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1. A CAUTION Never use an impact wrench to adjust wheel bearings A torque wrench is required to assure that the nuts are property 19 Procedure Three piece tang type lock washer system see Fig 2 1 Adjustments tightened Back off the inner nut one full turn Rotate the wheel hub Re tighten the inner nut to 50 Ibs ft 68 N M while rotating the wheel hub 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 025mm to 0 1 27mm end play Install the correct lock washer for the wheel nut system being used Install the Tang type lock washer on the spindle A IMPORTANT Never tighten the inner nut for alignment This can preload the bearing and cause premature failure G i D SS E D Bel T ai E Install the outer nut on the spindle and tighten to 250 Ibs ft 339 N M Verify end play see End Play Verification Procedure After verifying end play secure wheel nuts by bending one of the locking washer tangs over the outer wheel nut and another tang over the inner wheel nut as shown in Figure 4 below Bend two tangs one over inner nut and one over outer nut Outer nut Spindle aoe Inner nut Lockwasher Procedure Three piece dowel type lock washer system see Fig 1 1 Install the Dowel type lock washer on the spindle Note If the dowel pin and washer are not aligned remove wa
2. Input shaft vm ASSAS s d KC KL Kc k 1 Q lt lt Ser Lift up on eme EE pry bar to amp compress L input shaft G i D SS E D Bel T ai E 62 Inter Axle Differential Lockout Overhaul Standard or Current Model Lockout Overhaul Special Instructions Three differential model lockouts are used on Dana Tandem Axles To identify the lockout used on your axle refer to the illustra tions and related service instructions below Standard Lockouts Current and Non Current Models The current model is an improved version of and replaces the non current lockout Both are air operated to engage the lockout and spring released to disengage the lockout Dana Axles may be equipped with either of these lockouts The current model is interchangeable with the non current model as an assembly For service information refer to the following page Reverse Air Lockout The Reverse Air lockout is spring operated to engage the lockout and air operated to disengage the lockout This model is similar to the non current standard lockout It is not available in the new current lockout Procedure Disassemble and Remove Lockout 1 With axle installed in vehicle place differential lock selector valve in the disengaged or unlocked position Disconnect the air line at the lockout piston housing Low Cylin
3. 3 Disconnect lockout air line 4 Position drain pan under power divider cover 5 To remove power divider assembly remove cover cap screws and lock washers Support power divider see instructions above Then tap back face of input yoke to dislodge cover from differential carrier If cover does not dislodge easily strike the sides of the cover near the dowel pin locations see illustration Drain lube A CAUTION During removal of power divider the Inter axle differential may fall from carrier Exert caution to prevent damage or in jury D Pull power divider assembly forward until it is completely free of carrier then remove the assembly 7 With power divider removed the inter axle differential can be lifted off output shaft side gear Note Late model axles may be equipped with a compression spring and thrust button mounted between the input shaft and output shaft 8 Output Shaft If necessary remove output shaft as follows Disconnect inter axle driveline Remove nut flat washer and out put shaft yoke Pull output shaft assembly out of carrier 9 Axle Housing Cover and Output Shaft Bearing Parts If necessary remove these parts following instructions Dowel Pin Socket Head Capscrew 41 Power Divider Replacement Install Power Divider on Differential Carrier Special Instructions Lubricate all parts before installation Procedure 3 Inter axle Differential Install this assembly on output Shaft s
4. Cage in Press to Check Bearing Sleeve must Preload Press ram apply pressure to back face of _ outer bearing 29 Adjustments 3 Apply press load see chart below to the assembly and check rolling torque Wrap soft wire around the bearing cage attach Spring scale and pull Preload is correct when torque required to rotate the pinion bearing cage is from 10 20 in Ibs This Specification is translated into spring scale readings in the chart below specifications for Pinion Bearing Trial Build up Preload Test Press fit Outer Pinion Bearings Nominal Bearing Spacer spring Scale Reading without pinion Thickness seal for 10 20 in Ibs torque 1 1 2 3 N m eme mm oan TTT i Ke E GT D340 380 P 0 638 16 21 13 5 15 5 400 P D341 381 P 0 496 12 60 117 19 401 P 402 P 403 P 451 P 4 If necessary Adjust Pinion Bearing Preload by changing the pinion bearing spacer A thicker spacer will decrease preload A thinner spacer will increase preload 127 136 4 8 A IMPORTANT Once correct bearing preload has been established note the spacer size used Select a spacer 0 001 larger for use in the final pinion bearing cage assembly The larger spacer compensates for slight growth in the bearings which occurs when they are pressed on the pinion shank The trial build up will result in proper pinion bearing preload in three of four cases Do not assume that all assemblies wil
5. E CH SCH cD 4 Position a dial indicator on the end of the input shaft see illustration Dial indicator U bracket B Pry bar A Input shaft f A Y tlre ES x Lift up on pry bar to compress input shaft 5 Insert a pry bar through the U bracket with the end of the bar resting on the end of the input shaft see illustration 6 Zero the dial indicator and lift up on the pry bar to move the input shaft axially until it bottoms out within the bearing cover Measure the end play 90 Appendix 7 If end play is acceptable see chart remove U bracket and bearing cover Seal shim pack to prevent lube leak age Reinstall bearing cover and cap screws Torque cap screws to 75 85 ft Ibs 101 115 N m Continue axle assembly as necessary 8 If end play is incorrect change shim pack size as follows Add shims to increase end play Desired end play 0 003 to 0 007 Measured end play Step 6 0 001 0 001 Add shims to provide desired end play 0 002 to 0 006 Remove shims to decrease end play Measured end play Step 6 0 015 0 015 Desired end play 0 003 to 0 007 Remove shims to provide desired end play 0 01 2 to 0 008 9 Recheck end play and adjust as necessary until end play is within acceptable tolerance 10 When end play is correct remove U bracket and bearing cover Seal shim pack to prevent lube leakage Reinstal
6. Spicer Single Drive Axles SPICER Service Manual Spicer Single Drive Axles AXSM 0041 September 2007 Table of Contents Igel eu TEE 1 Failure ET EN H Itten NEE 9 Differential Carrier Assembly Parts 0 11 Differential Lockout ccnn 17 Power Divider Power Divider Parts Exploded View 23 Remove Power Divider scce 24 Remove Power Divider from Differential Carrier with carrier removed from axle housing 20 Disassemble Assemble and Overhaul TINGE OWEN H el 2 Install Power Divider on Differential Carrier with carrier assembled to axle housing 0 38 Install Power Divider on Differential Carrier with carrier removed from axle housing 40 Dissasemble Differential Carrier with power divider renge 54 Drive Pinion Drive Pinion Parts Exploded View 57 Disassemble and Overhaul Drive Pinion aac 58 Install Drive Pinion Aesemhhy 65 Wheel Differential Assembly Wheel Differential Assembly Parts le Il Housing and Rear Cover Assembly Parts Exploded View eccerre e e ERIE E EAE A AAE EE 92 Housing EC TE 94 Wheel End Seal Parts Exploded View aaaian 95 Remove and Overhaul Wheel End Seal 96 Wheel Adjustment Systems 97 Verify Wheel End play Procedure 0 99 Lubricate Wheel End 100 LUDACAUON ciie a ada taetemstatsatiee 102 Lube Change Intervals 103 chango LUDE e nenin een 104 DLAMOD IDES osaa 105 Torq
7. 454 AXIP 0200 34 000 52 000 Ibs With Controlled Traction Differentials AXI P 0084 Dual Range Planetary Double Reduction Tandem Drive Axles 34 000 45 000 Ibs AX P 0087 Single Reduction Dual Range Planetary Double Reduction Tandem Drive Axles 46 000 65 000 Ibs Axle Series 461 521 581 601 651 652 AX P 0085 Diff Lock Models 461 521 581 AX P 0085A Spicer Brakes All Models BRIP 0065 Spicer Steer Axles All Models AXIP 0074 Go cD hemm S E cD Y hemm E CH c cD service Manual 34 000 45 000 Ibs Axle Series 340 402 451 AXSM 0041 34 000 45 000 Ibs Axle Series 344 404 454 AXSM 0046 44 000 58 000 Ibs Axle Series 440 460 651 AXSM 0042 Dual Range and Planetary Double Reduction Tandem Drive Axles 34 000 45 000 Ibs Axles Series 340 402 451 AXSM 0045 44 000 65 000 Ibs Axle Series 440 460 651 AXSM 0044 Spicer Brakes EB amp ES Brakes AAXSM 0033 Spicer Steer Axles E 1000I E 12001 E 1320I E 14601 AXSM 0038 EFA12F3 12F4 13F3 13F5 20F4 22 12 15 2412 15 AXSM 0037 These publications may all be ordered through www spicerparts com lf additional help is needed call 1 800 826 HELP 4357 94 lt PANA gt SPICER Drivetrain Products Axles Driveshafts Off Highway Transmissions LONG Thermal Products Transmission Oil Coolers Engine Oil Coolers VICTOR REINZ Sealing Products Gas
8. Installing Power Divider Assembly with Chain Hoist and Sling Procedure Installing Power Divider Assembly with Chain Hoist and Sling 1 Install power divider cover cap screws and lock washers On pump models only install socket head cap screw in correct location see drawing on preceding page Torque cap screw to 110 125 ft Ibs 149 170 N m 2 Check and Adjust Input Shaft End Play With power divid er assembled to differential carrier Check end play with dial indicator If necessary adjust end play After input Shaft end play is within specifications complete assembly procedure as follows Dial indicator U bracket Os Fi Pry bar Input shaf AS Y A w s tt ARRAN i Ai y Lift up on pS a pry bar to zD T compress L input shaft Measuring Input shaft End Play with Dial Indicator 3 Measuring Input Shaft End Play with Dial Indicator 4 Connect drivelines Connect lockout air line 5 Fill axle to proper lube level see Lubrication Section A IMPORTANT When axle has been disassembled or housing gears axle shafts or wheel equipment replaced check axle as sembly for proper differential action before operating vehicle Wheels must rotate freely and independently Washer not used on axles with metric threaded nuts 43 Rear Axle Differential Carrier Replacement Remove Differential Carrier Assembly from Axle Housing Procedure Install Dif
9. Remove bearing cover cap screws and lock washers Remove cover and shim pack 3 To increase end play add shims Desired end play 0 003 to 0 007 Measured endplay Step 1 0 001 0 001 Add shims to provide desired end play 0 002 to 0 006 23 Adjustments 4 To decrease end play remove shims Measured end play Step 1 0 015 0 015 Desired end play 0 003 to 0 007 Remove shims to provide desired end play 0 012 to 0 008 5 To reassemble input shaft install the adjusted shim pack and bearing cover Install cap screws and lock washers Torque screws to 75 85 ft Ibs 101 115 N m Dial indicator U bracket D G Pry bar da AIRE A RE Lift up on pry bar to Sy compress L l input shaft Measuring End Play with Dial Indicator Input shaft 2 G i D SS E cD Bel T ai 2 be s S al y Note If difficulty is experienced in achieving correct torque on the input yoke nut torque the nut with truck on the ground and axle shafts installed D Install yoke flat washer and nut Tighten nut snugly Tap end of input shaft lightly to seat bearings 7 Measure input shaft end play with dial indicator If end play is still incorrect repeat Steps 2 through 6 8 With end play correct seal shim pack to prevent lube leakage then torque input shaft nut and cover cap screws see chart Note When power divider has been disassembled an
10. This process can affect the housing heat treatment and cause it to fail complete ly when under load Silicone Rubber Gasket Compound For more effective sealing Spicer uses silicone rubber gasket compound to seal the majority of metal to metal mating surfaces Spicer includes gasket compound and application instructions in many repair parts kits It is recommended that this compound be used in place of conventional gaskets The compound will provide a more effective seal against lube and is easier to remove from mating surfaces when replacing parts Seals Yoke amp Slinger Service Information During the 4th Quarter of 1990 new seals and yoke amp slingers were used on the models in this publication The new seals and slingers are noticeably different from the current seals and will affect interchangeability The upgraded seals can be used on axles originally equipped with the old seals Dana recommends the replacement of old yoke amp slinger assemblies when the new seals are installed The old yokes and slingers will work with the new seals but new yoke and slinger assemblies provide maximum sealing protection and prevent premature seal wear due to poor yoke condition New yoke and slinger assemblies cannot be used with the old seal design on the tandem forward axles New yoke and slinger assemblies can be used with the old seal on the tandem rear pinions Yoke Assembly amp Oil Seal Kits contain oil seal yoke amp slinger and instructio
11. 16 General Information Repair and Replacement A IMPORTANT To achieve maximum value from an axle rebuild Replace lower cost parts such as thrust washers seals etc These items protect the axle from premature wear or loss of lubricants Replacing these parts will not increase rebuild cost significantly lt is also important to replace other parts which display signs of heavy wear even though not cracked or broken A significant portion of such a parts useful life has been expended and the damage caused should the part fail is far in excess of its cost Steel Parts Gear sets input and output shafts differential parts and bearings are not repairable Worn or damaged parts should be discarded without hesitation Also discard mating parts in some cases Gear sets for example must be replaced in sets Miscellaneous Parts Seals and washers are routinely replaced None of these parts can be reused if damaged Fasteners using self locking nylon patches may be reused if not damaged but should be secured by a few drops of Loctite 277 on the threaded surface of the hole during installation and carefully torqued during installation Axle Housings Repairs are limited to removal of nicks or burrs on machined surfaces and the replacement of loose or broken studs A CAUTION Any damage which affects the alignment or structural integrity of the housing requires housing replacement Repair by weld ing or straightening should not be attempted
12. 32 35 34 Other Design Variations D341 381 P 401 P 402 P 403 P 451 P Inputs spins a 10 Drive Pinion Splines Rare Axle Shaft Side Gear Splines NN D340 16 D380 P 16 D381 P 402 P 403 P 41 Spicer Single Reduction Tandem Drive Axles Axle Series D340 380 P 400 P D341 381 P 401 P 402 P 403 P 451 P INTER AXLE 62 DIFFERENTIAL en 61 63 64 65 66 ASSEMBLY a j i 88 i OE o lt Go cD S E cD Y E CH SCH cD Note Before Replacing Seals Yokes and Slingers refer to the Repair and Replacement Instructions for interchangeability infor mation Spicer Single Reduction Tandem Drive Axles 1 Differential carrier amp bearing caps 2 Bearing capscrew 3 Flat washer 4 Lockwire 5 Dowel bushing 6 Bearing cap adjuster lock RH 7 Capscrew 8 Bearing cap adjuster lock LH 9 Cotter pin LH 10 Expansion plug upper 11 Expansion plug lower 12 Filler plug 13 Shift fork shaft 14 Carrier cover dowel pun 15 Shift unit mounting stud 16 Shift fork seal amp spring assembly 17 Flat washer 18 Stud nut 19 Shift fork amp roller assembly 20 Shift unit assembly 21 Sliding clutch 22 Differential bearing adjuster RH 23 Differential bearing cup RH 24 Differential bearing cone RH 25 Differential bearing adjuster LH 26 Differential bearing cup LH 2 Differential bearing co
13. Axle Differential Carrier Replacement brass drift in the center of the shaft head and striking the drift with a sharp blow from a hammer A IMPORTANT Do not strike the shaft head with a hammer Do not use chisels or wedges to loosen shaft or dowels Remove nuts and lockwashers fastening the carrier to the axle housing Remove the differentail carrier assembly A WARNING Do not lie under the carrier after fasteners are removed Use transmission jack to support the differential carrier assem ble during removal Axle Housing Cover and Output Shaft Bearing Parts The bearing parts can be replaced with cover removed or installed If necessary remove axle housing cover It is fastened with cap screws nuts and lock washers Remove oil seal and discard Remove bearing retaining washer A IMPORTANT D341 od e 401 P 402 P 403 P 451 P models do not use and output shaft rear bearing retain ing washer If replacement is necessary remove snap ring rear bearing and bearing sleeve A WARNING Snap ring is spring steel and may pop off Wear safety glasses when removing E Forward Axle Differential Carrier Replacement Install Differential Carrier Assembly special Instructions A IMPORTANT D341 381 P 401 P 402 P 403 P 451 P models do NOT use and output shaft Rear Bearing Retaining Washer Before installing carrier assembly inspect and thoroughly clean interior of axle housing A WARNING When installing
14. F 40 C to 21 C 75W 90 40 F to 100 F 40 C to 38 C 75W 140 40 F and above 40 C and above 80W 90 40 F to 100 F 40 C to 38 C 80W 140 40 F and above 40 C and above 85W 140 40 F and above 40 C and above 11 Lubrication Lube Change Intervals This product combines the latest manufacturing and part washing technology When filled with an Spicer approved synthetic lubricant at the factory the initial drain is not required Change the lubricant within the first 5 000 miles of operation when not using a Spicer approved synthetic lubricant in either a new axle or after a carrier head replacement Base subsequent lubricant changes on a combination of the following chart and user assessment of the application and operating environment severe Service Lubrication Change Intervals Severe service applications are those where the vehicle consistently operates at or near its maximum GCW or GVW ratings dusty or wet environments or consistent operation on grades greater than 8 For these applications the ON OFF HIGHWAY portion of the chart should be used Typical applications are construction logging mining and refuse removal Note Remove metallic particles from the magnetic filler plug and drain plugs Clean or replace the breather at each lubricant change Guide Lines Lube Change Intervals for Drive Axles Lubricant Type On Highway Miles Maximum change In On Off Highway Severe Maximum Change In terval servi
15. Magnetic Strainer for Axle with Lube Pump Note Lube fill capacities in the adjacent chart are good guidelines but will vary somewhat on the basis of the angle the axle is installed in a particular chassis Always use the filler hole as the final reference If lube is level with the bottom of the hole the axle is properly filled Axle Installation Angles Axles installed at angles exceeding 10 degrees or operated regularly in areas of continuous and lengthy grades may require stand pipes to allow proper fill levels For specific recommendations contact your local Spicer representative See back cover of this manual for phone numbers Lube Capacities Dana Housings single Reduction Tandem Series Forward Axle Pints liters Rear Axle Pints liters 380 P 381 P 400 P 401 P 39 18 5 36 17 0 402 P 403 P 451 P 39 18 5 36 17 0 Forward Axle Add an additional 2 pints 0 94 liters axle lubricant through filler hole at the top of differential carrier near the power divider cover Capacities listed are approximate The amount of lubricant will vary with angle of axle as installed in vehicle chassis 13 Wheel End Lubrication Lubrication Before operating the axle the wheel hub cavities and bearings must be lubricated to prevent failure When wheel ends are serviced follow Spicer s wheel end lubrication procedure before operating the axle Spicer axles may be equipped with either of two wheel end designs e Wheel ends
16. Press bearing cup in input bearing cover A IMPORTANT For correct cup installation use appropriate sleeve Take care to make sure cup is not cocked and is firmly seated all around 7 Install bronze bushings in helical side gear Note Helical Gears made after 1 3 95 have a step at the end of Inner Bore Bushings must reinstalled from the Curvic Tooth side inward towards this step Press flush against the shoulder of the step 06 Power Divider Overhaul Expansion plug 10 Check expansion plug in power divider cover see photo to make sure it is in place and firmly seated If loose seat by tapping with a hammer Replace plug if necessary Assemble lockout shift fork and sliding clutch with clutch teeth facing the helical side gear then install this assembly in power divider cover Note At this point in reassembly assemble and install lock out see pages 40 42 Slide input shaft and bearing assembly into power divider cover from the front side Engage shaft splines in lock out clutch Install bearing spacer on input shaft used only on D340 380 380 P 400 P Temporarily install input bearing cover assembly cap screws and lock washers Note Do not install any shims under bearing cover at this time Correct shim pack will be determined after the power divider is installed on differential carrier Refer to Adjust Input Shaft End Play page 39 A IMPORTANT For Axles with Spring and Thrus
17. SS E cD Bel T ai 2 Power Divider Overhaul 7 Remove oil seal from input bearing cover Remove bear 10 Remove oil pump cover cap screws and lock washers Re ing cup from cover move pump cover and O ring 11 NOTE When used remove woodruff key from gear Shaft Remove pump gears from power divider cover 8 Remove input shaft bearing cone Temporarily place lock out sliding clutch over rear of input shaft teeth toward bearing cone Place shaft in press and remove bearing cone 12 Unscrew and remove magnetic screen from power divider cover 9 Axles with Lube Pump With drive gear locknut previously removed step 2 and working through power divider cov er input shaft bore gently pry oil pump drive gear from its Shaft See steps 10 through 12 for pump disassembly 49 Power Divider Overhaul Disassemble Inter axle Differential Procedure 1 Punch mark differential case halves for correct position during reassembly 2 Remove locknuts and bolts Separate case halves and remove thrust washers side pinions bushings and spider Note Side Pinion Bushings Not used on tandems built after November 1 1991 Use when originally equipped Current production Inter Axle Differential Assemblies are only serviced as a complete assembly G i OD S E cD Case half Case half 5 E cD o hemm ra Thrust washer Non Current Production Inter Axle Different
18. Site Te sien s iren D D e Lockouts ze pen ne Lub Cemnnt Maal oma Push Amri D n dui K HA 26 aT 4 Ee aaia Drive Gear LOCKNUT Sire Fl libs Mm JI A7 47 01 1 2 Input Shaf NUT Site Fi Its hem Git 13 1301 5 40 105 gi 1 44G 1380 NOTE J Note 1 Metric Nut Used on Axles Produced After e Pump Cover CAP SCREW Sue Grade IN LBS Aum Vee 5 ASA pap Ved ony an DBO INEI 201 P 2 AS lt WS CT USED C aN BEJDE ee ie METITE FHE Sat 1 EN i Ji d i l EA MUTS bh M NOTE The drive shaft ondary puma models is quipped wiih a weed r Rey Qn late pump mide fhe kv Eeli nated The drive shat And Des tag im ech CAM Nate ann fhe ai ve cot Teri sntinigd Fem D se Pert LO ar ccommadate thei Nets e Correct tightening torque values are extremely important to assure long Dana Axle life and dependable performance Un der tightening of attaching parts is just as harmful as over tightening e Exact compliance with recommended torque values will assure the best results e The data includes fastener size grade and torque tightening values Axle models are included to pinpoint identification of fasteners for your particular axle e To determine bolt or cap screw grade check for designation stamped on bolt head see illustration Bolt head markings for grade identification Grade 5 Grade 8 35
19. Tang type lock washer el ea P N 119883 0 123 thick Washer P N 119883 Dowel type lock washer P N 119883 Inner nut P N 119882 Dowel pin 2 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 e 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 A 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 just the inner bearing and seal This can damage the seal and cause premature failure e Completely fill the hub cavity between the inner and outer bearing races with the same lubricant used in the axle sump 4 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 bearing with grease before installation Grease will prevent the proper circulation of axle lubricant and may cause wheel seal failure 5 Install the outer bearing on the spindle e Install the inner nut on the spindle e Tighten the inner nut to 200 Ibs ft 271 N M while rotating the wheel hub
20. and nut Tighten nut snugly Tap end 61 of input shaft lightly to seat bearings D Check input shaft end play with dial indicator positioned at yoke end of input shaft Move input shaft axially and mea Sure end play If end play is correct seal shim pack to pre vent lube leakage then torque input shaft nut and cover cap screws see chart D If end play is incorrect change shim pack size as follows Add shims to increase end play Example Desired end play New Parts 0 003 to 0 007 Measured end play Step 6 0 001 0 001 Add shims to provide desired end play 0 002 to 0 006 Remove shims to decrease end play Example Measured end play Step 6 0 015 0 015 Desired end play New Parts 0 003 to 0 007 Remove shims to provide desired end play 0 012 to 0 008 7 Toadd or remove shims remove input shaft nut flat washer and yoke Remove cap screws lockwashers and bearing cover Add or remove shims as required 8 Install bearing cover cap screws and lockwashers Install yoke flat washer and nut Seal shim pack to prevent lube leakage then torque input shaft nut and cover cap screws see chart Torque Chart Input Shaft Nut 1 5 8 18 780 960 1057 1301 Bearing Cover Cap Screw 1 2 13 Grade 5 75 85 101 115 M42 x 1 5 840 1020 1140 1383 Metric Nut used in Production Axles after 1 3 95 Power Divider Overhaul Dial indicator U bracket GP Pry bar LONS A Y lt
21. differential carrier assembly it is important to follow correct procedures to assure useful life Failure to cor rectly install rear bearing and retaining washer could result in premature axle failure Note Use silicone rubber gasket compound on axle housing mating surface as shown in the illustrations Compound will set in 20 minutes Install carrier and axle housing cover before compound sets or reapply Gel CH S E cD Y E CH SCH cD Procedure 1 Apply silicone gasket compound Install differential carrier assembly in axle housing Install nuts and lock washers Tighten to correct torque See Chart SILICONE GASKET COMPOUND SILICONE GASKET COMPOUND PATTERN DIFFERENTIAL CARRIER PATTERN HOUSING COVER MATING SURFACE MATING SURFACE Location of hole in rear cover Torque Chart Differential Carrier 5 8 18 Grade 8 stud 220 240 298 325 Axle Housing Cover 7 16 20 Grade 8 stod 78 86 94 116 Cap screw size 7 16 14 Grade 5 48 56 65 75 5 8 18 Grade 8 220 240 298 325 2 Axle Housing Cover and Output Shaft Bearing Parts If removed install cover and fasten with nuts cap screws and lockwash ers Tighten to correct torque If removed install bearing parts see steps 3 through 6 38 Forward Axle Differential Carrier Replacement 10 11 Install output shaft rear bearing Tap the outer race with a sleeve or drift until it is seated firmly in the machined
22. housing Shoulder washer must seat properly Note A new style Inter Axle Differential Lockout was being released as this publication was being printed If the Inter Axle Differential Lockout Assembly on your axle is not shown in this publication call your local Spicer representative 64 Gel cD S E cD Y E CH SCH cD Inter Axle Differential Lockout Overhaul Standard or Non Current Model Lockout Overhaul Retrofit Non Current to Current Model Lockout The current model only as an assembly is interchangeable with the non current lockout The original shift fork and push rod can be used for either model lockout and need not be replaced Retrofit Kits are available to convert the non current model to the current lockout Parts except the shift fork included in these kits are shown in the illustration on the preceding page For additional information refer to Dana Parts Books see back cover Retrofit as follows Disassemble and remove non current lockout Refer to instructions below Assemble and install current lockout following instructions on preceding page Note Do not use mounting screws from non current model They are too long to use with the new current model Special Instructions service Parts Availability The non current lockout assembly body piston and body cover are no longer available If any of these items ar
23. of these bearings under load and helps position the ring gear for proper gear tooth contact Procedure Adjust Diff Bearing Preload 1 Lubricate differential bearings 6 A IMPORTANT When installing bearing caps and adjuster ex ert care not to cross threads 2 Install adjusters and bearing caps Tighten bearing cap screws finger tight If this is difficult use a hand wrench Note Ring gear position for rear axle is illustrated 3 Loosen the bearing adjuster on the same side as the ring gear teeth until its first thread is visible 4 Tighten the bearing adjuster on the back face side of the ring gear until there is no backlash This can be tested by facing the ring gear teeth and push ing the gear away from the body while gently rocking the gear from side to side There should be no free movement Rotate the ring gear and check for any point where the gear may bind If such a point exists loosen and re tight en the back side adjuster Make all further adjustments from the point of tightest mesh 5 Atteeth side of ring gear tighten adjuster until it contacts the bearing cup Continue tightening adjuster two or three notches and this will preload bearings and provide back 1 3 lash Measure backlash with a dial indicator USED GEARING Reset to backlash recorded before dis assembly NEW GEARING Backlash should be between 0 006 and 0 016 If backlash is incorrect proceed a
24. power divider to enable the vehicle driver to lock out the inter axle differential and provide maximum traction under adverse road conditions In operation an air cylinder controlled by a cab mounted valve shifts a Sliding clutch To lock out inter axle differential action the clutch engages the helical side gear and causes this gear the input Shaft and differential to rotate as one assembly This action provides a positive drive to both axles With Lockout engaged torque is distributed to both axles without differential action The forward axle pinion and ring gear are driven by the helical side gear The rear axle gearing is driven from the output shaft side gear and inter axle driveline Note Varied road surface conditions can result in unequal torque distribution between the two axle assemblies Input torque Lockout engaged d a Inter axle differential Ei a not operating in S Drive is from input shaft through helical gears to forward gearing Drive is from output shaft side gear to rear gearing Torque is transmitted to both axles without inter axle differential action Spicer single Reduction Tandem Drive Axles Differential Carrier Assembly Exploded View Forward Axle Carrier Assembly Single Speed with Diff Lock 52 53 54 56 57 58 gees Tele DIFFERENTIAL amp RING GEAR 24 33 29 31
25. to remove each bearing See photos above This action will force puller halves under bearing and start moving bearing off pinion The same procedure can be used to remove pilot bearing and pinion inner bearing cone 73 Differential Carrier Overhaul Forward and Rear Axle Disassemble Wheel Differential Rear Axle Differential Illustrated DIFF BEARING THRUST SIDE SPIDER THRUST RING FLANGED BEARING DIFF BEARING CONE WASHER PINION WASHER GEAR CASE CONE BEARING ADJUSTER HALF ADJUSTER Go as lt CH CASE PLAIN RING RING BEARING cD BEARING CAP CASE SIDE GEAR GEAR CUP H CUP SCREW HALF GEAR BOLT NUT E CH as 3 hemm q gt Procedure 1 Remove nuts and bolts fastening ring gear to differential cases allowing gear to fall free If gear does not fall tap out er diameter with soft mallet to loosen 2 Punch mark differential cases for correct location during as sembly Remove cap screws and lift off plain differential case half 3 Lift out side gear and thrust washer 74 Differential Carrier Overhaul Forward and Rear Axle UUN Eu AANS ZU eege 4 J 6 Lift out spider side pinions and thrust washers Remove side gear and thrust washer Puller Mounted Vertically to Split Bearing Remove bearing cones from case halves using suitable pull er see photos Removing Bearing Cone from Flanged C
26. with an oil fill hole e Wheel ends without an oil fill hole Wheel Ends with an oil fill hole proceed as follows Fig 1 1 Rotate the wheel end hub until the oil fill hole is up 2 Remove the oil fill plug 3 Pour 1 2 pint of axle sump lubricant into each hub through the wheel end fill hole 4 Install oil fill plug and tighten to specified torque Wheel End with Oil Fill Hole Wheel End without Oil Fill Hole WHEEL END OIL FILL HOLE l LA YZ a AA ES SE dl E a i HSH Ss of FEISS vafa V N V P NA i SSS lt PROPER i PROPER l LUBRICANT LUBRICANT LEVEL LEVEL Fig 1 Cutaway views of typical wheel and assemblies Go cD S E cD Y E CH SCH cD 14 Lubrication Wheel Ends without an oil fill hole proceed as follows Fig 2 1 With axle level and wheel ends assembled add lubricant through filler hole in axle housing cover until fluid is level with the bottom of filler hole Raise the left side of the axle 6 inches or more Hold axle in this position for one minute Lower the left side Raise the right side of the axle 6 inches or more Hold axle in this position for one minute Lower the right side a as Se Ze With axle on a level surface add lubricant through housing cover oil filler hole until fluid is level with the bottom of the hole Note Axles without wheel end fill holes will require approximately 2 5 additional pints of lubricant to bring t
27. ARING _ CAP PEDESTAL 4 Rear Axle Drive Pinion Install pinion assembly Install bear ing cage cap screws and lock washers Torque cap screws to 110 125 ft Ibs 149 170 N m 9 Place ring gear and differential assembly in carrier During installation tilt carrier to allow differential case pilot to mesh properly with edge of bearing cap pedestal see photo above 6 Install bearing cups at both sides of differential case Install bearing adjusters and caps 85 Differential Carrier Overhaul Forward and Rear Axle 7 Install and tighten bearing cap screws finger tight If this is difficult use hand wrench The assembly is now read y for adjustment of differential bearing preload ring gear back lash and gear tooth contact 8 Atthe teeth side of ring gear position bearing adjuster until its first thread is visible 9 Atthe back face side of ring gear tighten adjuster until there is no backlash G i D SS E Si J T ai E 10 At the teeth side of ring gear tighten adjuster until it con tacts the bearing cup Continue tightening adjuster two or three notches This will preload bearings and provide back lash 11 Check Ring Gear Backlash Measure backlash with a dial in dicator Specifications are listed below Refer to page 21 for detailed instructions on adjusting backlash Ring Gear Backlash Specifications USED GEARING Reset to backlash recorded before disa
28. Correct Pattern New Gearing Could vary in length Pattern should cover 1 2 tooth or more face width Pattern should be evenly centered between tooth top land and root Pattern should be clear of tooth toe Check Tooth Contact Pattern USED GEAR Used gearing will not usually display the square even contact pattern found in new gear sets The gear will normally have a pock et at the toe end of the gear tooth which tails into a contact line along the root of 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 clear of the toe and centers evenly along the face width between the top land and root Otherwise the length and shape of the pattern are highly variable and is considered acceptable as long as it does not run off the tooth at any point Correct Pattern Used Gearing Pocket may be extended Pattern along the face width E could be aad A 32 Gel cD S E cD Y E CH SCH cD Adjustments Adjust Tooth Contact Patterns If necessary adjust the contact pattern by moving the ring gear and drive pinion Ring gear position controls the backlash This adjustment moves the contact pattern along the face width of the gear tooth Pinion position is determined by the size of the pinion bearing cage shim pack It controls contact
29. Forward Axle Differential Carrier Replacement Remove Differential Carrier Assembly from Axle Housing special Instructions A IMPORTANT D341 381 P 401 P 402 P 403 P 451 P models do NOT use and output shaft Rear Bearing Retaining Washer A WARNING The output shaft rear bearing retaining washer is frequently lost when the differential carrier assembly is removed It may adhere to the yoke to the face of the output shaft bearing fall on the floor or into the housing Locate this washer before continuing If itis not reinstalled the end of the yoke will wear the output shaft bearing very quickly If itis left in the housing it can be picked up by the ring gear motion and cause premature axle failure Procedure Go CH S E cD Y E CH SCH cD 1 Drain axle lubricant 2 3 F K 1 or E p a oe le Sek y j h Ge CR ee a S E wee EH d j aw d y t J i j i GE e gt j E Wi ae Se H Le 1 Se e Gei j i al D m H ch K re a ae e K i g se a en S WW r f TS ef i w 3 KT 5 pema Se of Ki 8 Gas a TS d 7 2 Disconnect inner axle driveline 3 Remove output shaft but flat washer and yoke 4 Disconnect differential lockout air line 5 Disconnect main driveline Losen inputshaft yoke nut but do not remove 6 Remove stud nuts and axle shafts if used remove lockwashers and taper dowels If necessary loosen dowels by holding a 36 Forward
30. P 402 P 402 P 451 P Slotted Nut and Roll Pin NN D 341 401 P 451 P only 1 5 8 18 15 381 P 402 P i A IMPORTANT Torque to 840 ft Ibs 1139 N m then continue tighten ing nut to align slot with the nearest hole in pinion shank Install roll pin Installing Pinion Helical Gear Note See Torque Chart for Pinion Nut Variations 8 Appendix Service Bulletin Supplement Input Shaft End Play for Axle Models equipped with an Input Shaft Axial Spring and Thrust Button In September 1988 an Axial Spring and Thrust Button were added between the input and output shafts The addition of these parts reduces shaft end play movement by loading the shafts axially in the direction of the yoke Thrust Butt NOTE 1 utton Axial Bushing Part 51228 Part 51228 Sorina Part 51238 Gel cD S E cD Y E CH SCH cD Location of Axial Spring and Thrust Button End play tolerances are the same for axles with or without the new Spring and Thrust Button However end play measurement procedure is different as described below Input Shaft End Play New or Rebuild with new parts 0 003 to 0 007 Rebuild with reused parts 0 013 to 0 017 Note Because of manufacturing variations in individual parts correctly adjusted end play could vary 0 010 after the unit is ro tated Acceptable End Play Tolerances when measuring as a regular maintenance procedure with ax
31. ase Half Remove bearing cone from plain case half in two steps First mount puller vertically to split bearing see photo This action will start moving bearing off case Second mount puller vertically to remove cone Remove bearing cone from flanged case half using suitable puller 19 Differential Carrier Overhaul Forward and Rear Axle Assemble Wheel Differential Special Instructions Lubricate differential parts with gear lube during reassembly Procedure 1 Press bearing cones on differential case halves see photos A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts the inner race of the cone Fig A Press Bearing Cone on Flanged Differential Case G i D SS E cD Bel T ai 2 Fig B Press Bearing Cone on Plain Differential Case 2 Place thrust washer and side gear in flanged differential case 3 Assemble side pinion and thrust washers on spider Place this assembly in flanged differential case Rotate gears and check for proper mesh 76 Differential Carrier Overhaul Forward and Rear Axle 4 Place side gear and thrust washer on side pinions Align punch marks and install plain case half Install cap screws and tighten to correct torque Check differential for free rotation by turning side gear hub Differential may re quire up to 50 ft Ibs 68 N m torque to ro
32. ation Procedure 1 Verify that end play meets specification using a dial indicator An indicator with 0 001 0 03 mm resolution is required 21 2 Adjustments Wheel end play is the free movement of the tire and wheel assembly along the spindle axis Attach a dial indicator with its magnetic base to the hub or brake drum as shown below End Play Adjustment With indicator mounted at bottom with Tire amp Wheel Push Pull at sides of drum End Play Adjustment Assembly with Wheel hub Gel cD S E cD Y E CH SCH cD 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 end play as the total indicator movement A CAUTION If end play is not within specification readjustment is required Procedure End Play Readjustment Procedure 1 Excessive End Play If end play is greater than 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 torque the outer nut Verify end play with a dial indicator Insufficient End Play If end play is not present remove the out
33. ce Miles terval Mineral Based 100 000 000 Yearly mm 000 Yeay Roadranger Approved 250 000 i Years a 000 Lubricant Changing Lube Draining Drain when the lube is at normal operating temperature It will run freely and minimize the time necessary to fully drain the axle Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container Inspect drain plug for large quantities of metal particles After initial oil change these are signs of damage or extreme wear in the axle and inspection of the entire unit may be warranted Clean the drain plug and replace it after the lube has drained completely Axles with Lube Pump Remove the magnetic strainer from the power divider cover and inspect for wear material in the same manner as the drain plug Wash the magnetic strainer in solvent and blow dry with compressed air to remove oil and metal parti cles A CAUTION Exercise care to direct compressed air into safe area Wear safety glasses 12 Go CH S E cD Y E CH SCH cD Lubrication Filling Remove the filler hole plug from the center of the axle housing cover and fill the axle with approved lubricant until level with the bottom of the hole Forward axles Add two pints 0 94 liters of lubricant through filler hole at the top of the differential carrier near the power divider cover Oil Filler Hole at top of Differential Carrier
34. d reassembled it may be desirable to adjust end play by measuring bear ing cover clearance and calculating shim pack size For procedures see page 39 Torque Chart Input Shaft Nut 15 8 18 780 960 a 1301 Bearing Cover Capscrew 1 2 13 75 85 101 115 M42 x 1 5 840 1020 1140 1383 Metric Nut used on Axles produced after 1 3 95 24 Adjustments Pinion Bearing Preload Special Instructions Most late model axles are provided with a press fit outer bearing on the drive pinion Some of the early model axles use an outer bearing which slips over the drive pinion Procedures for adjusting both types of pinion bearing design are contained in this sec tion Procedure Adjust Pinion Bearing Preload for Axles with Press fit Outer Pinion Bearings 1 Trial Build up Assemble pinion bearing cage bearings and spacer without drive pinion or oil seal Center bearing spacer between two bear ing cones Assemble these Parts for Trial Build up Inner Inner Bearing Outer Outer bearing bearing spacer bearing bearing cup variable cup cone Bearing cage Note When new gear set or pinion bearings are used select nominal size spacer from the specification chart below If orig inal parts are used use Spacer removed during disassembly 2 With the bearings well lubricated place the assembly in the press Position sleeve so that load is applied directly to the back face of the outer bearing cone
35. drical design Standard Current Model Lockout 2 Remove cap screws and lock washers fastening mounting bracket to power divider cover Remove bracket and piston hous ing 3 Remove locknut piston with O ring compression spring and shoulder washer from push rod Note The shift fork and push rod cannot be removed with power divider cover installed See Power Divider instructions 63 Inter Axle Differential Lockout Overhaul Procedure Assemble and Install Lockout 1 With shift fork and sliding clutch installed place the shoulder washer white plastic over push rod The large diameter side of the washer must face the power divider cover Install compression spring on push rod Lubricate O ring with silicone based lubricant and install O ring on piston Place piston assembly on push rod The large diameter end of piston must face power divider cover Install locknut on push rod and tighten to 13 17 Ift Ibs 18 23 N m Install piston housing making sure the housing is correctly seated and piloted in the shoulder washer Place mounting bracket over housing and position on power divider cover Install cap screws and lock washers and tighten to 48 56 ft Ibs 65 76 N m Note If axle is installed in vehicle apply sealant to air line fitting and connect air line When tightening air line hold piston housing in mounting position using a wrench applied to the hexagon configuration at outer end of
36. e Go cD S E cD Y E cD SCH cD 2 Press pilot bearing in pinion A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner bearing race 3 Stake pilot bearing using staking tool and press This is es sential to retain the bearing 82 Differential Carrier Overhaul Forward and Rear Axle 4 Press inner bearing cone on pinion A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cone 5 Install bearing spacer on pinion Note When new gear set or pinion bearings are used select nominal size spacer see chart page 20 If original parts are used use Spacer removed during disassem bly 6 Install bearing cage on drive pinion 7 Install pinion outer bearing cone Note At this stage in assembly check pinion bearing pre load de scribed in Adjustment Section of this manual for slip fit outer pinion bearing Rear Axle Do not in Stall oil seal until adjustment incomplete 8 Rear Axle Oil Seal and Yoke Installation of these parts is the same for slip fit and press fit bearings See page 49 step 8 and 9 for instructions Note For slip fit bearings pinion may be temporarily re moved to simplify seal installation 9 Forward Axle Helical Gear and Nut See page 53 for instruc tions 83 Inter Axle Differential Lockout Overhaul Procedure Assemble and Install Lockout 1 W
37. e a brass drift and a mallet Tap bearing cup into its bore mak ing certain cup is evenly and firmly seated Note Late Model Axles may be equipped with a spring and thrust button mounted between the input shaft and output shaft See page 54 2 Output Shaft Lubricate O rings then install output shaft assembly in carrier A Inter axle Differential Install differential assembly on output shaft side gear with nuts facing away from output shaft side gear 09 Power Divider Overhaul 4 Apply silicone gasket compound on carrier mating surface see illustration Silicone Gasket Compound 5 Install Power Divider Attach chain hoist to input yoke and install power divider assembly During installation rotate in put shaft to engage input shaft splines with inter axle differ ential After installation again rotate input shaft Output Shaft should turn when input shaft is rotated if assembly is correct G i D SS E cD Bel T ai 2 Note Lifting mechanism may create nicks and burrs on in put yoke Remove if present D Ifremoved install dowel pins in carrier Install power divider Power Divider Cover cover cap screws and lock washers On pump models only Dowel Pin Location place socket head cap screw at location shown on drawing Torque cap screws to 110 125 ft Ibs 149 170 N m Socket Head Capscrew 7 Adjust Input Shaft End Play Adjust end play with the power divider as
38. e Gear Bearing Cup If replacement is necessary use puller to remove bearing cup from carrier Note Late Model Axles may be equipped with a spring and thrust button mounted between the input shaft and output shaft Note For instructions on removing axle housing cover and output shaft rear bearing parts see page 26 Power Divider Overhaul 46 Gel cD S E cD Y E CH SCH cD Power Divider Overhaul Disassemble Power Divider Cover Power Divider Cover and Input Shaft without Lube Pump 1 2 3 4 5 6 7 8 OO oOo N OO BP Ww N ch Snap ring Helical side gear Thrust washer D washer Lockout sliding clutch Input shaft Bearing cone Lockwasher Lock nut Power divider cover Pipe plug Woodruff key O ring Pump cover Capscrew Lockwasher Dowel pin Pump gears Magnetic strainer Expansion plug Pump drive gear Capscrew Bearing cup shim Oil seal Yoke Flat washer Nut Capscrew Bearing cover Lockout unit See lockout service instructions for design variations Power divider cover shift fork and push rod Bushings NOTE The drive shaft on early pump models is equipped with a woodruff key On late pump models the key is eliminated The drive shaft end has two machined flats and the drive gear mounting hole is Shaped to accommodate these flats 41 Procedure 1 Remove snap ring from machined groove at rear of input Shaft A WARNING Snap ring i
39. e illustration 3 Install lockout body Secure with cap screws and lock washers Torque cap screws to 48 56 ft Ibs 65 76 N m Note Before installation soak piston felt oilers in SAE 30 engine oil and lubricate 0 rings with a high viscosity silicone oil or barium grease O ring lubricant 4 Install felt oilers and large O ring on piston 5 Axles with Lube Pump Before installing piston place piston stop at base of lockout body 6 Install compression spring over shift fork push rod Install piston in body and secure with O ring flat washer and nut Torque nut to 20 26 ft Ibs 27 35 N m 7 Install O ring in lockout body cover Install cover and secure with cap screws and lock washers Torque cap screws to 96 108 in Ibs 10 12 N m Gel CH S E cD Y E CH SCH cD Lockout Silicone Gasket Pattern 66 Inter Axle Differential Lockout Overhaul Reverse Air Lockout Overhaul The reverse air lockout unit is spring operated to engage lockout and air operated to disengage lockout A clutch engages or disengages the helical side gear to lock or unlock the inter axle differential Service Parts Availability A new design of the original Reverse Air Lockout has not been released at this writing The piston body and cover of the original lockout are no longer available as individual parts If these parts are not serviceable replace the complete unit For other par
40. e not serviceable replace lockout with the new current model per instructions above For other parts a Service Parts Kit see illustration is available to service the non current lockout Standard Non Current Model Lockout SHIFT FORK ye COMPRESSION O RINGS AND PUSH SPRING SSC CAP SCREW PISTON NUT mv CAP i d SCREW Le OM ann s i vc B i A PISTON STOP Used only on FELT BODY Axles with Lube Pumps OILERS WASHER TI Asterisk Identifies parts included in Service Kit 211201 Note Axles with Lube Pumps These axle models are equipped with a piston stop located at base of piston It is important that this stop be reinstalled in reassembly Procedure Disassemble and Remove Lockout 1 Remove cap screws and lock washers fastening cover to the body Remove cover and 0 ring 2 Remove nut flat washer and O ring from push rod 3 Remove body cap screws and lock washers then remove body and piston as an assembly Remove O ring and felt oilers from the piston Note The shift fork and push rod cannot be removed with power divider cover installed See Power Divider instructions 65 Inter Axle Differential Lockout Overhaul Procedure Assemble and Install Lockout 1 With shift fork and sliding clutch installed in power divider cover assemble and install lockout as follows 2 Apply silicone gasket compound to mounting surface on power divider cover Se
41. edure 1 Press bearing cone on output shaft side gear Gel cD S E cD Y E CH SCH cD A IMPORTANT Provide protection against possible gear teeth damage during press operation 2 Mount output shaft in vise Lubricate and install O rings If removed install bushing in end of output shaft NOTE 1 3 If removed install inner snap ring on shaft then install side gear and bearing cone assembly and outer snap ring A WARNING SNAP RING IS SPRING STEEL AND MAY POP OFF WEAR SAFETY GLASSES WHEN INSTALLING Note Late Model Axles may be equipped with a spring and thrust button mounted between the input shaft and output shaft see page 54 52 Power Divider Overhaul Assemble Inter axle Differential Special Instructions L ubricate parts with gear lube during assembly Procedure 1 2 Install bushings side pinions and thrust washers on inter axle differential spider Install spider assembly in one differential case half align punch marks and install other case half secure assembly with bolts and locknuts tighten to correct torque 17 23 ft Ibs 23 31 N m Note Side Pinion Bushings Not used on tandems built after November 1 1991 Use when originally equipped Assembling Non Current Production Inter Axle Differentials Note Starting in June 1993 production axles were made with bushing less output shaft 128736 Do not attempt to install bushings in shafts wi
42. ependently Refer to page 13 for service information on seals yokes amp slingers Note Washer not used on axles with metric threaded nuts Reference bulletin AXIB 9409 39 Power Divider Replacement Power Divider Replacement with differential carrier assembled to axle housing Special Instructions The power divider can be replaced with the axle assembly in or out of chassis and with differential carrier assembled to axle hous ing During removal and installation the power divider assembly must be supported as a safety precaution During removal or installation the Inter axle differential may fall from carrier Exert caution to prevent damage or injury Procedure Removing and Installing Power Divider 1 With axle out of chassis use chain hoist Fasten chain to input yoke to remove power divider N Removing Power Divider with Chain Hoist and Sling Note Lifting mechanism may create nicks and burrs on input yoke Remove if present 2 With axle installed in chassis use a transmission jack or a chain hoist and a sling Wrap sling strap around power divider and attach to chain hoist hook as shown in drawings 40 Go CH S E cD Y E cD SCH cD Power Divider Replacement Procedure Remove Power Divider from Differential Carrier 1 Disconnect main driveline L Main driveline Drain mo 2 Lockout Input airline yoke nut 2 Loosen but do not remove input yoke nut
43. er Overhaul Forward and Rear Axle Rear Axle Pinion Press Oil Seal in Cage with pinion installed 8 d 10 Rear Axle Only With pinion installed and bearing preload ad justment complete Install oil seal with a press Rear Axle Only Prior to installation of yoke lubricate oil seal and make sure yoke Is clean and dry Install yoke flat wash er and nut Torque nut to proper specification See page 24 Note After tightening pinion nut recheck pinion bearing rolling torque See Adjustment Section for Press fit outer pinion bearing Forward Axle Pinion Helical Gear and Nut These parts are in Stalled during pinion installation see page 53 A IMPORTANT Refer to page 13 for service information on Seals Yokes amp Slingers Nuts used on production axles after 1 3 95 are metric and do not use flat washer 81 Differential Carrier Overhaul Forward and Rear Axle Assemble Drive Pinion Slip fit outer pinion bearing Procedure i in ropriate sleev Us g app GN Race bearing BEES un Wee see Forward Axle Pinion Rear Axle Pinion adjacent drawings Press Bearing Cups Press Bearing Cups v in Cage PRES in Cage Cups must be firmly seated in cage A Caps must be firmly seated in cage Check with feeler gauge 1 0001 Check with feeler gauge 0 001 after installation after installation NOTE Install cups one at a time NOTE Install cups one at a tim
44. er if necessary Note Remove outer pinion bearing cone if Slip fit Forward Axle Remove pinion bearing cage cap screws Re move drive pinion and cage assembly from carrier Remove shim pack Rear Axle Remove pinion bearing cage cap screws then drive pinion cage and yoke assembly out of carrier A IMPORTANT Do not allow pinion to drop on hard surface Remove shim pack Forward and Rear Axle If gear set is to be reused keep pinion bearing cage shim pack intact for use in reassem bly If the original shims cannot be reused record the number and size of shims in the pack FORWARD AXLE AXLE FORWARD J 70 Gel cD S E cD Y E CH SCH cD Differential Carrier Overhaul Forward and Rear Axle Disassembly Drive Pinion Rear Axle Pinion Illustrated Q Pinion pilot bearing Bearing cage Drive Pinion Bearing cup outer Bearing cone inner Cage capscrew Spacer washer Bearing cone outer Bearing spacer variable Oil seal Bearing cup inner Input yoke Lockwasher Flat washer Bearing cage shim Pinion nut CO N O Om A WwW N ch Forward Axle Pinion Illustrated D341 381 P 401 P 402 P 403 P 451 P use self locking or slotted nut and roll pm Metric self locking nuts used as of 1 3 95 D340 380 P 400 P use self locking nut only Note Dana drive axles may be equipped with either slip fit or press fit outer pinion bearings Procedures are contained in
45. er 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 wash er and re torque the outer nut Verify end play with a dial indicator Fine Tuning the End Play If after performing the readjustment procedures end play is still not within the 001 005 025 mm to 12 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 end play with a dial indicator 22 Adjustments Differential Carrier Adjustments Adjustments help provide optimum axle life and performance by correctly positioning bearings and gears under load The tandem axles covered in this manual require the following adjustments Bearing Preload This adjustment is performed for both pinion and differential bearings It maintains proper gear alignments by creating correct bearing cone and cup relationships for free rotation under load The pinion pilot bearing does not require a preload adjustment Ring Gear Tooth Contact This adjustment positions ring gear and pinion for best contact under load Correct adjustment distrib utes torque evenly over gear teeth and helps maximize gear set life Input Shaft End Play Forward Axles This adjustment controls gear mesh in the inter axle differential Proper adjustment helps maximize life
46. ferential Carrier Assembly 1 Drain Lubricant 2 Disconnect inter axle driveline Note For easier disassembly the drive pinion nut can be loosened after driveline is disconnected 3 Remove axle shaft stud nuts lock washers and taper dowels if used If necessary loosen dowels by holding a brass drift in the center of the shaft head and striking it a Sharp blow with a hammer A IMPORTANT Do not strike the shaft head with a hammer Do not use Chisels or wedges to loosen shaft or dowels 4 Remove nuts and lock washers fastening carrier to axle housing Remove differential carrier assembly A WARNING Do not lie under carrier after fasteners are removed Use transmission jack to support and remove differen tial carrier assembly A IMPORTANT Before installing carrier assembly inspect and thor oughly clean interior of axle housing Note Use silicone rubber gasket compound on axle hous ing mating surface as shown in the illustration Compound will set in 20 minutes Install carrier be fore compound sets or reapply Axle Housing Silicone Gasket Compound Pattern 5 Install differential carrier assembly in axle housing Install Stud nuts and lock washers Tighten to correct torque see chart A IMPORTANT When axle has been disassembled or housing gears axle shafts or wheel equipment replaced check axle as sembly for proper differential action before operating vehicle Wheels must rotate freely and independen
47. g Preload Test Axle Model Nut Torque ft Ibs N m Press Load Tons Metric Spring Seal Reading without ee EE Seal Ibs kg Forward Axle Axle Keen 380 P 400 P 560 700 759 949 BEEN aa 15 5 12 2 14 0 aaa 2 3 5 4 Locking Nut D341 381 P 401 P 402 P 780 960 1057 1301 Self 17 19 15 4 17 2 5 12 2 3 5 4 403 P wi Locking Nut 840 1020 1140 1383 Metric 17 19 15 4 17 2 5 12 2 3 5 4 Nut 840 1139 Slotted Nut and 17 19 15 4 17 2 5 12 2 3 5 4 w Rear Axle All models 060 700 759 949 14 15 12 7 13 6 6 14 2 7 6 4 Torque nut to 840 ft lbs 1 139 N m Then continue tightening nut to align nut slot to nearest hole in pinion shank 4 Adjust Pinion Bearing Preload If necessary adjust pinion bearing preload Disassemble the pinion bearing cage as recom mended in this manual and change the pinion bearing spacer A thicker spacer will decrease preload A thinner spacer will increase preload A IMPORTANT Use the correctly sized spacer Do not use shim stock or grind spacers These practices can lead to loss of bearing preload and gear or bearing failure 28 Gel CH S E cD Y E CH SCH cD Adjustments Adjust Pinion Bearing Preload for Axles with Slip fit Outer Pinion Bearings Procedure 1 Lubricate bearings and assemble the drive pinion bearings and pinion bearing cage as recommended in the assembly section of this manual U
48. he hub cavity and bearing bores before reassembly Be sure to remove contaminants from all recesses and corners e The bearings thoroughly with solvent and examine for damage Replace damaged or worn bearings e Before installation lubricate with the same lubricant used in the axle sump e he inner bearing e The wheel seal following the directors provided by the seal supplier A IMPORTANT Always use the seal installation tool specified by the seal manufacturer Using an improper tool can distort or damage the seal and cause premature seal failure Procedure Wheel Bearing Adjustment 1 Identify the wheel nut system being installed Three systems are available e Three piece Dowel type wheel nut system Fig 1 e Three piece Tang type wheel nut system Fig 2 18 Adjustments e Four piece Tang Dowel type wheel nut system Fig 3 A 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 dowel type wheel 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 D oS Q V9 g gt S Tang type lock N Outer nut SD k Outer nut S EA 129132 P N 119881 H Xo P N 11249 9 GE 9 aN 3 Inner nut N D i Outer nut 3 O Ku Uf WO Inner nut P N 119881 es Ye P N 119882 DY P N 11249 Dowel Pin Dowel tvpe Lock
49. he lube level even with the bottom of fill hole OIL WILL OIL WILL RUN INTO RUN INTO WITH AXLE ON LEVEL SURFACE FILL HOUSING WHEEL END WHEEL END WITH OIL TO BOTTOM OF PLUG w Wun TEMPERATURE SENSOR TILT HOUSING SIDE TO SIDE 1 MINUTE PER SIDE THEN MOUNTING HOLE RECHECK OIL LEVEL IN AXLE Fig 2 Wheel end lubrication procedure 15 General Information Cleaning Inspection Replacement As the drive axle is disassembled set all parts aside for thorough cleaning and inspection Careful inspection will help determine whether parts should be reused In many cases the causes of premature wear or drive axle failure will also be revealed Cleaning The differential carrier assembly may be steam cleaned while mounted in the housing as long as all openings are tightly plugged Once removed from its hous ing do not steam clean differential carrier or any components Steam cleaning at this time could allow water to be trapped in cored passages leading to rust lubri cant contamination and premature component wear The only proper way to clean the assembly is to disassemble it completely Other methods will not be effective except as preparatory steps in the process Wash steel parts with ground or pol ished 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 combustibiliy It is unsafe in the wo
50. hen vehicle is moving in a forward direction pressurized lube is delivered to the vital power divider parts The pump lube system incorporates a magnetic strainer screen To keep the system clean the magnet traps minute particles and the screen blocks out large particles of foreign material General Information Torque Distribution with Lockout Disengaged Inter axle Differential is Operation Torque power flow from the vehicle driveline is transmitted to the input shaft and the inter axle differential spider At this point the differential distributes torque equally to both axles For the forward axle torque is transmitted from the helical side gear to the pinion helical gear drive pinion ring gear wheel differential and axle shafts For the rear axle torque is transmitted from the output Shaft side gear through the output shaft inter axle driveline to the drive pinion ring gear wheel differential and axle shafts Input torque Lockout disengaged Drive is from differential through helical gears to x forward gearing Drive is from differential through output shaft to mS ike SN Pa rear gearing Aw sa J2 Go cD S E cD Y E CH SCH cD Torque is transmitted to both axles through inter axle differential action Torque Distribution with Lockout Engaged inter axle Differential is Not Operation A lockout mechanism is incorporated in the
51. ial 50 Power Divider Overhaul Disassemble Output Shaft Output Shaft Assembly Output shaft Bushing Bearing cup Side gear Spring mounted in ze carrier O rings Bearing cone Button NOTE Late Model Axles may be equipped with a spring and thrust button mounted between the input shaft and output shaft Bushing removed from current production axles in Sept 1994 Output shafts with P N 129016 do not use bushings Procedure 3 Remove bearing cone from side gear using press and split type puller 1 Mount shaft assembly in vise using brass vise jaw protec tors Remove outer snap ring side gear and bearing cone Note For instructions covering output shaft rear bearing assembly If replacement is necessary remove inner snap parts see page 26 ring A WARNING Removing Bearing Cone from Output Shaft Side Gear Snap ring is spring steel and may pop off wear safety Note Starting in June 1993 production axles were made glasses when removing with bushing less output shaft 128736 Do not at tempt to install bushings in shafts with DIN e 2 Remove output shaft O rings If replacement is neces 128736 or 129194 stamped into them Ref bulle sary remove bushing mounted in end of output shaft tin AXIB 93 06 output shaft w metric threads NOTE 1 used in axles after 1 3 95 Ji Power Divider Overhaul Assemble Output Shaft Special Instructions Lubricate parts with gear lube during assembly Proc
52. ide gear with nuts facing away from side gear 1 Axle Housing Cover and Output Shaft Bearing Parts If removed install these parts following instructions on Silicone Gasket Compound page 27 Pattern ay Gel cD S E cD Y E CH SCH cD 2 Output Shaft If removed lubricate O rings then install Shaft assembly in differential carrier and housing cover Lubricate seal lip Make sure yoke is clean and dry then install yoke flat washer and self locking nut Torque nut to correct specification Power Divider Assembly Use silicone rubber gasket compound on differential carrier mating surface as shown in the illustration Note Compound will set in 20 minutes Install power di vider before compound sets or reapply A CAUTION During installation of power divider the inter axle dif ferential may fall from carrier Exert caution to prevent damage or injury Note Late Model Axles may be equipped with a spring and thrust button mounted in end of output shaft 42 Power Divider Replacement 5 Make certain dowel pins are installed in carrier See draw ing above then install power divider assembly Use a transmission jack or a chain hoist and sling see photo During installation rotate input shaft to engage input shaft Splines with inter axle differential After installation again rotate input shaft to check for correct assembly Output Shaft should turn when input shaft is rotated
53. in SAE 30 engine oil and lubricate O rings with a high viscosity silicone oil or barium grease O ring lubricant Place O ring on body cover Install compression spring cover Cap screws and lockwashers Torque cap screws to 96 108 in Ibs 10 12 N m Lockout Silicone Gasket Pattern N 68 7 cD S E cD Y E CH SCH cD Differential Carrier Overhaul Forward and Rear Axle Disassemble Differential Carrier with power divider removed Special Instructions If gear set is to be reused check tooth contact pattern and ring gear backlash before disassembling differential carrier Best results are obtained when established wear patterns are maintained in using gearing Omit this step if the gear set is to be replaced Procedure 1 Mount differential carrier in repair stand Note For easier disassembly loosen but do not remove pinion self locking nut When forward axle pinion is equipped with slotted nut remove roll pin with a pin punch then loosen nut 2 Punch mark differential bearing caps If reusing gear set also punch mark bearing adjusters for reference during as sembly 3 Cut lock wire Remove cap screws flat washers and bearing caps 69 4 Differential Carrier Overhaul Forward and Rear Axle Using a chain hoist lift ring gear and differential assembly out of Carrier Forward Axle Remove pinion nut see NOTE under Step 1 Remove helical drive gear using pull
54. ined herein are applicable to all axle models unless specified otherwise For brake information and axle mounting or suspension systems refer to pertinent truck manufacturer s literature Typical Dana Single Reduction Tandem Axle Two design variations of tandem axles are included in this manual The major difference is in the shaft spline design Note DS381 P axles manufactured after April 1985 are rated at 40 000 Ibs General Information Axle and Carrier Assembly Model Identification Drive Axle DS 461 P Gearing L Lube Pump D Forward Tandem Axle P Standard R Rear Tandem Axle P Optional S Single Reduction Design Level D Single Reduction with Wheel Differential Lock Capacity x 1000 Ibs T Dual Range Example 46 46 000 Ibs P Planetary Double Reduction Example DS Forward Tandem Axle Single Reduction RS Rear Tandem Axle Single Reduction Go cD S E cD Y E CH SCH cD Note Tags that do not include all the information shown here are older models before May 1987 3 CUST PART NO Spicer SPEC SERIAL NO 6 2 O He Monet PART NO RATIO T Data plate is located on the axle centerline INA ae Forward Axle Side View Rear Axle Top View 1 Country or origin 2 Axle model identification 3 Specification number assigned to
55. ith Pinion in Press 4 Adjust Pinion Bearing Preload If necessary adjust pinion bearing preload Disassemble the pinion bearing cage as recom mended in this manual and change the pinion bearing spacer A thicker spacer will decrease preload A thinner spacer will increase preload A IMPORTANT Use the correctly sized spacer Do not use shim stock or grind spacers These practices can lead to loss of bearing preload and gear or bearing failure Final Pinion Bearing Preload Test Slip fit outer pinion bearings Axle Model Nut Torque ft Ibs N m Press Load Tons Metric Spring Seal Reading without KE r seal Ibs kg Forward Axe 0 Axle Daian 380 P 400 P 560 700 759 949 BEE care 15 5 12 2 14 0 ae 2 3 5 4 Locking Nut D341 381 P 401 P 402 P 780 960 1057 1301 Self 17 19 15 4 17 2 5 12 2 3 5 4 403 P 451 P Locking Nut 840 1020 1140 1383 Metric 17 19 15 4 17 2 5 12 2 3 5 4 Nut e 840 1139 Slotted Nut and 17 19 15 4 17 2 5 12 2 3 5 4 role pin Rear Axle All models 560 700 759 949 14 15 12 7 13 6 6 14 2 7 6 4 Torque nut to 840 ft lbs 1 139 N m Then continue tightening nut to align nut slot to nearest hole in pinion shank 30 Gel cD S E cD Y E CH SCH cD Adjustments Differential Bearing Preload and Ring Gear Backlash Adjustment Special Instructions Correct differential bearing preload insures proper location
56. ith shift fork and sliding clutch installed place the shoulder washer white plastic over push rod The large diameter side of the washer must face the power divider cover Install compression spring on push rod Lubricate O ring with silicone based lubricant and install O ring on piston Place piston assembly on push rod The large diameter end of piston must face power divider cover Install locknut on push rod and tighten to 13 17 Ift Ibs 18 23 N m Install piston housing making sure the housing is correctly seated and piloted in the shoulder washer Place mounting bracket over housing and position on power divider cover Install cap screws and lock washers and tighten to 48 56 ft Ibs 65 76 N m Note If axle is installed in vehicle apply sealant to air line fitting and connect air line When tightening air line hold piston housing in mounting position using a wrench applied to the hexagon configuration at outer end of housing Shoulder washer must seat properly Note A new style Inter Axle Differential Lockout was being released as this publication was being printed If the Inter Axle Differential Lockout Assembly on your axle is not shown in this publication call your local Spicer representative 64 Gel cD S E cD Y E CH SCH cD Differential Carrier Overhaul Forward and Rear Axle SEAT DIFFERENTIAL CASE PILOT IN CARRIER BEARING CAP PEDESTAL BE
57. kets and Seals Cylinder Head Cover Modules Thermal Acoustic Protective Shielding Dana Aftermarket Group PO Box 321 Toledo Ohio 43697 0321 Warehouse Distributor 1 800 621 8084 OE Dealers 1 877 777 5360 www spicerparts com AXSM 0041 Printed in U S A Copyright Dana Limited 2012 All rights reserved Dana Limited
58. l bearing cover and cap screws Torque cap screws to 75 85 ft Ibs 101 115 N m Continue axle assembly as necessary 91 Gear Pinion Nut Fastening Chart Gear Pinion Nut Fastening Chart self Locking Pinion Nut D340 380 P 400 P 1 1 2 18 560 700 759 949 949 D341 381 P 401 P 1 5 8 18 780 960 Wl 1301 402 P eg bare od R All Modles 11 2 18 560 700 759 949 949 Slotted Nut and Roll Pin D341 381 P 401 P 1 5 8 18 402 P 403 P 451 P Note Torque to 840 ft Ibs 1139 N m then continue tightening nut to align Slot with the nearest Wie in ni shank Metric self locking Pin D341 402 P 403 P M42 x 1 5 840 1020 1140 1383 ion Nut 451 P Metric nuts produced after 4 95 incorporate a pre applied thread locking compund _ R All models M36 x 1 5 575 703 780 953 Nut Torques 92 Gel CH S E CH V hemm E CH cD Gear Pinion Nut Fastening Chart Note Reference Bulletin AXIB 9409 and AXIB 9503 for more information A CAUTION Metric nuts have an integral flange washer built into them Do not use separate washer in conjunction with these nuts English Inch Style Nut Metric Style Nut nen ouside Threads L Deech Integral Nylon Lock Flange Ring Washer Mechanical Locking Nut 93 Appendix Related Publications Parts Book 34 000 45 000 Ibs 340 380 400 341 381 401 402 403 451 AXIP 0089 34 000 45 000 Ibs 344 404
59. l in cage until bear ing preload is correctly adjusted penam A IMPORTANT i i i i l After bearing cups are installed preselect pinion bearing Cups must be firmly seated in cage A Caps must be firmly seated in cage 8 SEKR p we ae a oe spacer using the trial build up procedure described in NOTE Install cups one at a time NOTE Install cups one at a time the Adjustments Section of this manual 2 Press pilot bearing on pinion A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner bearing race Py 3 Stake pilot bearing using staking tool this is essential to re tain the bearing Note During pinion bearing installation locate each part in Same position that was used in Trial Build up Pre load Test Tim Meda 79 D Differential Carrier Overhaul Forward and Rear Axle Press inner bearing cone on pinion A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cone Install preselected bearing spacer on pinion Install bearing cage on drive pinion Press outer bearing cone on pinion A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cone At this stage of assembly final check pinion bearing preload See Adjustment Section of this manual 80 Go cD S E cD Y E CH SCH cD Differential Carri
60. l retain proper preload once bearings are pressed on pinion shank Final preload test must be made in every case 26 Go cD S E cD V E CH SCH cD Adjustments Final Pinion Bearing Preload Test Procedure 1 Assemble the complete pinion bearing cage unit as recommending the assembly section of this manual Measuring Bearing Preload with Pinion in Vise Note Forward axle pinion is equipped with helical gear For easier disassembly during bearing adjustment procedure use a dummy yoke if available in place of helical gear 2 Apply clamp load to the pinion bearing cage assembly Either install the yoke or helical gear and torque the pinion nut to specifications or use a press to simulate nut torque see chart below Vise Method If the yoke and nut are used mount the assembly in a vise clamping yoke firmly Press Method If a press is used position a sleeve or spacer so that load is applied directly to the back face of the outer bearing cone Measuring Bearing Preload with Pinion in Press 3 Measure Pinion Bearing Preload Use a spring scale to test the assembly rolling torque To use the spring scale wrap soft wire around the bearing cage attach the scale and pull Preload is correct when torque required to rotate the pinion bearing cage is from 15 to 35 in Ibs This specification is translated into spring scale readings in the chart below 2 Adjustments Final Pinion Bearin
61. le in truck Up to 0 060 with over 100 000 miles or 1 year service off road Up to 0 040 with less than 100 000 miles or 1 year service on road Note If end play exceeds limits disassemble power divider and replace worn parts 88 Appendix Special Instructions The addition of the Spring and Thrust Button between the input and output shafts necessitates the fabrication of a U bracket to assist in measuring the shaft end play Proceed as follows Procedure Measure and Adjust Input Shaft End Play 1 Fabricate a U bracket from 1 flat stock minimum thickness 0 125 as specified in the illustration GC Hole typical ET 2 _ e a 1 250 minimum 2 If axle is disassembled build up a 0 045 0 024 mm thick shim pack and place shim pack and bearing cover on power di vider cover Then proceed with Step 3 If axle is assembled remove input shaft nut flat washer and yoke NOTE Axles built with metric threaded nuts do NOT use flat washers Then proceed with Step 3 Note Bushing removed from current production output shafts See notes on page 35 89 Appendix 3 Install the U bracket on bearing cover using two bearing cover cap screws see illustration In tall all other cover cap screws and torque to 75 85 ft Ibs 101 115 N m yee Bearing cover capscrew e Lockwasher Fabricated U bracket Input bearing cover shim s Gel cD S E cD Y
62. le provides a vehicle with superior load carrying and roadability characteristics by dividing its work between two axles The complete tandem assembly consists of two axles coupled by a power divider Lube Pump System Power Divider In operation the power divider accepts the torque from the vehicle driveline and distributes it equally to the two axles This as sembly is of the two gear design consisting of an input shaft inter axle differential output shaft and two constant mesh helical gears The inter axle differential compensates for axle speed variations in the same way the wheel differential works between the two wheels of a single drive axle This unit also acts as a central point in distribution of torque to the two axles 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 Gearing The gearing for each axle is of the spiral bevel design with drive pinion positioned at centerline of the ring gear The differential and drive pinion are mounted on tapered roller bearings The wheel differential is a 4 pinion and 2 side gear design Lube Pump Tandem Axles with suffix letter P in Model No are equipped with a lube pump to provide positive lubrication to the inter axle differential and other power divider parts This pump is operated by a drive gear engaged with the input shaft splines W
63. ne LH 28 Differential case plain half 29 Differential case flanged half 30 Differential case capscrew 31 Ring gear amp drive pinion 32 Bolt 33 Nut 34 Differential side gear 36 Side pinion 37 Side pinion thrust washer 38 Spider 39 Pinion pilot bearing 40 Pinion bearing cone 41 Pinion bearing spacer washer 42 Pinion bearing spacer 43 Pinion bearing cup 44 Pinion bearing cage 45 Pinion bearing cage shim 46 Lock washer 47 Bearing cage capscrew 48 Pinion helical gear 49 Outer pinion support bearing one piece 50 Pinion shaft end nut 51 Pinion nut spring pin 52 Output shaft nut 53 Output shaft washer 54 Rear bearing retaining washer 55 Axle housing cover 56 Output shaft oil seal 57 Bearing snap ring 58 Output shaft bearing 59 Filler plug 60 Output shaft 61 Output shaft bushing 62 Output shaft O ring 63 Output shaft bearing cup 64 Output shaft bearing cone 65 Output shaft side gear 66 Side gear snap ring 67 Output shaft compression spring 68 Output shaft thrust bearing 69 Inter axle differential assemble 70 Inter axle differential case half 71 Case bolt 72 Case nut 73 Side pinion 74 Side pinion thrust washer 75 Spider 76 Helical side gear snap ring 7 Helical side gear 78 Helical side gear bushing 79 Helical side gear thrust washer 80 Helical side gear D washer 81 Lock
64. ng in pump cover making sure O ring is seated firmly in cover If removed install dowel pins Install pump cover on power divider cover and secure with cap screws and lock washers Tighten to correct torque 85 105 in Ibs 10 12 N m Install Pump Drive Gear Install drive gear on pump shaft end Note Some pump drive shafts use a woodruff key When key is used place key in shaft slot Position gear on Shaft engaging key Then install gear with driver and hammer Note Install and tighten drive gear nut after input shaft is assembled to power divider cover see step 10 Install magnetic screen in power divider cover Tighten to correct torque 40 60 ft Ibs 54 81 N m D9 Power Divider Overhaul 5 Press bearing cone on input shaft A IMPORTANT To prevent bearing damage be careful to use sleeve that only contacts the inner race of bear ing cone 6 SEAL INSTALLATION IMPORTANT Before installing seal refer to page 13 for service information on Seals Yokes amp Slingers Go cD S E cD Y E CH SCH cD Press oil seal in cover using a seal driver or suitable sleeve len correctly talled seal Note Check carrier date code see page 27 note before 5 ould be flush Units built before October 26 1987 87299 seal oo d should be flush with bottom of chamfer Units built af ter October 26 1987 87299 seal should be installed until 3 32 deeper than bottom of chamfer
65. ns Most non Dana aftermarket seals will not be compatible with the new Dana Yoke and Slinger assemblies spcier recommends the use of special installation tools conveniently packaged in one single kit listed below Refer to Dana parts Book AXIP 0089 and Eaton Bulletin 90 06 for additional information Seal Driver Installation Kit 272139 126917 Driver Rear Axle Pinion 127787 Adapter use with 126917 Driver for Forward Axle Input 127786 Driver Forward Axle Output 17 Adjustments Wheel Bearing Adjustment Special Instructions 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 Procedure Wheel End Seal 1 Remove e The outer bearing and wheel e he inner bearing e he oil seal or grease retainer and discard e The old wear sleeve 2 piece design only with a ball peen hammer and discard Wheel end seals can be easily damaged during handling Leave the seal in its package until installation to prevent dam age or contamination A CAUTION Do not cut through the old wear sleeve Damage to the housing may result Gel cD S E cD Y E CH SCH cD 2 Inspect e he spindle journal and hub bore for scratches or burns Recondition with emery cloth as required Note Deep gouges can be repaired by filling gouge with hardened gasket and smoothing with emery cloth 3 Clean e T
66. of all power divider parts Adjust Input Shaft End Play Specifications Input shaft end play requirements will vary with operating conditions mileage and rebuild procedures These vari ations are shown in the following chart Input Shaft End Play New or Rebuild with new parts 0 003 to 0 007 Rebuild with reused parts 0 013 to 0 017 Note Because of manufacturing variations in individual parts correctly adjusted end play could vary 0 010 after the unit is ro tated Acceptable End Play Tolerances when measuring as a regular maintenance procedure with axle in truck Up to 0 060 with over 100 000 miles or 1 year service off road Up to 0 040 with less than 100 000 miles or 1 year service on road Note If end play exceeds limits disassemble power divider and replace worn parts Procedure Measure and Adjust End Play 1 In September 1988 a Spring and a Thrust Button between the input and output shafts End play tolerances are the same for axles with or without this Spring and Button However end play measurement procedure is different than described below Refer to Service Bulletin Supplement at back of this manual for procedure variances With power divider assembled to differential carrier measure end play with dial indicator positioned at yoke end of input shaft Move input shaft axially and measure end play If end play is not correct see chart adjust as follows 2 Remove input shaft nut flat washer and yoke
67. on the tooth depth of the gear tooth These adjustments are interrelated As a result they must be considered together even though the pattern is altered by two distinct operations When making adjustments first adjust the pinion then the backlash Continue this sequence until the pattern is satisfactory Adjust Pinion Position lf the gear pattern shows incorrect tooth depth contact change drive pinion position by altering the shim pack Used gears should achieve proper contact with the same shims removed from the axle at disassembly INCORRECT PATTERN INCORRECT PATTERN Move pinion toward PFS Move pinion ring gear re F away from ring gear Pattern too close to tooth top land and off center Pattern too close or off tooth root If the pattern is too close to the top land of the gear tooth remove pinion shims If the pattern is too close to the root of the gear tooth add pinion shims Check ring gear backlash after each shim change and adjust if necessary to maintain the 0 006 to 0 016 Specifications Adjust Backlash If the gear pattern shows incorrect face width contact change backlash INCORRECT PATTERN INCORRECT PATTERN away from pinion Move ring gear to increase backlash toward pinion Move ring gear i a to decrease backlash Pattern too close to edge of tooth toe Pattern too far along tooth toward tooth heel With the pattern concentrated at the toe too far down the tooth add backlash by lo
68. osening the bearing adjuster on the teeth side of ring gear several notches Loosen the opposite adjuster one notch Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup Continue tightening the same adjuster 2 or 3 notches Recheck backlash lf the pattern is concentrated at the heel too far up the tooth remove backlash by loosening the bearing adjuster on the teeth Side of ring gear several notches Tighten the opposite adjuster one notch Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup Continue tightening the same adjuster 2 or 3 notches Recheck backlash 33 Fastener Tightening Specifications Fastener Tightening Specifications Specifications are for all axle models unless specified otherwise Forward Axle Differential Case CAP SCREW Size Grade EI ps Am Bearing Cap CAP SCREW Sire Grade EL Aha Nm 4 ae Ri Wa Bt Siiki Fr i ERR 115 150 EAR Output Shaft NUT Size Fl lpbs Nm d LHA 13 AS0 609 650 819 DAN M3601 5 575703 780 953 NOTE1 a wd e ee Used only on D340 380 P 4006 i ES l mc Ome 3 S w e wr EI va A wi er i Pa Di q d a 2 E HOT USED WITH Y METRIC THREADED MUIS i a 4 E E 4 i L c Ve e Ring Gear NUT BOLT Axle Housing Cover STUD NUT Sire Grade Fibs Nam Size Grade Ft lb
69. out sliding clutch 82 Input shaft 83 Input shaft bearing cone 84 Input shaft bearing cup 85 Input cover shim 86 Input bearing cover 8 Bearing cover capscrew 88 Input shaft oil seal 89 Input shaft nut washer 90 Input shaft nut 91 PDU carrier cover 92 Carrier cover capscrew 93 Lock washer 94 Pipe plug 95 Expansion plug 96 Magnetic filter screen 97 Pump gear amp shaft assembly 98 Cover O ring 99 Lube pump cover 100 Lock washer 101 Cover capscrew 102 Cover dowel pin 103 Pump drive gear 104 Drive gear locknut 105 Air operated lockout assembly 106 Shift fork amp push rod assembly Spicer Single Reduction Tandem Drive Axles Differential Carrier Assembly Rear Axle RS340 341 380 400 401 402 403 451 12 15 18 20 G i D SS E D Bel T ai E 2 4 3 6 28 25 26 23 30 36 ul Tm Gei IR INI D q OCC QOOEPee arg 1 29 S 32 1 Differential carrier amp bearing caps 12 Differential bearing cone 23 Pinion bearing cone 2 Bearing capscrew 13 Ring gear amp drive pinion 24 Pinion bearing spacer 3 Flat washer 14 Bolt and nut 29 Pinion bearing cage 4 Lockwire 15 Differential case flanged half 26 Pinion bearing cup 5 Bearing cap adjuster lock 16 Differential case capscrew 2 Pinion bearing spacer washer 6 Cotter pin 17 Differential side gear 28 Pinion bearing cage shim 7 Dowel b
70. perior 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 appear ance The family of Spicer TM gear lubricants represents a premium quality synthetic lube which fully meets or exceeds the requirements of MIL L 2105D These products available in both 75W 90 and 80 W 140 have demonstrated superior perfor mance 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 Spicer representative See back cover of this manual for appropriate phone number Makeup Lube Maximum amount of non synthetic makeup lube is 100 o Viscosity Ambient Temperature Recommendations The following chart lists the varies 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 Roadranger 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 tcontacting your local Spicer epresen tative 7oW 80 40 F to 80
71. pocket of the cover Secure with snap ring Lubricate and install the rear bearing sleeve on the output shaft Make certain it fits snugly against the shoulder at the forward edge of the shaft splines Install a new output shaft seal in the axle housing cover Note Check carrier date code on units built prior to 1988 Julian calendar date code could be found on the metal tag on the differential Units built before March 13 1987 87072 seal should be flush with bottom of chamfer Units built after March 13 1987 87072 seal should be installed until 3 32 deeper than bottom of chamfer Lubricate the seal diameter to prevent damage during yoke installation Slide the rear bearing retaining washer over the splines of the outer shaft until it seats flush against the output shaft bearing A IMPORTANT D341 381 P 401 P 402 P 403 P 451 P models do NOT use an output shaft Rear Bearing Retaining Washer Install output yoke flat washer and self locking nut Tighten to correct torque Install axle shafts and stud nuts if used also install lock washers and taper dowels Connect main and inter axle drivelines Fill axle with correct lubricant see Lubrication Section Connect differential lockout air line A IMPORTANT When axle has been disassembled or housing gears axle shafts or wheel equipment replaced check axle assembly for proper differential action before operating vehicle Wheels must rotate freely and ind
72. rkshop environment Go CH S E cD Y E CH SCH cD Wash castings or other rough parts in solvent or clean in hot solution tanks using mild alkali solutions If a hot solution tank is used make sure parts are heated thor oughly before rinsing Rinse thoroughly to remove all traces of the cleaning solution Dry parts immedi ately with clean rags Lightly oil parts if they are to be reused immediately Otherwise coat with oil and wrap in corrosion resistant paper Store parts in a clean dry place Inspection Inspect steel parts for notches visible steps or grooves created by wear Look for pitting or cracking along gear contact lines Scuffing deformation or discoloration are signs of excessive heat in the axle usually related to low lubricant levels or im proper lubrication practices Before reusing a gear set inspect teeth for signs of excessive wear Check tooth contact pattern for evidence of incorrect adjustment see Adjustment Section for correct pattern Inspect machined surfaces of cast or malleable parts They must be free of 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 fasteners for rounded heads bends cracks or damaged threads The axle housing should be examined for cracks or leaks Also look for loose studs or cross threaded holes Inspect machined surfaces for nicks and burrs
73. s sembly NEW GEARING Backlash should be between 0 006 and 0 016 86 Differential Carrier Overhaul Forward and Rear Axle Correct Pattern Used Gearing Pocket may be extended Pattern along the face width ue could be ec A Correct Pattern New Gearing Could vary in length Pattern should cover 1 2 tooth or more face width Pattern should be evenly centered between tooth Pinion Helical Gear Mounting Position NOTE See Torque Chart for Pinion Nut Variations POSITION LARGE CHAMFER TOWARD BEARING CONE 12 13 14 Torque Chart Check Ring Gear Tooth Contact Paint ring gear teeth and check tooth contact pattern Correct tooth patterns are illus trated below For checking and adjusting procedures see page 22 With ring gear and pinion adjusted correctly align adjusters and locks then tighten differential bearing cap screws to correct torque 360 440 ft Ibs 488 596 N m Install ad juster locks and cotter pins Lock wire differential bearing cap screws Forward Axle Helical Gear If dummy yoke was used remove nut and yoke Install helical gear on pinion positioned as shown in the illustration Install nut and tighten to correct torque see chart Forward Axle Pinion Nut D340 400 P 1 1 2 18 D341 401 P 451 P 1 5 8 18 D341 403 P M42 x 1 5 759 949 780 960 1057 1301 840 1020 1140 1383 380 P 560 700 381
74. s Nem A T H ar ere 244 298 PitG 20 Di Stud Ob ud 1 I CAPSCREW Differential Carrier STUD NUT Size Grade Ft ibs Hm Size Grade Ft ibs Hm Peli B 48 56 65 75 CB 3 220 240 8298 325 CAP SCREW Size Grade Ft lbs Hm 54 18 L I 2eU Ga PSaBaPS Rear Axle Diferential Case CAP SCREW Size Grade Fi lbs Nim Bearing Cage CAP SCREW a ga A 13 130 te bre Size Grace FA libs Hmi le ie TEME Bearing Cap CAP SCREW A Size Grade Ft Ibs N m a i 4 t WASHER NOT USED ON AXLES THAT USE METRIC NUTS 4 d D l A 4 i fe f gt a ka Y Geh i Ka a TE Gi pe v i Ny Se LK ay e Gre Pinion NUT Size Ft ibs Nm 1 1 2 18 560 700 759 949 M35 k15 575 703 780 953 INOTET Ring Gear NUT BOLT Differential Carrier STUD NUT Size Grade Fl ibs Hm Size Grade Ft Ibs Hm dt 150 7 4 zap 5 8 18 8 220 240 298 225 CAP SCREW Size Grade Ft IDs Hm 5 8 18 RI 270240 79832 34 Fastener Tightening Specifications Dana Single Reduction Tandem Models D340 380 P 400 P D341 381 P 401 P 402 P 403 P 451 P m inier agle Differential NUTS pours Power Divider Cover CAF SCREW Sree Grade E Abbe ar Gr Fafe Fi er N m a fifa et iig Ta O Mikr x SOCKET HEAD Puma Models oni LAR UC 1 3 95 Ref Chart PG 56 e Ra l l de Sei o r is Ce sn y KN a Y Hr ss S Let if imari be ie Magnetic Filler Screen Anie Series
75. s described below to re adjust Procedure Adjust Ring Gear Backlash To add backlash Loosen the adjuster on the teeth side of the ring gear several notches Loosen the opposite adjust er one notch Return to adjuster on teeth side of the ring gear and tighten adjuster until it contacts the bearing cup Continue tightening the same adjuster 2 or 3 notches Re check backlash To remove backlash Loosen the adjuster on the teeth side of the ring gear several notches Tighten the opposite ad juster one notch Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup Continue tightening the same adjuster 2 or 3 notches Re check backlash E ch DC Moving adjuster one notch is the movement of the lead edge of one adjuster lug to the lead edge of the next lug past a preselected point Lugs A 31 Adjustments Ring Gear and Pinion Tooth Contact Note Rear axle gearing is shown in the following instructions Correct tooth contact patterns and adjustments are the same for forward and rear axles Check Tooth Contact Pattern NEW GEAR Paint twelve ring gear teeth with marking compound and roll the gear to obtain a contact pattern The correct pattern is well cen tered on the ring gear tooth with lengthwise contact clear of the toe The length of the pattern in an unloaded condition is approx imately one half to two thirds of the ring gear tooth in most models and ratios
76. s spring steel and may pop off wear safety glasses when removing with snap ring removed the helical side gear may fall off shaft Exert care to prevent damage or injury slide helical side gear off input shaft then remove bronze thrust washer and D washer from shaft Axles with Lube Pump At this point in disassembly it is desirable to remove lube pump drive gear nut Hold input Shaft yoke to secure drive gear then loosen and remove drive gear nut Remove nut flat washer and yoke from input shaft Power Divider Overhaul Remove cap screws lock washers and input bearing cover and shim pack Slide input shaft assembly out of cover Remove bearing spacer from shaft used only on D340 380 P 400 P Remove Lockout Sliding Clutch and Shift Fork Starting with axles built early in 1991 the sliding clutch and helical Slide gear curvic teeth diameter was increased to provide greater tooth engagements For additional parts and ser vice information refer to Bulletin 91 01 To remove the larger diameter sliding clutch first remove the lockout See pages 40 42 Then remove the sliding clutch and shift fork with the two parts engaged Grasp the assembly by hand and maneuver the assembly past restrictions in the power divider cover To remove the smaller diameter sliding clutch used on earlier model axles the clutch can be disengaged and re moved without removal of the lockout and shift fork 48 G i D
77. se the pinion bearing spacer removed from the axle during disassembly If the original spacer cannot be used install the nominal spacer recommended in the adjacent chart Nominal Pinion Bearing Spacers Axle Model Spacer Thickness in mm D340 380 P 400 P 0 638 16 205 D341 381 P 401 P 402 P 403 P 0 492 12 497 451 P Rear Axle all models 0 638 16 205 Note Forward axle pinion is equipped with helical gear For easier disassembly during bearing adjustment procedure use a dummy yoke if available in place of helical gear 2 Apply clamp load to the pinion bearings Install the yoke or helical gear and torque the nut to specification or use a press to simulate nut torque by applying pressure to the assembly see chart below Vise Method If the yoke and nut are used mount the assembly in a vise clamping yoke firmly Press Method If a press is used position a sleeve or spacer so that load is applied directly to the back face of the outer bearing cone Measuring Bearing Preload with Pinion in Vise 3 Measure Pinion Bearing Preload Use a spring scale to test the assembly rolling torque To use the spring scale wrap soft wire around the bearing cage attach the scale and pull Preload is correct when torque required to rotate the pinion bearing cage is from 15 to 35 in lbs This specification is translated into spring scale readings in the chart below 29 Adjustments Measuring Bearing Preload w
78. sembled to the differential carrier See page 39 60 Power Divider Overhaul Measure and Adjust Input Shaft End Play Special Instructions Note After power divider overhaul and installation in power divider check and adjust input shaft end play Correct end play when new parts are used in overhaul is 0 003 to 0 007 with reused parts 0 013 to 0 017 Refer to page 15 for other variations A IMPORTANT September 1988 A Spring and a Thrust Button were added between the input and output shafts End play tolerances are the same for axles with or without this Spring and Button However end play measurement procedure is different than described below Refer to Service Bulletin Supplement at back of this manual for procedure variances Procedure 1 Remove input shaft nut flat washer and yoke Remove input bearing cover cap screws and lock washers Remove bear ing cover and shim pack if installed 2 Reinstall bearing cover without shims Hold in position with hand pressure and measure clearance between power divid er cover and bearing cover using a feeler gauge 3 The bearing cover clearance measured in Step 2 plus 0 005 will equal shim pack thickness required for desired end play rebuild with new parts Add 0 015 to shim pack for rebuild with used parts Install shim pack and bearing cover Install cap screws and lock washers Torque screws to 75 85 ft Ibs 101 115 N m 4 Install yoke flat washer
79. sher turn it over and reinstall If required loosen the inner nut just enough for alignment A IMPORTANT Never tighten the inner nut for alignment This can preload the bearing and cause premature failure 20 Adjustments 2 Install the outer nut on the spindle and tighten to 350 Ibs ft 475 N M 3 Verify end play see End Play Verification Procedure Procedure Four piece tang dowel type lock washer system see Fig 3 1 First install the Dowel type lock washer on the spindle Note If the dowel pin and washer are not aligned remove washer turn it over and reinstall If required loosen the inner nut just enough for alignment Never tighten the inner nut for alignment This can preload the bearing and cause premature failure 2 Install the Tang type lock washer on the spindle 3 Install the outer nut on the spindle and tighten to 250 Ibs ft 339 N M 4 Verify end play see End Play Verification Procedure 5 After verifying end play secure the outer nut by bending two opposing 180 apart tangs of the locking washer over the outer nut as shown in Figure 5 Figure 5 Bend two tangs over outer nut TH Spindle dy Inner nut KX Lockwasher Outer nut Procedure Install 1 Install a new gasket at axle shaft flange 2 Install axle shaft 3 Install axle flange nuts and tighten to specified torque 4 Lubricate axle wheel ends see Wheel End Lubrication Procedure Procedure End Play Verific
80. t Button between input shaft and output shaft For preliminary adjustment of input shaft end play install a 0 045 0 024 mm shim pack un der bearing cover see Service Bulletin Supplement page 54 Tighten bearing cover cap screws finger tight Install input yoke flat washer and nut Temporarily tighten nut snugly Axles with Lube Pump Install and tighten lube pump drive gear locknut holding input shaft to secure gear Torque nut to 35 45 ft Ibs 47 61 N m St Power Divider Overhaul 11 Slide D washer over input shaft up to base of sliding clutch Splines Note Make sure flat part of washer inside diameter engages Shaft properly Install bronze washer Install helical gear Secure with snap ring A WARNING Snap ring is spring steel and may pop off Wear safety glasses when installing 12 Install power divider cover assembly on differential carrier see page 38 G i D SS E D Bel T ai E ep 08 Power Divider Overhaul Install Power Divider on Differential Carrier with carrier removed from axle housing Special Instructions Note The following instructions pertain to installation of power divider on differential carrier with carrier removed from axle hous ing Note Before installing power divider install related parts as follows Procedure 1 Output Shaft Side Gear Bearing Cup If removed press bear ing cup in carrier Use a press and appropriate sleeve or us
81. tate Install ring gear Secure with bolts and nuts Torque nuts to 180 220 ft Ibs 244 298 N m 1 Differential Carrier Overhaul Forward and Rear Axle Assemble Drive Pinion Press fit outer pinion bearing Forward Axle Pinion Illustrated DRIVE BEARING BEARING BEARING BEARING eae ta one PINION CONE UP CAGE CUP INNER INNER OUTER r as St i lt ez oD r RS jr z BEARING BEARING CAGE S PILOT SPACER CAGE LOCK CAP HELICAL SELELOCKING gt BEARING VARIABLE SHIM WASHER SCREW GEAR NUT cD Rear Axle Pinion Iilustrated PINION BEARING BEARING BEARING BEARING Ee OIL SEAL INPUT PILOT CONE SPACER CAGE CAGE CU amp RETAINER YOKE BEARING INNER VARIABLE SHIM Oe y WASHER QO Gee BEARING KEN DRIVE CUP D ONE PINION PINION OUTER OUTER NUT CAGE CAP a NOT USED WITH LOCKWASHER SCREW re aie NUTS Special Instructions Dana drive axles may be equipped with either slip fit or press fit outer pinion bearings Procedures are contained in this section for assembly of both types Lubricate parts with gear lube during reassembly 78 Differential Carrier Overhaul Forward and Rear Axle Procedure Forward Axle Pinion Rear Axle Pinion i i 9 Press Bearing Cups bee eae Cie 1 Using appropriate Sleeve press bearing cups in cage see in Cage _ in Cage adjacent drawings Note On rear axles do not install oil sea
82. th DIN e 128736 or 129194 stamped into them Ref bulletin AXIB 93 06 output shaft w metric threads used in axles after 1 3 95 53 Power Divider Overhaul Assemble Power Divider Cover Power Divider Cover and Input Shaft without Lube Pump 4 Snap ring Capscrew Bearing cover Helical side gear Bearing cup Lockout unit See lockout service Thrust washer Shim instructions for design variations D washer Oil seal Lockout sliding clutch Yoke Input shaft Flat washer Power divider cover Shift fork and push rod Bushings Bearing cone Nut Lockwasher Capscrew 1 2 3 4 5 6 7 8 Power Divider Cover with Lube Pump Lock nut Power divider cover Pipe plug Woodruff key O ring Pump cover Capscrew Lockwasher Oo o N oO On A Ww N ch Dowel pin Pump gears ch ch Magnetic strainer NO Expansion plug oo Pump drive gear NOTE The drive shaft on early pump models is equipped with a woodruff key On late pump models the key is eliminated The drive shaft end has two machined flats and the drive gear mounting hole is shaped to accommodate these flats Note Axles with Lube Pump Assemble and install lube pump and magnetic screen See steps 1 to 4 54 ERW EITEL Power Divider Overhaul Procedure 1 see note on exploded view Install pump gears in power di vider cover position gear with long shaft in opening adja cent to input shaft Install O ri
83. the axle built by Spicer Identifies all component parts of the axle including special OEM requirements such as yokes or flanges 4 OEM part number assigned to the axle build 5 Carrier assembly serial number assigned by the manufacturing plant 6 Axle gear ratio 7 Carrier assembly production or service part number General Information Part Identification Axle Housing Axle Shaft 1 1D Tag 2 Axle shaft part number Axle Specification Number The complete axle is identified by the specification number stamped on the side of the axle housing This number identifies all component parts of the axle as built by Dana including special OEM requirements such as yoke or flange In addition some axles may include a metal identification tage General Information Ring Gear and Pinion Note Ring gear and drive pinion are matched parts and must be replaced in sets ke ont 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 General Information Power Flow and Torque Distribution Spicer tandem drive axles described in this publication are single reduction units designed primarily for highway or turnpike They are also for a variety of other applications This type of ax
84. this section for disassembly of both types IW Differential Carrier Overhaul Forward and Rear Axle Special Instructions A IMPORTANT During the following yoke removal procedure the drive pinion may fall out of bearings and cage Do not allow pinion to drop on hard surface Procedure 1 Rear Axle Pinion Yoke Remove yoke If pinion nut was not loosened during earlier disassembly clamp assembly in vise jaws use brass pads to prevent damage Loosen and remove pinion nut and flat washer Gel cD S E cD Y E cD SCH cD 2 Forward and Rear Axle Pinion Bearing Cage For pinion with press fit bearing cone support cage and press pinion out of bearing cage and bearing cone ber ll 3 For pinion with slip fit bearing cone the cage outer bearing and pinion can usually be disassembled easily without a press If difficulty is experienced use a press 4 Removing Bearing Cage Rear Axle illustrated 72 Differential Carrier Overhaul Forward and Rear Axle 5 Rear Axle Pinion Oil Seal and Outer Bearing Cone Remove oil seal and bearing cone from cage Discard oil seal Re move bearing cups with suitable puller 6 Remove and retain bearing spacer from pinion 7 Mount puller vertically to split the bearing 8 Mount puller horizontally to press pinion out of bearing 9 Remove pilot bearing and inner bearing cone from pinion using a split type puller Use two procedure steps
85. tly 6 Install axle shafts and stud nuts If used also install lock washers and taper dowels 7 Connect inter axle driveline 8 Fill axle with correct lube size 5 8 18 Grade 8 220 240 Ft Ibs 298 325 N m 44 Gel cD S E cD Y E cD SCH cD Power Divider Overhaul Remove Power Divider from Differential Carrier with carrier removed from axle housing Special Instructions Note It is assumed that the differential carrier and power divider assembly have been removed from axle housing prior to starting the following procedures Procedure 1 Mount differential carrier in repair stand Loosen input A CAUTION shaft nut During removal of power divider the Inter axle differ ential may fall off input shaft from differential carrier Exert caution to prevent damage or injury Power Divider Cover Dowel Pin Location Socket Head Capscrew Attach chain hoist to input yoke and lift power divider off carrier If power divider does not separate easily strike the cover near the dowel pin locations with a mallet see illus tration 2 Remove power divider cover cap screws and lock wash ers Note Lifting mechanism may create nicks or burrs on in put yoke Remove if present 45 4 Inter axle Differential Lift differential assembly off output Shaft side gear D Output Shaft Tilt carrier and remove the output shaft as sembly Cu 6 Output Shaft Sid
86. ts use a Service Parts Kit see illustration for contents For additional information refer to Dana Parts Books see back cover Reverse Air Lockout Shift fork Lockwasher Piston Compression and push rod O ring spring Capscrew 0 Piston Cover Capscrew T pao Push rod Body Lockout Felt Flat Nut Cover Lockwasher Seal ring O ring body oilers washer O ring Non serviceable parts Procedure Disassemble Lockout 1 Remove cap screws and lock washers fastening cover to body Remove cover O ring and compression spring 2 Remove push rod nut and flat washer 3 Remove body cap screws and lock washers Then remove body body O ring and piston as an assembly Remove seal ring from threaded end of push rod 67 Inter Axle Differential Lockout Overhaul Procedure Assemble and Install Lockout 1 With shift fork and sliding clutch installed in power divider cover assemble and install lockout as follows Install seal ring on shift fork push rod threaded end Install O ring in body Apply silicone gasket compound to lockout mounting sur face see illustration Install lockout body cap screws and lock washers Torque cap screws to 48 56 ft Ibs 65 76 N m Install felt oilers and O ring on piston Install piston assem bly in body and secure to push rod with flat washer and nut Torque nut to 20 26 ft Ibs 27 35 N m Note Before installation soak piston felt oilers
87. ue Chart woo cccesseccsssseeeseseseseees 107 Appendix Wheel Differential LOCK eeeeseeeeeeeseeeees 109 Differential Lock Theory of Operation 110 Control Systems 111 Dual Range Axle Shift Systems eeen 113 Troubleshooting 00 0 ccc cccceeeseessseeeesssesseeeneesessees 120 Proper Vehicle TOWING c ccccccssssscessseernssenesen 122 Axle Shift System Components s 124 Inter Axle Differential Lockout With Interlock Control Valve straight air type 126 Theory DEES 129 Power Flow and Torque Distribution ecce 130 Belger le 132 Torque Distribution in Low Range 136 el Les cD CO km A CA wel cD bes Gei Out of Vehicle Resetting Introduction Dana Corporation presents this publication to aid in maintenance and overhaul of Dana tandem drive axles Instructions con tained herein cover four basic axle models Their design is common with differences in load capacity Capacity variations are achieved by combining basic differential carrier assemblies in different axle housings axle shafts and wheel equipment Load Capacity Model No 34 000 be DS340 341 38 000 Ibs DS2380 P 38 000 be DS381 P 40 000 be DS400 P DS401 P DS402 P DS403 P 45 000 Ibs 06 DS451 P some models identified with letter P are equipped with a gear driven pump designed to provide additional lubrication to the inter axle differential and related parts Instructions conta
88. ushing 18 Side gear thrust washer 29 Bearing cage capscrew 8 Ring gear thrust screw 19 Side pinion 30 Oil seal 9 Thrust screw jam nut 20 Side pinion thrust washer 31 Input yoke 10 Differential bearing adjuster 21 Spider 32 Flat washer 11 Differential bearing cup 22 Pinion pilot bearing 33 Pinion nut 10 Lubrication Lubrication The ability of a drive axle to deliver quiet trouble free operation over a period of years is largely dependent upon the use of good quality gear lubricant in 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 Corporation Approved Lubricants General Gear lubrications acceptable under military specification MILSPEC MIL L 2105D Lubricating Oils Gear Multipur pose 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 I 0324A 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 Dana Drive Axles synthetic based Synthetic based gear lubricants exhibit su

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