Wheel Differential 9 Remove bearing cones from ring gear and differential case in Assemble Wheel Differential two steps Mount puller vertically to split bearing This action will 1 Press EES start moving the bearing off case and gear 2 Place thrust washer on the side gear Lubricate both sides of B Mount puller horizontally to remove cone ihe itis wa
53. perly phased Lubricate u joints 13 Add axle lubricant Fill to bottom of filler hole IMPORTANT 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 Road test vehicle to bring axle lubricant up to temperature Recheck joints drain and fill plugs for leakage Retighten as necessary Output Shaft Assembly amp Rear Cover Measure Correct endplay for a new assembly is 0 001 0 045 0 03 mm 1 143 mm The maximum endplay for a used assembly is no more than 0 045 1 143 mm If endplay is incorrect contact Dana 1 Install oil seal 2 Install yoke 3 Install a new yoke nut with the pre applied thread adhesive compound Tighten the nut to the specified torque See the Torque Chart on page 89 go e bi yeys 1nding 61 Seal Replace Replace Seal Spicer strongly recommends using seal drivers when installing new A CAUTION seals Use the proper driver to make sure that the seal is square and installed to the proper depth 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 A CAUTION proper driver Oil seals can be easily damaged prior to installation Use D Input Driver care when handling the new seal to prevent dama
54. pin and washer are not aligned remove washer turn it over and reinstall If required loosen the inner nut just enough for alignment CAUTION Never tighten the inner nut for alignment This can preload the bearing and cause premature failure B Install the outer nut on the spindle and tighten to 350 Ibs ft 475 Nem C Verify endplay Wheel End Seal Three piece Tang type Lock Washer System Four piece Tang Dowel type Lock Washer System Q V9 3 3 9 9 m S 9 z X et eJ 2 21 3 1 Inner Nut 2 Tang type Lock Washer 1 4 Nut 0 123 3 124 mm thick S 3 Outer Nut 2 Dowel Pin 3 Dowel type Lock Washer 4 Tang type Lock Washer A Install the Tang type lock washer on the spindle 0 0478 1 2065 mm thick 5 Outer Nut A CAUTION A Install the Dowel type lock washer on the spindle Never tighten the inner nut for alignment This can preload the bearing and cause premature failure Note If the dowel pin and washer are not aligned remove washer turn it over and reinstall If required loosen the inner nut just B Install the outer nut on the spindle and tighten enough for alignment to 250 Ibs ft 339 Nem C Verify endplay IMPORTANT D After verifying endplay secure wheel nuts by bending one of the locking washer tangs over the outer wheel Never tighten the inner nut for alignment This can preload the nut and another tang over the inner wheel nut
55. pletely under load Check all seals and gaskets Note Replace conventional gaskets with silicone rubber gasket compound included in many repair kits The compound 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 Components Inspect all steel parts for Notches visible steps or grooves created by wear e Pitting or cracking along gear contact lines e Scuffing deformation or discolorations These are signs of excessive heat in the axle and are usually related to low lubrication levels or improper lubrication practices In addition inspect the following for damage e Differential gearing Bearings for loose fit on drive pinion pilot bearing and differential bearings e All fasteners for rounded heads bends cracks or damaged threads Inspect machined surfaces of cast or malleable parts They must be free of nicks burrs cracks scoring and wear Look for elongation of drilled holes wear on surfaces machined for bearing fits and nicks or burrs in mating surfaces Inspect Primary Gearing Before reusing a primary gearset inspect teeth for signs of excessive wear Check tooth contact pattern for evidence of incorrect adjustment Endplay Procedure Check Input Shaft Endplay Forward Axle Check Output Shaft Endplay Forward Axle Note Before disassembling the power divider measure
56. put side gear hub Make sure the pin is lined up with the machined slot in the pump body 1 Machined Slot 2 Pin Hole Power Divider Power Divider Assembly 1 Install output side gear bearing cone and press until fully 4 Install the inter axle differential ted roper press tools seated Hse proper presstools Note Install in the same direction as removed s D 5 Install the helical side gear so that the clutch teeth are facing upward in the carrier 1 Press 2 Press Tool 2 Fully press the output side gear bearing cup into the carrier seat 3 Install the output side gear Apply a thin layer of oil to the output side gear boss before installing into the seal 6 Install helical side gear thrust washer 19 Power Divider 7 Install the v ring seal to the sliding clutch if removed 10 Assemble the sliding clutch shift fork and fork spring to the input shaft and install assembly into carrier Make sure that the shift fork rod is piloted in the carrier bore 8 Install the sliding clutch onto the input shaft so that the teeth are facing up IMPORTANT Before installing input cover inspect and thoroughly clean mating surfaces using an appropriate solvent and clean rag Note Completely remove all old gasket material prior to applying new Loctite 11 Apply a bead of Loctite 518 to the surface of the carrier as shown in the illustra
57. ratures e Were the gauges showing normal ranges of operation e 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 vehicle 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 Look for leaks cracks or other damage that can point to the cause of the failure e Make note of obvious leaks around plugs and seals A missing fill or drain plug would be an obvious cause for concern Look for cracks in the carrier housing harder to see but sometimes visible e Does the general mechanical condition of the vehicle indicate proper maintenance or are there signs of neglect Are the tires in good condition and do the sizes match f equipped with a torque limiting device is H 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 lo
58. ring cup outer 2 Pinion bearing cone inner 5 Pinion helical gear 8 Pinion bearing cone outer 3 Pinion bearing cup inner 6 Pinion bearing spacer 9 Pinion nut Rear Axle Pinion Assembly Parts Exploded View 7 CH 8 Qa 10 LS s v 2 1 Pinion 5 Pinion bearing spacer 8 Oil seal 2 Pinion bearing cone inner 6 Pinion bearing cup outer 9 Yoke 3 Pinion bearing cup inner 7 Pinion bearing cone outer 10 Pinion nut 4 Pinion shim 25 Drive Pinion Pinion Removal 1 Remove the pinion cover Use a flat chisel to remove the cover from the carrier 2 Before the pinion nut can be loosened you must de stake the nut from the slot of the pinion 3 To de stake the nut use a chisel or drift with a round tip The flange of the nut must be pushed far enough outward so that the staked area will not interfere with the pinion threads when the nut is removed 26 CAUTION Failure to de stake the pinion nut will result in damage to the drive pinion threads when removed The pinion nut should never be reused always replace with new 1 Round Tipped Chisel 2 Machined Slot In Pinion 3 Nuts Staking Flange 4 Remove the pinion nut Drive Pinion 5 Place carrier assembly into a press place a 2 x 6 x 6 wood 7 Forward Axles Remove the pinion spacer and the block under the pinion This will ensure that when the pinion is helic
59. s time If the backlash did not remain at 0 012 0 013 the cups should be removed and the backlash must be readjusted This process must be repeated until the specified backlash IMPORTANT is achieved with the bearing cups installed and torqued to Dana specifications Note Remember we just set our bearing preload at two notches When you back off one of the adjusters you must tighten the opposite adjuster the same number of notches Note For used gearing the backlash should be reset to what it was at the time of disassembly 16 With the backlash set at 0 012 0 013 install the flange biy half bearing cup Note If you have too much backlash move the ring gear closer to the pinion Count the number of notches you back off the plain half threaded cup Each notch equals about 0 003 0 08 mm of backlash 50 Rear Carrier 20 Measure the ring gear total backface runout Indicator reading should not exceed 0 010 0 25 mm In order to maintain the differential bearing preload you will need to turn the flange half threaded cup the same amount in the same direction If you need more backlash reverse the procedure 19 Measure the ring gear total radial runout Indicator reading should not exceed 0 010 0 25 mm Le F 51 Ring Gear Adjust Tooth Contact Position Adjust Ring and Pinion Tooth Contact Pattern Note Rear axle gearing is shown in the following
60. screws Torque the fasteners in a crisscross pattern to 250 20 Ibs ft 340 27Nm 21 vu s s 1 Power Divider 20 Install yoke and slinger assembly 21 Install input shaft flanged nut and torque to the proper specifications See Torque Chart on page 89 Note A torque multiplier is recommended If difficulty achieving 22 correct torque torque the nut with the truck wheels on the ground and with the axle shaft installed 22 Verify that the endplay is between 0 003 0 007 If not readjust until the proper specification is achieved 23 Use a punch with a round tip to stake the pinion nuts flange into the machined slot in the pinion shaft See diagram below CAUTION The stake must be deep enough to enter the machined slot of the input shaft See diagram below Ca 1 Round Tipped Chisel 2 Nuts Staking Flange 3 Machined Slot In Pinion WARNING Failure to stake the pinion nut properly may result in the nut coming loose during service The pinion nut should never be reused always replace with new Carrier Assembly Carrier Disassembly Forward Carrier Assembly For models having the wheel differential lock option refer to the 4 Remove the shift fork and sliding clutch assembly following procedure These parts must be removed first before further disassembly of the wheel differential can take place Note Do not disassemble th
61. se onto the barbed fitting and slide the clamp over the barbed nipple If the unit does not have a pump go to the Power Divider 3 Route the suction end of the hose through the holes in the Assembly section carrier casting to the bottom of the carrier If the unit contains a pump go to the Pump Assembly section 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 17 Power Divider Pump Assembly 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 During installation of power divider cover the inter axle differential IAD input shaft assembly or IAD shift system 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 18 2 Install the pump locking dowel pin into the hole in the out
62. sher elote installing N NA 3 Install the side gear and thrust washer in the differential case Wheel Differential 4 Start the full differential shaft into the shaft bores in the case that does not have a locking pin hole Side Pinion and Thrust Washer m Full Differential Shaft Locking Pin Holes 5 Install a side pinion and thrust washer and push the shaft through the side pinion Side Pinion and Thrust 6 Install the side pinion and thrust washer to the other side of the full shaft 7 Install a side pinion and thrust washer on the half shaft side Side Pinion and Thrust Washer 8 Install the half shaft so that the pin is facing upward and push it in until it stops 9 The end of the half shaft should fit into the hole of the full shaft at the same time as the hole in the case lines up with the hole in the half shaft Align Pin 11 Install outer side gear 39 i 2 Wheel Differential Note No thrust washer is used at this location A IMPORTANT DO NOT use the capscrews to draw the ring gear into place Only use a press 12 Lower the ring gear onto the case assembly aligning the locking dowels 15 Press new ring gear bearing cone 16 While the ring gear and differential assembly are in the press the ring gear bolts can be torqued to specification Apply enough press pressure to keep the different
63. suffix letter P in the model number indicates optional lube 130 1590 930 1960 pump The pump is designed to provide additional lubrication to the D40 155P D40 156P inter axle differential and related parts D46 155DP D40 156DP Heavy Tandems Model Listing D 40 1 5 5 P Options D Dual Drive Forward Axle C Controlled Traction with Inter Axle Differential D Differential Lock R Dual Drive Rear Axle E High Entry Single S Single Rear Axle N A H Heavy Wall Integral Brake L Limited Slip GAW Rating P Lube Pump 1000 Ibs N America R Retarder Ready x 1 Tn Europe S Select Track Housing W Wide Track Gear Type Design Level 1 Standard Single Reduction gt 3 2 Dual Range Head Assembly Series 3 Planetary Double Reduction 5 Direct Drive 4 Open 6 Over Drive 5 Helical Reduction General Information Model Identification Drive Axle 5 CUST PART NO Spice SPEC SERIAL NO 2 1 6 pe PART _ RATIO Forward Axle 1 Country or origin 2 Axle model identification 3 Specification number assigned to the axle built by Spicer Identifies all component parts of the axle including special OEM requirements such as yokes or flanges Parts Identification Axle Housing 1 ID Tag Rear Axle Top View 4 OEM part number assigned to the axle build
64. tch Assembly Consists of a sliding clutch differential to function normally splined to a axle shaft and a fixed clutch which is splined to the differential case hub e Shift Fork and Push Rod Assembly Engages and disengages the differential lock curvic clutch assembly The differential lock also includes a selector switch electric which senses clutch engagement and sends an electrical signal to a cab mounted indicator light or an audible signal device i lt eo h i GS D 1 Sliding clutch 5 0 ring 9 Pin 2 Spring 6 Piston cover 10 Carrier 3 Clutch fork 7 Washer 4 Piston and rod 8 Switch 81 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 compression 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 differential is unlocked and operates normally 5 a 1 3 JJ
65. te 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 The driver manually locks and unlocks the wheel differential using a cab mounted electric switch or air valve The following description assumes the system includes a cab mounted electric switch and a solenoid valve as shown in the illustration 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 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 cylinder A compression spring moves the shift fork to disengage the curvic clutch and unlock the wheel differential 4 79 bi i lt eo h D EI r Theory of Operation Direct Driver Controlled System
66. tion below 9 If removed press the new input bearing cone in place until seated using the proper press sleeve or bearing installer 1 Press 2 Press Tool 3 Bearing 4 Input shaft 20 Power Divider 12 Reinstall the same thickness of input shims that was removed 15 Now install the input nut to the input shaft Hand tighten SES 16 Install a dial indicator with the base mounted on the pinion cover and the tip of the indicator on the end of the input shaft 17 Place a socket on one of the capscrews With a long screwdriver pry upward on the input shaft to measure the total movement Endplay should be between 0 003 0 007 IMPORTANT When inserting the input shaft assembly through the IAD components turn the shaft as necessary to align the slot of the input shaft with the pump drive shaft The keyway on the threaded end of the input shaft is aligned with the pump driver m slot This can be used as a visual aid during assembly 18 If the endplay is incorrect remove the input cover to adjust the shim pack thickness to reach the endplay specification 19 Install a new input seal using the proper installation tools 13 Apply a bead of 518 to the top of the last shim the same way See page 64 as the application to the carrier Note Only apply sealant to the surfaces between the carrier and first shim and the input cover and the last shim 14 Install the input cover and cap
67. to turn the spacer thickness must be increased 12 Remove the carrier from the press and reinstall the pinion nut 14 Secure the carrier in a head stand rotate carrier so the pinion nut can be torqued Drive Pinion 17 Use a lbs in torque wrench and correct socket to check the rolling torque of the pinion Read torque while rotating the assembly Record the rotating torque not the breakaway torque Torque must be between 20 to 50 Ibs in If the torque recorded is not within the specified torque the pinion spacer must be changed Repeat Steps 5 16 TIP A torquing wedge can be made to hold the helical gear from turning while the nut is torqued 15 Install the wedge between the carrier wall and the teeth of the helical gear 18 Once the proper rolling torque is achieved use a punch with a round head to stake the nut collar into the slot in the pinion 16 Torque the nut to proper specifications See Torque Chart on page 89 33 f lt c 5 Drive Pinion CAUTION The stake must be deep enough to enter the machined slot of the pinion See diagram below L PN 1 Round Tipped Chisel 2 Nuts Staking Flange 3 Machined Slot In Pinion WARNING Failure to stake the pinion nut properly may result in the nut coming loose during service The pinion nut should never be reused always replace with new 19 Apply a bead of Loctite 518 sealant to the out
68. ure 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 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 e Talk to the operator of the truck Look at the service records e Find out when the truck was last serviced Ask the following questions e In what type of service is the truck being used Has this particular failure occurred before 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 Ask the following questions e Was the vehicle operating at normal tempe
69. 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 76 With Wheel Differential Lock Follow this procedure to remove all axle shafts preventing gear rotation with the drive wheels and possible lubrication damage 1 Engage the wheel differential lock indicator light is on move vehicle to verify engagement 2 Shift transmission into neutral 3 With vehicle stationary release the air pressure on the wheel differential lock shift system and apply the parking brake 4 Disconnect the air supply and fitting at the shift cylinder 5 Remove the axle shafts 6 Install temporary cover on hub to prevent contamination entering and also to prevent the loss of lubricant Theory of Operation Power Divider Operation Power Flow and Torque Distribution In operation the power divider accepts torque from the vehicle The inter axle differential compensates for minor variations in speed driveline and distributes it equally to the two axles between the two axles the same way the wheel differential works SE between the two wheels of a single drive axle This unit also acts as This assembly is of the two gear design consisting of an input a central point in distribution of torque to the two axles shaft inter axle differential output shaft and two

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