dana ps/pr1350 carrier assy,v2, manual,maintenance
Contents
1. uw q 444444444444444 4 za 1 1 11114144 lt M y E 7 PINION IN TOO FAR Move pinion out and re adjust ring gear for proper backlash 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 7 After proper ri gear pattern is chieved again proper mounting distance and contact pattern as torque the differd tial bearinfficap bolts to 150 160 ft shown in step 2 page 18 This is accomplished by Ibs 200 220 N Minstall a fusting ring retainers and choosing a thicker pinion bearing cage shim Readjust new coligr keys of 9 e 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 d mE NM Gi UR 4 a Y 6 If pattern is concentrated athe Waf top land as shown above the pinionafftoo far aW from the ring 8 On axles equipped with the differential lock option gear and must be movefiClosesf the rit gear to install the stationary collar onto the splined end flange establish its proper mapurmieodif stancg and tooth half of the differential support case contact pattern T is accOmaplish4f by selecting a thinner pinion hiring cage ST gFieadjust pinion to ring2. e um MS am MN 53555335533533333333533333333333333333333J3 3 3 im 3 Mount pinion assembly in a soft jawed vise holding yoke stationary and remove cotter pin nut and washer 4 Remove the end yoke using a suitable puller 5 Remove pinion gear from cage assembly NOTE it may be necessary to tap outer end of pinion gear with a soft hammer Replace pinion nut flush with end of pinion so damage to threads 6 Located between pinion brings Wa selective spacer used for pinion ba ring pyeload BRetain this spacer for possible use xeasg mbly 7 Remove old pinigil seWlffhid dird Always replace it with a pef seal at Ya ofeassembly 8 Lift out outer Pon Waring ce Remove inner pinion bearing cup use a suitable adapter and press or puller CAUTION Do not nick bearing bore 10 Remove oute inion beding cp CAUTION Do no pick beaging bore 12 Remove inner bearing cone from pinion gear 9 gt gt Pinion Assembly to tia e 2 s 1 8 m e 4 N c h A h 1 T LI H ol E y WW gt FA 3 1 Press inner pinion bearing cone onto the pinion 4 Ip R ll inner pinion bearing cup into pinion cage gear 3 Stake roller bearing in six places using staking tool 6 Use a feeler gauge or shim stock 0015 Approx to NOTE Make sure all cage bores are free of ni
3. 3 Mark the differential case halves so they may be reassembled in their original position remove differential case bolts and nuts and separate case halves CAUTION If a retaining bolt and washers are not available hold the differential case firmly as the last bolts are being removed from the case halves to absorb spring pressure and prevent possib injury aini Wbaffs and washers were used mount unit all pre as shown and remove nut Slowly 5 until spring pressure is released 5 ove side gears springs spring retainers driven clutc assemblies and spider assembly Cleaning and Inspection Wash all parts thoroughly with clean non flammable solvent Inspect all mating surfaces and splines for possible wear or damage Replace all worn or damaged parts before reassembly Springs shoyid have a compressed operating height of 620 inc load pounds 10 Replace with new springs if within these specifications Ld a pA A A CA CA em eum E E A A E A D gt g A a gt go gt gt gt QUOSPIN Differential Assembly 1 Wash the differential case ring gear differential case bolts and nuts and bearing assemblies in clean non flammable solvent Inspect for damage wear or corrosion Replace if necessary
4. eo B 4 e 5 E 2 E M Y lt q Om e t Ww quas pe LE o re ed b a 9 MAINTENANCE MANUAL amp 232232333333333333333333 9 y Models PS PR 1350 Carrier Assembly Pinion Mount Wet Disc Brakes NoSPIN Differential Option Differential Lock Option CONTENTS GENERAL INFORMATION General Precautions for Assembly and Disassembly L brcam Gange SENSES urn IN MEI ay v hm DR ERI SC ur Dis eee asini ak ode dpt Me Le Kd pede eos ee narco vim satin NS denti callon ul a sceau cusa AAN we mae bern RAO SOUCY 4 risa dx A YAA De EXER EXER ERES BERETS d CARRIER SECTION Carrier Assembly Tistrallor io sea 6 2 ex su a au Di I Removal of Carrier from Axle Housing Removal of Differential from Carrier 22 0 0 cece cece ee ee eee Diarental DISGSBOFHDNL MAA PICO DEROSSA 44 vamexes uo Queda ads Meee u RA TT PIDIO e ras re Pct dis eb AES GA Pin POSIIONE un oon a yh acta Ret Ri RR Diftereutial AssSembDW u eve cake ER e DEP ERES EET ar A c WE alo d Foral ec anne Ring Gear and Pinion Tooth Contact Pattern e of Carrier Assembly into Axle Housing TIONAL EQUIPMENT Pinion Mount Wet Disc Brake Disassembly Pinion Mount Wet Disc Brake Assembly NoSPIN Differential Disassembly vex NoSPIN Differential Assembly Installation Test NoS
5. mm they must be replaced Replace all seals when THOROUGHLY CLEAN replacing bonded discs E APPLY A THIN Inspect stationary discs for warpage using a straight edge If warpage is indicated discs must be replaced Inspect all brake discs for heat damage Replace if necessary NOTE If brake discs are within specifications the assembly was operating inner hydrauli seals do not need replacing However if di replacing replace piston seals also 7 To replace piston seal direct piston awa operator apply low air pressure 15 hydraulic inlet CAUTION If high pressure is may pop out with consic spray of hydraulic fluid Remove old O rings Clin tho aed replace with new seals UNKMORM COATING OF 2 PERMATEX TO BORE WALLS EFULLY INSTALL NEW SEALS UNTIL FLUSH MAKING SURE LIP DIRECTION IS THE SAME AS THE ORIGINAL SEAL ees R2 gt ART Fr BAT Y ce P cs ANA CE B To replace pinion seal or repair carrier assembly it will be necessary to remove power plate Remove power plate to carrier bolts as shown 22 e y 88 NOTE All parts must be thoroughly cleaned before reassembly Replace necessary seals and O rings at this time Lubricate all seals and O rings with hydraulic fluid 3333 1 Set power plate into position on pinion bearing cage assembly Make certain hydraulic inlet is at pr
6. 2 Inspect axle shafts for excessive wear or damage Fit axle shaft into side gear of NoSPIN to insure smooth tight fit If either the axles or side gears are rn they must be replaced Position the ring gear and differential case half shown in step one NOTE To protect bearing during the foll steps install bearing cup on bearing c 8 m LA Pa T m E AER Fu Ber Ur 7 ee a paw lace spring over the side gear spline and against retainer lip with the smaller diameter of the spring against the retainer Be sure the spring is not binding and re is good contact between end coil and when driven clutch and side gear splines ly meshed 8 Position the spider assembly over the driven clutch assembly Slot for Spider Key IMPORTANT Be sure the slot in the hold out ring is properly aligned over the long tooth of the spider 9 Place the remaining driven clutch assembly onto the spider NOTE Again be sure the slot in the hold out ring is properly positioned over the long tooth of the spider 10 Assemble the remaining retainer spring and side gear as in step 6 11 Mount the plain case half over the side gear and compress the springs be sure side gear splines are competely meshed with the driven clutch splines 12 Hold the case halves firmly together aligning marks and start at least 2 case bolts 180 apart To compress th
7. defective RER E M uec 11 Using a small drift punch and hammer drive pivot shaft out of shifter housing Inspect for wear or scoring Replace if necessary 9 Remove rod and spring from guide screw 12 Remove fork from shifter housing Inspect fork ends for wear Replace if necessary 32 D EB 2 mm NUES 566 560 EN EM EUN O M UEM UM 355355 5555555353535333333333333313231 o Jogoo EB NE NS 66 ES EN GM EM UB EM am 13 Inspect bronze pivot bushings in fork If worn replace oh Uis be TUM gt pe A x F eo o Y NOTE It may be nece air through the hy removal area of shifter g compressed air to avoid shop towel inside the t piston travel and prevent USE ONLY 15 PSI MAX AIR 33 Differential Lock Assembly 1 Install seal on piston 5 Inggfi shift fork in shifter housing and install pivot pin 2 Thoroughly clean shifter housing and apply a light coat of hydraulic oil to piston bore and piston essed approx 6 Stake area around both ends of pivot pin NOTE The following steps outlined the procedure for setting up the proper differential lock installing tool Dana tool engagement It is important that these steps be ended to prevent damage to closely followed in order to avoid possible damage to the differential lock during operation 3 Install piston into 2 until into
8. ge amp ba Rlash as required once proper mounting tance Was been established See Ea dj 33333333333333333333333333333333333333 pom 9 Install spiral locking ring into groove on splined end of differential support case 2 E 19 Ex bys Installation of Carrier Assembly O into Axle Housing 1 Thoroughly clean inside of axle housing Stone the A Install carrier assembly into axle housing housing mounting surface if necessary to remove burrs washers Torque bolts to 56 or nicks 2 Apply Permatex 2 gasket sealer to axle housing at carrier mounting flange A 1 4 inch bead around the outside of all carrier mounting studs and each stud hole is required 3A If studs are used to mount the carrier apply Loctite 271 or its equivalent to the threads and torque to 30 50 ft Ibs 3B If bolts are used to mount the carrier thread 2 studs 180 apart into the axle housing as S 4B If axle is equipped with differential lock insert sli installation aid collar into axle housing and engage on axle shaft spline prior to carrier assembly installation 5 Assemble axle shafts hubs brakes and all wheel end paris at this time following procedures outlined in the PS PR 1350 Wheel End Manual 6 Clean drain plug and install Fill unit with proper hypoid gear lubricant to same level as fill hole located K in bowl of axle housing
9. is normal Exercise Caution When Performing This Test 29 30 TROUBLESHOOTING THE NoSPIN DIFFERENTIAL Potential problems are stated on the left possible causes for those problems are listed by number on PROBLEM Hub studs shearing rear tire scuffing axle shaft breakage Steering difficulty vehicle pulls on straight forward driving or tends to go straight when making turns No differential action binding in turns Excessive driveline noise Excessive tire wear Grinding noises Continuous clicking sound in straight forward driving Excessive backlash in vehicle drivetrain engine lug or vehicle surge during turns Tendency to side slip or fishtail on icy surface Sluggish reengagement of NoSPIN differential clutch assemblies Difficulty in turning vehicle from standing start Erratic operation of NoSPIN differential premature wear or failure of NoSPIN differential parts NOTE NoSPIN differentials will emit occasional metallic sounds due 1 Improper installation defective differential Follow test procedures procedure 2 Overloading and or im ght and redistribute the load from side t to the vehicle manufacturer s in ive tires A smaller radius tire overrun constantly d her lire with the larger e driving Replace tires or adjust tire ling radii are equal t center lines Replace bent axle shafts or housing or realign hub faces and bolt circles in both differential carri
10. shift fork if required ee Di RER B GJ AE nomea 7 Install indicator switch into guide screw and tighte 34 M uu 8 Thread jam nut onto guide screw until bottomed 11 Install spring rainer gu against screw head shifter housing ar tighten 12 Apply 2 Permatex to shifter housing flange Install shifter assembly on axle housing Make sure fork engages groove in slide collar NOTE The installation of the differential lock stationary and slide collars is covered in the carrier section of this manual 9 Thread guide screw into sprin three turns Insert rod into guide screw DO NOT INSTALL RING AT THIS TIME 13 Install flat washers and mounting bolts Torque to 44 48 ft Ibs 35 36 14 While rotating pinion apply approx 50 PSI air 17 Thread jam nf against ring etainer and torque pressure through hydraulic inlet in shifter housing to to 100 ft lbs DOBIOT allow Wide screw to rotate completely engage mating differential lock collars NOTE Check individual wheel rotation to be sure collars are enagaged and differential action has been lost 18 Remove air preure 19 Remove spring retainer guide screw assembly from shifter housing 15 While continuingto Qolyffr pressure thread guide screw in until it stage indiWking rogfeont
11. until Nas asure backlash is within specification The wh cofact p ftern should now have the same generaLshaggand location as shown in step 2 If the contaciattern still does not conform less backlash than nggnal is required To avoid reducing differential _ preload excessively further loosening of the 0 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 Ihe exact amount of additional adjustment Decreasing backlash moves the ring gear toward the pinion RING GEAR IN TOO FAR Move ring gear away from pinion increase backlash 4 If the pattern is concentrated at the toe as shown above more backlash is required Recheck backlash To increase backlash tighten the right side adjusting ring further until the measured backlash is within specification The tooth contact pattern should now spread across the ring gear tooth as in step 2 If the contact pattern still does not conform more backlash than normal is required To avoid increasing differential bearing preload excessively further tightening of the right hand adjusting ring should be accompanied by equal loosening of the left hand adjusting ring Place a dial indicator directly on each adjusting ring to measure the exact amount of the additional adjustment Increasing backlash moves the ring gear away from the pinion N
12. 20 b 2i 27 ond inion Mount Wet Disc Brake Disassembly EX 13 12 11 10 1 Heax Head Bolt 2 Flat Washer 8 Stationary Disc 9 Rotating Disc 3 Sealing Washer 10 Piston 4 Oil Seal 11 O Ring 5 Housing 12 O Ring 6 Hex Socket Plug 13 Oil Seal 7 O Ring 14 Power Pla Remove drain plug and drain hydraulic oil 2 Remova inion nut ad washer gt to Lo EE gt u gt y 4 gt 5 v m hd ha 1 x a Mei gt A 24 te LU Ve 2 w va x te Cum 3 Turn assembly to vertical position as shown and lift pinion yoke or flange out of carrier assembly 555535555555555555533553 353353333333333333J 5 Lift housing off power plate assembly Inspect outer O ring seal and replace if damaged 21 x EA gt 6 Remove both stationary steel and rotating 9 Lift power pla pinign bearing cage rounded brake discs and clean thoroughly with assembly suitable petroleum base solvent Inspect rotating discs for wear in the involute splines Replace if worn If OK measure thickness of bonded friction material with 0 1 IMP TANT NC BEFORE micrometer If discs measure less than 240 in 6 1 A NG REPLACEMENT INPUT
13. DE PROBABLE CAUSE RECOMMENDED REPAIR Noise on Drive 1 Excessive pinion to ring gear 1 Adjust backlash 2 Worn pinion and ring gear 2 Replace 3 Worn pinion bearings 3 Replace 4 Loose pinion bearings 4 Adjust 5 Excessive pinion end play 5 Adjust 6 Worn differential bearings 6 Replace 7 Loose differential bearings 8 Excessive ring gear run oul 8 9 Low lubricant level 9 10 Wrong or poor grade lubricant 10 11 Bent axle housing 11 Axle noises heard on drive will usually be heard on coast although not as loud Noise on Coast See above 2 Pinion and ring gear too tight Adigst audible when decelerating and disappears when driving Intermittent 1 Warped ring gear 1 Replace Noise 2 Loose differential case bolts 2 Tighten Constant Noise 1 Flat spot on pinion o 1 Replace IF gear teeth a 2 Flat spoton b 2 Replace 3 Worn pinio 3 Replace 4 4 Replace 5 5 Replace 6 6 Replace Noisy on Turns Replace 2 Replace 3 Replace 5 Replace E 1 r j J specifications vary depending upon the model and type of service Applications approvals must be obtained oducts Division We reserve the right io change or modify our product specifications configurations or dout notice SPICER OFF HIGHWAY PRODUCTS DIVISION 1293 Glenway Drive Statesville NC 28625 Tel 704 878 5801 Fax 704 878 5860
14. PIN Differential Trouble Shooting NoSPIN Differenti Differential Lock Illustration Differential Lock Disassembly 4 Differential Lock Assembly DO 0o ao 670 3 0 O S 9 9 70 0 0 0 040 9 Vy A 674 0 0 0 0 90 0 9 O09 0 0 09 9 07 9 0 0 9 9 5 0 0 9 9 49 ae 56 40 9 4 9 09 9 0 0 9 9 9 9 BIO DEE GO 5 9 9 6 09 4 9 0 0 O 2 Oe ae 9 0 5 88 K 0 0 0 0 Ba o b po v 0 000 9 9 9 9 e 9 9 9 9 9 9 9 2 5 5 G0 8 8 b 6 000 Biere 8 C16 0 0 01 04 00 9 9 9 9 09 MA 010 0 0010 09 9 0 0 T 9 9 959 09 99 9 9 5 9 5 9 69 9 0 4 09 9 0 50 04 8 9 58 b 9 9 9 0 9 9 ris important to the safe reliable operation of all motor vehicles or driving axles The service ded and described in this service manual are effective methods for performing service operations Accordingly anyone who uses a service procedure or tool which is not recommended must first satisfy himself that neither his safety nor the vehicle safety will be jeopardized by the service methods he selects Should an axle assembly require replacement of component parts it is recommended that Original Equipment lacement paris be used They may be obtained through your service dealer or other original equipment manufacturer ris s
15. act with fork 15A Attach te fight tgfindica Switch terminals to verify rod is con matus fork 16 Turn screw in an additional 1 6 turn 20 Remove rod from guide screw Install spring over guide screw and re install rod 333333999 mm amp NE NB EM GEN GEM um um Saa IIIJ Y 21 Install complete spring retainer guide screw assembly into shifter housing and torque to 100 fi Ibs 22 Loosely connect hydraulic line to shifter housing and bleed air from line 23 Tighten hydraulic line and connect wires to indicator switch 24 Actuate differential lock from cab of vehicle a verify engagement with indicator light 25 Install steering cylinder 26 Connect drive shaft and lower vehicle 27 Refill axle to correct level with Refer to lubricant section of thisfgnan S lt 37 Inspection and Failure Analysis e This section is intended to serve as a guide for describing and explaining commonly encountered axle failures and for recommending appropriate repair procedures FAILURE MODE PROBABLE CAUSE RECOMMENDED REP AGE v Fracture of ring gear teeth atthe 1 Excessive loading of the gear beyond design intent Replace ring gear and pinio al el tooth heel 2 incorrect gear adjustment excessive backlash Carefully follow 90999 51 65 for adjusting
16. ard in the direction he NoSPIN differential should lock up 4 5 and 6 except hold the left he stops and rotate the right wheel e freely in both directions and produce a soft indexing or clicking sound The NoSPIN differential should not reengage until the direction of rotation is reversed IF YOU HEAR REPEATED LOUD INDEXING OR CLICKING SOUNDS when performing this installation test one of the driven clutch assemblies may not be properly assembled to the spider Recheck installation steps on pages 27 and 28 IF EITHER WHEEL DOES NOT ROTATE FREELY IN BOTH DIRECTIONS recheck each installation step Also check hand and foot brakes for possible drag caused by improper adjustment Operation Test Check to see that both wheels of each NoSPIN differential equipped axle are driving Make this test under load so that engine torque is applied through the NoSPIN differential with the wheels on the ground One way to achieve this load is to drive up against a solid obstruction on loose dirt or gravel if possible and attempt to spin both wheels together Perform this test in forward and reverse CHECK CAMMING ACTION On a flat surface with good traction drive the vehicle in a tight circle in forward and reverse to be sure that the outside wheel is free to overrun i e that the outside tire does not scuff A clicking or indexing sound may be heard The sound of gear reengagement may also be heard upon completion of the turn This
17. cks ensure bearing cups are completely seated in bearing dirt or any Contamination bores This is necessary for proper pinion position 7 Place selective preload spacer that was removed during disassembly onto pinion gm 8 Place pinion cage onto pip geaginne kearing 2 P p al e 9 Install outer pinion bearing cone onto pinion y D 10 Inspect end yoke or flange seal surface for grooves caused by lip of seal If grooves can be detected with fingernail it should be replaced 11 Install end yoke onto pinion without seal and torque to 325 ft Ibs 400 N M so bearing preload ch be checked NOTE Pinion cage should be rotated while tightening pinion end nut to seat and align me pinion bearings x 12 To mesure preload clamp flange horizontally in a Vk iaw vise Wrap a strong cord around pinion cage Attach end to spring scale Read scale only while inion cage is turning Scale reading or bearing preload must be between 5 14 Ibs NOTE When preload reading does not fall within allowable limits bearing load can be increased by using a thinner spacer or decreased by using a thicker spacer 001 025 mm change in preload spacer thickness changes scale reading by approximately 10 Ibs The pinion spacers are available in the following thicknesses Measure the spacer before assembly to assure
18. correct thickness INCHES M M INCHES M M 5135 13 04 5318 13 50 5165 13 12 5325 13 52 5195 13 19 5335 13 55 5225 13 27 5345 13 58 5245 13 32 5355 13 60 5255 13 35 5375 13 65 5265 19 27 5395 13 70 5275 13 40 5405 13 73 5284 13 42 5435 13 80 5295 13 45 5485 13 93 5305 13 47 NOTE Closer adjustment can be made by working next thinner spacer to desired thickness using emery cloth on a flat surface CAUTION Wash spacer thoroughly of emery cuttings before installing on pinion 11 Ring Gear and Pinion Tooth Contact Pattern PROFILE a TOP LAND r LENGTHWISE BEARING ARC TOE ROOT Gear tooth nomenclature The toe of the gear tooth is the portion of the tooth surface at the end towards the center The heel of the gear tooth is the portion of the tooth surface at the outer end The top land of a gear tooth is the surface of the top of the tooth 1 Paint ring gear tah with arkingfffompound and rotate with piniogffo obta4 con pattern w CO RSE ne 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 ring gear toward pinion decrease backlash 3 If the pattern is c BsentraiA more toward the heel as shoyfff above ba NEST must be reduced Rechgff amp backlash as described in step 6 page 17 To red e badg sh loosen the right side adjusting ring
19. cross shaft arms and pinion mate gears 1 Excessive wheel spinning 2 Inadequate lubrication 3 Extremely severe service 4 Unequal tire pressures Worn side gear splines Severe service xcessive backlash Scored or worn thrust washer 1 Insufficient lubrication surfaces 2 Improper lubricati Worn pinion roller bearing 1 Severe retainer bore 2 Exel 3 ContamiN amp ed lubricant Twisted or broken axle shaft es re vehigie operation Fractured axle sha he 1 j wheel bearing flange 2 Bent axle housing 3 Loose shaft to wheel hub bolts v Shock loading of differential components nspection and Failure Analysis RECOMMENDED REPAIR Replace the end yoke Check the pinion spline for excess Replace the ring gear and pinio necessary nded intervals eplace differential side gears and pinion mates as a set Replace worn axle shafts 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 level and change at recommended intervals Replace the shaft Replace the shaft Check housing distortion Make certain that wheel bearings are nol worn or misadjusted 39 Diagnosis of Rear Axle Problems FAILURE MO
20. e springs in the NoSPIN a press can be used to aid assembly CAUTION Do not release pressure until bolts are started and spring pressure has been safely contained Failure to follow procedure could release case halves under extreme pressure Spider Key 27 13 Install the remaining differential case bolts and torque to 80 90 ft Ibs 108 122 N M 14 Install ring gear and differential case into carrier following procedure in differential assembly section of this manual 28 353 2 6 an EB am mm UM Nx AN 2 am jee Ce 077 nstallation Test Step 1 With the engine turned off raise driving axle s until all tires are out of contact with any surface Step 2 Place the transmission in gear LEFT WHEEL Step 3 With an assistant on the opposite side start the installation test by rotating both wheels in a forward direction as far as possible Both wheels should stop after rotating a short distance wheel forward against the stog rearward while listening for an i Step 5 Rotate both wheels rearward as far as ssible Both wheels should stop after rotating a distance holding the right rotate the left w indexing or clicki e freely Grasp the left wheel to stop its ove it slightly rearw
21. ection ould be made only after performing the operation tests stated on page 29 and after consulting the trouble shooting guide on page 30 and determining that the NoSPIN differential or some other axle part is not working properly E b NoSPIN Differentials 4 Spring Retainer 5 Side Gear Differential Rem 1 With carrier mounted in a holding fixture remove adjusting nut lock and mark position of adjusting nut for proper adjustment when reassembling Bearing saddles must be replaced in original position Mark as shown above Remove bearing saddle bolts and lift ring gear and differential clear of carrier NoSPIN j differential assembly wy 2 e g7 Wing nut Retaining bolt Retaining washer TAA 22 4 7 2 Aretaining bolt and washers are useful to keep the NoSPIN differential assembly intact when removing it from the differential case and when reinstalling it in the axle housing You will note that the retaining washers must be small enough to pass through the case ends dimension A yet large enough to restrain the two side gears dimension B and the balance of the NoSPIN differential assembly when all parts are assembled and the springs are compressed 25 26 CAUTION Failure to use a retaining bolt or some other restraining means when separating the differential case halves can cause injury NOSPIN differentials contain compressed springs
22. er and axle housing 6 Larger than normal steering angle short turning radius Vehicles designed with high turning angles may surge have steering difficulty and cause tire wear during sharp turns Reduce maximum turning angle and have the drive decelerate when engine surge begins 7 Improper wheel alignment Correct as required the right The explanation of these possible causes follows below chart POSSIBLE CAUSE S 2 3 4 5 6 7 8 8 10 N 12 14 e 9 e 8 Worn or defective axle parts Check the condition of the ring gear pinion gear bearings seals etc Replace as required 9 Foreign matter in axle housing or improper assembly of axle parts Inspect for contamination Check assembly of axle parts 10 Incorrect ring and pinion adjustments worn driveline parts transmission gears U joints etc Replace or adjust parts as required 11 High crown in road poor traction surface under all drive wheels The tendency to side slip or fishtail on icy surface sloping toward the curb is more pronounced when using a traction differential than when using a conventional differential Stability can be retained when side slip occurs by decelerating letting off the accelerator CAUTION Do not apply brake To do so may result in loss of vehicle control 12 Heavy gear lubricant In sub zero temperatures gear lubricant can thicken and impede the normal function of the NoSPIN different
23. hydraulic system and either fill or hook up cooling lines to cooling section of wet disc brake Follow procedures outlined in vehicle maintenance manual 3333 33 am am am ES GM mE 6 OL A GA UM A III sI 2 3 2 32 2223335353 QNOSPIN Differential Disassembly 1 Spider Assembly 2 Clutch Member Assembly 3 Spring Description The NoSPIN differential provides equal amounts of drive line torque to both right and left driving wheels and also permits differential action for turning corners The unit is installed in the differential case in place of conventional gears pinions and spider The action of the unitis the same for both drive and coast loads CAUTION Turn the engine off and raise all driving wheels of a NoSPIN differential equipped axle when servicing wheels brakes axles or tires to prevent the vehicle from moving Axles equipped ith NoSPIN differentials deliver power to both heels even when only one wheel is on the ground Failure to observe these cautionary can result in damage or injury Routine Inspection Carefully follow the recommended preventative maintenance and ing e brake adjustments the wheels on both of the vehicle must be raised and the sion placed in neutral so that the ring gear and opposite wheels are free to rotate with the wheels on the side being adjusted y decision to disassemble the axle for insp
24. ial Spicer recommends that the axle oil be changed for cold weather operation to the lightest acceptable lubricant Such as 75W 75W 90 or 75W 140 Heat control devices garaging and a warm up period may also provide relief from this problem 13 Low cylinder pressure undersized cylinder D excessive angle of articulation excessive vehicle weight Correct as required 14 Improper application of product Review application guidelines of vehicle manufacturer am C ms am um us 66 am um Oe we UM 3 ifferential Lock Disassembly 14 Shifter Housing 15 Diff Case Flange Half 1 Indicator Switch 2 Screw Guide 3 Jam Nut 16 Collar Stationary 4 Spring Retainer 17 Retaining Ring Spiral 5 Spring 18 Collar Sliding 6 Rod 19 Axle Shaft 7 Fork 20 Axle Housing 1 Raise vehicle until wheels ofgxl lock clear ground Support y floor s 2 Disconnect drive shaft 3 Drain oil from 6 Remove mounting bolts from differential lock shifter assembly and remove shifter assembly from axle housing NOTE Removal of the differential lock stationary and slide collars is covered in the carrier section of this manual 31 QU 7 Remove indicator switch Check operation with test light Replace if
25. oper position 2 Bolts attachin jowe pilate to Warrier assembly must be cleaned a i coa with 271 Loctite or its equivalens c m NA bd AAA Be d Zu Y EM 6022 Ee 0 Be 4 eee Ee a NM NS hs 5553555535355355333335333323J ER Cum 3 Torque bolts to 100 125 ft Ibs 135 162 N M 1353333 Binion Mount Wet Disc Brake Assembly ee Tof wht 266 Ss 4 Position and A gcs before installing housingdfe over Positi ff Stationary steel disc first Alterg fe remaining rotating bonded discs and staf gpary acs as shown Install 2 housing bolts 180 apart Wifing stafff onary discs Slide yoke flange SIowly om pipi splines rotating from left to right until center an Fin rotating discs line up 9 Remove yoke and install outer O ring seal onto power plate in seal register Lube with hydraulic fluid Install housing as shown Visually align bolt holes and position drain hole on bottom side of carrier 6 Install flat washers and new sealing washers onto housing to power plate bolts Coat threads with 271 Loctite or its equivalent Install bolts through housing and alternately torque to 20 25 ft Ibs 26 32 N M 23 7 Install yoke flange and torque pinion nut to 325 ft Ibs 440 N M 8 After assembly has been installed into the vehicle it will be necessary to bleed
26. ring gear apinion backtash and tooth pattern P N Fracture of ring gear teeth atthe 1 Shock impact loading pinion as matched set looth 108 2 commended procedures for adjusting oa nd pinion backlash tooth pattern Incorrect gear adjustment insufficient backlash Scored and or scufled ring and Insufficient lubrication pinion gear teeth place ring gear and pinion as a matched sel eplace pinion bearings laking care to set ring and s Senieminaled bear sition and bearing preloads properly Wrong lubricant or lubricant with dep Worn pinion bearings which result j and incorrect ring and pinion tooth OO N correct lubricant fill to proper level and change at ommended intervals Overhealed ring and pinion gear teeth Look for discoloration of Prolonged operation at exce 1 Replace ring and pinion as a matched set D 2 Incorrect lubricant 3 Use correct lubricant fill to specified level and change Ihe gear teeth Low Gil love at recommended intervals 4 Contaminateg oricant of the abg can re in ina ate lubricant film between too rfa whichgauses surfaces I overhegishue to essive ton i Pitted drive pinion teeth Fiery Severe s amp Wice Replace ring gear and pinion as a matched set 2 ent luOTemtion Use correct lubricant fill to proper level and change at recommended intervals Bent axle housing Vehicle o
27. upplier The use of non original equipment replacement parts is not recommended as their use may cause unit failure and affect vehicle safety PAGES 2 7 MISSING Pinion Disassembly Pinion Nut Slotted Required Self Locking with 2 Speed Range Box or Pinion Mount Wet Disc Brake Cotter Pin Flat Washer End Yoke or Companion Flange Oil Seal Not Req w Pinion Wet Brake Bearing Cone Pinion Outer Hex Bolt Bearing Cup Pinion Outer Bearing Retainer Cap Pinion Bearing Spacer O 00 YO WN LES 2 x PAS vs I ALS x ati 1 Remove pinion cage cap screws which hold pinion assembly to the carrier housing p Pinion Inner ne Pinion Inner aring Assembly Straight Roller a 0 im Pinion Position C 3 16 Steering Cylinder Socket Optional 7 Slotted Nut 18 Cotter Pin 19 Carrier Sub Assembly Steering 20 Flat Washer 21 Locknut A 0 Herr 4 r ot APA Froda A 2 Remove pinion and cage assembly from carrier housing If difficulty is encountered in removing pinion assembly from carrier housing place brass drift on inner end of pinion gear and tap lightly NOTE Retain shims for possible use during reassembly 0111111144144444444444 diro a SON ez e7 e b am NE 6 42 Wm
28. verloading Vg Shock loading Replace axle housing e accident iE D Insufficient lubrication Replace bearing cups and cones in matched sels Contaminated lubricant Check roller ends for excessive wear by comparing used rollers with a new bearing b Very severe service e Use correct lubricant fill to proper level and change al Normal wear recommended levels WN Prolonged operation at excessive oil temperatures Replace the oil seal and mating surface if damaged Scored or dented yoke wear surface Use correct lubricant fill to proper level and change at Improperly installed oil seal the recommended intervals Nicked or cut seal lip nr QU N Contaminated lubricant continued on next page 38 N um Y W 7 a E 4 A d m E j a 2 y 1 ty 2 4 E 4 j gt PA up sien EB EB ES ENS NM V 2 2222222222 y o o FAILURE MODE PROBABLE CAUSE Excessive end yoke spline 1 Severe service looseness 2 Loose pinion nut 3 Pinion endplay Fatigue fracture of the pinion Severe service gear teeth Look for clear cut wavy fracture lines beachmarks Fracture ot differential side gears and pinion mates Scoring and or seizure of
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