Service Manual
Contents
1. NOTE The cover face of the carrier and the flat surface of the cover plate must be free of any oil film or foreign material Sealant material must meet specifications as described in the specification section of this manual Apply sealer to cover plate surface Ensure that the sealer bead is laid on the inside of the cover screw holes The bead is not to pass through the holes or outside of the holes The bead is to be 7s to 14 3 18 6 35 mm high and Ys to 4 3 18 6 35 mm wide Allow one hour cure time before filling carrier with the proper amount of specified lubricant and vehicle operation Assemble axle shafts and wheel end components Refer to your vehicle service manual for proper wheel bearing setting specification NOTES SECTION 4 SPECIFICATIONS DIFFERENTIAL LUBRICATION It is not our intent to recommend any particular brand or make of lubricant for the Spicer hypoid axle However an S A E 80W 90 multi purpose gear lubricant meeting Mil Spec L 2105C and suitable for A P Service Classification GL5 is suggested as a minimum requirement IMPORTANT Motor vehicles are operated under various requirements conditions and environments This manual specifies the minimum requirements that the lubricants should meet However it is recommended that the lubricants specified by the vehicle manufacturer be used They may provide additional lubricating characteristics which may be required for your vehicle s2. 8 18 15 13 10 08 05 03 0 03 5 15 13 10 08 05 03 0 03 05 43 13 10 08 05 03 0 03 05 08 0 10 08 05 03 0 03 05 08 10 3 08 05 03 0 03 05 08 10 13 5 05 03 0 03 05 08 10 13 15 5 03 0 03 05 08 10 13 15 18 10 0 03 05 08 10 13 15 18 20 Figure 3 20 Pinion Setting Chart Metric If metric pinion will be etched m some num ber Example m 5 Use these charts as a guideline to set pinion ESTABLISHING PINION GEAR DEPTH USING SERVICE TOOL GAGES Figure 3 21 View of master pinion bearing pinion height block scooter gage cross arbor arbor discs and master differential bearings NOTE Make sure that all carrier bores are free from all nicks dirt or any other contamination Figure 3 22 Step 24 Assemble the outer pinion bearing cup into carrier as shown Make sure cup is seated TOOL C 4171 Handle C 4308 Bearing Cup Installer Figure 3 23 Step 25 Assemble master pinion bearing on pinion TOOL C 4204 Bearing Cup Installer WARNING Gear teeth may have sharp edges When handling gears use care to avoid personal injury 3 7 Figure 3 24 Step 26 Assemble pinion with master bearing into housing Assemble outer pinion bearing cone end yoke washer and nut Torque nut until pinion gear and master bearing is snug seated in housing
3. 3 m 8 this would require 003 08 mm more shims than a pinion etched zero 0 Figure 3 29 Step 31 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 part of the total shim pack Figure 3 30 Step 32 Place the required amount of shims and baffle if used in the inner bearing bore Drive the inner bearing cup into the carrier Make sure cup is seated TOOL C 4308 Bearing Cup Installer C 4171 Handle Figure 3 31 Step 33 Assemble inner bearing cone and slinger if used on pinion Drive bearing on shaft until it is completely seated TOOL D 389 Bearing Installer 3 9 Figure 3 32 Step 34 Assemble pinion into carrier Assemble outer pinion bearing cone thrust washer and end yoke onto pinion spline NOTE Do not assemble preload shims or pinion oil seal at this time Use yoke installer as shown to assemble end yoke onto spline of pinion TOOL D 191 Pinion Yoke Installer 6719 Yoke Holder Figure 3 33 Step 35 Assemble washer and pinion nut Torque nut until it requires 10 Lbs in 1 13 Nom of torque to rotate the pinion Rotate pinion several times before checking pinion position This is to seat the bearings and assure a more accurate reading when
4. DRIVE PINION REMOVAL Check outboard spacers for damage e g caused CASE DISASSEMBLY Figure 3 5 Step 6 Remove differential bearing cones with a puller as shown Tag cones indicating from which side they were removed from TOOL DD 914 Press DD 914 99 Adapters DD 914 8 Adapter Ring DD 914 7 Extension DD 914 42 Button WARNING When pulling bearings do a not allow differential assembly to fall It Figure 3 7 DO l serious injury Figure 3 8 Step 9 Remove differential pinion mate shaft with drift Figure 3 9 Step 10 Rotate gears until the pinion mate 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 gear and thrust washers can be easily removed Step 11 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 CASE REASSEM BLY Step 12 Apply a small amount of grease on both side gear hubs Assemble new thrust washers onto side gears 3 3 Figure 3 10 Step 13 Assemble both side gears into case Hold top side gear up with fingers Assemble one pinion mate gear Rotate gears until pinion mate gear is directly in the center of the small opening of the case Line up the other pinion mate gear with the gear which has just been assembled Rotate gears until the h
5. The pinion gear should not have any end play NOTE Do not try to rotate pinion using master bearing Figure 3 25 Step 27 Place arbor discs large diameter and arbor into cross bores of carrier as shown TOOL 6776 Dummy Differential Bearing Set D 115 Arbor Figure 3 26 Step 28 Place pinion height block on top of the button end of the pinion gear and against arbor as shown TOOL 6775 Pinion Height Set j E d Figure 3 27 Step 29 Place scooter gage on pinion height block Apply pressure with fingers making sure the gage is flat on the pinion block While pressure is applied set indicator at zero 0 TOOL D115 2 6739 Scooter Gage Figure 3 28 Step 30 Slide scooter gage over arbor As gage slides over top of arbor it will travel in a clockwise direction When indicator is on center of arbor on top it will stop traveling in a clockwise direction If indicator starts to travel in a counter clockwise direction this means you have passed the center top of the arbor Record only the reading when the indicator is at the highest point This reading indicates the amount of shims necessary to obtain the shim pack plus or minus the etching on the button end of the pinion If the etching is zero 0 the shim pack will remain unchanged For example If the pinion is etched 3 m 8 this pinion would require 003 08 mm less shims than a pinion etched zero 0 If the pinion is etched
6. operation Contact your local service dealer or refer to your owner s manual for obtaining the proper lubricant specification AXLE LUBRICANT CHANGE SCHEDULE The following schedule is a suggested lubricant change schedule Lubricant in your vehicle may require more frequent changes depending upon the environment in which it is operated in Contact your local service dealer or refer to your owner s manual for obtaining the proper lubricant change schedule for your vehicle Drain lubricant at first oil change and refill with specified lubricant FOR NORMAL ON HIGHWAY USE change lubricant every 100 000 miles or 24 months whichever comes first FOR OFF HIGHWAY SANDY DUSTY OR WET CONDITIONS change lubricant every 25 000 miles or 6 months whichever comes first Lubricant may be drained by removing the carrier cover plate This also allows for visual inspection of the internal components Follow the service procedure in the manual for reassembly of the cover plate WHEEL BEARING LUBRICATION Wheel bearings are lubricated by packing with grease For grease packing it is recommended that a N L G 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 SUBMERSION OR DEEP WATER FORDING If the vehicle is exposed to water deep enough to cover the hubs it is recommended that th
7. should become familiar with and follow all safety precautions as recommended by the product manufacturer supplier All personnel involved with these materials should follow good industrial hygiene practices e g before eating hands and face should be thoroughly washed Eating drinking and smoking should be prohibited in areas where there is potential for significant exposure to these materials When discarding any of the materials observe all local state and federal laws and regulations for proper disposal procedures Safety Precautions A This symbol warns of possible personal injury y A serious or fatal injury can occur if you lack proper training if you fail to follow proper procedures if you do not use proper tools and safety equipment if you assemble components improperly if you use incompatible components if you use worn out or damaged components if you use components in a non approved application SAFETY GLASSES SHOULD BE WORN AT ALL TIMES WHEN WORKING ON VEHICLES OR VEHICLE COMPONENTS AXLE IDENTIFICATION MANUFACTURING DATE PART NUMBER X XX XXX XXXXXX X ODEL NUMBER RATIO TAG LIMITED SLIP LUBRICATION TAG WHEN REQUIRED Figure 1 1 Spicer axles are identified with a manufacturing date and complete part numbers stamped on the right hand tube The part number may also appear on a metal tag attached to the cover plate by the cover screws depending upon the requirements of
8. ECIFICATION DriveGear to Drive Pinion aaa aa aa KATABA NA eta KAKA hanes NYA 005 008 13 20 mm DRIVE PINION GEAR DEPTHSPECIFICATION 3 500 88 9 mm CENTERLINE OF RING GEAR Figure 4 2 The pinion setting dimension is measured from the centerline of differential carrier center line of ring gear to face of pinion button plus or minus the etch on the button of the pinion This dimension must be held within 002 in 05 mm For example The model 80 pinion setting dimension is 3 500 88 9 mm If the pinion etch is a 2 this dimension becomes 3 502 88 95 mm WHEEL BEARING SPECIFICATION SPECIFIED BY VEHICLE MANUFACTURER CONTACT YOUR LOCAL VEHICLE SERVICEDEALER OR REFER TO YOUR VEHICLE SERVICE MANUAL FCR OBTAINING THE PROPER WHEEL BEARING SPECIFICATION Notes 1 Torque to rotate drive pinion only plus 6 8 Ibs in 68 90 N em for ratios 4 63 to 5 13 NOTES PANA SPICER Drivetrain Products Axles Driveshafts Off Highway Transmissions LONG Thermal Products Transmission Oil Coolers Engine Oil Coolers VICTOR REINZ Sealing Products Gaskets 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 0053 Printed in U S A Copyright Dana Limited 2012 All rights reserved Dana Limited
9. NG GEAR SIDE Assemble shim pack to measurement B OPPOSITE SIDE OF RING GEAR Assemble shim pack to measurement C Add 010 25 mm for differential bearing preload and backlash EXAMPLE 1 Total amount of space measured without ring gear as shown in step 41 figure 3 40 Measurement A 105 2 67 mm 2 Total amount of space measured with gear set assembled in carrier as shown in step 44 figure 3 43 Measurement B 065 1 65 mm 3 Measurement A minus Measurement B equals calculated Measurement C 040 1 02 mm After the measurements and calculations have been made assemble the shim packs using the figures determined in A B amp C and adjusting the pack as described below RING GEAR SIDE Assemble shim pack to measurement B In this example it is 065 1 65 mm OPPOSITE SIDE OF RING GEAR Assemble shim pack to measurement C Add 010 25 mm for differential bearing preload and backlash 040 010 050 1 02 mm 25 mm 1 27mm 3 13 Figure 3 46 Step 47 Assemble differential bearing cups to differential bearing cones Install differential assembly into carrier Use a rawhide or plastic hammer to seat differential assembly into cross bores of carrier Care should be taken to avoid nicking the teeth of the ring gear and pinion during assembly Remove spreader A WARNING When differential assembly is installed into carrier use care to avoid pinching hand or fingers between differential bearing
10. RIER SECTION DISASSEMBLY NOTE The photos or pictures contained 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 Dimensions in parentheses followed by mm are in millimeters WARNING When removing axle assembly make sure vehicle is properly supported Improperly supported vehicle can cause serious injury or death Follow vehicle manufacturers recommendations for proper axle removal procedures assembly Step 1 Remove cover plate from housing and drain lubricant NOTE Before removing differential case assembly make sure the axle shafts are pulled out far enough for clearance to allow removal dee yee AI lt f E Figure 3 1 Step 2 Remove bearing caps Note mating letters stamped on caps and carrier This is important at time of assembly as they are to be assembled exactly as removed Letters or numbers are in vertical and horizontal position 3 1 Figure 3 2 Step 3 Mount spreader to housing DO NOT SPREAD CARRIER OVER 015 38 mm Use dial indicator as shown TOOL W 129 B Differential Spreader C 3339 Dial Indicator Set
11. SPICER
12. Shaft Flange Specified by vehicle manufacturer Differential bearing caps are part of the housing and cannot be serviced separately SECTION 2 SERVICE TOOLS PROCUREMENT Throughout the manual reference is made to certain tool numbers whenever special tools are required These tool numbers are numbers of Miller Special Tools 326 15 Park Lane Garden City MI 48135 They are used herein for customer convenience only Dana makes no warranty or representation to these tools Miller Tool Number Description 2 Jaw Puller DD 914 8 Adapter Ring DD 914 99 Adapters DD 914 95 Adapters D 115 Arbor C 4308 Bearing Cup Installer C 4204 Bearing Cup Installer D 4308 Bearing Cup Installer D 389 Bearing Installer DD 914 42 Button DD 914 42 Button C 3339 Dial Indicator Set W 129 B Differential Spreader 6776 Dummy Differential Bearing Set DD 914 7 Extension C 4171 Handle C 1490 Installer Long Handle break over bar wrench D 159 6775 Pinion Bearing Cup Remover D 191 Pinion Height Set DD 914 Pinion Yoke Installer DD 914 P Press D115 2 6739 Press 8152 Scooter Gage D 131 Slide Hammer Torque Multiplier Torque Wrench 6719 Yoke Holder Gage set for setting differential bearing preload gear backlash and pinion position Consist of D 106 5 dial indicator and D 115 2 Scooter Block The Torque Multiplier increases torque 4 to 1 by means of gear ratio 12 drive female Y4 drive male 2 1 NOTES SECTION 3 CAR
13. Spicer Single Speed Axle SPICER Service Manual Spicer 70HD 276 80 286 AXSM 0053 April 2001 INDEX SECTION 1 GENERAL INFORM ATION PAGE Important Safety Notice cias ngaa ta a A a 1 1 Safety Preca ti ns rra o da hide ad Ea 1 2 Axe 1dent Calon gt is a RE ASAS AA AA A es 1 3 Servicing Components Not Covered In This Manual 0 00 cece eee eee ee eee 1 3 Vehicle Storage or Prolonged Inoperation 0 00 cece eee 1 3 Exploded View of Axle Assembly eee eee eee 1 4 Pants Description a Sew hese Perce war Sema AA EA et Owe wa E 1 4 SECTION 2 SERVICE TOOLS Procurement dear dara NG 2 1 Service Tool Part Numbers and Description 000 cece ee ar 2 1 SECTION 3 CARRIER SECTION SERVICE PROCEDURES Disassembly ida carattere 3 1 Ring Gear Remo a ane ae E o are Se tee es a eee a 3 2 Servicing Standard Differential Case Assembly 0000 cette eee eee eee 3 2 Case Disassembly a ae wan ie tetas dada ene tan ae a 3 2 Case Reassembly ex fag otter dadas beet twee Chetan ad 3 3 Drive Pinion Removal soii aa a a ete a A ae MAT NAG 3 4 Ring Gear amp Pinion Gear Assembly Theory 22 cece eee eee 3 5 Establishing Pinion Gear Depth Using Service Tool Gages lt lt ooooommoonmmmo 3 6 Assembly of Differential ocio cra aw GaSe Ree nae hae ea 3 1 Worksheet for Calculating Ring Gear Backlash amp Differential Bearing Preload Shims acia a pac ae ee he ale ada Re 3 13 Applying RTV Silico
14. UED TO THE REQUIREMENTS OF A GRADE 8 FASTENER N N N N y N J N y GRADE 5 GRADE 7 GRADE 8 SPECIAL GRADE High Strength Customary Inch Bolts Identification marks correspond to bolt strength Increasing numbers Applications represent increasing strength Metric Bolts Identification class numbers correspond to bolt strength increasing numbers represent increasing strength Figure 4 1 Inch grade fasteners can be identified by the radial lines embossed upon the head of the fastener and will correspond to the fastener strength by two lines less than actual grade i e grade 8 fastener will display 6 radial lines on the head Metric fastener strength can be identified with the class identification embossed on the head of each fastener Increasing numbers represent increasing strength A S T M American Society for Testing and Material 4 2 WRENCH TIGHTENING TORQUE SPECIFICATIONS LBS FT 1 Nom Gover SCIGWS us pl na 35 47 5 Differential Bearing Cap Screws 1 eee eee 80 108 5 Drive PINION Nut coi PA PG ewe aes eee Ree ae ees 470 637 2 A th ah Ne ne AA ds ded 25 33 9 RING Gear Screws xii ANG e ALAN Da LR 220 298 3 PINION BEARING AND DIFFERENTIAL BEARING PRELOAD SPECIFICATION LBS IN Nem Torque to Rotate Drive Pinion Only New bearingsonly ooooooo 20 40 2 26 4 52 Torque to Rotate Drive Pinion and Differential Case Assembly Less Axle Shafts New bearings only SEE NOTE 1 BACKLASH SP
15. age 313 This reading will be measurement B Remove indicator and differential case assembly from the carrier Remove master differential bearings from the differential case Refer to the worksheet for calculating ring gear backlash and differential bearing preload shims page 3 13 Figure 3 44 Step 45 Assemble the required amount of shims onto hub ring gear side and opposite side as determined using the worksheet Place bearing cone on hub of case Use bearing installer to seat bearing cone as shown TOOL C 1490 Installer C 4171 Handle DD 914 42 Button NOTE Button is used to raise case from bench to protect bearing cone cage from being damaged when installing opposite bearing cone Figure 3 45 Step 46 Install spreader and indicator as shown DO NOT SPREAD CARRIER OVER 015 38 mm Remove indicator TOOL W 129 B Differential Spreader C 3339 Dial Indicator Set 3 12 WORKSHEET FOR CALCULATING RING GEAR BACKLASH AND DIFFERENTIAL BEARING PRELOAD SHIMS 1 Total amount of space measured without ring gear as shown in step 41 figure 3 40 Measurement A 2 Total amount of space measured with gear set assembled in carrier as shown in step 44 figure 3 43 Measurement B 3 Measurement A minus Measurement B equals calculated Measurement C After the measurements and calculations have been made assemble the shim packs using the figures determined in A B amp C and adjusting the pack as described below RI
16. checking the pinion depth setting TOOL Torque Wrench Figure 3 34 Step 36 Place arbor and discs large diameter end into cross bore of carrier Place pinion height block on button end of pinion Set dial indicator on height block high step of block Set dial indicator at zero 0 Slide scooter gage across or over arbor Indicator will read a plus or minus at its highest point depending on the etching of the pinion NOTE Indicator reading within 002 05 mm of etching is considered acceptable If pinion position is found to be within specification continue with build up If pinion position is not within specification change shim pack thickness under inner bearing cup Remove pinion nut washer end yoke and pinion Assemble preload shims onto pinion NOTE If old shims are available measure shim pack and build up new shim pack using new shims of the same thickness If old shim pack is not available for reference build shim pack up to 060 1 52 mm thick This will provide a starting point and may require adjustment Y Figure 3 35 Step 37 Apply a light coat of hypoid lubricant on the lip of pinion seal and assemble into carrier TOOL 8152 Seal Installer C 4171 Handle Figure 3 36 Step 38 Assemble pinion end yoke washer and new pinion nut Torque nut to specification TOOL 6719 Yoke Holder Torque Wrench NOTE Torque wrench must be capable of 500 Ibs ft 677 9 Nem torq
17. cup and carrier housing Gear teeth may have sharp edges When handling gear use care to avoid cutting hands Figure 3 47 Step 48 Install bearing caps Make sure the letters stamped on the caps correspond with those on the carrier Torque bearing cap screws to specification TOOL Torque Wrench Figure 3 48 Step 49 Check ring gear and pinion backlash in three equally spaced points with dial indicator as shown Backlash should be within specification and cannot vary more than 002 05 mm between points checked TOOL C 3339 Dial Indicator Set High backlash is corrected by moving the ring gear closer to the pinion Low backlash is corrected by moving the ring gear away from the pinion These corrections are made by switching shims from one side of the differential case to the other mig BE YA Figure 3 49 Step 50 Using an in lb torque e wrench as shown rotate pinion and differential assembly Torque reading should be within specifi ication If preload is to high remove an equal amount of shims from both sides of the differential case hubs If preload is to low add an equal amount of shims to both sides of differential case hubs NOTE If shims are added to one side only it will affect backlash reading APPLYING RTV SILICONE GASKET SEALER TO COVER PLATE Figure 3 50 Step 51 Apply gasket sealer to cover plate and assemble to carrier Torque screws to specification TOOL Torque Wrench
18. d be replaced Measure each shim separately with a microme ter and add together to get total shim pack thickness from the original build up If anew 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 differences of these two figures For example If the old pinion reads 2 m 5 and the new pinion is 2 m 5 add 004 10 mm shims to the original shim pack denih New Pinion Marking Marking 4 3 2 1 0 1 2 3 4 4 0 008 0 007 0 006 0 005 0 004 0 003 0 002 0 001 0 43 0 007 0 006 0 005 0 004 0 003 0 002 0 001 0 0 001 2 0 006 0 005 0 004 0 003 0 002 0 001 0 0 001 0 002 1 0 005 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 1 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 0 005 2 0 002 40 001 0 0 001 0 002 0 003 0 004 0 005 0 006 3 0 001 0 0 001 0 002 0 003 0 004 0 005 0 006 0 007 4 0 0 001 0 002 0 003 0 004 0 005 0 006 0 007 0 008 Figure 3 19 Pinion Setting Chart English U S Standard 3 6 datio New Pinion Marking Mari 10 3 5 3 0 3 5 8 10 10 20 18 15 E13 10 08 05 03 0
19. e wheel ends be diassembled and inspected for water damage and or contamination In the event the carrier housing should become submerged in water particularly if over the breather it is recommended that the hypoid gear lubricant be drained and internal parts be inspected for water damage and or contamination Clean examine and replace damaged parts if necessary prior to assembling the housing cover and refilling with the specified hypoid lubricant NOTE If the hubs are exposed to deep water it is possible that the water could enter the carrier at the point the axle shaft enters the tube in the wheel end This could also necessitate the draining of the hypoid lubricant as described above It is recommended that whenever bearings are removed they be replaced with new ones regardless of mileage 1A P 1 American Petroleum Institute 2N L G National Lubricating Grease Institute 4 1 RTV SILICONE RUBBER SEALER SPECIFICATION Sealant material must meet specification of A S T M 1 GE 503 Z1 Z2 23 FASTENER STRENGTH IDENTIFICATION IMPORTANT Whenever fasteners are replaced 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 TORQ
20. ep 19 Pull out pinion seal with puller as shown Discard seal REPLACE WITH NEW ONE AT TIME OF ASSEMBLY Cay Remove bearing cone and outer thrust washer TOOL D 131 Slide Hammer Figure 3 13 Step 18 Remove pinion by tapping with a rawhide or plastic hammer Catch the pinion with your hand to prevent it from falling and being damaged 3 4 Figure 3 15 Step 20 Turn nose of carrier down Remove outer pinion bearing cup Locate driver on back edge of cup drive cup out of carrier CAUTION DO NOT NICK CARRIER BORE Figure 3 1 7 Step 22 Remove pinion bearing with tools as shown TOOL DD 914 P Press TOOL D 159 Pinion Bearing Cup Remover ANG ARA Ring C 4171 Handle ue ee WARNING Do not allow gear to fall It can strike legs or feet and may cause serious injury Gear teeth may have sharp edges When handling use care to avoid cutting hands RING amp PINION GEAR ASSEMBLY THEORY Figure 3 16 Step 21 Remove the inner bearing cup with tools as shown TOOL C 4307 Bearing Cup Remover C 4171 Handle NOTE Shims are located between the bearing cup and carrier bore and may also include an oil baffle Figure 3 18 View of ring 81 pinion set Step 23 Ring gears and pinions are supplied in matched sets only Matching numbers on both the pinion and ring gear are etched for verification If anew gear set is being used verify the numbers of each pinion and ring gear before proceeding with assembly The
21. i t Figure 3 3 Step 4 Pry differential case from carrier with two pry bars After differential case has been removed remove spreader Use caution to avoid damage to components Tag bearing cups indicating from which side they were removed from See note below regarding the use of bearings NOTE lt is recommended that whenever bearings are removed they are to be replaced with new ones regardless of mileage RING GEAR REMOVAL ar ml Figure 3 4 Step 5 Note the differential bearing outboard spacers located on each side of the differential bearing bore Figure 3 6 l Remove and tag which side they were removed from Ring Step 7 Place differential case in vise or suitable holding gear side or opposite side They will be reused during fixture Remove ring gear screws Leave 4 screws loosely assembly unless damaged or worn assembled 90 degrees apart Place assembly on a solid bench Tap screws alternately and evenly to free ring gear NOTE from differential case Remove screws and ring gear Discard ring gear screws Ring gear screws are to be by worn bearings If damaged they should be replaced with new ones at time of reassembly replaced with new ones at time of reassembly o a E SERVICING STANDARD DIFFERENTIAL CASE ASSEMBLY Po The differential assembly may be serviced at this time if required If differential case side gears and pinion mate gears are useable and do not require servicing proceed to
22. ne Gasket Sealer to Cover Plate 1 0 eee eee 3 15 SECTION 4 SPECIFICATIONS Differential Lubrication iii AA OS ee a KA 4 Axle Lubricant Change Schedule 0 00 cece eee eee eee eee 4 1 Wheel Bearing Lubrication oti see oe a al a a a a NAA a a NAA 4 1 Submersion or Deep Water Fording 2 000 cece ee 4 1 RTV Silicone Rubber Sealer Specification 0 ccc ee ees 4 2 Fastener Strength Identification 0 0 0 cee eee 4 2 Wrench Tightening Torque Specifications eee 4 3 Pinion Bearing and Differential Bearing Preload Specification o oooooomm 4 3 Backlash Specification Drive Gear to Drive Pinion 1 0 0 cee es 4 3 Drive Pinion Gear Depth Specification 1 0 0 ccc es 4 3 Wheel Bearing Specification SECTION 1 GENERAL INFORM ATION IMPORTANT SAFETY NOTICE Should an axle assembly require component parts replacement it is recommended that Original Equip ment replacement parts be used They may be obtained through your local service dealer or other original equipment manufacturer parts supplier CAUTION THE USE OF NON ORIGINAL EQUIPMENT REPLACEMENT PARTS IS NOT RECOMMENDED AS THEIR USE MAY CAUSE UNIT FAILURE AND OR AFFECT VEHICLE SAFETY Proper service and repair is important to the safe reliable operation of all motor vehicles or driving axles whether they be front or rear The service procedures recommended and described in this service manual are effective methods f
23. nominal distance from the centerline of the ring gear to the button end of the pinion for the Model 80 axle is 3 500 88 9 mm depending upon the application If shims and baffle are bent or nicked they should be replaced at time of assembly 3 5 On the button end of each pinion there is etched a plus number a minus number or a zero 0 which indicates the best running position for each par ticular gear set This dimension is controlled by the shimming behind the inner pinion bearing cup For example If a pinion is etched a plus 3 m 8 this pinion would require 003 08 mm less shims than a pinion etched 0 This means by removing shims the mounting distance of the pinion is in creased to 3 503 88 98 mm which is just what a 3 m 8 indicates Or if a pinion is etched 3 m 8 we would want to add 003 08 mm more shims than would be required if the pinion were etched 0 By adding 003 08 mm shims the mounting distance of the pinion was decreased to 3 497 inches 88 82 mm which is just what a 3 m 8 indicates If the old ring and pinion set is to be reused mea sure the old shim pack and build a new shim pack to this same dimension If a baffle is used in the axle assembly it is considered as part of the shim pack To change the pinion adjustments use different combination of the pinion shims which come in different thicknesses NOTE If baffle or slinger is bent or mutilated it shoul
24. oles of pinion mate gears are in direct line with the holes of the differential case Step 14 Aft er making sure the gears are in alignment apply a small amount of grease to the new spherical washers Assemble washers between the gears and case Also line up the holes of the washers with those of the gears and case Assemble pinion mate cross shaft make sure lock pin hole of the shaft is in verticle position and lined up with the lock pin hole of the case wig Figure 3 11 Step 15 Assemble new roll pin Peen metal of case over pin to lock in place DRIVE PINION REMOVAL Step 16 Secure end yoke or flange with holding wrench edges When handling gears use care to and remove pinion nut and washer NOTE PINION NUT avoid personal injury HAS 500 LBS FT 677 9 Nom MAX OF TORQUE FOR RETENTION WARNING Gear teeth may have sharp NOTE TOOL 67 19 Yoke Holder On the spline end of the pinion there are bearing Torque Multiplier preload shims These shims may stick to the pinion Long Handle break over bar wrench or bearing or even fall out These shims are to be collected and kept together since they will be used later in assembly Try not to mutilate shims If shims are mutilated replace with new ones Figure 3 12 Step 17 Remove end yoke or flange with tools as shown If end yoke or flange shows wear in the area of the seal contact surface it should be replaced TOOL 2 Jaw Puller Figure 3 14 St
25. or performing service operations Some of these service operations require the use of tools specially designed for the purpose The special tool should be used when and as recommended CAUTION EXTREME CARE SHOULD BE EXERCISED WHEN WORKING ON COMPO NENTS UTILIZING SNAP RINGS OR SPRING LOADED RETENTION DEVICES FOR PERSONAL SAFETY IT IS RECOMMENDED THAT INDUSTRIAL STRENGTH SAFETY GOGGLES OR GLASSES BE WORN WHENEVER REPAIR WORK IS BEING DONE ON ANY VEHICLE OR VEHICLE COMPONENTS It is impossible to know evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way Accordingly anyone who uses a Service procedure or tool which is not recommended must first satisfy himself thoroughly that neither his safety or vehicle safety will be jeopardized by the service methods he selects WARNING Some vehicle manufacturers may require the assembly of brake components on Dana axles that utilize materials containing asbestos fibers BREATHING ASBESTOS DUST MAY BE HAZARDOUS TO YOUR HEALTH AND MAY CAUSE SERIOUS RESPIRATORY OR OTHER BODILY HARM Follow O S H A standards for proper protective devices to be used when working with asbestos materials SILICONE RUBBER SEALANT RTV AND LUBRICATING GREASE AND OILS Silicone rubber sealant is used as a gasket material on Dana axles as well as various lubricants for lubricating purposes Before using any of these materials one
26. should be moved far enough to cause the drivetrain compo nents to make several complete revolutions This procedure will help assure that all internal components receive adequate amount of lubrication to help reduce component deterioration caused by an undesirable environment e g high humidity 1 3 Figure 1 2 EXPLODED VIEW OF AXLE ASSEMBLY The model 80 single speed axle assembly is an integral type housing Shown in figure 1 2 is a Model 80 full float design Item Part Description Item Ring Gear and Drive Pinion Assembly 21 Inner Pinion Bearing Cone 22 Inner Pinion Bearing Cup Pinion Position Shims 23 Pinion Bearing Preload Shims 24 Outer Pinion Bearing Cup 25 Outer Pinion Bearing Cone 26 Thrust Washer 27 Pinion Seal 28 End Yoke and Flinger Assembly 29 Washer 30 Nut 31 Shipping Plug Shipping purposes only 32 Removed by vehicle manufacturer 33 Side Gear Thrust Washer 94 Pinion Mate Gear Thrust Washer 35 Differential Side Gear 36 Differential Pinion Mate Gear 37 Differential Pinion Mate Shaft Differential Outboard Spacer Differential Bearing Cup 1 4 Part Description Differential Bearing Cone Differential Bearing Preload and Backlash Shims Ring Gear Screw Differential Case Roll Pin Pinion Mate Shaft RTV Sealant Identification Tag Pill Plug Cover Plate Cover Screw Brake Line Clip Differential Bearing Cap Screw Housing Differential Bearing Cap Gasket Axle Shaft Flange Axle Shaft Screw Axle
27. the vehicle manufacturer The part number consisting of six digits reading from left to right is the basic number for identifying the particular axle assembly The seventh digit following the dash will identify ratio differential and end yoke options used in the assembly The next group of numbers is the manufacturing date of the axle and is inter preted as follows The first number is the month the second number is the day of the month the third number is the year the fourth is the line that built the axle and the letter is the shift NOTE It is recommended that when referring to the axle the complete part number and build date be ob tained To do this it may be necessary to wipe or scrape off dirt etc from the axle housing If the axle is unique on design such that the unit cannot be identified in the standard manner as de scribed above refer to the vehicle manufacturer s service and or parts manual for proper identification 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 e g brakes hubs rotors and wheel end 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 oper ated at least once every two weeks The vehicle
28. ue Figure 3 37 Step 39 Using an in Lbs torque wrench as shown rotate pinion Torque to rotate pinion should be within specification To increase preload remove shims to decrease preload add shims DIFFERENTIAL BEARING SHIM PACKS Figure 3 38 Theillustration in figure 338 shows the arrow in the pinion pointing in two directions The direction pointing towards the end yoke indicates that by removing pinion position shims the distance from the centerline of the axle to the pinion button is increased giving a plus reading The preload shim pack does not effect the pinion depth setting Arrows on the ring gear illustrate the method to increase or decrease backlash and differential bearing preload ASSEMBLY OF DIFFERENTIAL Figure 3 39 Step 40 Assemble master differential bearings onto case Remove all nicks burrs dirt etc from hubs to allow master bearings to rotate freely TOOL 6776 Dummy Differential Bearing Set Figure 3 40 Step 41 Assemble the differential bearing outboard spacers into the carrier housing as removed in step 5 figure 34 Assemble differential case into carrier less ring gear Mount dial indicator with a magnetic base as shown Locate tip of indicator on flat surface of case Force differential assembly as far as possible in the direction towards the indicator With force still applied set indicator at zero 0 TOOL C 3339 Dial Indicator Set NOTE Dial indicator should ha
29. ve a minimum travel capability of 200 5 08 mm Force the differential assembly as far as it will go in the opposite direction Repeat these steps until you have obtained the same reading Record the reading of the indicator on the worksheet page 313 This reading will be measurement A After making sure the readings are correct remove indicator and differential assembly from housing Remove master bearings from hubs and set aside Figure 3 41 Step 42 Place case assembly in a vise Be sure flange 3 11 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 specification TOOL Torque Wrench Figure 3 42 Step 43 Assemble master differential bearings onto case hubs Place differential assembly into housing Set up dial indicator as shown Locate tip of indicator on flat surface of one of the ring gear screws Force the differential case assembly ring gear away from the pinion gear With force still applied to the differential case set indicator at zero 0 TOOL C 3339 Dial Indicator Set Figure 3 43 Step 44 Force the differential case assembly and ring gear into mesh with the pinion gear Rock ring gear to allow the teeth of the gear to mesh Repeat until the same reading is obtained each time Record this reading on the worksheet p
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