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Service Manual - Dana Corporation

1. 3 wee Se ee 6 Oe dg a oe Se ee 7 Section 2 DIFFERENTIAL CARRIER CONTENTS TP 1 ANG 2 Cleaning Inspection and 4 6 Differential Carrier 10 DIFFERENTIAL CARRIER OVERHAUL Single Reduction 13 Dual Range and Double Reduction 22 ESD 18 Steer Drive Axle Introduction This manual includes instructions for the Spicer ESD 18 Steer Drive Axle capacity rating 18 000 Ibs This axle may include one of three types of gearing single reduction dual range or double reduction The single reduction gearing may be equipped with a Spicer Controlled Traction Differen tial For service information on this special differential refer to separate section in this manual The axle housing is one piece A special ball and socket assembly and wheel end equipment are provided at each end of the housing The axle shaft assembly on each side of the axle is equipped with cardan type universal joint These joints are housed in a trunnion type ball and socket assembly to provide steering capabilities The axle is equipped with Spicer Single Anchor Pin Air Brakes 16 1 2 x 5 Wheel Alignment and Wheel End Inspection Wheel Alignment Specification
2. AACE VARIABLE 1 Used en 232054 25054 10084 14054 2 Used aniy an 54 amd 22054 5 2 Disassemble Differential Carrier with power divider removed NOTE If gear set is to be reused check tooth contact pattern and ring gear backlash before disassembling differential carrier Best results are obtained when established wear patterns are maintained in using gearing Omit this step if the gear set is to be replaced 1 Mount the differential carrier 2 Punch mark differential bearing 3 Cut lockwire Remove in repair stand caps If reusing gear set also screws flat washers and bearing NOTE For easier disassembly punch mark bearing adjusters for caps remove pinion nut roll pin Loosen reference during assembly but do not remove pinion nut a 1 LL cn md 4 Using chain hoist lift ring 2 Forward Axle Remove pinion 6 Forward Axle Remove pinion gear and differential assembly out nut see Note under Step 1 bearing cage cap screws Remove of carrier Remove bearing and helical drive drive pinion and cage assembly gear using puller if necessary from carrier Remove shim pack NOTE Axle Series 185 220 only IMPORTANT If gear set is to be These models use a spacer reused keep pinion bearing cage between bearing and gear shim pack intact for use in reas sembly If the original shims can be reused record the number and s
3. 1 e Differential Carrier 2 3 si s peek eg 4 Differential Carriers Single Reduction 5 e Differential Carriers Dual Range and Double Reduction 6 Controlled Traction Differential 7 OMIM SYSICMS 8 Fastener Tightening Specifications 9 Spicer 4x4 Drive System Spicer combines a unique power divider with a Spicer conventional axle to provide a 4x4 rear drive axle This drive axle coupled by a driveline to a steer drive axle are the basic components of the Spicer 4x4 Drive System POWER DIVIDER CONVENTIONAL DRIVE AXLE Gearing Combinations The Spicer 4x4 Drive System is available in the following gearing combinations Operating Mode Front Steer Drive Axle Rear Drive Axle 4 4 4x2 Single Reduction Single Reduction 4 4 A Single Reduction Single Reduction with Controlled with Controlled Traction Traction Differential Differential 4 4 and 4x2 Double Reduction Double Reduction 4 4 and 4 2 Dual Range Dual Range 4 4 Low Range Single Reduction Dual Range 4x2 Low or low range of High Range Duai Range Example 7 17 5 29 7 21 Ratios must match within J difference Shift Systems The vehicle dri
4. a em te aN de E amp n 299 82 1 11 5 ul Ve 1 LI rm 1 xx DIL Aw SLIDING TIT LH DW RING DLER HIGH SPEED RING DIFF peer BEA FII AT PINION CLUTCH _ GEAR BE SANG AULES Cup BOLT PLATE CUP 3 Remove ring gear NOTE soft faced hammer or mallet may be required to dislodge gear from its mounting 4 To remove differential assembly place support case assembly on a bench or on the floor Position case on its side then slowly roll the case and slide differential assembly out of the case Remove small support case and um A A thrust washer 1 Remove nuts and bolts fasten Ing ring gear and support cases 6 Invert differential assembly to remove idler pins then remove idier pinions 5 Remove thrust washer from support case 7T Punch mark differential cases for correct location in reassembly Remove cap screws and separate case halves 6 6 4 4 Disassemble Wheel Differential gear thrust washers washer 11 First try to lift off Ah psa clutch plate by hand If it cannot be removed easily press off plate as follows b Use bar stock to block the center hole in the clutch plate and press against it with the press ram Insert properly sized
5. 8 Ring Gear and Pinion Tooth Contact 9 Differential Carrier Replacement L DIFF CARRIER OVERHAUL Single Reduction Exploded View Tem 13 Disassemble Differential Carrier 14 Disassemble Drive Pinion TIE 15 Disassemble Wheel Differential 16 Assemble Wheel Differential 17 Assemble Drive Pinion 18 Install Drive Pinion in Differential antt 0 Install Differential Assembly in Carrier 20 Adjust Differential Bearing Preload 21 DIFF CARRIER OVERHAUL Dual Range and Double Reduction Exploded View 22 Disassemble Differential Tr 23 Disassemble Drive PINION 24 Disassemble Wheel Differential Se ee 25 Assemble Wheel Differential 27 Assemble Drive Pinion 29 Install Drive Pinion in Differential Carrier 31 Install Differential Assembly in Carrier 31 Adjust Differential Bearing Preload 32 4x4 6x6 2 1 Lubrication The ability of a drive axle to deliver quiet trouble free operation over a period of years is largely dependent upon the use of good quality gear lubricant in correct quantity The most satisfactory results can be obtained by following the directions contained in this book Approved Lubricants
6. Moving adjuster one notch is the movement of the lead edge of one adjuster lug to the lead edge of the next lug past a preselected point Ring Gear and Pinion Tooth Contact __ NOTE Rear axle gearing is shown in the fallowing instructions Correct tooth BE patterns and adjustments are the same for forward and rear axles Check Tooth Contact Pattern NEW GEAR Paint twelve ring gear teeth with marking compound and roll the gear to obtain a contact pattern The correct pattern is well centered on the ring gear tooth with lengthwise contact clear of the toe The length of the E in an unloaded condition is approximately one half to two thirds of the ring gear tooth in most models and ratios RING GEAR TOOTH NOMENCLATURE wu TOOTH Could vary length Pattern should cover gt 1 2 tooth or more face width Pattern should be evenly centered between tooth i tap land and root OR P 7 FACE WIDTH Check Tooth Contact Pattern USED GEAR Used gearing will not usually display the square even contact pattern found in new gear sets The gear will normally have a pocket at the toe end of the gear tooth which tails into a contact line Pocket may along the root of tooth The more use a gear has extended had the more the line becomes the dominant Pattern along the characteristic of the pattem face width
7. _ SPICER Spicer Drive Axle Service Manual Spicer Drive Axle AXSM 0400 September 2007 This bulletin contains product improvement information Dana Corporation is not commited or liable for canvassing existing product Spicer Axle Service and Maintenance Instructions The Spicer 4x4 Drive System Dana Corporation presents this publication to aid in maintenance and overhaul of Spicer 4x4 Drive systems Axle models and other equipment covered in this publication are listed below Spicer Rear Drive Axles for 4x4 Drive Systems Model Identification Axle Capacity Axle Gearing Types 18 Rear 18554 Single Reduction 18 500 Ibs 185T4 Dual Range 185P4 Doubie Reduction Capacity ower Divider with 0 7 7232084 Single Reduction gle Reduction oe M 22 000 Ibs 22074 Dual Range 220P4 Double Reduction _ T Dual Range 23084 Single Reduction P Double Reduction 24 000 Ibs 230T4 Dual Range Available with Controlled 230P4 Double Reduction 25054 Single Reduction 26 000 165 260 4 Dual Range 250P4 Double Reduction 30084 Single Reduction 30 000 Ibs 300T4 Dual Range 300 4 Double Reduction 35084 Single Reduction 35 000 Ibs 350T4 Dual Range 350P4 Double Reduction Available with Controlled Traction Differential Contents Section No 4x4 Drive System page iii Steer Drive Axle
8. vehnis nor edad wath automan with dnvum SOMOS salary P CONSTANT AIR SUPPLY FLOW TO AXLE FLOW FROM AXLE FLOW THROUGH RANGE SHIFT UNIT REAR RANGE SHIFT UNIT TO ALL WHEEL DRIVE AND AXLE IN HIGH AANGE EXHAUST ABAR AXLE INTERLOGK SYSTEMS 4x4 IM LOW RANGE GRIVE AGAR AXLE IN LOW AANGE SEE 8 1 1 FOR OETAILSH NOTE Interlock system prevents axle range shift unless steer drive axle shifter valve is disengaged Also the system wrap up torques in the drivetrain may prevent immediate disengagement of the steer drive axle clutch even though the All wheel Drive selector valve is disengaged Backing the vehicle or continuing in a forward direction tor sufficient time to release these wrap up torques is neces sary before clutch will disengage Interlock on range selector shifter valve will then retract allowing range selec tion s desired 4 4 8 9 Dual Range Rear Axle with Single Reduction Steer Drive Axle Description and Operation Axie Range Shift System A manually aperated shifter valve changes rear axle range This valve is equipped with an interlock pin assembly which prevents axie range shifting when stear drive axie is engaged for 4x4 driva An air shift unit mounted an tha rear axla is mechanically connected to the axle snift fork and sliding gear which in turn shifts axle into Low or High Ranga One quick ralaase va
9. Pattern too close to tooth top land and off center If the pattern is too close to the top land of the If the pattern is too close to the root of the gear gear tooth remove pinion shims tooth add pinion shims NOTE Check ring gear backlash after each shim change and adjust if necessary to maintain 0 006 to 0 016 for Axle Series 185 220 0 008 to 0 018 for Axle Series 230 260 300 350 Adjust Backlash If the gear pattern shows incorrect face width contact change backlash INCORRECT PATTERN INCORRECT PATTERN Move ring gear away from pinion to increase backlash Move ring gear toward pinion to decrease backlash With the pattern concentrated at the toe too far If the pattern is concentrated at the heel too down the tooth add backlash by loosening the far up the tooth remove backlash by loosening the bearing adjuster on the teeth side of ring gear sev bearing adjuster on the teeth side of ring gear sev eral notches Loosen the opposite adjusteronenotch eral notches Tighten the opposite adjuster one notch Return to adjuster on teeth side of ring gear and Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup tighten adjuster until it contacts the bearing cup Continue tightening the same adjuster 2 or 3 Continue tightening the same adjuster 2 or 3 notches Recheck backlash notches Recheck backlash 3 14 4x4 Differential Carrier Replacement
10. MOVENM ENT CLOSES INTERLOCK CONTROL VALVE AXLE SHIFT UNIT ih la 1 WITH ALL WHEEL DRIVE SHIFTER VALVE DISENGAGED PRESSURE AT PISTON IS RELEASED RETURN SPRING MOVES PISTON TO DISENGAGE STEEH DRIVE AXLE SLIDING CLUTCH DISENGAGES DRIVE GEAR B 6 4x4 ALL WHEEL DRIVE SHIFTER VALVE VALVE LEVER 3 AIR PRESSURE IS APPLIED TO THE INTERLOCK PIN PIN MOVES TO BLOCK SHIFTER VALVE LEVER AXLE RANGE CANNOT BE CHANGED INTERLOCK PIN ASSEMBLY 3 AIR PRESSURE TO THE INTERLOCK PIN IS EXHALISTED THROUGH CONTROL VALVE FORT RETURN SPRING MOVES PISTON AND PIN TO RELEASE SHIFTER INTERLOCK FIM ASSEMBLY Le d aT JL T UN gi AIR EXHALIST Dual Range Axles with Range Interlock Trouble Shooting The following procedure is present ed in step by step sequence which enables checking the operation of all integrated systems and components 1 Initial Preparation Start system check by placing axle range shifter valve lever in Low Range position and All Wheel Drive selector valve lever in disengaged position Move vehicle in forward direction for a short distance then back vehicle up an equal distance Repeat this at least three times This will insure that all clutches are in proper posi tion Also park vehicle on a fiat sur face and do not apply spring brakes Do not move the vehicle until system c
11. Multigrade gear lubricants which meet the requirements of military specification MIL L 2105 C are recommended for use in Spicer drive axles These lubricants per form well over broad temperature ranges providing good gear and bearing protection in a variety of climates The MIL L 2105 C specifi cation divides lubricants into three major categories on the basis of lube viscosity at various tempera tures These are 75W 80W 90 and 85W 140 80W 140 lubricants are also available but are listed with 80W 90 by MIL L 2105 C Lubricants approved under MIL L 2105 B are also acceptable for use in Spicer Axles Synthetic Lubricants Use of synthetic lubricants in Spicer Axles is approved only after Engineering Choosing the Correct Gear Lube Axle gear lube should be selected on the basis of the ambient temperature range in which the vehicle normall operates This should also be considered when ever changes in vehicle location or primary operating area are made and the grade of lube changed if necessary Lube Change Intervals Initial Change The lube in a new or rebuilt axle should be changed within the first 5000 miles of opera tion This will remove fine particles of wear material generated during break in and prevent accelerated wear on gears and bearings Subsequent Changes Subse quent lube changes should be made at 100 000 mile intervals for Class A or AA highway operation Checking Lube Level Remove the
12. be evenly centered between tooth top land and root Pattern should be clear of tooth toe CORRECT PATTERN USED GEARING Pocket may be extended Pattern along the face width could be longer 4x4 6x6 2 9 Adjustments Adjust Tooth Contact Pattern If necessary adjust the contact pattern by moving the ring gear and drive pinion Ring gear position controls the backlash This adjustment moves the contact pattern along the face width of the gear tooth Pinion position is determined by the size of the pinion bearing cage shim pack It controls contact on the tooth depth of the gear tooth These adjustments are interrelated As a result they must be con sidered together even though the pattern is altered by two distinct operations When making adjustments first adjust the pinion then the backlash Continue this sequence until the pattern is satisfactory Adjust Pinion Position If the gear pattern shows incorrect tooth depth contact change drive pinion position by altering the shim pack Used gears should achieve proper contact with the same shims removed from the axle at disassembly Move pinion toward ring gear Pattern too close to tooth top land and off center If the pattern is too close to the top land of the gear tooth remove pinion shims INCORRECT PATTERN pinion away from ring gear Pattern too close or off tooth root If the pattern is too
13. 3 replace the clutch pack 9 Disassemble and Reassemble Wheel Differential Refer to the appropriate Spicer Axle Service Manual covering your specific axle SPLINED FRICTION PLATE TANGED FRICTION PLATE w GEAR SUPPO MEM FRICTION PLATE DRIVER RT Removing Tanged and Splined Friction Plates 6 If necessary remove rectangu lar snap ring from friction plate driver T If necessary to remove bearing cone from differential case cover place pilot punch in holes provided and tap on bearing cone inner race alternately through each hole until cone is removed Ax4 6x6 7 11 7 12 Heavy duty Overhaul Assemble and install Clutch Pack NOTE The clutch pack can be installed in gear support case with wheel differential assembled or disassembled With differential assembled proceed as follows NOTE Ring gear may fit loosely or have an interference fit on the gear support case Proceed as necessary to assemble ring gear to support case Step 1 or 2 1 Install Ring Gear with Interfer ence Fit Place gear support case assembly on bench with clutch pack side down Position ring gear gear teeth up on gear support case and align bolt holes Tempo rarily install two ring gear bolts to assure alignment then tap ring gear alternately on opposite sides with a soft nosed hammer until gear is fully seated against gear support case flange Turn
14. Install roll pin 5 10 4x4 Install Differential Assembly in Carrier Axia Series 185 220 NOTE Lubricate bearings during the following assembly procedures 2 Install bearing adjusters and 3 Install and tighten bearing cap caps screws finger tight If this is diffi cult use hand wrench NOTE Tighten bearing adjuster until its first thread is visible 1 Place ring gear and differential NOTE With bearing adjusters and caps assembled to carrier the assembly in carrier During instal carrier assembly is now ready for adjustment of bearing preload ring lation tilt Carrier to allow differen gear backlash and gear tooth contact see page 5 13 tial case pilot to mesh property with edge of bearing cap pedestal sea photo above Install Searing cups at both sides of differential case 4x4 5 11 Differential Carrier Overhaul Install Differential Assembly in Carrier Series 230 260 300 350 4 At back face side of gear m d AT CuFFEREN TUA 3 install and tighten bearing cap CARRIER CASE screws finger tignt If this is diffi instail bearing cap and cap screws cult use hand wrench Tighten cap screws finger tight If NOTE Tighten bearing adjuster tis is difficuit use hand wrench until its first thread is visible NOTE If removed install bearing cup in adjuster using press Place bar stock
15. PRESSURE b i 3 AIR PRESSURE I3 APPLIED TO THE INTERLOCK PIN PIN MOVES TO BLOCK SHIFTER VALVE LEVER AXLE RANGE m ee AIR PRESSURE CANNOT BE CHANGED CONTROL mE E SHIFT UNIT PISTON 5 peel ays ALLOWS IN K STEER DRIVE VALVE TO OPEN O AXLE SHIFT i UNIT Se LOCKOUT CONTROL VALVE e ON REAR AXLE RANGE SHIFT UNIT i RANGE INTERLOCK 1 WITH AXLE IN LOW RANGE SHIFTER PIN L _ LOCKOUT CONTROL VALVE IS OPEN VALVE ASSEMBLY AIR PRESSURE FROM ALL WHEEL DRIVE SHIFTER VALVE MOVES PISTON TO ENGAGE STEER ORIVE AXLE LOCKUP SLICING CLUTCH ENGAGES DRIVE GEAR Interlock Disengaged 4x2 Operation RESERVOIR AIR PRESSURE 1 AIR PRESSURE TO THE INTERLOCK PIN 4 EXHAUSTED THROUGH CONTROL INTERLOCH AIR EXHAUST um VALVE LEVER CONTROL EXHAUST 2 SHIFT UNIT PISTON MOVEMENT CLOSES INTERLOCK STEER QRIVE CONTROL VALVE AXLE SHIFT UNIT wa 1 AIR PRESSURE RELEASED WITH ALL WHEEL DRIVE SHIFTER VALVE DISENGAGED RETURN SPRING MOVES PISTON TO DISENGAGE STEER OR VE AXLE LOCKUP ndm t SLIDING CLUTCH CDISENGAGES DRIVE GEAR RANGE SHIFTEA VALVE AXLE um mem coms m oo VALVE PORT RETURN SPRING MOVES PISTON AND PIN TO RELEASE SHIFTER 4x4 INTERLOCK ASSEMBLY AIR E
16. Remove alignment bolts Installing Clutch Plates individually Permanent CTD Only 3 Install Friction Plates Individually Permanent CTD Only a If removed install snap ring on friction plate driver Then install driver assembly snap ring down in bore of support case engaging teeth of differential side gear b Place one external splined plate in ring gear bore engaging gear internal teeth Brush plate with lube c Place one internal splined plate on driver splines and on top of the externai splined plate Brush plate with luba d Hepeat this procedure until fourteen 14 friction plates seven internal splined and seven external splined are installed e Install the last external splined plate and pressure plate Then in stall springs and cover see Step 6 2 install Friction Plates and Driver Permanent CTD Only NOTE Brush surface of each plate as it is assembled with heavy appli cation of axle lube SAE 90 MOTE To assemble friction plates one of two procedures be used Install driver and plates individually Step 3 or install driver and clutch pack as an assembly Step 4 7 8 4 4 6 6 Installing Clutch Pack and Driver Assembly Permanent CTD Only 4 Install Driver and Clutch Pack as an Assembly Permanent CTD Only a If removed install snap ring on friction plate driver Then place driver snap ring down on work bench b Place one externai spli
17. m Mut Gd es ere es ee ere 1 1 2 18 840 1139 D466 P 486 P 588 656 P T 1 3 4 12 980 1328 IMPORTANT Torque nut to rated valua than continue tightening nut t align siot with nearest hole in pinion shank DRIVE PINION BEARING CAGE Cap Screw 3 18 12 8 155 175 210 237 POWER DIVIDER COVER NN Cap Screw ias Lx 8 16 12 8 110 125 149 170 LOCKUP SHIFT UNIT BODY Cap Screw 142 7 16 14 5 48 56 65 76 SHIFT UNIT BODY COVER mu 1 4 20 5 96 108 14 285 11 12 Nut ania 378 24 20 26 27 35 9 4 4 4 4x4 Rear Axle Differential Carriers Fastaner Axle Series 185 220 All Modeis Tightening Single Reduction Dual Range Double Reduction Specifications Specifications are the same unless specified otherwise Fastener Size Grade Ft iba RING GEAR Single Reduction BOI NUE 5 8 18 B 180 220 244 298 Dual Range amp Double Reduction 9 16 18 8 110 130 149 175 DRIVE PINION Nut slotted w rall pin 1 1 2 18 840 1129 Torque nut to rated value than continua tightaning nut to align slot with naarast hola in pinion shank DRIVE PINION BEARING CAGE Cap Screw 8 16 12 8 155 175 210 237 DIFFERENTIAL CASE Single Reductio
18. 1 install differential carrier assembly in axle housing Install stud nuts and lockwashers Tighten to correct torque see chart 2 Connect inter axle drive line 3 Dual Range Axle and Axles with Controlled Traction Differen tials Install shift unit nuts and lockwashers Torque nuts see chart Connect air line 4 Install axle shafts if they were removed Refer to Wheel End Overhaul Instructions If wheel end assembly was removed install the assembly and fasten socket ball to axle housing with nuts cap screws and lockwashers Torque nuts and cap screws see chart Con nect air brake lines and steering connections 5 Fill axle with correct lube see Lubrication Section IMPORTANT When axle has been disassembled or housing gears axle shafts or wheel equip ment replaced check axle assem bly for proper differential action before operating vehicle Wheels must rotate freely and independently 2 12 4x4 6 6 Axle Housing Silicone Gasket Compound Pattern Torque Chart Differential Carrier Stud Nut Fi lbs 5 8 18 220 240 Grade Stud Shift Unit Stud Nut Ft Ibs 7716 20 55 61 Grade 8 Stud Socket Ball to Housing Stud Nut Ft Ibs 3 4 16 280 360 Grade 8 Stud Cap Screw 5 8 11 170 220 231 298 Grade Differential Carrier Overhaul Differential Carrier Assembly Single Reduction BEARING DIFFERENTIAL CASE THRUST THA
19. 14 Install front output shaft and adjust end play see page 4 9 SPRING STEEL AND MAY POP OFF WEAR SAFETY GLASSES WHEN INSTALLING 8 Press bearing cup in input shaft nearing cover 9 removed install dowel pins in differential carrier 14 With power divider and input shaft installed on carrier adjust input shaft end play Temporarily install input bearing cover without snims and follow procedures in Step 2 through 3 page 4 8 4x4 Power Divider Overhaul Disassemble Power Divider Cover 230 260 300 350 Axis Series Power Divider Cover and input Shaft FRONT BEARING LOCK CAP ale m SPACER SCREW PLAT SEARING TL i SHiM COVER SEAL BEARING CUP I MOUNTED IM POWER DIVIDER COVER 1 Remove nut flat washer and 2 Remove cap screws lockwash 3 Ramove bearing spacer from yoke from input shaft ars input bearing cover and shim input shaft pack from power divider cover 4 Placa power divider cover in 5 Remova oil seal and bearing 6 To remove front bearing cone press inside area up and press cup from input bearing cover from input shaft temporarily place input out of rear bearing using suitable pullers helical gear on input shaft Place cone Then remove helical gear shaft in press and remove bearing and rear bearing cone from power divider cover 7 Remove in
20. Adjust used gear sets to display the same contact could be longer pattern observed before disassembly correct pattern is clear of the toe and centers evenly along the face width between the top land and root Otherwise the length and shape of the pattern are highly variable and is considered acceptable as long as it does not run off the tooth at any point 4x4 3 13 Adjustments Adjust Tooth Contact Pattern Lo If necessary adjust the contact pattern by moving the ring gear and drive pinion Ring gear position controls the backlash This adjustment moves the contact pattern along the face width of the gear tooth Pinion position is determined by the size of the pinion bearing cage shim pack It controls contact on the tooth depth of the gear tooth These adjustments are interrelated As a result they must be con sidered together even though the pattern is altered by two distinct operations When making adjustments first adjust the pinion then the backlash Continue this sequence until the pattern is satisfactory Adjust Pinion Position If the gear pattern shows incorrect tooth depth contact change drive pinion position by altering the shim pack Used gears should achieve proper contact with the amp ame shims removed from the axle at disassembly INCORRECT PATTERN INCORRECT PATTERN Move pinion Move pinion toward ring gear away from ring gear Pattern too close or off tooth root
21. Check Speedometer Adapter 1 sure adapter is grounded to vehicle chassis 2 Check wiring for shorts or grounds and trace eiectrical circuit from ignition switch through circuit breaker pressure switch to adapter 3 Check for power supply at adapt ar tarminal With axle shifter valve in High Range pressure switch is open and power is not delivered to adapter With shifter valve in Low Range the pressure switch is closed and power is delivered to operate the speedometer adapter power supply is okay adapter is fauity adapter assembly Check Pressure Switch In Law Range the pressure switch is closed and electrical circuit complete to the speedometer adapt In High Range air pressure opens the oressure switch breaks the alectric circuit to the speedoam ater adapter To check pressure switch opera tian shift to High Aange and probe switch terminais No voltage should present Replace fauity pres sure switch as an assembly 4 4 8 13 Shift Sytem Components Air Shifter Valves Typical Air Shifter Valve for All Wheel Drive Selection ervice instructions Ajl Wheel Drive For valve repair instructions Selection Instruction refer to pertinent manufacturer s Plate literature Typical Air Shifter Valve for Axle Range Selection with Interlock Pin Service Instructions For valve repair instructions refer to pertinent manufacturer s Axia Range Se
22. Continue tightening nut until cotter pin hole lines up with nut slot Install cotter pin 1 18 4x4 6x6 F installing Upper Bearing Cup 05354 X a ili M 0525 Assembly Assemble Socket to Axle Ball Cont d T Install kingpin bearing covers and shims top and bottom On the left hand wheel end the top cover includes the steering arm and is fastened with dowels nuts and lockwashers The bottom cover uses cap screws and lockwashers On the right hand wheel end the top cover uses nuts and lockwashers The bottom cover uses cap screws and lockwashers NOTE If original parts are used in reassembly install the shims spacers previously removed and identified during disassembly If new parts are used place a shim pack of 0 045 under each king pin bearing cover Shim location may be changed from upper to lower position vice versa to properly center the axle bali within the socket B Install kingpin covers and shims spacers pre viously removed and identified during disassembly If new parts are used place a shim pack of 0 045 under each kingpin bearing cover Shim location may be changed from upper to lower position or vice versa to properly center the axle ball within the socket NOTE The kingpin spreading fixture is still installed and will affect the drag 9 Lubricate both bearings using wheel bearing grease and a qun Operate gun until grease can be seen coming
23. Measure the line on the axle centerline see draw ing at front of the tires Repeat measurement at rear of tires Compare measurements Front measurement should be same ta shorter than rear measurement B Adjust tle rod as necessary to achieve these tolerances Caster VERTICAL LINE Caster Angle Should Be 3 Viewing Outside of Left Hand Wheel VERTICAL B REAR TOE IM B MINUS Toe in Should Be 0 to 19 Viewing Top of Axle 4x4 CASTER 39 KINGPIN CFL VERTICAL LINE 6x6 1 5 Lubrication Wheel Bearings Pack with wheel bearing grease NLGI No 1 or No 2 Lubricate during bearing adjustment or annually Axle Ball and Socket Use chassis lube Rotate axle ball socket to one extreme and coat inside area of socket with lube Turn ball socket to opposite extreme and lubricate ball Differential Carrier Refer to Lubrication Section 3 Brake Camshaft Bushings Use chassis lube and lube fitting located in brake chamber mount ing bracket Apply with lube gun until lube can be seen escaping from slack adjuster end of camshaft Upper Kingpin Bearings Lower Kingpin Bearings Tie Rod End Ball Stud Kingpin Bearings Use wheel bearing grease NLGI No 1 or No 2 Tie Rods Use chassis lube and Lubricate through lube fitting in upper bearing cover For lower bear lube fitting one in each tie rod ings remove pi
24. Remove Differential Carrier Assembly from Axle Housing 1 Drain axle lube 4 Disconnect front output shaft driveline to steer drive axle 2 Dual Range Axle Shift to low range Disconnect shift unit air line Remove shift unit 5 Disconnect lockup shift unit air lines 3 Axle with Controlled Traction Differential Shift to engaged posi tion Disconnect shift unit air lina Remove shift unit 6 Disconnect input driveline Loosen shaft nut but do not Loosen shaft nut but do not remove remove 7 Remove stud nuts and axle 8 Support differential carrier with shafts If used remove lockwash transmission jack or similar equip ers and taper dowels If neces ment Remove nuts and lockwash sary loosen dowels by hoiding a ers some models also use cap brass drift in the center of the screws fastening carrier to axle shaft head and striking drift housing Remove differential car sharp blow with a hammer rier and power divider assembly IMPORTANT Do not strike the WARNING DO NOT LIE UNDER shaft head with a hammer Do not CARRIER AFTER FASTENERS use chisels or wedges to loosen ARE REMOVED USE TRANS shaft or dowels MISSION JACK TO SUPPORT DIFFERENTIAL CARRIER ASSEMBLY Torque Chart Size Grade Ft Ibs N m DIFFERENTIAL CARRIERS Axle Series 185 220 Stud Nut 5 8 18 8 stud 220 240 298 325 230 260 300 350 Stud Mut 5 8 18
25. Steering and Wheel End Equipment Overhaul Assembly Install Ball Seal and Retainer 1 Ball seal retainer halves are furnished in matched sets and are identified by matching numbers stamped on the retainer faces First assemble seal and retainers as follows Place both retainer halves in a vise so they form a complete circle Instail seal in retainer with seal gaps away from retainer gaps see photo Trim or cut off seal at a slight angle so that the seal ends join together NOTE Lubricate seal lip with grease RETAINER GAP 2 To install seal and retainer assembly on axle remove from vise Then open one split in seal and retainer then slide retainer and seal over the axle ball see photo Join the retainer halves SEAL RETAINER ASSEMBLY 3 To correctly position retainer push it towards the socket and just before it is in place and while a gap between halves still exists insert two retainer gaskets see photo Complete installation by tap ping retainer in place and installing cap screws and lockwashers 4 Turn axle ball to one extreme and coat inside area of socket with grease Turn axle ball to one extreme and coat inside area of socket with grease Turn ball to opposite extreme and lubricate ball with grease Installing Retainer Gasket 1 20 4 4 6x6 Assembly Adjust Steering Stop Screws 1 If removed install stop screw and locknut screw 22 head should fa
26. 1 1 2 18 500 680 KINGPIN COVER Cap Screw 5 8 11 8 170 220 231 298 280 360 380 488 ut NTT Te CCC TCE ES eT Te Cee T B 14 450 613 AXLE BALL SEAL RETAINER Screw 3 8 18 5 30 40 AXLE BALL TO HOUSING Cap Screw 2 5 8 11 8 170 220 231 298 Stud Nut Lc 3 4 18 8 stud 280 360 380 488 AXLE SHAFT CAGE RING Cap Screw 1 2 20 8 95 130 TIE ROD END Ball Stud Mut ee 7 8 14 450 813 Clamp Bolt Mut 5 8 11 60 80 81 110 AIR CHAMBER MOUNTING Mut V 5 8 18 5 130 180 176 244 BRACKET TO SOCKET Cap Screw 172 13 8 80 110 110 149 SPINDLE TO BALL SOCKET Cap Screw T 220 350 BRAKE SPIDER amp SPINDLE TO AXLE BALL SOCKET 12 pt 5 8 11 8 170 220 231 298 9 2 4 4 6 6 Eaton Steer Drive Axle Differential Carriers Fastener Single Re Tightening Specifications Specifications the same for ail models unless specified otherwise Pastener Size Grade Ft Ibs N m RING GEAR Single Reduction Belt Nut 5 8 18 B 180 220 244 298 Dual Range amp Double Reduction 9 16 18 5 150 170 203 230 DRIVE PINION m Lp AMT 1 1 2 18 560 700 759 949 PINION BEARING CAGE Cap Screw ess 9 16 12 5 100 125
27. 136 170 DIFFERENTIAL CASE Single Reduction u Cap Screw 3 16 12 8 150 180 203 244 Dual Range amp Double Reduction 1 2 13 8 90 110 122 149 DIFFERENTIAL BEARING CAP Single Reduction Cap Screw 3 4 10 8 360 440 488 598 Dual Range amp Double Reduction 13 18 10 8 370 430 501 583 DIFFERENTIAL BEARING ADJUSTER LOCK gt Dual Range amp Double Reduction Cap Seraw m 5 8 11 5 160 176 217 239 DIFFERENTIAL CARRIER mmu u Stud Nut 5 8 18 8 stud 220 240 298 325 SHIFT UNIT MOUNTING 7 Stud Nut 7 18 20 8 stud 55 81 74 82 SHIFT FORK COVER Screw 7718 14 5 35 45 47 61 4x4 6x6 9 3 4x4 Rear Axle Power Dividers All Models Specifications are the same for ail Axle Series unless specified otherwise Tightening Specifications Fastener Size Grade Ft Ibs INPUT SHAFT _ 185 220 E nes 1 5 8 18 780 9650 1059 1301 1 7 8 12 020 1129 1383 INPUT SHAFT BEARING COVER Cap Screw FIN 1 2 13 5 75 85 101 115 FRONT OUTPUT SHAFT 2222 222224222 1 12 18 580 700 759 949 FRONT OUTPUT SHAFT BEARING COVER Cap Screw 7 16 14 8 48 56 85 76 9 16 12 8 110 125 149 170 1 3 4 12 840 1020 1139 1383 DRIVE PINION 0346 386 406
28. B stud 220 240 298 325 At Dowels 150 170 203 230 Cap Screw 12 pt 578 11 8 210 230 285 312 AXLE HOUSING COVERS Stud Nut Axle Series 185 220 230 260 7 18 20 8 stud 70 86 84 118 Cap Screw 7 16 14 5 48 56 85 75 Axle Series 300 350 Stud Nut 1 2 20 8 stud 110 130 149 176 Cap Serew 1 2 13 5 75 B5 101 115 SHIFT UNIT Dual Range Stud Nut 7 16 20 B stud 55 61 74 82 4 4 3 15 Differential Carrier Replacement Install Differential Carrier Assembly IMPORTANT Before installing carrier assembly inspect and thoroughly clean interior of axle housing NOTE Use silicone rubber gasket s itiCONE GASKET COMPOUND SILICONE GASKET COMPOUND compound on axle housing mating PATTERN DIFFERENTIAL CARRIER PATTERN HOUSING COVER surface as shown in the illustra MATING SURFACE MATING SURFACE tions Gasket compound will set in 20 minutes Install carrier and axie housing cover before com pound sets or reapply Follow procedure in numerica sequence 1 Dual Range Axle Shift to 2 Axle with Controlled Traction 3 Apply silicone gasket com low range Differential Shift to engaged A pound Install differential carrier position assembly in axle housing Install nuts and lockwashers Some Axle Models also use cap screws Tighten fasteners to correct torque
29. Drive Pinion Press fit outer pinion bearing conta Press Qi Saal in Cage a must be press on Jule Hara T Press outer pinion bearing B Install oil seal with a press Use NOTE Prior to installation of cone properly sized sleeve to fit seal to flange or yoke lubricate oil seal prevent distortion during installa lip and make sure flange or yoke tion is clean and dry 9 Install flange flat washer and nut Torque nut to 560 700 ft Ibs 759 949 IMPORTANT At this stage of assembly final check pinion bearing preload See Adjustment Section 4x4 6 6 2 19 Differential Carrier Overhaul Install Drive Pinion 1 Place shim pack on carrier making sure lube hole 1 clear NOTE If gear set is to be reused install same Quantity and size of shims removed during disas sembly When installing a new gear set use nominal shim pack 0 023 0 584 mm 2 Install pinion assembly Install bearing cage cap screws and lockwashers Torque cap screws to 100 125 ft Ibs 136 170 N m Install Differential and Ring Gear Assembly NOTE Lubricate bearings during the following assembly procedures 1 Place ring gear and differential assembly in carrier Carefully lower the assembiy until bearing canes rest on carrier 2 20 4x4 6x6 2 Install bearing cups at both sides of differe
30. Type Remove shift unit nuts and CARRIER AFTER FASTENERS washers Disconnect air line to ARE REMOVED USE TRANS permit removal of shift unit Place MISSION JACK TO SUPPORT sliding clutch in the engaged posi AND REMOVE DIFFERENTIAL tion Sliding clutch must be CARRIER ASSEMBLY engaged to allow removal of car Remove nuts and washers fasten rier from housing Remove shift ing carrier to axle housing unit Seasonal Engagement Type d carrier Remove nuts and washers from m shift fork cover retainer then remove cover retainer Place slid ing clutch in the engaged posi tion Sliding clutch must be engaged to allow removal of carrier from housing Permanent Engagement Type Sliding clutch is always engaged No procedure is necessary to remove differential carrier 3 REMOVE 4 4 6x5 2 11 Differential Carrier Assembly install Differential Carrier Assembly IMPORTANT Before installing carrier assembly inspect and thoroughly clean interior of axle housing NOTE Use silicone rubber gasket compound axle housing mat ing surface as shown in the illus tration Compound will set in 20 minutes Install carrier before compound sets or reapply Dual Range Axles Shift axle to Low Range before installing dif ferential carrier assembly Axles with Controlled Traction Differentials Place sliding clutch in the engaged position before installing differential carrier assembly
31. WASHER CUP PILOT NG BEARING SHIM LOCK BEARING BONE SPACER WASHER SCREW VARIABLE 1 Used only on Axle Series 230 260 300 350 2 Used only on Axle Serias 185 220 NOTE Lubricate parts with gear lube during reassembly 1 Using appropriate sleeve press bearing cups in cage see adjacent drawings IMPORTANT After bearing cups are installed preselect pinion bearing spacer using the trial build up procedure described in the Adjustments Section of this manual Press Bearing Cups in Cups meet Et Derby in cope Chemie with deer gan 0 6877 When correctly cups will be beige nier guef cu of cis Prosa one cue m at a me 6 10 4x4 zz na SNAP dale COVER M BUM BEARING PIN SPACER Assemble Drive Pinion Press fit outer pinion bearing Cont d gt IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner bearing race 5 Install preselected bearing spacer on pinion Also install Spacer washer on Axle Series 220 230 260 300 350 NOTE After tightening pinion nut recheck pinion Bearing rolling torque See Adjustment Section for Press fit outer pinion bearing STAKE PATTERN 3 Stake pilot bearing using stak ing tool This is essential to retain the bearing NOTE During pinion bearing installation locate each part in same
32. adapters round metal stock into two idler holes and invert the case assembly in a press The clutch plate should be down The adapter length should provide space for removal of the plate c Continue to press until the plate breaks loose from the plate dowel pins Setup for Removing High Speed Clutch Plate LL 12 Remove bearing cones from support cases using suitable puller see photo NOTE Holes are provided in case to enable removal of bearing cone with a pin punch see photo Tap alternately through each hole until cone removed WARNING WHEN USING A DRIFT PUNCH OR SIMILAR TOOL WEAR SAFETY GLASSES 1 8 Lift out thrust washer and side 9 Lift out spider side pinions and 10 Remove side gear and thrust TO REMOVE Removing Bearing fram Small Support Case using Puller 4x4 6 7 Differential Carrier Overhaul Assemble Wheel Differential Hear Axle Wheel Differential ilustrated T SDE THALSST DIFF WAS CASE WASHER gape i GEAR WASHER Ra GEAR CASE fuk pee Carscrew feat fro go sine 4 ME o E uS PLANETARY DICH m RECLICTKON AXLES OFF DIFF DEAA Sa p PRO T His ire Sita JJH GEAR BEARING SUPPORT CASE CASE SUPPORT SEARING BEARING GEAR RETAINEH ADJAISIEH CDHE
33. and side gear in flanged differential case 5 68 4 4 Press Bearing Cone on Flanged Differential 3 Assemble side pinion and thrust washers on spider Place this assembly in flanged differential case Rotate gears and check for proper mesh 5 Align punch marks and install plain case half install cap screws and tighten to correct torque Check differential for free rotation by turning side gear hub Ditferen tial may require up to 50 ft Ibs 68 N m torque to rotate Press Bearing Cone on Plain Differential Casa 4 Place side gear and thrust washer on side pinions 6 Install ring gear Secure with bolts and nuts Torque nuts to 180 220 ft Ibs 244 298 Torque Chart Differential Case Cap Screw 1 2 13 9 16 12 5 B 11 Grade Grade 8 Grade 8 Ft Ibs 90 110 116 130 165 195 122 149 157 176 224 264 Assemble Drive i Press it outer pinion bearing THESE PARTS wean ORIVE SPACER BEARING BEARING SEARING HELICA SNAP PINION WASHER GAGE ONE d HELICAL SLOTTED SNAP GIVIDEA COVER SUPPORT UN PILOT BEARING BEARING EM CAP ROLL SEARING BEARING CONE SPACER WASHER SCREW BEARING PIN AACE VARIABLE 11 Used only on Axis Geres ay 200 150 121 Used oniy an Ache Seres 145 NOTE Lubncate parts with gear lube during reassembly 1 Using appropriate sleeve press suena Gules bearing c
34. axie housing ie ai silicone rubber gasket compound on housing mating surface as shown in the illustration Compound will set in 20 minutes Install carrier before compound sets or reapply 1 Instail differential carrier assembly in axle housing Install stud nuts and lockwashers Tighten to correct torque 2 Install axie shafts and stud nuts If used also install lockwashers and taper dowels 3 Connect driveline 4 Fill axle with correct lube to correct level 5 Driver Controlled CTD Install shift unit on carrier engaging swivel with slot in shift fork shaft Install mounting nuts and flat washers Connect air line to unit B Seasonal CTD Position curvic clutch in the engaged or disengaged position then install shift fork cover retainer and secure with self locking nuts and washers NOTE Shift fork cover retainer can be installed in two different posi tions one to keep the sliding curvic clutch engaged and the other to keep it disengaged In the engaged position the shift fork cover retainer will have the adjusting screw facing the carrier and away from the carrier in the disengaged position IMPORTANT When axle has been disassembled or housing gears axle shafts or wheel equipment replaced check axle assembly for proper differential action before operating vehicle Wheels must rotate freely and independently 7 18 4x4 6x6 Service and Maintenance Instructio
35. bearing cone from Support case cover using suitable puller NOTE Holes are provided in the cover to enable removal of bearing cone with a punch Tap alternately through each hole until cone is removed Removing Support Case Cover 6 Permanent CTOs Only This unit includes a driver to en gage internal splined friction plates to the differential side gear With cover and springs removed the pressure plate clutch plate and driver can be withdrawn or lifted out of the ring gear bore The indi vidual parts can then be separated The snap ring an the friction plate driver acts as a stop for the plates Remove snap ring if replacement is necessary 9 Inspect Friction Plates With plates removed inspect surfaces for deeply scored or burned condi tion If a faulty condition is found or if torque check indicates a worn condition see Checking Effective ness of the Cantrolled Traction Differential page 7 3 replace the clutch pack 4 4 6x6 7 7 Medium duty Overhaul Assemble and Install Clutch Pack NOTE The clutch pack can be installed in differential and gear sup port case with wheel differential assembled or disassembled With dif ferential assembled proceed as follows 1 All Medium duty CTD Place dif ferential assembly on a work bench clutch pack mounting area install ring gear on support case flange aligning holes with two temporarily installed alignment bolts
36. cab and inspect assembly for component wear or binding After repalring check for correct operation by placing Ali Wheel Drive selector valve lever in engaged position and insuring that interlock pin on axle range shifter valve actu ates and also that it retracts when Ali Wheel Drive selector valve lever is placed in disengaged position 4 4 Dual Range Axles with Range Interlock Trouble Shooting conta Check Electrical System Check Solenoid Valve 1 When ignition switch is solenoid valve is energized and air pressure is available to operate the system When ignition switch is OFF solenoid valve is de ener gized and exhausts the system which downshifts axle to low range Check wiring and circuit breaker for defects that would cause shorts or open circuits 2 Make sure valve has a good ground connection to the frame With power at valve check opera tion as follows Disconnect lead wire and air line outlet at valve and install air pressure gauge Apply power to valve and observe air gauge reading Operating pres sure should be approximate reser voir pressure If gauge indicates approximate pressure valve is okay If gauge indicates low or no pres sure valve is faulty Replace valve assembly 8 8 4x4 Check Speedometer Adapter 1 Make sure adapter is grounded to vehicle chassis 2 Check wiring for shorts or grounds and trace electrical circuit from ignition switch thro
37. convenient but give the advantage of having every part needed for a good repair job 3 6 4x4 Adjustments Wheel Bearings Wheel bearings should be adjusted at regular intervals using the following procedure 1 Remove axle shafts Jack the wheel to be adjusted clear of the ground After securely blocking the vehicle to prevent rolling release the parking brake allowing the wheel to rotate freely WARNING INSURE THAT THE VEHICLE WILL NOT ROLL BEFORE RELEASING BRAKES a 2 Remove outer adjusting nut and nut lock Inspect the lock for ser viceability Replace if tangs are broken or badly misshaped 3 Using a torque wrench tighten the inner wheel nut with 50 foot pounds B8 N m torque while rotating the wheel in both forward and reverse directions The wheel should turn easily Back off the inner wheel nut 1 4 to 1 3 turn NOTE Inner nut must be installed with machined shoulder surface placed against wheel bearing cone INNER NUT NUT OU TER LOCK NUT 5 Replace the outer wheel nut and tighten to 250 to 275 foot pounds 339 373 M m torque 6 Repeat rotation of the wheel in both directions The wheel should rotate freely within limits of 0 001 to 0 010 end play T With adjustment complete secure adjusting nuts by bending one wheel nut lock tang over each nut Bend tangs over the closest flat perpendicular to the tang see Reinstall the axle shaft
38. could be longer a between tooth top land and root De evenly centered Fi Pattern should be clear of tooth 4x4 5 13 Differential Carriers for 4 4 Rear Axles Dual Range 185T4 220T4 230T4 260T4 30074 35014 Double Reduction 185P4 220 4 230P4 260P4 300P4 350P4 Differential Carrier Overhaul These instructions cover dual range and double reduc tion differential carrier assemblies for 4x4 rear axles It is assumed that the power divider assembly has been removed from the carrier Section 6 Contents Page No DIFFERENTIAL CARRIER OVERHAUL Exploded View 2 Disassemble Differential Carrier Disassemble Drive PINION 9 Disassemble Wheel Differential 6 Assemble Wheel Differential Assemble Drive PINION 10 Install Drive Pinion 12 Install Pinion Outer Support Bearing Race 12 Install Pinion Helical Gear 13 Install Differential Assembly in Carrier 14 Adjust Differential Bearing Preload 15 4 4 6 1 4 4 Dual Range 18514 22014 23074 26074 30014 35074 Double Reduction 185P4 220P4 230P4 260P4 300P4 350 4 Differential Carrier Assembly 4x4 Hear Axle SEARING CAP V LOCK FLAT WASHER
39. cw cw CEW 4x4 6x6 1 11 Steering and Wheel End Equipment Overhaul Disassembly conta Remove Brake Chamber 1 Remove cap screws lockwashers flat washers and guard covering slack adjuster 2 Disconnect air line at brake chamber Remove cotter pin and clevis pin at slack adjuster arm To remove brake chamber and bracket assembly remove cap screws and lockwashers fastening bracket to ball socket see photo 3 Inspect chamber for air leaks cracked housing bent push rod loose clamp ring clogged vent hales or loose air fitting Repair or replace as recommended by manufacturer Remove Slack Adjuster 1 Remove snap ring and shims then slide slack adjuster off camshaft splines see photo 2 Check for spline wear Measure backlash in slack adjuster If backlash is more than 0 094 measured 6 from camshaft centerline replace Slack adjuster Check for ability to rotate adjusting nut at least one complete revolution in both directions If excessive force is required greater than 15 ft Ibs replace slack adjuster For additional inspection procedures refer to manufacturer s instructions NOTE Repair of slack adjuster is not recommend ed Replace a faulty unit as an assembly Remove Camshaft 1 Before removing camshaft check for free rota tion Also check camshaft side movement with dial indicator If movement is greater than 0 020 cam shaft journals or bushings are worn When exces siv
40. damaged threads The axle housing should be examined for cracks or leaks Also look for loose studs or cross threaded holes Inspect machined surfaces for nicks and burrs 2 4 4x4 6x6 Repair and Replacement IMPORTANT To achieve maximum value from an axle rebuild replace lower cost parts such as thrust washers seals and bushings These items protect the axle from premature wear loss of lubricants Replac ing these parts will not increase rebuild cost significantly It is also important to replace other parts which display signs of heavy wear even though not cracked or broken A significant portion of such a part s useful life has been expended and the damage caused should the part fail is far in excess of its cost Steel Parts Gear sets input and output shafts differential parts and bearings are not repairable Worn or damaged parts should be discarded without hesitation Also discard mating parts in cases Gear sets for example must be replaced in sets Miscellaneous Parts Seals and washers are routinely replaced None of these parts can be reused if damaged Fasteners using self locking nylon patches may be reused if not damaged but should be secured Dy a few drops of Loctite 277 on the threaded surface of the hole during installation and carefully torqued during installation Axle Housings Hepairs are limited to removal of nicks or burrs on machined surfaces and the replacement of
41. end piay add shims Example Desired end play 0 0023 to 0 007 Measured end play Step 3 0 001 0 001 Add shims to provide desired and play 0 002 te 0 006 3 Ta decrease end play remove shims Example Measured end play 0 015 0 015 Desired end play Remove shims to provide desired end play 0 012 to 0 008 6 Raassembie adjusted shim pack and output shaft assambly to powar divider cover Install only the four output cover cap screws and lock washers to recheck and play Torque cap screws see chart T Recheck end play with dial indicator If and play is correct proceed to Step 8 If incorrect repaat shim pack adjustment BOR Bo Ro 4o RoR 4 B OR m Front Qutput Shaft BEARING QUTPFLT 3XeMEFTFONK BEARING G NE SHET 11 aed on 18 220 Serias 0 003 ta 0 007 Final Shaft Reassembly after End Play Correct 8 IMPORTANT If oil seal was assembled to cover during adjust ments it could have been dam aged Oil seal replacement is recommended to prevent possible lube leaks 9 After shaft and play is correctly adjusted remove the four cover Cap screws and lockwashars Remove output shaft cover and yoke assembly Coat mounting surfaces of both output and power divider covers with saalant to prevent lube leakage 10 Place shift fork in mounting position
42. except where specified otherwise This manual includes specific instructions for single reduction differential carriers both single drive and tandem axles equipped with Controlled Traction Differentials For service instructions covering other axle parts and adjustments refer to the appropriate Spicer axle service manuals 7 2 14 4 6x6 Description and Operation Spicer Controlled Traction Differen tials or CTD incorporate a friction plate assembly designed to transfer torque from the slipping wheel to the one with traction Engaged the opicer CTD converts to a biasing differential and assists in overcom ing adverse operating conditions Disengaged it restores convention al differential action for normal road conditions The CTD unit is basically a multiple disc clutch designed to slip above predetermined torque values This controlled slipping characteristic at higher torque values enables the vehicle to negotiate turns in a nor mal manner Resistance to slippage at lower torque values enables the vehicle to maintain an appreciable amount of tractive effort when one wheel encounters relatively poor traction The Controlled Traction Differential friction plate assembly clutch pack is under constant spring pressure The Heavy duty CTD clutch pack includes tanged and splined friction plates The tanged plates attached to the differential case drive both axle shafts through the splined plates thereby limi
43. filler hole plug located in the axle housing cover Lube should be level with the bottom of this hole IMPORTANT Lube level close enough to the hole to be sean or touched is not sufficient It must be level with the hole NOTE When checking lube level also check and clean housing breathers 2 2 4x4 6x6 Ambient Temperature Range Department review This is essen tial to ensure proper seal life and axle performance with a particular synthetic For additional informa tion contact Spicer Field Service Department or call Regional Office See back cover for address and phone numbers Oil Additives The use of oil additives is not approved for use in Spicer axles Proper Grade 40 F to 15 F 40 C to 26 15 F to 100 F 26 C to 38 15 F and above 26 C and above 10 F and above 12 and B5W 140 Class A operation is defined as well maintained highways of concrete or asphalt construction Terrain level to rolling with maximum 8 grades Class AA is turnpike For other type opera tions change lube at 40 000 mile intervals If the vehicle does not accrue enough mileage to require a lube change change the lubricant once yearly Adding Lube If the lube level falls below its proper level between changes it should be replenished as needed Lubricants approved under the MIL L 2105 C
44. in cover and on sliding clutch Then assemble shim pack and autput shaft assembly to power divider cover Install four cap screws and lockwashners fas tening output cover but do not tighten cap screws completely 11 Apply silicone gasket com pound to shift unit mounting sur face of the output cover see illus tration Assemble and install shift unit see Shift System Section 8 Torque output cover and shift unit mounting cap screws see chart To prevent possible lube leakage coat outer of shim pack with sealant 12 At this point in reassembly remove yoke and install new oil seal with seal driver Reinstail yoke flat washer and nut Torque nut see chart Torque Chart Front Output Shatt Cover Cap Screw Fi ibs 7 16 14 two 48 56 85 76 Grade 5 3 18 12 110 125 149 170 Grade 5 Output Shaft Nut Fi iba 1 1 2 18 560 700 759 949 Grade 5 Silicone Gasket Compound Pattern aia ehift Unit 4 4 4 9 Differential Carriers for 4x4 Rear Axles Single Reduction 18554 22054 23054 26054 30054 35054 Differential Carrier Overhaul These instructions cover single reduction differential carrier assemblies for 4 4 rear axles It is assumed that the power divider assembly has been removed from the carrier For service information on single reduction carriers equipped with Spicer Controlled Tract
45. loose or broken studs CAUTION ANY DAMAGE WHICH AFFECTS THE ALIGNMENT OR STRUCTURAL INTEGRITY OF THE HOLISING REQUIRES HOLISING REPLACEMENT REPAIR BY WELDING OR STRAIGHTENING SHOLILD NOT BE ATTEMPTED THIS PROCESS CAN AFFECT THE HOLISING HEAT TREATMENT AND CAUSE IT TO FAIL COMPLETELY WHEN UNDER LOAD Silicone Rubber Gasket Compound For more effective sealing Spicer uses silicone rubber gasket compound to seal the majority of metal to metal mating surfaces opicer includes gasket compound and application instructions in many repair parts kits It is recommended that this compound be used in place of conventional gaskets The compound will provide a more effective seal against lube seepage and is easier to remove from mating surfaces when replacing parts Always use Spicer Genuine Axle Parts and Parts Kits Genuine Spicer replacement parts are the same high quality tolerances as the original axle components and include the latest engineering improvements Parts Kits have only one part number which makes ordering stocking and servicing easier They are not only convenient but give the advantage of having every part needed for a good repair job 4 4 6x8 2 5 Adjustments 2 6 4x4 Differential Carrier Bearing Preload This adjustment is performed for both pinion and dif ferential bearings maintains proper gear alignment by creating correct bearing cone and cup rela tionship for free r
46. of two operational modes 4x4 and 4 2 When the system includes Controlled Traction Differentials these units are engaged and operating in 4x4 drive and disengaged in 4x2 drive With an additional valve in the cab the system may be set up for independ ant control of Controlled Traction Differential Operation Steer Drive Axle Lockup Controlled Traction Differentiais A manuaily operated shifter valve Two shift units ane on each axie angage or disengage controlled controls air pressure supply to the traction differentials shift unit which in turn engages or disengages the steer drive axle Engaged When shifter valve lever is moved to the engaged position The shift unit is mechanically con the valve is opened and air pressure is applied to the shift units Each nected to a shift fork and sliding shift unit is mechanically connected to a shift fork and a sliding clutch clutch The clutch engages or The sliding clutch moves to engage the controlled traction differential disengages a drive gear ta engage In the engaged position the unit is operational as a biasing differential or disengage the drive t the steer orive Disengaged When shifter valve lever is moved to the disengaged For detailad operation description position the is closed Air pressure in each shift unit is exhaust see page 8 3 ad The sliding clutch retracts and disengages the controiled traction differential the disengaged position t
47. press bearing cup in cover IMPORTANT For correct cup installation use appropriate sieeve to make sure cup is not cocked and is firmly seated all around NOTE Do not install oil seal in output cover until output shaft end play adjustment is completed NOTE At this point in reassembly the output shaft assambly and output Cover are ready to install for purposes of measuring cover clearance and adjusting output shaft and play page 4 3 NOTE When adjustment of output shaft end play is completed con tinue reassembly as described on 4 9 4x4 4 3 Power Divider Overhaul Disassemble Power Divider Cover 185 220 Axla Series Power Divider Cover and Input Shaft PLATE LOCKWASHER 7 bea CAPSCREW BEARING INPUT SEARING DIVIDER SEARING CONE SHAFT CONE COVER LOCKWASHER SHIM COVER YOKE ME amp em capPscREw m mn SEAL 1 E ym i i 1 KOF Jum E a m cae FLA BEAMING CUP SCREW WASHER eL LOCKWASHER d CAPSCREW GEARING CUP MOUNTED DIFF CARRIER IMPORTANT Input shaft and helical gear are manufactured as one component When yoke is removed in Step 1 procedura axert caution because the shaft and gear with bearing cones could fall out of power divider covar 1 Remove nut flat washer and 2 Remove two bearing cones 3 Remove cap screws lockwash yoke from input shaft R
48. rear axle Disconnect air line from cover of the steer drive axle lockup shift unit with selector valve lever in disen gaged position NOTE This air line is not to be confused with air line connected to interlock control valve installed in shift unit cover Leave this air line connected Place All Wheel Drive selector valve lever in engaged position and check for air flow at disconnected air line Place select or valve lever in disengaged position and insure air flow is discontinued If not remove All Wheel Drive selector valve and inspect Replace as required Place selector valve lever in disengaged position and reconnect air line Proceed to next step after insuring sufficient air pressure is available to continue system checks 5 Check Interlock System Move the All Wheel Drive selector valve lever to engaged position and check axle dual range shifter valve lever to make sure the interiock actuates interlock pin lacks the valve lever and prevents movement of the lever when in All Wheel Drive Move the selector valve lever to disengaged position and check for retraction of the interlock pin on the axle range shifter valve If interlock pin func tions correctly system check is complete If not proceed to Step 5a a If interlock pin does not function correctly move All Wheel Drive selector valve lever to disengaged position then disconnect air line on the side of the interlock control valve Move the All W
49. selector valve and or the lockout control valve mounted in the side of the rear axle range shift unit is malfunctioning Starting with the All wheel Drive selector valve disconnect the air line from the side of the valve with the lever in the disengaged position Move lever to engaged position and check for air flaw Place selector valve in disengaged position and insure air flow stops Replace vaive if it functions incorrectly nect air line to delivery port and proceed to Step B Next move to the lockout con trol on the rear axie range shift unit With the All Wneel Drive selector laver in the engaged ocsi tion and the axle range selector valve in Low Range check air flow fram the side port of the lock out control If air flow is nat present remove the valve and test by manually pushing the ball on the valve with air supplied to the end of the valve With the ball pressed in air should flow from the delivery port on the valve With the bail released airflow should be stopped if tha valve functions incorrectly it should replaced If it functions correctly reinstall in the snift unit and insure that air flaws through the valve when the All Wheel Drive selector lever in the engaged position axle range shifter vaive in Low Range and is stopped when the lever is in the disengaged posi tion If this does not occur the rear axle shift unit must ba inspected and re
50. shart nut NOTE There are blind cap screws fastening power divider cover to differential carrier These screws are accessible through front output shaft bearing cover opening Before attempting to remove power divider cover first remove front output shaft assem to make hese cap screws accessible see step 2 2 Remove Front Output Shaft Assembly Remove two shift unit cap screws and lockwashers Remove four output cover cap screws and lockwashers Then remove output shaft assembiy shaft cover gear yoke and shift unit from power divider cover Remove shim pack 4 To remove power divider cover assembly attach chain hoist to input shaft yoke and lift the cover assembly otf carrier If power divider cover does not separate easily strike cover near dowel pin locations with a soft mallet NOTE Lifting mechanism may create nicks and burrs on yoke Remove nicks and burrs if present 4x4 3 Remove power divider cover cap screws including the blind cap screws Two blind screws are used on 185 and 220 Axle Series one screw is used on 230 260 300 350 Axle Series Power Divider Overhaul Disassemble Front Output Shaft 1 Disassembie and remove lockup shift unit from output shaft cover see Shift System Section B 2 Remove nut washer and yoke from shaft Remove cover assembly and shift fork NOTE On 185 220 Axle Series remove bearing spacer from output shaft 3 To disa
51. shoe pin see photo 3 down on lower shoe with a sturdy lever see photo and install cam roller and pin Repeat procedure for upper shoe WARNING To avoid possibility of personal injury make certain you have a firm grip on prying lever before installing roller and pin 1 24 4x4 6x6 LOWER ets NL SPRING Positioning Shoes on Anchor Pin gt ul ing LOWER A SHOE Connecting Shoe Return Spring CAM ROLLER AMD Prying Down on Brake Shoe to Install Cam Haller and Pin Assembly Connect Tie Rod and Steering Drag Link 1 If tie rod end was disconnected from axle ball socket proceed as follows Install flat washer seal washer and tapered coil spring on tie rod end ball stud Connect stud to ball socket and secure with slotted nut Torque to 450 ft lbs 613 and install cotter pin On left hand wheel connect tie rod end using same procedure as above Also connect steering drag link to upper kingpin cover steering MOTE Refer to Wheel Alignment Section for tie rod adjustment Assemble and Install Wheel Hub and Drum MOTE During the following assembly procedure use wheel bearing grease see Lubrication Section 1 If bearing cups were removed from hub install with suitable driver Install cups until they seat firmly on shoulder inside hub 2 Line entire wall of hub with grease Fill hub with grease leaving only an opening large enough for t
52. slight hub drag Drag should produce a 4 to 10 Ibs pull at wheel mounting studs If drag is incorrect reset adiusting nut T After oearing adjustment is carrect install the nut lock in the adjusting nut slot Install cap screw and lockwasher in the nut to hold lock and adjust ing nut in position 8 Pack groove in hub cap with grease 1 2 thick layer 8 Using a soft nosed hammer install hub cap and secure with nuts and lockwashers Tighten nuts to 170 220 ft lbs torque 231 288 N m Install Wheels and Tires Lubricate Axle 1 Install wheels and tires 2 Fill Axle with carrect lubricant refer to Lubri cation Section 3 Check wheel alignment refer to Wheel Align ment Section 1 26 SCRE AND LOCK WASHER BEAR ING NP e installing Hub Cap Differential Carriers for ESD 18 Steer Drive Axles single Reduction Dual Range Double Reduction Differential Carriers These instructions cover service and maintenance for the steer drive axle differential carrier For information on single reduction gearing with Spicer Controlled Traction Differential refer to Section 7 Section 2 Contents Page No DIFFERENTIAL CARRIERS Lubrication 2 Ceaning Inspection Hanincemani T 4 Adjust Pinion Bearing Preload Differential Bearing Preload and Ring Gear Backlash Adjustment
53. specifi cation are compatible with each other and brands may be mixed To maintain proper viscosity levels however do not mix lube grades when adding to an existing supply Correct Lube level at bottom of filler hole Incorrect Lube level below Filler hole Changing Lube OIL FILLER HOLE Draining Drain when the lube is at normal operating temperature It will run freely and minimize the time necessary to fully drain the axle Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container Inspect drain plug for large quantities of metal particles After initial oil change these are signs of damage or extreme wear in the axle and inspection of the entire unit may be warranted Clean the drain plug and replace it after the lube has drained completely Axles with Lube Pump Remove the magnetic strainer from the power divider cover and inspect for wear material in the same manner as the drain plua Wash the magnetic strainer in solvent and blow dry with compressed air to remove oil and metal particles Filling Remove the filler hole plug from the center of the axle housing Lube Capacity cover and fill the axle with DO NOT OVERFILL AXLE approved lubricant until level with the bottom of the hole ESD 18 Steer Drive Axle 36 pints 17 liters NOTE Lube fill capacities in the adjacent chart are good guidelines but will vary somew
54. that may be wedged in the tread Check for holes or cuts that may permit air leakage from the tire and make the necessary repairs Inspect the tire side walls for cuts bruises and other damage If internal damage is suspected demount the tire from the wheel for further inspec tion and repair or replacement Check the tire valve for air leaks and replace the valve if neces sary Replace any missing valve caps Wheel Alignment and Wheel End Inspection Tie Rod and Tie Rod Ends Tie rods are of three piece construction consist ing of a tie rod and two rod end assemblies The ends are threaded to the rod and locked with clamp bolts Right and left hand threads are provided for loe in adjustment Tension on ball stud in the rod ends is self adjusting and requires no attention in service other than periodic inspection to see that the ball studs are tight in the steering knuckle arms Fittings are provided for periodic lubrication some types of tie rod ends Where no fittings are Used the tie rods have been lubricated at assembly andno further lubrication is necessary Wheel Alignment Factors In checking wheel alignment or when installing new axle parts both wheels should be checked in the following order 1 Camber 2 Caster 3 Toe in There are many types of alignment checking equipment that accomplishes the same purpose although the method of using the equipment may differ Refer to equipment manufacturer
55. through opening in differential Place bearing MOTE Lubricate baanngs during adjuster and cup assembly on the following assembly stock see photo procedures Raise and lower differential assembly while threading adjuster 1 Place ring gear and differential into proper position assembly in carrier Carefully war 35 bearing Carrier wail iubncated NOTE With bearing adjusters and caps assembled to carrier the carrier assembly is now ready for adjustment of bearing preload ring gear backlash and gear tooth contact sea page 5 13 NM 2 At teeth side of ring gear install 5earing cup bearing adjuster and Searing 5 12 4x4 Adjust Differential Bearing Preload 1 At the teeth side of ring gear position bearing adjuster until its first thread is visible 2 At the back face side of ring gear tighten adjuster until there is no backlash 3 At the teeth side of ring gear tighten adjuster until it contacts the bearing cup Continue tightening adjuster two or three notches This will preload bearings and provide backlash 4 Check Ring Gear Backlash Measure backlash with a dial indicator specifications are listed below Refer to Adjustment Section for detailed instructions on adjusting backlash Ring Gear Backlash Specifications USED GEARING Reset to backlash recorded before disassembly NEW GEARING Backlash should be as follows Axle Series 185 2
56. 20 0DE to 0 016 Axle Series 230 260 300 950 0 008 to 0 018 Check Ring Gear Tooth Contact Paint ring gear teeth and check tooth contact pattern Correct tooth patterns are illustrated below For checking and S pis procedures see Section Torque Charl Diff Carrier Bearing Cap Screws Fi Ibs N m 3 4 10 Grade 8 360 440 488 596 13 16 10 Grade 8 370 430 501 583 Bearing Adjuster Lock Cap Screws Ft Ibs Nem 5 8 11 Grade 5 160 176 217 239 6 With ring gear and pinion adjusted correctly align adjusters and locks then tighten differential bearing cap screws to correct torque see chart next page Install cotter pin in one adjuster lock Install cap screws in opposite adjuster lock and tighten to correct torque see chart next page Lockwire bearing and adjuster lock cap screws NOTE Axle Series 230 260 300 350 On teeth side of ring gear install lock and cotter pins On back face side of ring gear install T shaped lock and cap screws Torque screws see chart Lockwire all cap screws both sides of ring gear CORRECT PATTERN USED GEARING CORRECT PATTERN NEW GEARING Checking Hing Gear Backlash Could vary length O Pocket may be Pattern should cover extended V2 tooth or more lt Pattern along the face width Pon Pattern should
57. 360 440 ft lbs 488 596 Install adjuster locks and cotter pins Lockwire differential bearing cap screws CORRECT PATTERN USED GEARING ae Could vary in length T S CON NE a Packet may be Pattern should cover LI extended how Em 1 2 t othi or more Fi Fi SIN m F a Jr Ss a Pattern along the face width Fa rd face width of a Pattern should could be langer F uu be evenly centered gt between tooth top land and ue Dot m Patien should be clear of tooth toe 4x4 6x8 2 21 Differential Carrier Overhaul Differential Carrier Assembly Dual Range and Double Heduction THILZST WASHER RIDE PINION Vi SIDE THAL ST PINS SEAR WASH H DIFFERENTIAL ASSEMBLY HEAE MES BEARINGS THALIST HIGH SPEED BINE BEARING BEARING 40LETER Ete COBNHE ADJUSTER EAT i SURPAT gr aid CASE GEAR BEARING CGEAR hd cim AANGE BOLT PLAMETARY DOUBLE BEDUCTION AXLES RETAINER iY OM SHIFT FORE PRAET STUD SEAL WIPE SPRING DOWEL SHIFT SEAL 1 BUSHING FORK 4 SHIFT PORK COVER L CKWASHEH BEARIN
58. 4 Install the nut lock and snug it to the inner wheel nut BEND TANGS PERPENDICULAR TO CLOSEST FLAT WHEEL BEARING ADJUSTING NUT LOCK WHEEL BEARING ADJUSTING NUT 4 4 3 7 Adjustments Differential Carrier Adjustments help provide optimum axle life and performance by correctly positioning bearings and gears under load The tandem axles covered in this manual require the following adjustments Bearing Preload This adjustment is performed for both pinion and differ ential bearings It maintains proper gear alignment by creating correct bearing cone and cup relationship for rotation under load The pinion pilot bearing does not require a pre load adjustment ment positions ring gear and pinion for best contact under load Correct adjustment distributes torque evenly over gear teeth and helps maximize gear set life Adjust Input Shaft End Play specifications Input shaft end play requirements will vary with operat ing conditions mileage and rebuild procedures These variations are shown in the following chart Input Shaft End Play Chart New or Rebuild with new parts 0 003 to 0 007 variations in individual parts correctly adjusted end play could vary 0 010 after the unit is rotated Rebuild with reused parts 0 013 to 0 0017 Acceptable End Play Tolerances when measuring as a regular maintenance procedure with axle in truck Jp to 0 060 with over 100 000 NOTE If end play
59. 5 Remove cotter pins nuts and spacers from king pins Using suitable drift drive kingpins out of their bearings and mounting in the axle ball IMPORTANT Exercise care not to damage kingpin threads during above procedure 6 While keeping the kingpin bearing cones fully seated in their cups carefully drive the ball socket down until the upper bearing cup is moved up at least 1 8 above the bearing cover parting line Hepeat same procedure for lower kingpin bearing Removing Kingpin Top Cover 538 Partially Removing Top Bearing Cup 4x4 05363X 6x8 1 15 Steering and Wheel End Equipment Overhaul Disassembly conta 7 Remove ball socket as follows Hold upper kingpin bearing cone up in its full mounting position in its cup then tip ball socket and remove it from the axle bali see photo NOTE With ball socket removed the bearing cones can be removed The upper and lower bear ings vary in size Take note of their location to assure their return to original positions 8 Remove axle ball as follows Remove nuts cap screws and lockwashers fasten ing flange to axle housing Remove ball Inspect Axle Ball Socket and Related Parts 1 inspect ball for deep grooves or scratches Check clearance between ball bushing and journal area axle shaft that contacts bushing If clearance exceeds 0 015 replace ball and bush ing assembly 2 Inspect oil seal in
60. ASE CONE BEARING ADJUSTER HALF ADJUSTER e 0 PAS ma CASE PLAIN RING RING BEARING BEARING CAP CASE SIDE GEAR GEAR CLIP CUP SCREW HALF GEAR BOLT NUT 1 Remove nuts and bolts fasten ing ring gear to differential cases allowing gear to fall free If gear does not fall tap outer diameter with soft mallet to loosen 2 Punch mark differential cases for correct location during assem bly Remove cap screws and lift off plain differential case half 3 Lift out side gear and thrust 4 Lift out spider side pinions and 5 Remove side gear and thrust washer thrust washers washer 6 Remove bearing cones from case halves using suitable puller see photos 7 Remove bearing cone from plain case half in two steps First mount puller vertically to split bearing see photo This action will start moving bearing off case Second mount puller horizontally to remove cona Remove bearing from flanged case hal using suitable Puller Mounted Vertically Removing Bearing Cone puller to Split Bearing from Flanged Case Half 4x4 5 5 Differential Carrier Overhaul Assemble Wheel Differential NOTE Lubricate differential parts with gear lube during reassembly 1 Press bearing cones on ditfer ential case halves see photos IMPORTANT To prevent bearing damage use suitable sleeve that only contacts the inner race of the cone 2 Place thrust washer
61. CASE THRILIST CASE ADJLISTER 1 LARGE WASHER IDLER WASHER 3 iE m dj CLUTCH DIFF RING IDLE amp HIGH SPEED AF i RING F SE BEARING GEAR CLUTCH i GEAR BEARING Ripe BOLT PIN PLATE NLIT cue NOTE Lubricate internal parts with gear lube during reassembly 1 Press bearing cones on support cases see photos IMPORTANT To prevent bearing cone damage use suitable sleeve that only contacts the inner race of the cone me E i Pressing Bearing Cone on Large Pressing Bearing Cone on Small Support Case Support Case 15 Hi H SPEED RECESS CHAMFEH CLUTCH PLATE 1 Ja POS iON 35 SIDE PLATE TOWARD CASE 2 acu THALI 2 Position high speed clutch plate with chamfered end of clutch teeth 3 Place thrust washer and side toward idler pinions Press clutch plate on case gear in differential case IMPORTANT It is important that the ends of the dowel pins are recessed 1 B below surface of the clutch plate If pins extend beyond plate surface press pins to proper depth Don t press them in too far 6 8 4 4 Assemble Wheel Differential contra 4 Assemble side pinions and thrust washers on spider Place this assembly in differential case Differential Case Cap Screw 1 2 13 Grade 9 16 12 Grade 8 7 Install idler pins and pinions 10 To install differenti
62. E THE PISTON WILL POP OUT HOUSING UNDER SPRING PRESSURE EXERCISE CAUTION TO PREVENT POSSIBLE INJURY Remove locknut flat washer and piston from push rad Remove ring and felt oilers from piston COMPRESSION SPRING 4 Remove compression spring and piston stop from bore of shift unit housing 5 Remove clevis pin than remove push rod from shift unit housing Remove Ring trom push rod vx 3 7 ACTUATING LEVER BEARING 6 Remove actuating lever and pin assembly from shift unit housing Do not disassembie actuating lever Parts Inspection Shift Fork Seal inspect shift fork seal for defects and tight fit on shift fork A spring is used to assure a closer fit of seal around shift fork If this spring is nat present on axle being serviced install ane when reassembling unit OQ Rings Felt Oilers and Gasket Replace rings fait oilers and cover gasket when piston air shift unit is disassembled for repair Compression Spring nspect spring for distortion cracks or other visual defects Replace a fauity spring Actuating Lever and Pins Inspect lever pins and bearings for worn grooved condition Inspect actuating lever and push rod for worn or elongated holes at point where they are connected Replace fauity parts Piston inspect piston friction surface for worn grooved or damaged condition which will affect the pist
63. EXPANSION PLUG CAP SCREW SHIFT FORK SHAFT FILLER PLUG AT DOWEL PIN LOCKWIRE BEARING ADJUSTER LOCK PLANETARY DOUBLE REDUCTION AXLES E CAP SCREW LOCKWASHER SHIFT FORK COVER DIFFERENTIAL CARRIER OOWEL 72 BUSHING 300 350 ILLUSTRATED Prud SCREW EXPANSION PLUG LOCK WIRE DIFFERENTIAL ASSEMBLY BEARING ADJUSTER HiGH SPEED THRUST GEAR CLUTCH PLATE PINION WASHER SUPPORT Tii THAUST ANION OF FERENTIAL SEARING BEARING rr AANGE Boum e WASHER Pim ASSEMBLY CONE ADJUSTER FEE GEAR nn RETAINER SUPPORT SCREW CASE a PLANETAR Y DOUBLE REDUCTION AXLES f 1 PLAIN SIDE SIDE THRUST GEAR AMNION WASHER CASE i i DAVE 1 SEARING BEARING SUPPORT PINION SNAP THESE PARTS ARE MOUNTED PINION SPACER CUP Cup BEARING SLOTTED AING IN POWER OIvIDER COVER strane cae cone 00000 008 Go v6 Eri iti Used only on 220 260 200 350 BEARING 2 Used only on 183 and 220 FEARING SCREW SEARING CAL GEAR PILOT SPACER LOCK BEARING BEARING VARIABLE WASHER RACE 6 2 4 4 Disassemble Differenti al Carrier with power divider removed NOTE the gear se
64. FT FORK FOR DRIVER CONTROLLED AND SEASONAL CTD WASHER 8 LOCKWASHER 2 Remove two self locking nuts and bolts 180 apart fastening NUTS BOLTS support case cover then temporar install two clamping bolts and nuts see photo These clamping bolts will hold cover in position while ramov ing the other cover self locking bolts and nuts Remove cover self locking bolts and nuts Removing Case Covar with clamping nuts and bolts installed Remove and Disassemble Clutch Pack conta CLAMPING HUTS amp BOLTS Removing Clamping Nuts Bolts Removing Clutch Pack T If necessary the ring gear can be removed from its mounting on the differential and gear support case flanged case half If difficulty is encountered loosen gear by tap ping on opposite sides with a soft nosed hammer 10 Disassemble and Reassemble Wheel Differential Refer to the appropriate Spicer Axle Service Manual covering your specific axle 3 With cover self locking balts and nuts removed alternately loosen and remove the two clamp ing nuts and bolts 4 Lift off cover and remove springs 5 Driver Controlled and Seasonal CTDs Only With cover and springs removed the pressure plate and clutch pack friction plates can be withdrawn or lifted out of ring gear bore If difficulty is experienced first remove pressure plate then lift out friction plates individually 8 If necessary remove
65. G BEARING CAP in d LOCKWRBE HH BEARING BEARIMO OIL FLAT cap 7 aed x T WASHER BM 20 FLAT i WASHER DOWEL BUSHING i BEARING FFERENT LAL BE ant cim BEARING CARRIER BEARING CONE CNE YOKE NUT BEARING COTTER ADJUSTER BEARING EXPANSION DANE SPACER SCREW Fih LOCK PLUG PINION VARIABLE LOCRWASHEA 2 22 4x4 6x6 Differential Carrier Overhaul Disassemble Differential Carrier NOTE lf the gear set is to be reused check tooth contact pattern and ring gear backlash before beginning disassembly Best over naul results are obtained when used gearing is adjusted to run in established wear patterns Omit this step if the gear set is to be replaced When reusing the gear set remove the left hand bearing cap adjuster and lock a unit This will help return the gear set to its original adjustment during reassembly 3 2 Speed Axles Only Remove sliding clutch Planetary Double Reduction Axles sun gear is used in place of sliding clutch gear remove sun gear remove the retainer which holds gear in position then remove sn gear NOTE When reusing gearset punch mark bearing adjusters and adjustment during reassembly 4 On teeth side of ring gear cut lockwire and remove bearing cap screws Remove cap ad juster and lock On back side of ring gear cut lockwire and remove bearing cap screws f the gear set is to be reused remove b
66. GS ang SPRING R CARP SCREW m SCREW Lockout 5798579 FELT PLAT BODY CILERS WASHER LOCKWASHER PISTON STOP Used only on 4x4 Axle Series 185 220 and 6x6 Axle Series D346 P 386 P 406 P NOTE Inter axle differential lockout shift unit is only used 6x6 drive systems Disassemble Shift Unit 1 Remove cap screws and lock washers fastening cover to body ring from push rod Remove cover and ring 2 Remove nut flat washer and O 3 Remove body cap screws and lockwashers than remove body and piston as an assembly Remove ring and feit oilers from piston Assemble Shift Unit 1 Apply silicone gasket compound NOTE Before installation soak 4 install compression spring over to mounting surface on power piston felt oilers in SAE 30 engine shift fork push rod install piston in divider cover See illustration above ail and lubricate rings with body and secure with ring flat 2 Install lockout body Secure high viscosity silicone oil or barium washer and nut Torque nut to with cap screws and lockwashers grease O ning lubricant 20 26 ft lbs 27 35 Torque cap screws to 48 56 ft lbs 3 Install felt oilers and ring 5 Install O ring in lockout body 65 76 N m Shift Linit Silicone Gasket Pattern 4 4 Axie Series 185 220 406 P on piston cover Install cover assembly and Shift Units with Piston Stop See secure wi
67. IVE GEAR mE Troubleshooting Check for Air Pressure and Air Leaks simple method for quickly locat ing troubles in a shift system can ge accomplished by listening for possible air leaks and for sound feel by hand which would indicate mechanical shifting Steer Drive Axle and Controlled Traction Differential Shift systems 1 Initlal Preparation Start system check by placing All Wheei Drive selector valve laver in Cisengaged position Move vehicle in forward direction for a short distance then back vehicie up an equal distance Repeat this at least three times This will insure that all cluten s are in proper position If possible park vehicle on a flat surface do not apply spring brakes Oo not move the vehicle until system checks are completed Lastly insure that sufficient air pressure is built up to perform system checks Turn engine off 2 Move shifter valve lever to the Engaged position In this position air pressure should be present in the entire system Check for air leaks With Controlled Traction Differentials sure to check axie shift units and air lines 3 Move shifter valve lever to the Disengaged position In tnis position air pressure should be present only up to shifter valve 4 Operate shifter valve lever back and forth If the shift units are operating a definite reaction wiil evident by sound of parts movement 5 If air pressure is satisfactory and shift units do not func
68. R 7 COMPRESSION SPRINGS DIFFERENTIAL AMD GEAR SUPPORT CASE FLANGED HALF DIFFERENTIAL CASE PLAIN HALF D SELF LOCKING NUT Remove and Disassemble Clutch Pack Heavy Duty Type CLUTCH PACK ASSEMBLY FRICTION PLATE DRIVER PRESS ies ROUND 1 gt _ SNAP RING ALIGNMENT BOLT Removing Clutch Pack 3 Lift up and remove clutch pack assembly from the differential and gear support case see photo 4 If ring gear had an interference fit and did not fall off as previously mentioned in the warning note for Step 2 tap ring gear alternately on opposite sides with soft nosed hammer until ring gear is free of gear support case flange Compressing Clutch Pack in a Press with clutch pack installed in support case 5 Disassemble Clutch Pack To disassemble clutch pack use a press and suitable adapters NOTE This procedure can be accomplished with clutch pack removed from or installed in sup port case see photo Compress clutch pack then remove round snap ring Remove pres sure plate then alternately remove tanged and splined friction plates from friction plate driver B Inspect Friction Plates With plates removed inspect surfaces for deeply scored or burned condition If a faulty condition is found or if torque check indicates a worn condition see Checking Effectiveness of ag Controlled Traction Differential 7
69. R 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 Distributors 1 800 621 8084 OE Dealers 1 877 777 5360 www spicerparts com AXSM 0400 Printed in U S A Copyright Dana Limited 2012 All rights reserved Dana Limited SPICER
70. RING SPACER i CUP CONE BEARING SPACER Vwi SHER Cage in Press to Check Bearing Preload for slight growth in the bear ings which occurs when they are pressed on the pinion shank The trial build up will result in proper pinion bearing preload in three of four cases spacer 0 001 larger for use in the final pinion bearing cage assembly The larger spacer compensates Specifications for Pinion Bearing Trial Build up Preload Test Press fit Outer Pinion Bearings Nominal Bearing Spacer Thickness Axle Series in mm 185 220 0 496 12 6 230 260 300 350 0 185 4 69 Press Loads Tons Metric Tons 17 18 15 4 17 2 18 20 15 3 18 3 10 4 4 VARIABLE Used only on Axle Series 230 260 300 350 OUTER BEARING CONE OLITER BEARING CUP SLEEVE MUST APPLY PRESSURE TO BACK FACE OF OUTER BEARING IMPORTANT Do not assume that all assemblies will retain proper preload once bearings are pressed on pinion shank FINAL PRELOAD TEST MUST BE MADE IN EVERY CASE Spring Scale Reading without pinion seal for 10 20 in Ibs torque 1 1 2 3 N m lbs 3 7 3 7 2 3 2 3 Final Pinion Bearing Preload Test 1 Assemble the complete pinion bearing cage unit as recommended In the assembly section of this manual NOTE Forward axle pinion is equipped with helical gear For easier disassembly during bearing adjustment p
71. S 1 p 4x4 6x5 7 9 Heavy duty Overhaul Remove and Disassemble Clutch Pack Heavy duty CTD Illustrated WASHER AING SUPPORT PERMANENT SHIFT FORK OPENING COVER CAP SCREW LOCK WASHER 1 Place differential and gear support case clutch pack up on workbench WARNING EXERCISE CARE DURING DISASSEMBLY PROCE DURE Step 2 below THE GEAR SUPPORT CASE COVER IS UNDER SPRING PRESSURE AND THE RING GEAR MAY FALL OFF THE SUPPORT CASE AFTER THE LAST LOCKNUT IS REMOVED TAKE PRECAUTIONARY MEASURES TO PREVENT PER SONAL INJURY OR PARTS DAMAGE DURING PROCEDURE IN STEP 2 BELOW 2 Remove self locking nuts and bolts then lift off gear support case cover and compression springs Removing Gear Support Case Cover 7 10 4 4 6x6 SEASONAL CTD SHIFT FORK RETAINER ADJUSTING LOCK SCREW NUT DRIVER PERMANENT PRESSURE SUPPORT CASE FLATE COVER SLIDING NUT BEARING CLUTCH CONE AA Le 0 ite BEARING CUP BEARING COMPRESSION ADJUSTER SPRING SPLINED FRICTION PLATE TANGED FRICTION PLATE DRIVER 4 DRIVER CONTROLLED AND SEASONAL CTD rm TRE po P M DRIVER COMNTROLLED CTD SHIFT UNIT ZU SS FE EXPANSION PLUG WASHER SHIFT FORK FOR DRIVER CONTROLLED AND SEASONAL CTD GEAR SUPPORT CASE COVE
72. S SHAFT SHAFT SCREW CAP p men SCREW a ay NUT BOTTOM WASHER y __ SCREW ie PLUG WASHER BEARING BEARING CONE HUB CLAMP SCAEW SPINDLE BEARING LOCK WASHER CUP PULLER SCREW BEARING ADJUSTING jock CONE NUT WASHER Steering and Wheel End Equipment Overhaul Disassembly Remove Wheels and Tires Drain Lubricant 1 Jack up bath sides of the axle until tires clear the ground WARNING TO PREVENT DAMAGE PER SONAL INJURY USE PROPER AXLE STANDS OR SUPPORTS SO THAT VEHICLE DOES NOT REST ONLY ON THE JACKS 2 Remove wheels and tires 3 Drain axle lubricant NOTE Axle lube will drain from housing when axle shafts are removed Removing Hub with Puller Screws Remove Wheel Hub and Brake Drum en 1 Back off slack adjuster brake adjustment to pro vide sufficient lining clearance so that brake drums can be easily removed 2 Remove nuts lockwashers and hub cap NOTE Puller screw holes are provided if difficulty is experianced in removing hub cap see photo 3 Remove clamp screw and lockwasher from wheel bearing adjusting nut This will release the nut lock Remove lock then unscrew and remove bearing adjusting nut 4 Remove wheel outer bearing cone see photo NOTE If bearing cone is not to be replaced identify its location so it can be returned to its original position 9 Remove wheel hub and drum assembly se
73. SE GEAR SUPPORT BEARING BEARING GEAR TEE HER ADJUST R CONE CASE THRLIST THRUS CASE LARGE WASHER i WASBSHEH SMALL 6 x A om i 7 x wn Ly m 2 1 7 E j in 1 i 1 1 L L d 11 BE o8 41 1 MM m ul 16 a AJ 53 Gi ju an 7 n CLUTCH um RING IDLER rGH SPEED voa RING ANGE BEARING CE AJ PIFAD GLUT H bcr GEAR BEARING ANLIES BELT PP PLATE BAJT CLIP 3 Remove ring gear NOTE A soft Taced hammer or mallet may be required to dislodge gear from its mounting 4 To remove differential assembly place support case assembly on bench or onthe floor Position case on its side then slowly roll the case and slide differential assembly out of the case 2 Remove small support case and thrust washer 1 Remove nuts and bolts fasten Ing ring gear and support cases y on i Remove thrust washer from amp Invert differential assembly to T Punch mark differential cases support case remove idler pins then remove for correct location in reassembly idler pinions Remove cap screws and separate case halves 4x4 6x6 2 25 Differential Carrier Overhaul Disassemble Wheel Differential Cont d Lift out thrust washer and side 9 Lift out spider side pinions a
74. SE GEAR SUPPORT SEARING BEARING GEAR RETAINER ADJUSTER CASE THRLIST CASE COME ADJUSTER LARGE WASHER IDLER WASHER SMAL LI E E Ti B y DIFF EB BEARINGS Gear CLUTCH Cup Pry PLATE NOTE Lubricate internal parts with gear lube during reassembly 1 Press bearing cones on support cases see photos IMPORTANT To prevent bearing cone damage use suitable sleeve that only contacts the inner race of the cone Pressing Bearing Cone cn Large Support Case n Hlta3H SPEED CHAMEER CLUTCH PLATE 1 8 45 1 CHANMFER POST NN 35 SIDE OF PLATE CASE THAL ji HOLE 2 Position high speed clutch plate with chamfered end of clutch teeth toward idler pinions Press clutch plate on case IMPORTANT It is important that the ends of the dowel pins are recessed 1 8 below surface of the clutch plate If pins extend beyond plate surface press pins to proper depth Don t press them in too far e 20 p JN 4 CLUTCH FARE GEAR BEARINGS AXLES MUT Pressing Bearing Cone on Small Support Case 3 Place thrust washer and side gear in differential case 4 4 6x8 2 27 2 28 Differential Carrier Overhaul Assemble Wheel Differential Cont d 4 Assemble side pinions and thrust washers o
75. Size Grade a B 18 B Differential Case CAP SCREW Size Grade 3 18 12 8 Ft Iba Am 180 220 244 208 Ft Iba Nem 150 180 203 244 4x4 6x6 2 17 Differential Carrier Overhaul Assemble Drive Pinion NOTE Lubricate parts with gear lube during reassembly PINION BEARING BEARING BEARING PILOT CONE oF ACER CAGE CAGE BEARING INNER VARIABLE SHIM E Nd m ATI r u Ene te PINION INNER hs SCREW LOCK WASHER Press Bearing Cups in Caga MESS WEA Cur THE Guth be leery maed cage Cresk wilh healer gauge DIXI all amp r oa La alien When tallied cups wel be recess below ouler surtace of cope Pre one cup im asa tme 1 Press bearing cups in cage 2 Press pilot bearing on pinion IMPORTANT At this point select pinion bearing spacer by using the trial build up procedure described in the Adjustments Section of this manual BEARING BEARING OIL SEAL OUTER INPUT amp RETAINER YOKE FLAT WASHER BEARING CONE OUTER STARE PATTERN 3 Stake pilot bearing using stak ing tool NOTE During pinion bearing installation locate each part in same position that was used in Trial Buildup Preload Test 4 Press inner bearing cone on pinion 2 18 4x4 6x6 5 Install bearing spacer selected during trial build up on pinion 6 Install bearing cage on drive pinion Assemble
76. TE Rear axle gearing is shown in the following instructions Correct tooth contact patterns and adjustments are the same for forward and rear axles Ring Gear and Pinion Tooth Contact Check Tooth Contact Pattern NEW GEAR Paint twelve ring gear teeth with marking compound and roll the gear to obtain a contact pattern The correct pattern is well centered on the ring gear tooth with lengthwise contact clear of the toe The length of the pattern in an unloaded condition is approximately He half to two thirds of the ring gear tooth in most model and ratios RING GEAR TOOTH NOMENCLATURE mM DEPTH Check Tooth Contact Pattern USED GEAR Used gearing will not usually display the square even contact pattern found in new gear sets The gear will normally have a pocket at the toe end of the gear tooth which tails into a contact line along the root of tooth The more use a gear has had the more the line becomes the dominant characteristic of the pattern Adjust used gear sets to display the same contact pattern observed before disassembly A correct pattern is clear of the toe and centers evenly along the face width between the top land and root Otherwise the length and shape of the pattern are highly variable and is considered acceptable as long as it does not run off the tooth at any point Could vary in length Fattern should cover 1 2 tooth more face width Pattern should
77. TEEL AND MAY POP OFF WEAR SAFETY GLASSES 6 Press input rear bearing cup in power divider cover web Install yoke flat washer and nut Tighten nut snugly 210 280 300 150 Series 4 4 4 7 4 8 Power Divider Overhaul Adjust Input Shaft End Play NOTE After power divider overhaul and installation in power divider check and adjust input shaft end play Correct end play when new parts are used in overhaul is 0 003 to 0 007 with reused parts 0 013 to 0 017 Refer to Adjustments Section 3 Adjust End Play by measuring cover clearance and calculating shim pack thickness 1 Remove input shaft nut flat washer and yoke Remove input bearing cover cap screws and lockwashers Remove bearing cover and shim pack if installed 2 Reinstall bearing cover without shims Hold in position with hand pressure and measure clearance between power divider cover and bearing cover using a feeler gauge 3 The bearing cover clearance measured in Step 2 plus 0 005 will equal shim pack thickness required for desired end play rebuild with new parts Add 0 015 to shim pack for rebuild with used parts 4 Install shim pack and bearing cover Install cap screws and lock washers Torque screws to 75 85 ft lbs 101 115 N m 5 Install yoke flat washer and nut Tighten nut snugly Tap end of input shaft lightly to seat bearings 6 Check input shaft end play with dial indicator posit
78. UST DIFFERENTIAL CASE CUP PLAIN WASHER WASHER FLANGED HALF BEARING THRWST SIDE SIDE BEARING BEARING CONE WASHER ADJUSTER T 1 BE ARINU CAP E BEARINC ADJUSTER SCREW LOCEKEWIRE FLAT PIN WASHER PILOT DRIVE BEARING BEARING BEARING SEARING YOKE SELF BEARING PINION SPACER CAGE CAGE COME LOCKING VARIABLE SHIM E BEARING SCREW Cim d PIN 17 SCREW ADJUSTE ao DIFFERENTIAL BEARING BEARING LOK CARRIER COME Cur LOCK WASHER OL SEAL FLAT WASHER 4 4 6 6 2 13 Differential Carrier Overhaul Single Reduction Disassemble Differential Carrier NOTE If gear set is to be reused check tooth contact pattern and ring gear backlash before disassembling differential carrier Best results are obtained when established wear patterns are maintained in used gearing Omit this step if the gear set is to be replaced 1 Mount Differential Carrier 2 Punch mark differential bear Assembly in repair stand Loosen ing caps If reusing gear set also but do not remove pinion nut punch mark bearing adjusters for reference during assembly 4 Using a chain hoist lift ring 5 Remove pinion bearing cage gear and differential assembly out cap screws then drive pinion of carrier cage and yoke assembly out of carrier IMPORTANT Do not allow pinion to drop on hard surface Remove shim pack IMPORTANT gea
79. XHAUST 8 11 Dual Range Rear Axle with Single Reduction Steer Drive Axle SL Trouble Shooting The following procedure is present ed in step by step sequence which anables checking the operation of all integrated systems and components 1 Initial Preparation Start system check by placing axie range shifter vaive lever in Low Range position and All Wheel Orive selector in dis angaged position Move vehicle in forward direction a short dis tance followed by backing vehicle up egual distance Repeat this at least three times This will insure that ail clutches are in proper posi tion Also park vehicle on a flat spot and do not apply Do not move the vehicle until sys tam checks are completed Lastly insure that sufficiant air pressure is built up fo perform system checks engine aff 2 Check Solenoid Valve Turn en gine off If vehicle is equipped with solenoid valve turn ignition ON to energize and valve Check to insure that air pressure is present at the outlet of the solenoid valve 3 Check Axia Range Shift System Have an assistant in the cab begin moving the axle range shifter valve laver in the cab between Low and High Range Listen for mechanical movement at the rear axie range shift unit If movement is appar ant placa the shifter valve laver in the Low Range position and discon air line at the rear axie range s
80. a hammer Besure cap is fully seated and threads are aligned properly f trouble is encountered check for crass threading of bearing adjuster and carrier threads On teeth side of ring gear install the other adjuster and bearing cap observing same precautions to avoid cross threading 3 Install and tighten bearing screws finger tight If this is difficult use hand wrench NOTE With bearing adjusters and caps assembled to carrier the carrier assembly is now ready for adjustment of bearing preload ring gear backlash and gear tooth contact see next page Adjust Differential Bearing Preload 1 At the teeth side of ring gear position bearing adjuster until its first thread is visible 2 At the back face side of ring gear tighten adjuster until there is no backlash 3 At the teeth side of ring gear tighten adjuster until it contacts the bearing cup Continue tightening adjuster two or three notches This will preload bearings and provide backlash 4 Check Ring Gear Backlash Measure backlash with a dial indicator Specifications are listed below Refer to Adjustment Section for detailed instructions on adjusting backlash Ring Gear Backlash Specifications USED GEARING Reset to backlash recorded before disassembly NEW GEARING Backlash should be as follows Axle Series 185 220 sees 0 006 to 0 076 Axle Series 230 260 300 350 ICE 0 008 to 0 018 5 Check Ring Gear Tooth Co
81. ainer from the power divider cover and inspect for wear material in the same manner as the drain plug Wash the magnetic strainer in solvent and blow dry with compressed air to remove oil and metal particles CAUTION EXERCISE CARE TO DIRECT COMPRESSED AIR INTO SAFE AREA WEAR SAFETY GLASSES Filling Remove the filler hole plug from the center of the axle housing cover and fill the axle with approved lubricant until level with the bottom of the hole Forward Axles Add four pints 1 88 liters of lubricant through filler hole at the top of the differ ential carrier near the power divider cover NOTE Lube fill capacities in the adjacent chart are good guidelines but will vary somewhat on the basis of the angle the axle is installed in a particular chassis Always use the filler hole as the final reference If lube is level with the bottom of the hole the axle is properly filled Axles installed at angles exceeding 10 degrees or operated in areas of continuous and lengthy grades may require standpipes to allow proper fill levels Contact Spicer Field Service Department or call Regional Office for specific recommendations See back cover for address and phone numbers Vie OIL FILLER HOLE i 4 Magnetic Strainer for Axles with Lube Pump OW Filler Hole at of Differential Carrier Lube Capacities DO NOT OVERFILL AXLES Lube Capacity Axle Model Pints liters 4 4 Rear Axl
82. al assembly place support case and ring gear assembly bench or the floor Position case on its side Carefully lift and slide differential assembly into case Engage idler pinions with ring gear teeth to complete the installation NOTE During differential installa tion be sure thrust washer stays in its proper mounting position Torque Chart 5 Place side gear and thrust 6 Align punch marks and place washer in position on side pinions plain case on case with pins Install cap screws and torque see chart NOTE Turn side gear hub to check Ft Ibs N m for free differential rotation Rot 90 110 122 149 tion may require up t 50 ft Ibs 116 130 157 176 65 N m B Place thrust washer in support 9 During installation af ring gear case temporarily use two bolts in mount ing holes to assure bolt hole align ment Place ring gear on support case see photo then remove the two bolts 11 Install thrust washer and small support case over differential assembly 12 Carefully install ring gear bolts making certain flat on bolt head Is seated against the outside diameter of the support case Install nuts and torque to 110 130 ft lbs 149 176 N m NOTE Temporarily install sliding clutch or sun gear and check planetary for free rotation 4 4 6 9 Differential Carrier Overhaul Assemble Drive Pinion Press fit outer pinion bearing 1 DRIVE SPACER BEARING BEARING PINION CAGE
83. alve 4 4 6x6 8 17 Shift Sytem Components Air 3 hift Unit For Dual Range Axles and Controlled Traction Differentials TE O RING LOCKNUT HOUSING p COVER PISTON END 2 LOCKNUT OILERS WASHER 6E PISTON gt 1 NOTE Lockout Control Valve is used on Shift Systems with Single amp Reduction Steer Driva Axle and A SING Dual Range Axle Combinations COMPRESSION SPRING SCREW COVER WASHER HOUSING G ASSEMBLY ER 1 Tm HOUSING HOUSING nul SEARING COVER i BEARING LEVIS ACTUATING LEVER mis OIL FILLER MD BLOCK ASSEMBL amp LEVEL PLUG Typical Air Shift Unit Description and Operation M These Piston Air Shift Units are The shift units are mechanicaily actuating lever to the shift fork mounted on the axie differential connected t the axle shift forks shifting the axle into High Range carriers and are used to shift axles and clutches or engaging controlled traction differential Exhaust of air pressure permits the heavy duty spring to return the axle gearing to Low Range or disengage controlled traction differential for range selection and disen gagement and engagement Controlled Traction Differentials acras acce Ne ale Basically all shift units operate the admitted to the chamber cylinder same and contain simila
84. amp RH axle shafts removed the differential assembly can be removed from axle housing see Differential Carrier Section page 2 11 2 NOTE If faulty condition exists or excessive wear 15 indicated it is recommended that the axle shaft be replaced as an assembly Check axle shaft splines for damage cracks or wear Check axle shaft journal area that contacts bushing in axle ball for scoring or excessive 2274 grooving Check for excessive clearance between Removing Axle Shaft Assembly axle shaft yoke trunnions and cage rings If exces sive clearance greater than 0 050 is suspected disassemble axle shafts as follows and measure clearance 3 IMPORTANT Punch mark cage rings and yoke PL nil trunnions for identification in reassembly see ONE PUNCH MARK photo If axle shaft parts are to be reused the trunnions must be replaced in the original cage ring holes to assure correct operation AXLE SHAFT ASSEMBLY p bam a NU TWO PUNCH MARK Identifying Cage Rings 4 4 1656 1 13 Steering and Wheel End Equipment Overhaul Disassembly 4 To disassemble remove socket screws from both sides of cage rings then separate ring halves and shafts see photo Using suitable gauges measure trunnion diameters and their mounting holes in the cage rings If clearance is greater than 0 050 it is recommended that axle shaft a
85. arts with gear lube during reassembly PINION BEARING BEARING BEARING BEARINGS BEARINGS OIL SEAL PILOT CONE SPACER CAGE CAGE CUP amp RETAINER YOKE BEARING INNER VARIABLE SHIM OUTER FLAT WASHER 12 200 BEARING CAP BEARING mE CBE CONE INIOR PINION INNER SCREW IOUTER NUT LOCKWASHER Press Gearing Cups in PRESS ker isa _ Aan wii be recessed below priar of cage i cse in ab Time 1 Press bearing cups in 2 Press pilot bearing on pinion 3 Stake pilot bearing using stak IMPORTANT At this point select MEE aal i wl build up procedure described same position that was used in in the Adjustments Section of this Trial Buitdup Preload Test manual 4 Press inner bearing cone or 5 Install bearing spacer selected 6 Install bearing cage on drive pinion during triai build up on pinion i 4 4 6x6 2 29 Differential Carrier Overhaul Assemble Drive Pinion Press fit outer pinion bearing Press Oi Seal cines mugi h da Ge iga outer Target 7 Press on outer pinion bearing 8 install seal with press Use NOTE Prior to installation of cone properly sized sleeve to fit seal to flange or yoke lubricat
86. assembly over then place in press gear teeth down on hard wood blocks Position blocks to the outside of the ring gear to allow clearance for installation of two alignment bolts Install alignment bolts then pro ceed with reassembly procedures in Step 3 4 Place one tanged friction plate over friction plate driver position ing tangs into slots in gear support case see photo Brush top of fric tion plate with a heavy application of axle lube SAE 90 Place one splined friction plate over friction plate driver and brush top of this plate with lube 4x4 6x6 2 Install Ring Gear with Loose Fit Place ring gear in press gear teeth down on hard wood blocks Posi tion blocks to the outside of the ring gear to allow clearance for installation of the gear support case assembly and two alignment bolts Place gear support case assembly in ring gear and align bolt holes Install two alignment bolts in mounting holes then proceed with reassembly procedures in Step 3 SPLINED FRICTI ON PLAT E TANGED FRICTION PLATE GEAR SUPPORT CASE Installing Friction Plates FRICTION SNAP RING CLUTCH ae Installing Friction Plate Driver 3 Install snap ring in square ring groove of friction plate driver Place friction plate driver with snap ring down in center of gear support case 5 Repeat procedures in Step 4 until there are ten friction plates of each tanged and s
87. asten both E av V retainer and adjuster lock cap screws Tighten screws to correct torque 00 see chart and lockwire all cap screws LOCK EAS rie Ves LL z Planetary Double Reduction Axle B For dual range axles Position shift fork in carrier opening then install sliding clutch 9 With clutch installed engage shift fork yoke with clutch collar Then install shift fork shaft Install expansion plugs to seal openings 10 Install shift unit seal and spring Installing Shift Fork Shaft Bearing Adjuster Lock and Sun Gear Retainer Cap Screw Size Grade Ft Ibs 5 B 11 5 180 176 217 238 Torque Chart Ditferential Bearing Cap Cap Screw Size Grade Ft Ibs N m 13 15 10 8 370 430 501 583 4 4 6x6 2 33 Service and Maintenance Instructions 4x4 Drive System Rear Axle These instructions cover the differential carrier and power divider assembly for the 4x4 rear axle Contents are divided into major sections as indicated below Section 3 Contents Page No 4x4 REAR AXLE Lubrication RO Rh deae Cleaning Inspection Repair T 5 Adjustments T f Differential Carrier Replacement 15 POWER DIVIDER OVERHAUL Section 4 DIFFERENTIAL CARRIER OVERHAUL Single Reduction Sections DIFFERENTIAL CARRIER OVERHAUL Dual Range and Double Reduction Se
88. ber free stroke see below place slack adjuster guard in mounting position on air chamber and secure with flat washers lockwashers and cap screws Adjust Air Chamber Push Rod Free Stroke 1 Air chamber free stroke is the movement of the push rod from the released to the applied brake positions To determine free stroke first measure the distance with brake released Apply brakes using a lever to rotate slack adjuster and repeat the measurement Subtract the released dimension from the applied dimension to obtain free stroke Free stroke should be 1 2 5 8 in 12 7 15 8 mm If free stroke is not within specifications depress locking sleeve on slack adjuster and adjust as required m E Install Air Chamber and Bracket Assembly 4x4 6x6 1 23 Steering and Wheel End Equipment Overhaul Assembly Install Brake Shoes NOTE When brake shoes are relined use new shoe retainer and return springs in reassembly When reusing brake shoes be sure to place them in their original location as identified in disassembly IMPORTANT Leading and trailing brake shoe linings may vary with air chamber mounting Make sure brake shoes are properly installed see Brake Reline page 1 11 1 To install brake shoes attach retainer springs to both shoes then position shoes on anchor pin see photo 2 With bath shoes in mounting position attach return spring to upper shoe Lift lower shoe and connect spring to
89. bly in Axle Housing TOT 16 4x4 6 6 7 1 Spicer Axle Service and Maintenance Instructions Controlled Traction Differentials Introduction Spicer Corporation presents this publication to aid in maintenance and overhaul of Spicer single reduction axles equipped with a biasing type controlled traction differential In this manual this unit is termed Controlled Traction Differential or CTD Two design types are contained in this manual Medium duty CTD Heavy duty CTD Inciudes 15 friction i Includes 21 friction ER plates designed for plates designed for single drive axles single drive axles 19 000 bs to 22 000 23 000 Ibs to 35 000 a lbs capacity and tandems 34 000 165 to 40 000 Ibs capacity a Ibs capacity and 2 il tandems 44 000 Ibs to 65 000 Ibs capacity ryg d E inimi SN 1 Ln mm a e Medium duty Controlled Traction Heavy duty Controlled Traction Differential for Differential for Steer drive Axles ESD 18B 4x4 Rear Axles 18554 and 22054 6x6 Tandem Axles DS346 F 05386 05406 Driver Controlled Type Illustrated 4x4 Rear Axles 23054 26054 30054 35054 D 6x6 Tandem Axles 05466 P DS486 P 05586 05656 Drivar Controlled NOTE In this manual instructions for both CTD design types are the same
90. bore of ball for defects If faulty replace the seal Remove with suitable pullar 3 Inspect kingpin bearings for pitted or worn roll ars or cup surfaces and other faulty condition Replace as a set bearing cone and cup Inspect kingpins for wear Replace worn kingpins 4 If replacement is necessary remove bearing cup from ball socket using suitable driver see photo The bearing cups vary in size When removing take note of cup location so they can be returned to their original position 3 Inspect camshaft bushings in ball socket for wear as follows Install camshaft in bushings and check side movement with dial indicator If move ment 15 greater than 0 020 replace oil seals bush ings and or camshaft To remove bushings drive them out of ball socket using a suitable driver 1 16 4 4 6x6 hc Hemoving Kingpin Bearing Cup Assembly Assemble Ball Socket INSTALL OIL SEALS E LIPS 1 If camshaft bushings are to be replaced proceed POINTING IN THE 5 as follows to install new bushings DIRECTION TOWARD CAMSHAFT SPLINES Install bushings using suitable driver Ream bronze bushings to 1 500 after installation Non metallic bushings do not require reaming They are presized at the factory 2 camshaft oil seals are faulty or were removed install new seals as follows Lise suitable driver to install seals IMPORTANT Molded lip type seals must be
91. by an electrical switch mounted on or near the quick release valve The switch is normally closed and is opened by air pressure With axles in Low Range the switch is closed and the adapter is ener gized The adapter operates with a ratio compatible with the axle Low Range for proper road speed read ings With axles in High Range the air lines are pressurized and the pressure switch is open The adapter now operates with 1 1 ratio for prop er speed readings in High Range Description and Operation Axle Range Shift System Opera lion must be in 4x2 drive High Range When shifter valve lever is moved to High Range the valve is opened and air pressure is supplied through the quick release valve to the axle shift units When driveline torque is interrupted the shift units will shift axles to High Range Low Range When shifter valve lever is moved to Low Range the valve is closed Air pressure in the shift units is exhausted through the quick re lease valve When driveline torque is interrupted axles are shifted to Low Range and held in this position by shift unit return springs NOTE In 4x4 drive axle range shift er valve lever is blocked and range cannot be changed Axle Range Interlock System The interlock system prevents changing axle range when drive is in 4 4 mode The system includes an interlock control valve mounted on the steer drive lockup shift unit and an inter lock pin mounted in cover of t
92. ce axle bail in ball socket aan 2 Steering stop screws should be adjusted to limit STOP SCREW 22 angle turn in either direction A plate fabri A LOCKAUT cated with a 22 angie see illustration will help Fi in making this adjustment 3 Adjusting Steering Stop see illustration To Fc Pee use the fabricated 22 angle plate and adjust stop maL G screw proceed as follows py age CE uis i w Remove the two top cap screws fastening ball KU nm to axle housing WEM b Position plate between bali flange surface A 5 su l and ball socket surface B With socket in this E NE position adjust stop screw until it touches the ball Tighten locknut to secure stop screw ANGLE PLATE d Install axle ball to housing cap screws Torque TM cap screws to 170 220 ft lbs 231 298 N m Adjusting Steering Stop NOTE Use same procedure for both left and right hand wheel ends NOTE In service the Pitman arm stops should be set to limit wheel cut before adjusting stop screw contacts on axle ball Assemble Axle Shaft and Cage Ring Assembly 1 If axle shaft and cage ring were disassembled proceed as follows Place a thin layer of lubricant on shaft yoke trun nions and their mounting holes in the cage rings With cage rings and shaft yokes in correct position marked for position during disassembly engage rings and shaft yokes Insta
93. cklash Specifications USED GEARING Reset to backlash recorded before disassembly NEW GEARING Backlash should be between 0 006 and 0 016 5 Check Ring Gear Tooth Contact Paint ring gear teeth and check tooth contact pattern Correct tooth patterns are illustrated below For checking and adjusting procedures see Adjustment Section Checking Ring Gear Backlash CORRECT PATTERN NEW GEARING Could vary in length a Pattern should cover 1 2 tooth more f 2 face width 4 Pattern should be evenly centered between tooth top land and root CORRECT PATTERN USED GEARING Pocket may be extended Pattern along the face width could be longer Pattern should be clear of tooth toe B With ring gear and pinion adjusted correctly align adjusters and locks then tighten differential bearing cap screws to correct torque see chart next page Install cotter pin in one adjuster lock Install cap screws in opposite adjuster lock and tighten to correct torque see chart next page Lockwire bearing and adjuster lock cap screws 2 32 4x4 6x6 Adjust Differential Bearing Preload Contd SUN GEAR BEARING HETAIMER 5 Th 290 7 7 For planetary double reduction axles on backface side of ring gear Po g Uy GEAR install sun gear and retainer then install cap screws that f
94. close to the root of the gear tooth add pinion shims NOTE Check ring gear backlash after each shim change and adjust if necessary to maintain the 0 006 to 0 016 specifications Adjust Backlash If the gear pattern shows incorrect face width contact change backlash INCORRECT PATTERN Move ring gear away from pinion to increase backlash Pattern too close to edge of tooth toe With the pattern concentrated at the toe too far down the tooth add backlash by loosening the bearing adjuster on the teeth side of ring gear sev eral notches Loosen the opposite adjuster one notch Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup Continue tightening the same adjuster 2 or 3 notches Recheck backlash 2 10 4x4 6x6 Move nng gear toward pinion to decrease backlash Pattern too far along tooth toward tooth heel If the pattern is concentrated at the heel tao far up the tooth remove backlash by loosening the bearing adjuster on the teeth side of ring gear sev eral notches Tighten the opposite adjuster one notch Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup Continue tightening the same adjuster 2 or 3 notches Recheck backlash Differential Carrier Replacement Remove Differential Carrier Assembly from Axle Housing NOTE To permit removal of the differential carrier assembly
95. ction 6 4x4 REAR AXLES Single Reduction 18554 22084 23054 26054 30084 35054 Dual Range 185T4 220T4 23014 260T4 300T4 350T4 Double Reduction 185P4 220P4 230P4 260P4 300P4 350P4 4 4 3 1 Lubrication The ability of a drive axle to deliver quiet trouble free operation over a period of years is largely dependent upon the use of good quality gear lubricant in correct quantity The most satisfactory results can be obtained by following the directions contained in this book Approved Lubricants Multigrade gear lubricants which meet the requirements of military specification MIL L 2105 C are recommended for use in Spicer drive axles These lubricants per form well over broad temperature ranges providing good gear and bearing protection in a variety of climates The MIL L 2105 C specifi cation divides lubricants into three major categories on the basis of lube viscosity at various tempera tures These are 75W 80W 90 and 85W 140 80W 140 lubricants are also available but are listed with 80W 90 by MIL L 2105 C Lubricants approved under MIL L 2105 B are also acceptable for use in Spicer Axles Synthetic Lubricants Use of synthetic lubricants in Spicer Axles is approved only after Engineering Choosing the Correct Gear Lube Axle gear lube should be selected on the basis of the ambient temperature range in which the vehicle normally operates This should al
96. ctly move All wheel Drive selector laver to disengaged posi tion than disconnect air line on the side of the interlock control valve on the steer drive axle lockup shift unit Move the All Vheel Drive selector laver to tha engaged posi tion and check for air flow from the side port of the interlock control Valve If air fow 13 not present place the selector lever the disengaged position and remove interlock con trol valve from shift unit cover b Place Ail Wheal Drive selector lever in engaged position and again check for air flow from the side part of the interlock control valve If air flow is present depress the plunger on the vaive and insure air supply is shut off from the valve side port if valve does not function correctly remove and replace Place All heal Drive selector lever in disengaged position and reinstall interiock control vaive in shift unit cover and adjust properly sea page 8 18 Place tha All Wheel Drive selector laver in the engaged posi tion If air flow 18 still not present at the interlock control valve side part remove the shift unit fram tne rear axie and inspect components for binding or excessive wear After repair follow the above steps until proper functioning is obtained c Reconnect the air line and place the All Wheel Drive selector lever in the engaged position if the inter lock on the axle range shifter valve does not actuate proceed to the next step If the inter
97. d Oil Seal Installation 4x4 6x6 1 17 Steering and Wheel End Equipment Overhaul Assembly Assemble Socket to Axle Ball 1 Tip axle ball socket see photo and install it on the axle ball Position socket on ball to maintain correct relationship between top and bottom of te ball and socket 2 Install Kingpins special spreading fixture is recommended for installation of kingpins This tool can be obtained from Oshkosh Truck Corporation 2307 Oregon St Oshkosh Wisconsin 54903 Kingpin Spreading Fixture Position kingpins and spreading fixture in ball socket engaging fixture pins with head of kingpins Adjust fixture nut until kingpins are seated in their mounting holes IMPORTANT Leave fixture in position until Steps 2 thru 10 are completed 3 Install upper kingpin bearing cone using suitable driver driver should only contact inner race of cone NOTE The upper bearing cone has a smaller out side diameter than the lower cone Make certain correct cone is installed 4 Install upper bearing cup using suitable driver see photo Tap cup into mounting position until It is flush with the kIngpin cover surface NOTE The upper cup has thicker wall as com pared to the lower cup Make certain the correct cup is installed 5 Instali lower bearing cone and cup using same procedures in Step 3 and 4 6 Install kingpin spacers and nuts Tighten nuts to 500 ft Ibs 680 N m
98. d secure with and locknuts Tighten lock nuts evenly to a torque of 108 132 IN LBS 12 15 N m 7 Fill shift unit with SAE 10 aii or automatic transmission Huid see LuBrication when axle is installed in acto M Am m Installing Push Rod Clavis Pin Lubrication Lubricant Lse SAE 10 moter for temperature above 0 18 C For temperatures below 0 18 C mix three parts of 5AE 10 motor oil with one part of sene This cold weather mixture can be safely used up to 32 F 0 C NOTE Commercially available automatic transmission fluid may be used in place of SAE 10 motor oil Automatic transmission fluid can be used for all temperatures Do not mix kerosene with auta matic transmission fluid Lubricant Check and Lavel Each 20 000 miles or six months remove pipe plug in shift unit AGuS ing cover to check lubricant level Lube should be level with bottom of fillar hole Lubricant Change aAt least once yaar remove shift unit housing cover and drain old lubricant Wash parts thoroughly and air dry Reinstall cover Remove pipe plug in cover Fill through pipe piug opening until lube 13 level with bottom of filler hole 8 20 4 4 6 6 Service and Maintenance Instructions Faster Tightening Specifications 4x4 Drive Systems These instructions include fastener tightening torque values for the steer drive and tandem axles for 4
99. de adjuster Make all further adjustments from the point of tightest mesh Adjust Ring Gear Backlash To add backlash Loosen the adjuster on the teeth side of the ring gear several notches Loosen the opposite adjuster one notch Return to adjuster on teeth side af the ring gear and tighten adjuster until it contacts the bearing cup Continue tightening the same ad juster 2 or 3 notches Recheck backiash 3 12 4 4 NOTE Ring gear position for rear axle is illustrated 3 Loosen the bearing adjuster on the same side as the ring gear teeth until its first thread is visible 5 At teeth side of ring gear tighten adjuster until it contacts the bearing cup Continue tighten ing adjuster two or three notches and this will preload bearings and provide backlash 6 Measure backlash with a dial indicator USED GEARING Reset to backlash recorded before disassembly NEW GEARING Backlash should be as follows Axle 185 220 0 006 to 0 016 0 008 to 0 018 If f backlash is is as described below to readjust morvrr r v rvrpmvns rvrrprsomrsoasassrrmn s To remove backlash Loosen the adjuster on the teeth side of the ring gear several notches Tighten the opposite adjuster one notch Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup Continue tightening the same adjuster 2 or 3 notches Recheck backlash
100. djust mant is completed page 4 8 10 Apply silicone gasket com pound to carrier mating surface see illustration Silicone Gasket Compound Parrarn 13 After input sha t end piay is correct make sure bearing cover nuts and input shaft nut are torqued proper y see chart page 4 4 Also seal shim pack to pre Pal iube leakage Step 9 page 1 8 NOTE instali the following parts Step 2 through Step 6 if they were removed 2 Press front output shaft bearing cup n power divider 3 Install pinion outer support bearing race in power divider cover using a driver and hammer a press and suitable sieeve install snap ring to secure bearing race h WARNING SNAP RING IS 5 Install input shaft rear bearing cup in differential carrier B Press bearing cones on each end af input shaft IMPORTANT To prevent bearing damage careful to use a sieava that only contacts inner race of bearing cona 11 Place input shaft gear and bearing assembly in carrier then install power divider cover IMPORTANT When installing cover make sure pinion outer sup port bearing is aligned with bear ing race Install cap screws and lockwash ers placing socket head cap screws at location shown on gasket compound drawing MOTE Make sure the two blind cap screws instailed through output shaft bearing cover opening Tighten cap screws to correct torque see chart page 4 3
101. e seal prevent distortion during installa lip and make sure flange or yoke tion is clean and dry 9 Install flange flat washer and nut Tighten nut to correct torque 560 700 ft lbs 759 949 N m IMPORTANT At this stage of assembly final check pinion bearing preload See Adjustment Section of this manual 2 30 4x4 6 6 Install Pinion 1 Place shim pack on carrier making sure lube hole is clear see photo NOTE If the gear set is to be re used use same quantity and size shims removed during disassem bly new gear set is to be in stalled install a nominal shim pack see chart 5 gm pum n Nominal Shim Pack in 0 023 mm 0 584 Install Differential in Carrier SEAT DIFFERENTIAL CARRIE B BEHANG Daa PEDESTAL BEAF T3 PEDEGSTAL CASE PILOT Lubricate bearings during the following assembly procedure 1 Place ring gear and differential assembly in carrier Insure that ring gear and drive pinion mesh properly During installation tilt carrier to allow support case pilot t rest in carrier then install bearing cup as shown in photo Also install bearing cup on opposite side of differential F i 2 If the same gear set is used install the assembled bearing cap adjuster and lock on the backface side of the ring gear Otherwise install adjuster and cap separately NOTE Whe
102. e photo To disassemble hub remove oil seal and spacer then lift out inner bearing cone amp Inspect bearing cones and cups for pitting wear or other faulty condition If cup replacement is necessary remove from hub using suitable puller Replace bearings in sets cup and cone T Inspect brake drums for cracks discoloration due to hard spots heat checking glazing grooving or severe out of round condition Replace cracked drums WHEEL AUG AND DRUM ASSEMBLY Removing Wheel Hub and Drum Assembly 4x4 6x6 1 9 Steering and Wheel End Equipment Overhaul Disassembly Remove Brake Shoes and Inspect Lining 1 Pry down on lower or rear brake shoe using a sturdy lever see photo until cam roller and pin can be removed Repeat procedure for other shoe WARNING AVOID POSSIBILITY OF PER SONAL INJURY MAKE CERTAIN YOU HAVE FIRM HOLD ON PRYING LEVER BEFORE REMOVING ROLLER AND PIN 2 Lift lower or rear shoe to relieve tension then remove shoe return spring see photo 3 Lift upper or forward shoe off anchor pin then remove both shoes and shoe retainer springs see photo 4 Inspect brake linings as follows and replace if any one of the following conditions exists a Lining thickness is 3 18 4 5mm or less at the thinnest point or if lining is worn to 1 16 1 5mm or less to rivet heads b Lining 13 cracked or improperly worn c Lining 15 loose on shoe Replace loose
103. e Series 185 220 38 18 230 260 iara ac Rcx RR ROC RN RR Rt 44 21 300 350 41 18 Add an additional 4 pints 1 88 liters axle lubricant through filler hole at the top of the differential carrier near the power divider cover See photo above Capacities listed are approximate The amount of lubricant will vary with angleof axle as installed in vehicle chassis Figures do not apply to housings not designed or manufactured by Spicer 4x4 3 3 Lubrication Wheel Bearing Lubrication Under normal operating conditions axle wheel bearings are protected by lubricant carried into the wheel ends by the motion of axle shafts and gearing Lube becomes trapped in the cavities of the wheel end and remains there insuring that lube is instantly available when the vehicle is in motion IMPORTANT In cases where wheel equipment is being installed either new or after maintenance activity these cavities are empty Bearings must be manually supplied with adequate lubricant or they will be severely damaged before the normal motion of gearing and axle shafts can force lube to the hub ends of the housing To avoid the risk of premature damage to wheel bearings they must be prelubed any time the wheel equipment is being installed There are two methods of doing this The correct method will depend on the type of wheel equipment being used Hubs Equipped with Lube Filler Holes Pour a pint of standard axle lubricant into the hub thr
104. e the spacer size used Select a spacer 0 001 larger for use in the final pinion bearing cage assembly The larger spacer compensates for slight growth in the bear ings which occurs when they are pressed on the pinion shank The trial Build up will result in proper pinion bearing preload in three of four cases IMPORTANT Do not assume that al assemblies will retain proper preload once bearings are pressed an pinion shank FINAL PRELOAD TEST MUST BE MADE IN EVERY CASE 6x6 a 2 RR Assemble these Parts for Trial Build up INMER INNER BEARING OUTER OUTER BEARING BEARING SPACER BEARING BEARING VARIABLE 2 SLEEVE MUST APPLY PRESSURE TO BACK FACE OF OUTER BEARING CONE Cage in Press to Check Bearing Preload PRESS RAM SPRING Specifications for Pinion Bearing Spring Trial Build up Preload Test Scale Reading Press fit Outer Pinion Bearings without S pinion seal for 10 20 In Iba torque Nominal Bearing Spacer Thickness Press Loads in mm Tons Metric Tons Ibs ESD 18 Steer Drive 13 5 15 5 122 140 4 8 2 4 Axle Differential Carrier Final Pinion Bearing Preload Test 1 Assemble the complete pinion bearing cage unit as recommended in the assembly section of this manual NOTE Forward axle pinion is equipped with helical gear For easi
105. e wear 15 Indicated replace oil seals bushings and or camshaft 2 With snap ring and slack adjuster removed as described previously withdraw camshaft from ball socket see photo At this time again inspect cam shaft Visually check journals for wear or corrosion If wear or roughness is present and can be felt by hand replace camshaft Also check camshaft spline for cracks or deforma tion Check S cam for brinelling cracking or flat spots Heplace if ridge can be felt between worn area and cam surface 1 12 4x4 6x6 Removing Carnshaft Disassembly Remove Spindle and Brake Spider 1 Remove cap screws fastening spindle and spider to ball socket 2 Before removing spindle and spider place con tainer under ball socket to catch falling grease 3 Remove spindle and spider see photo If spindle removal Is difficult loosen by tapping with a soft nosed hammer SPINDLE IMPORTANT Exercise care when tapping spindle striking too hard could crack the spindle metal wall 4 Inspect anchor pin for secure mounting in brake spider If pin is loose or if grooved more than 0 031 replace spider and pin as an assembly Ramoving Spindle and Brake Spider Remove Inspect and Disassemble Axle Shaft Assembly 1 Turn ball socket to a perfect straight ahead position Then remove axle shaft assembly inner and outer shafts and universal joint sea photo NOTE With both LH
106. earing cap adjuster and lock as an assem bly This will facilitate correct positioning of ring gear during reassembly 1 Mount the differential carrier in a repair stand 2 Remove shift fork seal and spring Remove expansion plugs then working at the lower or small plug hole drive out the shift fork shaft WARMING WHEN USING DRIFT PUNCH OR SIMILAR TOOL WEAR SAFETY GLASSES bearing caps for location and easier 5 Remove bearing cups then lift ring gear and differential assem bly out of carrier T IMPORTANT During removal of drive pinion assembly do not allow pinion to drop on hard surface 6 Remove pinion bearing cage cap screws then drive pinion and cage assembly out of carrier If the gear set is to be reused keep the shim pack intact for use during reassem bly If the original shims cannot be reused record the number of shims in the pack and the size of each 4 4 6 6 2 23 Differential Carrier Overhaul Disassemble Drive Pinion PINION BEARING BEARING BEARING BEARING BEARING OIL SEAL INPUT PILOT CONE SPACER CAGE CAGE CUP amp RETAINER YOKE A x A BEARING INNER VARIABLE SHIM n f ri 0 90 090 Gree ua SEARING DRIVE CUP PINION PINION INNER NUT LOCKWASHER IMPORTANT During the follow 2 For pinion with press fit bea
107. emove from input shaft using suitable ers input bearing cover and shim input shaft helical gear and bear pullers pack from power divider cover ing cone assembly 4 Remove oil seal and bearing 3 Remove input rear bearing cup 8 Remove snap ring securing cup from input bearing cover differential carrier using pinion outer support bearing race using Suitable pullers suitable puller Zh WARNING SNAP RING IS SPRING STEEL AND MAY POP 7 Remove front output shaft OUT WEAR SAFETY GLASSES bearing cup from power divider WHEN REMOVING Remove pinion outer support bear ing race using suitable puller Torque Chart Input Shaft Nut Fl Ibs N m SE 1 5 8 18 780 980 1059 1301 Cover Plate Cap Screws 7116 14 _ 48 56 85 76 Grade 5 Power Divider Cover Cap Screws g 18 12 110 125 149 170 Grade 5 Input Shalt Bearing Cover Cap Screws 1 2 13 75 85 101 115 Grade 8 4 4 4 4 install Input Shaft and Power Divider Cover on Differential Carrier 185 and 220 Serias 1 Check expansion plug in power divider cover to make sure it is in place and firmly seated If loose seat by tapping with hammer Replace piug if necessary 4 Apply silicone gasket compound to cover plate mounting surfaces on power divider cover Install cover plata and fasten with cap scraws and lockwashers Torque cap screws sea chart 7 NOTE Do not install oil seal until input snaft and play a
108. er 5 Remove pilot bearing and inner bearing cone from pinion using a split type puller Use two procedure steps to remove each bearing see photos above Second mount puller horizontally al aring to remove bearing 4 4 6x6 2 15 Differential Carrier Overhaul Disassemble Wheel Differential DIFF BEARING THRLIST BEARING CONE WASHER ADJUSTER CASE PLAIN BEARING CASE CUP SCREW HALF J Lift out side gear and thrust washer 6 Remove bearing cones from case halves using suitable puller see photos 7 Remove bearing cone from plain case half in two steps First mount puller vertically to split bearing see photo This action will start moving bearing off case Second mount puller horizontally remove cone B Remove bearing cone from flanged case half using suitable puller 2 16 4x4 6x6 SIDE SPIDER PINION THRUST RING WASHER GEAR BING SIDE GEAR GEAR BOLT IMPORTANT During following procedure place differential assembly on malleable surtace to prevent damage when ring gear falls off its mounting position 1 Remove nuts and bolts fasten ing ring gear to differential cases allowing gear to fall free If gear does not fall tap outer diameter with soft mallet to loosen 2 Punch mark differential cases for correct location during assem bly Remove cap screws and lift off plain differential case half 4 Lift out sida side pinion
109. er disassembly during bearing adjustment procedure use a dummy yoke if available in place of helical gear 2 Apply clamp load to the pinion bearing cage assembly Either install the yoke or helical gear and torque the pinion nut to specifications or use a press to simulate nut torque see chart below Vise Method if the yoke and nut are used mount the assembly in a vise clamping yoke firmly Press Method If a press is used position a sleeve or spacer so that load is applied directly to the back face of the outer bearing cona 3 Measure Pinion Bearing Preload Use a spring scale to test the assembly rolling torque To use the spring scale wrap soft wire around the bearing cage attach the scale and pull Preload is correct when torque required to rotate the pinion bearing cage is from 15 to 35 inch pounds This specification is translated into spring scale readings in the chart below 4 Adjust Pinion Bearing Preload f necessary adjust pinion bearing preload Disassemble the pinion bearing as recommended in this manual and change the pinion bearing spacer thicker spacer will decrease preload amp thinner spacer will increase preload IMPORTANT Use the correctly sized spacer Do not use shim stock or grind spacers These practices can lead to loss of bearing preload and gear or bearing failure Specifications for F Inal Pinion Bearing Preload Test Press fit Outer Pinion Bearings Nut Torque Pre
110. eration is defined as well maintained highways of concrete or asphalt construction Terrain level to rolling with maximum 8 grades Class AA is turnpike For other type opera tions change lube at 40 000 mile intervals If the vehicle does not accrue enough mileage to require a lube change change the lubricant once yearly m em Adding Lube If the lube level falls below its proper level between changes it should be replenished as needed Lubricants approved under the MIL L 2105 C specifi cation are compatible with each other and brands may be mixed To maintain proper viscosity levels however do not mix lube grades when adding to an existing supply Correct Lube level at bottom of filler hole Incorrect Lube level below Filler hola Changing Lube Draining Drain when the lube is at normal operating temperature It will run freely and minimize the time necessary to fully drain the axle Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container Inspect drain plug for large quantities of metal particles After initial oil change these are signs of damage or extreme wear in the axle and inspection of the entire unit may be warranted Clean the drain plug and replace it after the lube has drained completely Axles with Lube Pump Remove the magnetic str
111. ese parts can be reused if damaged Fasteners using self locking nylon patches may be reused if not damaged but should be secured by a few drops of Loctite 8277 on the threaded surface of the hole during installation and carefully torqued during installation Axle Housings Repairs are limited to removal of nicks or burrs on machined surfaces and the replacement of loose or broken studs Ah CAUTION ANY DAMAGE WHICH AFFECTS THE ALIGNMENT OR SIRUCTURAL INTEGRITY OF THE HOUSING REQUIRES HOUSING REPLACEMENT REPAIR BY WELDING OR STRAIGHTENING SHOULD NOT BE ATTEMPTED THIS PROCESS CAN AFFECT THE HOUSING HEAT TREATMENT AND CAUSE IT TO FAIL COMPLETELY WHEN UNDER LOAD Silicone Rubber Gasket Compound For more effective sealing Spicer uses silicone rubber gasket compound to seal the majority of metal to metal mating surfaces Spicer includes gasket compound and application instructions in many repair parts kits It is recommended that this compound be used in place of conventional gaskets The compound will provide a more effective seal against lube seepage and is easier to remove from mating surfaces when replacing parts Always use Spicer Genuine Axle Parts and Parts Kits Genuine Spicer replacement parts are the same high quality tolerances as the original axle components and include the latest engineering improvements Parts Kits have only one part number which makes ordering stocking and servicing easier They are not only
112. exceeds limits miles or 1 year service off road disassemble power divider and replace worn parts Up to 0 040 with less than 100 000 miles or 1 year service on road Measure and Adjust End Play 1 With power divider assembled to differential carrier measure end play with dial indicator positioned at yoke end of input shaft Move input shaft axially and measure end play If end play is not correct see chart adjust as follows 2 Remove input shaft nut flat washer and yoke Remove bearing cover cap screws and lockwashers Remove cover and shim pack 3 To increase end play add shims Desired end play 0 003 to 0 007 Measured end play Step 1 0 001 0 001 Add shims to provide desired end play 0 002 to 0 006 4 To decrease end play remove shims Measured end play Step 1 0015 0 015 Desired end play 0 003 to 0 007 Remove shims to provide desired end play 0 012 to 0 008 5 To reassemble input shaft install the adjusted shim pack and bear ing cover Install cap screws and lockwashers Torque screws to 75 85 ft ibs 101 115 N m Ring Gear Tooth Contact This adjust NOTE Because of manufacturing Input Shaft End Play This adjust ment controls gear mesh in the inter axle differential Front Output Shaft End Play This adjustment maintains correct rela tionship of the output shaft bear in
113. g damage use suitable sleeve that only contacts inner race of bearing cone IMPORTANT At this stage of assembly final check pinion bearing preload See Adjustment Section of this manual Install Drive Pinion 1 Place shim pack on carrier NOTE If gear set is to be reused install same quantity and size of shims removed during disas sembly When installing a new gear set use nominal shim pack indicated below Nominal Shim Pack in mm 0 024 0 610 2 Install drive pinion assembly Install bearing cage cap screws and iockwashers Torque cap iiu to 155 175 ft Ibs 210 237 my At this phase of reassem bly use a dummy yoke if avail able in place of helical gear This will result in easier disassembly and reassembly during carrier adjustments If dummy yoke is not available proceed with helical gear installa tion see next Install Pinion Outer Support Bearing Hace 1 removed install bearing in power divider cover using driver and hammer 2 Install snap ring to secure bearing WARNING SNAP RING IS SPRING STEEL AND MAY POP OUT WEAR SAFETY GLASSES WHEN INSTALLING 3 Input Shaft Bearing Cup only on Axle Series 185 and 220 If removed install bearing cup in carrier 4x4 5 9 Differential Carrier Overhaul Install Pinion Helical Gear Series 185 220 After differential adjust Pi
114. gear set is to be bearing adjusters for reference lockwire and remove bearing reused remove bearing cap during assembly screws Remove cap adjuster and adjuster and lock as an assembly lock This will facilitate correct position ing af ring gear during reassembly T Remove bearing cups then lift 8 Drive Pinion For pinion instructions refer to appropriate ring gear and differential assembly Spicer Axle Service Manual covering your specific axle model out of carrier 4 4 6x6 7 5 Medium duty Overhaul Hemove and Disassemble Clutch Pack Medium duty CTD Illustrated THRUST WASHER PERMANENT SHIFT FORK OPENING COVER CAP WASHER 1 Place differential assembly clutch pack up on workbench WARNING TAKE PRECAUTION ARY MEASURES TO PREVENT PERSONAL INJURY OR PARTS DAMAGE DURING REMOVAL OF GEAR SUPPORT COVER Step 2 THE COVER IS UNDER SPRING PRESSURE AND MAY POP OFF WHEN THE LAST LOCKNUT IS REMOVED 7 6 4x4 6x6 SEASONAL CTD SHIFT FORK RETAINER ADJUSTING LOCK SCREW NUT SMAP AING DRIVER SUPPORT PERMANENT PRESSURE CTD ONLY PLATE Feria FEM CLUTCH C din 60 0 aD ANAL BEARING BEARING SPLINED PLATE COMPRESSION CUP ADJUSTER EXTERNAL SPRING SPLINED PLATE EXPANSION E SHIFT ee SPRING SEAL DRIVER CONTROLLED CTO SHIFT UNIT EXPANSION PLUG SHI
115. gh tne quick re lease valva When driveline torque is interrupted axle is shifted to Low Range and Meld in this position oy shift unit return spring NOTE In 4x4 drive axle range shift ar valve levar is blocked and range cannot be changed Interiock System The interlock system consists of a lockout control valve mounted on the Axia Range shift unit and an interlock control valve mounted on the stear driva lockup shift unit This intarlocking system dalivers air pressure to the axle range shifter valve interlock pin when in 4 4 drive which in turn operates to lock the range shifter lever in axle Low Flange When in 4 2 drive with axle in High Range the lockout control valve is closed and prevents shifting to 4x4 drive Steer Drive Lockup A manually operated All VVheel Drive shifter vaive is used to control a shift unit mounted on the rear axie This shift unit is mechanically connected to a shift fork and a slid ing clutch The operational modes of the steer drive axle are controlled by movement of the sliding clutch With the shifter valve in the angaged position the drive to the steer drive axie is engaged for 4x4 drive rear axle in Low Range With the shifter valve in the disen gaged position the drive to the steer drive axie is disengaged for 4 2 operation Interlock System Operation with Duai Range Rear Axia Interlock Engaged 4x4 Operation Rear Axle in Low Range RESERVOIR
116. ght coating of grease on camshaft bush ing journals Place spacer on camshaft next to cam Install camshaft in ball socket Install washer slack adjuster and shims on splined end of cam shaft Secure with snap ring 2 Adjust camshaft end play between 0 005 and 0 045 by adding or removing shims between snap ring and slack adjuster 1 22 4x4 6 6 Installing Brake Camshaft Installing Slack Adjuster Assembly Adjust Air Chamber Push Rod Length 1 NOTE Before installing air chamber check push rod length Push rod length should be 2 5 8 1 16 66 5 1 5mm Measure distance from mounting face of air chamber to centerline of clevis pin hole To adjust loosen locknut and turn clevis on push rad NOTE After adjustment is made make sure push rod does not project into clevis more than two threads Install Air Brake Chamber and Lubricate Camshaft Bushings 1 Install air chamber and mounting bracket assembly on ball socket Secure with cap screws and lockwashers Torque to 80 110 ft lbs 110 149 N m Connect slack adjuster arm to air chamber clevis Install clevis pin and cotter pin 2 Pressure lubricate camshaft bushings with chassis lube through fitting in brake chamber bracket Continue filling lube until excess or over flow is evident at slack adjuster NOTE Lube overflow should not be seen at 5 cam if oil seals have been properly installed 3 After adjusting air cham
117. gl E EX Pattern along the face width pg face width Pattern should ae T ur could be longer between tooth top land and root be evenly centered 7 s Pattern should be clear of tooth toa 6 With ring gear and pinion adjusted correctly align 7 Seasonal and Driver Controlled CTD Only Posi adjusters and locks then tighten differential bearing tion shift fork in carrier opening then install sliding cap screws to correct torque Install cotter clutch With clutch installed engage shift fork yoke adjuster lock Install cap screws in opposite adjuster with clutch collar Then install shift fork shaft Install lock and tighten to correct torque Lockwire bearing expansion plugs to seal openings Install shift fork and adjuster lock cap screws seal and spring over end of shift fork Move shift fork to place sliding clutch in engaged position Sliding clutch must be engaged to allow installation of car rier on housing 4 4 6x6 7 15 Overhaul Install Differential Carrier Assembly Axle Housing All Types CTD IMPORTANT The following instructions cover single drive axles and tandem rear axles For tandem forward axles diff with power divider m refer to the appropriate axle service manual Silicone Gasket Compound IMPORTANT Before installing carrier assembly inspect and thor Aid M ded tial Carrier oughly clean interior of
118. gs and related parts Proper adjustment of both input and output shafts help maximize life of all power divider parts Measuring End Play with Dial Indicator 6 Install yoke flat washer and nut Tighten nut snugly Tap end of input shaft lightly to seat bearings 7 Measure input shaft end play with dial indicator lf end play is still incorrect repeat Steps 2 through 6 B With end play correct seal shim pack to prevent lube leakage then torque input shaft nut and cover cap screws see chart NOTE When power divider has been disassembled and reassem bled it may be desirable to adjust end play by measuring bearing cover clearance and calculating shim pack size For procedures see Power Divider Section 4 Torque Chart Input Shaft Nut Fi ibs N m 1 5 8 18 780 960 1059 1301 1 7 8 12 840 1020 1138 1383 Bearing Cover Cap Screw 1 2 13 75 B5 101 115 Grade 5 NOTE If difficulty is experienced in achieving correct torque on the input yoke nut torque the nut with truck on the ground and axle shafts installed 3 8 4 4 Adjust Front Output Shaft End Play NOTE The following instructions apply to a completely assembled dif ferential carrier and power divider For instructions during reassembly when overhauling power divider refer to Power Divider Overhaul Section 4 Specifications 0 003 to 0 007 shaft end play Measure and Adjust End Play 1 Measure end play with dial indicato
119. hat on the basis of the angle the axle is installed in a particular chassis Always use the filler hole as the final reference If lube is level with the bottom of the hole the axle is properly filled Axles installed at angles exceeding 10 degrees or operated in areas of continuous and lengthy grades may require standpipes to allow proper fill levels Contact Spicer Field Service Department or call Regional Office for specific recommendations See back cover for address and phone numbers 4x4 6x6 2 3 Cleaning Inspection Replacement As the drive axle is disassembled set all parts aside for thorough cleaning and inspection Careful inspection will help determine whether parts should be reused In many cases the causes of premature wear drive axle failure will also be revealed Cleaning The differential carrier assembly may be steam cleaned while mounted in the housing as long as all openings are tightly plugged Once removed from its housing do not steam clean differential carrier or any Compo nents Steam cleaning at this time could allow water to be trapped in cored passages leading to rust lubricant contamination and premature component wear The only proper way to clean the assembly is to dis assemble it completely Other methods will not be effective except as preparatory steps in the process Wash steel parts with ground or pol
120. he axle range shifter valve The interlock system controls deli vary af air pressure to the axle range shifter valve interlock pin which in turn operates to lock the range shifter valve lever position and prevent axle range shifting Steer Drive Axle Lockup One manually operated shifter valve is used to control the steer drive axle lockup shift unit mounted on the rear axle The shift unit is mechanically connected to a shift fork and a sliding clutch The operational modes of the steer drive axle are controlled by movement of the sliding clutch When the shifter valve is in the engaged position the steer drive axle lockup is engaged providing 4 4 drive With the shifter valve in the dis engaged position the steer drive axle lockup is disengaged for 4x2 operation 4 4 8 5 Dual Range Axles with Range Interlock Interlock system Operation with Dua Range Axles Interlock Engaged 4x4 Operation RESERVOIR AIR PRESSURE INTERLOCK ___ cue AIR PRESSURE CONTROL VALVE I I 2 SHIFT UNIT PISTON E MOVEMENT ALLOWS INTERLOCK CONTROL VALVE TO OPEN AIR PRESSURE FROM STEEHR DRIVE AXLE MOVES PISTON TO ENGAGE STEER DRIVE AXLE LOCKUP SUDING CLUTCH ENGAGES DRIVE GEAR Interlock Disengaged 4x2 Operation RESERVOIR AIR PRESSURE AIR EXHAUST INTERLOCK CONTROL VALVE EXHAUST 7 2 SHIFT UNIT PISTON
121. he spindle to pass through 3 Pack bearing cones with grease Install inner bearing cone in hub Install bearing spacer cone with chamber at inner diameter facing out 4 Install oil seal in hub using suitable driver or press Press seal into hub until it is flush with face of the hub Tie Rod End Replacement IMPORTANT When tie rod ends are replaced they must be threaded into the tie rod sufficiently so that when the clamp is applied the clamping action will be directly over the threads on the ball end Be sure that the end is in far enough past the clamp to provide adequate clamping and the bolt In the clamp is installed next to over the slot in the tie rod Torque the clamp bolt to 60 80 ft lbs 81 110 05 368 Installing Bearing Cone and Spacer Installing Hub seal 4 4 6 6 1 25 Steering and Wheel End Equipment Overhaul Assembly Assemble and Install Wheel Hub and Drum Cont d WHEEL HUB AND DAW ASSEMBLY Installing Wheel Hub and Drum 9 Install hub and drum on spindle Install outer bearing cone 6 Install wheel bearing adjusting nut Tighten nut to seat the bearings Rotate drum while tightening nut After nut is seated firmly against bearing cona back off until the slot in the adjusting nut aligns with slot or groove in axle spindle NOTE Searing adjustment is important The nut should be tight enough to eliminate hub end play and create a
122. he unit functions with con ventional differential action For operational description of the shift unit see page 8 18 2 4 4 Steer Drive Axle Lockup Shift Unit Operation Description This shift unit is of the straignt air type Air operated for engagement and spring released for disengagement The piston is mechanically connected to snift fork and siiding clutch The engages or disengages a drive gear to angage and disengage the steer drive axie Disengaged When the shifter valve ever is moved to the disengaged position this valve i closed and air pressure in the shift unit is exhausted Air pressure at piston is released Spring pressure moves piston shift fork and sliding clutch Clutch is disengaged rom a drive gear The steer drive axle is disengaged from tha drive train MOTE Controlled Traction Differential if aquipped is dis engaged and not operating Engaged When the shitter valve lever is moved t the engaged position the Valve is Opened and supplies air pressure to tne shirt unit Air pressure enters the cover and moves the piston fork and gliding The clutch engages a drive gear The steer drive axie is angaged into the drive train NOTE Controlled Traction Dif ferential if equipped is engaged and operating Lockup Shift Unit us cR gt Fi ROD FRONT INPUT SHAFT COVER SLICING CLUTCH ENGAGES DISENGAGES OR
123. hecks are completed Lastly insure that sufficient air pressure is built up to perform system checks Turn engine off 2 Check Solenoid Valve If vehicle is equipped with solenoid valve turn ignition ON to energize and open valve Check to insure that air pres sure is present at the outlet of the solenoid valve 3 Check Axle Range Shift System Have an assistant in the cab begin moving the axle range valve lever in the cab between Low and High Range Listen for mechanical move mant at the rear axle range shift unit and the steer drive axle range shift unit If movement is appar ent place the axle range valve lever in the Low Range position and dis connect air lines at the rear axle and the steer drive axle range shift units Place axle range valve lever in High Range position Air flow shauld be present through the dis connected air lines If air flow is not present inspect the axle range shift er valve and the quick release valve Replace as required Place axle range valve lever in Low Range position Air flow should not be present in any of the discon nected air lines Reconnect air lines and insure that sufficient air supply exists to per form following checks to the remainder of the system 4 Check Lockup System Have an assistant move the All Wheel Drive selector valve lever from disengaged to engaged position Check for mechanical movement in the steer drive axle lockup shift unit mounted on the
124. hee Drive selector valve leverto engaged posi tion and check for air flow trom side port of interlock control valve If air flow is not present place selector valve lever in disengaged position and remove interlock control valve from shift unit cover b Place All Wheel Drive selector valve lever in engaged position and again check for air flow from the side port of the interlock control valve If air flow is present depress plunger on interlock control valve and insure air supply is shut aff from valve side part If valve does not function correctly remove and replace Place All Wheel Drive selector valve lever in disengaged position and reinstall interlock con trol vaive in shift unit cover and adjust properly see page 8 16 Place All Wheel Drive selector valve lever in engaged position If air flow is still not present at valve side port remove shift unit from rear axle and inspect components for binding or excessive wear After repair follow the above steps until proper func tioning is obtained c Reconnect air line and place All Wheel Drive selector valve lever in the engaged position If interlock pin on axle range shifter valve does not actuate proceed to Step d If inter lock pin functions correctly system is operating correctly and check 1 complete d If interlock pin still does actuate when All Wheel Drive select or valve lever is placed in engaged position remove axle range shifter valve in
125. helical gear in mounting position Using a press install input shaft pressing it through the helical gear splinas and into rear bearing cona 10 Make sure power divider cover dowel pins are installed in differ antial carrier 12 Install power divider cover making sure pinion outer support bearing is aligned Install cap screws and lockwashers MOTE Make sure the one blind Screw is installed through output shaft bearing cover opening Tighten cap screws to correct torque see chart 4 5 4 f removed install pinion outer support bearing race in power divider cover using a driver and a hammer or a press and suitable sleeve 5 Press bearing cup in input bear ing cover NOTE Do not install oil seai until input shaft end play adjustment is completed see page 4 8 MOTE The following assembly procedures assuma input shaft end play adjustment will b made after cover is installad on carrier see procedures step 2 through 9 page 4 8 B For easier adjustment tempo rarily install input bearing cover Iwithout shims cap screws and lockwashers Tighten screws finger tight 11 Apply silicone gasket com pound to carrier mating surface see illustration 13 Adjust Input Shaft End Play Adjust end play and complete tne assembly procedure when power divider is assembled to carriar page 4 8 3 Install snap ring to secure bearing race WARNING SNAP RING IS SPRIMG S
126. hift unit Place shifter valve laver in High Range position Air flow should be present through the dis connected air line If air flow is not present inspect the axle range shifter valve and the quick release valve Replace as required Place range shitter in Low Range position Air flow shauld not be present in the disconnected air lime Reconnect air line and insure that sufficient air supply exists to per form following checks to the remainder of the system 8 12 4x4 4 Check Lockup System After insuring that the axle range shifter valve 15 in the Low Range position nave an assistant move All Wheel Drive selector valve lever from disengaged to engaged posi tion Check for mechanical move mant in the steer drive axie lockup shift unit mounted on the rear axie Disconnect the air line from cover of the steer driva axle lockup shift unit with All Whee Drive selector laver in disengaged position NOTE This air line is not to be confused with air line connected to interlock control valve installed shift unit Gover Leave this air line connected Place All Wheel Drive selector valve in engaged position and check for air flow at discon nected air lina Place lever in disengaged position and insure air flow is discontinued If system functions correctly proceed to Step 7 If not proceed to Step 5 5 Check Lockout Control If improper operation is evident in Step 4 the All Wheel Drive
127. ial Indicator NOTE If difficulty is experienced in achieving correct torque on tha input yoke nut torque the nut with truck on the ground and axle shafts installed Adjust Front Output Shaft End Play and Final Assembly of Output Shaft MOTE After power divider overhaul and installation on carrier check and adjust front output shaft and play Correct end piay is 0 003 to 0 007 Adjust End Play by measuring cover clearance and calculating shim pack thickness NOTE With output shaft and related parts assembled as described on 4 3 proceed with step 1 NOTE Do not install shift fork shift unit or seal until adjustment is com pleted 1 Install output shaft assembly shaft gear and bearing cones in power divider cover Hoid cover in mounting position with hand pressure and measure clearance between the two covers using feelar gauge This measured clearance plus 0 005 will aqual shim pack thickness required for desired shaft and play 2 install the output cover with calculated shim pack Install the four cover cap screws and lockwashers Torque cap screws see chart Install yoke flat washers and nut Tighten nut snugly 3 Check output shaft and play with dial indicator positioned at yoke and of shaft If and play is not correct remove cover yoke and output shaft as an assembly and change shim pack steps 4 through 7 If end play is correct proceed to step 8 Adjust Shim Pack 4 To increase
128. idence of incorrect adjustment see Adjustment Section for correct pattern Inspect machined surfaces of cast or malleable parts They must be free of cracks scoring and wear Look for elongation of drilled holes wear on surfaces machined for bearing fits and nicks or burrs in mating surfaces Inspect fasteners for rounded heads bends cracks or damaged threads The axle housing should be examined for cracks or leaks Also look for loose studs or cross threaded holes Inspect machined surfaces for nicks and burrs 4 4 3 5 Cleaning Inspection Replacement Repair and Replacement IMPORTANT To achieve maximum value from an axle rebuild replace lower cost parts such as thrust washers seals and bushings These items protect the axle from premature wear or loss of lubricants Replac ing these parts will not increase rebuild cost significantly It is also important to replace other parts which display signs of heavy wear even though not cracked or broken significant portion of such part s useful life has been expended and the damage caused should the part fail is far in excess of its cost Steel Parts Gear sets input and output shafts differential parts and bearings are not repairable Worn or damaged parts should be discarded without hesitation Also discard mating parts in some cases Gear sets for example must be replaced in sets Miscellaneous Parts Seals and washers are routinely replaced None of th
129. ider on Differential Carrier 5 230 260 300 350 AXLE SERIES Disassemble Power Divider 6 Assemble Power Divider Cover and Input Shaft then Install Power Divider on Differential Carrier 7 ALL MODELS Adjust Input Shaft End Play 8 Adjust Front Output Shaft End Play and Final Assembly of Output Shaft CCP 9 4 4 4 1 4 2 4x4 Power Divider Transfer Gearing Description The transfer gearing consists of three gears 1 Input shaft and helical gear integral component on 185 and 220 Axle Series Helical gear is splined to input shaft on 230 260 300 350 Axle Series 2 Drive Pinion helical gear splined to pinion shaft 3 Output shaft helical gear gear floats on shaft The output shaft is equipped with a sliding clutch This clutch engages or disangages helical gear to controi power flow to the stear driva axle The output shaft sliding clutch is operated by an air type lockup shift unit Remove Power Divider from Differential Carrier INPUT INPUT HELICAL GEAR Integral with shatt 185 and 220 Axt Serres Gear splined to shaft 230 260 300 350 Axie serias DCRIVE PINION HELICAL GEAR FRONT OUTPUT SHAFT 7 HELICAL GEAR STEER ORIVE AXLE SLIDIMG CLUT CH with carriar removed from axie housing 1 Mount differential carrier in repair stand Loosen input
130. ilable proceed with helical gear installa tion see next page Install Pinion Outer Support Bearing Hace 1 If removed install bearing race in power divider cover using driver and hammer 6 12 4x4 2 Install snap ring to secure bearing race WARNING SNAP RING IS 3PRING STEEL AND MAY POP QUT WEAR SAFETY GLASSES WHEN INSTALLING Install Pinion Helical Gear Series 185 220 NOTE After diffarantial adjust Pinion ment is compiata or if dummy Helical yoke was used remove nut and Gear and yoke Then continue to assemble Support pinion as follows Searing 1 Install helical gear on pinion installation positioned shown in the illustration 2 Install support bearing spacer 3 Install support bearing using properly sized driver and hammer 4 install slotted nut and tighten according to instructions in torgue chart Torque Chart Drive pinion Siotted Nut and Pin Ft ba 1 1 2 18 840 1 2 4 12 ago IMPORT ANT Torque nut to torqua shown in chart then con tinue tightening nut to align siot with nearest hola in pinion shank Install roll pin Install Pinion Helical Gear Axia Serias 230 260 300 350 NOTE After differential adjust mant i complete or if dummy used remove nut and yoke Then continua to assembie pinion as follows ini 1 Install helical on pinion installation using driver and hammer 2 Install pinion outer suppor
131. in stalled with both lips pointing in the same direction see drawing Failure to install seals properly may fe result in oil soaked brake linings or blowing out the seals pun CAMSHAFT BUSHINGS BALL IF NECESSARY REAM TO 15007 SOCKET AFTER INSTALLATION NON METALLIC Assemble Axle Ball BUSHINGS DO NOT REQUIRE REAMING 1 If ball bushing for axle shaft is to be replaced Camshalt Bushing and Oil Seal Installation install new bushing as follows AL RETAINER Position bushing in axle ball with chamfered end down and the open end of lube groove facing up or towards the outside of the axle ball see drawing After installation check shaft journal to bushing clearance BALL SHAFT BUSHING IMPORTANT A clearance of 0 003 to 0 005 is OF LUBE GROOVE TOWARD AO imperative If necessary ream bushing to maintain eem us this clearanca 2 If oil Seal is faulty or has been removed install BUSHING CLEARANCE INSTALLATION anew LN BALL REAM NECESSARY BALL SHAFT BUSHING NOTE Position seal with sealing lip toward ball LA bushing see drawing Seal should seat firmly against shoulder in mounting bore of ball Install Axle Ball on Axle Housing 1 Place axle ball on axle housing studs Install nuts and lockwashers Install cap screws and lockwashers Torque nuts to 280 360 ft lbs 380 488 Torque cap screws to 170 220 ft lbs 231 298 Ball Bushing an
132. iner 20 Adjust Steering Stop Screws 21 Assemble Axle Shaft and Cage Ring Assembly 21 Install Axle Shaft Assembly 22 Install Brake Spider and Spindle 22 Install Brake Camshaft and Slack Adjuster 22 Adjust Air Chamber Push Rod Length 23 Install Air Brake Chamber and Lubricate Camshaft Bushings 23 Adjust Air Chamber Push Rod Free Stroke 23 Install Brake Shoes 24 Connect Tie Rod and AW 29 Assemble and Install Hub and Drum 25 Install Wheels and Tires Lubricate Axle 26 4x4 6x6 1 7 Steer Drive Axle Steering and Wheel End Equipment LUBE LOCHUMASHER COVER p COTTER F DIFFERENTIAL CARRIER ASSEMBLY 5 402 5 mua WHEEL END 4 B DRAIN PLLIG FITTING FILLER PLUG i TIE AG TIE AGD ENO UT LOCKWASHER LUBE FITTING NUT BALL STUD WASHER DOWEL COTTER PIN i s GTEERING ARM P a __ MUT SHIMS WASHER SEAL cel BEARING RETAINER RR CAGE BEARING CONE RING 2 c2 i RETAINER LOCK a i GASKET m AXLE BALL NUT WASHER STOP SCREW Ay SHIN
133. ion Differential refer to Section 7 Section 5 Contents Page DIFFERENTIAL CARRIER OVERHAUL Exploded View 2 Disassemble Differential Carrier OE A Disassemble Drive Pinion 4 Disassemble Wheel Differential 5 Assemble Wheel Differential 6 Assemble Drive Pinion T Install Drive PINION 9 Install Pinion Outer Support iet Race 9 Install Pinion Helical Gear 10 Install Differential Assembly in Carrier 11 Adjust Differential Bearing Preload 13 4x4 5 1 4 4 Single Reduction 18554 22084 23084 260S4 30084 35084 Differential Carrier Assembly 4x4 Rear Axle LOCKWASHER SEARING CAP LOCK WIRES _ n CARRIER FOR 21094 28084 30094 15054 PULLER PLUG DOWEL LOCK EXPANSION DIFFERENTIAL CARRIER FOR 18534 AMD 22054 DIFFERENTIAL ASSEMBLY F SIDE THRUST CIFF CASE BEARING BEARING PINION WASHER PLAIN cong ACIS SPACER BEARING EAR BEARING HEL THE HELICAL SLOTTED SMAR ARE WASHER CUP CAGE COME GEAR AUT RING CATH M SUPPORT yim POWER DIVIDER COVER r T CEA j 06310 LOT BEARING BEARS JHIA CAPE T SOLL SEARING BEARIMO GEHE SPaCEA WASHEA SCRE W
134. ioned at yoke end of input shaft Move input shaft axially and measure end play If end play 1 correct seal shim pack to prevent lube leakage then torque input shaft nut and cover cap screws see chart T If end play is incorrect change shim pack size as follows Add shims to increase end play Example Desired end play New Parts TC 0 003 to 0 007 Measured end play Step 6 2 0 001 0 001 Add shims to provide desired end play 0 002 to 0 006 Remove shims to decrease end play Example Measured end play Step 6 Te Desired end play New Remove shims to provide desired end play 0 012 to 0 008 8 To add or remove shims remove input shaft nut flat washer and yoke Remove cap screws lockwashers and bearing cover Add or remove shims as required 9 Install bearing cover cap screws and lockwashers Install seal using a seal driver or suitable sleeve Install yoke flat washer and nut Seal shim pack to prevent lube leakage then torque input shaft nut and cover cap screws see chart 0 015 0 015 Torque Chart Input Shaft Nut Ft Iba M m 1 5 8 18 780 960 1059 1301 1 7 8 12 840 1020 1139 1383 Cap Screw 1 2 13 75 85 101 118 Grade 8 Tightening Yoke Nut 4 4 0 003 to 0 007 Measuring Bearing Cover Clearance Installing Bearing Cover and Shim Pack Measuring End Play with D
135. ished surfaces in solvent There are many suitable commercial solvents avail able Kerosene and diesel fuel are acceptable WARNING GASOLINE 15 NOT AN ACCEPTABLE SOLVENT BECAUSE OF ITS EXTREME COMBUSTIBILITY IT 15 UNSAFE IN THE WORKSHOP ENVIRONMENT Wash castings or other rough parts in solvent or clean in hot solution tanks using mild alkali solutions If a hot solution tank is used make sure parts are heated thoroughly before rinsing Rinse thoroughly to remove all traces of the cleaning solution Dry parts immediately with clean rags Lightly oil parts if they are to be reused immediately Otherwise coat with oil and wrap in corrosion resistant paper Store parts in a clean dry place Inspection Inspect steel parts for notches visible steps or grooves created by wear Look for pitting or cracking along gear contact lines npe deforma tion or discoloration are signs of excessive heat in the axle usually related to low lubricant levels or improper lubrication practices Before reusing a gear set inspect teeth far signs of excessive wear Check tooth contact pattern for evidence of incorrect adjustment see Adjustment Section for correct pattern Inspect machined surfaces of cast or malleable parts They must be free of cracks scoring and wear Look for elongation of drilled holes wear on surfaces machined for bearing fits and nicks or burrs in mating surfaces Inspect fasteners for rounded heads bends cracks or
136. ith nearest hole ir pinion shank DRIVE PINION BEARING CAGE Screw 3 16 12 8 155 175 210 237 DIFFERENTIAL CASE Single Reduction 5 8 11 8 165 195 224 264 Dual Range amp Double Reductlon 9 16 12 8 116 130 157 176 DIFFERENTIAL BEARING CAP Cap Screw 13 16 10 8 370 430 501 583 DIFFERENTIAL BEARING ADJUSTER LOCK Duai Range amp Double Reduction 5 8 11 5 160 176 217 239 DIFFER ENTIAL CARRIER Stud Nut een ss B B 18 8 stud 220 240 298 325 At Dowels 150 170 203 230 Cap Screw 12 pt 5 8 11 210 230 285 312 AXLE HOUSING COVERS 230 260 Axle Series Stud Nut 7718 20 8 stud 70 86 94 116 5 7 16 14 8 47 58 84 75 300 350 Axle Series Stud Mut 1 2 20 B stud 110 130 149 176 Cap Scr amp w 1 2 13 5 78 85 101 115 SHIFT UNIT Dual Range Stud Mut 7 16 20 B stud 55 81 74 82 SHIFT FORK COVER Double Reduction 7 16 14 5 35 45 47 81 9 6 4x4 lt PANA gt SPICER Drivetrain Products Axles Driveshafts Off Highway Transmissions LONG Thermal Products Transmission Oil Coolers Engine Oil Coolers VICTO
137. ive shaft and remove axle shafts Remove differential carrier to axle housing cap screws and lockwashers or stud nuts Remove differential carrier Remove Differential and Clutch Pack Assembly from e NOTE If the gear set is to be reused check tooth contact pattern and ring gear backlash before beginning disassembly Best over haul results are obtained when used gearing is adjusted to run in established wear patterns Omit this step if the gear set is to be replaced When reusing the gear set remove the left hand bearing cap adjuster and lock as a unit This will help return the gear set to its original adjustment during reassembly 1 Mount the differential carrier in a repair stand 7 4 4 4 6 6 gt Removing Shirt Fork 2 Driver Controlled and Seasonal CTD Only Remove shift fork seal and spring Hemove expansion plugs then working at the lower or small plug hole drive out the shift fork shaft WARNING WHEN USING DRIFT PUNCH OR SIMILAR TOOL WEAR SAFETY GLASSES Removing Sliding Clutch 3 Driver Controlled and Seasonal CTD Only Disengage shift fork yoke from sliding collar Then remove clutch and shift fork Remove Differential and Clutch Pack Assembly from Carrier 6 back side of ring gear cut lockwi d remove bearing ca 4 f reusing gear set punch mark 5 On teeth side of ring gear cut g cap ibd screws If the
138. ize of shims in the pack T Input Shaft Bearing Cup only on Axle Series 185 220 If replacement is necessary use suitable puller to remove bearing cup from carrier 4 4 5 3 Differential Carrier Overhaul Disassemble Drive Pinion 1 SPACEM SEARING BEARING WASHER CUP CAGE BEARING CUP a THESE PARTS ARE MOUNTED POWER BEARING HELICAL SLOTTED SNAP COVER GEAR RING SUPPORT SEARING PILOT BEARING BEARING SHIM LOCK 2 SEARING JEARING CONE SPACER WASHER SCREW BEARING AACE VARIABLE SPACEH 11 Used oniy on Aste 210 280 300 120 2 Used only on Axie Senes 185 220 1 Support pinion bearing cage in press and press pinion out of bearing cage and outer bearing Cone 2 Remove spacer and spacer washer from pinion Spacer Washer i used only on Axle Series 185 220 4 replacement is necessary remove bearing cups from bearing cage using suitable pullers 5 4 4x4 3 Remove pilot bearing and inner bearing cone from pinion using split type puller Use two procedure steps to remove each bearing see photos above First mount puller vertically to split Second mount puller horizontally the bearing fo remove bearing Disassemble Wheel Differential DIFF BEARING THRUST SIDE SPIDER THRUST RING FLANGED BEARING DIFF BEARING CONE WASHER PINION WASHER GEAR C
139. lbs 148 176 N m 4x4 8x6 7 13 Overhaul Install Drive Pinion NOTE If the drive pinion was removed refer to the appropriate opicer Service Manual covering your specific axle for instructions install Differential and Clutch Pack Assembly in Carrier Types ae 4 cage Pat E 2 f the same gear set is used 3 Install and tighten bearing cap ird install the assembled bearing cap screws finger tight If this is diffi adjuster and lock on the backface use hand wrench t EAM side of the ring gear Otherwise NOTE Th p 9 metall adi The assembly is now ready voee rf PEDESTAL install adjuster and cap separately for adjustment of differential bear NOTE When instal ing Cap It may ing preload ring gear hacklash NOTE Lubricate bearings during be necessary to tap it lightly with a and gear tooth contact T Uu ec hammer sure cap is fully he f the following assembly procedure seated and threads are aligned 1 Place ning gear and differential pro perly If trouble is encountered assembly in carrier Insure that check for cross threading of bear ring gear and drive pinion mesh ing adjuster and carrier threads On teeth side of ring gear install During installation tilt carrier to the other adjuster and bearing allow support case pilot to rest in cap observing same precaution
140. lection litarature See below for Interlock Instruction Plate Fin Assembly repair Axle Range Shifter Valve interlock Pin Assembly NOTE Before reassembly lubri cate O nngs with a high viscosity silicone oil barium grease Q ring lubricant Assemble Pin Install O rings on piston and piston stop Insert spnng piston and piston stop in housing and secure with snap ring NOTE Interlock pin and piston NOTE The interlock pin assembly must reciprocate freely in the piston may be disassembled for cleaning housing when compressed against and inspection However parts the compression return spring only available as a complete assem NOTE For ease of assembly bly shifter valve and interlock insert a pin or drill bit 5 64 max assembly diameter into the piston stop to pu Har Disassemble Pin Remove snap guide the piston stop as it is ring then remove piston stop installed into the piston housing Assembly DM spring from piston sc 3 INTERLCKZK PISTON iii COMPRESSION PISTON HOLSINO SPRING RINGS 8 14 6x6 4 4 Shift Units for Standard Type Inter axle Differential Lockout and Steer Drive Axle Lockup Singie Reduction Hear Ax es and Steer Orve Axles Standard Lockout Straight air type gmaFT FOR LOCRKWASHER COMPRESSION GU MIN
141. less Steer Drive Axle shifter valve is disengaged 4x2 drive Also the system wrap up torques in the drivetrain may prevent immediate disengagement of the Steer Drive Axle clutch even though the All Wheel Drive selector valve is disengaged Backing the vehicle or continuing in a forward direction for sufficient time to release these wrap up torques is necessary before clutch will disengage Interlock pin on range selector shifter valve will then retract allowing range selec tion as desired 8 4 4 4 Dual Range Axles with Range Interlock Axle Range Shift System One manually operated shifter valve changes range of both axles This valve is equipped with an interlock pin assembly which prevents axle range shifting in 4x4 drive Two air shift units mounted on the axles are mechanically connect ed to the axle shift forks and sliding clutch gears which in turn shift axles into Low or High Range One quick release valve provides fast release of air pressure from all both axle shift units For vehicles not equipped with automatic safety brakes an ignition controlled solenoid valve exhausts the system and downshifts the axles when the ignition switch is turned off The electrical circuit is protect ed by a circuit breaker For vehicles equipped with trans mission drive speedometers the system includes a speedometer adapter which compensates speed ometer readings when axles are in Low Range The adapter is operated
142. ll socket head cap screws 05366 X Assembling Cage Rings 2 Referring to the photograph check for correct assembly Note the relationship of tha relieved shape of cage ring and shaft yokes Rotate shaft assembly and note movement angle The shafts should be able to move freely 30 to both sides during a 360 revolution Torque screws to 95 ft lbs 130 Lock screws with punch marks across threaded end of cap screws Qg5J5 nx Checking Axle Shaft Movement Angie 4x4 6x6 1 21 Steering and Wheel End Equipment Overhaul Assembly Install Axle Shaft Assembly 1 Turn ball socket to straight ahead position Grease axle shaft bushing in axle ball and pack inner walls of axle ball with 3 4 layer of grease Be sure to leave an opening for installing axle shaft 2 If necessary polish axle shaft spline ends to eliminate possible nicks or burrs Micks or burrs could damage axle shaft ail seal located in axie ball Lubricate axle shaft polished surfaces Install axle shaft being careful not to damage oil seal or bushing in axle ball As shaft is installed use extra grease forced out of ball to completely coat the Cage rina Install Brake Spider and Spindle 1 Place spider on shoulder at axle side of spindle then piace this assembly on ball socket Fasten with cap screws Tighten screws to torque of 170 220 ft lbs 231 298 N m Install Brake Camshaft Slack Adjuster and Adjust End Play 1 Place li
143. lock oin functions correctly systam is operating carrectly and check is complete d If interlock pin still does not actu ate when All Vheel Drive selector lever is placed in engaged position remove the axle range shifter valve in the and inspect the assembly tor component wear or binding After repairing check for correct operation placing the All Wheel Orive selector lever in the engaged position and insuring that the inter on the axle range shifter valve activates and aiso that it retracts when the All Wheel Drive selector lavar is placed in the disengaged position Check Electrical System Check Solenoid Vaive 1 When ignition switch is ON solenoid valve is energized and air pressure is available to operate the system When ignition switch is OFF solenoid valve is de ener gized and exhausts the system which downshifts axle to low range Check wiring and circuit breaker for defects that would cause shorts open circuits 2 sure valve has good ground connection to the frame With power at valve check opera tion as follows Disconnect lead wire and air lina outlet at valve and install air pressure gauge Apply power to valve and observe air gauge reading Operating pres sure should be approximate raser voir pressure If gauge indicates approximate pressure valve is okay If gauge indicates low or pres sure valve is fauity Replace valva assembly
144. lve provides fast release of air pressure from the axle shift units For vehicles not equipped with automatic safety brakes an ignition controlled solenoid valve exhausts the system and downshitts the axle when the ignition switch is turned off The electrical circuit is protect ed bv a circuit breaker For vehicles equipped with trans mission drive speedometers the system includes a speedometer adapter which compensates speed ameter readings when axie is in Low Range The adapter is operated oy an electrical switch mounted on or near the quick release vaive Tha switch is normally closed and is opened by air pressure With rear axia in Low Range the switch is closed and the adapter is anaergized The adapter operates with ratio compatible with the axle Low Range for proper road speed readings With in High Range tha air lina is pressurized and the pressure switch is open The adaptar now operates with 1 1 ratio for prop speed readings in High Range B 10 4x4 Axle Range Shift System Opera tion must be in 4x2 drive High Range When shifter valve laver is Moved to High Range the valve is opened and air pressure is supplied through the quick release valve to the axle shift unit When driveline torque is interrupted the shift unit will shift to High Range Low Range When shifter valva lever is moved to Low Range the valve is closed Air prassure in the shift unit is axhausted throu
145. miles yearly after that Front Wheel Bearings 1 When the front wheel bearings are excessively worn or damaged check the bearing cups for proper installation before removing them for replacement If a cup is improperly seated in the hub inspect the hub for burrs rough spots or other irregular surfaces that would prevent seating the cup properly Bearing damage is often caused by lack of lubrication or improp er adjustment When installing bearing cups or cones and rollers make sure that the specified lubricant is properly used Adjust the bearings after installation Wheels 1 Wheel stud nuts should be inspected and tightened twice in the first 500 miles and again after 1 000 miles to avoid accidental loosening of the wheels Loose wheel stud nuts may cause shim my and vibration Elongated stud holes in the wheels may also result from loose stud nuts Keep the wheels and hubs clean Stones or lumps of mud wedged between the wheel and drum will unbalance a wheel and tire Check for damage that would affect the runout of the wheels Wobble or shimmy caused by a damaged wheel will eventually damage the wheel bearings Inspect the wheel rims for dents that could permit air to leak from the tires Tires 1 The tires should be checked frequently to be sure that the air pressures agree with those specified for the tires and vehicle model Inspect the tire treads and remove all stones nails glass or other objects
146. mpression spring over shift fork push rod Install piston in body Install ring over push rod and in piston Instail hex nut piston and tighten to 20 26 ft lbs 27 35 N m Install ring on piston Shift Unit Silicone Gasket Pattern 4 4 Axle Series 185 220 6x6 Axle Series D346 P 386 2 408 P 4 4 6 6 5 Install ring in lockout body cover Install cover assembly and secure with cap screws and lockwashers Torque cap screws 10 96 108 IN L83 11 12 6 Adjust interlock control valve Interlock Locxout Straight air type CAR L HEX ELT OMEA AR PISTON STOP Used only on 4x4 Axle Series 185 220 and 6x6 Series D346 P 386 P 406 MOTE Intar axle differential lockout shift units are only used on 6x6 drive systems Interlock Control Valve Repair and Replacement Replace faulty valve as an assembly TOM aTOP Remove Valve 1 Loosen locknut and unscrew valve body from cylinder body Install and Adjust Vaive NOTE If button is not assembled to valve stem install as follows insert valve stem to full depth of the button Lock in place with set screw Torque sat screw to 6 IN LBS 0 7 1 With button assembled to valve install locknut and lockwasher on valve body With lockout cylinder exhausted screw the valve assembly into the lockout cylinder cover until the valve is seated on hex nut piston 2 adjust unscrew cont
147. n Cap Serew 9 16 12 8 116 130 157 176 Dual Range amp Double Reduction 1 2 13 8 90 110 122 149 DIFFERENTIAL BEARING Single Reduction 3 4 10 8 360 440 488 596 Dual Range amp Double Reduction 13 16 10 B 370 430 501 583 DIFFERENTIAL BEARING ADJUSTER LOCK Dual Range amp Double Reduction Cap Screw 878 11 5 160 176 217 239 DIFFERENTIAL CARRIER Stud Nut T 5 8 18 8 stud 220 240 298 325 AXLE HOUSING COVERS Stud Nut 7 16 20 8 stud 70 86 34 118 Cap Screw 7 18 14 5 48 56 65 75 SHIFT UNIT Duai Range Stud Mut T 18 20 8 stud 55 61 74 82 SHIFT FORK COVER Double Reduction Serew 7 18 14 5 35 45 47 61 4 4 9 5 4x4 Rear Axle Differential Carriers Fastener Axle Series 230 260 300 350 All Models Single Reduction Dual Range Double Reduction peciicauorns Specifications are the same unless specified otherwise Fastener Size Grade Fi lbs Ni m RING GEAR Single Reduction Bolt Nut TT 22 878 18 8 180 220 244 298 Dual Range amp Doubie Reduction 3 16 18 8 110 130 149 176 DRIVE PINION Nut slotted w rall pin 1 3 4 12 880 1329 IMPORTANT Torque nut rated value than continue tigntening nut te align siot w
148. n installing cap it may be necessary to tap it lightly with a hammer Be sure cap is fully seated and threads are aligned properly If trouble is encountered check for cross threading of bear ing adjuster and carrier threads On teeth side of ring gear install the other adjuster and bearing cap observing same precautions to avoid cross threading 2 Install driv pinion assembly NOTE Make certain lub holes in carrier shims and cage are aligned Install bearing cage cap screws and lockwashers Torque cap screws to 100 125 ft lbs 136 170 3 Install and tighten bearing cap screws finger tight If this is diffi cult use hand wrench NOTE The assembly is now ready for adjustment of differential bearing preload ring gear back lash and gear tooth contact 4x4 6 6 2 31 Differential Carrier Overhaul Adjust Differential Bearing Preload 1 At the teeth side of ring gear position bearing adjuster until its first thread is visible 2 At the back face side of ring gear tighten adjuster until there is no backlash 3 At the teeth side of ring gear tighten adjuster until it contacts the bearing cup Continue tightening adjuster two or three notches This will preload bearings and provide backlash 4 Check Ring Gear Backlash Measure backlash with a dial indicator Specifications are listed below Refer to Adjustment Section for detailed instructions on adjusting backlash Ring Gear Ba
149. n spider Place this assembly in differential case 7 Install idler pins and pinions 10 To install differential assembly place support case and ring gear assembly on a bench or the floor Position case its side Carefully lift and slide differential assembly into case Engage idler pinions with ring gear teeth to complete the installation NOTE During differential installa tion be sure thrust washer stays in its proper mounting position 4 4 6x6 5 Place side gear and thrust washer in position on side pinions 6 Align punch marks and place plain case on case with pins In stall cap screws and torque to 90 110 ft lbs 122 149 N m NOTE Turn side gear hub to check for free differential rotation Rota tion may require up to 50 ft lbs 65 N m 8 Place thrust washer in support case 9 During installation of ring gear temporarily use two balts in mount ing holes to assure bolt hole align ment Place ring gear on support case see photo then remove the two bolts 11 Install thrust washer and small support case over differential assembly 12 Carefully install ring gear bolts making certain flat on bolt head is seated against the outside diameter of the support case Install nuts and torque to 150 170 ft lbs 203 230 NOTE Temporarily install sliding clutch or sun gear and check planetary for free rotation Assemble Drive Pinion NOTE Lubricate p
150. nal Pinion Bearing Preload Test Bp Spring Scale Reading Press fit Outer Pinion Bearings without pinion seal for 15 35 in Ibs torque Nut Torque Press Loads 1 7 4 N m Axle Models Ft Ibs N m Tons Metric Tons Ibs kgs 185 220 840 1139 17 19 15 4 17 2 5 12 2 5 230 260 300 350 980 1329 18 20 16 3 18 5 12 2 5 Torque nut to torque shown above than continue tightening nut t align slot to nearest hole in pinion shank 4 4 3 11 Adjustments Differential Bearing Preload and Ring Gear Backlash Adjustment Correct differential bearing preload insures proper location of these bearings under load and helps position the ring gear for proper gear tooth contact Follow procedures in numerical sequence Adjust Diff Bearing Preload 1 Lubricate differential bearings IMPORTANT When installing bearing caps and adjuster exert care not to cross threads 2 Install adjusters and bearing caps Tighten bearing cap screws finger tight If this is difficult use a hand wrench 4 Tighten the bearing adjuster on the back face side of the ring gear until there is no backlash This can be tested by facing the ring gear teeth and pushing the gear away from the body while gently rocking the gear from side to side There should be no free movement Rotate the ring gear and check for any point where the gear may bind such a point exists loosen and retighten the back si
151. nd 10 Remove side gear and thrust gear thrust washers 11 First try to lift off high speed clutch plate by hand If it cannot be removed easily press off plate as follows a Insert properly sized adapters round metal stock into two idler pin holes and invert the case assembly in a press The clutch plate should be down The adapter length should provide space for removal of the plate Setup for Removing High Speed Clutch Plate 12 Remove bearing cones from support cases using suitable puller see photo NOTE Holes are provided in case to enable removal of bearing cone with a pin punch see photo Tap alternately through each hole until cone is removed WARNING WHEN USING A DRIFT PUNCH OR SIMILAR TOOL WEAR SAFETY GLASSES UN m HOLES PROVIDED TO REM CVE BEARING COPE washer b Use bar stock to block the center nale in the clutch plate and press against it with the press ram c Continue to press until the plate breaks loose from the plate dowel pins Removing Bearing fram Small Support Case using Pullar 2 26 4x4 6 6 Assemble Wheel Differential wt Pre WASH WASHER gige 1 SPIDER CASE PLANTS _ WITH CASE gt FINS SCREW y i P 5 1 i F I PLANETARY DOUBLE ee REDUCTION AXLES Dire DIFE GEAR SUPPORT SUPROAT RING DEAA DIFF DIFF SUN 5 BEARING BEARING SUPPORT CASE CA
152. ned plate on driver Brush plate with lube c one internal splined plate on top of the external splined plate Brush plate with luba d Repeat this procedure unti fourteen 14 friction plates seven external splined and seven internal splined are installed Then install the last external splined plate and pressure plate e Rotate external splined piates as necessary to align the teeth Then grasp the entire assembly by hand see photo and install it in the ring gear NOTE As the assembly is installed maneuver plates with external splines to align them with the ring gear teeth Also make sure the driver engages teeth of the differ ential side gear Install compression springs and case cover Step 6 Assemble and Install Clutch Pack 2 Install Friction Plates Driver Controlled and Seasonal CTD Only NOTE During friction plate internal splines installation align each plate as it is installed in ring gear using the sliding clutch If plates are not in aliqnment it will be difficult to install sliding clutch after clutch pack is assembled Also as each plate is installed brush top of plate with a heavy application of axle lube SAE 90 Proceed as follows a Place one external splined plate in ring gear bore engaging gear internal teeth Brush plate with lube b Place one internal splined plate on top of the external splined plate and brush plate with lube For alignment pu
153. nion ment is complete or if dummy Halicai yoke was used remove nut and Gear and yoke Than continue to assemble Support ARE MOUNTED pinion as follows Searing 1 Install helical gear on pinion Installation positioned as shown in tha illustration 2 Install support bearing spacer 3 Install support bearing using property sized driver and hammer 4 Install slotted nut and tighten according to instructions in torque chart Torque Chart Drive pinion Slotted Nut and Poil Pin Ft ba 1 1 2 18 Bai 1 2 4 12 980 IMPORT ANT Torque nut to torque shown in chart than con tinue tightening nut to align siot with naarast hole in pinion shank Install roll pin Install Pinion Helical Gear Series 230 260 300 350 NOTE After differential adjust mant is complete or if dummy Pinion yoke was used remove nut and Helicai yoke Then continue to assemble Gear and pinion as follaws RACE ARE MOUNTED iM WEA 1 Install helical gear on pinion installation reium COVER using driver and hammer 4 Install pinion outer support bearing using driver and hammar 3 Install slotted nut and tighten ing according to instructions in torque chart Torque Chart Drive pinion Siotted Nut and Pin Ft lba 1 1 2 18 40 1 2 4 12 3aQ IMPORTANT Torque nut to torque shown in chart than con tinue tightening nut to align siot with nearest hole in pinion shank
154. ns 4x4 Drive Shift Systems These instructions include service and maintenance for four variations in 4x4 Drive Shift Systems as shown in the index below Section 8 Contents Page 4x4 DRIVE SHIFT SYSTEMS single Reduction or Double Reduction Axles 2 Single Reduction with Controlled Traction Differentials T uuu 2 Dual Range Axles with Range Interlock 4 Dual Range Rear Axle with Single Reduction PIG VG 9 SHIFT SYSTEM COMPONENTS Air Shifter Valves 15 Standard Lockup Shift Unit 16 Interlock Type Lockup Shift Unit 14 Special Components D 17 Air Shift Unit Dual Range Selection and Controlled Traction Differential 18 4 4 8 1 4x4 Drive Shift Systems Single Heduction Axles with Standard or Controlled Traction Differentials Double Reduction Axles with Standard Differentials STEER DRIVE AXLE are SHIFTER LOCKUF SHIFT UNIT VALV un pressure m a ORIVE d VALVE ENGAGED ANO OPEN LOT Ano SHIFT UNITS TO SYSTEM FOR COMTHOLLEO TRACTION DIFFERENTIAL omy um TANK M RI Aer seb met TUER HEAH AXLE amp TEEH ORIVE AXLE CONTROLLED TRACTION DIFFEREMTILIAL SHIFT UNITS Description and Operation These systems provide salection
155. nt of tightest mesh Adjust Ring Gear Backlash To add backlash Loosen the adjuster on the teeth side of the ring gear several notches Loosen the opposite adjuster one notch Return to adjuster on teeth side of the ring gear and tighten adjuster until it contacts the bearing cup Continue tightening the same ad juster 2 or 3 notches Recheck backlash 4 4 6 6 NOTE Single Reduction Gearing lliustrated 6 Measure backlash with a dial indicator NEW GEARING Backlash should be between 0 006 and 0 016 NEM 3 Loosen the bearing adjuster on the same side as the ring gear teeth until its first thread is visible 5 At teeth side of ring gear tighten adjuster until it contacts the bearing cup Continue tighten ing adjuster two or three notches and this will preload bearings and provide backlash USED GEARING Reset to backlash recorded before disassembly If backlash is incorrect proceed as described below to readjust To remove backlash Loosen the adjuster on the teeth side of the ring gear several notches Tighten the opposite adjuster one notch Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup Continue tightening the same adjuster 2 or 3 notches Recheck backlash Moving adjuster one notch is the movement of the lead edge of one adjuster lug to the lead edge of the next lug past a preselected point NO
156. ntact Paint ring gear teeth and check tooth contact pattern Correct tooth patterns are illustrated below For checking and adjusting procedures see Adjustment Section CORRECT USED Pockel may s gt 2 M 5 FR Pattern along the D gt face width could be longer Could vary in length Pattern should cover 1 9 tooth more face width Pattern should be evenly center between tooth top land and root Pattern should be clear of tooth toe 6 With ring gear and pinion adjusted correctly align adjusters and locks then tighten differential bearing cap screws to correct torque see chart next page Install cotter pin in one adjuster lock Install cap screws in opposite adjuster lock and tighten to correct torque see chart next page Lockwire bearing and adjuster lock cap screws 4 4 6 15 Differential Carrier Overhaul Adjust Differential Bearing Preload cont 7 For planetary double reduction axles on backface side of ring gear install sun gear and retainer then install cap screws that fasten bath retainer and adjuster lock cap screws Tighten screws to correct torque see chart and lockwire all cap screws 8 For dual range axles Position shift fork in carrier opening then install sliding clutch 9 with clutch installed engage shift fork yoke with clutch collar Then install shift fork shaft Install expansion plugs to seal
157. ntial case Install bearing adjusters and caps 3 Install and tighten bearing cap screws finger tight If this is diffi cult use hand wrench NOTE The assembly is now ready for adjustment of differential bearing preload ring gear back lash and gear tooth contact Adjust Differential Bearing Preload 1 At the teeth side of ring gear position bearing adjuster until its first thread is visible 2 At the back face side of ring gear tighten adjuster until there is no backlash 3 At the teeth side of ring gear tighten adjuster until it contacts the bearing cup Continue tightening adjuster two or three notches This will preload bearings and provide backlash 4 Check Ring Gear Backlash Measure backlash with a dial indicator Specifications are listed below Refer to the Adjustment Section for detailed instructions on adjusting backlash Ring Gear Backlash Specifications USED GEARING Reset to backlash recorded before disassembly NEW GEARING Note Check ring gear backlash after each shim change and adjust if necessary to maintain the 006 to 016 specifications 5 Check Ring Gear Tooth Contact Paint ring gear teeth and check tooth contact pattern Correct tooth patterns are illustrated below For checking and adjusting procedures see Adjustment Section 6 With ring gear and pinion adjusted correctly align adjusters and locks then tighten differential bearing cap screws to correct torque
158. of ring gear cut lockwire and remove bearing cap screws If the gear set is to be reused remove bearing cap adjuster and lock as an assembly This will facilitate correct posi tioning of ring gear during reassembly Remove pinion nut see Note under Step 1 Remove bearing and helical gear using puller if necessary NOTE Axle Series 185 and 220 These models use spacer be tween support bearing and helical gear 6 4 4x4 7 Remove bearing cups then lift ring gear and differential assembly out of carrier 9 Remove pinion bearing cage 10 Input Shaft Bearing Cup cap screws and lockwashers Axle Series 185 and 220 If Remove and cage assembly replacement is necessary use from carrier Remove shim pack suitable puller to remove bearing IMPORTANT gear set is tobe EYP from carrier reused keep pinion bearing shim pack intact for use in reas sembly If the original shims can not r used record the number and size of shims in the pack Disassemble Drive Pinion DRIVE PINION BEARING HELICAL SLOTTED SNAP mi NUT DIVIDER COVER Th SPACER SEARING CAGE WASHER CUP CAG COME GEAR SHIM LOCK a PILOT BEARING BEARING BEARING SPACER ASHER SCHEW Vr 11 Used oniy on Acie 230 260 300 350 2 Used oniy on Acie Senes 185 220 1 Support pinion bearing cage in press and press
159. on movement in cylinder Replace a faulty piston dxd 6x6 8 19 Shift Sytem Components Air Shift Unit Overhaul Cont d Assembie Unit NOTE Prior to assembly the piston felt oilers should soaked in SAE 10 oil for hour Lubri cate O rings with a high viscosity silicone oil or barium grease ring lubricant 1 Assemble pin to actuating lever and install this assembly in shift unit housing 2 Assembla O ring and piston to push rod and fasten with flat washer and locknut Tignten nut ta a torque of 120 150 IN LB83S 14 17 Install feit oilers and O ring in piston CAUTION CURING THE FOLLOWING PROCEDURE USING PRESS MAKE CERTAIN COMPONENTS ARE PROPERLY ALIGNED IM PRESS TO PREVENT POSSIBLE PERSONAL INJURY PARTS 3 Insert piston stop and compres sion spring in shift unit housing Place piston and push rod assem bly in housing Position housing assembly in arbor press 4 Apply pressure piston until actuating lever is in alignment with push rod end install clevis pin Release press 5 Place covar gasket in position on shift unit nausing then install cover and bearing assembly and tasten with cap screw and lock washers f necessary use a sealer on threads of cap screws to vent any leaking Tighten screws ta a tarque of 30 110 14 485 10 12 Mem 8 Place 0 ring in groove of shift unit housing then instail housing cover an
160. openings 10 Install shift unit seal and spring Torque Chart Differential Bearing Cap Cap Screw Size Grade Ft Ibs 13 16 10 370 430 Bearing Adjuster Lock and Sun Gear Retainer Cap Screw Size Grade Ft Ibs 5 8 11 5 160 176 5 16 501 583 N m 217 238 SUM GEAR BEARING a Ta Pd n amp I 2 1 e SUN GEAR 9 oc E ul AMNES mM a A NS SS 2 2 acm zw kl Planetary Double Reduction Axle Installing amp hift Fork Shaft SCREW pani ADJUSTER LOS CK Service and Maintenance Instructions Controlled Traction Differentials Section 7 Contents Page No Description and Operation 2 Checking Effectiveness of Controlled Traction Differential 3 CTD OVERHAUL All Types Remove Differential Carrier Assembly from Axle Housing 4 Remove Differential and Clutch Pack from Carrier 4 Medium Duty Remove and Disassemble Clutch Pack 6 Assemble and Install Clutch Pack 8 Heavy Duty Remove and Disassemble Clutch Pack MT 10 Assemble and Install Clutch Pack 12 All Types Install Differential and Clutch Pack Assembly in Carrier 14 Adjust Differential Bearing Preload 15 Install Differential Carrier Assem
161. otation under pinion for best contact under load load The pinion pilot bearing does Correct adjustment distributes not require a preload adjustment torque evenly over gear teeth and Ring Gear Tooth Contact This helps maximize gear set life ad justment positions ring gear and Adjust Pinion Bearing Preload for Axles with Press fit Outer Pinion Bearings Trial Build up 1 Assemble pinion bearing cage bearings and spacer without drive pinion or oil seal Center bearing spacer between two bearing cones NOTE When new gear set or pinion bearings are used select nominal size spacer from the speci fication chart below If original parts are used use spacer removed during disassembly 2 With the bearings well lubri cated place the assembly in the press Position sleeve so that load is applied directly to the back face of the outer bearing cone 3 Apply press load see chart below the assembly and check rolling torque Wrap soft wire around the bearing cage attach spring scale and pull Preload is correct when torque required to ratate the pinion bearing cage is from 10 20 inch pounds This specification is translated into spring scale readings in the chart below 4 If necessary Adjust Pinion Bearing Preload by changing the pinion bearing spacer A thicker spacer will decrease preload thinner spacer will increase preload IMPORTANT Once correct bear ing preload has been established not
162. ough the filler hole provided Lubrication when Hubs Have no Filler Holes Follow procedure in numerical sequence 1 Fill axle with lube through axle housing cover filler hole 2 Jack up left side of axle Maintain this position for oo one minute to allow lube preceding pages to flow into wheel ends at right side 4 With vehicle level again add lube through axle housing cover filler hole The axle should require two additional pints of lube to bring level up to bottom of filler hole Alternate Method If conditions do not permit adding lube to wheel ends pack the wheel bearings with good quality grease before assembly 3 4 4 4 Wheel Hub Lube Cavity d m ii E i Spp tee Fr FI pw P UU wom F LED 3 Jack up right side of axle Maintain this position for one minute to allow lube to flow into wheel ends at left side Cleaning Inspection Replacement As the drive axle is disassembled set all parts aside for thorough cleaning and inspection Careful inspection will help determine whether parts should be reused In many cases the causes of premature wear drive axle failure will also be revealed Cleaning The differential carrier assembly may be steam cleaned while mounted in the housing as long as all openings are tightly plugged Once removed from its housing do not steam clean differential carrier or any compo nen
163. out of bearing cones 10 Remove the kingpin spreading fixture and tighten top cover nuts to correct torque see chart below NOTE At this point of assembly check bearing preload or drag of axle socket movement on the ball pull of approximately 38 to 42 165 should be required to continue not start the socket movement on the ball Add or reduce shims to obtain proper bearing preload operation the socket should not contact or rub the ball at any position between the extreme range of its travel Adjust socket and ball position by exchanging shims between top and bottom covers It is recommended that some shims be left in both upper or lower position No cover should be installed without at least one shim In some in stances it may be necessary to grind a small amount of the socket away to provide necessary clearance and still maintain a minimum of one cover shim 11 With ball adjusted properly apply lubricant in the trough formed on the back side of the socket between socket and ball Remove grease fitting from iower bearing cover and install a pipe plug King Pin Cover Torque Chart Screws 170 220 ft Ibs 231 298 N m Nuls RE 280 350 fr Ibs 80 489 Nm 5362 X Installing Kingpin Top Cover and Steering Arm rm Lubricating Kingpin Bearings Checking Kingpin Bearing Preload 4 4 gi 05265x 053659 X 6x6 1 18
164. paired not proceed t step 7 until proper operation 13 obtained T Place the axie range shifter valve in the High Range position and the All Wheel Drive selector lever in the angaged position Return to the lock out control valve and insure that air fl w is not present at the side port of the valve This is the feature that prevents All Wheel Drive oper tion in High Range If air flow is present the lockout control valva and or axle range shift unit must be inspected nat proceed to Step 8 until proper functioning Occurs NOTE See next page for Step 8 m Last E L LGCLLIUGUS Dual Range Rear Axle with Single Reduction Steer Drive Axle Trouble Shooting conta 8 Check Interlock System Place the axie range shifter valve in the Low Range position This lever must remain in this position for the re mainder ofthe system checks Move the All W heel Drive selector lever to angaged position On axie dual range shifter valve insure that inter lock pin actuates which prevents movement of the range selector laver when in All nee Drive Move the All Wheel Drive selector lever to the disengaged position and check for retraction of the inter lock on the axle range selector valve If interiock pin functions cor rectly system check is complete If not proceed to Step Ba If interlock pin doas not function corre
165. pe plug and install lube fitting Lubricate with lube qun end Lubricate at axle lube then reinstall plug Frequency Lubricate at Axle Lube Change change intervals Slack Adjuster Lubricate with lube gun at fitting mounted on slack adjuster Lubricate at Axle Lube Change 1 6 4 4 6x6 Steering and Wheel End Equipment Overhaul o The following instructions cover wheel end equipment for both sides of the axle Instructions are the same for left hand and right hand wheel ends except where specified otherwise Left hand and right hand are determined by facing the differential carrier side of the axle Section 1 Contents Page No DISASSEMBLY Remove Wheels and Tires Drain Lubricant 9 Hemove Wheel Hub and Brake Drum 9 Remove Brake Shoes and Inspect Linings 10 Brake Reline Lining Selection 11 Remove Brake Chamber 12 Remove Slack Adjuster 12 Remove Camshaft 12 Remove Spindle and Brake Spider _ Remove Inspect and Disassemble Axle Shaft 13 Remove and Disassemble Axle Ball and Socket 14 Inspect Axle Ball Socket and Related Parts 16 ASSEMBLY Assemble Ball Socket 17 Assemble Axle Ball eevee Install Axle Ball on Axle Fausing ERE 17 Assemble Socket to Axle Ball 18 Install Axle Ball Seal and Reta
166. pin is inclined toward the front or rear of the truck as viewed from the side of the truck The caster angle can range from a positive angle to negative angle Positive caster is the tilting of the top of the kingpin toward the rear of the truck while negative or reverse Caster is the tilting of the top of the kingpin toward the front of the truck Positive caster imparts a trailing action to the front wheels while a negative or reverse caster causes a leading action The correct amount of caster helps to Keep the wheels in the straight ahead position When turning a curve caster acts as lever assisting the driver to return the wheels to the straight ahead position Caster specifications are established and adjusted in all new trucks However variations in spring equipment type of service tire or wheel size or even wheel base may make a slight change in caster angle desirable to provide the best possible steering stability The caster angle must be equal at both wheels Adjust Toe in Toe in should be set at 0 to amp The front of the wheels should be the same distance apart or ta closer than the rear of the wheels Change adjustment by turning tie rod to change its length Adjustment can be checked as follows Scribe line at center of each tire tread completely around the tire line must begin and end at the same point This can be done by rotating wheel while holding chalk against tire tread
167. pinion out of bearing cage and outer bearing cona _ 2 Remove spacer and spacer washar from pinion Spacer washer is used only on Axle series 230 260 300 350 4 f raplacement is necessary remove bearing cups from bearing cage using suitable pullers 3 Ramove pilot bearing and inner bearing cone from pinion using split type puiler Use two procedure steps to remove each bearing see photos above First mount puller vertically to split Second mount puller horizontally the bearing to remove bearing 4 4 6 5 Differential Carrier Overhaul Disassemble Wheel Differential Hear Axle Wheel Differential Ilustrated THRUST _ pe SIDE THALIET pus GEAR WASHER MASHER SIDE So OBR 1 owe CX ANTH Dues m ir a S s CASE P Dea ot a CaP SCREW 4 ve SIDE No da mcs d 3 h zo PERO 15 i 3 F TUA My PR E EX E PLANETARY COUBLE REDLICTION mns GEA DIFF Zt ii SUM GEAR RE ARIES BEARING IJEF CR CASE GEAR BE APIRES RESAMIG RETAINER ADJUSTER DASE ThRLIST TRIALS CASE COONE AD RISTER 1 l LARGE WASHER WA SE SMALL L L EN i ql zie s
168. plined mounted on the friction plate driver NOTE Early model CTDs use 25 plates 12 splined 13 tanged Late models use 21 plates 10 splined 11 tanged Assemble and Install Clutch Pack Heavy duty 6 Place last tanged friction plate and pressure plate over friction plate driver Then using a press and suitable adapters compress DRIVER clutch pack and install round snap ring in groove of friction plate driver T If removed press bearing cone on gear support case cover in Press COMPRESSION ALIGNMENT SPRINGS ALIGNMENT BOLT PRESSURE PLATE Positioning Compression Springs on Pressure Plate B Place compression springs in smallest possible circle on pressure plate Place gear support case cover over springs and temporarily install two alignment bolts Reach through hole in gear support case cover and move compression springs radially outward as far as they will go E ALIGNMENT GEAR SUPPORT CASE Compressing Clutch Pack PRESS Pressure SMAP RING PRESS ALIGNM ENT BOLT Compressing Springs to Assemble Ring Gear Case and Cover 9 Compress springs until gear case cover bottoms against gear support case With press pressure still applied install ring gear bolts all bolt heads on ring gear side and locknuts Remove assembly from press then tighten locknuts to correct torque 110 130 ft
169. position that was used in Trial Build up Preload Test Sy d E 6 Install bearing cage on drive pinion B Pinion Helical Gear and Mut These parts are installed during pinion installation see page 6 12 and 6 13 4 Press inner bearing cone on pinion IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bear ing cona 7 Press outer bearing cone on pinion IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cona IMPORTANT At this stage af assembly final check pinion bearing preload See Adjustment Section of this manual 4x4 6 11 Differential Carrier Overhaul Install Drive Pinion 1 Place shim pack on carrier NOTE If gear set is to be reused install same quantity and size of shims removed during disas sembly When installing a new gear sel use nominal shim pack indicated below Nominal Shim Pack in mm 0 024 0 610 2 Install drive pinion assembly Install bearing cage cap screws and lockwashers Torque cap scraws t 155 175 ft Ibs 210 237 Nem 3 Input Shaft Bearing Cup only on Axle Series 185 and 220 lf removed install bearing cup in Carrier NOTE At this phase of reassem bly use a dummy yoke if avail able in place of helical gear This will result in easier disassembly and reassembly during carrier adjustments If dummy yoke is not ava
170. put rear bearing cup 8 Remove snap ring securing 9 Remove front output shart from power divider using suitable pinion outer support bearing race bearing cup from power divider puiler WARNING SNAP RING IS cover using suitable puller SPRING STEEL AND MAY POP OUT WEAR SAFETY GLASSES WHEN REMOVING Remove pinion outer support bear ing race using suitable puller Torque Chart Input Shaft Nut Ft bs N m 1 7 8 12 840 1202 1129 1383 Input Shaft Bearing Cover Cap Screws 1 2 13 75 85 101 115 Grade 5 Power Divider Cover Cap Screws 8 16 12 110 125 148 170 Grade 5 4 5 4x4 Assemble Power Divider Cover and Input Shaft then Install Cover and Shaft Assembly on Differential Carrier 230 260 300 350 Axia Sarias 1 removed press front output shaft rear bearing cup in power divider cover 4 IMPORTANT Assembia and install input shaft in power divider cover before cover is installed on carrier Steps 3 through 7 NOTE Install front output shaft and adjust end play after power divider cover is installed on carrier A blind cap screw fastens power divider cover and it is only acces sible through output shaft opening sem page 4 9 IMPORTANT During pressing operation when installing input shaft Step 7 support power divider cover at rear bearing web to prevent possible damage to web T To install input shaft place rear bearing cone in cup mounted in power divider Place
171. r 3 Remove oil seal and bearing ing yoke removal procedure the ing cone support cage and press cone from cage Discard seal drive pinion may fall out of bear pinion out of bearing cage and Remove bearing cups with suitable ings and cage Do not allow pinion bearing cone puller to drop on hard surface 1 Remove yoke If pinion nut was not loosened during earlier disas sembly clamp assembly in vise jaws use brass pads to prevent damage Loosen and remove pinion nut Hemove yoke from pinion 5 Remove pilot bearing and inner bearing cone from pinion using a split type puller Use two procedure steps to remove each bearing see photos above 4 Remove and retain bearing spacer from pinion First mount puller vertically to split Second mount puller horizontally bearing to remove bearing 2 24 4x4 6x6 Disassemble Wheel Differential Hear Axle Wheel Differential iiustrated RE THRL ST THAL T m DIFF ULT Sn e iA Sa n E CASE ii SIDE ASA a SPIDER 20 e GEAR Ep 7 CASE c he fal CREW x ME yx if i i 7 Z 48 C S pl P auis LM E ua pebuct EDLICTIODIR AXLES nFF DIFF GEAR SUPPORT SUPPORT RING GEAR DIFF DIFF FUN GE AR BEARING BEARING SUPPORT CASE CA
172. r compo the piston travels downward against nents Mounting configuration may compression spring transferring change with axle applications mation through a push rod and The unit consists of an air chamber 8 18 4x4 6x6 Shift Sytem Components Air Shift Unit Heplacement Remove Unit Disconnect air line at shift unit cover Remove nuts flat washers and piston air shift unit from differ ential carrier NOTE When shift unit is removed Bpravide container to catch oi that escapes from reservoir Famove shift fork seal and spring Install Unit 1 Lubricate shift fork Slide seal and spring assembly over fork and seal on differentiai carrier studs Shift axle into Low Range 2 Place shift unit on mounting studs and make certain shitt fork actuating lever engages siot in shift fork install flat washers and stud nuts Tighten nuts to 55 81 ft lbs 74 82 3 When axie is installed in veni cla fill shift unit housing to level at filler plug with SAE 10 or automatic transmission fluid see Lubrication on following page Coat threads of filler plug with sealer and install plug 4 Connect air lines to shift unit cover Air Shift Unit Overhaul Disassemble Unit TN 1 Remove cap screws lock washers cover and gasket from nousing Drain lubricant 2 Remove bolts locknuts cover at piston end of housing Remove 07 ring CAUTION DURING THE FOLLOWING PROCEDUR
173. r less replace the clutch pack Check bias torque values as follows a Disconnect drive shaft at drive pinion b Block one wheel or otherwise restrain vehicle Jack up other wheel free of the ground t WARNING USE JACK STAND AS ADDITIONAL SUPPORT OF VEHICLE TO PREVENT PER SONAL INJURY OR VEHICLE DAMAGE d Using a torque wrench rotate pinion and note torque reading e Formula Torque times axle ratio equals bias differential torque 4x4 6 6 7 3 Overhaul Remove Differential Carrier Assembly from Axle Housing IMPORTANT Detailed procedures for each type capacity or imodel axle may vary For specific service instructions on your axle refer to the appropriate Spicer service manual The following instructions are applicable to axles equipped with Controlled Traction Differentials 1 Driver Controlled Remove shift unit nuts and flat washers Dis connect air line to permit removal of shift unit Place sliding clutch in the engaged position Sliding clutch must be engaged to allow removal af carrier from housing 2 Seasonal CTD Remove nuts and washers from shift fork cover retainer then remove cover retainer Place sliding clutch in the engaged position Sliding clutch must be engaged to allow removal of carrier from housing 3 Permanent This type is always engaged No procedure i5 necessary 4 All Types CTD Drain lubricant Disconnect dr
174. r positioned at yoke end of output shaft If end play is not correct adjust as follows 2 Remove Front Output Shaft Assembly Remove two shift unit cap screws and lockwashers Remove four output cover cap screws and lockwashers Then remove output shaft assembly shaft cover gear yoke and shift unit from power divider cover Remove shim pack 3 To increase end play add shims Example Desired end play eras sa s 0 003 Measured end play Step D Pr 0 001 0 001 Add shims to provide desired end play 0 002 to 0 006 4 To decrease end play remove shims Example Measured end play 0 015 0 015 Desired end play 5 0 003 to 0 007 Remove shims to provide desired end play 0 012 ta 0 008 5 Adjust shim pack size as necessary Reassemble adjusted shim pack and output shaft assembly to power divider cover Install only the four output cover cap screws and lockwashers to recheck end play Torque cap screws see chart 6 Recheck shaft end play If end play is incorrect remove shaft assembly and readjust shim pack Steps 2 thru 5 When end play is correct proceed to Step 7 T Final Shaft Assembly after End Play Is Correct IMPORTANT Removing and installing output shaft as an assembly during adjustment procedure could possibly damage seal When tnis procedure is used it is recommended that a new oil seal be installed 8 Af
175. r set is to be reused keep pinion bearing cage shim pack intact for use in reassembly If the original shims cannot be reused record the number and size of shims in the pack 3 Cut lockwire Remove cap screws flat washers and bearing 2 14 4x4 6x6 Disassemble Drive Pinion PINION SEARING BEARING BEARING BEARING BEARING OIL SEAL INPUT PILOT CONE SPACER CAGE CUP amp RETAINER YOKE OUTER nmm BEARING INNER VARIABLE FLAT WASHER Vl _ d m J 3 p i i 1 1 L A UO Qs ea BD QJ LU WO LO Cia O i CAGE N BEARING CAP BEARING BIEN DRIVE CUP GL SCREV CONE dli PINION INNER SCREW OUTER fad IMPORTANT During the follow ing yoke removal procedure the drive pinion may fall out of bear ings and cage Do not allow pinion to drop on hard surface 1 Remove yoke If pinion nut was not loosened during earlier disas sembly clamp assembly in vise jaws use brass pads to prevent damage Loosen and remove pinion nut Remove yoke from pinion 2 4 Remove and retain bearing spacer from pinian 5 ing cone support cage and press pinton out of bearing cage and bearing cone First mount puller vertically fo spit LOC KWASHEH For pinion with press fit bear 3 Remove oil seal and bearing cone from Discard oil seal Hemove bearing cups with suitable pull
176. rade 110 125 148 170 Output Shaft Nut Fit lIbs 1 1 2 18 580 700 759 949 Silicone Gasket Compound Pattern Lockup Shift Unit 4 4 3 9 Adjustments Adjust Pinion Bearing Preload for Axles with Press fit Outer Pinion Bearings Trial Build up 1 Assemble pinion bearing cage bearings spacer and spacer washer without drive pinion or oil seal Center bearing spacer and spacer washer between two bearing cones NOTE When new gear set or pinion bearings are used select nominal size spacer from the speci fication chart below If original parts are used use spacer removed during disassembly 2 With the bearings well lubri cated place the assembly in the press Position sleeve so that load is applied directly to the back face of the outer bearing cone 3 Apply press load see chart below to the assembly and check ralling torque Wrap soft wire around the bearing cage attach spring scale and pull Preload is correct when torque required to rotate the pinion bearing cage is from 10 20 inch pounds This specification is translated into spring scale readings in the chart below 4 If necessary Adjust Pinion Bearing Preload by changing the pinion bearing spacer A thicker spacer will decrease preload thinner spacer will increase preload IMPORTANT Once correct bear ing preload has been established Assembie these Parts for Trial Build up INNER INNER GEARING BEARING BEA
177. rivets or Bolts d Lining is oll soaked or contaminated with other foreign material MOTE Replace brake springs with a brake reline 1 10 4 4 6x6 ROLLER AND PIN STURDY Prying Down Brake Shoe to Remove Cam Roller and Pin SHOE M PETA SPRING UPPER SHOE LIPPER PEN SHOE f a Lg 1 ai Slr LOWER ta rem _ SHOE RETAINER SPRING Removing Brake Shoes Brakes Left hand Illustrated SLACK ADJLISTER GUARD LUBE LOCKWASHER FITTING COTTER SCREW SHOE CAP SCREW PIN nA ER ASSEMBLY LOCKWASHER Ur 9 BRAKE QU CHAMBER 73 CLEVIS FLAT WASHER 5 ilis 20 BRACKET SNAP 2 I4 RING SHIMS WASHER OIL SEAL BUSHING BALL SOCKET 2 ANCHOR SNAP RING Brake Reline iLining Selection When wheel and brake camshaft rotation is in the CAMSHAFT ROTATION OPPOSITE WHEEL ROTATION same direction linings for the leading and trailing Brake chamber mountad toward front of axle shoes are the same When wheel and brake cam WHEEL WHEEL shaft rotation is in opposite directions linings will ROTATION ROTATION LEADING vary LEADING CCW Cw SHOE SHOE CAMSHAFT CAMSHAFT amp LINING LINING ROTATION ROTATION 556 gt a Cw COW LEFT SIDE RIGHT SIDE WHEEL CAMSHAFT WHEEL CAMSHAFT CCW
178. rocedure use a dummy yoke if available in place of helical gear 2 Apply clamp load to the pinion bearing cage assembly Either install the yoke or helical gear and torque the pinion nut to specifications or use press to simulate nut torque see chart below Vise Method If the yoke and nut are used mount the assembly in vise clamping yoke firmly Press Method press is used position a sleeve or spacer so that load is applied directly to the back face of the outer bearing cone 3 Measure Pinion Bearing Preload Use a spring scale to test the assembly rolling torque To use the spring scale wrap soft wire around D 44 9 the bearing cage attach the scale and pull Preload is correct when Hu torque required to rotate the pinion bearing cage is from 15 to 35 inch Measuring Bearing Preload with rudi Md specification is translated into spring scale readings in the Pinion in Vise chart below 4 Adjust Pinion Bearing Preload If necessary adjust pinion bearing preload Disassemble the pinion bearing cage as recommended in this manual and change the pinion bearing spacer A thicker spacer will decrease preload thinner spacer will increase preload IMPORTANT Use the correctly sized spacer Do not use shim stock or gnnd spacers These practices can lead to loss of bearing preload and gear or bearing failure Measuring Bearing Preload with Pinion Press Specifications for Fi
179. rol valve until the valve air delivery port is aligned with the lockout cylinder air inlet port MOTE Do not unscrew valve more than 360 Lock the valve in place with locknut Torque locknut to 35 IN LBS 3 9 N m Shift Linit Silicone Gasket 4x4 Axla Series 230 280 300 350 6x6 Axle Series D466 P 4865 P 586 P 856 Special Components for Shift Systems with Dual Hange Axles speedometer Adapter The speedometer adapters are lubricated and sealed for life of the unit No maintenance is required Replace a faulty unit Lockout Control Valve Solenoid Valve PU QM Replace solenoid valve as an assembly The valve should not be serviced Quick Release Valve If quick reiease pnm valve fails to operate arly 1 may be GENE repaired 35 follows Dis i AN assemble valve ingpect valve body valve sea g and spring i used for vi dence of faulty operation Replace faulty parts hen reassemble valve Pressure Switch 4 Replace pressure mw Cc switch as an assembly s For 4x4 Systam with Dual Range Raar Axia and Singla Reduction Stear Oriva Axia and 6x6 System with Dual Range Tandem Singla Raduction Stear Driva Axia If lockout control valve fails to Operate properly unscrew cap nut and remove internal parts Inspect plunger and valve parts for avi dence of faulty operation Replace faulty valve assembly Lockout Contro V
180. rposes temporarily insert sliding clutch to engage side gear and plate splines Remove clutch c Repeat this procedure until fourteen 14 friction plates seven internal splined and seven externai splined are installed d Install the last external splined plate and the pressure plate And again insert sliding clutch to make sure internal splined plates are in alignment Install springs and case cover see Step 6 CLUTCH PLATE Installing External Splined Friction Plate 6 Install Compression Springs and Cover All Types CTD POSITION SPRINGS ON SMALLEST CIRCLE LE a Install springs on pressure plate positioning them in the smallest circle possible see photo CLAMPING NUTS amp BOLTS w M TH po La SLIDING CLUTCH Aligning Internal Splined Friction Plate with Sliding Clutch 1 b Place support case cover over springs and install two z alignment bolts heads up c Temporarilv install two clamping nuts and bolts nuts up Remove alignment bolts Alternately tighten clamping nuts until cover is in mounting position on ring gear d Install bolts and self locking nuts that fasten cover to ring gear Remove the temporarily installed clamping nuts and bolts and install the remaining cover bolts and self locking nuts Torque nuts to 110 130 ft Ibs 149 176 N m CLAMPING BOLT
181. s Camber Caster General Inspection Proper wheel alignment promotes longer tire wear ease of handling and minimizes strain on front suspension and axle components Do not check and adjust front wheel alignment without first making the following inspection for front end maladjustments damage or wear 1 Check the air pressure in all the tires Make sure that the pres sures agree with those specified for the tires and vehicle model being checked 2 Raise the front of the vehicle off the floor Grasp each front tire at the front and rear and push the wheel inward and outward If any free play is noticed between the brake drum and the brake back ing plate adjust the wheel bearings Replace the bearings if they are worn or damaged Adjust and or replace worn or damaged bearings Check brakes for dragging and wheels for proper balance Check all steering linkage for wear or maladjustment Adjust and or replace worn parts 5 Check the steering gear mounting bolts and torque them wherever required Check the front spring clips U bolts and the spring tie bolt and tighten them if necessary 6 Spin each front wheel with a wheel spinner and check and bal ance each wheel as required 7 Rotate each front wheel slowly and observe the amount of lateral or side runout If the wheel run out exceeds 1 8 inch replace the wheel or install the wheel on the rear Kingpin Check kingpin bearing nut tightness after first 1000
182. s carrier bore then install bearing to avoid cross threading cup as shown in photo Also install bearing cup on opposite side of differential 7 14 4x4 6x6 Adjust Differential Bearing Preload 1 At the teeth side of ring gear position bearing adjuster until its first thread is visible 2 At the back face side of ring gear tighten adjuster until there is no backlash 3 At the teeth side of ring gear tighten adjuster until it contacts the bearing cup Continue tightening adjuster two or three notches This will preload bearings and provide backlash 4 Check Ring Gear Backlash Measure backlash with a dial indicator Specifications are listed below Ring Gear Backlash Specifications USED GEARING Reset to backlash recorded before disassembly NEW GEARING Backlash should be as follows Axles with 16 1 2 or smaller ring gear diameter 0 006 to 0 016 Axles with 18 ring gears 0 008 to 0 018 5 Check Ring Gear Tooth Contact Paint ring gear teeth and check tooth contact pattern Correct tooth patterns are illustrated below NOTE For detailed instructions on checking and adjusting procedures refer to the appropriate Spicer Service Manual covering your specific axle CORRECT PATTERN USED GEARING Could vary in length Pocket may be Pattern should cover T i 7 3 KU MI extended Ea i 2 1 2 tooth or mare p
183. s and thrust washers Puller Mounted Vertically to Split Gearing FLANGED BEARING DIFF CASE CONE BEARING HALF ADJUSTER 4 RING BEARING GEAR CUP ALT 5 Remove side gear and thrust Washer Removing Bearing Cane from Flanged Case Assemble Wheel Differential NOTE Lubricate differential parts with gear lube during assembly 1 Press bearing cone on flanged differential case 4 Assemble side pinion and thrust washers on spider Place this assembly in flanged differen tial case Rotate gears and check for proper mesh 7 Install ring gear Secure with bolts and nuts and tighten to correct torque see chart 2 Press bearing cone on plain differential case 5 side gear and thrust washer on side pinions NOTE Fasteners using self locking nylon patches may be reused if not damaged but should be secured by a few drops of Loctite 277 on threaded surface af differential case during follow ing assembly procedures 3 Place thrust washer and side gear in flanged differential case pm T hn LN e Align punch marks and install plain case half Install cap screws and tighten to correct torque see chart Check differential for free rotation by turning side gear hub Differ ential may require up to 50 ft lbs BB N m torque to rotate Torque Chart Ring Gear BOLT NUT
184. s instruc tions for correct procedures Regardless of make ar type of equipment used the checking and adjusting operations should be done in the sequence outlined above NOTE When checking wheel alignment make sure the truck is placed on a level floor Camber Camber Angle Camber is the amount in degrees that the wheel inclines away from the vertical at the top as viewed from the front of the truck HORIZONTAL LINE CAMBER 1 INCLINATION 07 1 IE Positive camber is an outward tilt or inclination of the wheel at the top Negative or reverse camber is an inward tilt of the wheel at the top The amount of camber used depends on the amount in degrees the wheel end is inclined An incorrect camber angle causes the side of the thread to wear resulting in abnormal tire wear Unequal camber in the front wheels will cause the truck to lead to the right ar left The truck will lead to the side which has the most positive camber Norma camber angle is gt degree Camber is nonadjustable and is only changed if the axle ball assembly or axle housing becomes bent 1 4 4x4 6 6 HUB CL 1 p i D 1 1 1 im j ha TIRE Camber Angle Should Be 187 Left Hand Wheel Viewing Rear of Axle Caster Angle Caster is the amount in degrees the top of the king
185. see chart page 3 15 4 Install axle shafts and stud 5 Connect front output shaft 6 Connect input shaft driveline nuts If used also install lock driveline to steer drive axle washers and taper dowels T Fill axle with correct lube 8 Connect lockup shift unit air 9 Dual Range Axle Install shift see Lubrication Section lines unit nuts and lockwashers Tighten to correct torque see chart page 3 15 Connect air line 10 Axle with Controlled Traction Differential used install shift unit nuts and lockwashers Torque nuts see chart page 3 15 Connect air line IMPORTANT When axle has been disassembled or housing gears axle shafts or wheel equipment replaced check axle assembly for proper differential action before operating vehicle Wheels must rotate freely and independently 3 16 4x4 Power Divider Overhaul for 4x4 Rear Axles Power Divider Overhaul These instructions cover all 4x4 rear axle power dividers It is assumed that the differential assembly has been removed from the axle housing Section 4 Contents Page No POWER DIVIDER OVERHAUL Transfer Gearing Description 2 Remove Power Divider from Differential Carrier 2 ALL MODELS Disassemble Front Output Shaft 3 Assemble Front Output Shaft 3 185 220 AXLE SERIES Disassemble Power Divider Cover 4 Install Input Shaft and Power Div
186. so be considered when ever changes in vehicle location or primary operating area are made and the grade of lube changed if necessary Lube Change Intervals Initial Change The lube in a new or rebuilt axle should be changed within the first 5000 miles of opera tion This will remove fine particles of wear material generated during Dreak in and prevent accelerated wear on gears and bearings Subsequent Changes Subse quent lube changes should be made at 100 000 mile intervals for Class or AA highway operation Checking Lube Level Remove the filler hole plug located in the axle housing cover Lube should be level with the bottam of this hole IMPORTANT Lube level close enough to the hole to be seen or touched is not sufficient It must be level with the hole NOTE When checking lube level also check and clean housing breathers 3 2 4x4 Ambient Temperature Range 15 F to 100 F 26 C to 38 40 F to 15 F 40 C to 26 C Department review This is essen tial to ensure proper seal life and axle performance with a particular synthetic For additional informa tion contact Spicer Field Service Department or call Regional Office See back cover for address and phone numbers Oil Additives The use of oil additives is not approved for use in Spicer axles 15 F and above 26 C and above 10 F and above 12 C and above Class A op
187. ss Loads Ft Ibs Tons ESD 18 Steer Drive Axle Differential Carrier 560 700 759 949 13 5 15 5 12 2 14 0 EL Measuring Gearing Prefoad with Pinion in Visa Measuring Bearing Preload with Pinion in Press Spring Scale Reading without pinion seal for 15 35 in Ibs torque 1 7 4 N m Metric Tons dxd 6x6 2 7 Adjustments Differential Bearing Preload and Ring Gear 1 1 1 1 1 Backlash Adjustment Correct differential bearing preload insures proper location of these bearings under load and helps position the ring gear for proper gear tooth contact Follow procedures in numerical sequence a a ss a rr eT 2 8 Adjust Diff Bearing Preload 1 Lubricate differential bearings IMPORTANT When installing bearing caps and adjuster exert care not to cross threads 2 Install adjusters and bearing caps Tighten bearing cap screws finger tight If this is difficult use a hand wrench 4 Tighten the bearing adjuster on the back face side of the ring gear until there is no backlash This can be tested by facing the ring gear teeth and pushing the gear away from the body while gently rocking the gear from side to side There should be no free movement Rotate the ring gear and check for any point where the gear may bind If such a point exists loosen and retighten the back side adjuster Make all further adjustments from the poi
188. ssemble output cover remove oil seal and bearing cup using suitable pullers 4 To disassemble output shatt place assembly in press helical gear up Press inner bearing cone and gear off snaft Assemble Front Output Shaft 1 Mount output shaft in press yoke splines down Install helical gear on shaft with clutch teeth down facing yoke splines 4 Press outer large bearing cone on shaft IMPORTANT To prevant bearing damage be careful to use sieeve that oniy contacts inner race of bearing cone Front Output Shaft SEARING OUTPUT SHEET FOAM BEAMING m SEARING Sieg CUP CLUTCH SHE A ELS C3 EAR CONE 11 Used on 185 220 Series 5 Remove outer bearing cone using split type puller Remove sliding clutch 2 Press inner small bearing cone on output shaft IMPORTANT To prevent bearing damage be careful to use sleeve that only contacts inner race of bearing cona After bearing cone installation helical gear should rotate freely 5 185 220 Axle Series only install bearing spacer washer on spline end of output shaft 6 if replacement remove inner bearing cup from power divider cover using suitable puller 3 Reverse position of output shatt in press yoke splines up Place sliding clutch on shaft splines with clutch teeth facing helical gear 5 To assembie bearing cover
189. ssembly be replaced d 05364X _ Measuring Trunnions and Mounting Holes Remove and Disassemble Axle Ball and Socket 1 Disconnect tie rod ends or remove tie rod assembly as follows Right Hand Wheel End Hemove cotter pin nut and fiat washer from ball stud at ball socket Discon nect the tie rod end With rod end disconnected the tapered coil spring seal cover rubber seal washer and flat washer can be removed from the ball stud Left Hand Wheel End Disconnect end using same procedures as described above for right hand wheel end Also disconnect steering drag link from ball stud mounted in steering arm at top of ball socket 2 As the ball socket is disassembled identify socket and related parts location to insure that these parts will be returned to their original positions 3 Remove ball seal retainer cap screws and lock washers then carefully pry retainer and seal from its mounting see photo 1 14 4x4 6 6 Disassembl V 4 Remove kingpin covers as follows Left Hand Wheel End Remove nuts lockwashers and dowels tapered split type from steering arm and top cover see photo Remove cap screws and lockwashers from bottom cover Remove covers and shims Identify shims removed Right Hand Wheel End Remove nuts and lock washers from top kingpin bearing cover and cap screws and lockwashers from bottom cover Remove covers and shims Identify shims removed
190. t bearing using driver and hammer 3 Install slotted nut and tighten ing according to instructions in torque chart Pinion Halical Gear and Torque Chart Drive pinion Slotted Nut and Roll Pin Ft ba 1 1 2 18 8 0 1 3 4 12 380 IMPORT ANT Torque nut to torque shown in chart then con tinue tightening nut to align siot with nearest hole in pinion shank Install roll pin 4x4 96 13 5 14 Differential Carrier Overhaul Install Differential Assembly in Carrier i im ae F DIFFEFREHTIAL CASE CARRIEFI HEARING Cae AE Aeon CAP T T PEDESTAL 1 Lubricate bearings during the following assembly procedure Place ring gear and differential assembly in carrier Insure that ring gear and drive pinion mesh properly During installation tilt carrier to allow Support case pilot to rest in carrier bore then install bearing cup as shown in photo Also install bearing on opposite side of differential Et 1 4 At tha teeth side of ring gear position bearing adjuster until its first thread is visible At the back side of ring gear tighten adjuster unti there is no backlash 4x4 LEFT 2 f the same gear set is used install the assembled bearing cap adjuster and lock on the backface side of the ring gear Otherwise install adjuster and cap separately NOTE When installing cap it may necessary to tap it lightly with
191. t is to be reused check tooth contact pattern and ring gear backlash before beginning disassembly Best overhaul results ar obtained when used gearing is adjusted to run in established wear patterns Omit this step if the gear set is to be replaced When reusing the gear set remove the left hand bearing cap adjuster and lock as a unit This will help return the gear set to its original adjustment during reassembly 1 Mount the differential carrier In a repair stand NOTE For easier disassembly remove pinion nut roll pin Loosen but do not remove pinion nut 3 Dual Range Axles Only Dis engage shift fork yoke from sliding collar Then remove clutch and shift fork Planetary Double Reduction Axles sun gear is used in place af sliding clutch gear To remove Sun gear remove cap screws and the retainer which holds gear in position then remove sun gear 4 If reusing gear set punch mark bearing adjusters for reference during assembly 2 Dual Range Axles Only Remove shift fork seal and spring Remove expansion plugs then working at the lower or small plug hole drive out the shift fork shaft WARNING WHEN USING DRIFT PUNCH OR SIMILAR TOOL WEAR SAFETY GLASSES 5 On teeth side af ring gear cut lockwire and remove bearing cap screws Remove cap adjuster and lock 4x4 6 3 Differential Carrier Overhaul Disassemble Differential Carrier conta 6 On back side
192. ter shaft end play is correctly adjusted remove the four cover cap screws and lockwashers Remove output shaft cover and yoke assembly Coat mounting surfaces of both output and power divider covers with sealant to prevent lube leakage 9 Assemble shim pack and output shaft assembly to power divider cover Install four cap screws and lockwashers fastening output cover but do not tighten cap screws completely Front Output Shaft LOCKUP SHIFT FRONT BEARING OUTPUT SHIFT FORK BEARING BEARING CONE SHAFT amp PUSH AOD COVER LOCAW ASHER oi SCREW aL ipic BEARING 3 OL CLUTCH SPACER SEAL SEARING CONE SCREW LOCEKWATSHER BEARING Cus HELICAL YOKE FLAT GEAR WASH Used only an 185 220 Series 10 Before installing shift unit cap screws apply silicone gasket compound to the mounting sur face of the output cover see illus tration If difficulty is experienced remove shift unit see Shift Sys tem Section 8 With compound applied install shift unit cap screws Torque output cover and shift unit cap screws see chart To prevent possible lube leakage coat outer edge of shim pack with sealant 11 At this point in reassembly remove yoke and replace oil seal Reinstall yoke flat washer and nut Torque nut see chart Torque Chart Front Output Shaft Cover Ft Ibs 48 56 N m 65 T6 Cap Screw 7 16 14 Grade 81 8 16 12 four G
193. th screws and lock emet ishers Torque screws to illustration Before installing piston 3 torque sc place piston stop at base of lockout 98 108 IN LBS 11 12 N m body Shift Unit Silicone G asket 4 4 Axle Series 230 260 300 350 6x6 Axia Serres 0346 386 P Axle Series O466 P 486 P 586 P 856 4x4 6x6 8 15 Shift Sytem Components Shift Units for Interlock Type Inter axie Differential Lockout and Steer Drive Axle Lockup Dual Range Rear Axlas and Staar Driva Axles or Dual Range Raar Axias with Sing a Reduction Steer Drive Axiasi 8 16 Disassembie Cylinder 1 He mova cap screws lockwash ars covar assembly and OQ ring 2 Remove hex nut piston and rings 3 Remove body cap screws and lockwashers then remove body and niston an assembly Assemble Cylinder 1 Appiy gasket compound to mounting surface on power divider cover 2 Install lockout body Secure with cap screws and lockwashers Torque cap screws to 48 56 ft los 65 76 NOTE Before installation soak piston felt oilers in SAE 30 engine oil and lubricate rings with a high viscosity silicone oil or barium grease ring lubricant 3 Install feit oilers and ring on piston Shift Units with Platon Stop See illustration Before installing piston place piston stop at base of lockout body 4 install co
194. the axle shafts must be disengaged from the differential side gears This can be accomplished by removing the wheel end parts 4 PULL WHEEL END and the axle shaft Refer to Wheel End Overhaul Instructions DISENGAGE SIDE GEAR Or if equipment is available the axle shafts can be disengaged by separating the wheel end assem bly from the axle housing see 1 Drain axle tube E CAP SCREWS 2 separate wheel end assem bly from axle housing remove cap screws and nuts fastening socket ball flange to the hausing Provide equipment to handle the wheel end assembly Then dis connect air brake lines and steer gt ing connections necessary to permit moving the wheel end assembly outwardly until the axle AND STEERING shaft is disengaged from the dif CONNECTIONS 1 SUPPORT ferential side gear Disengage THE WHEEL axle shaft on both sides of axle 3 Dual Range Axles Shift to _ Axle Low Range Disconnect shift Separating or removing Wheel End Assembly to Disengage unit air line Remove shift unit Axle Splines Side Gear NOTE When shift unit is removed provide container to catch oil that escapes from reservoir 4 Axles with Controlled Traction 5 Disconnect drive shaft Loosen 6 Remove differential carrier Differentials but do notremove drive pinion nut assembly Driver Controlled Engagement WARNING DO NOT LIE UNDER
195. ting differential action The Medium duty CTD clutch pack includes internal splined and external splined plates The external splined plates engaged with internal teeth of the ring gear drive the axle shafts through the internal splined plates thereby limiting differential action In operation the clutch pack resists spin out and directs torque to the wheel with better traction Operating Types The CTD is available in three operating types 1 Driver Controlled CTD Engagement is controlled by a cab mounted air valve using an Eaton straight air shift system See Sec tion 8 for description service and maintenance 2 Seasonal Engagement Manual adjustment in the shop 3 Permanent Engeagement Constantly engaged DISENGAGED ILLUSTRATED CLUTCH SHIF T PACK FORK DISENGAGED ILLUSTRATED ENGAGE COMPRESSION SPRING Medium Duty with Optional Fark for Seasonal or Driver Controlled Engagement SHIFT CLUTCH FORK PACK 1 IN 1 COMPRESSION SPRINGS Heavy Duty with Optional Fork for Seasonal or Driver Controlled Engagemant Checking Effectiveness of Controlled Traction Differentials to determine friction plate condition The bias torque of a new unit will check out at approximately 4 000 ft lbs or higher for Heavy duty 3 000 ft lbs or higher for Medium duty bias torque value drops to 1 500 ft lbs o
196. tion disassemble and inspect shift units 4x4 8 3 Dual Range Axles with Range Interlock Description and Operation Operational Modes 1x2 Drive with axles in High or Low Range B 4x4 Drive with axles in High or Low Range The system includes an interlocking feature that prevents axle range shift when in 4x4 drive STEER DArviE ARLE LOCKUP SHIFT 81 pom Erit Fea T V BREAKER t1 A aim E E TH HALE LEE TR ID e E plages aia CE mium trn VA Pressure switch and speedometer adapter required for vehicles with transmission drive speedomaters AIR FLOW TO AXLE RANGE SHIFT UNITS FROM AIR SUPPLY AXLES IN HIGH RANGE CONSTANT AIR SUPPLY ALL WHEEL DAVE SFSTEM AXLE RANGE SELECTION SYSTEM Solenoid valve required for vehicles not equipped with automatic safety brakes AIR FLOW FROM AXLE RANGE SHIFT UNITS TO EXHAUST AXLES IN LOW RANGE AXLE SHIFTER VALVE ENOAG POSITION TS oh doner INTERLOCK SOLENOID VALVE t SYSTEM WHEN DE ENERGLE AIR FLOW THROUGH ALL WHEEL DRIVE AND INTERLOCK SYSTEMS IN 4 4 DRIVE SEE PAGE 8 6 FOR DETAILS NOTE Axle Range shift cannot be made un
197. ts Steam cleaning at this time could allow water to be trapped in cored passages leading to rust lubricant contamination and premature component wear The only proper way to clean the assembly is to dis assemble it completely Other methods will not be effective except as preparatory steps in the process Wash steel parts with ground or polished surfaces in solvent There are many suitable commercial solvents avail able Kerosene and diesel fuel are acceptable WARNING GASOLINE IS NOT AN ACCEPTABLE SOLVENT BECAUSE OF ITS EXTREME COMBUSTIBILITY IT IS UNSAFE IN THE WORKSHOP ENVIRONMENT Wash castings or other rough parts in solvent or clean in hot solution tanks using mild alkali solutions If a hot solution tank is used make sure parts are heated thoroughly before rinsing Rinse thoroughly to remove all traces of the cleaning solution Dry parts immediately with clean rags Lightly oil parts if they are to be reused immediately Otherwise coat with oil and wrap in corrosion resistant paper Store parts in a clean dry place Inspection Inspect steel parts for notches visible steps or grooves created by wear Look for pitting or cracking along gear contact lines Scuffing deforma tion or discoloration are signs of excessive heat in the axle usually related to low lubricant levels or improper lubrication practices Before reusing a gear set inspect teeth for signs of excessive wear Check tooth contact pattern for ev
198. ugh circuit breaker pressure switch to adapter 3 Check for power supply at adapt er terminal With axle shifter valve in High Range pressure switch is open and power is not delivered to adapter With shifter valve in Low Range the pressure switch is closed and power is delivered to operate the speedometer adapter If power supply is okay adapter is faulty Replace adapter assembly Check Pressure Switch In Low Range the pressure switch is closed and electrical circuit is complete to the speedometer adapt er In High Range air pressure opens the pressure switch breaks the electric circuit to the speedom eter adapter To check pressure switch opera tion shift to High Range and probe switch terminals Mo voltage should be present Replace a faulty pres sure switch as an assembly Dual Range Rear Axle with Single Reduction Steer Drive Axle Description and Operation Operational Modes Steer Drive Rear Axle Axle 4x4 Drive Engaged Low Range 4 2 Drive Disengaged Low Range 4x2 Drive Disengaged High Range The system includes an interlocking feature that prevents axle range shift when in 4x4 drive STE R QRIV AXLE VALVE OPEN ENGAGED SOL Baa eerie wesEN DE ENERO FED IN LOW MANGE j f Poe ppc ang iosedomabar adapter requar d lor verecies Solenced vahe required
199. ups in cage see adjacent drawings TRE IMPORTANT After bearing cups are installed presalect pinion bearing spacer using the trial build up procedure described the Adjustments Section of this manual 4x4 5 7 Differential Carrier Overhaul Assemble Drive Pinion Press fit outer pinion bearing Cont d 2 Press pilot bearing on pinion IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner bearing race 5 Install preselected bearing spacer on pinion Also instal spacer washer on Axle Series 220 230 260 300 350 NOTE After tightening pinion nut recheck pinion bearing rolling torque See Adjustment Section far Press fit outer pinion bearing 5 8 4 4 6 Install bearing cage on drive pinion STAKE PATTER 3 Stake pilot bearing using stak ing tool This is essential to retain the bearing NOTE During pinion bearing installation locate each part in same position that was used in Trial Build up Preload Test 1 hu B Pinion Helical Gear and Mut These parts are installed during pinion installation see page 5 9 and 5 10 a 4 Press inner bearing cone on pinion IMPOATANT To prevent bearing damage use suitable sleeve that only contacts inner race of bear ing Cone 7 Press outer bearing cone on pinion IMPORTANT To prevent bearin
200. ve uses cab mounted air control valves to control the drive system operating modes axle range selections and controlled traction differential operation Detailed descriptions of air shift systems which control these functions are contained in the Shift System Section of this manual Operation The power divider transfer gearing provides the means to deliver power to the steer drive axle Operating modes and power flow are illustrated below The transfer gearing includes a mechanical sliding clutch which in turn controls engagement and disengagement of the driveline to the steer drive axle 4x4 Operating Mode In 4x4 mode the sliding clutch is engaged and drive is direct from transmission to the helical gear train in the power divider At this point power is distributed through the three helical gears to the rear axle and to the steer drive axle CIE TORQUE INPUT Fa zl ITI ul ed Bis El 2 L7 ce TO _ DRIVE AXLE ENGAGED 4x2 Operating Mode For 4x2 operating mode the sliding clutch is disengaged and power flow is direct from transmission through two helical gears with 100 to rear axle TORQUE IMPUT 2 TO as STEER Em AXLE CLUTCH j DISENGAGEO Spicer Axles amp Brakes Contents Section 1 Page No ESD 18 STEER DRIVE AXLE gucci terete Beer 2 STEERING AND WHEEL END EQUIPMENT Wheel Alignment and Wheel End
201. x4 Drive Systems Contents are listed below Correct tightening torque values are extremely impor tant to assure long Spicer Axle life and dependable performance Under tightening of attaching parts is just as harmful as over tightening Exact compliance with recommended torque values will assure the best results Boit head markings for grade identification The data includes fastener size grade and torque tight ening values Axle models are included to pinpoint identification of fasteners for your particular axle To determine bolt or cap screw grade check for designation stamped on bolt head see illustration Section 3 Contents Page Mo STEER DRIVE AXLE ESD 18 Steering and Wheel End Equipment 2 Differential Carriers all gearings 3 4x4 REAR AXLES Power Divider all models 4 DIFFERENTIAL CARRIERS Axle Series 185 220 Single Reduction Dual Range and Double Reduction 5 Series 230 260 300 350 5 Reduction Dual Range and Double Reduction 6 4 4 9 1 Eaton Steer Drive Axle Steering and Wheel End Equipment htening ESD 18 Specifications Fastener Size Grade Ft iba HUB CAP Nut PER 170 220 231 298 WHEEL BEARING ADJUSTING NUT 3 8 24 5 40 55 KINGPIN i rr

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