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dana ps/pr7036,v1, manual,maintenance

1. A reading larger than 009 in is corrected by moving ring gear closer to pinion A reading smaller than 005 in is corrected by moving ring gear away from pinion Move the ring gear by tightening and loosening the adjusting nuts Both adjusting nuts must be moved the same amount A 1 4 turn in with one nut should be accompanied by a 1 4 turn out for the opposite nut 10 When backlash is adjusted properly rotatiig torque at the pinion shaft nut should be 5 10 ch Ib higher than the torque you had when setmg eion shaft bearing preload Tighten adjusting nuts until adjuS Wag nut locks can be installed 11 Torque the bearing cap bolts WOU Ibs Force the ring gear in the opposite direction until it contacts the pinion gear and observe the dial face This figure is your backlash setting Backlash should be 005 009 inch with no more variation around gear than 003 inch Ring Gear and Pinion ToettCofftact Pattern md CC TOP LAND LENGTHWISE CORRECT TOOTH A CONTACT ROOT Gear tooth nomenclature The toe of the gear tooth db theWfftion of the tooth surface at the end towaffis the ceN ar The heel of the gear ihe portion of the tooth surface at the OUI ent UL Pp ane ga gear too ghe surface of the top 2 The tooth contact patterns should have the same general shape and position as the ring gear teeth shown above RING GEAR OUT TOO FAR Move neg gear toward
2. tain 90 100 VES Een VERS ENN EV KER BER CES E GOR EU HER EX EA UN CR 85 ee E AE A NA E 80 90 EES 140 Min Note A dM RES RUE WEN ROS Uae Een ENDE e Var E ve pra RU 60 70 AMMESSI HM n E H tater R 80 100 Mc sss hb mem BAR 9 94 Padi Rs Ld Eni Hed exkl Qd HJ Bad aa 174 191 Wet Disc Brake W MSCIOWS ous cos nes ke EII DR OCA V DUAMEN VON PUES CIG ENS UN VOCE REN EUN GIA EV ES 45 EEN 90 100 A If cotter pi ed after minimum torque is attained the nut must be advanced until cotter pin can be installed D SPECIFICATIONS Pi lo New Bearings ORI sex mran ears was aces scans EEN CT RES KC ow eme 20 40 in Ibs to Rotate Required or Differential New Bearings Only rss avau ces ses s sp SS OEP KOS ROS Vs EVA CV Cx v2 5 10in Ibs higher than required for Pinion Bearing Preload Setting ing Pin Bearing Torque to Rotate Knuckle oes xs ses HEN m oes KE SEH CES Ee EN CNN wes es voa cus 8 15 ft Ibs surement is made less hub components axle shaft tie rod and steering cylinder BACKLASH SPECIFICATIONS IDE EEE A nuca ria vidt nee odis VC EE MODI E ER 005 009 in eo CRRA RARE EEE EE OME dd 4 4 x x nmm e mi itn a Y Bd Sa A A Wi NE er X471 La LA UA LA IA LA La La S w res and specifications vary depending upon the model type of service Applications approvals must be obtained way Products Division We reserve the right to change or modify our product specifications configuration
3. Sieger NR ring gear and differential into carrier housing so 3 Be sue bearing Set seated on bearing cones damage to ring gear pinion bearings or bearing and ag emble differential bearing caps Install bearing bores do not occur cap Polts ger tight only so adjusting nuts can still be Qed NOTE Wake ure the match marked bearing cap and leg ofie carrier are on the same side for correcgireassembly B d L ra FS S E 9 E H 2 Install adjusting nuts place read in adjusting nuts until all slack is raffiovedabetwWan bearing cups and bearings NOTE Adjustigff nuts Wust b installed with side of nut having he dapper Ass facing the bearing Installed gnpS itg the adjusting nut would clamp prp E against4ffe beaNag cage restricting movement 1 Dial Indicator 2 Adjusting Nut 3 Notch 4 Position a dial indicator on housing lip and index indicator dial to back face of the ring gear Zero the indicator Turn adjusting nut on the backside of the ring gear in until the indicator stops moving 5 Next tighten adjusting nut on tooth side of ring gear until bearing cup is seated Checking backlash 6 Position dial indicator on lip of differential housing and indicate to side of one tooth on ring gear 7 Move ring gear as far as it will go in one direction K before it moves the pinion 1 Bearing Cup 2 Adjusting Nut 8 0 the dial on the indicator face 49
4. Inspect and replace components as required NOTE Always replace gears as a complete set Do not mix new gears with old gears as this may cause uneven wear and short gear life C Limited Slip Differential 1 Large Section of Case 2 Dished Plate 3 Dished Disc 4 Flat Plate 5 Flat Disc 6 Clutch Ring 7 Side Gear 8 Pinion Gear 9 Cross Shaft 10 Small Section of Case 11 Bolt and Tapered Sleeve U ark both sections of differential case to ure proper reassembly Also mark end of the cross NOTE If any plates or discs are scored or worn nearest the differential case punch marks entire set must be replaced on both sides 2 Remove the small section of differential case side NOTE Clutch rings must be replaced in sets gear clutch ring plates and discs NOTE Side gears or pinion gears showing wear 3 Remove pinion gears cross shafts side gear must be replaced in sets clutch ring plates and discs from large section of NOTE If cross shaft shows signs of wear replace differential case in sets NOTE The differential has a serial number NOTE If wear is evident at V notch for the cross stamped on the small case section When ordering shaft on either small or large case section replace parts always include the complete part number as a set Pinion Disassembly NOTE If carrier has optional pinion mounted parking brake refer to pinion parking brake section of manual for removal of b
5. K AAAAAAAAAAAAAAAAAAAA Wheel End 3 65 Reduction 1 Snap Ring 2 Sun Spur Gear 3 Flat Spacer 4 Planetary Ring Gear 5 Roll Pin 6 Lock Nut 7 Bearing Cone Outer 8 Bearing Cup Outer 9 Wheel Mounting Nut 10 Planetary Hub 11 Wheel Mounting Bolt 12 Bearing Cup Inner 13 Hub Slinger For Axles Without Wheel End Brakes Only 14 Bearing Cone Inner 15 Oil Seal Hub 16 Spindle 17 Bushing Outer Shaft 18 Oil Seal Outer Shaft ar 3333333333333332332332323 A 3533533333331 5353553333333 10 Tube Brake Bleeding 11 O Ring 12 Shim Adjusting 010 011 012 013 014 015 020 030 Thick 13 O Ring 14 Planetary Ring Gear 15 Bearing Cone Outer Wet Disc Brake Wheel End 3 65 Reduction 16 Bearing Cup Outer 17 Planetary Hub 18 Wheel Mounting Nut 19 Wheel Mounting Bolt 20 Bearing Cup Inner 21 Bearing Cone Inner 22 Oil Seal Hub 23 Deflector Hub Oil Seal 24 Fitting Brake Inlet 25 Spindle 26 Guard Fitting Bleeder 27 Seat insert 28 Bleeder 29 Bushing Outer Shaft 30 Oil Seal Outer Shaft Tie Rod amp Steering Cylinder Mounting f Ce A d X X Sage Y i sc V V FOR STEER CYLINDE N SEE STEER CYLI ION OF MANUAL S A 1 Tie Rod Assembly Items 2 thru 5 2 Tie Rod y Items 7 and 8 y y y 6 Steer Cylinder Vertical Socke
6. e 5553 Assembly of Steering Knuckles 1 Install inner axle shaft bushing and seal into housing yoke bore 2 Apply 2 Permatex to grease retainers Install grease retainers and king pin bearing cups into housing yoke NOTE The grease retainer must be installed with its dished portion positioned toward the inside of the axle housing yoke Installed opposite the retainer would restrict the bearing cup from seating properly in the housing bore and clamp against the bearing cone cage restricting movement 6 Place original Wims in B sitiSQ on knuckle or king pin cap dis 7 Install bearing caps washers and bolts Torque to 3 Install pregreased king pin bing Ehnes Ms 80 90 ft Ibs bearing cups 4 Install king pin seals NOTE Inspect the sp idle mountig studs in steer knuckle for damage ad lace if Necessary 8 To check king pin bearing preload turn knuckle all the way to the right Place torque wrench on one of the king pin cap bolts Rotate knuckle through complete turn angle Torque reading should be 8 15 ft Ibs Measurement is made less hub components axle shaft tie rod and steering cylinder To increase preload remove shims from top or bottom ET E king pin bearing To decrease preload add shims to i E top or bottom king pin bearing Keep top and bottom 5 Place knuckle in position over housing yoke shim packs as equal as possible 23 Installation of Tie Rod and Stee
7. 1 Insert yoke shaft 6 into brake mod bearing and internal hex of spline ring 2 Attach snap ring 3 in groove on tain spline ring 3 Install cover plate 1 on carrier pini Apply sealant between flange and cover plate surfaces 4 Attach cover plate 1 to axl UNF hex bolts grade 5 and torque evenly to 90 100 ft Ibs 5 Install brake module 4 a sembly into cover 1 engaging internal yoke shaft spline with pinion spline Orient bra at mounting bolt holes are in alignment and brake module seats properly on cover flang e pressure and bleeder ports are facing up Insert four 1 2 13 ad cap screws 5 thru brake module 4 and into cover plate 1 Torque screws e evenly to 85 ft e 54 E J 3535333535555555 55 15555555335525232353532323 55953 ASSEMBLY Parking Brake Disassembly Assembly enn 4 f Y LI e Y Qe 11 14 3 DISASSEMBLY 1 Remove case gasket 3 from cover 1 2 Press out oil seal 2 from cover 1 if replacement required 3 Remove outer spline 4 from brake module 4 Remove four socket head shoulder bolts 5 A suitable holding fixture is useful to hold brake in position CAUTION Do not remove shoulder bolts without pressurization of brake approx 300 psi or dama may result 5 Remove primary disc 7 seven rotor discs se stator discs 9 NOTE Primary disc 7 is offset from oth 9 Reinstall new plates in same seq iscs 390
8. 3 Wrong lubricant or lubricant with depleted additives Worn pinion bearings which result pinion end play and incorrect pinion tooth contact EY icle overloading ehicle accident Shock loading Insufficient lubrication Contaminated lubricant Very severe service Normal wear Prolonged operation at excessive oil temperatures Scored or dented yoke wear surface Improperly installed oil seal Nicked or cut seal lip Contaminated lubricant Inspection and Failure Analysis This section is intended to serve as a guide for describing and explaining commonly encountered axle problems or failures and for recommending appropriate repair procedures RECOMMENDED REPAIR Replace ring gear and pinion as ma hed set Carefully follow the recommende procedures for adjusting ring gear and pinion backlash and todWpattern Replace ring gear anG ainic as pt ched set Carefully follow ae nded procedurg asing ring gear and pinion poth aattern Replac and pinion as a matche set Re iace pinion bearings taking ca set ring and pinion position and bearing preloads properly e correct lubricant fill to proper level ange at recommended intervals Replace ring and pinion as a matched set Use correct lubricant fill to specified level and change at recommended intervals Replace ring gear and pinion as a matched set Use correct lub
9. EXTREME CARE SHOULD BE EXERCISED WHEN WORKI SNAP RINGS OR SPRING LOADED RETENTION DEVICES FOR PERSQ AF ETY IT IS RECOMMENDED THAT INDUSTRIAL STRENGTH SAFETY GOGGLES OR GLASSES BE Wag IS BEING DONE ON ANY VEHICLE OR VEHICLE COMPON It is impossible to know evaluate and advise the service tra nceivable ways in which service might be done or of the possible hazardous consequences of each way i j or tool which is not recommended must first satisfy hi be jeopardized by the service methods he selects materials containing asbestos fibers BREATHING ASBESTOS DUST MAY DOUS TO YOUR HEALTH AND MAY CAUSE SERIOUS RESPIRATORY OR OTHER BODI Follow O S H A standards for pr tectiye devices to be used when working with asbestos materials SILICONE RTV AND LUBRICATING GREASE AND OILS Silicone rubber sealant aSKet material on some Dana axles as well as various lubricants and other materials Before u se materials one should become familiar with and follow all safety precautions as rec y the product manufacturer supplier All personnel involved with these materials shoul ustrial hygiene practices e g before eating hand and face should be thoroughly wash inking and smoking should be prohibited in areas where there is potential for significapft se materials When dis irding e materials observe all local state and federal laws and regulations for proper disposal p t e if you assemble components improp
10. 2 980 is required to press bearing from bore store the bearing should be removed only if ament is required LUBRICATE ALL RUBBER COMPONENTS FROM REPAIR KIT WITH CLEAN TYPE FLUID USED IN THE SYSTEM 1 Clean all parts thoroughly before assembling 2 If removed press new bearing 19 in pressure plate bore 18 Insert snap ring 20 3 Press seal 21 into pressure plate 18 until flush with end of pressure plate 14 15 16 17 18 19 NOTE Earlier brakes do not have additional dow pins 10 installed The plate stack 7 8 amp 9 is retai only by shoulder bolts 5 1 Cover Plate 2 Oil Seal 3 Case Seal 2 4 Outer Spline 5 Shoulder 6 Cap Scr 7 Primary 8 LP b M _ 18 Pressure Plate 19 Bearing 20 Retaining Ring 21 Oil Seal s 14 amp 16 on piston 13 toward 5 amp 17 on piston 13 Be sure o rings ists removed CAUTIOIS Care must be taken so as not to scratch or r pis on Lubricate pressure plate piston bore 18 with type fluid ed in system Carefully press piston 13 into pressure ate 18 Be sure piston is oriented such that threaded holes in piston are in alignment with thru holes in spring plate 11 when installed Press piston until it bottoms on pressure plate 18 7 Install twelve springs 12 in piston 13 8 Install case gasket 3 on spring plate 11 9 Install spring plate 11 on pressure plate 18 Compress springs 12 until
11. NOTE When making changes note that two variables are involved Example If you have the backlash set correctly to specifications and you change the pinion position shim you may have to readjust the backlash to the correct specification before checking the pattern Refer to patterns as shown PATTERN MOVEMENTS SUMMARIZED 1 Decreasing backlash moves the ring gear closer to the pinion Drive pattern convex side of gear moves slightly lower and toward the toe Coast pattern concave side of gear moves lower and toward the toe 2 Increasing backlash moves the ring gear away from the pinion Drive pattern moves slightly higher and toward the heel Coast pattern moves higher and towards the heel 3 Thicker pinion position shim with the backlash constant moves the pinion closer to the ring gear Drive pattern moves deeper on the tooth flank contact and slightly toward the toe Coast pattern moves deeper on the tooth and toward the heel 51 b F E wel e EA E EN E 5 A ES EN E E E E EN EN m A E E SS e SS E SS A e E gt e ei SS ech e SS wi e 4 Thinner pinion position shim with the backlash constant moves the pinion further from the ring gear Drive pattern moves toward the top of the tooth face contact and toward the heel Coast pattern moves toward the top of the tooth and slightly toward the toe 7 After the proper pinion position is determined tem
12. it is very important that the fastener be replaced with one of equal or higher grade and quality Fasteners should be torqued as recommended or specified for the application WARNING If fasteners of a lower grade or class are torqued to the requirements of a higher grade or class fastener it may result in component failure e g Grade 5 fastener torqued to the requirements of a grade 8 fastener GRADE 5 GRADE 7 PECIAL GRADE High Strength Customary Inch Bolts Identification marks correspond to bolt strength Inca Applications represent increasing strength e fastener and will astener will display 6 radial Inch grade fasteners can be identified by the radial lines embossed upon tht correspond to the fastener strength by two lines less than actual e i e gre lines on the head NOTE Male and female threads should be dry and unlub and free from scale and dirt WRENCH TIGHTENING TORQUE SPECIFICATIONS less purchased new as such clean POSITION WRENCH TORQUE FT LBS Drive Pinion NUT aes d Ven Es QNI Saa NES E ss us dis eia gas n3 Uu we wu SSG DX i 240 300 Differential Bearing Cap Capscrews en ARES ees ouo ors ecramsas vas S cms gx re ees 180 200 Ring Gear Capscrews ces eanas 120 140 Limited Slip Differential Capscrews 49 WW M eee s Ke nnn eee ee HH MIHI 95 110 Carrier Assembly Mounting Capscrewsf M A 100 115
13. pinion decrease backiash a Za 1 Paint ring gear teeth with marking compound and 3 If the pattern is concentrated more toward the heel rotate with pinion to obtain contact pattern as shown above backlash must be reduced p Am 1 Recheck backlash as described in differential installation section of manual To reduce backlash loosen the right side adjusting ring until the measured backlash is within specification The tooth contact pattern should now have the same general shape and location as shown in step 2 If the contact pattern still does not conform less backlash than normal is required To avoid reducing differential bearing preload excessively further loosening of the right hand adjusting ring should be accompanied by equal tightening of the left hand adjusting ring Place a dial indicator directly on each adjusting ring to measure the exact amount of additional adjustment Decreasing backlash moves the ring gear toward the pinion RING GEAR IN TOO FAR Move ring gear away from prion increase backlash 4 If the pattern is concentrated at the toe as shown above more backlash is required Recheck Da To increase backlash tighten the right side adus ring further until the measured backlash ig ithin specification The tooth contact pattern Mould gw spread across the ring gear tooth as in staf the contact pattern still does not Confort eere Backin than normal is required To av
14. prevent damage to the pistons NOTE If the piston becomes seized or cocked release the air pressure and realign the piston tapping with a soft faced hammer Reapply air pressure to remove the piston 4 Remove boot from piston and seal from caliper bore Discard boot and seal CLEAN AND INSPECT CALIPER COMPONENTS 1 Remove any rust or corrosion from the external machined surfaces of the caliper housing DO NOT use any abrasive material in the piston bores 2 Remove any rust or corrosion from the machined surfaces on the caliper mounting bracket 3 Clean the caliper housing and piston bores using denatured alcohol Use dry compressed air to clean and dry all grooves and passages NOTE Make sure all alcohol is completely removed before reassembly 4 Inspect the piston bore boot groove seal groove and piston for damage for excessive wear Replace piston if it is pitted scored or worn Remove any corrosion that may be present in the piston bores and grooves with a fiber brush 5 Inspect caliper support spring and key Replace if necessary CALIPER REASSEMBLY 1 Lubricate piston seal and piston bore with brake fluid Refer to BRAKE FLUID SECTION and install seal in groove in piston bore Be sure seal is fully seated and not twisted 2 Coat outside of piston and dust boot lips with brake fluid Slide dust boot over the piston and position it at bottom closed end of piston 3 Position piston and boot over pi
15. spanner wrench in drilled holes in gland and carefully clean all cavities and grooves prior to rotate 360 in proper direction to remove lockwire replacing parts d 8 EN E EN E EN A E EN am m E EN ES E A E A A A ki 333333333333333323232 ASSEMBLY 1 Install all seals Do not over stretch seals to facilitate easier installation 2 Make sure all seals are not twisted or distorted in grooves Q 0 3 Install gland on rod with inner seal facing exposed section of rod 08 4 Install piston on rod turn down NOTE Two 2 jam nuts can be use end of shaft to hold while torquin 6 Lubricate all parts and inside of cylinder with hydraulic oil 7 Push the piston into the cylinder bore with a steady even pressure 8 Push gland bore until shoulder of gland bufs up to the barrel ough milled slot in the en rotate the gland 360 wemblies on the steering Install the socket clamp bolt and nut finger Il be made when steering cylinder re installed on the axle assembly Disassembly and Assembly of Wheel End Disc Brake 2 If petroleum based mineral oil is used the brake must have green colored seals and dust Petroleum based mineral oil must meet Mil Mil H 5606 requirements SERVICE PRECAUTIONS MAINTENANCE GENERAL It is difficult to determine an exact maintenance interval time and mileage since vehicles w
16. Maintenance Manual Loo E atei 2d n 70 26 9499499499409499 e P f SPICER OFF HIGHWAY COMPONENTS di sss dd III A KKK EKKKKKEKEKEKE MAINTENANCE MANUAL Models PS PR 7036 CONTENTS SECTION 1 General Information important Safety NOCD sss a 159 sass screws saree aN WARRANT A78 ER e KEIER CAUSA NRI SA Urat aae ra SHIGE PIOCBUDOIIS iuo soie AA He tis os ase UAINS E EE T Puedo NOB uen c il ci Mo SEE GOT Ser den GS BOD unes casio ween pana vocatis v RC CR 09 eE 7 OE Ea Rea neon en a caia te p a re d Servicing Components not Covered in this Manual Vehicle Storage or Prolonged Inoperation eee et PPP Submersion or Deep Water FOG ie ge vEKEER nm oai EE 5506 6a E 9 ah ee RENE va jode Lubricant Change EEN General Precautions for Assembly and Disassembly eee SECTION 2 Planetary Wheel End Wheel End Brakes Axle Shaft Steering Knuckle Steering Cylinder and Tie Rod Illustrations 3 850 DIVE FIBHOB aage x vasa uev ey a queo adu y PEW EE IRR Va Wheel End 3 0650 HOGUCION E Ra ER para riter yr Wet Disc Brake Wheel End 3 650 Reduction Tie Rod and Steering Cylinder Mounting e x ven rode Or qa 125 GE SR ENS PR ERE UY pA aa Anon tna Lie IONS a ai Bee a Kee gx Removal of Planetary Drive Flange Assembly Disassembly of 3 650 Drive Flange ss s s x s
17. RONE Nn da E ton dim e ERR d 55 z See EE E E E p oro mamma eur iet odii aac aes 56 OOO and Fallure REAP EDs S DO a ds o a i ai 09 EN EH Cs SURI rad 57 SH SECTION 4 Specifications Spicer Axio Lubricant Recommondaliors ass zt A en enu ERSTEN va t deen VERT G A TRE lc dead 59 e Fastener Strength Meet uus oss qv VEFESENES A MIEENFE REES LASER RC ER ESCHER CE NR VU UR MIU IIR e 60 Wendt nahen ee ea R V S Omer rtr lk ii a in t es 60 e Bey Preload Spee e E re fares asocia ran to 98 HIVER Te M CTT K Rech AC KR ERN 761 0 KREIEN EEN EN H A CS dk E 60 ei Dee Pinion Ring Gear Backlash Da Sea cx es SE RS rr tera I RI NUI RR EIN ER EK ENEE EIN RS I d n 475 AR EX wi e d 60 ei Si e d a SECTION 1 GENERAL INFORMATION IMPORTANT SAFETY NOTICE Should an axle assembly require component parts replacement it is recommended that Original Equipm replacement parts be used They may be obtained through your local service dealer or ot i manufacturer parts supplier CAUTION THE USE OF NON ORIGINAL EQUIPMENT ME ARTS IS NOT RECOMMENDED AS THEIR USE MAY CAUSE UNIT FAILURE AND OR AFFEC Proper service and repair is important to the safe reliable operation of all motor v they be front or rear The service procedures recommended and described in this methods for performing service operations Some of these service operationgssili use of tools specially designed for the purpose The special tool should be used when and as rg i CAUTION
18. Thrust 34 Case Differential Standard 8 Outer Bearing Cone 35 Capscrew Drive Gear Mounting 9 Outer Bearing Cup 36 Capscrew Brake Mounting Optional 10 Shim Pinion Bearing Preload Adjusting 37 Parking Brake Optional 11 Spacer Flat 38 Flange Half Limited Slip Differential Case 12 Capscrew Carrier Mounting 39 Cap Half Limited Slip Differential Ca 13 Washer Flat 40 Shaft Differential 14 Carrier 41 Pinion Differential 15 Cap Differential Carrier 42 Side Gear Differential 16 Washer Flat 43 Ring Differential Side Gear 17 Capscrew Bearing Cap Mounting 44 Plate Differential 18 Lock Bearing Adjusting Nut 45 Disc Differential 19 Washer Flat 20 Capscrew Lock Mounting 21 Shim Pinion Position 003 005 010 Thick 22 Inner Bearing Cup 23 Inner Bearing Cone 24 Gear and Pinion Matched Set 25 Side Bearing Cone 51 Pi 26 Side Bearing Cup 52 Pug Pipe Drain and Fill Level 27 Adjusting Nut Differential Side Bearings 53 Meshina Axle Pivot Hinges Grease Removal of Carrier Tram Axe Housing 4 Disconnect hydraulic lines to and remove steering NOTE Use of safety glasses during disas cylinder assemblies from the steer knuckle and carrier assembly procedures is recommende 1 If it becomes necessary to disasse anchor points inside the carrier it is suggested that 5 Remove the tie rod assembly from the steer knuckle removed from the vehicle and helc anchor points rack NOTE Do not al
19. ar 7 Tighten case section bolts to 95 100 ft Ibs 4 Assemble pinion gears on cross shafts Assemble NOTE Match case halves together by punch cross shafts together marks 45 5333533333333333333333333333333333333333323 UJ C Ring Gear and or Differential Side Bearing Cones U X I 1 Place case in a vise L Be sure flange face of the case is free of nicks or burrs Assemble ring gear to case Line up holes of the ring gear with those of the case Use new ring gear screws Draw up screws alternately and evenly Torque ring gear screws to 120 140 ft Ibs Pinion Position and A Pinion Position RING GEAR amp PINION TOOTH PATT installer to seat be een oe as shown 2 Place bearing D of case Use bearing Bes ey are fully seated OSE Be ff re bearing cone and case bearing jour 2 cleaf prior to assembly e e e r r e e e ez e e e ez eZ e EP e US A ATION manuals required a final pinion position check by using ine of the differential carrier center line of ring gear to the face of the pinion button This surface button is not us establish the proper am verified by using the gears for verifying the pinion position The service tools will be used to nis required prior to installing the pinion gear The final pinion position will be PATTERN METHOD as described in this manual The distance from the centerline o
20. as part of the shim pack To change the pinion adjustment shims are available in thicknesses of 003 005 and 010 NOTE If baffle or slinger is bent or mutilated it should be replaced Measure each shim separately with a micrometer and add together to get total shim pack thickness from original build up o amp E 2 3 gt sl a S 1 Measure each shim separately with a micrometer and add together to get total shim pack thickness If baffle is required it is to be included in the shim pack If slinger is used between the inner bearing cone and thrust face of pinion the slinger is also to be measured and included as a part of the total shim pack Pinion Marking If a new gear set is being used notice the or etching on both the old and new pinion and adjust the thickness of the new shim pack to compensate for the difference of these two figures For example If the old pinion reads 2 and the new pinion is 2 add 004 shims to the original shim pack The above procedures also apply to pinion a on the front axle which includes the oil slinger the inner bearing cone and pinion and the inner bearing and carrier e this chart as a guideline to set pinion Pinion setting chagSho S B Pinion Assem Ge WW e bi PO w 8 p S b E be ME AN 2 Place the required amount of shims and baffle if used in the inner bearing bor
21. at seal is to be discarded because of possible damage G A inspect the spindle mounting studs in steer knuckle or axle housing rigid axle for damage and replace if necessary EZ e I K a A a E E E E m A rA WU X s E 1A Remove spindle mounting nuts and flat washers m On planetary equipped with disc brake the caliper tion outer ES mounting bracket can be removed when the spindle shaft Seal and bronze bushing in the spindle bore mounting nuts are removed Theg shod be replaced if necessary E D a a ie f G 1B On planetary eau wes disc brake wheel ends remove brai inlet Tagg a bleeder screw Remove spindiffftmoup ing me washers and if used the fitting bleed jagards 6 nibo PL vi 4 To remove axle shaft assembly on the steering axle hold shaft level and pull straight out to avoid damaging inner shaft oil seal NOTE To remove axle shaft on rigid axles pull shaft straight out 39335323533333333221 2 Tap spindle with soft faced hammer to loosen from steering knuckle or housing flange Remove spindle L 19 3 393 ni 5 Cad 5 To separate inner and outer axle shafts on steering axle first remove all bearing cap retaining rings Removal of Steering Cylind r and Tie Rod Assemblies 1 Disconnect the hydraulic hoses to the steering cylinders Plug the open fittings kai EAM Ser th cotter pins fro
22. at the point the inner axle shaft en h the hypoid lubricant as described above The following sched frequent changes Oe dealer or refer t nvironment in which it is operated Contact your local authorized service ual for obtaining the proper lubricant change schedule for your vehicle BREAK IN AFTER OVERHAUL operation the lubricant should be When refilling the axle assembly or planetary hub d with fresh lubricant to the assembly after it has been disassembled for service e type specified the lubricant should be filled to the bottom of the fill hole located in the bowl of the axle housing or the planetary drive flange After 24 hours of operation n nded that the lubricant be changed at recheck the lubricant level and bring it up to the S gt of operation When yearly usage is less bottom of the fill hole again if necessary This ban 4000 hours the lubricant should be changed procedure is recommended to replenish the small e yearly amount of lubricant that is retained in the differential support case or planetary gearing during initial operation of the axle immediately following an overhaul gt NP w r S P 1 333333333333333333333 4 General Precautions for Assembly and Disassembly IMPORTANT READ THIS SECTION BEFORE STARTING THE DETAILED ASSEMBLY OR DISASSEMBLY PROCEDURES USE ONLY GENUINE REPLACEMENT PARTS FOR SATISFACTORY SERVICE NOTE The photos or pictures c
23. cimced until the cotter pin can be installed ng 3 Connect the steering cylinder assemblies to the carrier and steer knuckle anchor points Torque the socket assembly slotted nuts to 140 ft Ibs minimum NOTE If repairs were made to or the retracted length of the steering cylinder assembly was inadvertently changed the retracted length of the assembly will require resetting as follows A Remove slotted nuts from and remove rod end socket assemblies from steer knuckles Push in or use air pressure retract the rod into the barrel assembly of both cylinders m EI e A A A 2 E Ee e A A A A c ch A A rA T f SEAAAAAAAAAAAAAAA KX 1 SY on the rod end and also barrell end if required B Turn steering knuckle to full inside turn position on either the right or left hand side C Adjust the socket assembly position in or out such that its retracted length matches the length required for assembly to its steer knuckle CAUTION Protect the rod from damage while adjusting socket position Reconnect the cylinder assembly as noted in step 3 Torque the cylinder socket clamp bolts and nuts to 60 70 ft Ibs D Turn the other steer knuckle to its full inside turn position Adjust its steer cylinder retracted length as noted in step C 4 Install cotter pingf nd D n anin over to lock it in place NOTE If cotter p Cannot e installed after minimum torque isQitaig d the
24. csto and install outer and inner Lobos piston O rings VATER 10 Install brake piston NOTE Use of a special piston refhover TWStaller tool Dana tool 451164 S re 9T prevent damage to th pistor ded to 11 Install sun gear onto outer de shaft l em e 12 Install snap ri ring int xoove ort Outboard end of outer shaft 13 Push inward on end of axle shaft to seat sun gear against wheel retainer This will prevent rotating disc from Cropping behind my installation LE 14 Install brake plates and discs into wheel end du each Start with a steel stationary plate first then a grooved friction disc shown second Alternate until 4 of each are in place NOTE If new discs are installed presoak in the correct lubricant as recommended by the vehicle manufacturer for a minimum of 15 minutes prior to assembly 4 4 ER A C AAAAAAAAAAAAAAAA AAA AAA 3533532333323232333323323232 P e Assembly of 3 650 Drive Flange 1 Install thrust button and vent into drive flange AAA RAARO AAA OPES KRE ot EES ei e D H 3 f v SCH j j Sex g Z2 cere e t x M E we E 1 x T K f tU K B 1 E E r en e E WA K d f 7 v T 1 P Ave io pah L d am 3 a D D lt ru 2 a t wat d Ton H a 2 Grease inside of planet gear Install two rows of needle bearings 25 per row se
25. d replace if worn pitted or damaged When replacing bearings use a suitable puller or pressing fixture to remove them Avoid using drifts and hammers which may mutilate or distort component parts Inspect planetary and carrier components for wear or damage Replace if the following conditions are found e Worn chipped pitted or scored gears e Worn pitted or scored thrust washers Worn or scored planet gear or differential pinion gear shafts s Axle shafts or worn splines bends cracks or for torsional fractures or other indications of impending failure BOLTS Make sure all bolts are torqued tohe recommended specifications LUBRICATION Coat bearings sea with lubricant to provide initial lubrication an damage during assembly forces to both races of the b If another type of driver is use meer Off Highway Axle erves the right to make changes from 33 54 SECTION 2 Planetary Wheel End Wheel End Brakes Axle Shaft Steering Knuckle Steering Cylinder Tie Rod 3 650 Drive Flange KAAAAAAAAAAAAAAAA A iy 1 Capscrew Self Locking Flange Mounting 2 Pipe Plug or Vent 3 Recessed Drive Pipe Plug Magnetic 4 Planetary Drive Flange 5 Planetary Gear Shaft 6 Roll Pin 7 Drive Flange Washer Thrust Washer 8 Flat Spacer Thrust Washer 9 Needle Roller Bearing 10 Spacer dee di 11 Planetary Spur Gea 12 Plate Lining Stop Wheel End Wet Disc Brake Use Only
26. e cA A rA cA E a 13 555 935355353535533353332323929 Be gt Z T S y Kg asi 1 Using a hammer and punch drive roll pins out of planet gear shafts Remove lining stop plate for wheel end wet disc brake if used So Ex eer rot Sage Kan pu y d Gene Dry baffinto groove in planet gear shaft and remove Geasenaft i VS q Lat d s d 4 The planet gears are supported on the planet shafts by two rows of needle bearings divided by a spacer ring and a thrust washer on each end 5 Inspect the thrust button located in the center of the drive flange If worn replace WARNING Keep the groove under the thrust button open It is the access to the air vent if used 3333333133233 13333332323 3999933333333339 C L vU Disassembly of Wheel End Hub NOTE the following procedure is the same for both rigid and steer axles ETE CCS S V mp A E oo 1 Insert small screwdriver under end and remove locking ring from end of axle shaft by rotating around shaft 3 Remove ring gear Use a suitable puller if necessary NOTE DO NOT pilot puller on axle shaft This may damage the inboard axle seal L soc uere KE i TEAN Km ed 4 Remove the wheel bearing adjuStag nw ising a three pin spanner wrenc 4861125 NOTE If axle is equianed Wh wheel and disc brakes remove thf calip aSqambly at this time as outlined in th di
27. e drive the inner bearing cup into carrier with tools as shown 47 3 Assemble the outer pinion bearing cup into carrier as shown aring installer over pinion shaft as ing on shaft until it is completely 5 Install pinio into carrie Assemble outeRainion baring cone slinger if used yoke ontO T9 mon spline er as shown to assemble end yoke pinion P El ANT 6 Assemble washer and pinion nut Torque nut until it requires 10 Ibs inch to rotate pinion Rotate pinion several times before checking pinion position This is to seat the bearings and assure a more accurate indication of the pinion position NOTE The reason for not assembling preload shims and new pinion oil seal at this time is due to the possibility of having to adjust pinion preload or pinion adjustment It would be necessary to again remove the seal and as mentioned whenever seals are removed they are to be discarded because of possible damage 7 Install the differential assembly into the carrier Refer to the ring gear pinion tooth contact pattern and differential installation sections of manual to properly set the pinion position and backlash 55533333333333335 L 1533232 DW E f 353323355359 555995 923529 Differential Installation 1 Install ring gear and differential assembly into carrier housing CAUTION Care should be used when installing och ata
28. el and change at recommended intervals Replace the shaft Replace the shaft Check housing distortion Make certain that wheel bearings are not worn or misadjusted 1 Adjust Replace Replace Adjust Adjust Replace Adjust Replace Replenish 10 Replace 11 Replace OONAAAWN 1 Adjust or replace See above 2 Adjsut E AK EEE EET TTX XARXA LLL LLL LL LLL LLL KL LL lt FAILURE MODE PROBABLE CAUSE RECOMMENDED REPAIR Intermittent 1 Warped ring gear 1 Replace Noise 2 Loose differential case bolts 2 Tighten Contant Noise Flat spot on pinion or ring gear teeth 1 Replace Flat spot on bearings LOM Worn pinion splines 2 Replace Bent axle shaft 3 Replace 4 Replace Noisy on Turns 1 Worn differential side gears and 1 Replace pinions 2 Worn differential spider 2 Replace 3 Worn differential thrust washers 3 Replace 4 Worn axle shaft splines 4 Replace SECTION 4 Specifications Spicer Axle Lubricant Reco IMPORTANT Motor vehicles are operated under variougrequire manual specifies the minimum requirements that tbe lu amp icants sould meet However it is recommended that the lubricants specified by the vehicle manufa They may provide additional lubricating characteristics which may be required for your vehicle operation Contact your local service dealer or refer to your owner s manual for obtaining pr f ie29 spec
29. er operation in system pressurizing side inlet port and allowing air to escape from top port Pressure should not exceed 100 psi during bleeding SERVICE DIAGNOSIS PROBLEM CAUSE EXPLANATION ACTION Sum filtersgmose size Brake slips A Excessive pressure If there is back pressure in the brakes US fi i in hydraulic system actuation line the holding torque of A De other brakes is reduced avulli components B Oil in brake if de Dry linings generate 50 more bl Rep ace oil seal in brake signed for dry use than linings saturated with Qj heck motor seal brake has oil in it check th type of eck piston seals hydraulic or gearbox Note Internal compo 1 Gearbox oil nents will need to be 2 Hydraulic oil inspected cleaned and replaced as required C Disc plates worn The thickness M thaffflisc ack set the Check disc thickness torque le A t wgstackeduces torque D Springs broken or BrokerWor set sprflgs can cause re Check release pressure have taken a perma nent set A Low actuation pressure gue 4 rare occurence hould be pressurized to Of 20 psi over the specified 2 pressure under normal operat If the should fail a large amount of drag can be generated Brakes are designerd to come on when system pressure drops below stated re lease pressure If pressure cannot get to brake the brake will not release 4 B Bad o rings If re
30. erly e if you use incompatible components if you use worn out or damaged components if you use components in a non approved application This symbol warns of possible personal injury A serious or fatal injury can occur if you lack proper training SAFETY GLASSES SHOULD BE WORN e if you fail to follow proper procedures A AT ALL TIMES WHEN WORKING ON e if you do not use proper tools and VEHICLES OR VEHICLE safety equipment COMPONENTS v 5333333333332332323232 x 555555553533333333323232323233 Axle Identification SPIC E gereent Sch ae 7036 000000_ S N The identification tag located on the rear of th housing contains the axle assembly number t number and the build date It is recommended referring to components of the axle ass the information recorded on this tag be obtained in the correct identification Gear Set Identification Manufacturer s date date gear set was made Dana Dana name and location of manufacturing 572199C91 part number of ring gear Typical Tooth combination i e 37 6 indicates the pinion p 7 has 6 teeth and the ring gear 37 teeth which results in in OQ NA a 6 17 1 ratio E LG a Matched set number Spicer ring and pinions are manufactured as a matched set Both pieces arg marked with a corresponding number i e 268 indentifies them as a matched set A gear set that does not have the sam tchi numbers sho
31. ever bearings are removed they are regardless of mileage to be replaced with new ones NOTE If replacement of a damaged bearing cup or cone is necessary the cup and cone must be replaced as a set OIL OR GREASE SEALS Whenever it becomes necessary to remove an oil or grease seal to gain access to an adjacent component for replacement or repair that seal is to be discarded because of possible damage CLEANING Parts with machined or ground surfaces such as gears bearings and shafts should be cleaned with emulsion cleaners or petroleum based cleaners Steam cleaning of internal components and the interior of the planetary hub and axle housing is not recommended Water can cause corrosion of critical parts Rust contamination in the lubricant can cause gear and bearing failure Clean all surfaces of old gasket material DRYING Use clean lintless towels to dry components after cleaning DO NOT dry bearings by spinning with compressed air This can damage mating surfaces due to lack of lubrication 5525535353325333333333353 After drying components should be lightly coated with oil or rust preventive to protect them from corrosion If components are to be stored for a prolonged period they should be wrapped in wax paper INSPECTION Prior to reassembly inspect parts for signs of wear or damage Bearing surfaces should be inspected for pitting wear or overheating Inspect all bearings cups and cones an
32. ew 5B Remove inner diameter piston O ring Discard and replace with new 17 amp c 9 Remove planetary rian OUR hep end 6 Safely support hub assembly with a lifting device Inspect outboard wheel D Ing Reprice if necessary Remove wheel retainer capscrews Remove wheel 10 With hub Supp Go Sy remove it from retainer and preload shims Wire shims to retainer to the spindle facilitate re assembly e 11 Inspect wheel bearings cups and seal Replace if necessary e NIE NOTE It is recommended that whenever bearings e a Ki d d they are regardless of mileage to 7 Remove oil passaqff O rip fS fron groove on initis summa d inboard face of wawel taller If d maged replace If be replaced with new ones ok save for re zfSembly NOTE If replacement of a damaged bearing cup or cone is necessary the cup and cone must be replaced as a set NOTE Whenever it becomes necessary to remove an oil or grease seal to gain access to an adjacent component for replacement or repair that seal is to be discarded because of possible damage 2 UA NEN E ke A A 8 Remove and inspect outer diameter O ring on inboard side of wheel retainer Replace if necessary 18 Removal enc Disassembly of Spindle and Axle Shaft 4532323 NOTEW neneyg it becomes necessary to remove all oil or resf e seal to gain access to an adjacent comp m envior replacement or repair th
33. f stack has to be replaced replace with the same thickness NOTE The front and rear axle carrier section may vary in pinion bore depth due to the possibility of the need for either a baffle or slinger or both The baffle serves the same purpose of assisting the lube to flow up through the oil channels to lubricate the pinion bearings If used they are part of the pinion setting adjustment ow gear to fall It can strike le ay cause serious inj ear teeth May have sharp edges ommended that whenever bearings they are regardless of mileage to ced with new ones If replacement of a damaged bearing cup or is necessary the cup and cone must be eplaced as a set EON ERT cu te ee 6 Turn nose of carrier down Remove outer pinion bearing cup as shown Locate driver on back edge C cup drive cup out of carrier if necessary CAUTION Do not nick carrier bore Differential Aes i A Standard Di ford ia One Piece Case 1 Apply a small amoupff f grease both side gear the center of the small opening of the case Line up hubs Assemble new rustygashers nto side gears the other pinion mate gear with the gear which has just been assembled Rotate gears until the holes of pinion mate gears are in direct line with the holes of the differential case 2 Assemble both side gears into case Hold top side gear up with your fingers Assemble one pinion mate gear Rotate gears until pinion mate gear is direct
34. f the ring gear to the bari button end of the pinion for the Model 70 Front and 4 WEB sa EN ini Rear axle is 3 500 inches approx On the button end of each pinion there is etched a plus number a minus number or a zero 0 number which indicates the best running position for each particular gear set This dimension is controlled by the shimming behind the inner bearing cup 11111111111 For example If a pinion is etched 3 this pinion would require 003 less shims than a pinion etched 0 This means by removing shims the mounting distance of the pinion is increased to 3 503 which is just what a 3 indicates Or if a pinion is etched 3 we would want to add 003 more shims than would be required if the pinion were etched 0 By adding 003 shims the mounting distance of the pinion was e s ch Ae View 7 ring qu pinion d Ring gears and pinions are supplied in matched sets only Matching numbers on both the pinion and ring gear are etched for verification If a new gear set is being used verify the numbers of each pinion and ring before proceeding with assembly decreased to 3 497 which is just what a 3 etching indicated If the old ring and pinion set is to be reused measure the old shim pack and build a new shim pack to this 335335533333333333333 4 L EEE EEE EEE EEE EEE EEE EEE b wo same dimension If a baffle is in the axle assembly it is considered
35. g gear backlash Worn pinion and ring gear Worn pinion bearings Loose pinion bearings Excessive pinion end play Worn differential bearings Loose differential bearings Excessive ring gear run out Low lubricant level Bent axle housing odovo ocmecolnm Noise on Coast not as load 2 Pinion and ring gear too tight audible when decelerating and disappears when driving weal 3 Loose shaft to wheel hub bolts Wrong or poor grade lubricant Axle noises heard on drive will usually be heard on coast although bh ee ud RECOMMENDED REPAIR SR Replace the end yoke Check the pinion spline for excessive Replace the ring gear and Winion as a matched set if necessary Replace the ring gea ion as a matched set ial gears pinion aft as a set Replace differe mate a x ferential side gears pinion shaft and thrust washers se corgect lubricant fill to proper level ge at recommended intervals Replace differential side gears and pinion mates as a set Replace worn axle shafts Lh ae ee ee A ff XE we Ab Om XE SO dE Replace any scored washer and any washer that is 005 inch thinner than a new one Use correct lubricant fill to proper level and change at recommended intervals Replace carrier housing Check pinion for excessive endplay Use correct lubricant fill to proper lev
36. ification endations K d nts conditions and environments This To ensure proper lubrication and operati temperature in Spicer Axles it is importa rope lubricants be used and correct lubri maintained RECOMMENDED LUBRICAN Multi purpose gear lubric L 2105C and suitable fo Spicer Industrial SAE viscosity g t air temperature 42 KEE si o an Pc HH F 40 15 410 32 440 60 80 100 K AMBIENT AIR TEMPERATURE Is impose additional requirements on lubricants which may not be covered by the above y vehicle manufacturers find it necessary to specify a special lubricant or limited slip additive for King pin bearings are lubricated by packing with grease For grease packing it is recommended that a No 2 lithium EP grease suitable for automotive wheel bearings be used Contact your local vehicle service dealer or refer to your owner s manual for obtaining the proper lubricant specification and maintenance schedule WHEEL END WET DISC BRAKE LUBRICATION Wheel end wet disc brakes impose additional requirements on lubricants which may not be covered by the above specifications Many vehicle manufacturers find it necessary to specify a special lubricant or additive for use with them Contact your local vehicle service dealer or refer to your owner s manual for obtaining the proper lubricant specification 59 FASTENER STRENGTH IDENTIFICATION IMPORTANT Whenever fasteners are replaced
37. ill be used in a wide variety of applications and conditions A regular schedule for periodic inspection should established based on past experience and type o operation Disc brakes do not require adjustment since clearance is maintained by movement and piston e hub and disc assembly or damaged caliper dust boots and ginal brake pads are to be reused mark some manner so they can be installed in the location After any brake service be sure to test brakes prior to returning vehicle to service A firm pedal should be felt during brake application CAUTION DO NOT move vehicle until a firm brake pedal is obtained BRAKE PADS To inspect brake pads for we to floor stands and remove wheel A SERVICE PROCEDURES at each visible end and caliper CALIPER AND PADS REMOVAL at the same tj i anced braking of the axle Or pitting is a normal characteristic d lining material which does not isually inspect calipers for defects or brake fluid kage If necessary follow repair procedures in the and Caliper portion of this section BRAKE FLUIDS The Bendix disc brake is designed to use either a standard brake fluid or petroleum base mineral oil 1 If brake fluid is used the brake must have black colored seals and dust boots Brake fluid must meet SAE 1703 or Super Heavy Duty DOT 3 brake fluid 3 Pry the caliper outboard retracting the caliper specifications pistons into the cylinder bore 1 Positio
38. isassembly A Ring Gear and or Differential Side Bearing Cones Bol Za o n n 2 3 Tap ring gear with a 2er to free it from the case Remove case alhring geartrom vise on shaft needs to be replaced ring e Ion shaft must be replaced as a EE NEN AJ Wu Oo0 0070070 1 If replacement of differential bearings is required remove differential bearings with a puller as shown NOTE It is recommended that whenever bearings are removed they are regardless of mile be replaced with new ones NOTE If replacement of a damage arings cu cone is necessary the cup and co replaced as a set E WS 1 Place holding fixture into vise Place case onto holding fixture as shown Drive out lock pin m D 4m vb 2 If removal of ring gear from case is required place a few shop towels over the vise to prevent the ring gear SC teeth from being nicked after it is free from the case e J mer ON Place case in vise Remove ring gear screws and x discard them A a E C F e Ring gear screws are to be replaced with new ones at 2 Reposition case on holding fixture as shown Drive time of reassembly out cross pin using a drift and hammer 41 42 3 Rotate gears until the pinion mate gears small gears enter the large opening of the case Remove pinion mate gears and spherical washers After removal of the pinion mate gears the side gears and thrust washers can be easily removed
39. itiormi sp that when the brake caliper assemlly is installlid it will be on the cover side of the axle houN ag 3 org o clock position Also the suppoj key and of the bracket is to be on the 149 side Install the mounting washers and nuts agf torqu to 80 100 ft Ibs N Di d g Ten 6B On planetary equipped with wet disc brake wheel ends proceed as follows 1 Install the fitting bleeder guards if used on the mounting studs Guards are not to be installed in the area between the bleeder and inlet ports but just outside of that area and such that they will not interfere with the installation of the bleeder screw and inlet fitting 2 Install the mounting washers and nuts and torque to 80 100 ft Ibs 3 Install the bleeder screw in the top port and tighten until it is seated properly 4 Install the brake inlet fitting in the other port and tighten until it is seated properly Assembly of Wheel End Hub 1 Install inner and outer bearing cups into hub Install inboard bearing and hub seal 2 Install hub onto spindle NOTE A lifting device is recommended for assemblies having a rotor attached ZS nt y d 6 Install ring qgea he roll gih on the back face of the ring gear must be Akedi the bearing adjusting nut hole Ug punch mark on front of ring gear as an aligoifent aig Aie e 4 ys 4 Install bearing adjusting nuiorquagias200 250 ft lbs Back nut off 1 8 turngg
40. lease piston will not hold pressure brake will not release C Discs frozen Brakes are designed for only limited dynamic braking A severe emergency stop or prolonged reduced release pressure operation may result in this type of damage Place pressure gauge in bleed port amp check pressure with system on Brake drags or runs hot Replace bearing L Brake will not MM Stug release Place pressure gauge in bleed port check for adequate pressure Replace defective line or component Replace o rings Replace disk stack i 3 FAILURE MODE at the tooth heel Fracture of ring gear teeth 1 at the tooth toe and pinion gear teeth gear teeth Look for discoloration of the gear 2 teeth 4 Pitted drive pinion teeth Bent axle housing Worn or ed hring M D y A A c a a a a m c A A A A a A G K K E E e A V ug r XU PROBABLE CAUSE Fracture of ring gear teeth 1 Scored and or scuffed ring 1 4 Overheated ring and pinion 1 temperatures Incorrect lubricant Low oil level Excessive loading of the gear beyond design intent Incorrect gear adjustment excessive backlash Shock impact loading 2 Incorrect gear adjustment insufficient backlash Insufficient lubrication 2 Contaminated lubricant
41. ly in a small amount of grease to the new spherical Son A Y x d ras E PRI Ry 1 E AA R P M P washers Assemble washers between the gears and case Also line up the holes of the washers with those of the gears and case 4 Assemble cross pin Make sure lock pin hole of the cross pin is in a vertical position and lined up with the lock pin hole of the case Drive cross pin into case with a hammer until the cross pin hole is in alignment with the hole of the case E f S KK K C Le CS 2 Ki 5 Assemble lock Yin Peen Metal of case over pin to lock in place 1 Large Section of Case 2 Dished Plate 3 Dished Disc 4 Flat Plate 5 Flat Disc 6 Clutch Ring 7 Side Gear 8 Pinion Gear 8 9 Cross Shaft 10 Small Section of Case 11 Bolt and Tapered Sleeve ubricate all internal parts with axle lubricant assembly 5 Install cross shafts to large section of case so V 2 Alternately install plates and discs into large section portion of cross shaft mates with V cut out in case of case as illustrated 6 Assemble side gear clutch ring and clutch discs for NOTE Install dished plate and disc with concave small case section on spider assembly as it sits on surface toward case section work bench Install case section being sure it seats 3 Install clutch ring and side gear Engage splines of fully discs and clutch ring on side ge
42. m the steering cylinder soket asSqiblies 20 6 Next press out u joigisisearing Webs Mid remove cross 7 Inspect u joint AS ima Cas and cross and replace if necessary 3 Remove the slotted hex nuts that fasten the cylinder socket assemblies to the anchor points on the carrier and steering knuckle Tap the threaded end of socket assembly lightly with a soft faced hammer to unseat them Carefully remove steering cylinder assemblies Mark cylinder assemblies rightside leftside to aid reassembly CAUTION Protect chrome finish on rod at all times Damage to surface of rod can cause premature seal failure NOTE Refer to steering cylinder disassembly and assembly section of manual if further disassembly of cylinder assembly is required qaqqeaeteeceqeqeaeqete assa EEN RM 9355353353535333535333333333343333333333333333332333 4 4 Remove the cotter pins from the tie rod socket assemblies A A N Disassembly of Steen 5 Remove the slotiasieex nS that fasten the tie rod socket assembliefto the WerM Knuckle anchor points Tap the tllleaded enot the socket assembly lightly with a softWaced haner to unseat them Remove the tie rod Qagaagg ily Match marked tie rod end aa steering knuckle to aid in reassembly NOSE Do get alter the tie rod adjustment unless furMair isgrequired to tie rod components epa s regfired or tie rod adjustment is inadvertempy changed it
43. n vehicle on floor stands and remove wheel 2 Inspect master cylinder fluid level and remove fluid if necessary d i 1 d s i i S p 5 Using a hammer and drift ve dit calia Support key spring 6 Disconnect hydra hose if moving caliper to A service other than ke pgs g A A A A P ST S SP ST Du A 7 Remove caliper from mounting bracket Do not let caliper hang on brake hose 3333 8 Remove inboagpas icormesaliper mounting bracket Inspect caliper r leak ada Rewuild if necessary NOTE If the c liper doesnot require rebuilding retract the pistes intoZfie caliper to obtain necesm ry Ceararr zor reassembly over the rotor Posif n a metal bar over both pistons then use a SS clam to force both pistons into the caliper CALIPERVPISASSEMBLY 1 Dig jonnect brake hose from caliper inlet Cap the hosgff amp nd inlet to prevent brake fluid leakage Avoid geng grease or brake fluid on brake pads 2 Clean exterior of caliper in denatured alcohol 3 Remove pistons from caliper NOTE It may be necessary to use compressed air to aid in removal of pistons CAUTION Use no more than 15 PSI air pressure to ease pistons from bore Stay clear of area between piston and caliper housing to avoid personal injury Avoid spray of brake fluid as pistons are dislodged from bores Use shop towels to restrict piston travel and
44. nd Wany hore in nut with a major spline on th Spindle Wake sure hub rotates freely Use Daffa Tog 4511299 N oe e C Ze 5 As an aid mark the end of the aligned spline NOTE If axle is equipped with wheel end disc brakes the brake caliper assembly can be installed at this time as outlined in the disc brake section of the manual 8 Install snap ring onto axle shaft 27 9 93395532323232333233333233233233523333233333333333 1 Install inner and outer bearing cups into hub Install inboard bearing and seal and deflector 2 Using a suitable lifting device install hub assembly onto spindle SPECIAL SERVICE NOTE If the planetary ring gear brake piston and wheel retainer were removed as a unit described in disassembly section and it was not necessary to replace wheel bearings or cups use the following lettered steps for reassembly Otherwise proceed Qe steps 3 MEasert both on into grooves on mboard Tace of wheel retainer using a small amount of petroleum jelly to hold them in place and facilitate aqsembly B Install ring ar pist yasSgmbly onto spindle spline making sure di passage Wole in ring gear is to bottom of axle at 6 o C amp ck positi Mounting holes in wheel retainer will aligreebusfre way c Install wheel talian capacrews with Loctite 271 compound applied to the threads and torque to 45 ft Ibs D Skip following steps 3 thru 10 and continue assembly
45. nut must be advanq until the cotter pin can be installed 5 C inect se hydraulic hoses to the steering cylindes did big d the system Assembly and Installatidn ol Axle Shaft and Spingl 1 To assfemble nneNand outer axle shafts insert u joint koss Sf yoke Uf outer shaft and press in bearing Ses Repgat with center yoke and inner shaft dA fs Zu d e AKTE f 4 r E d EREA E i De c M H E P Ik E D i 3 gt hi n 7 BLE 4 Bit pad Bag 3 Support shaft assembly and slide into axle housing and engage in differential side gear Care should be taken when installing shaft as not to damage axle shaft oil seal NOTE On rigid axles install the axle shaft into the axle housing until it engages the differential side gear 2 Install all bearing cap retaining rings Grease u joint 25 5 Install spindle over the axle shaft ad or knuckle or housing flange studs NOTE Care should be take when slide spindle over the end of tlf amp axleagfi so as not to damage the outer shaf sed f bushing if so equipped NOTE On planeta meoffippedawith wet disc brake wheel ends Pspind is toe assembled to the mounting gids w h tITbfke bleeder port positioned agth iop 12 O clock position and the brake Met poon the carrier side of the axle housifig 6A On planetary equipp d wtf aree brake install th caliper mounting fi mon Wee mounting studs The bracket is to bdiiDos
46. oig fncreagiing dental bearing preload excessively furtger Leet the right hand adjusting ring sb tild beWcompanied by equal loosening of the leifhandsdjuSQsg ring Place a dial indicator directly offfgachf justing Ting to measure the exact hour er the agditional adjustment IncrgffSing backsh fioves the ring gear away from the Dion INK IN T 2 FAR IVE pini and at nina gear for prope cklash tt 5 If a pattern is concentrated at the ring gear tooth root as shown above the pinion is too close to the ring gear It must be moved out and away to establish its proper mounting distance and contact pattern as shown in step 2 This is accomplished by decreasing the thickness of the inner pinion bearing shim pack as described in the pinion assembly and position sections of manual Readjust pinion to ring gear backlash as required once proper pinion mounting distance has been established PINION OUT TOO FAR Move pinion in and re adjust ring gear for proper backlash 6 If patifffn is concentrated at the tooth top land as show abovg the pinion is too far away from the ring gear hist begpoved closer to the ring gear to lishe praser mounting distance and tooth contact pate This is accomplished by increasing the thickgess of the inner pinion bearing shim pack as describgli in the pinion assembly and position sections dal Readjust pinion to ring gear backlash as required once proper mounting distance has been btablished
47. ontained herein are for illustrative and instructional purposes only The appearance of your axle assembly and or components may vary from that shown However the service procedures described will apply If it becomes necessary to disassemble any parts inside the carrier it is suggested that the entire axle be removed from the vehicle and held tight in a stand or rack All dimensions are in inches unless otherwise stated WARNING When removing axle assembly make sure vehicle is properly supported Improperly supported vehicle can ca serious injury or death Follow ve manufacturers recommendatiog id be steam cleaned prior to penings before steam cleaning irt and water which can damage If the axle assembly is removed from the vehicle it must be safely supported at three points on the housing If the axle is to remain in the vehicle use the OEM recommended support method A suitable holding fixture should be used rebuilding the carrier assembly A lifting device should be used to relocate the carrier assembly and to install or remove the ring gear and support case assembly CAUTION Hammering on en END YOKES AND FLANGES remove or install them is not on the yoke or flange itself serious internal damage needle bearings Serious damage be removed or installed using a hod such as that described and lubricate all bearings just prior to assembly OTE It is recommended that when
48. parated by spacer ring ES 4 Be 2 3 Place thrusi washer OTTS flange 4 Install planet gear and remaining thrust mear 5 Install Dem ear shaft Mto drive flange If equipped with weWslisc bzffKes install lining stop plate Align hes and instat Toll pins 6 AGoN small bead of Permatex 2 gasket sealer around drive flange NOTE DO NOT use silicone sealer on drive flange It can cause flange to loosen 7 Align gears and install drive flange into hub Rotate hub to align bolt holes 8 Install and torque bolts 90 100 ft Ibs 31 SES Dis 7 8 9 d and Static Seal ockwire Rod Seal U Cup 12 Rod Wiper NOTE Prior to disassembly of st i CAUTION Protect chrome finish on rod at all assembly loosen the socket as times Damage to surface of rod can cause and nut and remove the socket as i premature seal failure the steering cylinder DISASSEMBLY 3 Pull on the rod to remove the piston and gland 4 Remove the nut from the end of the rod 5 When the cylinder is disassembled all seals should on prior installation Check lockwire be replaced before reassembling position for correct rotation CLEANING AND INSPECTION 1 Check rod and cylinder bore for nicks burrs scratches or rust Slight defects may be removed with fine sand paper 2 All parts removed from the cylinder that are to be reused should be thoroughly cleaned Be sure to 2 Locate
49. porarily remove the differential assembly from the carrier for the proper setting of pinion bearing preload 8 Remove pinion nut washer end yoke slinger and bearing cone Assemble preload shims which were removed during disassembly onto pinion Assemble bearing cone slinger NOTE If carrier has optional pinion mounted parking brake refer to pinion parking brake section of manual for installation of brake assembly pinion input yoke washer and nut to the carrier h as shown rotate Id read between 20 40 plete the installation of the brake the carrier 9a Apply a light coat of hypo the pinion seal and ass 9b If pinion parking plate and inner pinio 14 Install adjusting nut locks mounting bolts and washers Torque mounting bolts to 15 17 ft Ibs ARN ge i 10 Assemble end yoke washer and new pinion nut Torque nut to 240 300 Ibs ft 52 Installation of Carrier Assembly into Axle Housing K 1 Thoroughly clean inside of axle housing Stone the cleaned and threads coated with Loctite 271 or its housing mounting surface if necessary to remove equivalent burrs or nicks Zi 4 Assemble axle shafts and wheel end nts at this time following procedures outlined in the el Ba end section of manual 5 Clean Drain plugs and install carrier housing Fill with p required levels for planet housing Inspect wheg a d housi g for oil leaks 2 Appl
50. rake assembly from carrier 1 Hold end yoke or flange with tool similar to the one shown and remove pinion nut and washer Discard nut as new one should be used at reassembly D shown If yoke or seal contact i 4 Enge ould AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA Ae e 3 Remove pinion by tapping with a rawhide hammer Catch the pinion with your hand to prevent it from falling to the ground and being damaged Vas a vIIIS WARNING Gear teeth may have sharp edges When handling gears use care to avoid personal injury NOTE On the spline end of the pinion th bearing preload shims These shims may the bearing pinion or even fall out The will be used later in assembly Try not to mu shims If shims are mutilated r ones shims are available in 005 010 and 030 NOTE If ring gear and replaced ring gear and replaced as a mat VP Y X gt E ae Ska ge 4 Pull out pinion seal with puller as shown DISCARD SEAL Replace with new seal at time of assembly Remove bearing cone and outer pinion oil slinger 5 Remove the inner bearing cup if necessary with tools as shown NOTE Shims are located between the bearing cup and carrier bore and may also include an oil baffle depending upon the application If shims and baffle are bent or nicked they should be replaced at time of assembly Wire the stacks together and measure each I
51. re the caliper piston is fully bottomed in the piston bore 3 Position outboard pad on caliper 4 Apply a small amount of special lubricant NLG 2 extreme temperature lithium grease to the machined surfaces of the caliper vee way grooves and caliper mounting bracket rails which are in contact during the sliding action of the caliper ef e 353533553355333553333333333232323233332323232333223 9 E za e 333323 4 5 Position caliper into caliper mounting bracket Avoid cutting piston dust boots 7 Install key retaining SC and tOrqee to 12 18 ft Ibs and bleeder fitting in removed e 6 Hold caliper in position and 17 ppo Ka support key between caliper weet Usg a soft faced hammer to drive th keySa Spring assembly into position 37 SECTION 3 Carrier Assembly Limited Slip Differential Pinion Mounted Dry Disc Parking Brake Carrier Assembly 2 D A A A e cA e SW a e ee Gel CS a e e a e e P i AAAAAAAAAAAAAAAAAAAAA 1 Nut Pinion 28 Shaft Differential 2 Washer Pinion Nut 29 Pinion Differential 3 Pinion End Yoke Assembly Includes Item 4 and 5 30 Thrustwasher Differential Pinion 4 End Yoke or Companion Flange 31 Side Gear Differential 5 Deflector 32 Thrustwasher Differential Side Gear 6 Oil Seal Pinion 33 Lock Differential Shaft 7 Washer Bearing
52. ricant fill to proper level and change at recommended intervals Replace axle housing Replace bearing cups and cones in matched sets Check roller ends for excessive wear by comparing used rollers with a new bearing Use correct lubricant fill to proper level and change at recommended levels Replace the oil seal and mating surface if damaged Use correct lubricant fill to proper level and change at the recommended intervals 97 FAILURE MODE PROBABLE CAUSE Excessive end yoke spline 1 Severe service looseness 2 Loose pinion nut 3 Pinion endplay Fatigue fracture of the Severe service pinion gear teeth Look for clear cut wavy fracture lines beachmarks Fracture of differential side Shock loading of differential gears and pinion mates components Scoring and or seizure of 1 Excessive wheel spinning cross shaft arms and 2 Inadequate lubrication pinion mate gears 3 Extremely severe service 4 Unequal tire pressures Worn side gear splines Severe service Excessive backlash 1 Insufficient lubricagPn 2 Improper lubricatiqg Scored or worn thrust washer surfaces Worn pinion roller bearing 1 Sey retainer bore 2 essive 3 NT Bate lubrication ini d lubricant ere v ef operation at the Loose wheel bearing Bent axle housing Twisted or broken axle shaft Fractured axle sh flange Noise on du Excessive pinion to rin
53. ring Cylinder Assemblies NOTE The carrier assembly and steering knuckles are to be installed prior to proceeding with the installation of these components 1 Connect the tie rod ass mbiyeeffthe steering knuckle anchor points rque theWecket assembly slotted nuts to 140 TZS mugfmum Sheck to make sure the position af S et in tif tie rod clears the carrier assembiffn full pog ion both directions The tie rod adgembishou e switched around end for end if f ll tief farance is not found and the slotted fts retorG ed NOT amp If thie roa djustment toe in has been Chand will b necessary to readjust it Loosen Sad c enp zfSembly bolt and nut Position the steeging kS Kles in a straight ahead 0 turn andSimsition Position measuring bars on the 2indle mounting face of the steering knuckles N asure across them on the carrier side and cover sid of the axle housing and compare readings Remove tie rod adjust the overall socket to socket length in or out reinstall the tie rod assembly and remeasure Repeat this procedure until equal measurements are attained zero toe in or the toe in specified by the vehicle manufacturer is attained Retorque slotted nuts to 140 ft Ibs minimum Torque the tie rod clamp assembly bolts and nuts to 60 70 ft Ibs 24 s 3 r S NSE cottgffDins and bend the pin over to lock it in place NOTIS If cotter pin cannot be installed after minium torque is attained the nut must be a
54. s or SPICER OFF HIGHWAY PRODUCTS DIVISION 1293 Glenway Drive Statesville NC 28625 Tel 704 873 2811 Fax 704 878 5616 1 pe R4
55. s s c lt x x s e eens Disassembly of Wheel End Hub T Disassembly of Wet Disc Brake Wheel End i Removal and Disassembly of Spindle and Axle Sh Removal of Steering Cylinder and Tie Rod Assem Disassembly of Steering Knuckles Assembly of Steering Knuckles Installation of Tie Rod and Steering Cyli Assembly and Installation of Axle Shaft a Assembly of Wheel End Hub m Gee Assembly of Wet Disc Brake Whedftndys HR ET EEN d DEET o AN t Dm turn cnm rapit ri t Disassembly and Assembiout WhewwaErid DISC Brakg asss 6 s oie sie rrr tao uan rro Ra KE C9 a error ro ore pU res 34 SECTION 3 Carrier Slip Differential Option c c Parking Brake Option Illustration GH Carrier As eh v SER Se ee ne A ree 38 Removal of C i LTD CST TIT TDIT II TLITIIT IIT 39 um ed AE ar DOS SES IN DEENEN OF ER Gani vp dE NEC 40 TTT ET E NAR TU ERR E EE NEE 41 ES PUEDEN CB Seeocnnad nttdaus cune ee EE 43 TUNE ET IRE RTT ERIT TEILT DIXLTITCOIT T 44 ED AMbn PE ON BAL EE KEE Gees somitr cic n OR olt icd 46 EE 0 wa TL EK EE 49 x Ang Pirion Tool Contact EE 50 D CET ASSOMV ERG A sie indio har NARI AMET RARI e OE omit c omn a ei d 53 22 igion i TH Dine PRENIDEE OEKE anan a REX AC GAME REIR el on sa o nci a eg 53 A ains CIES meter annsna en ERREUR KK YZE Tear BELTS a er a 54 Pinno Brake Reegel a oor RI ERR ROM RIS n OE AUN
56. sc brai section of this manual T C lies MA SI 5 Remove the outer wheel bearing while supporting the hub assembly l Di T M d VIV ege TER 6 With the hub supported carefully remove it from the spindle NOTE A lifting device is recommended for assemblies having a rotor attached 15 8 Rest hub on drive flange mounting face and remove the hub seal and inner wheel bearing 9 Inspect wheel bearings and cups and replace if necessary Remove cups with a suitable puller NOTE It is recommended that whenever bearings are removed they are regardless of mileage to be replaced with new ones NOTE If replacement of a damage cone is necessary the cup and con replaced as a set NOTE Whenever it becomes an oil or grease seal to ga component for replacement to be discarded bec 7 If the axle is equipped with disc brakes the rotor can be removed at this time Disassembly of Wet Disc Brake b d NOTE the following procedure is the same for both rigid and steer axles 3 Remove brake plates and discs Check friction material thickness on discs If groove depth is less than 005 they must be replaced Inspect stationary plates for warpage with a straight edge If warpage is observed they must be replaced Inspect all plates and discs for heat damage Replace if necessary a 1 Insert s scysiivdriverWnder locking ring on axle shaft ap re y rotating around shaf
57. spring plate bottoms on pressure plate 10 Install four socket head cap screws 6 SEE NOTE BELOW Torque bolts to 55 ft Ibs A suitable holding fixture is useful to hold brake in position 11 Install stator discs 9 and rotor discs 8 Begin with a stator disc 9 and alternate with rotor discs 8 CAUTION Slots in stator discs 9 should engage with fixed dowel pins 10 in spring plate 11 12 Install primary disc 7 offset from other stator discs 9 13 Align tabs on primary disc 7 with thru holes in spring plate 11 and partially screw in four socket head shoulder bolts 5 into piston 13 SEE NOTE BELOW 14 Using outer spline 4 align and center rotor discs 8 in brake module Be certain outer spline 4 is installed with counterbored end towards bearing in brake 15 Pressurize brake release port approx 300 psi to completely release discs Torque shoulder bolts to 18 ft Ibs and release pressure A suitable holding fixture is useful to hold brake in position 16 Press oil seal 2 into cover 1 Note direction of seal during installation 17 Install case gasket 3 in cover 1 NOTE Bolts should have Loctite applied Place one or two drops of Loctite to the threads 6 Parking Brake Bleeding Trouble Shooting BLEEDING 1 Install brake in system and connect pressure lines 3 Apply sufficent pressure to release brake and check 2 Bleed pressure release section of brake by for prop
58. ston bore and install lip of boot into groove near top of bore Be sure boot lip is fully seated 4 Press straight in on piston until it bottoms in bore 5 Assemble other parts on caliper and install as outlined in the Pad and Caliper Installation section CLEANING AND INSPECTION OF ROTOR AND PARTS 1 Measure lining thickness If any point is less than 3 16 4 76 mm new pads should be installed on bot wheels of that axle INNER PAD pads contaminated with oil grease or not easily removed with a clean rag 0 381 mm 015 T Examine the pads for flatness of the control surface Any shoe found with a concave or convex bend more than 0 015 0 381 mm should be replaced 2 Inspect rotors While rotors are mounted on wheel end use dial indicator to check for warpage of braking surface If surface varies more than 003 076 mm it will be necessary to machine rotor to acceptable tolerance Use standard automotive procedures Rotors with cracks or burnt spots must be replaced NOTE The minimum allowable thicknes rotor braking surfaces is 1 320 inch Thi cast on the rotor If the amount of machining to eliminate warpage dec decrease the thickness to less than the mi Before reassembling the r the hub make sure the roto surface and pilot dia Position the rotor on 1 Position the inboard smaller pad into the caliper mounting bracket with lining towards rotor 2 Be su
59. t nn a H AEN e d i r NOTE If any of the above conditions exist it is necessary to replace all discs and plates together as a set Piston O rings should also be replaced at this time If brake discs and plates are within specifications and brake was operating properly it is not necessary to remove brake piston or replace piston O rings SPECIAL SERVICE NOTE If the service procedure being performed does not require replacement of piston or wheel retainer O rings the hub assembly may be removed using the following steps 3 r M po yY J 1 A A 2 Remove sun gear from axle shaft A Safely support hub assembly with lifting device 5 EA EA EA m ai A a um Si A s EA A z AAD een anaa naaa ts ad int TER ES K K d 1 ba EM 1 z HET d K X d K 8 A x gt g y 4E KS 1 2 ao d ey N D Remove oil passage O rings from grooves on inboard face of wheel retainer If damaged replace If Ok save for re assembly kAAAAAAAAAAAAAAAAAAAA E Skip following steps 4 thru 9 Continue disassembly with step 10 Bac 4 Remove brake ston Trombheel end NOTE Use of a sp sial piOn remover installer tool Dag amp tool 74517995 is recommended to prevepdamacge to the piston aulis 9 d K Uo EM T am 5A Remove outer diameter piston O ring Discard and replace with n
60. t Assembl 7 Vertical Socket Assembl 4 Clamp Assembly Tie Rod 8 Steer Cylinder 3 Vertical Socket Assembl 5 Vertical Socket Assembl e AKAAKAAAAAAKEAAAAA AAA AA ke 6 Center Yoke 7 Shaft Inner Yoke Short 8 Shaft Inner Yoke Long 9 Deflector inner Shaft Seals 10 Oil Seal Inner Shaft 11 Bushing lnner Shaft 12 Steering Knuckle e c 3 c e c e c A A c aft or Shaft o A 3 Cross Assembly Assembly 17 A A 2111 Axle Steering Joints 13 Stud Spindle Mounting Steer Axle 14 Locknut Spindle Mounting 15 Washer Flat 16 Fitting Grease 17 Capscrew King Pin Cap Mounting 18 Washer Flat 19 Cap King Pin 20 Shim King Pin Bearing Adjusting 21 Seal King Pin Bearing 22 Bearing Cone King Pin 23 Bearing Cup King Pin 24 Retainer Grease 25 Stud Spindle Mounting Rigid Axle 11 Wheel End Disc Brake 9 Bleeder Screw 10 Caliper Bracket 3 Dust Boot Shield 11 Compression Spring Caliper Support 4 Dust Boot 12 Caliper Support Key 5 Piston 13 Socket Head Screw Caliper Support 6 Piston Seal 14 Hydraulic Fluid Fitting 7 Caliper Housing 15 Disc Rotor 8 Bleeder Screw 16 Hex Bolt Removal of Planetary Drive Flange Assembly A NOTE The following procedures are the same for both rigid and steer axles 1 Rotate hub so drain plug is down Remove plug and drain oil EN el e m m wm A
61. ter the tie rod adjustment NOTE If axle assembly is still in vehicle be sure carrier assembly is securely supported before it is separated from housing If axle assembly has been removed from vehicle be sure it is set securely in support stands with carrier pinion positioned up 6 Remove mounting bolts and washers from carrier rier housing Be gege flange Carrier assembly and axle housing is aligned e wheel ends and axle shafts SIN HAS pins d x 7 Remove carrier assembly from housing and mount in suitable holding fixture such as a carrier repair teering axle skip steps 4 and 5 cland 9 H 39 e Removal of Differential from Carrier a gt A i m i Lo ai LA aad N 2 Match mark one differegtial nagro Cap end leg of carrier with center punci r chiseWior correct reassembly E Vu km A 6 Carefully lift the ring gear and differential sub assembly out of carrier NOTE Prevent bearing cups from falling as you remove differential Use care to avoid damage to ring and pinion gears If either is damaged it must be replaced as part of a matched set NOTE If replacement of a damaged bearing cup or cone is necessary the cup and cone must be replaced as a set 122222222205 4444444444444 4 405444 3 Remove bearing cap retaining bolts 4 Remove bearing caps D 555555535553333323333333533535353333332333333339 Q 5535353 Differential D
62. uld not be run together If herring gear or pinion require replacemen be ke Ze replaced as a matched set M MFG DANA PART STEEL HEAT TOOTH DATE TRADEMARK NUMBER CODE COMBINATION MATCHED SET NUMBER BACKLASH ETCHED Servicing Components Not Covered In This Manual Service procedures for some components may not be covered in this manual because they are unique to the vehicle application Refer to the vehicle manufacturer s service manual for servicing those components Vehicle Storage Or Prolonged Inoperation If the vehicle has not been operated on a regular daily basis it is recommended that the vehicle be operated least once every two weeks The vehicle should be moved far enough to cause the drivetraif omponents to make several complete revolutions This procedure will help assure that all internal components amount of lubrication to help reduce component deterioration caused by an undesirable en humidity recomme Submersion Or Deep Water Fording If the vehicle is exposed to water deep enough to cover the hubs it4 at the wheel ends be disassembled and inspected for water damage and or contamin icularly if over the breather it is recommended that the hypoid gear lubricant be drained and int inspected for water damage and or contamination Clean examine and replace damaged parts if necess lubricants NOTE If the hubs are exposed to deep water it carrier
63. will require the resetting of thisjadjustment for proper toe in Knuckles gt 1 Remove the wheel end components pindia axle shaft steer cylinder and tie rod prior t WlisadSembly of steer knuckle components IS D 2emove bearing cap bolts and washers from both upper and lower bearing caps 3 Remove both upper and lower bearing caps and shims Wire shims together with their respective bearing caps to facilitate reassembly 21 SZ ep l LA Lad PPA rubr n es Hs M A P LI b zi Zei Gei j i E v Ce A7 T AY T Kee d t 2 ko o xi nc M a N i v IM MEAS 4 Tip the steering knuckle slightly and remove from housing yoke i EE xl WS L nnn a enert 5 Inspect boing CMe andgplace if necessary A 6 Inspect axle seal arn ieushing If replacement is necessary regf ve Wa sumable puller 7 Inspect bearing cup and seal replace if necessary NOTE It is recommended that whenever bearings are removed they are regardless of mileage to be replaced with new ones NOTE If replacement of a damaged bearing cup or cone is necessary the cup and cone must be replaced as a set NOTE Whenever it becomes necessary to remove an oil or grease seal to gain access to an adjacent component for replacement or repair that seal is to be discarded because of possible damage M s 3555333333333333533333333333333333333339
64. with step 11 3 Install outboard wheel bearing onto planetary ring gear A 5555335333333333333333 5555455555533333333235 4 Install planetary ring gear onto spindle spline making sure oil passage hole in ring gear is to bottom of axle at 6 o clock position rarigi wheel pre load shims onto inboard side of Wigggfretainer and install into planetary ring gear Nlake Sure bleeder tube in retainer is to top of axle aii 2 o clock position 5 Lubricate and install outer gffimeteg O ringWnto groove around inboard side Ohea rever AA AAAS HAAS ks 7 AC 42 3 vow e e 7 we NR 8 E 8 Install wheel retainer capscrews with Loctite 271 L4 NA compound applied to the threads Gradually increase torque value on capscrews using a crossing pattern until 45 ft Ibs is achieved on each capscrew 3A NOTE At this point check wheel bearing preload P Torque to rotate wheel should be 50 80 in Ibs when measured with a torque wrench from the center of the hub If a spring scale is used wrap a cord around the wheel pilot diameter Readings 6 Insert both oil passage O rings into grooves on taken with this method should be 10 15 Ibs Pull inboard face of wheel retainer Use a small amount of while the hub is rotating petroleum jelly to hold them in place and facilitate To increase preload add shims To decrease preload assembly subtract shims 30 9 ubfi
65. y Permatex 2 gasket sealer to axle housing at din g carrier mounting flange A 1 4 inch bead around the outside of all carrier mounting dowels and each bolt hole is required NOTE If Steering hat s time install tie rod 3 Install carrier assembly into axle housing Install proceduwges outline i in those specific sections of washers Torque bolts to 100 115 ft Ibs Bolts must be the m mual fer them Pinion Mounted Dry DiseParkirfg Brake K TYPICAL BRAKE ROTOR DISC PISTON STATOR DISC FIGURE 1 PRIMARY DISC e Ki om D gt cm cm Ze gt 9 2 gt gt p gt D E D D a e cA UA SHOULDER BOLT E SN OUTER SPLINE S vs CS R L eeveves 427 n T4 le L Ob i E hen LSS IS JS SE IA sSsstart uw Ce 53 wm y XU TER REMOVAL INSTRUCTIONS 1 Disconnect driveline from yoke shaft 6 and position away fro 2 Disconnect hydraulic pressure line used for releasing brake 3 Remove nut 8 and washer 7 which retains yoke shaft 6 n shaft on axle Discard nut 8 4 Remove four 1 2 13 UNC socket head cap screws 5 e module 4 to cover plate 1 5 Pull brake module 4 and yoke shaft 6 assembly ayy from cov te 1 6 from brake module 4 1 to carrier pinion input flange Remove cover 7 Remove eight 9 16 18 UNF hex bolts 2 which plate 1 from axle INSTALLATION INSTRUCTIONS

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