37R Hydraloc D&C Service Manual (Final)
Contents
1. 1 13 4 52 Nm 10 40 LBF IN If within specification remove nut spacer and flange If not within specification repeat steps in figures 118 120 making appropriate spacer substitution If rolling resistance is too low reduce spacer thickness If rolling resistance is too high increase spacer thickness Figure 121 Em 114 me Figure 122 Apply thin continuous coat of Loctite 620 or equivalent to pinion seal bore Figure 123 Using appropriate driver install pinion seal Refer to tool drawing on page 51 37R 43R Hydraloc Differential Service Manual Figure 124 Figure 127 Apply thin continuous coat of Loctite Install grease fitting 620 or equivalent to grease seal bore i Figure 125 Figure 128 Using appropriate driver install grease seal and thrust Apply grease to seal retainer bore washer Refer to tool drawing on page 51 Figure 126 Figure 129 Install o ring Apply grease to pinion and grease seal lips 38 37R 43R Hydraloc Differential Service Manual Wear Sleeve Installation Figure 130 Position seal retainer in bore Figure 133 Apply continuous coat of Loctite 620 or equivalent to wear sleeve 1 0 Figure 131 Index retainer so eye brows align Figure 134 Using appropriate dri2. Figure 84 Figure 87 Install side gear Lubricate sun gear Lube Groove T Figure 85 Figure 8 Lubricate both sides of reaction disc and install Install thrust washer 31 37R 43R Hydraloc Differential Service Manual Figure 89 Figure 92 Install piston outer seal back up ring Install piston inner seal ring NOTE Back up ring must be installed prior to seal ring Figure 90 Figure 93 m Install piston outer seal ring Lubricate piston seals and bore position piston in NOTE Back up ring must be installed prior to seal ring bore 1 Figure 91 Figure 94 Install piston inner seal back up ring Carefully tap piston into bore evenly with mallet 32 37R 43R Hydraloc Differential Service Manual Figure 95 Figure 98 Install differential flange half Clean foreign material and or cured thread NOTE Align identification marks as shown locking compound from holes with M16x2 tap Remove remaining residue from holes Figure 96 Apply Loctite 262 or equivalent to 2 screws and install Figure 99 Use hone stone or file to remove nicks or burrs from mounting face NOTE Be sure to remove all abrasive residue ix Figure 97 Figure 100 Ti
3. 5 lt n 32 NN UG FETT 22277 Ps 15 250 7 THREAD WIG 11 4 E ROS 91 125 egre L NN SSN lt lt 8 12 _ JS 1 000 8 X 1 50 DP MIN THREAD RELIEF x 613 aN 1 00 SS NN N LLL 15 00 555455 m 5 PERMISSIBLE ENDS AN GUP DRIVER 1 dr REF P N 247568 CPU Re 55 60 H715311 HOT BLACK OXIDE 10 25 5 25 4 25 38 n STAMP TOOL NUMBER 325 DETAIL NUMBER AND PART NUMBER 777 777 2 CN d bd 92 25 18 CUP DRIVER __ NZ 1 MATERIAL 8620 CARB 035 045 DP HON Rc 55 60 HOT BLACK OXIDE 3 SOCKET 1 REQ D 91 508 gt MATERIAL 8620 035 045 DP 9 32 1 502 22 130 55 60 HOT BLACK OXIDE 49 E E Q 2 I em lt c m em gt c 0 gt 9 gt PINION BEARING CUP DRIVER HEAVY DUTY BEARING 06 364 00 8 00 28 THD 1 50 DEEP 90 15 00 1 250 1 THREAD 130 5 i IIN THREAD RELIEF 1 500 499 03 x 45 CHANFER UNLESS OTHERWISE SPECIFIED 03 010 MUST BE FREE OF BURRS AND SHARP EDGES gt 8620 CARBUR ZE 035 045 DEEP HARDEN HRC 55 60 FINISH BLACK OXIDE CENTERS PERMISS
4. 5 8 11 5 8 18 3 4 10 3 4 16 METRIC FASTENERS Lubricated and Plated Bolts CapScrews and Studs Class 8 8 Class 10 9 Class 12 9 8 8 on Bolt Head 10 9 on Bolt Head 12 9 on Bolt Head LBF Nm LBF FT Nm LBF FT Nm 15 37R 43R Hydraloc Differential Service Manual PLUG amp ELASTIC STOP NUT TORQUE CHARTS O RING PLUGS P N Size LBF FT Nm 5 16 24 24K 1 5 7 3 8 24 24K 2 8 11 7 16 20 24K 3 10 14 1 2 20 24 4 13 18 9 16 18 24K 5 15 20 3 4 16 24K 6 25 34 7 8 14 24K 7 35 47 1 1 16 12 24 8 50 69 1 3 16 12 24 9 60 81 1 5 16 12 24 10 75 102 1 5 8 12 24 11 85 115 1 7 8 12 24 12 85 115 PI PE PLUGS Size NPTF LBF FT Nm 1 16 27 7 9 1 8 27 10 14 1 4 18 20 27 3 8 18 30 41 1 2 14 35 47 3 4 14 45 61 1 11 1 2 55 75 1 1 4 11 1 2 65 88 ELASTI C STOP NUTS Size LBF FT Nm 1 20 200 270 1 1 4 18 250 340 1 1 2 18 350 475 1 3 4 12 450 610 16 37R 43R Hydraloc Differential Service Manual Hydraloc Differential Disassembly Figure 4 Loosen pinion nut Figure 1 Figure 2 Figure 5 Position unit bench support with blocks as shown Remove pinion nut Drive Flange V Ring and Wear Sleeve Removal Figure 6 Remove pinion spacer spacer seal ring and o
5. lt pana gt SPICER Off Highway Products service Manual 37R amp 43R Hydraloc Differential Supplement ASM 0147 August 2009 378 43R Hydraloc Differential lt gt Service Manual FOREWORD This manual has been prepared to provide the customer and maintenance personnel with information and instructions on the maintenance and repair of Dana Products Extreme care has been exercised in the design and selection of materials and manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product it s principle of operation troubleshooting and adjustments it is urged that mechanics study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only Dana approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment Dana does not warrant repair replacement parts or failures resulting from the use of parts which are not supplied or approved by Dana Important Always furnish serial and model numbers when ordering parts
6. 5 09 55 4 5 3GIXO gt 1 LOH SPXZU Lus E Q 2 I em lt c m em 6 gt c 0 gt 9 gt FLANGE WEAR SLEEVE DRIVER H 0 03 X 45 2 PLCS 0 12 X 45 56 Service Manual SEAL RETAINER INSTALLATION TOOL
7. 1 75 STAMP TOOL NUMBER 1 38 AND DIFF CASE FLANGE SIDE 25 13 2 0 5 63 NNI 1 T NS 02336 2265 f H ain 2 88 11000000 ZN POLISH _ 2 N 1 2 SQUARE DRIVE ZZ 1 2 SQUARE DRIVE IMPACT SOC 15 16 HEX ARMSTRONG 20 030 Deja pesurnov EDU I VER b UT DRIVEI 1 REQ D HOT BLACK OXIDE STRESS RELIEVE 1 ALL 2 PLACE DIMENSIONS 1 16 UNLESS OTHERWISE SPECIFIED HARDEN BEFORE WELD 54 37R 43R Hydraloc Differential Service Manual HYDRALOC SLEEVE DRIVER 2115110 WINYOD HSI1Od OEEZ SEE 20 SC _ Sct 9 I IKA 2 ZZ page 7500510 V 43133 AN I q034 1014 2 JGXO 32V 18 LOH 09 55 gt dd 0 460 SW pESONS 77 55 25559595250 5 9 05 5555525552 Med 0 440 0 0 0 049 0 0 0020 ah WP ah WP a P P c Q 50095000050 s 00009090000 lt Q 104949455 KIRKE 2 SS SESS 0 KE 55 5070 45 OOS L AAA 22227 Stv X CL 44 0071 X 1 00 E gt A 505 TYNN WNIGAW 007 719134 UIGNNN TOOL dNVLS Q033 1
8. SAFETY PRECAUTI ONS To reduce the chance of personal injury and or property damaged the following instructions must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced with a Dana specified replacement part Do not use a replacement part of lesser quality The service procedures recommended in this manual are effective methods of performing service and repair Some of these procedures require the use of purpose designed tools Accordingly anyone who intends to use a replacement part service procedure or tool which is not recommended must first determine that neither his safety or the safe operation of the machine will be jeopardized by the replacement part service procedure or tool selected It is important to note that this manual contains various Cautions and Notices that must be carefully observed in order to reduce the risk of personal injury during service or repair I mproper service or repair may damage the unit or render it unsafe It is important to understand that these Cautions and Notices are not exhaustive It is impossible to warn of all possible hazardous consequences that may result from following or failing to follow these instructions 37R 43R Hydraloc Differential Service Manual 00 uU U N 13 14 15 16 TABLE OF CONTENTS Foreword And Safet
9. UTTO RECOMMENDED FOR DANA DRI VE AXLES Viscosity Class SAE 30 SAE 20 30 SAE 15 30 Weights MANUFACTURER AMOCO AQUI P Aral Lubricants GMBH Bochum D Avia Mineralol AG Munchen D BP BP Australia LTD Silverwaters AUS BP Oil International London GB BP Oil International London GB Caltrex Petroleum Corp London GB Case New Holland Castrol International Swindon GB Cheveron Dea Mineralol AG Hamburg D ESSO Lubricants Europe Brussel B Ford Fuchs Dea Schnierstoffe Mannhein D Imperial Oil Toronto CDN John Deere Waterloo USA John Deere Waterloo USA Kuwait Petroleum Europoor NL Mobil Oil Company LTD Coryton GB Mobil Oil Do Brasil Sao Paulo BR Mobil Pakelo Motor Oil San Bonifacio I Panolin AG Madetswil CH Schwechat A Shell Aseol AG Bern CH Shell International London GB Shell Texaco Belgium N V Brussels B Texaco Total Fina NOTES TRADE NAME AMOCO1000 AQUI P Supertractor Aral Fluid HGS Avia N56 BP Eldoran UTH Tractran TF 10 Tractran TF 9 Terrac Fluid 9 Caltex Textran TDH Premium Hytrans Castrol AGRI Powertrans Chevron THF Deagear TDH OMV AG ESSO Torque Fluid 56 Ford 134D UTF Titan Hydra 20 Torque Fluid N56 Deere Hydgard J 20 C John Deere Hy Gard Europa Q8 T 2000 Mobilfluid 424 Mobilfluid 424 Mobil 424 UTF Pakelo UTTO Fluid 4D Panolin JD 303 OMV Austromatic I GB Aseol Multitrac 85W Shell Donax TD 80W Shell Donax TD Textran TDH Premium Texaco TDH Trac E
10. providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner CAUTION Care should be exercised to avoid skin rashes and inhalation of vapors when using alkali cleaners Thoroughly dry all parts cleaned immediately by using moisture free compressed air or soft lintless absorbent wiping rags free of abrasive materials such as metal filings contaminated oil or lapping compound I NSPECTI ON The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date BEARI NGS Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use Do not replace a bearing without replacing the mating cup or cone at the same time After inspection dip bearings in clean light oil and wrap in clean lint free cloth or paper to protect them until installed OIL SEALS GASKETS AND RETAI NI NG RINGS Replacement of spring loaded oil seals gaskets and snap rings is more economical when unit is disassembled than to risk premature overhaul to replace these parts at a
11. shoulder on the shaft until the cone grabs on to the shaft The hot cone will pull away from the cold shoulder unless it is held in position Use 002 05 feeler gages to make sure the cone is fully seated against the shoulder after the parts are cooled Many loose bearing settings excessive end play are caused by an unseated cone working back against the shoulder in service 378 43R Hydraloc Differential lt gt Service Manual CLEANING AND INSPECTI ON CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and agitated slowly until parts are thoroughly cleaned of all old lubricants and foreign materials CAUTION Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type cleaners BEARI NGS Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean Dry bearings using moisture free compressed air Be careful to direct air stream across bearings to avoid spinning Bearings may be rotated slowly by hand to facilitate the drying process HOUSI NGS COVERS AND CAPS Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions
12. 178 Tighten seal retainer screws to 24 27 Nm 18 20 LBF FT 87177 Figure 179 Apply Loctite 262 or equivalent to differential adjusting nut lock screw Install adjusting nut lock screw in one of the two holes that allow it to clear the lugs on the adjusting nut Figure 180 Tighten adjusting nut lock screw to 48 50 Nm 35 37 LBF FT 47 37R 43R Hydraloc Differential Service Manual Air Pressure Test Figure 184 Install 2 brake supply port plugs and tighten to 18 Nm 13 LBF FT Figure 181 Air pressure test per procedure on page 6 Hydraulic Pressure Test f Figure 185 2 Install 2 Hydraloc port plugs and tighten to gue 182 Port 20 Nm 15 LBF FT Port 18 Nm 13 LBF FT Hydraulic pressure test per procedure on page 6 Figure 186 Install drain and oil level plugs Tighten to 18 Nm 13 LBF FT Figure 183 Install 2 bleeder valves and seats Tighten to 24 27 Nm 18 20 LBF FT 48 8 4 c 9 9 0 gt 5 E gt gt DIFFERENTI AL CARRI ER CUP DRI VERS LOC TITE IN PLACE 4 S 17 2 XV Ey MIN REUEF 94 250 SF MTH TIMKEN 4715311 a 22000 ANN AS 91 489 T NE
13. Driver Flange Wear Sleeve Driver Seal Retainer Installation Tool 37R 43R Hydraloc Differential Service Manual EXPLODED VI EW AND PARTS DESCRIPTION Item Qty Description l A m H Screw Socket Head Capscrew Retainer Seal Plug Seal Retainer 6mm Plug Seal Retainer 3mm Seal Ring Nut Differential Brg Adj Capscrew Retainer Differential Plug Differential Retainer O Ring Capscrew Washer Seal Outer Ring Piston Sleeve Wear Seal Inner Cup Bearing Cone Bearing Capscrew Case Diff Flange Half Seal Inner Piston Item Qty 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 HERR AAR Description Seal Inner Piston Backup Piston Seal Outer Piston Seal Outer Piston Backup Plate Friction Plate Reaction Washer Side Gear Thrust Gear Side Washer Pinion Gear Thrust Gear Pinion Gear Side Spider Differential Assy Cap amp Clutch Hsng Washer Capscrew Cone Bearing Cup Bearing Gear Ring Housing Carrier Nut Differential Brg Adj Lock Differential Adj Nut Capscrew 4 Item Qty Description 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 2 gt 23 Plug Magnetic O Ring Plug Gear Pinion Cone Pinion Inner Bearing Cup Pinion Inner Bearing Sh
14. GEAR PINION IN THIS DIRECTION PINION IN THIS DIRECTION END ALL CONTACT BEARINGS SHOWN BELOW ARE ON RIGHT HAND SPIRAL RING GEAR THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH FIG 1 TYPICAL PREFERRED BEARING ON BOTH SIDES OF WHILE UNDER A LIGHT LOAD FIG 2 TOE BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOVING GEAR AWAY FROM PINION FIG 3 HEEL BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY AND COULD RESULT IN EARLY GEAR FAILURE TO MOVE BEARING TOWARD TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARO PINION FIG 4 LOW BEARING ON GEAR AND HIGH BEARING ON PINION CORRECT BY PULLING PINION AWAY FROM GEAR INCREASE MOUNTING DISTANCE FIG 5 HIGH BEARING ON GEAR AND LOW BEARING ON PINION CORRECT BY MOVING PINION TOWARD GEAR DECREASE MOUNTING DISTANCE BACKLASH BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICULAR TO THE TOOTH SURFACE AT THE EXTREME HEEL SEE SHEET NO 2 FOR BACKLASH VALUES 14 37R 43R Hydraloc Differential Service Manual 1 4 20 FASTENER TORQUE CHART STANDARD FASTENERS Lubricated and Plated Bolts CapScrews and Studs Grade 5 Grade 8 3 Radial Dashes On Bolt Head 6 Radial Dashes On Bolt Head LBF Nm LBF FT Nm 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 1 2 13 1 2 20 9 16 12 9 16 18
15. future time Loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing member should be handled carefully particularly when being installed Cutting scratching or curling under lip of seal seriously impairs its efficiency At reassembly lubricate lips of oil seals with Multipurpose Lithium grease Grade 2 37R 43R Hydraloc Differential Service Manual P g CLEANI AND INSPECTI ON CONT GEARS AND SHAFTS If Magna Flux or a dye penetrant process is available use process to check parts Examine teeth and the ground polished surfaces of all gears and shafts carefully for wear pitting chipping nicks cracks or scoring If gear teeth are cracked or show spots where case hardening is worn through replace with new gear Small nicks may be removed with suitable hone stone Inspect shafts to make certain they are not sprung bent or have twisted splines HOUSI NGS COVERS AND CAPS Inspect housings and covers to be certain they are thoroughly cleaned and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or conditions which can cause oil leaks or failures 378 43R Hydraloc Differential lt gt Service Manual RECOMMENDED LUBRICANTS FOR DANA DRIVE AXLES Recommendations Extreme pressure gear lubricant is recommended for use in all drive steer and rigid drive axles except where explici
16. nut lock screw Remove 2 seal retainer seal rings 4 p TEC J Figure 20 Figure 23 Remove 4 seal retainer screws Remove seal retainer inner oil seal Figure 24 Remove seal retainer Remove seal retainer outer oil seal 20 37R 43R Hydraloc Differential Service Manual Figure 25 Remove 4 differential retainer screws E Figure 26 Loosen differential adjusting nut Refer to tool drawing on page 54 Figure 27 Remove differential adjusting nut 21 x PM Figure 280 Install 2 8 eye bolts Figure 29 Install 2 chain clevises attach hoist Figure 30 Remove differential retainer 37R 43R Hydraloc Differential Service Manual Differential Assembly Removal Figure 34 Attach hoist and remove differential assembly and ring gear Figure 31 Remove seal rings Ring Gear Removal Figure 32 Remove 2 ring gear mounting screws Figure 35 and washers 180 from each other Remove 14 ring gear screws and washers Figure 33 Figure 36 Install 2 M16 eye bolts Position wood blocks or equivalent under ring gear and tap with mallet to remove from differential body Refer to figure 37 22 37R 43R Hydraloc Differential Service Manual Fi
17. ring Figure 3 Heat pinion nut to release thread locking compound 17 37R 43R Hydraloc Differential Service Manual Figure 7 Remove flange Figure 8 Remove v ring seal from flange Figure 9 Mark flange wear sleeve in three equally spaced locations as shown across the full width of sleeve 18 Figure 10 Grind the cutting edge of chisel to radius as shown Figure 11 Use rounded tip chisel to expand and remove wear sleeve by striking evenly across the width of the sleeve in the three marked locations IMPORTANT Do not cut through wear sleeve as damage to the flange will occur Pinion Seal Retainer Cartridge and Seal Removal Figure 12 Install 2 M8 screws and flat washers in puller holes 37R 43R Hydraloc Differential Service Manual Figure 13 Remove seal retainer cartridge Figure 14 Remove pinion seal from cartridge Figure 15 Remove grease seal and thrust washer 19 Figure 16 Remove o ring Figure 17 Remove grease fitting Differential Retainer and Adjuster Removal Figure 18 Remove differential adjusting nut screw and lock 37R 43R Hydraloc Differential Service Manual Lu cos c 0 73 E Figure 19 Figure 22 Remove adjusting
18. 2 piston rings and coat with grease Install 4 retainer screws and tighten 4 to 24 27 Nm 18 20 LBF FT 110 C gre Figure 156 Install 2 alignment pins located 180 apart 43 37R 43R Hydraloc Differential Service Manual Backlash and Contact Pattern Setup and Adjustment Figure 159 B Tighten differential adjusting nuts to a minimum of 273 Figure 162 41 Nm 30 LBF FT Rotate pinion back and forth while Install differential adjusting nut lock performing this step to assure that detectable backlash exists IMPORTANT Advance adjusting nut if necessary to and ring gear is not being forced into pinion gear line up mounting holes Do Not loosen back off nut Refer to tool drawing on page 54 mer Figure 160 Set up magnetic base dial indicator as shown to measure ring and pinion back lash Figure 163 Apply Loctite 262 or equivalent to 2 nut lock screws and install Tighten to 24 27 Nm 18 20 LBF FT With ring gear being held stationary rock the pinion flange back and forth gently while watching the reading on dial indicator Backlash specifications are as follows 37R 4 100 ratio with DIN 180 Flange 56 88 mm 022 035 37R 4 100 ratio with DIN 150 Flange 46 74 mm 018 029 43R 4 100 ratio with DIN 180 Flange 53 89 mm 021 035 4 364 ratio with 8 5 CTP Flange 48 79 mm 019 031 4 556 ra
19. AGLE BOTH ENDS 50 EE c 0 2 Q 5 gt m N m 5 E 2 gt ho GREASE AND OIL SEAL DRIVER 04 50 1 50 SF 20 88 x 0 53 DEEP Pa 1 SEAL DRIVER 0 06 0 09 R 1 REQ D POLISHED 012 X 45 MATERIAL 8620 RADIUS CORNERS 2 PLCS CARB 035 045 DP HARDEN Rc 50 55 STAMP TOOL NUMBER BLACK OXIDE AND PART NUMBER SECTION 8 8 51 EE c 0 2 Q 5 gt m N m gt c 0 gt 9 gt INNER LI P SEAL DRIVER 79 12x45 2 PLCS 53 THRU 880 C BORE x 0 53 DEEP 38 SECTION 1 SEAL DRIVER INNER I REQ D MATERIAL 8620 CARB 035 045 DP HARDEN Rc 50 55 DETAIL HOT BLACK OXIDE SCALE 2 1 52 c 0 2 Q 5 gt I m n m gt c 0 gt 9 gt OUTER LIP SEAL DRIVER 0 53 THRU 880 C BORE x 0 53 DEEP 0 06 0 09 R POLISHED RADIUS CORNER SECTION A A SEAL DRIVER OUTER LIP I REQ D MATERIAL 8620 CARB 035 045 DP HARDEN Rc 50 55 HOT BLACK OXIDE 53 E c thes 2 J 2 gt cc m cc N m 5 E 2 gt ho USTI NG NUT DRIVER 38 CENT 12 LUGS 6 00 4 75
20. Pontiax LS Kompressol Hypoid EW Leprinxol LS LM Hypoidgetriebeol GL Megol Hypoidgetriebeol Pennasol Sperrdiff Getr Mobilube LS Mobilube HD 80W 90 L Carrier Hykomol LS Motul 90 PA Gearing Wonder LS 85V Gear G3 Lube Special L Getriebeol Hypoid LS 9 OMV Gear Oil LS Orfy Tucana LS Pakelo Universal Gear E Panolin Super Duty LS 4096 80W 90LS HP 80W 90 HG Getriebeol LS 90 S EP Autoblocante Gulf LS Rear Axle Oil Wintershall Wiolin RSH Aseol Topress LS Shell Getriebeol 90 LS SK G LS 80W 90 Gear Geartex LS Mutligear EP 80W 90 Total Transmission DA Turbotank Bosche Bodeker Bremen D Turbo Getriebeol LS Unil Deutschland GMBH Bremen D Unil Opal Rueil Maimaison F Veedol International Swindon GB Yacco SA St Pierre LES Elbeuf F Unil Gear AB EP Unil Opal Gear AB EP Veedol Multigear L Yahypo BN 90 NOTES 1 The above list of oils is not meant to be an all inclusive list of acceptable oils for use in Dana products 2 It is the end users responsibility to select the best grades of oils available in the local area that provide proper viscosity and limited slip friction additives for long product life and noise free operation 3 Intermixing of GL5 oils with GL4 oils is not recommended as they are not compatible D 5 D 3 0 5 c 2 da UJ 2 lt Q E zh D D 5 ct 37R 43R Hydraloc Differential Service Manual LEFT HAND SPIRAL
21. S 80W 90 Citgo Synthetic 75W 90 Antar BLS HRD EP GL Tranself Typ BLS Gear Elf BIS90 Elimo Hypoid LS Esso Getriebeoel LSA 85W90 Esso GX LS 80W 90 Esso Extra LS 75W 90 Fina Pontonic LS Fina Dynatrans LS Fuchs Dea Schmierstoffe Mannheim D Dealear LS Fuchs Dea Schmierstoffe Mannheim D Titan Gear LS90 Fuchs Dea Schmierstoffe Mannheim D Dealear AWB Furukawa LTD Japan Genol GMBH Wiena A Ginouves Georges SA LA Farieda F HAFA Paris F gol France Paris F Indian Oil Corp Faridabad l nd Kyoseki FK Axle 80W90 Genol Hypolube LS 90 York 798 LS Hypoid PA 190 BPA Servp Gear Super LS 90 MANUFACTURER Italiana Petroli Genova A I Kompressol OEL Koin D Leprince Siveke GMBH Herford D Liqui Moly GMBH ULM D Meguin GMBH Saariouis D MI N OL Raffin Dollbergen Uetza D Mobil Oil Wedel D Mobil USA Mol Hungarian Oil Komarom H Motul AS Valres Sur Marne F Nova Stilmoll SPA Modena l Nova Stilmoll SPA Modena l Oest G Min OI Werk Freudenstadt D OMV AG Schwechat A Orfy International Vieux Thann F Pakelo Motor Oil San Bonifacio l Panolin AG Madetswil CH Pennzoil NA Quaker State NA Raiffeisen HG Nord AG Hannover D Repsol Distribucion SA Madrid E SAEL Madrid E Schmierstoffraffinerie Saizbergen D Shell Aseol AG Bern CH Shell I nternational London GB SK Corporation Eeoul Korea Texaco Belgium N V Brussels B Texaco USA Total Raffinage Distr Paris F TRADE NAME IP
22. SPIRAL BEVEL AND HYPOID TOOTH BEARING CHART MOVE PINION TOWARD CENTER roe 277 GEAR IN THIS DIRECTION MOVE PINION AWAY FROM ADDENDUM PROFILE 977 CONVEX DEDENDUM Yor MOVE GEAR AWAY FROM PINION IN THIS DIRECTION PINION IN THIS DIRECTION LARGE END ALL CONTACT BEARINGS SHOWN BELOW ARE ON LEFT HAND SPIRAL RING GEAR THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH FIG 1 TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH WHILE UNDER LIGHT LOAD FIG 2 TOE BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOVING GEAR AWAY FROM PINION FIG 3 HEEL BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY AND COULD RESULT IN EARLY GEAR FAILURE TO MOVE BEARING TOWARD TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD PINION FIG 4 LOW BEARING ON GEAR AND HIGH BEARING ON PINION CORRECT BY PULLING PINION AWAY FROM GEAR INCREASE MOUNTING DISTANCE FIG 5 HIGH BEARING ON GEAR AND LOW BEARING ON PINION CORRECT BY MOVING PINION TOWARD GEAR DECREASE MOUNTING DISTANCE BACKLASH BACKLASH SHOULD BE MEASURED WITH DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICULAR TO THE TOOTH SURFACE AT THE EXTREME HEEL SEE SHEET NO 2 FOR BACKLASH VALUES 13 37R 43R Hydraloc Differential Service Manual RIGHT HAND SPIRAL SPIRAL BEVEL AND HYPOID TOOTH BEARING CHART MOVE PINION TOWARD GEAR IN THIS DIRECTION MOVE PINION AWAY FROM MOVE GEAR AWAY FROM MOVE
23. Step 1 Number from ring gear 186 106 mm 7 3270 Bearing height 45 974 mm 1 8100 Total 232 080 mm 9 1370 tep 2 232 560 mm 9 1559 232 080 mm 9 1370 480 mm 0189 Number from housing Total from step 1 Shim thickness required Figure 108 Heat and install pinion inner bearing cone Refer to bearing heating and freezing guidelines Figure 109 Install pinion outer bearing Figure 110 Install mounting distance shim as determined in figure 107 Figure 111 Freeze and install pinion inner bearing cup 35 37R 43R Hydraloc Differential Service Manual Figure 112 Figure 115 Check for proper seating of pinion inner and outer Lubricate pinion outer bearing cone bearing cups Refer to bearing and freezing guidelines Figure 113 Figure 116 Lubricate pinion inner bearing cone Heat and install pinion outer bearing cone Figure 114 Figure 117 Install pinion Install flange 36 37R 43R Hydraloc Differential Service Manual Figure 118 Install pinion spacer Figure 119 Install pinion nut and tighten to 1261 1396 Nm 930 1030 LBF FT Figure 120 Check pinion bearing rolling resistance and record Pinion rolling resistance recorded in figure 120 should be 37R 1 13 3 95 Nm 10 35 LBF IN
24. e 145 Lock or hold pinion shaft from turning Figure 146 Remove 1 of 2 ring gear screws and mark head of remaining screw for identification purposes Figure 147 Apply Loctite 262 or equivalent to 15 ring gear mounting screws and install with washers Run down but do not tighten IMPORTANT Perform the procedures shown in figures 147 149 in a timely manner before the Loctite begins to cure 41 37R 43R Hydraloc Differential Service Manual Figure 148 Remove marked screw apply Loctite 262 or equivalent and install with washer Figure 149 Tighten 16 ring gear mounting screws in a star pattern to 286 316 Nm 211 233 LBF FT Using a brass bar or equivalent sharply shock assembly in several locations around the bolt circle Immediately retighten all screws in a star pattern to 286 316 Nm 211 233 LBF FT Figure 150 Release pinion shaft Differential Retainer Installation Figure 151 Install differential bearing cup Figure 152 Install differential retainer o ring and lubricate with grease Figure 153 Install differential bearing adjusting nut 37R 43R Hydraloc Differential Service Manual Figure 154 Figure 157 Lubricate differential bearing cone with axle lubricant Install differential retainer Figure 155 Figure 158 Install
25. ferential flange half on bench as shown Use compressed air to push piston out of bore 25 37R 43R Hydraloc Differential Service Manual Figure 55 Remove piston Figure 58 Install pinion nut to protect threads and tap pinion through outer bearing cone Figure 5 Remove outer piston seal and back up ring Figure 57 Figure 60 Remove inner piston seal and back up ring Remove pinion inner bearing cone 26 37R 43R Hydraloc Differential Service Manual Figure 64 Remove pinion outer bearing cup Figure 62 Figure 65 Remove differential bearing adjusting nut and cup Remove bleeder screw and seat Figure 63 Figure 66 Remove pinion inner bearing cup and shim Remove plug and o ring 27 37R 43R Hydraloc Differential Service Manual Figure 67 Remove plug and o ring Hydraloc Differential Reassembly Figure 68 Apply thin continuous coat of Loctite 620 or equivalent to wear sleeve mounting surface Figure 69 Apply thin continuous coat of Loctite 620 or equivalent to inside diameter of wear sleeve Figure 70 Install wear sleeve on flange half NOTE End of sleeve should be flush with end of journal Refer to tool drawing on page 55 28 37R 43R Hydraloc Differential Service Ma
26. ghten 2 screws to Use hone stone or file to remove 24 27 Nm 18 20 LBF FT nicks or burrs from mounting face NOTE Be sure to remove all abrasive residue 33 37R 43R Hydraloc Differential Service Manual Pinion Installation and Adjustment Figure 101 Heat ring gear to 93 100 200 212 F and Install Caution Use gloves to avoid injury Figure 104 Locate ring gear mounting distance dimension located in this area and record Figure 102 Temporarily install 2 ring gear mounting screws 180 apart and tighten to 135 Nm 100 LBF FT Allow assembly to cool before installing additional screws IMPORTANT Using 05 mm 002 feeler gauge check several ANN locations around ring gear to be sure there is no gap between Figure 105 the ring gear and differential body mounting faces Number as it appears in figure 104 NOTE Assembly is shown with ring gear down for clarity This procedure should be performed with assembly in same position as shown in figure 101 Figure 103 Figure 106 Heat and install differential bearing cone Refer to Locate ring gear mounting distance bearing heating and freezing guidelines dimension on ring gear and record 34 37R 43R Hydraloc Differential Service Manual Figure 107 Measure height of pinion inner bearing cup and cone and record Calculate ring and pinion mounting distance shim as follows
27. gure 37 Wood blocks or equivalent placed under ring gear to prevent ring gear damage Differential Body Disassembly i Figure 38 Mark case as shown in 2 places for proper alignment during reassembly T 1 E i E Figure 39 Remove 2 screws eS Figure 40 Remove case flanged half Figure 41 Remove side gear thrust washer in S Figure 42 Remove reaction and friction discs 37R 43R Hydraloc Differential Service Manual Figure 43 Remove side gear Figure 44 Remove 12 screws and washers Figure 45 Remove differential cap 24 M t m Ay EST 1 pi Figure 46 Remove side gear thrust washer Remove side gear Figure 48 Remove spider with pinion gears and thrust washers 37R 43R Hydraloc Differential Service Manual Figure 49 Figure 52 Remove 4 pinion gear thrust washers Apply heat and remove wear sleeve ry 2 dee iy A i Figure 50 Figure 53 Remove 4 pinion gears Apply heat and remove differential bearing cone Piston Removal Figure 51 i Apply heat and remove differential bearing cone u _ Figure 54 Refer to bearing heating and freezing guidelines Position dif
28. im Pinion Bearing Cup Pinion Outer Bearing Cone Pinion Outer Bearing O Ring Fitting Grease Cartridge Seal Retainer Seal Pinion Seal Grease Washer Thrust Seal V Ring S eeve Wear Flange O Ring Seal Spacer Spacer Pinion Nut Pinion 37R 43R Hydraloc Differential Service Manual CROSS SECTION 37R 43R Hydraloc Differential Service Manual HYDRALOC DI FFERENTI AL PRESSURE TEST INSTRUCTI ONS 1 Air Pressure Test Air pressure test the pressure and tank port seals and system Ports P amp T Apply 83 kpa 12 psi to pressure and tank ports simultaneously and allow stabilization period of 20 seconds minimum Lock off pressure and measure decay in 10 seconds Maximum allowable decay is 23 pa 0033 psi in 10 seconds Alternate decay period is 69 kpa 1psi per 5 minutes 2 Hydraulic Pressure Test Hydralic pressure test the pressure port seals and system Port P Apply 4137 kpa 600 psi to pressure port with open tank line back to tank Allow stabilization period of 20 seconds minimum and release Reapply 4137 kpa 600 psi and monitor fluid for a 1 one minute period Fluid flow rate should not exceed 2 83 lpm 75 gpm 37R 43R Hydraloc Differential Service Manual lt gt BEARI AND FREEZI NG GUIDELINES Bearings often must be cooled or heated to aid assembly removal Since temperature extremes can cause permanent bearing metal
29. lf C4 1000 1 The above list of oils is not meant to be an all inclusive list of acceptable oils for use in Dana prod ucts 2 Itis the end users responsibility to select the best grades of oils available the local area that provide proper viscosity and limited slip friction additives for long product life and noise free operation GL5 CLASS GEAR LUBRICANTS WITH LIMITED SLIP ADDITI VES RECOMMENDED FOR DANA DRI VE AXLES Viscosity Class SAE 75W 90 80W 90 85W 90 90 MANUFACTURER Addinol Mineralol GMBH Krump A D Agip Petroli Spa Rom Aral Lubricants GMBH Bochum D Avia Mineraloi AG Munchen D Baywa AG Munchen D Blaser Swisslube Hasie Ruegsau CH BP Oil International London GB BP Oil International London GB Bucher AG Langenthal Calpam GMBH Aschaffenburg D Castrol International Swindon GB Castrol International Swindon GB Citgo USA Citgo USA ELF Lubricants Paris F ELF Lubricants Paris F ELF Lubricants Paris F ELF Lubricants North America Eller Montan Comp Duisburg D ESSO Lubricants Europe Brussel B ESSO Imperial Oil NA ESSO Imperial Oil NA Fina Europe SA Brussel B Fina Europe SA Brussel B TRADE NAME Addinol Getriebeol 85W90 LS Agip Rotra MP S Aral Degol 3216 Avia Hypoid 90 LS Baywa Getriebeol Hypoid LS 90 Hypoid Getriebeol LS Frontal Getriebeol LS Energear Limslip 90 Motorex Gear Oil LS Calpam Gear Oil LS 90 Castrol Hypoy LS Castrol LSX Citgo Premium L
30. lurgical damage it Is important to take proper precautions and use correct methods when heating and cooling bearings Cups that are to be assembled in hubs or housings with a press fit may be shrunk in deep freeze unit Standard class bearings should not be cooled below 65 F 54 C In addition to cooling the bearing cup in some instances it may be necessary to heat the housing To control temperature is best to use a thermostat along with a freezer unit or a properly calibrated thermometer If a suitable freezer or thermometer is not available your Timken service representative can suggest liquid combinations that freeze the bearing cup at the optimal temperatures Regardless of the method check the cup s final seating against the housing shoulder with feeler gauges Take extreme care that standard product bearings are never heated above 149 C 300 Fl If bearings are heated above this temperature their metallurgical structure may soften rendering them unsuitable for use There are a number of recommended methods for heating bearings Electric ovens or electrically heated oil baths may be used but only when accompanied by proper thermostatic control If you use a hot plate to heat the oil never rest bearings directly on the bottom of the pan Instead protect bearings from the heat source with a simple wire screen holder or similar device Use heat resistant gloves to handle heated cones Hold the hot cone solid against the cold
31. nual 4 egg Im ADS Figure 71 Figure 74 Use compressed air to blow excess sealant Lubricate spider with axle lubricant and from oil passage install 4 pinion gears T Figure 72 Clean cured thread locking compound from tapped holes Lubricate and install 4 thrust washers with M14x2 tap Remove remaining residue from holes Figure 73 Figure 76 Heat and install differential bearing cone on cap half Install assembly in clutch housing Refer to bearing heating and freezing guidelines 29 37R 43R Hydraloc Differential Service Manual Figure 77 Install side gear ni LJ fou aut pod x tube ee Figure 78 Lubricate side gear Figure 79 Install thrust washer 30 Figure 80 Lubricate thrust washer Figure 81 Install differential cap NOTE Align identification marks Figure 82 Install 12 socket head screws and washers 37R 43R Hydraloc Differential Service Manual Lube Groove Figure 83 Figure 86 Tighten screws in a star pattern to Lubricate both sides of friction disc and install 183 202 Nm 135 149 LBF FT Alternately install remaining reaction and friction discs Align lube grooves with each other
32. oc seal NOTE Seal is installed with sealing down or towards center of seal retainer Refer to tool drawing on page 51 45 37R 43R Hydraloc Differential Service Manual Figure 169 Apply continuous coat of Loctite 620 or equivalent to outside diameter of outer Hydraloc seal Figure 170 Using appropriate driver install outer Hydraloc seal NOTE Seal is installed with sealing lip down or towards center of seal retainer Refer to tool drawing on page 53 Figure 171 Apply Loctite 262 or equivalent to seal retainer plug Figure 172 Install seal retainer plug NOTE Plug end to be flush with mating surface j il d ui 3 7 4 ij 4 r j P E ag j ji 1 T d 1 4 d 173 Coat with grease to hold in position and install 2 seal rings in seal retainer La s Figure 174 Insert seal retainer installation tool Refer to tool drawing on page 57 46 37R 43R Hydraloc Differential Service Manual ri wal Figure 175 Coat inner and outer Hydraloc seal lips with grease 1 Figure 176 Carefully install seal retainer i AM Figure 177 Install 4 seal retainer screws Figure
33. ronmental and duty cycle conditions is 1000 hours in all off highway applications and 10 000 miles in on highway applications Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination Judgement must be used to determine the required change intervals for extreme conditions Extended Oil Change Interval Extended oil service may result when using synthetic lubricants Appropriate change intervals must be determined for each application by measuring oxidation and wear metals over time to determine a base line Wear metal analysis can provide useful information but an axle should not be removed from service based solely on this analysis Vehicles which are prone to high levels of ingested water in the axle or water as a result of condensation should not use extended drain intervals Friction Modifiers Friction modifiers may be used with the lubricant to reduce Posi Torq limited slip differential noise or liquid cooled brake noise If friction modifiers are used follow instructions on TSB 278E The use of aftermarket lubricant additives other than those specified is not recommended and may reduce the life of the axle and void the warranty Viscosity Based on Prevailing Ambient Temperature 80W90 75W90 40 30 20 10 0 10 20 30 140 50 40 4 14 32 50 68 86 104 122 10 37R 43R Hydraloc Differential Service Manual UNI VERSAL TRACTOR TRANSAXLE OILS
34. tio with 8 5 CTP Flange 53 89 mm 021 035 5 429 ratio with DIN 150 Flange 53 94 mm 021 036 If the readings are out of specification move the differential adjusting nuts inward or outward together IMPORTANT Recheck differential bearing preload after the proper backlash reading is achieved Refer to Figure 159 NOTE If checking the backlash with an indicator on the ring gear tooth while holding the pinion the specifications are as follows 37R 25 33 mm 010 013 43R 23 38 mm 009 015 Figure 161 44 37R 43R Hydraloc Differential Service Manual Differential Load Test Figure 164 Install stub shaft NOTE The axle shaft and socket can be used to perform this procedure Figure 165 Step 1 Hold pinion and rotate side gear five turns in each direction Differential clutch must turn freely with a maximum torque of 34 Nm 25 LBF FT Step 42 Hold side gear and rotate pinion in both directions to make several passes through the gear contact checking compound on the ring gear Figure 166 Inspect tooth contact pattern on ring gear Refer to charts on pages 13 amp 14 y Hydraloc Seal Retainer Assembly and Installation Figure 16 Apply continuous coat of Loctite 620 or equiva lent to outside diameter of inner Hydraloc seal Figure 168 Using appropriate driver install inner Hydral
35. tly stated differently by Dana Off Highway Products Engineering Mineral Based Acceptable lubricants must meet API GL 5 MT or MIL PRF2105E qualifications The highest viscosity grade must be used given the prevailing ambient temperatures from the chart below Limited slip designated GL 5 oil brands are preferred for quiet operating characteristics Universal Tractor Transmission Oils UTTO Fluids Acceptable lubricants must meet Dana MS266 or J Deere J20C specifications Use the highest viscosity grade for the ambient temperatures from the temperature chart below Synthetics Synthetic lubricants are recommended providing they meet API GL 5 MT 1 qualifications The highest viscosity grade must be used given the prevailing ambient temperatures from the chart below In general synthetic oils have a lower pressure viscosity response than mineral oil lubricants as the contact pressure between the gears increases This produces a thickening of the mineral oil at the contact point This increase in viscosity helps to maintain lubricant film thickness reducing the possibility of surface and spalling fatigue Synthetic lubricants do not thicken as much under pressure unless specifically formulated to do so Before using a synthetic lubricant in heavy applications the customer must check with the lubricant supplier on the issue of high pressure lubricant applications Normal Oil Change Intervals Oil change intervals for mineral based lubricants in normal envi
36. ver install wear sleeve Refer to tool drawing on page 56 Pinion Flange Installation Figure 1 Carefully tap retainer with a soft mallet B d evenly around diameter to install Figure 135 Install v ring seal 39 37R 43R Hydraloc Differential Service Manual Pu eens i Figure 136 Install input flange Figure 137 Install o ring and o ring spacer Figure 138 Install pinion spacer identified in figures 118 120 Figure 139 Apply Loctite 262 or equivalent to pinion nut threads Figure 140 Tighten pinion nut to 1261 1396 Nm 930 1030 LBF FT Refer to Figure 131 for fitting location and apply grease to input seals until it comes out from around the dust lip NOTE Seals should be greased at every normal servicing interval Machines in conditions where the axle routinely becomes submerged should be serviced more often Carrier Housing Assembly A Figure 141 Install differential bearing cup 40 37R 43R Hydraloc Differential Service Manual Figure 142 Install differential bearing adjusting nut Differential Assembly Installation Figure 43 Paint 5 to 6 ring gear teeth with contact checking compound e PATET TOYS EN aad I Figure 144 Install differential assembly in housing Figur
37. y Precautions Table of Contents Exploded View and Parts Description Cross Section Hydraloc Differential Pressure Test Instructions Bearing Heating and Freezing Guidelines Cleaning and Inspection Recommended Lubricants Spiral Bevel and Hypoid Tooth Bearing Chart LH Spiral Bevel and Hypoid Tooth Bearing Chart RH Fastener Torque Chart Plug and Elastic Stop Nut Torque Charts DISASSEMBLY SECTION 17 17 18 19 22 22 23 25 26 Hydraloc Differential Disassembly Drive Flange V Ring and Wear Sleeve Removal Pinion Seal Retainer Cartridge and Seal Removal Differential Retainer and Adjuster Removal Differential Assembly Removal Ring Gear Removal Differential Body Disassembly Piston Removal Pinion Removal REASSEMBLY SECTION 28 33 34 37 39 39 40 41 42 44 45 45 48 48 Hydraloc Differential Reassembly Ring Gear Installation Pinion Installation and Adjustment Pinion Seal Installation Wear Sleeve Installation Pinion Flange Installation Carrier Housing Assembly Differential Assembly Installation Differential Retainer Installation Backlash and Contact Pattern Setup and Adjustment Differential Load Test Hydraloc Seal Retainer Assembly and Installation Air Pressure Test Hydraulic Pressure Test SPECIAL TOOL SECTI ON 49 amp 50 Differential Carrier Cup Drivers 51 52 53 54 55 56 57 Grease and Oil Seal Driver Inner Lip Seal Driver Outer Lip Seal Driver Adjusting Nut Driver Hydraloc Sleeve
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