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all-wheel drive 6x6 drive system

1. 14 Standard Lockup Shift Unit 15 Interlock Type Lockup Shift Unit 16 Special Components 17 Air Shift Unit Dual Range Selection and Controlled Traction Differential 18 6x6 8 1 Dual Range Axles with Range Interlock 6x6 Drive Shift Systems Single Reduction Axles with Standard or Controlled Traction Differentials Double Reduction Axles with Standard Differentials INTER AXLE DIFF STE R DRIVE AXLE LOCKOUT SHIFT UNIT LOCKUP SHIFT UNIT H wave wr PHessune IN 6x6 ORIVE VALVE ENGAGED AND OPEN ADO SHIFT UNITS TO SYSTEM X FOR CONTROLLED TRACTION DIFFERENTIALS DRY AIR TANK Alt Wheel Drwe Operating Instructions Engage mo DORE nes nt TANDEM STEER DRIVE REAR AXLE FORWARD AXLE AXLE CONTROLLED TRACTION DIFFERENTIAL SHIFT UNITS Description and Operation These systems provide selection of two operational modes 1 6x6 Drive Inter axle Differential is locked out not operating Controlled Traction Differential when equipped is engaged operating 2 6x4 Dr
2. 1 1 4 12 480 600 650 813 D466 P 486 586 656 P 1 3 4 12 840 1020 1139 1383 FRONT OUTPUT SHAFT ee 1 1 2 18 560 700 759 949 FRONT OUTPUT SHAFT BEARING COVER cnccncccscecescedvecees 7 16 14 5 48 56 65 76 9 16 12 5 110 125 149 170 DRIVE PINION D346 P 386 P 406 P 355 55 544454 5552 5 2 24 4 1 1 2 18 840 1139 0466 486 586 656 1 3 4 12 980 1329 IMPORTANT Torque nut to rated value then continue tightening nut to align slot with nearest hole in pinion shank DRIVE PINION BEARING CAGE 9 16 12 8 155 175 210 237 POWER DIVIDER COVER SCIaW e o RR 9 16 12 5 110 125 149 170 LOCKOUT amp LOCKUP SHIFT UNIT BODY SOFOW ed dA dn 7 16 14 5 48 56 65 76 SHIFT UNIT BODY COVER Cap SOOW accio ie eorr caccrsvgeck 1 4 20 5 96 108 IN LBS 11 12 SHIFT UNIT PUSH ROD coser sek es ev REESE 3 8 24 20 26 27 35 LUBE PUMP Cap Screw 1 4 20 5 85 105 IN LBS 10 12 LUBE PUMP DRIVE GEAR MEME c 7 16 20 35 45 47 61 LUBE STRAINER 3 4 14 40 60 54 81 6x6 9 4 6x6 Tandem Axle Differential Carriers Fastener Single Reduction DS346 P 386 P 406 P Tightening Forward and Rear Axles Specifications Specifications are the sa
3. 2 IT 6 WE 0 uris 5 Pa INN SLIDING RH LH CLUTCH DIFF RING 1 i SPEED RING wal mes BEARING GEAR PINION CLUTCH GEAR BEARING AXLES BOLT PIN PLATE NUT 2 Remove small support case and thrust washer 1 Remove nuts and bolts fasten ing ring gear and support cases 6 Invert differential assembly to remove idler pins then remove idler pinions 5 Remove thrust washer from support case 2 25 4x4 6x6 3 Remove ring gear NOTE A soft faced hammer or mallet may be required to dislodge gear from its mounting 4 To remove differential assembly place support case assembly ona bench or on the floor Position case on its side then slowly roll the case and slide differential assembly out of the case 7 Punch mark differential cases for correct location in reassembly Remove cap screws and separate case halves Differential Carrier Overhaul Disassemble Wheel Differential Cont d 8 Lift out thrust washer and side 9 Lift out spider side pinions and 10 Remove side gear and thrust gear thrust washers washer 11 First try to litt off high speed 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 a Insert properly sized adapters round metal
4. 2 INTERLOCK CONTROL VALVE 4 AIR PRESSURE IS ROUTED 5 AIR PRESSURE 15 APPLIED A OPENS WHEN INTER AXLE THROUGH INTERLOCK SHUTTLE TO INTERLOCK PIN D PIN DIFF SHIFT UNIT 5 ENGAGED VALVE BLOCKS AXLE RANGE SHIFTER VALVE LEVER LI gt CONSTANT AIR SUPPLY 5 INTERLOCK PIN 0 PROPS Ei 3 INTERLOCK CONTROL VALVE 64 ENGAGED AIR CRESSURE 18 OPENS WHEN STEER DRIVE Son AXLE SHIFT UNIT IS ENGAGED AXLE 4 SHIFTE INTER AXLE VALVE DIFF SHIFT UNIT STEER DRIVE AXLE SHIFT UNIT ELICAL SIDE GEAR SLIDING CLUTCH ENGAGES DRIVE GEAR interlock Disengaged 6x4 Operation EXHAUST 2 AIR PRESSURE AT PISTON 4 AIR PRESSURE FLOWS BACK 5 AIR PRESSURE INTERLOCK CONTROL VALVE THROUGH SHUTTLE INTERLOCK PIN D 15 15 CLOSED CONNECTING VALVE C AND EXHAUSTS EXHAUSTED PIN RE RETRACTS THROUGH PORT ON INTERLOCK ALLOWING AXLE RA CONTROL VALVE SHIFTER VALVE LEVER M OR B TO BE MOVED TO LOW OR HIGH RANGE EXHAUST PORT 3 AIR PRESSURE PISTON 15 RELEASED STEER DRIVE AXLE 94 SHIFT UNIT IS DISENGAGED 2 INTERLOCK CONTROL VALVE 8 15 CLOSED CONNECTING OUTLET TO EXHAUST 1 STEER DRIVE AXLE AND INTER AXLE DIFF ARE DISENGAGED AIR PRESSURE TO SHIFT UNITS IS CUT OFF
5. 1 2 tooth or more PE face width Pattern should tts A ta be evenly centered between tooth y top land and 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 Install cotter pin in one adjuster lock Install cap screws in opposite adjuster lock and tighten to correct torque see chart Lockwire bearing and adjuster lock cap screws 6x6 6 18 Adjust Differential Bearing Preload conta 7 For planetary double reduction axles on backface side of ring gear install sun gear and retainer then install cap screws that fasten both 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 openings 10 Install shift unit seal and spring Torque Chart Differential Bearing Cap Cap Screw Size Grade Ft Ibs 13 16 10 8 370 430 501 583 Bearing Adjuster Lock and Sun Gear Retainer Cap Screw Size Grade Ft Ibs 5 8 11 5 160 176 217 239 6 19 6 6 SUN GEAR BEARING SCREW RETAINER ADJUSTER LOCK
6. 7 16 14 5 35 45 47 61 6x6 9 8 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 AlI Wheel Drive selector in dis engaged position Move vehicle in forward direction for a short dis tance followed by backing 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 flat spot and do not apply spring brakes Do 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 Check Solenoid Valve Turn en gine off If vehicle is equipped with solenoid valve turn ignition to energize and open valve Check to insure that air pressure is present on the outlet of the solenoid vaive 3 Check Axle Range Shift System Have an assistant in the cab begin moving the axle range shifter valve lever in the cab between Low and High Range Listen for mechanical movement at the tandem axle range shift units If no movement is appar ent place the shifter valve lever in the Low Range position and discon nect air lines at the tandem forward and rear shift units Place axle range shifter valve in High Range position
7. i 43 7 Remove bearing cups then lift ring gear and differential 8 Drive Pinion For pinion instructions refer to appropriate assembly out of carrier Spicer Axle Service Manual covering your specific axle model 4x4 6x6 7 5 Medium duty CTD Overhaul Remove and Disassemble Clutch Pack Medium duty CTD Illustrated THRUST WASHER GEAR 1 SUPPORT RING CASE GEAR PERMANENT CTD SHIFT FORK OPENING COVER CAP SCREW 1 Place differential assembly clutch pack up on workbench WARNING TAKE PRECAUTION ARY MEASURES TO PREVENT PERSONAL INJURY OR PARTS DAMAGE DURING REMOVAL OF gt GEAR SUPPORT COVER Step 2 THE COVER IS UNDER SPRING PRESSURE AND MAY POP OFF WHEN THE LAST LOCKNUT 15 REMOVED 6 4x4 6x6 SEASONAL CTD SHIFT FORK RETAINER 4 ADJUSTING SCREW SNAP RING DRIVER SUPPORT PRESSURE CASE COVER PLATE PERMANENT CTD ONLY CLUTCH NUT gearing SLIDING T pack y x CONE CLUTCH D T 5 i GG INTERNAL A M SPLINED PLATE COMPRESSION CUP ADJUSTER RIN EXTERNAL SPLINED PLATE o d FORK SHAFT SHIFT FORK DRIVER CONTROLLED CTO SHIFT UNIT NUT Og LOCK WASHER EXPANSION PLUG SHIFT FORK FOR DRIVER CONTROLLED AND SEASONAL _ 6 LOCKWASHER 2 Remove two self locking nuts and bolts 180 apart fastening support cover
8. N m 759 949 1139 1383 1 1 2 18 1 3 4 12 gt 4 Press inner bearing cone on pinion IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cone 7 Press outer bearing cone on pinion IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cone IMPORTANT At this stage of assembly final check pinion bear ing preload See Adjustment Sec tion of this manual NOTE After tightening pinion nut recheck pinion bearing rolling torque See Adjustment Section for Press fit outer pinion bearing 10 Forward Axle Pinion Helical Gear and Nut These parts are installed during pinion installation see page 6 15 Differential Carrier Overhaul 1 Forward Axle 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 1 If removed install bearing race in power divider cover using driver and hammer Install Drive Pinion Forward Axle Install Pinion Outer Support Bearing Race FORWARD 2 Forward Axle Drive Pinion Install drive pinion assembly Install bearing cage cap screws and lockwashers Torque cap screws to 155 175 ft lbs 210 237 NOTE At this phase of reassem bly use
9. AXLE INTER AXLE E DIFF SHIFT UNIT STEER DRIVE AXLE SHIFT UNIT SLIDING CLUTCH DISENGAGES HELICAL SIDE GEAR SLIDING CLUTCH DISENGAGES DRIVE GEAR gt CONSTANT AIR AIR FLOW FROM PAiR FLOW oo SUPPLY CONSTANT AIR SUPPLY SHUTTLE VALVE C THROUGH INTERLOCK TO EXHAUST PO T ON CONTROL VALVES A amp B INTERLOCK CONTROL THROUGH SHUTTLE VALVE VALVE A OR B AND TO INTERLOCK 6x4 OPERATION IN 0 ON AXLE RANGE SHIFTER VALVE 6x6 OPERATION 6 6x6 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 flat surface and do not apply spring brakes Do 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 Check Solenoid Valve If vehicle is equipped with solenoid valve turn ignition ON to energize and open valve Check to insure that air pre
10. DIFFERENTIAL CARRIER i SPIDER SNAP BEARING SNAP THRUST BUSHING RING CONE RING WASHER CASE HALF ac POWER DIVIDER BEARING BEARING BEARING FLAT COVER COVER SPACER WASHER SNAP BUSHINGS D INPUT BEARING LOCK 2 RING WASHER SHAFT CONE WASHER SCREW SHIM OIL SEAL r HELICAL THRUST SLIDING SCREW LOCK WASHER I GEAR WASHER CLUTCH PR xiii i cip PIN SA LOCKOUT SHIFT UNIT SCREW SHIFT EXPANSION MAGNETIC FORK PLUG STRAINER LOCKWASHER 1 Two Snap Rings LOCKWASHER ore baer BEARING HELICAL FRONT SHIFT BEARING SHIM BEARING LOCKUP One Snap Ring is used i GEAR OUTPUT FORK CUP COVER SHIFT UNIT on 0466 0486 0586 0656 2 Spacer used only on 0466 0486 D586 P jm D656 4 4 gt 939 BEARING SLIDING BEARING p NUT CONE CLUTCH SPACER 3 FLAT OIL SEAL YOKE WASHER BEARING LOCK CAP CONE WASHER SCREW LUBE PUMP O RING PUMP CAP coven SCREW gt ORIVE PUMP DOWEL LOCK GEAR GEARS PIN WASHER 6x6 4 3 Power Divider Overhaul Remove Power Divider from Differential Carrier with carrier removed from axle housing 1 Mount differential carrier assembly in repair stand Loosen input shaft nut NOTE There are blind cap screw
11. SONGLE SPEED STEER DAIVE AXLE REDUCTION SS INTERLOCK SHUTTLE Spicer dew Maree 8 Wiveet Drine gt VALVE Operation Vei Pom m a v ung 3 f aege w s ere nm INTERLOCK 181 SYSTEM nem m EP INTERLOCK INTERLOCK CONTROL CONTROL 576 AXLE VALVE o wrTER AXLE DiF LOCKOUT ALL WHEEL SHW DRIVE SYSTEM SPEEDOMETER _ BRE SHIFTER VALVE LOPEN IN ENGAGED STEER DRIVE AXLE LOCKUP AND INTER AXLE DIFF SHIFT UNIT PRESSURE ADAPTER SWITCH NORMALLY CLOSED 1172 T e INTERLOON V lt Qu 5 5 1 eo SELECTION SYSTEM Ah AXLE 4 LA LOPEN IN HIGH RANGE tOCKOuT UNT CONTRO VALVES 14 5 CLOSED HIGH AANGE T j OPEN LOW RANGE T M N SOLENOIDO VALVES EXHAUSTS SYSTEM 4 WHEN DE ENERGIZED 1 Pressure switch and speedometer adapter required for vehicles 3 Solenoid valve required for vehicles not equipped with automatic with transmission drive speedometers safety brakes CONSTANT AIR SUPPLY AIR FLOW TO AXLE AIR FLOW FROM AXLE AIR FLOW THROUGH RANGE SHIFT UNITS RANGE SHIFT UNITS TO ALL WHEEL ORIVE AND TANDEM IN HIGH EXHAUST TANDEM INTERLOCK SYSTEMS IN 6x6
12. cup in at a bme Rear Axle Pinion Press Bearing Cups in Cage A Cups must be firmly seated in cage Check win gauge 02017 shor installation When correctly wstalled cups wil be facessed below outer surlace of Press cup in at a ome 6x6 6 12 Differential Carrier Overhaul Assemble Drive Pinion Press ftit outer pinion bearing Cont d Be 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 install spacer washer on D466 P 486 586 P 656 P Rear Axle Pinion Press Oil Seal in Cage rates with pinion installed Steewe must be sized 10 press seat outer flange 8 Rear Axle Only With pinion installed and bearing preload ad justment complete install oil seal with a press 6 13 6x6 STAKE PATTERN 3 Stake pilot bearing using staking tool This is essential to retain the bearing NOTE During pinion bearing in stallation locate each part in same position that was used in Trial Build up Preload Test 6 Install bearing cage on drive pinion 9 Rear Axle Only Priorto installa tion of yoke lubricate oil seal and make sure yoke is clean and dry Install yoke flat washer and nut Torque nut as follows Torque Chart Drive Pinion Nut Ft Ibs 560 700 840 1020
13. 0 015 0 015 Desired end play 0 003 to 0 007 Remove shims to provide desired end play 0 012 to 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 7 Final Shaft Assembly after End Play Is Correct IMPORTANT Removing and installing output shaft as an assembly during adjustment procedure could possibly damage oil seal When this procedure is used it is recommended that a new oil seal be installed 8 After 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 rid FRONT BEARING OUTPUT SHIFT FORK BEARING BEARING CONE SHAFT amp PLUSHROD CUP COvER LOCKWASHER ER mum CLUTCH SPACER Seat BEARING 1 YOKE FLAT CONE SCREW WASHER LOCKWASHER
14. Viewing Outside of Left Hand Whee Toe in VERTICAL VERTICAL LINE LINE TIRE C L REC NE TIRE TIRE C L gt t TIRE B REAR TOE IN B MINUS A Toe in Should Be 0 to Viewing Top of Axle 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 mounting 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 Bail Stud Kingpin Bearings Use wheel bearing grease NLGI No 1 or No 2 Lubricate through lube fitting in upper bearing cover For lower bear ings remove pipe plug and install lube fitting Lubricate with lube gun then reinstall plug Frequency Lubricate at Axle Lube Change Tie Rods Use chassis lube and lube fitting one in each tie rod end Lubricate at axle lube change intervals Slack Adjuster Lubricate with lube gun at fitting mounted on slack adjuster Lubricate at Axle Lube Change 4x4 6x6 1 6 Steering Wheel End Equipment Overhaul The follo
15. 9 16 18 8 110 130 149 176 DRIVE PINION Forward Axle Nut slotted w roll pin 1 3 4 12 980 1329 IMPORTANT Torque nut to rated value then continue tightening nut to align slot with nearest hole in pinion shank Rear Axle Nut self locking 1 3 4 12 840 1020 1139 1383 DRIVE PINION BEARING CAGE Forward Axle Cap Screw 9 16 12 8 155 175 210 237 Rear Axle 5 8 11 5 160 176 217 239 DIFFERENTIAL CASE Cap Screw 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 SOFUW issreso essc e hue 5 8 11 5 160 176 217 239 DIFFERENTIAL CARRIER Forward Axles Stud Nuta eel roro 5 8 18 8 stud 220 240 298 325 At Dowels 150 170 203 230 Cap Screw 12 pt 5 8 11 8 210 230 285 312 Rear Axles Stad NUE 54542 5 22 25 2 222 5 8 18 8 stud 220 240 298 325 AXLE HOUSING COVERS DT DP466 P 486 P Forward Axles Stud Nut 7 16 20 8 stud 70 86 94 116 Cap Screw 7 16 14 5 47 55 64 75 DT DP586 P 686 P Forward Rear Axles Stud Nut 1 2 20 8 stud 110 130 149 176 BOON 1 2 13 5 75 85 101 115 SHIFT UNIT SUXNNUL 7 16 20 8 stud 55 61 74 82 SHIFT FORK COVER Cap Screw
16. Carrier IMPORTANT Do not assume that all assemblies will retain proper preload once bearings are pressed on pinion shank FINAL PRELOAD tL MUST BE MADE IN EVERY 4x4 6x6 2 6 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 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 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 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 ing Bearing Preload with pounds This specification is translated into spring scale readings in the inion in Vise chart below 4 Adjust Pinion Bearing Preload necessary adjust pinion bearing preload Disassemble the p
17. 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 If gear 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 4x4 6x6 2 14 Disassemble Drive Pinion PINION BEARING BEARING BEARING BEARING BEARING OIL SEAL INPUT PILOT CONE SPACER CAGE CAGE CUP amp RETAINER YOKE BEARING INNER VARIABLE SHIM OUTER FLAT WASHER Wi y TiU BEARING P BEARING DRIVE CUP fi SCREW CONE PINION PINION INNER OUTER NUT LOCKWASHER IMPORTANT During the follow 2 For pinion with press fit bear 3 Remove oil seal and bearing ing yoke removal procedure the ing cone support cage and press cone from cage Discard oil seal drive pinion may fall out of bear pinion out of bearing cage and Remove bearing cups with suitable ings and cage Do 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
18. 110 125 149 170 759 949 Ft Ibs 560 700 Silicone Gasket Compound Pattern Lockup Shift Unit Differential Carriers for 6x6 Tandem Axles Single Reduction DS346 P 386 P 406 P 466 P 486 P 586 P 656 P Differential Carrier Overhaul Forward and Rear Axles These instructions cover single reduction differential carrier assemblies for 6x6 tandem forward and rear axle tandems It is assumed that the power divider assembly has been removed from the forward axle carrier For service information on single reduction carriers equipped with Spicer Controlled Traction Differential refer to Section 7 Section 5 Contents Page No DIFFERENTIAL CARRIER OVERHAUL Exploded View 2 Disassemble Differential Carrier Tandem Forward Axle 4 Disassemble Differential Carrier Tandem Rear Axle 5 Disassemble Drive 6 Disassemble Wheel Differential 8 Assemble Wheel Differential 9 Assemble Drive Pinion 10 FORWARD AXLE Install Drive Pinion 12 Install Pinion Outer Support Bearing Race 12 Install Pinion Helical Gear 13 Install Differential Assembly in Carrier 14 REAR AXLE Install Drive Pinion 16 install Differential Assembly in Carrier 16
19. INCORRECT PATTERN INCORRECT PATTERN Move pinion gt Move pinion toward ring gear away from ring gear f Pattern too close to tooth top land and off center Pattern too close or off tooth root 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 the 0 006 to 0 016 specifications 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 Pattern too far along tooth toward tooth heel Pattern too close to edge of tooth toe 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 adjuster one notch 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
20. NOTE These air lines are not to be confused with air lines connected to interlock control valves installed in shift unit covers Leave these air lines connected Place All Wheel Drive selector valve lever in engaged position and check for air flow at disconnected air lines 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 lines 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 interlock pin actuates interlock pin locks 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 lines on the sides of the interlock control valves on the tandem inter axle dif ferential and steer drive axle lockup shift units Move the All Wheel Drive selector valve lever to engaged posi
21. 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 3 12 6x6 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 D346 P 386 406 P 0466 486 586 656 4 0 006 to 0 016 0 008 to 0 018 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 WR 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 o Adjustments Ring Gear and Pinion Tooth Contact NOTE Re
22. SPICER Spicer Drive Axle Service Manual Spicer All Wheel 6 x 6 Drive System AXSM 0600 February 1994 Spicer All Wheel 6x6 Drive System Axles Brakes Spicer Steer Drive Axles ESD 18 Spicer 6x6 Tandem Axles D346 P 386 P 406 P 466 P 486 586 P 656 P Gearing Single Reduction Dual Range Double Reduction Spicer Axle Service and Maintenance Instructions The Spicer 6x6 Drive System Spicer presents this publication to aid in maintenance and overhaul of Spicer 6x6 Drive Systems Axle models and other equipment covered in this publication are listed below Spicer Steer Drive Axles Model No Identification Steer Drive Axle ESD 18S Steer Drive Axle Available with Controlled Traction Differential Contents 6x6 Drive System Section No Description Operation Steer Drive Axle Differential Carriers Tandem Drive Axle Power Divider Differential Carriers Single Reduction Capacity x 1000 18 000 Ibs Axle Gearing Types S Single Reduction Single Reduction with Controlled Traction Differential T Dual Range P Double Reduction Differential Carriers Dual Range and Double Reduction Controlled Traction Differential Shift Systems Fastener Tightening Specifications Spicer Tandem Axles Model No Identification Tandem Axle D Series Tandem with Inter axle Differential Gearing S Single Reduction T Dual Range P Double Reduction Available with Co
23. Steering and Wheel End Equipment Overhaul Disassembly 1 Jack up both sides of the axle until tires clear the ground WARNING TO PREVENT DAMAGE OR 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 Remove Wheels and Tires Drain Lubricant X Removing Hub Cap with Puller Screws Remove Wheel Hub and Brake Drum 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 experienced 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 5 Remove wheel hub and drum assembly see photo To disassembie hub remove oil seal and spacer then lift out inner bearing cone 6 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 7 Inspect brake
24. b Use stock to block the center hole in the clutch plate and press against it with the press ram 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 c Continue to press until the plate breaks loose from the plate dowei pins 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 Removing Bearing from Small Support Case using Puller 6 9 6x6 Differential Carrier Overhaul Assemble Wheel Differential Rear Axle Whee Differential Illustrated SIDE THRUST THRUST Case WASHER cing lt ER WEAR gem ae PLAIN CASE M FINS CAS Ww a gt SCREW dyes P VJ i V SY LO PLANETARY DOUBLE REDUCTION AXLES DIFF DIFF GEAR SUPPORT SUPPORT DIFF SUN SUN GEAR BEARING BEARING SUPPORT CASE CASE SUPPO a BEARING GEAR RETAINER ADJUSTER CONE CASE THRUST THRUST E ADJUSTER LARGE WASHER IDLER WASHER amp PINION A eh a 186 TN Mem
25. nee 9 NOTE Check expansion plug in power divider cover see photo below to make sure it is in place and firmly seated If loose seat by tapping with a hammer Replace plug if necessary _ 10 install shift fork in power divider cover 11 Place sliding clutch in power divider cover engaging clutch with shift fork Position clutch teeth toward helical side gear 12 At this point in reassembly install lockout see Shift System Section 8 4924 13 Slide input shaft into power divider cover Engage shaft splines in lockout sliding clutch Install bearing spacer on input shaft used only on D466 P 486 P 586 P 656 P 14 NOTE Input shaft end play must be adjusted after power divider cover is assembled to dif ferential carrier see page 4 13 For easier adjustment temporarily install input bearing cover cap screws and lockwashers Tighten cap screws finger tight 15 Make sure yoke bearing sur face is clean and dry then install yoke flat washer and nut Tem porarily tighten nut snugly 16 IMPORTANT At this point in reassembly install pump drive gear locknut Torque nut to 35 45 ft Ibs 47 61 N m 17 Slide D washer over input shaft up to base of sliding clutch splines Install bronze thrust washer Install helical side gear Secure with snap ring WARNING SNAP RING IS SPRING STEEL AND MAY POP OFF WEAR SAFETY GLASSES WHEN INSTALLING 18 Ins
26. 2 At teeth side of ring gear install bearing cup bearing adjuster and bearing cap 6x6 5 15 Differential Carrier Overhaul Rear Axle Install Pinion 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 0 023 0 584 HOLE CLEAR 1 Rear Axle Place shim pack on Torque Chart 2 Rear Axle Drive Pinion install carrier making sure lube hole is T ana pinion assembly Install bearing clear Bearing Cage cage cap screws and lockwashers crews Torque cap screws see chart Ft lbs 9 16 12 Grade 5 100 125 136 170 5 8 11 Grade 5 160 176 217 239 Hear Axle Install Differential NOTE Lubricate bearings during the following assembly procedures a 1 Place ring gear and differential 2 Install bearing cups at both 3 Install and tighten bearing cap assembly in carrier Carefully lower sides of differential case Install screws finger tight If this is diffi the assembly until bearing cones bearing adjusters and caps cult use hand wrench rest on carrier NOTE The assembly is now ready for adjustment of differen tial bearing preload ring gear backlash and gear tooth contact see page 5 17 5 16 6x6 Differential Carrier Overhaul Forward and Rear Axle Adjust Differential Bearing Preload 1 At the teeth side of ring gear position b
27. tion and check for air flow from side ports of interlock control valves If air flow is not present place selector valve lever in disengaged position and remove interlock control valves trom shift unit covers b Place All Wheel Drive selector valve lever in engaged position and again check for air flow from the side ports of the interlock control valves If air flow is present depress plungers on each interlock control valve and insure air supply is shut off from valve side ports If valves do not function correctly remove and replace Place All Wheel Drive selector valve lever in disengaged position and reinstall interlock con trol valves in shift unit covers 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 ports remove shift units from tandem for ward axle and inspect components for binding or excessive wear After repair follow the above steps until proper functioning is obtained Reconnect air lines 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 is complete d Disconnect air line from side port of interlock shuttle valve Place All Wheel Drive selector valve lever in engaged position and insure air flow is present at shuttle va
28. wear as follows Install camshaft in bushings and check side movement with dial indicator If move ment is greater than 0 020 replace oil seals bush 95363X ings and or camshaft To remove bushings drive Removing Kingpin Bearing Cup them out of ball socket using a suitable driver g KON 4x4 6x6 1 16 Steering Wheel End Equipment Overhaul Assembly Assemble Ball Socket 1 If camshaft bushings are to be replaced proceed as follows to install new bushings Install bushings using suitable driver Ream bronze bushings 10 1 500 after installation Non metallic bushings do not require reaming They are presized at the factory 2 If camshaft oil seals are faulty or were removed install new seals as follows Use suitable driver to install seals IMPORTANT Molded lip type seals must be in stalled with both lips pointing in the same direction see drawing Failure to install seals properly may result in oil soaked brake linings or blowing out the seals Assemble Axle Ball 1 If ball bushing for axle shaft is to be replaced install new bushing as follows 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 IMPORTANT A clearance of 0 003 to 0 005 is imperative If necessary ream bushing to maintain this clearance
29. 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 sive wear is 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 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 Replace if ridge can be felt between worn area and cam surface 4x4 6x6 1 12 Steering and Wheel End Equipment Overhaul Disassembly Remove Spindle
30. 406 Tandem Rear Axles D466 P 486 586 P 656 P Tandem Forward and Rear Axles 16 2 13 5 15 5 12 2 14 0 4 699 18 20 16 3 18 3 10 6 6 OUTER BEARING CONE Used only on 0466 486 P 586 656 SLEEVE MUST APPLY PRESSURE TO BACK FACE OF OUTER BEARING CONE IMPORTANT Do not assume that all assemblies will retain proper preload once bearings are pressed on pinion shank FINAL PRELOAD pace id BE MADE IN EVERY Spring Scale Reading without pinion seal for 10 20 in Ibs torque 1 1 2 3 N m Ibs kgs 3 7 2 3 4 8 Adjustments 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 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 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 assembl
31. Ambient Temperature Range 40 to 15 F 40 C to 26 C 15 F to 100 F 26 C to 38 C 15 F and above 26 C and above 10 F and above 12 C and above Lube Change Intervals 3 2 6x6 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 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 seen or touched is not sufficient It must be level with the hole NOTE When checking lube level also check and clean housing breathers 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 chanaes it should be replenished as needed Lubricants approved under the MIL L 2105 C specifi cation are compatible
32. 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 05368 X 05367 X Installing Hub Oil Seal Steering and Wheel End Equipment Overhaul Assembly Assemble and Install Wheel Hub and Drum Cont d WHEEL HUB AND DRUM ASSEMBLY Installing Wheel Hub and Drum 5 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 cone back off until the slot in the adjusting nut aligns with slot or groove in axle spindle NOTE Bearing adjustment is important The nut should be tight enough to eliminate hub end play and create a slight hub drag Drag should produce a 4 to 10 Ibs pull at wheel mounting studs If drag is incorrect reset adjusting nut T After bearing adjustment is correct 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 f 8 groove inh t se 1 2 thick pe T layer 9 in hub cap with grease 1 2 s installing Hub Cap 9 Using a soft nosed hammer install hub cap and secure with nuts and lockwashers Tighten nuts to 170 220 ft lbs torque 231 298 Install Wheels
33. FORWARD AND REAR AXLE Adjust Differential Bearing Preload LE 6x6 5 1 6x6 Tandem Axle Single Reduction DS346 P 386 P 406 P 466 P 486 P 586 P 656 P Differential Carrier Assembly LOCKWASHER BEARING Forward Axle CAP SCREW COTTER PIN LOCK WIRE4 ADJUSTER LOCK N FILLER PLUG DOWEL BEARING RETAINING FLAT WASHER SNAP BEARING HOUSING WASHER YOKE 1 RING amp SLEEVE COVER CARRIER PARTS FOR 05466 486 586 656 P FILLER PLUG DOWEL LOCK EXPANSION PLUG DOWEL FILLER COTTER ADJUSTER PLUG PIN LOCK lade CARRIE OSMER 386 406 ILLUSTRATED DIFFERENTIAL amp RING GEAR LOCKWIRE EXPANSION 5 PLUG DIFF CASE BEARING BEARING FLANGED RING THRUST SIDE THRUST BEARING ADJUSTER CONE HALF GEAR WASHER SPIDER GEAR WASHER SCREW BEARING NUT BOLT SIDE THRUST DIFF CASE BEARING BEARING CUP PINION WASHER PLAIN CONE ADJUSTER HALF 3 THESE PARTS n ARE MOUNTED 1 DRIVE SPACER BEARING BEARING BEARING HELICAL SLOTTED SNAP pha GOVER PINION WASHER CUP CAGE NUT BEARING SUPPORT BEARING l 000000 0 06 PILOT BEARING BEARING SHIM LOCK 2 3 ROLL BEARING BEARING CONE SPACER WASHER SCREW GEAR BEARING PIN RACE VARIABLE SPACER SPACER 1 Used only on DS466 P 486 586 656 P 2 Used only on DS466 P 3 Used only on DS346 P 386 40
34. HELICAL GEAR 1 Used only on 0346 D386 P D406 P 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 Cap Screw 7 16 14 two Grade 5 Ft lbs 48 56 65 76 9 16 12 four Grade 5 Output Shaft 1 1 2 18 Grade 5 110 125 149 170 Ft lIbs Nem 560 700 759 949 Silicone Gasket Compound Pattern Lockup Shift Unit 6x6 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 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 Posit
35. LOCK SS WIRE Planetary Double Reduction Axle Installing Shift Fork Shatt Service and Maintenance ESD 18 Instructions Steer Drive Axle opicer Axles amp Brakes Contents Section 7 Page No Description and Operation 2 Checking Effectiveness of Contreolled Traction Defferential 3 CTD Overhaul Types Remove Differential Carrier Assembly from Axle Housing 4 Remove Differential and Clutch Pack a 4 Medium Duty CTD Remove Desassemble Clutch Pack 6 Assemble and Install Clutch Pack 8 Medium Duty CTD Remove and Desassemble Clutch Pack 10 Assemble and Install Clutch Pack 12 All Types Install Differential and Clutch Pack Assembly in Carrier 14 Adjust Differential Bearing Preload 15
36. Move pinion away from ring gear Pattern too close or off tooth root If the pattern is too 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 0 006 to 0 016 for D346 P 386 P 406 P 0 008 to 0 018 for D466 P 486 P 586 P 656 P 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 3 14 6x6 INCORRECT PATTERN y S Move ring gear toward pinion gt LA 27 to decrease backlash Pattern too far along tooth toward tooth heel If the pattern is concentrated at the heel too 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 Cont
37. ONT BOLT a Compressing Clutch Pack ina Press COMPRESSION e ALIGNMENT SPRINGS ALIGNMENT BOLT ALIGNMENT BOLT GEAR SUPPORT CASE P sn Positioning Compression Springs on Pressure Compressing Springs to Assemble Ring Gear Plate Case and Cover 8 Place compression springs in 9 Compress springs until gear smallest possible circle on pressure case cover bottoms against gear plate Place gear support case support case With press pressure cover over springs and temporarily still applied install ring gear bolts install two alignment bolts Reach all heads on ring gear side through hole in gear support case and locknuts Remove assembly cover and move compression from press then tighten locknuts springs radially outward as far to correct torque 110 130 it ibs as they will go 149 176 4x4 6x6 7 13 CTD Overhaul Install Drive Pinion NOTE If the drive pinion was removed refer to the appropriate Spicer Service Manual covering your specific axle for instructions Install Differential and Clutch Pack Assembly in Carrier Types SEAT COFFERENTIAL CASE PILOT PH IN CARRIER zb BEARING f PEDESTAL NOTE Lubricate bearings during GEARING cae PEDESTAL the following assembly procedure 1 Place ring gear and differential assembly in carrier Insure that ring gear and drive pinion mesh properly During
38. Outer Bearing Cone Remove oil seal and bearing cone from cage Discard oil seal Remove bearing cups with suitable puller 6x6 6 6 Differential Carrier Overhaul Disassemble Drive Pinion conta Forward Axle Pinion lllustrated THESE PARTS ARE MOUNTED Mi IN POWER DRIVE ACER BEARING BEARING BEARING HELICAL SLOTTED SNAP DIVIDER COVER PINION WASHER CUP CAGE CONE GEAR NUT RING BEARING SUPPORT BEARING nil PILOT BEARING BEARING SHIM LOCK CAP 2 3 ROLL BEARING BEARING CONE SPACER WASHER SCREW GEAR BEARING PIN RACE VARIABLE SPACER SPACER 1 Used only on 0466 486 P 586 656 2 Used only D466 P 3 Used only on D346 P 386 406 P 4 Remove spacer and spacer 5 Remove pilot bearing and inner bearing cone from pinion using a washer from pinion Spacer split type puller Use two procedure steps to remove each bearing see washer is used only on D466 P photos above 6 7 6x6 486 P 586 P 656 P First mount puller vertically to split Second mount puller horizontally the bearing to remove bearing Differential Carrier Overhaul Disassemble Wheel Differential Rear Axle Wheel Differential Illustrated SIDE THRUST DIF WASMER SIDE Qut CASE itt 2 CASE PLAININ GEAR so CAS CASE wA 78 CAP SCREW 4 Iro gt E d RY VJ wy PLANETARY DOUBLE 1 _ _ m REDUCTI
39. Remove 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 remove bearing 2 15 4x4 6x6 Differential Carrier Overhaul Single Reduction Disassemble Wheel Differential DIFF BEARING THRUST SIDE SPIDER THRUST RING BEARING CONE WASHER PINION WASHER GEAR ADJUSTER 00383 CASE PLAIN RING BEARING CAP CASE SIDE GEAR CUP SCREW HALF GEAR BOLT IMPORTANT During following procedure place differential assembly on malleable surface 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 a 4 Lift out spider side pinions and thrust washers 3 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
40. Spreading Fixture Position kingpins and spreading fixture 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 a thicker wall as com pared to the lower cup Make certain the correct cup is installed 5 Install lower bearing cone and cup using same procedures in Step 3 and 4 6 Install kingpin spacers and nuts Tighten nuts to 500 ft lbs 680 Continue tightening nut until cotter pin hole lines up with nut siot Install cotter pin 05364X Installing Axle Ball Socket m w wp 05364x installing Upper Bearing Cup 4x4 6x6 1 18 Steering and Wheel End Equipment Overhaul Assembly Assemble Socket to Axle Ball Cont d 7 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
41. 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 or vice versa to properly center the axle ball within the socket 8 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 gun Operate gun until grease can be seen coming out of bearing cones Mir ss 10 Remove the kingpin spreading fixture and tighten Cow ii 05365x top cover nuts to correct torque see chart below Lubricating Kingpin Bearings NOTE At this point of assembly check bearing preload or drag of axle socket movement on the ball A pull of approximately 38 to 42 Ibs should be required to continue not start the socket movement on the bail Add or reduce shims to obtain pro
42. bly for proper differential action before operating vehicle Wheels must rotate freely and independently 4x4 6x6 2 12 Differential Carrier Overhaul Differential Carrier Assembly Single Reduction BEARING DIFFERENTIAL CASE THRUST THRUST DIFFERENTIAL CASE PLAIN HALF WASHER WASHER FLANGED HALF BEARING THRUST SIDE SIDE BEARING BEARING CONE WASHER PINION GEAR CONE ADJUSTER BEARING CAP SIDE ADJUSTER SCREW GEAR SPIDER NUT LOCKWIRE COTTER PILOT DRIVE BEARING BEARING BEARING BEARING YOKE SELF BEARING PINION SPACER CAGE CAGE CONE LOCKING VARIABLE SHIM NUT BEARING 7 0000 006 iT SCREW ADJUST BEARING ADJUSTER DIFFERENTIAL BEARING BEARING LOCK CAP LOCK CARRIER CONE CUP LOCKWASHER OIL SEAL FLAT WASHER 2 13 4x4 6x6 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 3 Cut lockwire Remove cap Assembly in repair stand Loosen ing caps If reusing gear set also screws flat washers and bearing but do not remove pinion nut punch mark bearing adjusters for caps
43. used only on D466 P 486 586 656 P 7 BEARING CAP CUP SCREW YOKE NUT BEARING COVER SPACER FLAT WASHER WASHER 1 LOCKWASHER 1 Used only on D466 P 486 586 656 P 7 Remove input shaft bearing cone Temporarily place lockout sliding clutch over rear of input shaft teeth toward bearing cone Place shaft in press and remove bearing cone 8 Remove sliding clutch 6x6 4 5 Power Divider Overhaul Disassemble Power Divider Cover 9 NOTE Shift fork cannot be 10 Remove oil pump cover 11 Lift out pump gear short removed until lockout shift unit is screws lockwashers Remove shaft Then with pump drive gear removed see Shift System Sec pump cover and O ring locknut previously removed step tion 8 Shift fork push rod is 2 remove pump gear long shaft secured to the lockout piston with and drive gear If difficulty is a nut LOCKNUT experienced gently pry the drive gear off shaft as the pump long shaft gear is being withdrawn from power divider cover O RING LOCKWASHER PUMP COVER BLOT T EXPANSION MAGNETIC PUMP DOWEL CAP PLUG SCREEN GEARS PIN SCREW 12 Remove snap ring securing 13 Remove pinion outer support 15 Unscrew and remove magnetic pinion outer support bearing race bearing race with suitable puller strainer from power divider cover 4 6 6x6 14 replacement is necessary remove
44. 285 312 R466 486 586 656 Stud Nut 5 8 18 8 stud 220 240 298 325 AXLE HOUSING COVERS 5 Stud Nut D346 P 386 P 406 P 466 P 486 P 7 16 20 8 stud 70 86 94 116 Cap Screw 7 16 14 5 47 55 64 75 Stud Nut D586 P 656 P R586 656 1 2 20 8 stud 110 130 149 176 Cap Screw 1 2 13 5 75 85 101 115 REAR OUTPUT SHAFT mE D346 P 386 P 406 P Mb 252454544551 ET 1 1 4 12 480 600 650 813 0466 486 586 656 isl OEE 1 3 4 12 840 1020 1139 1383 SHIFT UNITS All Models Stud Nut 2 0 nnar 7 16 20 8 stud 55 61 74 82 Power Divider Overhaul for 6x6 Tandem Axles Power Divider Overhaul These instructions cover the Spicer 6x6 power divider assembly and related parts Instructions are the same for all axle gearing and models except where specified otherwise by Tandem Axle Series No Section 4 Contents Page No POWER DIVIDER OVERHAUL Transfer Geerlnd 2 Exploded View Remove Power Divider 4 Disassemble Power Divider Cover 5 Disassemble Inter axle Differential 7 Disassemble Rear Output Shaft 7 Disassemble Front Output Shaft 8 Assemble Front Output Shaft 8 Assemble Rear Output Shaft 9 Assemble Inter a
45. 3 18 0466 486 586 656 Rear Axles Self locking Nut 840 1020 1139 1383 18 20 16 3 18 Torque nut to torque shown above then continue tightening nut to align slot to nearest hole in pinion shank 6x6 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 If such a point exists loosen and retighten the back side 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
46. 50 foot pounds 68 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 LOCK 5 Replace the outer wheel nut and tighten to 250 to 275 foot pounds 339 373 N 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 7 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 a Reinstall the axle shaft 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 6x6 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 Ring Gear Tooth Contact This adjust performed for both pinion and differ ment positions ring gear and pinion ential bearings maintains proper for best contact under load Correct gear alignment by creating correct adjustment distributes torque evenly bearing co
47. 6x4 Dual Range Dual Range 6x6 Low Range Single Reduction Dual Range 6x4 Low and low range of High Range Dual Range Example 7 17 5 29 7 21 Shift Systems The vehicle operator uses cab mounted air con trol valves to change drive system operating modes axle range selections and opera tion of controlled traction differentials Detailed descrip tions of air shift systems which control these func tions are contained in the Shift System Section of this manual 6x6 ii Ratios must match within 3 difference Operation The power divider transfer gearing provides the means to deliver power to the steer drive axle Operating modes and power flow are shown in the illustrations below The transfer gearing includes two mechanical clutches which in turn control the drivelines from transmission to the input shaft and from front output shaft to the steer drive axle 6x6 Operating Mode Power Divider Transfer Gearing Driver flips an air control valve to engage steer drive axle and tandem inter axle differential lockout Gearing Single Reduction Dual Range Double Reduction TANDEM AXLE jim REAR AXLE T b Q SEU peg TORQUE M INPUT L wn THE om CLUTCH ENGAGED INTER AXLE DIFFERENTIAL Uu uL OPERATION LOCKED OUT EN TO STEER JA DRIVE AXLE QV TRANSFER GEAR CLUTCH ENGAGED 6x6 Operating Mode Power Divid
48. A E 95 4 OBO wat S Lp 7 0 gt Se ge me E N r yates TT D X SLIDING CLUTCH i DIFF RING IDLER HIGH SPEED RANGE BEARING GEAR PINION CLUTCH BEARING AXLES cue BOLT PIN PLATE NOTE Lubricate interna parts with gear iube during reassembty 1 Press bearing cones suppor cases see photos IMPORTANT To prevent bearing cone damage use suitable sieeve that only contacts the inner race of the Pressing Bearing Cone cn Large Pressing Bearing Cone on Small Support Case Support Case 1 15 HIGH SPEED RECESS CHAMFER CLUTCH PLATE v8 35 4 CHAMFER POSITION QN 25 SIDE N MOM OF PLATE CASE THAU TOWARD v CASE d 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 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 6x6 6 10 Differential Carrier Overhaul Assemble Wheel Differential Cont d 4 Assemble side pinions and 5 Place side gear and thrust 6 Align punch marks and place thrust washers on spider Placethis washer in position on side pinions plain case on case with pins assembly in dif
49. Differential 10 Assemble Drive Pinion 12 FORWARD AXLE Iretall Drive PIDIOD 5 5 55 gt 55 1 5 5 8 14 Install Pinion Outer Support Bearing Race 14 Install Pinion Helical Gear 15 Install Differential Assembly in Carrier 16 REAR AXLE install Dive PUNO 5 5 3 5 53 4 5 17 Install Differential Assembly in Carrier 17 FORWARD AND REAR AXLE Adjust Differential Bearing Preload 18 6 1 6x6 6x6 Tandem Axle Dual Range DT346 P 386 P 406 P 446 P 486 P 586 P 656 P Double Reduction DP346 P 386 P 406 P 446 P 486 P 586 P 656 P Differential Carrier Assembly COTTER PIN Forward Axle BEARING ADJUSTER LOCK FLAT WASHER EXPANSION PLUG CAP SCREW SHIFT FORK SHAFT LOCKWIRE FILLER PLUG BEARING LH o DOWEL PIN FLAT ES ou SNAP BEARING ADJUSTER LOCK N LEEVE C 8 DOWEL BUSHING q 1 BEARING RETAINING i WASHER DIFFERENTIAL CARRIER gea BUSHING 586 P ILLUSTRATED EXPANSION PLUG LOCKWIA PLANETARY DOUBLE REDUCTION AXLES DIFFERENTIAL 1 F SCREW 8 RING GEAR LoCKwasHEn SHIFT FORK COVER BEARING BEARING HIGH SPEED IDLER THRUST GEAR BEARING ADJUSTER CLUTCH PLATE PINION RING BOLT 26 SLIDING CLUTCH NG THR
50. Do not allow pinion bearing cone puller IMPORTANT During the follow 2 For pinion with press fit bear 3 Remove oil seal and bearing 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 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 Paring fo remove Dearing 3 4x4 6x6 2 24 Differential Carrier Overhaul Disassemble Wheel Differential Rear Axle Wheel Differential Illustrated SIDE THRUST FF THRUST E z CASE WASHER 2 _ SPIDER M ami JR CASE PL SINN gt A gt WITH CASE 4 x PINS CAP SCREW TM if t SIDE gt v uU PINION iL Ki TO I e Ys on ter 2744 PLANETARY DOUBLE r REDUCTION AXLES OFF DIFF GEAR RENT SUPPORT RING GEAR DIFF DIFF SUN SUN GEAA BEARING BEARING SUPPORT CASE SUPPORT BEARING BEARING GEAR RET pe ADJUSTER CONE CASE THRUST T CAS CONE ADJUSTER LARGE WASHER IDLER Wi SHER SMALL PINION Van AN c dde He
51. Install Differential Carrier Assembly in Axle Housing 16 4x4 6x6 7 1 Spicer Axle Service and Maintenance Instructions Introduction Spicer 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 Includes 15 friction Includes 21 friction ES a plates designed for plates designed for single drive axles sirigle drive axles 19 000 Ibs to 22 000 23 000 Ibs to 35 000 Ibs capacity ibs capacity and tandems 34 000 Ibs tandems 44 000 Ibs to 40 000 Ibs capacity to 65 000 Ibs capacity 3 Medium duty Controlled Traction Heavy duty Controlled Traction Differential for Differential for Steer drive Axles ESD 18 4x4 Rear Axles 23054 26054 30054 4x4 see Axles 18554 and 22054 35054 6x6 Tandem Axles DS346 P 6x6 Tandem Axles 05466 05386 05406 05486 05586 05656 Driver Controlled Type Illustrated Driver Controlied Type Illustrated NOTE In this manual instructions for both CTD design types are the same except where specified otherwise This manual includes
52. PRESSURE IS 5 PRESSURE 5 ROUTED THROUGH APPLIED TO INTERLOCK SHUTTLE VALVE C1 PIN D PIN BLOCKS AXLE RANGE SHIFTER VALVE LEVER 2 INTERLOCK CONTROL VALVE OPENS WITH INTER AXLE DIFF SHIFT UNIT ENGASED STEER DRIVE AXLE AND INTER AXLE DIFF ARE ENGAGED TANDEM AXLE IS IN LOW RANGE LOCKOUT INT R AXLE 000 TUNIT AND FORWARD AXLE SHIT UNIT Low NGE AIR FLOW FROM ALL WHEEL DRIVE SHIFTER VALVE 2 INTERLOCK CON gno ME A 15 5 Ose 2m 4 AIR PRESSURE st INTERLOCK PIN 0 15 A E EXHAUST PORT IN n EXHAUST PORT IN INTERLOCK VALVE Aj OR B M 3 INTERLOCK CONTROL VALVE 8 15 CLOSED VALVE OUTLET PRESSURE n 15 EXHAUSTEO EXHAUST INTERLOCK PIN DI 4 1 AIR PRESSURE zn iio did js 4 eL i is E 3 5 E i gt SPRING JL LI PRE AIR EXHAUST WNTER AXLE DIFF SHIFT UNIT STEEP DRIVE AXLE SHIFT UNIT SLIDING CLUTCH End SENGAGES HELICAL SIDE GEAR SLIDING CLUTCH ma DISENGAGES DRIVE GEAR 1 TANDEM ae Sree UN LOW IN LOW RANGE PSX RANGE FLOCKOUT CONTROL VALVE CONTROL ER AIR FLOW TO EXHAUST VALVE AT ALL WHEEL DAVE SHIFTER VALVES CONSTANT AIR FLOW THROUGH INTERLOCKING SYSTEM AIR FLOW FROM SUPPLY FROM AIR SUPPLY WHEN SELECTING 6x6 D
53. RANGE IN LOW RANGE ORIVE TANDEM AXLE IN LOW RANGE SEE PAGE 8 11 FOR DETAILS NOTE Axle Range shift cannot be made unless Steer Drive Axle and Inter axle Differential shifter valve is disengaged 6x4 drive Also the system wrap up torques in the drivetrain may prevent immediate disengagement of the Steer Drive Axle clutch and the Inter axle Differential 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 clutches will disengage Interlock pin on range selector valve will then retract allowing axle range selection as desired 6x6 8 9 Dual Range Tandem Single Reduction Steer Drive Description and Operation Axle Range Shift System One manually operated shifter valve changes tandem axle range This valve is equipped with an interlock pin assembly which prevents axle range shifting when steer drive axle is locked up for 6x6 drive Two air shift units mounted on the tandem axle are mechanically connected 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 the axle shift units For vehicles not equipped with automatic 5 brakes an ignition controlled solenoid valve exhausts the system and downshifts the axles when the ignition switch is turned off The elect
54. Shaft 1 Disassemble and remove lockup shift unit from output shaft cover see Shift System Section 8 2 Remove nut flat washer and yoke from shaft Remove cover assembly and shift fork NOTE On 0346 P 386 P 406 P remove bearing spacer from output shaft 3 To disassemble output cover remove oil seal and bearing cup using suitable pullers 4 To disassemble output shaft place assembly in press helical gear up Press inner bearing cone and gear off 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 prevent bearing damage be careful to use sleeve that only contacts inner race of bearing cone 4 8 6x6 Assemble Front Output Shaft Front Output Shaft BEARING FRONT SHIFT FORK OUTPUT S amp S PUSH ROD BEARING HELICAL SLIOING cur GEAR CLUTCH 1 Used only on 0346 386 406 5 Remove outer using split type puller 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 cone After bearing cone installation helical gear should rotate freely 5 On D346 P 386 P 406 P only install bearing spacer washer on spline end of output shaft BEARING Cur Power Divider
55. 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 page 3 If removed install output shaft bearing cup in carrier 2 Install snap ring to secure bearing race WARNING SNAP RING IS SPRING STEEL AND MAY POP OUT WEAR SAFETY GLASSES WHEN INSTALLING 6x6 6 14 Differential Carrier Overhaul NOTE After differential adjust ment is complete or if dummy yoke was used remove nut and yoke Then continue to assemble pinion as follows 1 Install helical gear on pinion positioned as 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 torque chart Torque Chart Drive pinion Slotted Nut and Roll Pin Ft Ibs 1 1 2 18 840 1 3 4 12 980 IMPORTANT Torque nut to torque shown in chart then con tinue tightening nut to align slot with nearest hole in pinion shank Install roll pin NOTE After differential adjust ment is complete or if dummy yoke was used remove nut and yoke Then continue to assemble pinion as follows 1 On D466 P only install helical gear spacer Install helical gear on pinion using driver and hammer 2 Install pinion outer support bearing using driver and h
56. 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 a 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 equip ment 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 steer ing stability The caster angle must be equal Adjust Toe in Toe in should be set at 0 to 1 80 The front of the wheels should be the same distance apart or 1 8s clos er than the rear of the wheels Change adjustment by turning tie rod to change its length Adjustment can be checked as follows Scribe a 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 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 A should be same or 1 8 shorter than rear measurement B Ad just tie rod as necessary to achieve these tolerances 1 5 4x4 6x6 Caster 4 CASTER 3 VERTICAL LINE KINGPIN C L Caster Angle Should Be 3
57. be level with the bottom 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 Class A operation is defined as well maintained highways of concrete or asphalt construction Terrain level to rolling with maximum 8 grades Class 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 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 Y Correct Lube level at bottom of filler hole Incorrect Lube level below filler hole 4x4 6x6 2 2 Changing Lube Draining garrs Drain when the lube is at normal operating temperature It will run freely 1 co 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 particl
58. cage cap screws then drive pinion assembly out of carrier IMPORTANT Do not allow pinion to drop on hard surface Remove shim pack IMPORTANT Forward and Rear Axle If gear 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 Differential Carrier Overhaul Disassemble Drive Pinion Rear Axie Pinion Illustrated PINION BEARIN PILOT CONE BEARING INNER DRIVE PINION 1 Used only on R466 R486 f 00 0 BEARING BEARING BEARING BEARING OIL SEAL PINION SPACER CAGE CAGE Cue amp RETAINER NUT VARIABLE SHIM OUTER 1 BEARING CAGE BEARING 2 SPACER INPUT FLAT WASHER WASHER INNER LOCKWASMER SCREW OUTER YOKE 1586 8650 2 Used only R346 R386 R406 IMPORTANT During the following yoke removal procedure the drive pinion may fall out of bearings and cage Do not allow pinion to drop on hard surface 1 Rear Axle Pinion Yoke 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 Forward and Rear Axle Pinion Bearing Cage Support cage and press pinion out of bearing cage and bearing cone 3 Rear Axle Pinion Oil Seal and
59. 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 4x4 6x6 2 10 Differential Carrier Replacement Remove Differential Carrier Assembly from Axle Housing NOTE To permit removal of the differential carrier assembly the axle shafts must be disengaged from the differential side gears This can be accomplished by removing the wheel end parts and the axle shaft Refer to Wheel End Overhaul Instructions Or if equipment is available the axle shafts can be disengaged by separating the wheel end assem bly from the axle housing see illustration 1 Drain axle lube 2 To separate wheel end assem bly from axle housing remove cap screws and nuts fastening Socket ball flange to the housing Provide equipment to handle the wheel end assembly Then dis connect air brake lines and steer ing connections as necessary to permit moving the wheel end assembly outwardly until the axle shaft is disengaged from the dif ferential side gear Disengage axle shaft on both sides of axle 3 Dual Range Axles Shift to Axle Low Range Disconnect shift unit air line Remove shift unit NOTE When shift unit is removed provide container to catch oil that escapes from reservoir 4 Axles with Controlled Traction Differentials Driver Controlled Engagement Type Remove shift unit nuts and washers Disconnect ai
60. drums for cracks discoloration due to hard spots heat checking glazing grooving or severe out of round condition Replace cracked drums WHEEL HUB AND DRUM ASSEMBLY Removing Wheel Hub and Drum Assembly 1 9 4x4 6x6 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 TO AVOID POSSIBILITY OF PER SONAL INJURY MAKE CERTAIN YOU HAVE A FIRM HOLD ON PRYING LEVER BEFORE REMOVING ROLLER AND PIN ROLLER AND PIN gt STURDY LEVER Prying Down on Brake Shoe to Remove Cam Roller and Pin SHOE 1 a RETURN 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 16 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 is cracked or improperly worn c Lining is loose on shoe Replace loose rivets or bolts d Lining is oil soaked or contaminated with other foreign material NOTE Replace brake springs with a brake reline RETAINER SPRING Re
61. equipped with Controlled Traction Differentials they are engaged and operating SLIDING CLUTCH ENGAGES OR CISENGAGES DRIVE GEAR LOCKOUT SHIFT N Powe DIVIDER SHIFT FORK COVER SLIDING CLUTCH ENGAGES OR DISENGAGES HELICAL SIDE GEAR All Wheel Drive and Controlled Traction Differential Shift Systems 1 Initial Preparation Start system check by placing 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 position If possible park vehicle a flat surface and do not apply spring brakes Do not move the vehicle until system checks are completed Lastly insure that sufficient air pressure is built up to per form 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 be sure to check axle shift units and air lines 3 Move shifter valve lever to the Disengaged position In this 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 will be evident by sound of parts movement 5 If air pressure is satisfactory and shift units do not function disassemble and inspect
62. 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 these 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 277 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 CAUTION ANY DAMAGE WHICH AFFECTS THE ALIGNMENT OR STRUCTURAL 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 su
63. 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 Removing Sliding Clutch 1 Mount the differential carrier in 2 Driver Controlled and Seasonal 3 Driver Controlled and Seasonal a repair stand CTD Only Remove shift fork seal CTD Only Disengage shift fork and spring Remove expansion yoke from sliding collar Then plugs then working at the lower remove clutch and shift fork or small plug hole drive out the shift fork shaft WARNING WHEN USING DRIFT PUNCH OR SIMILAR TOOL WEAR SAFETY GLASSES 7 4 4x4 6x6 Remove Differential Clutch Assembly from Carrier conta 6 On back side of ring gear cut iockwire and remove bearing cap 4 If reusing gear set punch mark 5 On teeth side of ring gear cut screws If the gear set is to be bearing adjusters for reference lockwire and remove bearing reused remove bearin during assembly screws Remove cap adjuster and adjuster and 2 lock This will facilitate correct position ing of ring gear during reassembly
64. illus tration Compound will set in 20 minutes Install carrier before compound sets or reapply Dual Range Axles Shift axle to Axle Housing Silicone Gasket Low Range before installing dif Compound Pattern ferential carrier assembly Axles with Controlled Traction Differentials Place sliding clutch Torque Chart in the engaged position before installing differential carrier Differential Carrier assembly Stud Nut Ft Ibs 1 Install differential carrier 5 8 18 220 240 298 325 assembly in axle housing Install Grade 8 Stud stud nuts and lockwashers Shift Unit yc ues torque Stud Nut Ft Ibs 2 Connect inter axle drive line Stud 55 61 3 Dual Range Axle and Axles with Controlled Traction Differen Socket Ball to Housing tials Install shift unit nuts and Stud Nut Ft Ibs N m lockwashers Torque nuts see 3 4 16 280 360 380 488 chart Connect air line Grade 8 Stud 4 Install axle shafts if they were Cap Sc removed Refer to Wheel End p screw Overhaul Instructions 5 8 11 231 298 Grade 8 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
65. installation tilt carrier to allow support case pilot to rest in carrier bore then install bearing cup as shown in photo Also install Dearing opposite side of cifferential 2 If the same gear set is used install the assembied bearing adjuster and lock on the backface side of the ring gear Otherwise install adjuster and cap separately NOTE When installing cap it may be necessary to tap it lightly witha 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 3 Install and tighten bearing cap screws finger tight If this is diffi cult use hand wrench NOTE The assembiy is now ready tor adjustment of differential bear ing preload ring gear backlash and gear tooth contact 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 in
66. mode It consists of an interlock shuttle valve and two interlock control valves The control valves are mounted on the lockout and lockup shift units The interlock system controls deli very of 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 and Inter axle Differential Lockout System One manually operated shifter valve is used to control two shift units mounted on the tandem forward axle These shift units are mechani cally connected to shift forks and sliding clutches The operational modes of the steer drive axle and the inter axle differential are con trolled by movement of these slid ing clutches When the shifter valve is in the engaged position the drive to the steer drive axle is engaged and the inter axle differential is locked out not operating for 6x6 drive with maximum traction With the shifter valve in the disen gaged position the drive to the steer drive axle is disengaged for 6x4 operation and the inter axle differential is unlocked operating normally 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 6x6 8 5 Dual Range Tandem Single Reduction Steer Drive Interlock System Operation Interlock Engaged 6x6 Operation
67. range Disconnect shift unit air line Remove shift unit 5 Disconnect lockout and lockup shift unit air lines 8 Remove stud nuts and axle shafts If used remove lockwash ers and taper dowels If neces sary loosen dowels by holding a brass drift in the center of the shaft head and striking drift a sharp blow with a hammer IMPORTANT Do not strike the shaft head with a hammer Do not use chisels or wedges to loosen shaft or dowels 11 Remove oil seal and discard 3 Axle with Controlled Traction Differential Shift to the engaged position When equipped discon nect shift unit air line Remove shift unit 6 Disconnect input driveline Loosen shaft nut but do not remove 9 Support differential carrier with transmission jack or similar equip ment Remove nuts and lockwash ers some models also use cap screws fastening carrier to axle housing Remove differential car rier and power divider assembly WARNING DO NOT LIE UNDER CARRIER AFTER FASTENERS ARE REMOVED USE TRANS MISSION JACK TO SUPPORT DIFFERENTIAL CARRIER ASSEMBLY 12 Remove bearing retaining washer IMPORTANT D346 P 386 406 P models do NOT use an output shaft Rear Bearing Retaining Washer 6x6 3 15 Forward Axle Differential Carrier Replacement Install Differential Carrier Assembly IMPORTANT D346 P 386 P 406 P models do NOT use a rear output shaft Rear Bearing Retaining Washer AJ WARNING WHEN INSTALLING
68. screws NOTE Forward Axle Only D466 P 486 P 586 P 656 P 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 Could vary in length Pocket may be Pattern should cover SIINE extended 1 2 tooth or more 2 pi Pattern along the face width face width Pattern should be evenly centered between tooth top land and Za root 2 could be longer Pattern should be clear of tooth toe 6x6 5 17 6x6 Tandem Axle Dual Range DT346 P 386 P 406 P 446 P 486 P 586 P 656 P Double Reduction DP346 P 386 P 406 P 446 P 486 P 586 P 656 P Differential Carrier Overhaul Forward and Rear Axles These instructions cover dual range and double reduc tion differential carrier assemblies for 6x6 tandem for ward and rear axle tandems It is assumed that the power divider assembly has been removed from the forward axle carrier Section 6 Contents Page No DIFFERENTIAL CARRIER OVERHAUL Exploded View 2 Disassemble Differential Carrier 4 Disassemble Drive Pinion 6 Disassemble Wheel Differential 8 Assemble Wheel
69. 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 Continue to press until the plate breaks loose from the plate dowel pins 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 HOLES PROVIDED LTO REMOVE BEARING Removing Bearing from Small Support Case using Puller 4x4 6x6 2 26 Differential Carrier Overhaul Assemble Wheel Differential THRUST DIFF WASHER anc 6 GEAR WASHER pier PLANETARY DOUBLE REDUCTION AXLES DIFF DIFF GEAR SUPPORT SUPPORT AING EAR DIFF SUN GEAR BEARING BEARING SUPPORT CASE CASE GEAR SUPPORT BEARING BEARING GEAR RETAINER ADJUSTER CONE THRUST CASE CONE ADJUSTER IDLER WASHER SMALL 5 PINION Fe M 4 ow IPF OY G CLUTCH DIFF RING IOLER HIGH SPEED Ws Ie BEARING GEAR PINION CLUTCH BEARING AXLES BOLT UP NOTE Lubricate internal parts with gear lube during reassembly 1 Press bearing cones on support cases see photos IMPORTANT To prevent bea
70. surface of cage Press one cup in at bene 1 Press bearing cups in cage 2 Press pilot bearing on pinion 3 Stake pilot bearing using stak ing too IMPORTANT At this point select pinion bearing spacer by using the NOTE During pinion bearing installation locate each part in same position that was used in Trial Buildup Preload Test trial build up procedure described in the Adjustments Section of this manual 4 Press inner bearing cone on 5 Install bearing spacer selected 6 Install bearing cage on drive pinion during trial build up on pinion pinion 2 29 4x4 6x6 Differential Carrier Overhaul Assemble Drive Pinion Press fit outer pinion bearing conta Press Seal in Cage Sleeve must be sred to press on seal outer lange m 7 Press on outer pinion bearing 8 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 Tighten nut to correct torque 560 700 ft Ibs 759 949 IMPORTANT At this stage of assembly final check pinion bearing preload See Adjustment Section of this manual 4x4 6x6 2 30 Differential Carrier Overhaul Install Pinion 1 Place shim pack on carrier making sure lube hole is clear se
71. 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 2 9 4x4 6x6 CORRECT PATTERN NEW GEARING Could vary in length Pattern should cover 1 2 tooth or more face width Pattern should be evenly centered between 74 top iand and 4 root Pattern should be clear of tooth toe CORRECT PATTERN USED GEARING Pocket may extended Pattern along the face width could be longer 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
72. then temporar ily install two clamping bolts and nuts see photo NOTE These clamping bolts will hold cover in position while remov ing the other cover self locking bolts and nuts Remove cover self iocking bolts and nuts CLAMPING NUTS amp BOLTS Removing Case Cover with clamping nuts and bolts installed Remove and Disassemble Clutch Pack conta CLAMPING NUTS amp BOLTS Removing Clamping Nuts and Boits Removing Clutch Pack 7 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 bolts and nuts removed alternately loosen and remove the two clamp ing nuts and boits 4 Liftoff 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 difficuity is experienced first remove pressure plate then lift out friction plates individually 8 If necessary remove 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 altern
73. to 0 007 Measured end play 5 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 play Step 1 0 015 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 truck on the ground and axle shafts installed 3 8 6x6 NOTE If difficulty is experienced in achieving correct torque on the input yoke nut torque the nut with 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 ings 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 If end play is still incorrect repeat Steps 2 through 6 8 With end play correct seal shim pack to prevent lube leakage then torque input shaft nut and cover cap screws see chart NOTE Whe
74. 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 6x6 3 13 Forward Axle Differential Carrier Replacement Adjust Tooth Contact Pattern 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 INCORRECT PATTERN Move pinion f DS toward ring gear ff NAY s 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
75. torque to rotate Torque Chart Ring Gear BOLT NUT Size Grade Ft Ibs N m 5 8 18 8 180 220 244 298 Differential Case SCREW Size Grade Ft Ibs N m 9 16 12 8 150 180 7 Install ring gear Secure with bolts and nuts and tighten to correct torque see chart 2 17 4x4 6x6 Differential Carrier Overhaul Assemble Drive Pinion NOTE Lubricate parts with gear lube during reassembly PINION BEARING BEARING BEARING BEARING SEARING OIL SEAL INPUT PILOT CONE SPACER CAGE CAGE CUP RETAINER YOKE BEARING INNER VARIABLE SHIM OUTER FLAT WASHER Bw omm j 1 lt 7 y ORS oL MES 36 PINION INNER NUT LOCKWASHER Press Bearing SLEEVE Cups mus be seated m cage Check with teeter gauge 100017 alter vigtallamon When cups wet be recessed below outer surface cage Press one cuo in st bene 1 Press bearing cups in cage 2 Press pilot bearing on pinion 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 Preioad Test IMPORTANT At this point select pinion bearing spacer by using the trial build up procedure described in the Adjustments Section of this manual dhe 4 Press inner bearing cone 5 Install bearing spacer selected 6 Inst
76. 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 Differential Carrier Overhaul Changing Lube Drainin 9 OIL FILLER Drain when the lube is at normal operating temperature It will run freely HOLE 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 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
77. 2 If oil seal is faulty or has been removed instail a new seal NOTE Position seal with sealing lip toward ball bushing see drawing Seal shouid 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 Ibs 380 488 Torque cap screws to 170 220 ft Ibs 231 298 1 17 4x4 6x6 INSTALL OIL SEALS WITH LIPS POINTING IN THE SAME DIRECTION TOWARD CAMSHAFT SPLINES CAMSHAFT R CAMSHAFT BUSHINGS IF NECESSARY REAM TO 1 500 AFTER INSTALLATION NON METALLIC BUSHINGS DO NOT REQUIRE REAMING Camshaft Bushing and Oil Seal Installation BALL SOCKET SEAL RETAINER BALL SHAFT BUSHING INSTALL WITH OPEN OF LUBE GROOVE TOWARD XINGPIN SEAL INSTALLATION SEAL LIP TOWARD BALL SH Ball Bushing and Oil Seal Installation Steering and Wheel End Equipment Overhaul Assembly Assemble Socket to Axle Ball 1 Tip axie ball socket see photo and install it on the axle ball Position socket on ball to maintain correct relationship between top and bottom of the ball and socket 2 Install Kingpins A special spreading fixture is recommended for installation of kingpins This tool can be obtained from Oshkosh Truck Corporation 2307 Oregon St Oshkosh Wisconsin 54903 11888850 LIA NS Kingpin
78. 56 P 8 9 1 6x6 Spicer Steer Drive Axle Fastener Tightening Steering and Wheel End Equipment Specifications Model ESD 18 Fastener Size Grade Ft ibs N m HUB CAP Nut TEITTE 170 220 231 298 WHEEL BEARING ADJUSTING NUT Cap Screw 3 8 24 5 40 55 KINGPIN T TET 1 1 2 18 500 680 KINGPIN COVER Cap Screw 5 8 11 8 170 220 231 298 NE vs 3 4 16 280 360 380 488 STEERING ARM BALL STUD ET ee oe ew ME 7 8 14 450 613 AXLE BALL SEAL RETAINER SGT cvcscciccrivsadsasarines 3 8 16 5 30 40 AXLE BALL TO HOUSING Cap Screw 5 8 11 8 170 220 231 298 Stud Nut 3 4 16 8 stud 280 360 380 488 AXLE SHAFT CAGE RING Cap Screw 1 2 20 8 95 130 TIE ROD END Stud Nut 7 8 14 450 613 Clamp Bolt Nut 5 8 11 60 80 81 110 AIR CHAMBER MOUNTING ee 5 8 18 5 130 180 176 244 CHAMBER BRACKET SOCKET Cap Screw 1 2 13 8 80 110 110 149 SPINDLE TO BALL SOCKET Cap Screw 220 350 BRAKE SPIDER amp SPINDLE TO AXLE BALL SOCKET 12 pt 5 8 11 8 170 220 231 298 6x6 9 2 Spicer Steer Drive Axle Fastener Tightening Steering and Wheel End Equipment Specifications Model ESD 18 Fastener Size
79. 6 P 5 2 6x6 RS346 386 406 466 486 586 656 Differential Carrier Assembly Rear Axle BEARING PLAIN DIFFERENTIAL THRUST THRUST FLANGED DIFFERENTIAL CUP CASE HALF WASHER WASHER CASE HALF BEARING THRUST SIDE SIDE BEARING BEARING CONE WASHER PINION GEAR CONE ADJUSTER BEARING CAP SIDE BEARING ADJUSTER SCREW GEAR SPIDER NUT CUP LOCKWIRE FLAT COTTER WASHER PILOT DRIVE BEARING BEARING BEARING YOKE NUT BEARING PINION SPACER CAGE CONE N VARIABLE gt SPACER SCREW eod WASHER COTTER Q6 Q DN 0 6 BEARING CAP Lb ADJUSTER CAGE SHIM SCREW LOCK ADJUSTER BEARING DIFFERENTIAL BEARING BEARING LO FLAT LOCK CAP CARRIER CONE Cue WASHER OIL SEAL WASHER 1 Used only on R466 R486 8586 R650 2 Used only R346 R386 R406 6x6 5 3 Differential Carrier Overhaul Disassemble Differential Carrier with power divider removed Forward Axle 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 Differential Carrier 2 Punch mark differential bearing 3 Cut lockwire Remove Assembly in repair stand On caps reusing gear set also screws flat washers and bearing models with slotted nut remove punch mark bearing adjust
80. Air flow should be present through each of the disconnected air lines If air flow is not present inspect the axle range shifter valve and the quick release valve Replace as required Place axle range shifter in Low Range position Air flow should not be present in any of the disconnect ed air lines Reconnect air lines and insure that sufficient air supply exists to per form following checks to the remainder of the system 9 8 6x6 4 Check Lockup System After insuring that the axle range shifter valve is in the Low Range position have an assistant move the All Wheel Drive selector valve lever from disengaged to engaged posi tion Check for mechanical move ment in the inter axle differential lockout shift unit and steer drive axle lockup shift unit mounted on the tandem forward axle Alternatively disconnect air lines from cover of inter axle differential lockup unit and steer drive axle lockup shift unit with All Wheel Drive selector lever in disengaged position NOTE These air lines are not to be confused with air lines connected to interlock control valves installed in shift unit covers Leave these air lines connected Place All Wheel Drive selector valve in engaged position and check for air flow at disconnected air lines Place lever in disengaged position and insure air flow is discontinued If system functions correctly pro ceed to Step 7 If not proceed to Step 5 5 Check Lockout Control Valve
81. DIFFERENTIAL CARRIER ASSEMBLY IS IMPORTANT FOLLOW CORRECT PROCEDURES TO ASSURE USEFUL LIFE FAILURE TO CORRECTLY INSTALL REAR BEARING AND RETAINING WASHER COULD RESULT IN PREMATURE AXLE FAILURE IMPORTANT Before installing carrier assembly inspect and thoroughly clean interior of axle housing NOTE Use silicone rubber gasket s GASKET COMPOUND SILICONE GASKET COMPOUND compound 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 axle housing cover before com pound sets or reapply Follow procedure in numerical sequence 1 Dual Range Axle Shift to low range 4 Axle Housing Cover and Rear Output Shaft Bearing Parts 1 removed install cover and fasten with nuts cap screws and lock washers Tighten to correct torque If removed install bearing parts see steps 5 through 8 7 Install a new output shaft seal in the axle housing cover and lubricate the seal inner diameter to prevent damage during yoke installation 10 Install axle shafts and stud nuts If used also install lock washers and taper dowels 13 Dual Axle Install shift unit nuts and lockwashers Torque nuts see chart page 3 18 Connect air line 3 16 6x6 2 Axle with Controlled Traction Differential Shift to engaged position 5 Install out
82. Grade Ft ibs RING GEAR Single Reduction Bolt Nut 5 8 18 8 180 220 244 298 Dual Range 8 Double Reduction 9 16 18 5 150 170 203 230 DRIVE PINION 4 gt 2 24 1 1 2 18 560 700 759 949 PINION BEARING CAGE Cap Screw 9 16 12 5 100 125 136 170 DIFFERENTIAL CASE Single Reduction Cap Screw 9 16 12 8 150 180 203 244 Dual Range amp Doubie Reduction 1 2 13 8 90 110 122 149 DIFFERENTIAL BEARING Single Reduction Cap Screw 3 4 10 8 360 440 488 596 Range 8 Double Reduction 13 16 10 8 370 430 501 583 DIFFERENTIAL BEARING ADJUSTER LOCK Range amp Double Reduction Cap Screw 5 8 11 5 160 176 217 239 DIFFERENTIAL CARRIER SHINY 5 8 18 8 stud 220 240 298 325 SHIFT UNIT MOUNTING 7 16 20 8 stud 55 61 74 82 SHIFT FORK COVER BOW sis 7 16 14 5 35 45 47 61 9 3 6x6 Fastener Size Grade Ft Ibs INPUT SHAFT D346 P 386 P 406 P 1 5 8 18 780 960 1059 1301 D466 P 486 586 656 1 7 8 12 840 1020 1139 1383 INPUT SHAFT BEARING COVER Cap Screw 1 2 13 5 75 85 101 115 INTER AXLE DIFFERENTIAL Bolts Nuts 5 16 24 8 17 23 23 31 REAR OUTPUT SHAFT D346 P 386 P 406 P 44 5 5
83. Grea FLAT 297 WASHER DOWEL A Bushe BEARING DIFFERENTIAL PILOT BEARING cue BEARING PINION CARRIER BEARING CONE CONE YOKE NUT BEARING COTTER ADJUSTER BEARING EXPANSION DRIVE SPACER CAP SCREW PIN LOCK CAP PLUG PINION VARIABLE LOCKWASHER 4x4 6x6 2 22 Differential Carrier Overhaul Disassemble Differential Carrier 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 originai adjustment during reassembly 3 2 Speed Axles Only Remove 5 Remove bearing cups then lift sliding clutch Planetary Double ring gear and differential assem Reduction Axles A sun gear is bly out of carrier used in place of sliding clutch gear To remove sun gear remove the retainer which holds gear in position then remove sun gear NOTE When reusing gearset punch mark bearing adjusters and bearing caps for location and easier adjustment during reassembly 4 On teeth side of ring gear cut 1 Mount the differential carrier in lockwire and remove bearing repair stand cap screws Remove cap juster and lock back side of ring gear cut lockw
84. If this does not occur the rear axle shift units must be inspect ed and repaired Do not proceed to Step 7 until proper operation is obtained 7 Place the axle range shifter valve in the High Range position and the All Wheel Drive selector lever in the engaged position Return to the lock out control valves and insure that air flow is not present at the side ports of each valve This is the feature that prevents All Wheel Drive operation in High Range If air flow is present the lockout control valves and or axle range shift units must be inspected Do not proceed to Step 8 until proper functioning occurs NOTE See next page for Step 8 lt pana gt SPICER Drivetrain Products Axles Driveshafts Off Highway Transmissions LONG Thermal Products Transmission Oil Coolers Engine Oil Coolers VICTOR REINZ Sealing Products Gaskets and Seals Cylinder Head Cover Modules Thermal Acoustic Protective Shielding Dana Aftermarket Group PO Box 321 Toledo Ohio 43697 0321 Warehouse Distributors 1 800 621 8084 OE Dealers 1 877 777 5360 WWW Spicerparts com AXIB 9501 Printed in U S A Copyright Dana Limited 2012 All rights reserved Dana Limited
85. LIDING CLUTCH BEARING 1 Used only D346 P 386 406 P 4 14 6x6 Final Shaft Reassembly after End Play Is 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 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 10 Place shift fork in mounting position in cover and on sliding clutch Then assemble shim pack and output shaft assembly to power divider cover Install four cap screws and lockwashers 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 edge of shim pack with sealant 12 At this point in reassembly remove yoke and install new oil seal with seal driver Reinstall yoke flat washer and nut Torque nut see chart Torque Chart Front Output Shaft Cover Cap Screw Ft Ibs 7 16 14 two 48 56 Grade 5 9 16 12 four Grade 5 Output Shaft Nut 1 1 2 18 Grade 5 65 76
86. NAP NUT BEARING CLUTCH RING CUP BEARING THRUST 71 I 5 SPLINED FRICTION COMPRESSION ADJUSTER WASHER RING cus d PLATE SPRING GEAR SURE HT TANGED FRICTION 17 PLATE eS EXPANSION DRIVER SHIFT _ DRIVER CONTROLLED AND SEASONAL CTO PAET SPRING PERMANENT CTD SEASONAL CTD DRIVER CONTROLLED SHIFT FORK SHIFT FORK RETAINER CTD SHIFT UNIT OPENING COVER CAP SCREW EXPANSION PLUG WASHER ADJUSTING LOCK SCREW NUT SHIFT FORK FOR DRIVER CONTROLLED AND SEASONAL 1 Place differential and gear support case clutch pack up on workbench WARNING EXERCISE CARE GEAR SUPPORT DURING DISASSEMBLY PROCE CASE COVER 7 DURE Step 2 below THE GEAR UPPORT CASE COVER 15 UNDER SPRING PRESSURE AND COMPRESSION SPRINGS THE RING GEAR MAY FALL OFF THE SUPPORT CASE AFTER THE LAST LOCKNUT IS REMOVED DIFFERENTIAL TAKE PRECAUTIONARY AND GEAR MEASURES TO PREVENT PER SUPPORT CASE SONAL INJURY OR PARTS FLANGED DAMAGE DURING PROCEDURE IN STEP 2 BELOW 2 Remove self locking nuts and bolts then lift off gear support case cover and compression springs DIFFERENTIAL CASE PLAIN HALF Removing Gear Support Case Cover 2 SELF LOCKING NUT 7 10 4x4 6x6 Remove Disassemble Clutch Pack Heavy Duty Type CLUTCH PACK ASSEMBLY SPLINED FRICTION PLATE 9 gt Sr
87. NG SUPPORT ne 9000000 0 C 4 5 PILOT BEARING BEARING SHIM d 3 ROLL BEARING BEARING CONE SPACER WASHER SCREW GEAR BEARING PIN _ RACE VARIABLE 1 Used only on 0466 486 586 656 2 Used only 0466 3 Used only on D346 P 386 406 P Rear Axle Pinion Illustrated SPACER SPACER PINION BEARING BEARING BEARING READING BEARING Of SEAL PINION PILOT CONE SPACER CAGE 1 CuP RETAINER NUT BEARING od NOTE Lubricate parts with gear lube during BEARING reassembly DRIVE SPACER CUP PINION WASHER INNER 1 Used only on R466 R486 R586 R650 2 Used only on R346 R386 R406 1 Using appropriate sleeve press bearing cups in cage see adjacent drawings NOTE On rear axles do not install oil seal in cage until bearing preload is correctly adjusted IMPORTANT After bearing cups are installed preselect pinion bearing spacer using the trial build up procedure described in the Adjustments Section of this manual Forward Axle Pinion Press Bearing Cups Cups must be anated in cago Check with teeter gouge 00017 aher stsl abon When correctly installed cups will be recessed DelOw outer surface of cage Press one cup m st a time 5 10 6x6 L M 2 INPUT FLAT WASHER CONE LOCKWASHER SCREW OUTER YOKE Rear Axle Pinion Press Bearing Cups in Cage Press recessed below outar surfac
88. NTIAL MAY FALL FROM DIFFERENT CARRIER EXERT CAUTION TO PREVENT DAMAGE OR INJURY 6 Rear Output Shaft Tilt carrier and remove output shaft assembly Removing Inter axle Differential Assembly 4 4 6x6 Removing Rear Output Shaft Removing Rear Output Shaft Side Gear Bearing Cup Disassemble Power Divider Cover Power Divider Cover and Input Shaft HELICAL THAUST LOCKOUT SIDE WASHER SLIDING GEAR CLUTCH D WASHER RING BUSHINGS 1 Remove snap ring from machined groove at rear of input shaft WARNING SNAP RING S SPRING STEEL AND MAY POP OFF WEAR SAFETY GLASSES WHEN REMOVING WITH SNAP RING REMOVED THE HELICAL SIDE GEAR MAY FALL OFF SHAFT EXERT CARE TO PREVENT DAMAGE OR INJURY Slide helical side gear off input shaft then remove bronze thrust washer D washer from shaft 2 Axles with Lube Pump At this point in disassembly it is desirable to remove lube pump drive gear nut Hold input shaft yoke to secure drive gear then loosen and remove drive gear nut 3 Remove nut flat washer and yoke from input shaft INPUT SHAFT CONE ie BEARING POWER e0 DIVIDER NCAP SCREW LOCKWASHER LOCKOUT SHIFT UNIT 4 Remove cap screws lock washers and input bearing cover and shim pack 5 Remove oil seal from bearing cover 6 Slide input shaft assembly out of cover Remove bearing spacer from shaft
89. ON AXLES DIFF DIFF GEAR 5 SUPPORT RING DIFF SUN SUN GEAR BEARING BEARING SUPPORT gt CASE GEAR BEARING BEARING GEAR RETAINER ADJUSTER THRUST THRUST CONE ADJUSTER LARGE WASHER 5 PINHON 3 x N V 2 lt gt Des 1 0385 4 32 SLIDING CLUTCH DUA IDLER HIGHS DIFF RANGE FINION CLUTCH BEARING AXLES PIN PLATE 3 Remove ring gear NOTE A soft faced hammer or mallet may be required to dislodge gear from its mounting 4 To remove differential assembly place support case assembly bench or on the 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 5 Remove thrust washer from 6 Invert differential assembly to 7 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 6x6 6 8 Differential Carrier Overhaul Disassemble Wheel Differential conta 2 o B Lift out thrust washer and side 9 Lift out spider side pinions and 10 Remove side gear and thrust gear thrust washers washer h speed clutch plate by hand If it cannot be 11 First try to lift off nig plate as follows removed easily press of
90. OW THROUGH RANGE SHIFT UNITS FROM RANGE SHIFT UNITS TO ALL WHEEL DRIVE AND AIR SUPPLY AXLES IN EXHAUST AXLES IN LOW INTERLOCK SYSTEMS IN 6x6 HIGH RANGE RANGE cane SEE PAGE 8 6 FOR LS NOTE Interlock system prevents axle range shift unless steer drive axle and inter axle differential shifter valve is disengaged Also the system wrap up torques in the drivetrain may prevent immediate disengagement of the steer drive axle clutch and inter axl differential 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 clutches will disengage Interlock pin on range selector shifter valve will then retract allowing range selection as desired 8 4 6x6 Dual Range Axles with Range Interlock Description and Operation Axle Range Shift System One manually operated shifter valve changes range of all three axles This valve is equipped with an inter lock pin assembly which prevents axle range shifting in 6x6 drive Three 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 three axle shift units For vehicles not equipped with automatic safety brakes an ignition controlled solenoid valve exhaus
91. Overhaul BEARING LOCKUP COVER SHIFT UNIT LOCKWASHEA CAP SCREW oa 1 42 6 If replacement is necessary remove inner bearing cup from power divider cover using suitable puller 3 Reverse position of output shaft in press yoke splines up Place sliding clutch on shaft splines with clutch teeth facing helical gear 6 To assemble bearing cover press bearing cup in cover IMPORTANT For correct cup installation use appropriate sleeve Take care to make sure cup is not cocked andis 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 assembly and output cover are ready to install for purposes of measuring cover clearance and adjusting output shaft end play page 4 14 NOTE When adjustment of output shaft end play is completed con tinue reassembly as described on page 4 14 Power Divider Overhaul Assemble Rear Output Shaft NOTE Lubricate parts with gear lube during assembly 1 Press bearing cone on output shaft side gear IMPORTANT Provide protection against possible gear teeth damage during press operation 2 Mount output shaft in vise Lubricate and instal rings 11 removed install bushing in end of output shaft 3 D346 P 386 P 406 P Two snap rings are used to secure side gear If removed install inner snap ring on output shaft the
92. PORTANT Punch mark cage rings and yoke trunnions for identification in reassembly see photo If axle shaft parts are to be reused the trunnions must be replaced in the original cage ring holes to assure correct operation 1 13 4x4 6x6 AXLE SHAFT ASSEMBLY Removing Axle Shaft Assembly ONE PUNCH MARK PUNCH MARK Ass TR 2 ae a eas rie ELO edle ua 05363X Identifying Cage Rings 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 Separating Cage Rings 5 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 assembly bereplaced 05364 Measuring Trunnions 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 Remove cotter pin nut and flat washer from ball stud at socket Discon a e nect the tie rod end With rod end disconnected the tapered coil spring seal cover rubber seal 45 4 j washer and flat washer can be removed from the ball stud Left Hand Wheel End Disconnect tie rod end using same procedures as described above for right hand wheel end Also disconnect steering drag link from bail stud mou
93. R OVERHAUL Dual Range and Double Reduction Exploded View 22 Disassemble Differential Carrier 23 Disassemble Drive Pinion 24 Disassemble Wheel Differential 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 2 1 4 4 6x6 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 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 8 are also accept able f
94. R of sliding clutch gear To remove TOOL WEAR SAFETY GLASSES sun gear remove cap screws and the retainer which holds gear in position then remove sun gear 4 If reusing gear set punch mark 5 On teeth side of ring gear cut bearing adjusters for reference lockwire and remove bearing cap during assembly screws Remove cap adjuster and lock 6x6 6 4 Differential Carrier Overhaul Disassemble Differential Carrier Cont d 6 On back side 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 7 Remove bearing cups then lift ring gear and differential assembly out of carrier FORWARD AXLE FORWARD AXLE 10 Forward Axle Remove pinion bearing cage cap screws and lock washers Remove pinion and cage assembly from carrier Remove shim pack 9 Forward Axle Remove drive pinion helical gear and related parts as required by models Remove Helical Gear 0346 386 P 406 P Remove pinion nut Remove sup port bearing bearing spacer and helical gear using suitable puller Remove Helical Gear 0466 486 586 P 656 P Remove pinion nut Remove bear ing and helical drive gear using suitable puller Remove helical gear spacer D446 P only 6 5 6x6 REAR AXLE 8 Rear Axle Remove pinion bearing
95. RIVE INTERLOCKING AVAILABLE ONLY WHEN TANDEM IS IN LOW RANGE SYSTEM TO EXHAUST IN HIGH RANGE THE LOCKOUT CONTROL VALVES WHEN SELECTING 6x4 ON AXLE SHIFT UNITS ARE CLOSED BLOCKING AIR DRIVE FLOW TO INTERLOCKING SYSTEM 6x6 8 11 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 Ali Wheel Drive selector in dis engaged position Move vehicle in forward direction for a short dis tance followed by backing 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 flat spot and do not apply spring brakes Do 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 Check Solenoid Valve Turn en gine off If vehicle is equipped with solenoid valve turn ignition ON to energize and open valve Check to insure that air pressure is present on the outlet of the solenoid valve 3 Check Axle Range Shift System Have an assistant in the cab begin moving the axle range shifter valve lever in the cab between Low and High Range Listen for mechanical movement at the tandem axle range shift units If no movement is app
96. SHIM CAGE SEAL WASHER DOWEL BUSHING BEARING DIFFERENTIAL PILOT BEARING CUP BEARING PINION CARRIER BEARING CONE CONE YOKE NUT BEARING COTTER ADJUSTER BEARING EXPANSION DRIVE SPACER CAP SCREW PIN LOCK CAP PLUG PINION VARIABLE LOCKWASHER 1 Used only on R466 R486 Asaa R650 2 Used only on R346 R386 R 6 3 6x6 Differential Carrier Overhaul Disassemble Differential Carrier with power divider removed NOTE if the gear set is to be reused check tooth contact pattern and ring gear backlash before beginning disassembly Best overhaul 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 Rear Axle NOTE For easier disassembly remove pinion nut roll pin with a pin punch Then loosen but do not remove pinion nut 2 Dual Range Axles Only 3 Dual Range Axles Only Dis Remove shift fork seal and spring engage shift fork yoke from sliding Remove expansion plugs then collar Then remove clutch and working at thelower or small plug shift fork hole drive out the shift fork shaft planetary Double Reduction AS WARNING WHEN USING Axles A sun gear is used in place DRIFT PUNCH OR SIMILA
97. SNAP RING ALIGNMENT BOLT GEAR SUPPORT CASE assembly from the differential and Compressing Clutch Pack in a gear support case see photo Press with clutch pack installed Removing Clutch Pack 3 Lift up and remove clutch pack in support case Removing Tanged and Splined 4 If ring gear had an interference Friction Plates fit and did not fall off as previously mentioned in the warning note for ie apres Step 2 tap ring gear alternately press and suitable adapters on opposite sides with soft nosed hammer until ring gear is free of NOTE This procedure can be gear support case flange accomplished with clutch pack 6 If necessary remove rectangu lar snap ring from friction plate driver 7 if necessary to remove bearing cone from differential case cover eal nl m place pilot punch in holes provided and tap on bearing cone inner race Compress clutch pack then remove aiternately through each hole until round snap ring Remove pres cone is removed sure plate then alternately remove tanged and splined friction plates from friction plate driver 8 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 the Controlled Traction Differential page 7 3 replace the clutch pack 9 Disassemble and Reassembie Wheel Differe
98. 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 4 ASSEMBLY 3 correctly position retainer push it towards the socket and just before it is in place and while 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 4x4 6x6 1 20 Steering and Wheel End Equipment Overhaul Assembly Adjust Steering Stop Screws 1 If removed install stop screw and locknut screw head should face axle ball in ball socket 2 Steering stop screws should be adjusted to limit 22 angle turn in either direction A plate fabri cated with a 22 angle see illustration will help in making this adjustment 3 Adjusting Steering Stop see illustration To 5 use the fabricated 22 angle plate and adjust stop screw proceed as follows SOCKET a Remove the two top cap screws fastening ball to axle housing b Position plate between ball flange surface A and ball socket surface B With socket in thi
99. Torque nut to rated value then continue tightening nut to align slot with nearest hole in pinion shank Rear Axle Nut self locking 1 3 4 12 840 1020 1139 1383 DRIVE PINION BEARING CAGE Forward Axle Cap Screw 9 16 12 8 155 175 210 237 Rear Axle 5 8 11 5 160 176 217 239 DIFFERENTIAL CASE DS466 P Forward Rear Axles Cap Screw 9 16 12 8 116 130 157 176 05486 586 P 656 P Forward Rear Axles 5 8 11 8 165 195 224 264 DIFFERENTIAL BEARING CAP Cap Screw 13 16 10 8 370 430 501 583 DIFFERENTIAL CARRIER Forward Axles oe 5 8 18 8 stud 220 240 298 325 At Dowels 150 170 203 230 Cap Screw 12 pt 5 8 11 8 210 230 285 312 Rear Axles 5 8 18 8 stud 220 240 298 325 AXLE HOUSING COVERS DS466 P 486 P Forward Axles Stud Nut 7 16 20 8 stud 70 86 94 116 Cap Screw 7 16 14 5 47 55 64 75 DS586 P 686 P Forward Rear Axles SIUud Nut eos 1 2 20 8 stud 110 130 149 176 Cap Screw 1 2 13 5 78 85 101 115 9 7 6x6 6x6 Tandem Axle Differential Carriers Fastener Dual Range and Double Reduction DT DP466 P 486 P 586 P 656 P Tightening Forward and Rear Axles Specifications Specifications are the same unless specified otherwise Fastener Size Grade Ft Ibs RING GEAR Bolt Nut
100. UST PINION DIFFERENTIAL BEARING e DUAL RANGE 1 ne GEAR WASHER PIN ASSEMBLY CONE ADJUSTER SUPR THRUST SPIDER CAP SCREW RETAINER SUN SUPPORT GEAR CASE WASHER PLANETARY DOUBLE pay 1 CTION AXLES SIDE SIDE THRUST DIFF GEAR PINION WASHER CASE DRIVE 1 BEARING BEARING SUPPORT PINION SNAP THESE PARTS ARE MOUNTED PINION SPACER T CUP BEARING SLOTTED 7 POWER DIVIDER COVER s A CAGE BEARING CONE frou 000 40 01 43 0 oniy Dang P 2 Ueed on D466 P alan BS ow SPACER 3 Used only D346 P 386 P 406 alus HELICAL GEAR PILOT SPACER LOCK HELICAL GEAR SPACER BEARING BEARING VARIABLE WASHER RACE 6x6 6 2 Differential Carrier Overhaul Differential Carrier Assembly Rear Axle THRUST WASHER SIDE Pinion 2 1 SPIDER CASE THRUST SIDE SIDE THRUST WASHER GEAR GEAR WASHER DIFFERENTIAL ASSEMBLY BEARING BEARING THRUST HIGH SPEED RING GEAR BEARING BEARING ADJUSTER CONE WASHER CLUTCH PLATE CONE ADJUSTER GEAR IDLER SUPPORT RING SLIDING PINION IDLER THRUST CASE GEAR BEARING CLUTCH PIN PINION WASHER LH NUT CUP DUAL RANGE PLANETARY DOUBLE REDUCTION AXLES RETAINER ae SHIFT B STUD SEAL LOCKWIRE CAP SPRING DOWEL SHIFT SEAL E s FORK SCREW ge SHIFT UNIT COVER LOCKWASHER EN qun m CAP le t CAP SCREW T 9 2 SPACER BEARING BEARING OIL FLAT WASHER CAGE
101. ail bearing cage on drive pinion during trial build up on pinion pinion F 4x4 6x6 2 18 Differential Carrier Overhaul Assemble Drive Pinion Press fit outer pinion bearing conta Press Oi Seal in Cage E 7 Press on outer pinion bearing 8 Install oil seal with a press Use NOTE Prior to installation of cone properly sized sieeve to fit seal to flange or yoke lubricate seal prevent distortion during installa lip and make sure flange or 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 2 19 4x4 6x6 Differential Carrier Overhaul Install Drive Pinion NOTE 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 1 Place shim pack on carrier making sure lube hole is clear Install Differential and Ring Gear Assembly NOTE Lubricate bearings during the following assembly procedures 3 Install and tighten bearing cap screws finger tight If this is diffi 1 Place ring gear and differential 2 Install be
102. ammer 3 Install slotted nut and tighten ing according to instructions in torque chart Torque Chart Drive pinion Slotted Nut and Roll Pin Ft Ibs 1 1 2 18 B40 1 3 4 12 980 IMPORTANT Torque nut to torque shown in chart then con tinue tightening nut to align slot with nearest hole in pinion shank Install roll pin 6 15 6x6 Install Pinion Helical Gear 0346 386 P 406 P Pinion Helical Gear and Support Bearing Installation Install Pinion Helical Gear 0466 486 P 586 656 P Pinion Helical Gear and Support Bearing Installation SUPPORT BEARING THESE PARTS RACE ARE MOUNTED IN POWER SNAP RING DIVIDER COVER NUT 7 Se _ Ud d BEARING Scene ROLL PIN IMPORTANT POSITION RECESSED HUB TOWARD SUPPORT BEARING SUPPORT BEARING THESE PARTS RACE ARE MOUNTED IN POWER SNAP RING COVER m nou SLOTTED NUT HELICAL GEAR AB P ONLY Differential Carrier Overhaul Forward Axle Install Differential Assembly in Carrier r 2 If the same gear set is used 3 install and tighten bearing cap SEAT DIFFERENTIAL install the assembled bearing cap screws finger tight If this is CASE ILOT LOT adjuster and lock on the backface difficult use hand wrench BEARING side of the ring gear Otherwise install adjuster and cap separately NOTE When installing cap it may be necessary to tap it light
103. and Brake Spider 1 Remove cap screws fastening spindle and spider to 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 IMPORTANT Exercise care when tapping spindle Striking too hard could crack the spindle metai 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 Removing 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 see photo NOTE With both LH 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 is indicated it is recommended that the axle shaft be repiaced 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 grooving Check for excessive clearance between axle shaft yoke trunnions and cage rings If exces sive clearance greater than 0 050 is suspected disassemble axle shafts as foilows and measure clearance 3 IM
104. and Tires Lubricate Axle 1 Install wheels and tires 2 Fill Axle with correct lubricant refer to Lubri cation Section 3 Check wheel alignment refer to Wheel Align ment Section 4x4 6x6 1 26 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 LICR ouis 2 Ceaning Inspection and Replacement 4 Adjust Pinion Bearing Preload 6 Differential Bearing Preload and Ring Gear Backlash Adjustment 8 Ring Gear and Pinion Tooth Contact 9 Differential Carrier Replacement 11 DIFF CARRIER OVERHAUL Single Reduction Exploded View 13 Disassemble Differential Carrier 14 Disassemble Drive Pinion 15 Disassemble Wheel Differential 16 Assemble Wheel Differential 17 Assemble Drive Pinion 18 Install Drive Pinion in Differential Carrier 20 Install Differential Assembly in Carrier 20 Adjust Differential Bearing Preload 21 DIFF CARRIE
105. and torque to 90 110 ft lbs 122 149 NOTE Turn side gear hub to check for free differential rotation Rota tion may require up to 50 ft Ibs 65 9 During installation of 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 head is seated against the outside diameter of the support case Install nuts and torque to 150 170 ft ibs 203 230 NOTE Temporarily install sliding clutch or sun gear and check planetary for free rotation 4x4 6x6 2 28 Differential Carrier Overhaul Assemble Drive Pinion NOTE Lubricate parts with gear lube during reassembly PINION BEARING BEARING BEARING BEARING BEARING OIL SEAL INPUT PILOT CONE SPACER CAGE CAGE amp RETAINER YOKE BEARING INNER VARIABLE SHIM OUTER FLAT WASHER Vl g lt lt 0 i r 7 m 8 Qe OOD POG 4 BEARING CASE BEARING U CONE PINION PINION INNER TDN SCREW OUTER NUT LOCKWASHER Press Bearing Cups in Cage STAKE PATTERN LAT Cups must be hemty seated cage Check with teeter gauge 100017 ther enstallation a When correctby wrstalied cups be recessed below outer
106. ar ent place the shifter valve lever in the Low Range position and discon nect air lines at the tandem forward and rear shift units Place axle range shifter valve in High Range position Air flow should be present through each of the disconnected air lines If air flow is not present inspect the axle range shifter valve and the quick release valve Replace as required Place axle range shifter in Low Range position Air flow should not be present in any of the disconnect ed air lines Reconnect air lines and insure that sufficient air supply exists to per form following checks to the remainder of the system 8 12 6x6 Dual Range Tandem Single Reduction Steer Drive 4 Check Lockup System After insuring that the axle range shifter valve is in the Low Range position have an assistant move the All Wheel Drive selector valve lever from disengaged to engaged posi tion Check for mechanical move ment in the inter axle differential lockout shift unit and steer drive axle lockup shift unit mounted on the tandem forward axle Alternatively disconnect air lines from cover of inter axle differential lockup unit and steer drive axle lockup shift unit with All Wheel Drive selector lever in disengaged position NOTE These air lines are not to be confused with air lines connected to interlock control valves installed in shift unit covers Leave these air lines connected Place Ail Wheel Drive selector valve in engaged p
107. ar Axle Differential Carrier Replacement 1 Drain axle lube 4 Disconnect inter axle driveline Loosen drive pinion nut but do not remove IMPORTANT Before installing carrier assembly inspect and thoroughly clean interior of axle housing NOTE Use silicone rubber gasket compound on axle housing mating surface as shown in the illustra tion Compound will set in 20 minutes Install carrier before compound sets or reapply 1 Dual Range Axle Shift to low range 2 Axle with Controlled Traction Differential Shift to engaged position 5 Install axle shafts and stud nuts If used also install lockwashers and taper dowels 8 Dual Range Axle Only Install shift unit nuts and lockwashers Torque nuts see chart page 3 18 Connect air line Install Differential Carrier Assembly Remove Differential Assembly from Axle Housing 2 Dual Range Axle Shift to low range Disconnect shift unit airline Remove shift unit 5 Remove axle shaft stud nuts lockwashers and taper dowels 15 used If necessary loosen dowels by holding a brass drift in the center of the shaft head and strik 3 Axle with Controlled Traction Differential Shift to engaged posi tion If used disconnect shift unit air line Remove shift unit 6 Remove nuts and washers fastening carrier to axle housing Remowve differential carrier assem bly using a transmission jack or similar equipment ing it a sharp blow with a hamme
108. ar axle gearing is shown in the following instructions Correct tooth patterns and adjustments 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 pattern 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 CORRECT PATTERN NEW GEARING Could vary in length Pattern should cover 1 2 tooth or more face width Pattern should be evenly centered oi ah between tooth d top land and ODE V c root MU Y N LA TOOTH gt DEPTH Pattern should be clear of tooth toe Check Tooth Contact Pattern USED GEAR Used gearing will not usually display the square even contact pattern found in new gear sets The CORRECT PATTERN USED GEARING gear will normally have a pocket at the toe end um oo of the gear tooth which tails into a contact line Pocket may b 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 pattern face width Adjust used gear sets to display the same contact could be longer pattern observed before disassembly A correct pattern is clear of the
109. arance 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 Ibs 101 115 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 positioned at yoke end of input shaft Move input shaft axially and measure end play If end play is correct seal shim pack to prevent lube leakage then torque input shaft nut and cover cap screws see chart 7 If end play is incorrect change shim pack size as follows Add shims to increase end play Example Desired end play New 0 003 to 0 007 Measured end play Step 6 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 0 015 0015 Desired end play New 5 0 003 to 0 007 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
110. aring cups at both cult use hand wrench assembly in carrier Carefully lower sides of differential case Install NOTE The assembly is now the assembly until bearing cones bearing adjusters and caps ready for adjustment of differential rest on carrier bearing preload ring gear back lash and gear tooth contact 4x4 6x6 2 20 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 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 adj
111. ately through each hole until cone is removed Removing Support Case Cover 6 Permanent CTDs Oniy This type 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 on 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 Controlled Traction Differential page 7 3 replace the clutch pack 4x4 6x6 7 7 Medium duty CTD 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 Medlum duty CTD Place dif ferential assembly on a work bench clutch pack mounting area up Install ring gear on support case flange aligning boit holes with two temporarily installed alignment bolts Remove alignment bolts Installing Clutch Plates Individually Permanent CTD Only 2 Install Friction Plates and Driver Permanent CTD Only NOTE Brush surfac
112. bearing cover cap screws and lockwashers Install oil seal using 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 Torque Chart Input Shaft Nut Ft Ibs N m 1 5 8 18 780 960 1059 1301 1 7 8 12 840 1020 1139 1383 Bearing Cover Cap Screw 1 2 13 75 85 101 115 Grade 5 Tightening Yoke Nut Measuring Bearing Cover Clearance Installing Bearing Cover and Shim Measuring End Play with Dial Indicator 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 6x6 4 13 Power Divider Overhaul Adjust Front Output Shaft End Play and Final Assembly of Output Shaft NOTE After power divider overhaul and installation on carrier check and adjust front output shaft end play Correct end play 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 pages 4 8 proceed with step 1 NOTE Do not install shift fork shift unit or oil seal until adjustment is completed 1 Install output shaft assembly shaft gear and bearing cones in power divider cover Hold cover in mounting position with hand pressure and measure clearance between the two co
113. bly 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 arm NOTE Refer to Wheel Alignment Section for tie rod adjustment Assemble and Install Wheel Hub and Drum NOTE 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 the spindle to pass through 3 Pack bearing cones with grease Install inner bearing cone in hub Install bearing spacer on cone with chamber at inner diameter facing out 4 Install oil seal in hub using suitable driver press Press seal into hub until it is flush with face of the hub 1 25 4x4 6x6 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 wil be directly over the threads on the ball joint end
114. ction Careful inspection will help determine whether parts should be reused In many cases the causes of premature wear or 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 polished surfaces in solvent There are many suitable commercia solvents avail able Kerosene and diesel fuel are acceptable WARNING GASOLINE 15 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 I
115. d spring id Installing Shift Fork Shaft ee Torque Chart Differential Bearing Cap Cap Screw Size Grade Ft Ibs 13 16 10 8 370 430 501 583 Bearing Adjuster Lock and Sun Gear Retainer Cap Screw Size Grade Ft Ibs N m 5 8 11 5 160 176 217 239 2 33 4x4 6x6 Service and Maintenance Instructions ESD 18 Steer Drive Axle Axles Brakes These instructions cover the 6x6 tandem drive axle the differential carrier and power divider assembly and the tandem rear axle differential carrier Contents are divided into major sections as shown below Contents Lubrication Cleaning Inspection Replacement Adjustments Differential Carrier Replacement Power Divider Overhaul Differential Carrier Overhaul Single Reduction Differential Carrier Overhaul Dual Range and Double Reduction 6x6 Tandem Axle Models Single Reduction Dual Range Double Reduction Section 3 Page No 2 5 7 15 Section 4 Section 5 Section 6 DS346 P 386 P 406 P 466 486 586 656 DT346 P 386 P 406 P 466 P 486 P 586 P 656 P DP346 P 386 P 406 466 P 486 P 586 P 656 P 6x6 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 direct
116. dicator 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 Checking Ring Gear Backlash CORRECT PATTERN USED GEARING CORRECT PATTERN NEW GEARING Could vary in length Pattern should cover MS gt Pocket may be extended Pattern along the face width could be longer 1 2 tooth or more face width Pattern should between tooth P top land and root SU be evenly centered po A Pattern should be clear of tooth toe 6 With ring gear and pinion adjusted correctly align 7 Seasonal and Driver Controiled 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 pin in one clutch With clutch installed engage shift fork yoke adjuster iock Install cap screws in opposite adjuster with clutch collar Then install shift for
117. duction 22 1 1 4x4 6x6 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 an Spicer Controlled Traction Differential 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 4x4 6x6 1 2 ESD 18 Steer Drive Axle Wheel Alignment and Wheel End Inspection Wheel Alignment Specifications Camber 1 2 Caster Mur 0 1 8 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 tire
118. e cage Press one cup in al Sme Differential Carrier Overhaul Assemble Drive Pinion Press fit outer pinion bearing Cont d 2 Press pilot bearing pinion IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner bearing rey 5 Install preselected bearing spacer on pinion Also install spacer washer on D466 P 486 P 586 656 Rear Axle Pinion Press Oil Seal in Cage with pinion installed i A ust be sized to press on sex outer flange 8 Rear Axle Only With pinion installed and bearing preload ad justment complete install oil seal with a press STAKE PATTERN 3 Stake pilot bearing using staking tool This is essential to retain the bearing NOTE During pinion bearing in stallation locate each part in same position that was used in Trial Build up Preload Test pinion 9 Rear Axle Only Prior to installa tion of yoke lubricate oil seal and make sure yoke is clean and dry Install yoke flat washer and nut Torque nut as follows Torque Chart Drive Pinion Nut Ft ibs 1 1 2 18 560 700 759 949 1 3 4 12 840 1020 1139 1383 4 Press inner bearing cone on pinion IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cone gt 7 Press outer bear
119. e photo NOTE If the gear set is to be re used use same quantity and size shims removed during disassem bly If a new gear set is to be in stalled install a nominal shim pack see chart SEAT DIFFERENTIAL 3 CASE PILOT IN CARRIER BEARING CAP PEDESTAL BEARING CAP PEDESTAL NOTE 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 to rest in carrier bore then install bearing cup as shown in photo Also install bearing cup on opposite side of differential 2 31 4x4 6x6 Install Differential in Carrier Nominal Shim Pack in mm 0 023 0 584 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 When 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 drive pinion assembly NOTE Make certain lube holes in carrier shims and cage are aligned Install bearing cage cap
120. e of each plate as it is assembled with heavy appli cation of axle lube SAE 90 NOTE To assemble friction plates one of two procedures can be used Install driver and plates individually Step 3 or install driver and clutch pack as an assembly Step 4 3 Install Friction Plates Individually Permanent CTD Only 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 internai teeth Brush plate with lube c Place one internal splined plate on driver splines and on top of the external splined plate Brush plate with lube d Repeat 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 7 8 4x4 6x6 Installing Clutch Pack and Driver Assembly Permanent CTD Only 4 Install Driver and Clutch Pack as an Assembly Permanent CTD Only a removed install snap ring on friction plate driver Then place driver snap ring down on work bench b Place one externai splined plate on driver Brush plate with lube c Place one internal splined plate on top of the external splined piate Brush plate with lube d Repeat this procedure until
121. earing 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 Adjustments Section 3 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 D346 P 386 406 P 0 006 to 0 016 0466 486 P 586 656 P 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 For checking and adjusting procedures see Adjustments Section 3 Torque Chart Diff Carrier Bearing Cap Screws Ft 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 N m 5 8 11 Grade 5 160 176 217 239 6 With ring gear and pinion adjusted correctly align adjusters and Checking Ring Gear Backlash locks then tighten differential bearing cap screws to correct torque see chart Install adjuster locks and cotter pins Lockwire differential bearing cap
122. ed Engagement SHIFT CLUTCH FORK PACK DISENGAGEO ILLUSTRATED TO COMPRESSION SPRINGS Heavy Duty CTD with Optional Fork for Seasonal or Driver Controlled Engagement d Using a torque wrench rotate pinion and note torque reading e Formula Torque times axle ratio equalis bias differential torque 4x4 6x6 7 3 CTD Overhaul Remove Differential Carrier Assembly from Axle Housing IMPORTANT Detailed procedures for each type capacity or model axle may vary For specific service instructions on your axle refer to the appropriate Eaton Service Manual The following instructions are applicable to axles equipped with Controlled Traction Differentials 1 Driver Controlled CTD Remove 2 Seasonal CTD Remove nuts 3 Permanent CTD This type CTD shift unit nuts and flat washers Dis and washers from shift fork cover is always engaged No procedure connect air line to permit removal roig then remove cover retainer is necessary of shift unit Place sliding clutch ace sliding clutch in the engaged i the engaged position Sliding position Sliding clutch must be clutch must be engaged to allow engaged to allow removal of carrier axle shafts Remove differential removal of carrier from housing from housing carrier to axle housing cap screws and lockwashers or stud nuts Remove differential carrier Remove Differential and Clutch Pack Assembly from Carrier NOTE If the
123. eleased dimension from the applied dimension to obtain free stroke Free stroke should be 1 2 5 8 in 12 7 15 9 mm If free stroke is not within specifications depress locking sleeve on slack adjuster and adjust as required 1 23 4x4 6x6 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 both shoes in mounting position attach return spring to upper shoe Lift lower shoe and connect spring to shoe pin see photo 3 Pry 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 N RETAINER SPRING SHOE Positioning Shoes on Anchor Pin CAM ROLLER AND PIN STURDY LEVER C Prying Down on Brake Shoe to Install Cam Roller and Pin 4x4 6x6 1 24 Steering Wheel End Equipment Overhaul Assem
124. ential parts with gear lube during reassembly 1 Press bearing cones on differ 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 and side gear in flanged differentia case Press Bearing Cone on Flanged Differential Case 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 fr e rotation by turning side gear hub Differen tial may require up to 50 ft Ibs 68 torque to rotate Press Bearing Cone on Plain Differential Case 4 Place side gear and thrust washer on side pinions 6 Install ring gear Secure with bolts and nuts Tighten nuts to correct torque see chart Torque Chart Differential Case Cap Screw 9 16 12 5 8 11 Grade 8 Grade 8 Ring Gear Bolt Nut 5 8 18 Grade 8 Ft Ibs N m 116 130 157 176 165 195 224 264 180 220 6x6 5 9 Differential Carrier Overhaul Assemble Drive Pinion Press fit outer pinion bearing Forward and Rear Axles Forward Axle Pinion Illustrated THESE PARTS WESCE DRIVE SPACER BEARING BEARING BEARING HELICAL SLOTTED SNAP PINION WASHER CUP CAGE _ GEAR NUT DIVIDER COVER BEARI
125. er Transfer Gearing Driver flips valve back two clutches disengage removing torque from steer drive axle and allow ing inter axle differential to function conventionally TANDEM AXLE TO TANDEM REAR AXLE TORQUE Bi g INPUT CLUTCH INTER AXLE IFFERENTIAL L OPERATING STEER DRIVE AXLE TRANSFER GEAR CLUTCH DISENGAGED 6x6 iii Service and Maintenance ESD 18 Instructions Steer Drive Axle Contents Section 1 Page No ESD 18 STEER DRIVE AXLE introduction P e 2 Steering and Wheel End Equipment Steering and Wheel End Inspection lt 3 Lubrication 6 a 7 Differential Carrier Section 2 Page No Contents 1 Lubrication eee 2 Cleaning Inspection and Replacement 4 Adjustments _ 6 Differential CarrieriReplacement 22 eh ee ete 10 Differential Carrier Overhaul Single Reduction lt 5 lt lt lt 2124 2 2484 22 42 54 2165 Scarce es Sasa sae pose eenia 13 Dual Range and Double Re
126. er 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 Lugs 4x4 6x6 2 8 NOTE Rear axle gearing is shown in the following instructions Correct tooth contact patterns and adjustments are the 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 length of the pattern in an unloaded condition is approximately one haif to 4 of the ring gear tooth in most models and ratios RING GEAR TOOTH NOMENCLATURE TOOTH pert 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 normaily 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
127. ers for caps roll pin Then loosen but do not reference during assembly remove pinion nut 4 Using a chain hoist lift ring 5 Remove drive pinion helical 6 Remove pinion bearing cage gear and differential assembly gear and related parts as required screws and lockwashers out of carrier by models Remove pinion and cage assembly Remove Helical Gear D346 P from carrier Remove shim pack 386 P 406 P IMPORTANT gear set is to be Remove pinion nut Remove sup reused keep pinion bearing cage port bearing bearing spacer and shim pack intact for use in reas helical gear using suitable puller sembly If the original shims can not reused record the number Remove Helical Gear 0466 and size of shims in the pack Tert 586 P 656 P 7 Output Shaft Side Gear Bearing Remove pinion nut Remove bear If replacement is necessary ing and helical drive gear using use suitable puller to remove bear puller Remove helical gear spacer ing cup from carrier 466 P only 5 4 6x6 I Differential Carrier Overhaul Disassemble Differential Carrier Rear Axle 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 but do not remove pinion nut pu
128. es Rear Axle Differential Illustrated DIFF BEARING THRUST SIDE SPIDER THRUST RING FLANGED BEARING DIFF BEARING CONE WASHER PINION WASHER GEAR CASE CONE BEARING ADJUSTER HALF ADJUSTER P 1 52 M lt Fo s SP 0 2 NB a 20 ek Cz 2 5 F 3 CASE PLAIN RING RING BEARING BEARING CAP CASE SIDE GEAR GEAR 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 773 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 cone m 2 8 Remove bearing cone from flanged case half using suitable Puller Mounted Vertically Removing Bearing Cone puller to Split Bearing from Flanged Case Half 5 8 6x6 Differential Carrier Overhaul Assemble Wheel Differential NOTE Lubricate differ
129. es 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 compietely Axles with Lube Pump Remove the magnetic strainer from the power divider cover and inspect for wear material 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 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 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 Service Department or call Regional Office for specific recommendations See back cover for address and phone numbers 2 3 4x4 6x6 Cleaning Inspection Replacement As the drive axle is disassembled set all parts aside for thorough cleaning and inspe
130. f gauge indicates low or pres sure valve is faulty Replace valve assembly 8 8 6x6 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 through 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 completeto 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 No voltage should be present Replace a faulty pres sure switch as an assembly Dual Range Tandem Single Reduction Steer Drive Description and Operation Operational Modes Steer Drive Tandem Inter axle Axle Axle Differential 6x6 Drive Engaged Low Range Engaged 6x4 Drive Disengaged Low Range Disengaged 6x4 Drive Disengaged High Range Disengaged 5x6 DRIVE SHIFT SYTEM DUAL RANGE TANDEM AXLE WITH RANGE INTERLOCK
131. ferential case Install cap screws Torque screws FOR Ae omne d hub to check Turn side gear hub to chec Differential Case Cap Screw Ft ibs N m for free differential rotation Rota 1 2 13 Grade 8 90 110 122 149 tion may require up to 50 ft Ibs 65 9 16 12 Grade 8 116 130 157 176 7 Install idler pins and pinions 8 Place thrust washer in support 9 During installation of 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 10 To install differential assembly place support case and ring gear assembly on a bench or the floor Position case on its side Carefully 11 Install thrust washer and small support case over differential lift and slide differential assembly assembly into case Engage idler pinions with ring gear teeth to complete the 12 Carefully install ring gear bolts making certain flat on bolt head is installation seated against the outside diameter of the support case Install nuts and NOTE During differential installa torque to 110 130 ft Ibs 149 176 tion be sure thrust washer stays NOTE Temporarily install sliding clutch or sun gear and check its proper mounting position planetary for free rotation 6 11 6x6 Differential Carrier Overhaul Assemble Drive Pinion Press tit outer pinion bearing Forward and Rear Axles Forward Axle Pinion Il
132. fourteen 14 friction plates seven external splined and seven internal splined are instailed Then install the last external splined plate and pressure plate e Rotate external splined plates 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 f Install compression springs and case cover Step 6 Assemble Install Clutch Pack conta 5 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 alignment it will be difficult to install sliding clutch after clutch pack is assembied Also as each piate is installed brush top of plate with a heavy application of axle lube SAE 90 Proceed as follows a Place one external splined plate PLATE CLUTCH 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 purposes temporarily insert sliding ciutch to engage side gear and plate splines Remove clutch c Repeat this procedure until fourteen 14 friction plate
133. front output shaft bearing cup using suitable puller Power Divider Overhaul 1 Punch mark differential case halves for correct position during reassembly 2 Remove locknuts and bolts Separate case halves and remove thrust washers side pinions bush ings and spider 1 Mount shaft assembly in vise using brass vise jaw protectors Remove outer snap ring side gear and bearing cone assembly If replacement is necessary remove inner snap ring on models D346 P 386 406 Other tandems do not use inner snap ring WARNING SNAP RING IS SPRING STEEL AND MAY POP OFF WEAR SAFETY GLASSES WHEN REMOVING Disassemble Inter axle Differential Disassemble Rear Output Shaft CASE HALF PUNCH MARK a BUSHING SIDE PINION ee THRUST WASHER Rear Output Shaft Assembly OUTPUT SHAFT BUSHING amp 43252005 He 1 Inner Snap Ring used only on 0346 386 406 2 Remove output shaft O rings If replacement is necessary remove bushing mounted in end of output shaft 3 Remove bearing cone from side gear using press and split type puller NOTE For instructions covering rear output shaft rear bearing parts see Section 3 page 3 15 BEARING CONE SNAP RING OUTER SNAP RING INNER 1 V RINGS BEARING cue MOUNTEO IN DIFFERENTIAL CARRIER SIDE GEAR Removing Bearing Cone from Output Shaft Side Gear 6x6 4 7 Disassemble Front Output
134. g 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 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 through 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 completeto 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 No voltage shou
135. heck 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 as semblies The ends are threaded to the rod and locked with clamp bolts Right and left hand threads are provided for toe 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 on some types of tie rod ends Where no fittings are used the tie rods have been lubricated at assembly and no further lubrica tion 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 accom Cambar plishes the same purpose although the method of using the equipment may differ Refer to equipment manufacturer s instruc tions for correct procedures Regardless of make or type of equipment used the check ing and adjusting operations should be done in the sequence outlined CAMBER above j KINGPIN NOTE When checking wheel alignment make sure the truck is placed INCLINATION 09 level floo
136. hrust 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 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 repair able 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 these 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 277 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 CAUTION ANY DAMAGE WHICH AFFECTS THE ALIGNMENT OR STRUCTURAL INTEG RITY 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 Gaske
137. ined 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 a Spicer straight air shift system See Sec tion 8 for description service and mainte nance 2 Seasonal Engagement Manual adjustment in the shop 3 Permanent Engagement Constantly engaged 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 CTD 3 000 ft lbs or higher for Medium duty CTD If bias torque drops to 1 500 ft ibs or less replace the clutch pack pinion restrain vehicle Checking Effectiveness of Controlled Traction Differentials Check bias torque values as follows a Disconnect drive shaft at drive b Block one wheel or otherwise c Jack up other wheel free of the ground _ WARNING USE JACK STAND AS ADDITIONAL SUPPORT OF VEHICLE TO PREVENT PER SONAL INJURY OR VEHICLE DAMAGE CLUTCH SHIFT FORK DISENGAGED ILLUSTRATED 7 ENGAGE COMPRESSION SPRING Medium Duty CTD with Optional Fork for Seasonal or Driver Controll
138. ing cone pinion IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cone IMPORTANT At this stage of assembly final check pinion bear ing preload See Adjustment Sec tion of this manual NOTE After tightening pinion nut recheck pinion bearing rolling torque See Adjustment Section for Press fit outer pinion bearing 10 Forward Axle Pinion Helical Gear and Nut These parts are installed during pinion installation see page 5 13 6x6 5 11 Differential Carrier Overhaul Install Drive Pinion Forward Axle 1 Forward Axle 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 1 If removed install bearing race in power divider cover using driver and hammer 5 12 6x6 Install Pinion Outer Support Bearing Race 2 Forward Axle Drive Pinion Install drive pinion assembly Install bearing cage cap screws and lockwashers Torque cap screws to 155 175 ft lbs 210 237 N m 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 available proceed with helical gear installa tion see next page 2 Install s
139. inion bearing cage as recommended in this manual and change the pinion bearing spacer A thicker spacer will decrease preload A 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 Measuring Bearing Preload with Pinion in Press Specifications for Final Pinion Spring Scale Reading Bearing Preload Test without pinion seal Press fit Outer Pinion Bearings for 15 35 in ibs torque 1 7 4 Nut Torque Press Loads Ft Ibs ESD 18 Steer Drive Axle 560 700 759 949 13 5 15 5 12 2 14 0 Differential Carrier 2 7 4x4 6x6 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
140. inue tightening the same adjuster 2 or 3 notches Recheck backlash gt gt Forward Axle Differential Carrier Replacement Remove Differential Carrier Assembly from Axle Housing IMPORTANT 0346 P 386 P 406 P models do NOT use a rear output shaft Rear Bearing Retaining Washer WARNING THE OUTPUT SHAFT REAR BEARING RETAINING WASHER IS FREQUENTLY LOST WHEN THE DIFFERENTIAL CARRIER ASSEMBLY IS REMOVED IT MAY ADHERE TO THE YOKE TO THE FACE OF THE OUTPUT SHAFT BEARING FALL ON THE FLOOR OR INTO THE HOUSING LOCATE THIS WASHER BEFORE CONTINUING IF IT IS NOT REINSTALLED THE END OF THE YOKE WILL WEAR THE OUTPUT SHAFT BEARING VERY QUICKLY IF IT IS LEFT IN THE HOUSING IT CAN BE PICKED UP BY THE RING GEAR MOTION AND CAUSE PREMATURE AXLE FAILURE Follow procedure in numerical sequence 1 Drain axle lube 4 Disconnect inter axle driveline Remove rear output shaft nut flat washer and yoke 7 Disconnect front output shaft driveline Loosen shaft nut but do not remove 10 Axle Housing Cover and Rear Output Shaft Bearing Parts The bearing parts can be replaced with cover removed or installed If necessary remove axle housing cover It is fastened with cap screws nuts and lockwashers Disassemble as follows 13 If replacement is necessary remove snap ring rear bearing and bearing sleeve WARNING SNAP RING IS SPRING STEEL AND MAY POP OFF WEAR SAFETY GLASSES WHEN REMOVING 2 Dual Range Axle Shift to Low
141. ion 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 rolling 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 f necessary Adjust Pinion Bearing Preload by changing the pinion bearing spacer A thicker spacer will decrease preload A thinner spacer will increase preload IMPORTANT Once correct bear Assemble these Parts tor Trial Build up INNER INNER BEARING BEARING BEARING SPACER CONE CuP WASHER Cage in Press to Check Bearing Preload SPRING VARIABLE PRESS RAM y ing preload has been established note the spacer size used Select a spacer 0 001 larger for use in the final pinion bearing cage assembly 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 The larger spacer compensates of four cases Specifications for Pinion Bearing Trial Build up Preload Test Press fit Outer Pinion Bearings Nominal Bearing Spacer Thickness Axle Models in mm 0346 386 P 406 P 0 496 12 6 Press Loads Tons Metric Tons 17 19 15 4 17 2 Tandem Forward Axles R346 386
142. ions contained in this book Approved Lubricants Multigrade gear lubricants which tures These are 75W SOW 90 and Department review This is essen tial meet the requirements of military 85W 140 SOW 140 lubricants are to ensure proper seal life and axle specification MIL L 2105 C are also available but are listed with performance with a particular synthet recommended for use in Spicer SOW 90 MIL L 2105 C Lubricants For additional informa tion contact in drive axles These lubricants per form approved under MIL L 2105 B are Spicer Field Service Department or 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 also accept able for use in Spicer Axles 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 Synthetic lubricants Use of syn thetic 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 also be consid ered when ever changes in vehicle location or primary operating area are made and the grade of lube changed if necessary
143. ire and remove bearing cap screws If the gear set is to IMPORTANT During removal of be reused remove bearing cap drive pinion assembly do not allow adjuster and lock as an assem pinion to drop on hard surface bly This will facilitate correct 6 Remove pinion bearing cage cap screws then drive pinion and cage assembly out of positioning of ring gear during carrier the gear set is to be reassembly 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 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 WARNING WHEN USING A DRIFT PUNCH OR SIMILAR TOOL WEAR SAFETY GLASSES 2 23 4x4 6x6 Differential Carrier Overhaul Disassemble Drive Pinion PINION BEARING BEARING BEARING BEARING BEARING OIL SEAL INPUT PILOT CONE SPACER CAGE CAGE CUP amp RETAINER YOKE BEARING INNER VARIABLE SHIM OUTER FLAT WASHER _ 4 A BEARING SERE BEARING ORIVE CUP 8 cp sc CONE PINION PINION INNER SCREW OUTER NUT _ ES ing yoke removal procedure the ing cone support cage and press cone from cage Discard oil seal drive pinion may fall out of bear pinion out of bearing cage and Remove bearing cups with suitable ings and cage
144. ive Inter axle Differential is unlocked functioning normally Controlled Traction Differential when equipped is disengaged not operating NOTE Controlled Traction Differential may be independently controlled by adding a valve in the cab to the system Steer Drive Axle Lockup Controlled Traction Differentials Inter axle Differential Three shift units one on each axle engage or disengage controlled Lockout traction differential One manually operated shifter valve controls air pressure supply Engaged When shifter valve lever is moved to the engaged position to two shift units which in turn the valve is opened and air pressure is applied to all three shift units engage or disengage the steer drive Each shift unit is mechanically connected to a shift fork and a sliding axle and inter axle differential clutch The sliding clutch moves to engage the controlled traction dif The shift units are mechanically ferential In the engaged position the unit is operational as a biasing connected to shift forks and sliding X Cifferential clutches The clutches engage OT pisengaged When shifter valve lever is moved to the disengaged beg aps ig related gears to lockout position the valve is closed Air pressure in each shift unit is exhaust or unlock the inter axle differential The sliding clutch retracts and disengages the controlled traction and steer drive axle differential In the disengaged p
145. k pin on the axle range selector valve If interlock pin func tions correctly system check is com plete If not proceed to Step a If interlock pin does not function correctly move All Wheel Drive selector lever to disengaged posi tion then disconnect air lines on the sides of the interlock control valves on the tandem inter axle dif ferential and steer drive axle lockup shift units Move the All Wheel Drive selector lever to the engaged posi tion and check for air flow from the side ports of the interlock control valves If air flow is not present place the selector lever in the dis engaged position and remove inter lock control valves from shift unit covers b Place All Wheel Drive selector lever in engaged position and again check for air flow from the side ports of the interlock control valves If air flow is present depress the plungers on each valve and insure air supply is shut off from the valve side ports If valves do not function correctly remove and replace Place All Wheel Drive selector lever in dis engaged position and reinstall inter lock control valves in shift unit cov ers and adjust properly see page 8 16 Place the All Wheel Drive selector lever in the engaged posi tion If air flow is still not present at the interlock control valve side ports remove the shift units from the tandem axle and inspect com ponents for binding or excessive wear After repair follow the above steps un
146. k 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 ir engaged position Sliding clutch must be engaged to allow installation of car rier on housing 4x4 6x6 7 15 CTD Overhaul Install Differential Carrier Assembly in 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 refer to the appropriate axle service manual Silicone Gasket Compound IMPORTANT Before installing carrier assembly inspect and thor 2 Carrier oughly clean interior of axle housing aung NOTE Use silicone rubber gasket compound on axle housing mating surface as shown in the illustration Compound will set in 20 minutes Install carrier before compound sets or reapply 1 Install differential carrier assembly in axle housing Install stud nuts and lockwashers Tighten to correct torque 2 Install axle shafts and stud nuts If used also install lockwashers and taper dowels 3 Connect driveline 4 Fill with correct lube to correct level 5 Driver Controlled Install shift unit on carrier engaging swivel with slot in shift fork shaft Install mounting nuts and flat washers Connect air line to unit 6 Seasonal CTD Position c
147. ld be present Replace a faulty pres sure switch as an assembly 6x6 8 13 Service and Maintenance ESD 18 Instructions Steer Drive Axle Axles Brakes These instructions include fastener tightening torque values for the steer drive and tandem axles for 6x6 Drive Systems Contents are listed below Bolt head markings for grade identification Correct tightening torque values are extremely impor tant to assure long Spicer Axle life and dependable per formance Under tightening of attaching parts is just as harmful as over tightening Exact compliance with recommended torque values will assure the best results The data includes fastener size grade and torque tight ening values Axle models are included to pinpoint identification of fasteners for your particular axle Grade 5 Grade 8 To determine bolt or cap screw grade check for designation stamped on bolt head see illustration Section 9 Contents Page No STEER DRIVE AXLE ESD 18 Steering and Wheel End Equipment 2 Differential Carriers all gearings 3 TANDEM DRIVE AXLES Power Divider all models Pax d DIFFERENTIAL CARRIERS Single Reduction DS346 P 386 P 406 P 5 Dual Range and Double Reduction DT DP346 P 386 P 406 P 6 Single Reduction DS466 P 486 P 586 P 656 P TP EE Dual Range and Double Reduction DT DP466 P 486 P 586 P 6
148. ld cover DIS 7 extended ff I 1 2 tooth or more Sy Pattern along the po face width aoe width 4 should d J he tonger f ff L be evenly centered 7 4 v between tooth 2 C gt top land and lt root 2 2 e 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 4x4 6x6 2 32 Differential Carrier Overhaul Adjust Differential Bearing Preload Contd CAP SUN GEAR BEARING 5 RETAINER ADJUSTER LOCK install sun gear and retainer then install screws that fasten both retainer and adjuster lock cap screws Tighten screws to correct torque 7 For planetary double reduction axles on backface side of ring gear runi see chart and lockwire ail cap screws Double Reduction Axle 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 openings 10 install shift unit seal an
149. lue then continue tightening nut to align slot with nearest hole in pinion shank Rear Axle Nut self locking 1 1 2 18 560 700 759 949 DRIVE PINION BEARING CAGE Forward Axle Cap Screw 9 16 12 8 155 175 210 237 Rear Axle 9 16 12 5 110 125 149 170 DIFFERENTIAL CASE SOOW cesses eov 1 2 13 8 90 110 122 149 DIFFERENTIAL BEARING CAP GOTON 13 16 10 8 370 430 501 583 DIFFERENTIAL BEARING ADJUSTER LOCK SCTOW 4 gt 5242 25 5552 lt 5 8 11 5 160 176 217 239 DIFFERENTIAL CARRIER Stud Nut 5 8 18 8 stud 220 240 298 325 AXLE HOUSING COVERS Forward Axle Stud Nul 4 7 16 20 8 stud 70 86 94 116 SOOW exbkvysEnas 7 16 14 5 48 56 65 75 SHIFT UNIT Dual Range 7 16 20 8 stud 55 61 74 82 SHIFT FORK COVER Double Reduction Cap Screw 7 16 14 5 35 45 47 61 6x6 9 6 6x6 Tandem Axle Differential Carriers Fastener Single Reduction DS466 P 486 P 586 P 656 P Tightening Forward and Rear Axles Specifications Tightening torques are the same except where specified otherwise Fastener Size Grade Ft ibs RING GEAR Bolt Nut 5 8 18 8 180 220 244 298 DRIVE PINION Forward Axle Nut slotted w roll pin 1 3 4 12 980 1329 IMPORTANT
150. lustrated 1 DRIVE SPACER SPANING BEARING HELICAL SNAP PINION WASHER CUP CAGE CONE GEAR Ed 10 PILOT rt rt SEARING SHIM LOCK CAP 2 BEARING WASHER SCREW GEAR 1 Used only on D466 P 486 586 P 656 P 2 Used only on 0466 13 Used only D346 P 386 P 406 P Rear Axle Pinion Illustrated THESE PARTS E MOUNTED DIVIDER COVER vi 3 ROLL BEARING BEARING PIN VARIABLE SPACER SPACER PINION BEARING BEARING SEARING BEARING BEARING SEAL PINION PILOT CONE SPACER CAGE CUP 8 RETAINER BEARING UINNEA VARIABLE SHIM OUTER NOTE Lubricate parts with gear lube during 1 BEARING CAGE BEARING 2 reassembly DRIVE SPACER cue CONE INPUT FLAT WASHER s PINION WASHER INNER LOCKWASHER SCREW JOUTER YOKE 1 Used R466 R485 R586 P R650 2 Used only on R346 8385 8406 1 Using appropriate sleeve press bearing cups in cage see adjacent drawings NOTE On rear axles do not install oil seal in cage until bearing preload is correctly adjusted IMPORTANT After bearing cups are installed preselect pinion bearing spacer using the trial build up procedure described in the Adjustments Section of this manual Forward Axle Pinion Press Bearing Cups Cube must be finely seated cage Check with fogier gauge 220017 otter snstatlamon When correctly cups wit be recessed below outer surface of cage Press
151. lutions 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 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 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 6x6 3 5 Cleaning Inspection Replacement Repair and Replacement IMPORTANT To achieve maximum value from an axle rebuild replace lower cost parts such as t
152. lve side port If air flow is not present replace shuttle valve If air flow is present proper operation is evident e If interlock pin still does not actuate when All Wheel Drive select or valve lever is placed in engaged position remove axle range shifter valve in cab and inspect assembly for component wear or binding After repairing check for correct operation by placing All 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 All Wheel Drive selector valve lever is placed in disengaged position 6x6 8 7 Dual Range Axles with Range Interlock Trouble Shooting conta Check Electrical System Check Solenoid Valve 1 When ignition switch is ON solenoid valve is energized and air pressure is availabie 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 I
153. ly for adjustment of differen tial bearing preload ring gear backlash and gear tooth contact see page 6 18 6 17 6x6 Differential Carrier Overhaul Forward and Rear Axle 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 Adjustments Section 3 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 0 006 0 016 D466 P 486 586 656 0 008 to 0 018 5 Check Ring Gear Tooth Contact Paint ring gear teeth check tooth contact pattern Correct tooth patterns are illustrated below For checking and adjusting procedures see Adjustments Section 3 CORRECT PATTERN USED GEARING Pocket may be extended Pattern along the face width could be longer CORRECT PATTERN NEW GEARING Couid vary in length ye Pattern should cover
154. ly witha hammer Be sure capis fully seated and threads are aligned properly If trouble is encountered check for cross threading of bearing adjuster assembly in carrier Insure that and carrier threads ring gear and drive pinion mesh On teeth side of ring gear install the other adjuster and bearing During installation tilt carrier to observing same precautions to allow support case pilot to rest in avoid cross threading carrier bore then install bearing cup as shown in photo Also install bearing cup on opposite side of differential CAP PEDESTAL 1 Lubricate bearings during the following assembly procedure Place ring gear and differential 4 At the teeth side of ring gear NOTE With bearing adjusters and caps assembled to carrier the position bearing adjuster until its carrier assembly is now ready for adjustment of bearing preload ring first thread is visible gear backlash and gear tooth contact see page 6 18 At the back side of ring gear tighten adjuster until there is no backlash 6x6 6 16 Differential Carrier Overhaul KEEP LUBE HOLE CLEAR 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 If a new gear set is to be in stalled install a nominal shim pack see chart NOTE Lubricate bearings during the following as
155. me unless specified otherwise Fastener Size Grade Ft Ibs RING GEAR Bolt Nut 5 8 18 8 180 220 244 298 DRIVE PINION Forward Axle Nut slotted w roll pin 1 1 2 18 840 1139 IMPORTANT Torque nut to rated value then continue tightening nut to align slot with nearest hole in pinion shank Rear Axle Nut self locking 1 1 2 18 560 700 759 949 DRIVE PINION BEARING CAGE Forward Axle Cap Screw 9 16 12 8 155 175 210 237 Rear Axle 9 16 12 5 100 125 136 170 DIFFERENTIAL CASE SOIOW 9 16 12 8 116 130 157 176 DIFFERENTIAL BEARING CAP Cap Screw 3 4 10 8 360 440 488 596 DIFFERENTIAL CARRIER Forward Axles STUNT 5 8 18 8 stud 220 240 298 325 AXLE HOUSING COVER Stud Nut 7 16 20 8 stud 70 86 94 116 Cap Screw 7 16 14 5 48 56 65 75 9 5 6x6 6x6 Tandem Axle Differential Carriers Fastener Dual Range and Double Reduction DT DP346 P 386 P 406 P Tightening Forward and Rear Axles Specifications Specifications are the same unless specified otherwise Fastener Size Grade Ft Ibs N m RING GEAR 2 445245 2 2 555 lt 4 9 16 18 8 110 130 149 176 DRIVE PINION Forward Axle Nut slotted w roll pin 1 1 2 18 840 1139 IMPORTANT Torque nut to rated va
156. moving Brake Shoes 4x4 6x6 1 10 Steering and Wheel End Equipment Overhaul Brakes Left hand illustrated SLACK ADJUSTER GUARD LUBE F LOCKWASHER n COTTER AP SCREW SHOE CAPSCREW PIN Logt ASSEMBLY LOCKWASHER BRAKE AXLE BALL Brake Reline Lining 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 mounted 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 C cew SHOE CAMSHAFT CAMSHAFT LINING ROTATION ROTATION 55 Cw ccw TRAILING SHOES acs LEFT SIDE RIGHT SIDE WHEEL CAMSHAFT WHEEL CAMSHAFT ccw cw cw ccw 1 11 4x4 6x6 Steering and Wheel End Equipment Overhaul Disassembly 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 holes or loose air fitting Repair or replace as recommended by manufacturer Remove Slack Adjuster
157. n install side gear and bearing cone assembly and outer snap ring D466 P 486 P 586 P 656 P Only one snap ring outer is required WARNING SNAP RING IS to secure side gear Install side SPRING STEEL AND MAY POP gear and bearing assembly and OFF WEAR SAFETY GLASSES outer snap ring WHEN INSTALLING Assemble Inter axle Differential 1 Install bushings side pinions and thrust washers on inter axie differential spider LUBRICATE BUSHING 2 Install spider assembly in one 4 S DURING ASSEMBLY differential case half align punch marks and install other case half Secure assembly with bolts and locknuts Tighten to correct torque 17 23 ft Ibs 23 31 N m 4 PUNCH MARKS Assembling Inter axle Differential 6x6 4 9 Power Divider Overhaul Assemble Power Divider Cover Power Divider Cover and Input Shaft HELICAL THRUST LOCKOUT INPUT BEARING SHIM BEARING SPACER FLAT SIDE WASHER SLIDING SHAFT CONE COVER WASHER WASHER GEAR CLUTCH 1 Ot SEAL i Pm mn 0 0 gt 60 473 1 eam WASHER k L SHIFT FORK as 487 BEARING SNAP amp PUSH ROD i SCREW YOKE NUT RING BUSHINGS POWER oa CAPSCREW LOCKWASHER LOCKWASHER LOCKOUT SHIFT UNIT 1 Used only on D466 P 486 586 P 656 P f Lube Pump PUMP DRIVE GEAR EXPANSION PLUG LOCKNUT 1 Assemble and install Lube Pump Position pump drive gear in mounting po
158. n power divider nas been disassembied 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 N m 1 5 8 18 780 960 1059 1301 1 7 8 12 840 1020 1139 1383 Bearing Cover Cap Screw 12 13 75 85 101 115 Grade 5 Adjustments 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 indicator positioned at yoke end of output shaft If end play is not correct adjust as follows 2 Remove Front 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 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 decrease end play remove shims Example Measured end play
159. nap ring to secure bearing race WARNING SNAP RING IS SPRING STEEL AND MAY POP OUT WEAR SAFETY GLASSES WHEN INSTALLING 3 If removed install output shaft bearing cup in carrier Differential Carrier Overhaul NOTE After differential adjust ment is complete or if dummy yoke was used remove nut and yoke Then continue to assemble pinion as follows 1 Install helical gear on pinion positioned as 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 torque chart Torque Chart Drive pinion Slotted Nut and Roll Pin Ft Ibs 1 1 2 18 840 1 3 4 12 980 IMPORTANT Torque nut to torque shown in chart then con tinue tightening nut to align slot with nearest hole in pinion shank Install roll pin NOTE After differential adjust ment is complete or if dummy yoke was used remove nut and yoke Then continue to assemble pinion as follows 1 On D466 P only install helical gear spacer Install helical gear on pinion using driver and hammer 2 Install pinion outer support bearing using driver and hammer 3 Install slotted nut and tighten ing according to instructions in torque chart Torque Chart Drive pinion Slotted Nut and Roll Pin Ft Ibs 1 1 2 18 840 1 3 4 12 980 IMPORTANT Torque nut to torque shown in chart then con tinue tighte
160. nch mark bearing adjusters for caps reference during assembly M DA 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 If gear 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 1 Mount Differential Carrier 2 Punch mark differential bear 3 Cut lockwire Remove cap Assembly in repair stand Loosen ing caps If reusing gear set also screws flat washers and bearing 6x6 5 5 Differential Carrier Overhaul Disassemble Drive Pinion Forward and Rear Axles Rear Axle Pinion Illustrated PINION BEARING GEARING BEARING BEARING BEARING SEAL PINION PILOT CONE SPACER CAGE CAGE Cue RETAINER NUT BEARING INNER VARIABLE SHIM OUTER 1 BEARING CAGE BEARING 2 DRIVE SPACER cue CAP CONE INPUT FLAT WASHER PINION WASHER INNER LOCKWASHER SCREW OUTER YOKE 1 Used only A466 R486 R585 R650 21 Used only R346 R386 R406 IMPORTANT During the following 2 Forward and Rear Axle Pinion 3 Rear Axle Pinion Seal and yoke removal procedure the drive Bearing Cage Support cage and Outer Bearing Cone Remo
161. ne cup relationship for over gear teeth and helps maximize free rotation under load The pinion gear set life pilot bearing does not require a pre load adjustment 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 NOTE Because of manufacturing 0 003 to 0 007 variations individual parts correctly adjusted end play could vary 0 010 after the unit is rotated Rebuild with reused parts 0 013 to 0 017 Acceptable End Play Tolerances when measuring as a regular maintenance procedure with axle in truck Up to 0 060 with over 100 000 NOTE If end play 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
162. ning nut to align slot with nearest hole in pinion shank Install roll pin Install Pinion Helical Gear 0346 386 406 P Install Pinion Helical Gear 0466 486 586 P 656 P Pinion Helical Gear and Support Bearing Installation THESE PARTS A IN POWER SNAP RING EEXILLLLTCCECCEIT A DIVIDER COVER E orn 7 PINION OUTER _ SUPPORT d BEARING BEARING SPACER SLOTTED NUT IMPORTANT POSITION RECESSED HUB TOWARD SUPPORT BEARING Pinion Helical Gear and Support Bearing Installation SUPPORT BEARING RACE SNAP RING THESE PARTS ARE MOUNTED IN POWER DIVIDER COVER aou en SLOTTED NUT PINION HELICAL HELICAL GEAR SPACER 0466 ONLY 6x6 5 13 Differential Carrier Overhaul Install Differential Assembly in Carrier 0346 386 P 406 P Forward Axle NOTE Lubricate bearings during the following assembly procedures SEAT DIFFERENTIAL CASE PILOT IN CARRIER BEARING CAP PEDESTAL BEARING 77 PEDESTAL 1 Place ring gear and differential assembly in carrier During instal lation tilt carrier to allow differen tial case pilot to mesh properly with edge of bearing cap pedestal see photo above Install bearing cups at both sides of differential case 5 14 6x6 2 Install bearing adjusters and 3 Install and tighten bearing cap caps screws finger tight If this is diffi cult use hand w
163. nspect 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 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 e 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 4x4 6x6 2 4 Repair 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 A significant portion of such a part s useful life has been expended and the damage caused should the part fail is
164. nted 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 05262 Removing Seal and Retainer 4x4 6x6 1 14 Steering and Wheel End Equipment Overhaul Disassembly conta 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 t 05363x 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 05363x 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 Repeat same procedure for lower kingpin bearing 05363x Partially Removing To
165. ntial Refer to the appro priate Eaton Axle Service Manual covering your specific axle 4x4 6x6 7 11 Heavy duty CTD 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 oposite sides with a soft nosed hammer until gear is fully seated against gear support case flange Turn assembly over then place 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 two alignment bolts Instail 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 l
166. ntrolled Traction Differential Axle Capacity 34 000 Ibs 38 000 Ibs 40 000 Ibs 46 000 Ibs 48 000 Ibs 58 000 Ibs 65 000 Ibs page ii page iii DS386 P Power Divider Lube Pump Capacity x 1000 38 000 Ibs Axle Model Type DS346 P Single Reduction DT346 P Dual Range DP346 P Double Reduction DS386 P Single Reduction DT386 P Dual Range DP386 P Double Reduction DS406 P Single Reduction DT406 P Dual Range DP406 P Double Reduction DS466 P Single Reduction DT466 P Dual Range DP466 P Double Reduction DS486 P Single Reduction DT486 P Dual Range DP486 P Double Reduction DS586 P Single Reduction DT586 P Dual Range DP586 P Double Reduction 05656 Single Reduction DT656 P Dual Range DP656 P Double Reduction Power Divider with 6x6 Transfer Gearing Spicer 6x6 Drive System The Spicer 6x6 Drive System is a new design concept It consists of an Spicer standard tandem axle incorporating a unique transfer gearing in the power divider POWER DIVIDER WITH TRANSFER Gearing Combinations GEARING The Spicer 6x6 Drive Systems are available in the following gearing combinations Operating Mode Steer Drive Axle Tandem Axle 6x6 or 6x4 Single Reduction Single Reduction 6x6 Single Reduction Single Reduction 6x4 Inter axle with Controlled with Controlled Differential operating Traction Traction CTD disengaged Differential Differential 6x6 or 6x4 Double Reduction Double Reduction 6x6 or
167. off case Second mount puller horizontally to remove cone 8 Remove bearing cone from flanged case half using suitable puller Puller Mounted Vertically fo Split Bearing FLANGED BEARING DIFF CASE CONE BEARING ADJUSTER UU RING BEARING GEAR NUT 2o or gt SEES _ 2 5 Remove side gear and thrust washer Removing Bearing Cone from Flanged Case Half 4x4 6x6 2 16 Differential Carrier Overhaul Single Reduction Assemble Wheel Differential NOTE Lubricate differential parts with gear lube during assembly 3 Place thrust washer and side gear in flanged differential case 2 Press bearing cone on plain 1 Press bearing cone on flanged differential case differential case 6 Align punch marks and install 4 Assemble side pinion and 5 Place side gear and thrust plain case half Install cap screws thrust washers on spider Place washer on side pinions and tighten to correct torque see this assembly in flanged differen cae and check NOTE Fasteners using self for proper mesh locking nylon patches may be reused if not damaged but should be secured by a few drops of Check differential for free rotation Loctite 277 on threaded surface by turning side gear hub Differ of differential case during follow ential may require up to 50 ft lbs ing assembly procedures 68 N m
168. or use in Spicer Axles Synthetic Lubricants Use of synthetic lubricants in Spicer Axles is approved only after Engineering 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 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 also be consid ered when ever changes in vehicle lo cation or primary operating area are made and the grade of lube changed if necessary Ambient Temperature Range 40 to 15 F 40 C to 26 C 15 F to 100 F 26 C to 38 C 15 F and above 26 C and above 10 F and above 12 C and above 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 filler hole plug located in the axle housing cover Lube should
169. osition the unit functions with con For detailed operation description ventional differential action For operational description of the shift see page 8 3 unit see page 8 18 8 2 6x6 Steer Drive Axle Lockup and Differential Lockout Operation Disengaged 6x4 Drive 1 When the shifter valve lever is moved to the disengaged position this valve is closed and air pressure in the shift units is exhausted through the shifter valve 2 Air pressure at both pistons is released Spring pressure moves pistons shift forks and sliding clutches Clutches disengage from drive gears The steer drive axle and inter axle differential are dis engaged for 6x4 operation NOTE If equipped with Controlled Traction Differentials they are disengaged and not operating Trouble Shooting Check for Air Pressure and Air Leaks A simple method for quickly locat ing troubles in a shift system can be accomplished by listening for possible air leaks and for sound or feel by hand which would indicate mechanical movement Engaged 6x6 Drive 1 When the shifter valve lever is moved to the engaged position the valve is opened and supplies air pressure to both shift units 2 Air pressure enters both shift unit covers and moves pistons shift forks and sliding clutches The clutches engage drive gears The steer drive axle and inter axle dif ferential are engaged for 6x6 operation NOTE If
170. osition and check for air flow at disconnected air lines Place lever in disengaged position and insure air flow is discontinued If system functions correctly pro ceed to Step 7 If not proceed to Step 5 5 Check Lockout Control Valves If improper operation is evident in Step 4 the All Wheel Drive selector valve and or the lockout control valves mounted in the side of the tandem axle dual range shift units are 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 flow Place selector valve in disengaged position and insure air flow stops Replace valve if it functions incorrectly Recon nect air line to delivery port and proceed to Step 6 6 The lockout control valves on the tandem axle dual range shift units are connected in series With the All Wheel Drive selector lever in the engaged position and the dual range selector in Low Range check for air flow from the side ports of the lockout control valves If air flow is not present remove the valves 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 ball released air flow should be stopped If the valves function incorrectly they should be replaced If they function correctly rein
171. p Bearing Cup 1 15 4x4 6x6 Steering and Wheel End Equipment Overhaul Disassembly 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 ball see photo NOTE With ball socket removed the bearing cones 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 on axle shaft that contacts bushing If clearance exceeds 0 015 replace ball and bush C5362Xx ing assembly Removing Ball Socket 2 Inspect oil seal in bore of ball for defects If faulty replace the seal Remove with suitable puller 3 Inspect kingpin bearings for pitted or worn roll ers 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 bail 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 5 Inspect camshaft bushings in ball socket for
172. per bearing preload In 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 some 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 05369X 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 lower bearing cover and instail a pipe plug Checking Kingpin Bearing Preload King Pin Cover Torque Chart Cap Screws 170 220 ft lbs 231 298 280 360 ft lbs 380 488 1 19 4x4 6x6 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 Install 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 2
173. properly 2 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 1 3 4x4 6x6 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 2 Keep the wheels and hubs clean Stones or lumps of mud wedged between the wheel and drum will unbalance a wheel and tire 3 Check for damage that would affect the runout of the wheels Wobble or shimmy caused by a damaged wheel will eventually dam age 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 speci fied for the tires and vehicle model 2 Inspect the tire treads and remove all stones nails glass or other objects 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 3 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 4 C
174. 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 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 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 NOTE Single Reduction Gearing 3 Loosen the bearing adjuster Illustrated 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 between 0 006 and 0 016 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 adjust
175. put shaft rear bearing Tap the outer race with a sleeve or drift until it is seated firmly in the machined pocket of the cover Secure with snap ring 8 Slide the rear bearing retaining washer over the splines of the outer shaft until it seats flush against the output shaft bearing IMPORTANT D346 P 386 P 406 P models do NOT use rear output shaft Rear Bearing Retain ing Washer 11 Connect front output shaft and input drivelines 14 Axle with Controlled Traction Differentials If used install shift unit nuts and lockwashers Torque nuts see chart page 3 18 Connect air line Location of hole in rear Cover 3 Apply silicone gasket com pound Install differential carrier assembly in axle housing Install nuts and lockwashers Tighten to gorant torque see chart page 18 6 Lubricate and install the rear bearing sleeve on the output shaft Make certain it fits snugly against the shoulder at the forward edge of the shaft splines 9 Install rear output yoke flat washer and nut Torque nut see chart page 3 18 Connect inter axle driveline 12 Connect lockout and lockup shift unit air lines 15 Fill axle with correct lube see Lubrication Section 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 Re
176. r 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 Positive camber is an outward tilt or inclination of the wheel at the top HORIZONTAL Negative or reverse camber is an inward tilt of the wheel at the top LINE il iG The amount of camber used depends the amount in degrees the HUB wheel end is inclined 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 or left The truck will lead to the side which has the most positive camber Normal camber angle is 7 degree Camber is nonadjustable and is only changed if the axle ball assembly i or axle housing becomes bent Camber Angle Should Be 7 VERTICAL _ 1 Left Hand Wheel Viewing LINE r4 Rear of Axle 4x4 6x6 1 4 ESD 18 Steer Drive Axle Caster Angle Caster is the amount in degrees the top of the kingpin 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 a 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
177. r A WARNING DO NOT LIE UNDER IMPORTANT Do not strike the shaft head with a hammer Do not use chisels or wedges to loosen shaft or dowels Axle Housing Silicone Gasket Compound Pattern 3 Apply silicone gasket com pound to axle housing surface see illustration 6 Connect inter axle driveline 9 Axle with Controlled Traction Differentials If used install shift unit nuts and lockwashers Torque nuts see chart page 3 18 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 CARRIER AFTER FASTENERS ARE REMOVED USE TRANS MISSION JACK TO SUPPORT AND REMOVE DIFFERENTIAL CARRIER ASSEMBLY 4 Install differential carrier assem bly in axle housing Install stud nuts and lockwashers Tighten to a a torque see chart page 18 7 Fill axle with correct lube see Lubrication Section 6x6 3 17 Differential Carrier Replacement 3 18 6x6 Tor que Chart Forward and Rear Axles Size Grade Ft Ibs DIFFERENTIAL CARRIERS AXLE HOUSING D346 P 386 P 406 P R346 386 406 Stud NU 5 8 18 8 stud 220 240 298 325 D466 P 486 P 586 P 656 P Stud Nut 5 8 18 8 stud 220 240 298 325 At Dowels 150 170 203 320 Cap Screw 12 pt 5 8 11 8 210 230
178. r Brake Chamber and Lubricate Camshaft Bushings 23 Adjust Air Chamber Push Rod Free Stroke 23 Install Brake Shoes 24 Connect Tie Rod and Steering Arm 25 Assemble and Install Hub and Drum 25 Install Wheels and Tires Lubricate Axle 26 1 7 4x4 6x6 Steering and Wheel End Equipment Overhaul Steer Drive Axle Steering and Wheel End Equipment NUT LUBE 6 LOCKWASHER TOP COVER _ COTTER PIN DIFFERENTIAL CARRIER ASSEMBLY 2 STUD lt WASHER PLUS NE 4 DRAIN PLUG LUBE FITTING FILLER PLUG TIE ROD END LOcKWAGHER FITTING NUT BALL STUD ot cones DOWEL COTTER PIN lt STEERING ARM wt SK NUT gt SHIMS COTTER WASHER SEAL 4 e BEARING _ BEARING CONE KING 0 USHING rM RETAINER amp GASKET BALL P WASHER STOP SCREW SHIMS SHAFT SHAFT SCREW P SCREW WASHER v COTTER PIPE F a PLUG SCREW BEARING BEARING CONE CLAMP SCREW HUB BEARING i CUP LOCK WASHER NOE c E SPACER LOCK 3 a PULLEA 0090 oo T L CO NuT CAP NUT ARI CONE O BEARING ADJUSTING Lock WHEEL NU WASHER STUD ORUM 4x4 6x6 1 8
179. r 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 rod 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 z and lockwashers Torque to 80 110 ft ibs 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 ie 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 S cam if oil seals have been properly installed 3 After adjusting air chamber 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 ns a l Air Chamber and Bracket Assembly 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 r
180. r 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 8 4 6x6 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 of premature wear or drive 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 polished 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 IS UNSAFE IN THE WORKSHOP ENVIRONMENT Wash castings or other rough parts in solvent or clean in hot solution tanks using mild alkali so
181. r line to permit removal of shift unit Place sliding clutch inthe engaged posi tion Sliding clutch must be engaged to allow removal of car rier from housing Remove shift unit Seasonal Engagement Type Remove nuts and washers from 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 iy qnam Type Sliding clutch is always engaged No procedure is necessary to remove differential carrier 2 11 4x4 6x6 4 PULL WHEEL END ASSEMBLY OUTWARD UNTIL SPLINES DISENGAGE SIDE GEAR 2 DISCONNECT AIR LINES AND STEERING CONNECTIONS 1 SUPPORT THE WHEEL END Separating or removing Wheel End Assembly to Disengage Axle Shaft Splines from Side Gear 5 Disconnect drive shaft Loosen but do not remove drive pinion nut 6 Remove differential carrier assembly WARNING DO NOT LIE UNDER CARRIER AFTER FASTENERS ARE REMOVED USE TRANS MISSION JACK TO SUPPORT AND REMOVE DIFFERENTIAL CARRIER ASSEMBLY Remove nuts and washers fasten ing carrier to axle housing Remove differential carrier assembly 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 on axle housing mat ing surface as shown in the
182. rench NOTE Tighten bearing adjuster until its first thread is visible NOTE With bearing adjusters and caps assembled to carrier the car rier assembly is now ready for adjustment of bearing preload ring gear backlash and gear tooth contact see page 5 17 Differential Carrier Overhaul Install Differential Assembly in Carrier 0466 486 586 656 P Forward Axle SEAT DIFFERENTIAL 3 Install and tighten bearing cap 4 At back face side of gear GAP PEDESTAL a screws finger tight If this is diffi install bearing cap and cap screws cult use hand wrench Tighten cap screws finger tight If NOTE Tighten bearing adjuster this is difficult use hand wrench until its first thread is visible NOTE If removed instal bearing cup in adjuster using a press Place bar stock through opening in differential Place bearing NOTE Lubricate bearings during adjuster and cup assembly on bar 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 lower the assembly until bearing cones rest on carrier NOTE Make sure adjuster threads are well lubricated 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 page 5 17
183. rfaces 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 2 5 4x4 6x6 Adjustments Differential Carrier Bearing Preload This adjustmentis tionship for free rotation under pinion for best contact under load performed for both pinion and dif load The pinion pilot bearing does Correct adjustment distributes ferential bearings It maintains not require a preload adjustment torque evenly over gear teeth and proper gear alignment by creating Ring Gear Tooth Contact This helps maximize gear set life correct bearing cone and cup rela adjustment 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 Assemble these Parts for Trial Build up INNER INNER BEARING OUTER OUTER spacer between two bearing cones NOTE When new gear set or CONE T VARIABLE CUP CONE pinion bearings are used select nominal size spacer from the speci fication cha
184. rical 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 by an electrical switch mounted on or near the quick release valve The switch is normally closed and is opened by air pressure With tandem axle in Low Range the Switch is closed and the adapter is energized The adapter operates with a ratio compatible with the axle Low Range for proper road speed readings 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 8 10 6x6 Axle Range Shift m Opera tion must be in 6x4 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 6x6 drive axle range shift er valve lever is blocked and range cannot be changed Interlock S
185. ring cone damage use suitable sleeve that only contacts the inner race of the cone oe Pressing Bearing Cone cn Large Pressing Bearing Cone on Small Support Case Support Case 15 HIGH SPEED RECESS CHAMFER CLUTCH PLATE 1 8 CHAMFER POSITION 35 SIDE OF PLATE TOWARD CASE 2 Position high speed clutch plate with chamfered 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 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 2 27 4x4 6x6 Differential Carrier Overhaul Assemble Wheel Differential Cont d 4 Assemble side pinions and thrust washers on 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 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 5 Place side gear and thrust 6 Align punch marks and place washer in position on side pinions plain case on case with pins In stall cap screws
186. rque cap screws to 110 125 ft Ibs 149 170 4 12 6 6 2 Rear Output Shaft Lubricate O rings then install output shaft assembly in carrier Pattern PIN SOCKET HEAD CAP SCREW DOWEL PIN 0466 486 P 586 P 656 P IMPORTANT Make sure blind cap screws fastening power divider cover are installed and torqued Two are used on D346 P 386 P 406 P One is used on D466 P 486 P 586 P 656 P 3 Inter axle Differential Install differential assembly on output shaft side gear with nuts facing away from output shaft side gear Silicone Gasket Compound Pattern 0346 386 P 406 7 Adjust Input Shaft End Play Adjust end play with the power divider assembled to the differen tial carrier see page 4 13 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 aca with reused parts 0 013 to 0 017 Refer to Adjustments ection 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 cle
187. rried into the wheel ends by the motion of axle shafts Lube Cavity 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 through 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 NOTE For complete lubrica 3 Jack up right side of axle Maintain this position for tion instructions see Maintain this position for one minute to allow lube preceding pages one minute to allow lube to flow into wheel ends at to flow into wheel ends at right side left side 4 With vehicle level again add lube through axle housing cover fille
188. rt 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 BEARING BEARING SPACER BEARING BEARING Cage in Press SLEEVE MUST rolling torque Wrap soft wire to Check Bearing APPLY PRESSURE around the bearing cage attach Preload TO BACK FACE spring scale and pull Preload is OF OUTER correct when torque required to rotate the pinion bearing cage is from 10 20 inch pounds This specification is transiated 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 A thinner spacer will increase 2 CONE preload IMPORTANT Once correct bear ing preload has been established Speciiteatione for en ae note the spacer size used Select a up es spacer 0 001 larger for use in the pu E final pinion bearing cage assembly The larger spacer compensates Nomina Bearing for slight growth in the bear Spacer Thickness ings which occurs when they are in mm pressed on the pinion shank The ESD 18 trial build up will result in proper Steer Drive f 13 5 15 5 12 2 14 0 pinion bearing preload in three Axie of four cases Differential
189. s If improper operation is evident in Step 4 the All Wheel Drive selector valve and or the lockout control valves mounted in the side of the tandem axle dual range shift units are 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 flow Place selector valve in disengaged position and insure air flow stops Replace valve if it functions incorrectly Recon nect air line to delivery port and proceed to Step 6 6 The lockout control valves on the tandem axle dual range shift units are connected in series With the All Wheel Drive selector lever the engaged position and the dual range selector in Low Range check for air flow from the side ports of the lockout control valves If air flow is not present remove the valves 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 ball released air flow should be stopped If the valves function incorrectly they should be replaced If they function correctly reinstall in the shift units and insure that air flows through the valves when the All Wheel Drive selector lever is in the engaged position axle range shifter valve in Low Range and is stopped when the lever is in the disengaged position
190. s 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 ment at the tandem axle range shift units and the steer drive axle range shift unit If no movement is ent place the axle range valve lever in the Low Range position and dis connect air lines at the tandem and the steer drive axle range shift units Place axle range valve lever in High Range position Air flow should be present through the disconnected air lines If air flow is not present inspect the axle range shifter 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 Lockout and Lockup System Have an assistant move the All Wheel Drive selector valve lever from disengaged to engaged posi tion Check for mechanical move ment in the inter axle differential lockout shift unit and steer drive axle lockup shift unit mounted on the tandem forward axle Alternatively disconnect air lines from cover of inter axle differential lockout shift unit and steer drive axle lockup shift unit with selector valve lever in disengaged position
191. s 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 backing plate adjust the wheel bear ings Replace the bearings if they are worn or damaged Adjust and or replace worn or damaged bearings 3 Check brakes for dragging and wheels for proper balance 4 Check all steering linkage for wear or maladjust ment Adjust and or replace worn parts 5 Check the steering gear mounting bolts and torque them wherev er 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 balance 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 1 Check kingpin bearing nut tightness after first 1000 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
192. s fastening power divider cover to differential carrier These cap screws are accessible through front output shaft bearing cover opening Before attempting to remove power divider cover first remove front output shaft assem bly to make these cap screws accessible see step 2 4 To remove power divider cover assembly attach chain hoist to input shaft yoke and lift the cover assembly off 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 Remowve nicks and burrs if present 7 Rear Output Shaft Side Gear Bearing Cup If necessary use puller to remove bearing cup from differential carrier NOTE For instructions on remov ing axle housing cover and rear output shaft rear bearing parts see Section 3 page 3 15 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 f unit from power divider cover Remove shim pack 5 inter axle Differential Lift dif ferential assembly off output side gear 3 Remove power divider cover cap screws including the blind cap screws Two blind screws are used on D346 P 386 P 406 P one screw is used on D466 P 486 P 586 P 656 P CAUTION DURING REMOVAL OF POWER DIVIDER THE INTER AXLE DIFFERE
193. s position adjust stop screw until it touches the ball c Tighten locknut to secure stop screw d Install axle ball to housing cap screws Torque m cap screws to 170 220 165 231 298 N m Adjusting Steering Stop NOTE Use same procedure for both left and right hand wheel ends NOTE service the Pitman arm stops should be set to limit wheel cut before adjusting stop screw contacts on axle ball ADJUSTING STOP SCREW amp LOCKNUT FLANGE ANGLE PLATE 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 Install socket head cap screws 05365X Assembling Cage Rings 2 Referring to the photograph check for correct assembly Note the relationship of the 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 N m Lock screws with punch marks across threaded end of cap screws 05366x Checking Axle Shaft Movement Angle 1 21 4x4 6x6 Steering and Wheel End Equipment Overhaul Assembly Install Axle Shaft Assembly 1 Turn ball socket to straigh
194. s seven installing External Splined Friction Aligning Internal Splined Friction internal splined and seven external pjate Plate with Sliding Clutch 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 6 Instali Compression Springs and Cover All Types CTD POSITION SPRINGS ON SMALLEST CIRCLE POSSIBLE ALIGNMENT BOLTS a Install springs on pressure plate positioning them in the smallest circle possible see photo b Place support case cover over springs and temporarily install two alignment boits h pP gnment boits heads up ac T E NUTS amp BOLTS CLAMPING NUTS 4 BOLTS c Temporarily 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 seif locking nuts that fasten cover to ring gear Remove the temporarily installed clamping nuts and boits and instail the remaining cover bolts and self locking nuts Torque nuts to aa 110 130 ft Ibs 149 176 4x4 6x6 7 9 Heavy duty CTD Overhaul Remove and Disassemble Clutch Pack DRIVER Heavy duty CTD Illustrated PERMANENT CTD SIDE PRESSURE BOLT SUPPORT CASE GEAR PLATE COVER SLIDING S
195. screws and lockwashers Torque cap screws to 100 125 ft ibs 136 170 4 3 Install and tighten bearing 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 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 Backlash 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 USED GEARING CORRECT PATTERN NEW Gi GEARING Could vary in length Pocket may Pattern shou
196. sembly 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 to rest in carrier bore then install bearing cup as shown in photo Also install bearing cup on opposite side of differential Rear Axle Install Pinion Rear Axle Install Differential in Carrier Nominal Shim Pack in mm 0 023 0 584 Torque Chart Drive Pinion Bearing Cage Cap Screw Ft Ibs 9 16 12 Grade 5 5 8 11 Grade 5 110 125 149 170 160 176 217 239 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 When installing 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 drive pinion assembly NOTE Make certain lube holes in carrier shims and cage are aligned Install bearing cage cap screws and lockwashers Torque cap screws see chart 5 d 3 Install and tighten bearing cap screws finger tight If this is diffi cult use hand wrench NOTE The assembly is now read
197. shift units 6x6 8 3 Dual Range Axles with Range Interlock Description and Operation Operational Modes 6x4 drive with axles in High or Low Range 6x6 drive with axles in High or Low Range The system includes an interlocking feature that prevents axle range shift when in 6x6 drive 656 DRIVE SHIFT SYSTEM s Dua RANGE ES wi TH RANGE INTERLOCK z g as E a INTERLOCK Wheel SHUTTLE gt VALVE gt H eee 1 m _ Cera S c if VT oa T a N INTERLOCK a SYSTEM j INTER OCK INTERLOCK a T 1 ONE Ot 1 i STEEn DIUVE AXLE EXHAUST AND INTER ARLE DIFF j 2 EXHAUST INTER AXLE STEEA DAIVE 0604 i Owr LOCKOUT ALL WHEEL AXLE LOCKUP PORTION SHIFT UNIT DRIVE SYSTEM SHIFT UNT BREAKCR 11 mmm van c EIL e OUICK RELEASE VALVE a gt 7 L J IGNITION SWITCH 1 EXHAUST t Pressure switch and speedometer adapter required for vehicles 1 Solenoid valve required for vehicles not equipped with automatic with transmission drive speedometers safety brakes gt CONSTANT AIR SUPPLY AIR FLOW AXLE gt AIR FLOW FROM AXLE AIR FL
198. sition in power divider cover At the same time insert pump gear long shaft in cover engaging mounting hole in drive gear If difficulty is experi enced lightly tap the drive gear on the shaft using a driver and hammer 3 Install short shaft pump gear in power divider cover Installing Pump Cover 4 10 6x6 MAGNETIC PUMP SCREEN O RING LOCKWASHER PUMP COVER DOWEL CAP GEARS PIN SCREW 2 Install and tighten drive gear nut after input shaft is assembled to power divider cover step 16 4 Install ring in pump cover making sure ring is seated firmly in body If removed install dowel pins Install pump cover on power divider cover and secure with cap screws and lockwashers Tighten to correct torque 85 105 IN LBS 10 12 N m Assemble Power Divider conta Power Divider Overhaul 5 Install pinion outer bearing race in power divider cover using a driver and hammer Install snap ring to secure bearing race WARNING SNAP RING IS SPRING STEEL AND MAY POP OFF WEAR SAFETY GLASSES WHEN INSTALLING shaft Input Bearing Cover Oil Seal and Bearing Cup Installation 7 Press bearing cup in input bear ing cover NOTE Do not install oil seal until input shaft end play adjustment is completed see page 4 13 Helical Side Gear Bushing Installation 14 8 Install bronze bushings helical side gear see illustration for dimensional tolerances
199. 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 4x4 6x6 Description and Operation Spicer Controlled Traction Differentiats or CTD incorporate a friction plate assembly designed to transfer torque from the slipping wheel to the one with traction Engaged the Spicer 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 ap preciable 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 limiting differential action The Medium duty CTD clutch pack includes internal spl
200. stall in the shift units and insure that air flows through the valves when the All Wheel Drive selector lever is in the engaged position axle range shifter valve in Low Range and is stopped when the lever is in the disengaged position If this does not occur the rear axle shift units must be inspect ed and repaired Do not proceed to Step 7 until proper operation is obtained 7 Place the axle range shifter valve in the High Range position and the All Wheel Drive selector lever in the engaged position Return to the lock out contro valves and insure that air flow is not present at the side ports of each valve This is the feature that prevents All Wheel Drive operation in High Range If air flow is present the lockout control valves and or axle range shift units must be inspected Do not proceed to Step 8 until proper functioning occurs NOTE See next page for Step 8 Dual Range Tandem Single Reduction Steer Drive Trouble Shooting conta 8 Check Interlock System Place the axle range shifter valve in the Low Range position This lever must remain in this position for the re mainder of the system checks Move the All Wheel Drive selector lever to engaged position On axle dual range shifter valve insure that interlock pin actuates which prevents movement of the range selector lever when in All Whee Drive Move the All Wheel Drive selector lever to the disengaged position and check for retraction of the interloc
201. t 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 convenient but give the advantage of having every part needed for a good repair job 3 6 6x6 Adjustments Whee 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 ness RELEASING BRAKES E SST es 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
202. t ahead position Grease axle shaft bushing in axle ball and pack inner walls of 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 Nicks or burrs could damage axle shaft oil seal located in axle ball Lubricate 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 ring Install Brake Spider and Spindle 1 Place spider on shoulder at axle side of spindle then place this assembly on ball socket Fasten with cap screws Tighten screws to torque of 170 220 165 231 298 Install Brake Camshaft Slack Adjuster and Adjust End Play 1 Place light 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 Installing Brake Spider and Spindle Installing Brake Camshaft Installing 7 Slack y Adjuster 4x4 6x6 1 22 Steering and Wheel End Equipment Overhaul Assembly Adjust Air Chamber Push Rod Length 1 NOTE Before installing ai
203. tall magnetic strainer in power divider cover Torque to 40 60 ft lbs 54 81 19 For power divider cover instal lation refer to page 4 12 6x6 4 11 Power Divider Overhaul Install Power Divider on Differential Carrier with carrier removed from axle housing NOTE Instali front output shaft after power divider cover is installed on differential carrier Blind cap screws fasten the power divider cover and these are only accessible through output shaft opening NOTE Before installing power divider install related parts as follows 1 Output Shaft Side Gear Bearing Cup If removed press bearing cup in carrier Use a press and appro priate sleeve or use a brass drift and a mallet Tap bearing cup into its bore making certain cup is evenly and firmly seated 4 Apply silicone gasket com pound on carrier mating surface see illustrations 5 Install Power Divider Attach chain hoist to input yoke and install power divider assembly During installation rotate input shaft to engage input shaft splines with inter axle differential After installation again rotate input shaft Output shaft should turn when input shaft is rotated if assembly is correct NOTE Lifting mechanism may create nicks and burrs on input yoke Remove if present 6 If removed install dowel pins in carrier Install power divider cover cap screws and lockwashers Place socket head cap screw at location shown on drawings To
204. the differ ential carrier near the power divider cover Magnetic Strainer for Axles with Lube Pump Oil Filler Hole at top of Differential Carrier NOTE Lube fill capacities in the adjacent chart are good guidelines but will vary Lube Capacities somewhat on the basis of the angle the DO NOT OVERFILL AXLES axle is installed in a particular chassis Lube Capacity Always use the filler hole as the final Axle Model Pints liters reference If lube is level with the bottom 6x6 Tandem Axles Forward Rear of the hole the axle is properly filled D346 P D386 P D406 P 36 17 Axles installed at angles exceeding 37 18 10 degrees or operated in areas of 39 18 continuous and lengthy grades may D586 P D656 P 36 17 require standpipes to allow proper fill levels Forward Axles Add an additional 4 pints 1 88 liters axle lubricant through filler hole at the top of the differential carrier near Contact Spicer Field Service the power divider cover See photo above Department or call Regional Office for specific recommendations See back cover for address and phone numbers Capacities listed are approximate The amount of lubricant will vary with angle of axle as installed in vehicle chassis Figures do not apply to housings not designed or manufactured by Spicer 6x6 3 3 Lubrication Wheel Bearing Lubrication Under normal operating conditions axle wheel bearings are protected Wheel Hub by lubricant ca
205. til proper functioning is obtained c Reconnect the air lines and place the All Wheel Drive selector lever in the engaged position If the inter lock pin on the axle range shifter valve does not actuate proceed to the next step If the interlock pin functions correctly system is operating correctly and check is complete d Disconnect the air line from the side port of the shuttle valve Place All Wheel Drive selector lever in the engaged position and insure air flow is present at the shuttle valve side port If air flow is not present re place the shuttle valve If air flow is present proper operation is evident e If interlock pin still does not actu ate when All Wheel Drive selector lever is placed in engaged position remove the axle range shifter valve in the cab and inspect the assembly for component wear or binding After repairing check for correct operation by placing the All Wheel Drive selector lever in the engaged position and insuring that the inter lock pin on the axle range shifter valve activates and also that it retracts when the All Wheel Drive selector lever is placed in the disengaged position Check Electrical System Check Solenoid Valve 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 wirin
206. ts 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 adapteris operated 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 Axle Range Shift rm Opera tion must be in 6x4 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 drivelinetorque is interrupted axles are shifted to Low Range and held in this position by shift unit return springs NOTE 6x6 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 6x6
207. ube 7 12 4x4 6x6 2 Install Ring Gear with Loose Fit Place ring gear in press gear teeth down on hard wood biocks 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 boit holes Install two alignment bolts in mounting holes then proceed with reassembly procedures in Step 3 SPLINED FRICTION PLATE Installing Friction Plates FRICTION SIDE GEAR AND CURVIC CLUTCH Lc 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 splined mounted on the friction plate driver NOTE Early modei CTDs use 25 plates 12 splined 13 tanged Late models use 21 plates 10 splined 11 tanged Assemble install Clutch Pack conta Heavy duty CTD 6 Place last tanged friction plate and pressure plate over friction FRICTION plate driver Then using a press PLATE and suitable adapters compress DRIVER clutch pack and install round snap ring in groove of friction plate driver 7 If removed press bearing cone on gear support case cover PRESS GEAR SUPPORT CASE w 1 y tem 77 7 SNAP RING ALIGNMENT
208. urvic 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 16 4x4 6x6 Service and Maintenance ESD 18 Instructions Steer Drive Axle opicer Axles Brakes Contents 6x6 Drive Shift Systems Section 7 Page No Single Reduction or Double Reduction Axles 2 Single Reduction with Controlled Traction Differentials 2 Dual Range Axles with Range Interlock 4 Dual Range Tandem with Single Reduction Steer Drive 9 Shift System Components Air Shifter Valves
209. usters and locks then tighten differential bearing cap screws to correct torque 360 440 ft lbs 488 596 Install adjuster locks and cotter pins Lockwire differential bearing cap screws CORRECT PATTERN USED GEARING Could vary in length Pattern should cover 1 2 tooth or more f face width 2 7 Pattern should f be evenly centered A between tooth Pray top land and root 7 Pattern should clear of tooth toe Pocket may extended Pattern along the face width VY could be longer 2 21 4x4 6x6 Differential Carrier Overhaul Differential Carrier Assembly Dual Range and Double Reduction THRUST WASHER SIOE PINION e SPIDER CASE THRUST SIDE SIDE THRUST PINS WASHER GEAR GEAR WASHER DIFFERENTIAL ASSEMBLY BEARING BEARING THAUST HIGH SPEED RING GEAR BEARING BEARING ADJUSTER CONE CLUTCH PLATE CONE ADJUSTER GEAR IDLER SUPPORT RING SLIDING RING SUPPORT PINION IDLER THRUST CASE GEAR BEARING CLUTCH L mia ae CASE PIN PINION WASHER NUT CUP DUAL RANGE SHIFT SHAFT STUD SEAL N CAP SPRING DOWEL SHIFT SEAL CAP M FORK SHIFT FORK SCREW le a SHIFT UNIT COVER LOCKWASHER nm BEARING CUP p 9 BEARING BEARING OIL FLAT P SHIM CAGE SEAL WASHER Screw N ao A 90 e
210. ve oi pinion may fall out of bearings and press pinion out of bearing cage seal and bearing cone from cage cage Do not allow pinion to drop and bearing cone Discard oil seal Remove bearing on hard surface cups with suitable puller 1 Rear Axle Pinion Yoke 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 5 6 6x6 Differential Carrier Overhaul Disassemble Drive Pinion conta Forward Axle Pinion Illustrated THESE PARTS Hi ARE MOUNTED DRIVE SPACER BEARING BEARING BEARING HELICAL SLOTTED SNAP PINION T CUP CAGE _ GEAR NUT RING DIVIDER COVER SUPPORT BEARING PILOT LOCK pi 2 BEARING BEARING CONE SPACER WASHER SCREW GEAR BEARING PIN VARIABLE SPACER SPACER 1 Used only on D466 P 486 P 586 656 2 Used only on D466 P 3 Used only on 0346 386 P 406 4 Remove spacer and spacer 5 Remove pilot bearing and inner bearing cone from pinion using washer from pinion Spacer split type puller Use two procedure steps to remove each bearing see washer is used only on D466 P photos above 486 586 656 First mount puller vertically to split Second mount puller horizontally the bearing to remove bearing 6x6 5 7 Differential Carrier Overhaul Disassemble Whee Differential Forward and Rear Axl
211. vers using a feeler gauge This measured clearance plus 0 005 will equal shim pack thickness required for desired shaft end 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 end play with dial indicator positioned at yoke end of shaft If end 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 end play add shims Example Desired end play 0 003 to 0 007 Measured end play Step 3 0 001 0 001 Add shims to provide desired end play 0 002 to 0 006 5 decrease end play remove shims Example Measured end play Step 3 0 015 0 015 Desired end play 0 003 to 0 007 Remove shims to provide desired end play 0 012 to 0 008 6 Reassemble adjusted shim pack and output shaft assembly to power divider cover Install only the four output cover cap screws and lock washers to recheck end play Torque cap screws see chart 7 Recheck end play with dial indicator If end play is correct proceed to Step 8 If incorrect repeat shim pack adjustment Front Output Shaft FRONT SMiFTFORK GEARING OUTPUT amp PUSHROD CUP SHAFT S
212. wing 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 Remove 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 Hemod Camshaft 4 8 34 5555 555 2 12 Remove Spindle and Brake Spider 13 Remove Inspect and Disassemble 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 17 Install Axle Ball on Axle Housing 17 Assemble Socket to Axle Ball 18 Install Axle Ball Seal and Retainer 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 Ai
213. xle Differential 9 Assemble Power Divider Cover 10 Install Power Divider 12 Adjust Input Shaft End Play 13 Adjust Front Output Shaft End Play 14 INTER AXLE DIFFERENTIAL LOCKOUT AND FRONT OUTPUT SHAFT LOCKUP SHIFT CYLINDERS For Service Instructions refer to Shift System Section 8 6x6 4 1 Power Divider Overhaul for 6x6 Tandem Axles Power Divider Transfer Gearing The transfer gearing consists of an input shaft helical side gear forward axle pinion helical gear and an output shaft helical gear The input gear is equipped with an integral clutch which allows engagement and disengagement of the inter axle differential The output gear is also equipped with a clutch The output clutch con trols power flow to the steer drive axle Each clutch is equipped with a shift unit air operated INTER AXLE DIFFERENTIAL LOCKOUT CLUTCH INPUT SHAFT HELICAL GEAR DRIVE PINION HELICAL GEAR REAR OUTPUT SHAFT HELICAL GEAR FRONT OUTPUT SHAFT STEER DRIVE AXLE CLUTCH Power Divider Transfer Gearing 4 2 6x6 Tandem Power Divider Axle Series D346 P 386 P 406 P 466 P 486 P 586 P 656 P Power Divider Assembly D346 P 386 P 406 P Illustrated OUTPUT O RINGS BEARING SIDE INTER AXLE CAP CASE BUSHING SHAFT CUP GEAR DIFFERENTIAL SCREW HALF G SIDE PINION ASSEMBLY
214. y 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 ing Bearing Preload with pounds This specification is translated into spring scale readings in the m Press chart below 4 Adjust Pinion Bearing Preload 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 A 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 Measuring Bearing Preload with Pinion in Vise Specifications for Final Pinion Bearing Preload Test Press fit Outer Pinion Bearings Spring Scale Reading without pinion seal for 15 35 in Ibs torque 1 7 4 N m Ibs kgs Press Loads Tons Metric Tons Nut Torque Ft Ibs N m Slotted Nut and Roll Pin 840 1139 Self locking Nut 560 700 759 949 Slotted Nut and Roll Pin Axle Models 0346 386 406 P Tandem Forward Axles R346 386 406 Tandem Rear Axles D466 P 486 586 P 656 P Tandem Forward Axles 17 19 15 4 17 2 13 5 15 5 122 140 980 1329 18 20 16
215. ystem The interlock system consists of two lockout control valves mounted on the Axle Range shift units an interlocking shuttle valve and two interlock control valves mounted on lockout and lockup shift units This interlocking system delivers air pressure to the axle range shifter valve interlock pin which in turn operates to prevent axle range shift ing when in 6x6 drive Steer Drive Axle Lockup and Inter axle Differential Lockout System One manually operated shifter valve is used to control two shift units mounted on the tandem forward axle These shift units are mechani cally connected to shift forks and sliding clutches The operational modes of the steer drive axle and the inter axle differential are con trolled by movement of these slid ing clutches The tandem axle must be in Low Range before shifting from 6x4 to 6x6 drive If not the shift to 6x6 drive will not occur With the shifter valve in the engaged position the drive to the steer drive axle is engaged and the inter axle differential is locked out not operating for 6x6 drive with maximum traction With the shifter valve in the disen gaged position the drive to the Steer drive axle is disengaged for 6x4 operation and the inter axle differential is unlocked operating normally Dual Range Tandem Single Reduction Steer Drive Interlock System Operation Interlock Engaged 6x6 Operation Tandem axle in Low Range 4 AIR

all-wheel drive 6x6 drive system

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