SPICER. AXLE - K5BlazersPlus
Contents
1. NO n Q2 eS Figure 2 ey The following detailed Bst of eJ special service tools require to sucio s Model 60 Front or Rear exe l 10 11 12 1d 14 15 16 TOOL NO 1 08 D 116 0 116 D 116 1 D 1162 D 117 U 139 D 368 0 128 0 18 0 14 0 142 D 153 D 165 D 168 D 101 DESCRIPTION Ie Maller Rea Plnlon Bearing Cup Scooter Gauge Arbor Pinion Height Block Arbor Discs Master Gearing Distervails Master Pinion Block Installer Front Spindle Needing Bearing Dial Set Puller Slide Hammer InstaDer Frant Spindip Bushing Installer King Pin Besring Cup Heavy Duty Tnstalle Front f rnhe lub Inaer Bearing Cup Rug Installer Front Bruke Jiub Grease Seal Reg amp Heavy S uty Rewover Front Beanng Cup lustalier Closed Bal Spindle ushng 17 1B 19 21 24 29 26 27 28 80 di D 162 D 163 D 164 D 167 D 122 D 194 C 432 BD 91 P DD 91 4 7 0 914 DD 914 3 DD 914 42 DB 914 62 C 293 31 CBS A Remover Reur Pinion Boring Cup Installer Pinion Gil Seal National Pinion Oll Seal iChcago Rawhidel Sproeder Differential Carrier Remover amp Installer Tapera King Pin Upper Ball Join Pivot Stud 1 Rexme Kmaklo Lower Bemrmg Seal Removes Universal Joint Companion Flange or Yoke Aller Presa Extension Reducer King2. master hearings Figura 186 1018 108 Sed up dal indicator as Shown Be aur to locate dial Indicator on same location as markod figure 63 Force ring gear into mesh with the pinion Bock sing to allow the teetb of the gears to mesh Wish force sat applied to the differential case adicmor at zero 0 Took FD 28 xb ar Figura 188 1016160 Forea the differential case ring from the pinion geer te obtain an indlcetor reuding Mepeet until the same reading is ehtmined cob Lime Thie reading will be the necessary amount of shine required between the differontia l caso and differentia bearings on the ring gear dde Remove indiealor and differectia case from the carier Remove master warings from differential case 47 Figuie 187 wow Assxmbic the required amouct of shim onto hud ring gear adel determined in Agure 186 bewing eooe on hub of case Use installer to seat bearing cone as shown Tools C 4082 A tnetelier VDD 9 4 42 Button Assemble the remaining of the teta shim pack which wag deleimlaed in figure 164 cu the eppos te sue of che differenilal Add additional 915 38 mm of shima on thus side to cempensare for dfforevilal bearing ptelead Assemble differen tia bearing using the aame tools as shown in gure 187_ figure 164 less inion tots of 107 cuhentor was recorded In figue 196 with fi
3. as sbewn Figure 147 tm To remeve side gers and pinion mate ears ratate the side gcara This will allow the pinion mate gears io turn io the opening of the Remove pinion mate 64175 and also the spherical washers behind the geaca Lift ow slde gears and thrust washer laspeci e paca including the machined surfaces of tho case itself If excessive wear visible on ol parts it is suggested that the complete differential assembly he replaced if any one of th gears are to bc replaced THEY ARE TO BE REPLACED AS A SET NOTE Axle shefts which end play adjust ments heve a ater Ulock in the differentiul case The specer block controla tho end thrust of the axle shaft If the enda of thc spsecr block ere worn it ls to be replaced dur ng assembly Spacer block must not be used ball or unstize d deel deoringe CARRIER SECTION Figure 148 1008 048 oose of aner in buriaamua priim remove punion nig Hold end fode flange with as ebowp and remove pinion nut and weaber Tool C 3281 Holding Wreach Figure 149 mea Remove end yoke of flange wich teola shown If end voke or flange shows wear in the trea of the eontact il shoald be replaced Tools amp C 3281 Holding Wrench C 463 Yoke Romover Figure 150 1909 160 Remove pinion by teppmg with rawhide hammers Catch the with your Rand to ponent it from failing to the gund and being
4. Figure 200 1012200 nste lockscrew making sure hele i the dif erentiul cross shaft is lined up with the acruw hole NOTE in the differential cuse Make threads in dif New locksawws istyle AJ have lecking ferential case uod en the leckscrow aro free of dut 12terial un the threads that secures the pin and eil Terque lockscew to 15 25 ibs Ft 120 34 when place New iockscrewa style B have N emi fer stylu B and 8 12 ibs ft 11 16 Nem for special threods that secures the pin when in style place Therefore WHENEVER THE LOCK Tee 524 Torque Wrench SCREW 15 REM VED 17 15 BE DIS CARDED AND REPLACED WITH A NEW GNE Before mstatling lockac ew make sure hole ia free of dirt and oil Ln 5309 3 WE SUPPORT VOLUNTARY MECHANIC CERTIFICATION THROUGH Dana Caorprzation Spieer Axle Division reserve the night to make time to Lime withoot oot ce a obligation m 6pCilcetuons descriplious and illustrates end 0 discontinue modeks revise dagus Questions regarding this manual should be directed tx Spicee Axle Division Dena Corperation P O Bex 120 Wayne Indiana 46801 Attention Engineering Technle il Service Dugg
5. standard metal cleaning solvent to clean eul Ihe bearing bore in the housing Wipe this area clean making eure it is free frem dirlor any other that tight he present NOTE The bearing bore must We ree rom nicks and burrs Wipe the bore wilh enc eth to assure a smooth aurface Clean bure oul with a standard metal cleaning selvent If bere has burrs or spalled areas and a new beunng ts insla led it may lead te eacky fayly ving AXLE SHAFT AND WHEEL BEAAING SEAL ASSEMBLY Figure 11B 1010 118 Assemble bearing aszemibly into beexing bore of the tube as shewn Differentia lube should be plaecd lhe beanng fer eacier assembly nad for the pesrible prevention of scwrimg the tube bere The teol will step agains the tube end when bearing ts seeted to tbo proper depth Tools D 247 natafler Press 1248 Bearng inslallet CALITION DO NOT DRIVE THE BEARING INTO TUBE DRIVER AS BORE WITH A BEARING DAMAGE TO THE BEARING MAY OCCUR Figure 119 1916 138 Assemble new eil seal inte housing as shean Tool wil stap against tube end when eil seal seated to the proper deplh Tools C 4171 Handle amp D 223 Seal Insialler Figure 120 19 120 fabricate WeLween seal lips aod lubricate new beaing with a geed qualicy number 2 E P Extreme Pressure Lithium s ap whee bearing Erase 1014 121 Figure 121 Assemblo axle shaft into housing Care sbould
6. Figure 60 Remove king pin as shown Tool amp D 192 Xung Pin lagajer and Remover Figure 61 1010 61 emove king pin Deming cup cono Besse retainer and 23 at the same time Asacmble end use tools exactly os shown in Figure 62 Discard sea and replaee with oew ono at Umo of assambly If grease ret lner is damaged replaco with new one at time of assembly Teols D 141 4 4171 Handle ASSEMBLY Figura 82 Assemble new grense retainor and king pin beanng cup Tools JD 142 Toa sllez 4C 4171 Haodioe Figure 63 un Fil the area in grease rersiner vith spexifed grease grease bearing cone and install install new l ng pin bearing oll 900 Tools FD 194 Vusteller C 4171 FRONT AXLE F igure 64 pisi king Torque king pm 300 600 Lb Ft 0678 813 Tools D 192 King Pin Unealle and flomover 8DD 994 Torque Wrench F igure 65 103j 6 amp Arsemble felt eral king pin assemblo knuckle assemble tapered bushing over bing pin 1016 40 Figure 66 Ass mble bearing cap with feur cap scrows Tjyhten cap ecrews alternately and evenly Torque scrows to 70 90 Lb Ft 95 133 Nem Tool 4C 524 A Torque Wrencb Figure 6 wor Assemble retaix and cmmpressmn spring on king pi bushng Assewble amp eenog arm w h new gaske over our sius Tighltn mis alternatelv and evenly Torque nuts 70 90 Lb Ft 195 122 N
7. Kaducer King Botton Adup cr Set Bifferential Hearing Cornes Adapter Set Rear Pinion Resring Cane Instafier Rear Pwiop IT amp M TOOL BESCRIPLTION NO NO 32 C 3781 Wrench Universal Cange o Yoke 3 C sng installer Uctveraal Joint or Yoko 34 balie O ffore ntial Side Bearings 36 C 4028 A installer Axio Shaft Outer Seal 4836 SP 320 Washers 837 SP 8817 Adepter Ring 938 SP 5026 Bolts 98 SP 5440 Adapter Ring insuuler 4o SP 5441 Adapter Set Removing 4 5 5443 Flange Plate 44942 0 1952 Screw 442843 D 195 1 Installer Front Axle OU ferentia inner Saal 44 D 193 Torque Weench 50 Inch Pound 45 C 24 A Torque W tench 100 Foot Pound 44 Torque Wrench 30 Foot Pound 47 Bb 994 Torque Wreath IU Font Pound C 417 A Wrench Whoa Hesri ng Lock Nut Adiusting 49 C 4171 Handle Unnersal 50 C 4903 Installer Ftoni Pinico 1 p 332 1 52 D 247 Press 55 0 248 Installer Bearing 4 D 233 Inetaller Oil Seal 5 0 255 Remover Hub amp Bruni 66 1 16 Whee Bearing Wrench 67 D 207 Cup Kemover 6a 0 2654 Inataller Cup Outer Hub amp Rogar 59 0 250 ingaler Cup lnner Hub amp Aotori 60 D 253 Seal naaMNer Poion Setting Gauge and Master Oislcrentia Bearing Kit D 116 50 Axle Shaft Gearing Removing end ivsalli y 348 600 22 Inner Asle Shaft Seal Inctalliag 95 NOTE Torque Wr
8. Remove feut cap screws Qom the bottem bearlog Use a ecrevxviver to loeesn the bearing cap from the favuchle f occusfacy NOTE King pin bearing prelwed shins are located betweca the botem beating cap and knuckle Wire shims togesher as they wil be used during essarebly Shims may stick te either the knuckle er hearidy cap Be sure you have them al callected Shims ore available in thicknesses of OX D s IO and 030 mm 08 19 25 and TB Remove axle shaft joint assembly 10 Figure 26 1218 28 Remove knuckle fron ball voke CAUTION Tho bottom bearmg cone wil fall eui as tbe knuckle is being removed To prevent to the bearing catch it with hand Figure 27 Nes Place knuckle in vise as shown Remove stee erm Tap hazhily mth rawhide hammer to free X tom 1 he knuckle NOTE Some axles are equipped with censtant shim pack botween the steering arm bearing cap and knuckle If used this pack ia to be saved and uscd during assembly FRONT AXLE Remove king pm buaring kom spherical ball voke with tool as shown Tool D 131 Slide Hammer 1016 23 Figure 29 Remove branze bushing from ball yoke Tool 4 D 131 Side Rawmer ASSEMBLY Figure 30 Assemble new king plo bearing cupa into apia ica baD yobe Use tools as shown Tool D 142 Installer 4C 4171 Handie Figure 31 Assem ble aew broas
9. SPICER AXLE MAINTENANCE MANUAL FRONT AND REAR CARRIER TYPE INDEX LUBRICATION ox LV ues Pa PORN opor TA GR A VER Ve 3 IDENTIFICATION OF SERVICE TOOLS ee eee ce eee ehh ERA AXE IDENTIFICATION phi ie 84 HE PD eee GR 5 FRONT AXLES WHEEL ENOS Closed Knuckle Design Hub amp Dium QULA E Spring Loaded King Pin Design amp Rotor ee re ee ee ee ee tes t4 REAR AXLES WHEEL ENDS SEMI FLOAT DESIGN ON ue emer 66 20 Lubricated with Hypoid Gear Lube init Wheel Bearl gas n atm qu lorte M e Le le 4 OT DR 22 Lubsicated with Grease Shatt Hiding Bearing EE EM ARR o EEA SENS Lubricated with Hypoid Gear Lube REAR AXLES WHEEL ENDS FULL FLOAT D GIGN oe ete medai 32 CARRIER SECT ION r4 42 do eerie as l ae ie om RR A 34 REAR AXLE SEMI FLOAT SHAFT RIDING BEARING DESIGN 0 eee eee ee 50 IMPORTANT SAFETY NOTICE Should axic ssemnbiy require component parts replacement itis recommended tbat Original Equipment replacement ports be used They may be obtaincd through your local sorvice dealer oc other ginal equip m ent manufacturer ports upplicr CAUTION THE USE OF NON ORIGINAL EQUIPMENT REPLACE MENT PARTS 15 NOT REACOMMENBER AS THEIR USE MAY CAUSE UNIT FAILURE AND OR AFFECT VEHICLE SAFETY Protwr service an d repalr i important t
10. and knuckle Shime ase available in thicknesses of 083 005 910 and 030 mm 08 13 26 and 7A Figure 40 Assemble new 01 seal Into Be sure spl t of seal to the top of the axle Aasemblo new felt rctoiner plates and twelve cap semwa Torque screws w 15 Lb Fe 20 Nemt figure 41 Assoemble rod to steering arm for specified terque on tie rod nut refer to Vehicle Servoe Manual Assemble eotter key 13 Figure 42 Pudren piade in vise as howo and new bushmg Grease inside af bushing wih giaase Teala 41 141 Installer C 4171 Handle Assemble spindle to knuckle Figure 43 1018 43 Assemble brabe backing plite assemthty Refer to V e icie Manual fot Remove mapeciion level to the plug lole wuh specified fudticant Assemble inafiectien plug NOTE To set refer to Vehicle Server Manos Adjustznonis can be made by lammming clamps vu the tie rod After proper edjastomenta sre mede retighten tie rod clamps FRONT AXLE 40 STEER SPRING LOADED Figure 46 4019 49 Remove bub and rotor assembly spring retainer 308 24 and outer wheel beating wil slide oul as reor is Figure 44 L D eaten DISASSEMBLY OF WHEEL ENDS HUB AND ROTOR NOTE If 4 i necessary to replace brake components such as disc brake pads backing plate etc yefer to Veliice Service Manual Remove Wheel from Hub aod Rotor Assembly
11. damagrd 27 NOTE On she spline cad of the pinion there ae bearing prelead shims These shams moy stick to the pinion or bearing or even out These sAm te ba collected and hept together Since they will be used eter in assembly Try net t mutilate ahlms If shims are mutilated replace with new ones Shims are avaiable in thichneseca uf 809 005 010 and 030 Imm O8 19 25 end 76 Figure 151 vule Pull eut 07100 sea wit puller as showo Dirard seat REPLACE NEW ONE AT TIME ASF BLY Remove anag cone and outer 5 Tool 0181 Side Hammer 10 6182 Figure 162 Tum of carrier down Remove outer pinion bearing cup Locaste driver on back edge of drive cup ou of carrier Caution Do not nick caster bore Tools D 158 Cup Removcc 417 Handle CARRIER SECTION id Figure 153 pini NOTE The front and rear carrier section may vary in pinlan here depth due to the possibility of the need for either baffle ar alinger or both The baile serves the same purpose a dam to thal the pinion bearings are maintained with lubricant The ange aerves the purpose of assi ting the luhe to Flow up threugh the oil channels to lubricate the pinion bearlnge If used are part uf the union seing edjustmens in figure 153 we show the four opina date 154 Flgure 154 Remove the inner bean c
12. lt may be necessary to wipe or mape off che dirt ete from tlre tube NOTE On front driving axles the above numbers can be either on the long or short tube AXLE IDENTIFICATION The Scar test ia located on the left side uf the corer plate or t the botom let hand side ef the cover piale and is held ln place with one or iwe cowry plate screws Tha iag gives the tooth combination of the ring and and also the Vota gear ratio Figure 4 ow FRONT AXLE DISASSEMBLY AND REASSEMBLY OF HUBS DRUMS WHEEL BEARINGS ETC CLOSED KNUCKLE DESIGN Figura 19192 Remeve nuts and wnahera from drive flange studs Figure L 6 Remove wheel from drum assembiy 1018 5 Figure Remove drive dange and gasket Discard gasket i once Replace mth new at Lime of assembiy Fo free Figure 6 Toe Mange from bub tap lighi with a rawhide Remove hub cap and sap ing hamper FRONT AXLE Figure 8 Remove locknut lockriag and ianer wheel Tool OCA 170 Wheel Wreoch Figure t0 Remove drum assembly Outer whee banag will slido out drum cemeved NOTE il ia necessary to repleee brake compoounta euch shoes backing plute ett refor te vehicle service manual Figure t Remove graso see and imer cone seal and replece wub one lime of esseanhfy 82 13 Sido Hammer
13. Figure 135 vere jas Aszermbie new grease seal Apply a amall amount of the apea fied grease around Lip of seal Figure 134 1919 139 Tesla D 156 Seal Installer 4171 Handle Assemble new euter bening tup Asaemb le hub aeaembly onto epundle Pack with Tools 4308 Cup Installer 4171 Handle gitase and sesemble now outor anng cone REAR AXLE Figure 138 1009 129 Assemble inner wheel bearing adjusting nut loeklab and outer wheel bearing lock nut Tools DD 1241 Wrench Socket Adapter NOTE For final wheel besring adjustment and torque specifications iefer to Vehicle Service Map ual AC 4202 Figure 137 codi Asscmble new gasket assemble axle shuft torquo nuts or cap Screws Refer to Vebicle Service Manual foc proper ior amp ue speafivations CARRIER SECTION 1019198 Figure 138 L P Carrier Section DISASSEMBLY NOTE if becomes necessary to disassemble any ports inslde of he camer il is suggested t t the atire axle bo remewed from the vehicle and held tight Sn stand er rmx Remove drain plug and drain lubricant If thers is no drain plug in the carrier the lube will drain cut as the cover plate is removed 10919 1328 Flgure 138 Remeve cover plate screwa sever plato and cover plaic gasket Discard old gasket Tp anier be allew lube to drain completely Also during this time clean the cover of the carrier making surt it Js free ftem an Y nick
14. Follow the vehicle manufacturers recommen Figura 4 10947 datiens er the removal of the hub lok assembly if Remeve ease seal and inner bearing cone used Discard seal and replace with new one at time of assembiv Teok wD 13 Slide Hammer Figure 45 101945 Figure 48 Remove wheel bearing lock nut jock cing and the Remeve inner and outer wheel bearing cups wheel bearing adjusting nut Tools B 255 Bvadng Cup Remover touter Tool D 165A Wheel Bearing Wrench 9 257 Bearing Cup Remover inner 14 FRONT AXLE Flgure 49 ea Assemble omer whee beanng cup Toole 40 254 C 417 Hendlo 101950 Figura 60 Assomble inner wheel bearing cup Tools 12268 Installer amp C 417 IHiendlo BiMrlbute a sufi cient ameurt of ronse Inside tho hub between che beming cups Pack inner hearing vone full with the specifled groase Wipe the exces grease around he rollers Assemble Inner Wheel bearing come into cup Figure 51 15 Acembie new grease seal Apply a amall emeunt of grease around Ep of seal Toals D 53 Seed npstaller EC 4171 Haadie Figure 52 10219 83 Assemble hub and rotor ento spindle outer wheel bearing with apecified grease wipe excess gres around the Agsemble onto ap dia Figure 3 kd To adjust wheel boarings torque inner adjusting nut to 3 Lb Ft 88 Nm bo eeat bearings Rotele hub then bach off inner adjusting nut one fourth turn Assem
15. Use these two bolas to gulde cover plate into posit nn on the warrier Inst all remaining ecnews fighten alternately and avanly Torque screws to 30 48 1 Pt 41 54 Neq Allow ane hour cure time before filling carer with the proper amount of specified lubricant und vehick operation Figure 195 1050 105 n cover plate of the rib desti a gasket muz be used De not use silicene sealer Terque screws 90 40 Lbs Ft 441 54 N ml REAR AXLE SEMI FLOAT SHAFT RIDING BEARING DESIGN OIL SEAL BEARING Figure 196 A V E n 0 1799 0 Me M o TROTE 20 34 Nom Figure 197 ts 08 v9 Axes built in mode 1980 and model year 1981 used Jockscrew style A Starting Jn model year 1982 axles were built usog lockscrcw etyle B LX Figure 198 CAUTION THE LOCKSCREWS ARE NOT INTER CHANGEABLE Cere should be e xerased ta assure thet the replecemant lockscrew isiden tical to one removed To identify the for proper selection measure the distance from the cooterUine of the crose shalt hole to the surface where che lockscrew enters the caso it measures approaimately 1 000 le will require locksciaw style A 1f it measures approwmately 3 2 it will cequire lock screw style B REAR AXLE SEMI FLOAT SHAFT RIDING BEARING DESIGN Figure 199 1019 583 Rer eve the differentia pinson shaft as shown
16. are equipped with an ier axle shaft oil seal aa shown in figure BRAKE BACKING PLATE lj Olt SEAL OUTBOARD UNIT BEARING OR SEAL INBOARD ___ BEARING RETAINER Figure amp L D 1018 86 Uni wheel beuring 1 D with grease Figure 86 Tn Remove inner axlc shaft seal using puller as atvewn Tool B 131 Slide Hanmer Discard seal and replace with new one at time ef assembly NOTE Avoid contacting seats with cleaning solvent ng Uperation CLEANING INSPECTING AND RELUBRICATING UNIT BEARINGS Clean hearing cup with any of he standard metal cleaning anlventa Inspect cup for any possible wear nicks etc The cone assembly be cleaned in Mace onthe shaft Use a standard metal cleaning solvent aid stiff bristle brush to toesen the old grease To ensure removal of the eld grease and any contamination that might be present use coroprea sed air Air should be directed at the cone assembly thut it goes through the bearing Gom uf the rollers to he other it is jmpar ant mot to Spin REAR AXLE Dry the bearing with cEnpramed eir Spiaaing the dry bearing may score the rerewayo and collera due to the lack of Use s Ganda mca cleaning soivori o clean out the bearing and of seal bore in the housme Wipe his dean making sure is free fiom any old grease or other eontaminstian that made be present After the he
17. between the eera and cup NOTE If grease ia not upparent on the small ends of the rofiers repeat the samo steps until grease ja evident between the small end uf the redler aad cup Remove tape REAR AXLE SEMI FLOAT SHAFT RIDING BEARING DESIGN LUBRICATED WITH HYFOID LUBRICANT pa b i Mb e H he 3 JR 1619 108 Figure 107 Picture of Shaft Riding Hearing Design Figure 108 1016 108 After wheel is removed remove brake drum Remove dialn plug and drain lubecant 1f there is no diain in the carrier the lube will drain oul AS che cover plate removed 27 REAR AXLE Figure 109 flecsove ews cover pists end cover giate gacet Dinard old gasket Tip casrier to lube so drain Also during this tiroe clean the cover face of the carrier making eure it is free from any oicke and any patticlesieft by the old gasket DO NOT USE GLEANING SOLVENTS OF ANY TYPE Use of cleaning solvente may prevent the RTV sealer fram edhesnk tho cover plate and carrier reasu ting in leaks of axle lubricont Figure 110 1016 11 Clean cover pinte making aure it ia free from nicks und ony pnrticles left by the old grabo malerlal Use a clean rag er blunt tol for removing comaining geeket mater ia DO NOT USE CLEANING SOLVENTS OF ANY TYPE Uae of cleaning solvents may ptevent the BTV eeslkor from adhering to the cover plate and cervier reaking in leeks o
18. houalng Wipo this area cken making eure it i8 free from diri or any other caalaninatinn that might be present Afler the bearing has been inspovted sand upproved for continved service mual be jubri cated prior to installation The beannag must be lubricated by applying s small amount of the epecified lube around tbe roQcte of bearing Figure BO texting piste bolis and backing Figure 81 Assemble beating nto bearing bore of the tube Make sure the cup backface is against tho hearlng seat of the tubt 1018 82 Figure 62 Assembta axle shuft nto housing Care should be taken not to damage the bearing rollers Line up the holes of the retaloer plate wish the as far tols pusb axle shaft into the bouseme mabe REAR AXLE 108 8 Figure 83 Start nuts backing plate bolts by hand Use a apeed wrench eae shown and tighien to spproxi mately t6 Lb Ft 20 N mi Thu units should be Ughtened in manner that assures that the sea and cup rib ring ere drawn evenly ag ainst the cup in the housing Figure B4 Using a torque wrench a shown verdue nuls to 26 05 Lb Ft 34 47 N ml Assemble brake drums retainer nuta wheels otc 1019 34 Tee 534 A Torque Wrench UNIT WHEEL BEARING DESIGN LUBRICATED WITH GREASE NOTE Uait wheel bearing thal are dependent m grease for Jubricarion rather than hypuid geer tube frem the axle housing
19. innere bearing cup Remeve pinion nut washer end yeke slinger bearing cone Assemble prelead sbims which were remeved during onbo pinion Assemble bearing cone and CARRIER SECTION Figure 164 SN Using ann Ld rque wrench gs shown rotate piniea Torque to rotate pinion should read between 20 40 Lb 2 26 4593 N ml To increase preload remove shims te decrease ptoload add shims Figure 181 1018 1 81 Apply amp light cect of hype d lubricant on the Lip of seal and assembie into carrier Tools D 165 National Ses Installer 2164 Chicage Rewhidc Seal Installer 4171 Handle Figure 184 L D Carrler TU ue Tbe illustration in fizu e 184 shows the arrow in the Wnion peinting in wu direcb ons The direction painting tewerds the cnd voke indicates that by i removing pinien positien shims the distance from the centerline of the ade to pion butea Figure 182 T me increased giving a plus reading Tho preload shim Assemble end wesher and new pinion cif does ict weit Toraue not to 248 388 Lb Ft 325 406 7 FIM 5 4 5 on the ring MTusttale tbe meihod to Tools 4C 4052 Torque Wrench 0C 3280 Yoke incresse or decrease backlash and differential Holder bearing preload 16 CARRIER SECTION ASSEMBLY OF DIFFERENTIAL Pace differential assembly wah pini instal Into housing Oiffreotial 9 0 be assembled to
20. moving ring gear away frem the pinim These carrect ens are made by awitching shims from one side of the differentia case to the ather NOTE 17 3ccvicing the sem eflogit shaft riding beating design unit refer to ihe monua section fer that unit After Jasta log awe shafts new Jock pin is insialted 959 19 Figure 192 instal cever gaaket and install cever plate Torque screws to 30 40 Lb Ft 141 54 Nem l ool 4C 334 A Torque Wrench CARRIER SECTION NOTE There are two different design pover plates Gne cover is of the flat mount mE_surfaee and the ether design is of the nbs belweon screw helez Figure 193 Figure 193 shows the flat movnting surface cover piete en Daca design axles This cever plate requires the use of a ailicone rubber sealer materw rather than gasket Se Tihs ett Fidure 194 1012 94 The cover face of career and the flat surface of the cover plete must be free of any oil or foreign material 49 Sealant mateclal must meet specifications ef ASTMI GE3 3 A19 B37 E16 E36 Z1 22 and Z3 sedunt Apply sealer le cover plate surface Ensure that the sealer bead la laid on the inside of the cover screw heles The bead js not te pass through the holes or outside f the heles The bead isto be 1 8 to 1 4 13 18 6 35 mm high and 1 8 o 1 4 13 18 6 35 mm wide Assemble we cever screws into cover at o cieck and 2 o clock posit wn
21. torque apecificatiens Figure 19 wots Assemble snap ring and hub cap Tap lightly with hammer te seat hub cap DISASSEMBLY AND REASSEMBLY OF SHAFTS SPINDLE KNUCKLES AND ETC CLOSED KNUCKLE DESIGN Remeve wheel hub exi drom assembly shown in Pigvre 6tbru 10 Fiqure 20 NUES Remove backing plate screws and remeve back ing plate NOTE The brake backing plate assembly can be retained with screws or nuts If the n uts are of the torque prevailing design they aru te replaced with new ones FRONT AXLE 1019 11 Remove spindle Tap lightly with rawhide hammer to break the spindle leese from the kneeckle Figure 21 Figura 22 R Place spindle in vise do nei lecate bearing diarxters CAUTION Be sure ha the vie jaws are eqnipped with brass protectora or simila type o protect the macAhiped of any paria that ate to bc placed in the vise Remove brome bushing with sidc henimer puller Teal 4D 181 Slide Hammer 3 ipri Figure 23 Remove cotter key end lossen tie rod nut Tap on nut with rawhide hammer te break the stud loose from the eteejing arm Remove nut und disconnect Lie rod FRONT AXLE Figuie 24 bi Remove twelve cap acrews wo retamer plates felt seal and oil sea Diacard vetaincr plates felt scal Replece with new ones at time af assembly Cut felt sea in half to dicasaemble Figure 25 1016 25
22. 05 and 010 mm 13 and 26 NOTE If baffle er slinger is bent or mutated Ht should be replaced cach stum separately with miceameter and add texether to xet Shim pack chickness rem the build up 1 a new gear aet is being used notice the or etching on the old and new pinion and adjust the thickness of the new shim pack to compensate fer the difference of these two figures For example If the old pinien reads I 2 m 6 and the new pinion is 0 1 2 4m 6 udd 94 10 mm ahima to the orginal shim pack The above procedures also apply te pinien adjustment en the front axte which includes the wl slinger betwec o Lhe inner bearing cene and Sad ballile between he mer cus aad carrier Mow Finan Marking a 2E OE es ums com soos wm Pinion Setting Chart English U S Standard 41 CARRIER SECTION Figure 187 Pinion Selting Chart Melric V metric used pinion ill be etched Exp m4 6l Use these choris as a guideline to set Pinlon Mabe sure hat all casyies bares are free from all nids dirt or any other Conlaminstian t Figure 186 10 180 View of master pinion block pinion height block scooter gage cross Pin and master beating disce NOTE Cross master beanag discs and scooter Figure 169 mem master pidon block into the pinion bare of gago can
23. Figure 12 10813 Remeve inner and outer whee bearing cups Toole D266 Cup Remover C 4171 Handle ASSEMBLY Figure 13 Assemble outer wheel beanng cup Teols C 4028 insteller FC 4171 Handle FRONT AXLE Figure 14 1919 14 inner wheei Wearlog cup Teols YP 118 Installez 4171 Handle Distiibute a auff cleni amount of grease inside the hub between the bearing cups Pack inner bearing coac full with the specfted grease Wipe the excess ccase around the rollers Assemble inner wheel bening eene into cup Figure 15 9019 16 Assomb e new urease col Apply ameynt of rease mound lip of seul Toels 0 155 Seal Iitstallor C4171 Handle Figure 16 uem Assemble hub and deum onte spindle Peck euter wheel beating with specified grease wipe oxoess grease around the ro lecs Assemble onto spindle Figure 17 1099 17 To adjust wheel bearings tegue inner adjusting nut to 50 Ib Ft 165 WN ml to seat beurinzs Retate hub then back eff innec adjusting aut one feurth tum maximam Xesembte leck washer urn nut to the nearesa bele in washer Assemble outer lecknut and torque to 50 Ib Et 68 N m Finel bearings adjustment be 084 010 03 25 mmi tetal eod play Tools C 41 0 W beel Benting Wrench 4C 524A Tor amp ue Wrench 1028 16 Figure 18 Assemble new gaskel drive flange Jockwashera and nuts Refer te Vehicle Service Manua fer proper
24. RING LUBRICATION bee bearing are Inbccsted by one of two different nsthada la to pack the wheal bearing with gres ex while the athar method 13 to Jubsicate the wheel taning w b the gear lube in the housing Fer geasas pack og it recommended that aumber 2 consiatency base 12 hydroxy steoreie grease containing sn E P additive be used Such a lubricant would pase loadcastying test at 40pounda 112 5 Kg minimum with base oil pour point at 10 F 23 C maximum NOTE We suggeat thal wheel bearing lubricants selected fur use with Disc Brake applications in addition te the E P properties expressed Ln thie manus sheuld be eompstible with elevated temperatures i amp high tempereture lubricant epecified wheel beer ng lubricant cefer to Vehicle Service Manual CLOSED WHEEL END STEERING KNUCKLE LUBRICATION Thaclosed steering muckle ces lubrication from source other than the amp eac carrier assembly Inboard tube seals contain the hypoid geur lube in the housing te previde adequate lubricant level for the goare bear ing etc Thle then cayquires an additions Inbricant bevel to be maintained outboard n each steering knuckle which can b observed by moving fillplug9 op ech knackle Adequete leve would be to the butzan of the fill piug Sole when valide is observed to be arzal bornaentes Becnaxnende i amp n S A EK 140 multi porpuse gea
25. aring has been jinapeacd and upbroved for cantinued service il must bo lubn cuted prior to installation Tho Brease should be good quality number 2 E P Extreme Pressuce lithium soep wheel beonring grease Figure 69 After the full of grease wrap tape cangletely around the rib ring and sea as shown io vcn the cavity Figure 87 Push seal and away tom the bearing to allow cavity between the sea and boaring Figure 90 1016 00 With nil wrepped around the push seal up unu it contactu the rib This will force the grease up through the NOTE lf grease i not appareng an Smal end of Figure 88 101 48 rollers repeat these steps until grease the area or cavity beCween the seal and appears dearing with the caumme nded grease REAR AXLE Figure 91 Remeve tape end wipe excess grease en roller bodies ASSEMBLY Figure 92 1018 82 Assemble new gresse seal buusing C 4626A Seal Inateller C 4171 Handle After sea has been assembled grease lip ef seal gt m nae Figura S3 Asicmble baekng plMe belts end backing plate assembly 24 Figure 84 mo Assemble beanne cup bearing bere ef the tule Moke swe the cup backface is against the wearing seat ef the tube Figure 5 Assemble axle shalt Ino henging Care should be not to damage the seal lip and tear
26. asket js present between gale shaft flange and hub discard gasket and repince with new one at time of assembly Figure 125 if wheel bearing lockswashec is ef the design in which ihe eara are bent ever the Nals ef the wheel bearing nuta bend eat up from the oulerle nut Remeve euter lecknot leckwasher and inner wheel bearing adjusting nut Teol 4WPB 1241 Wrench C 4202 Seckel Adapter NOTE Lue to various design wheel bearing nuts wrenches of different sizes which alsa use adapter C 4202 are avilable and are as follows WRENCH OPENINGS DD 438 3 1 8 x 3 6 8 Odugon DD 824 2 9 18 O taron DD 917 B 3 1 4 Octagon DD 926 J 1 27 x 4 Hexagen DT 1246 2 0 8 Hexagun D 12380 2 0 4 x 7 8 Oxtagon asi Figure 130 1019 30 Remeve hub and diura asscembiv The outer wheel beaxing ome wil aide out as the hub remo ved Figure 131 1010 33 Place hub on bench and remove grease ceal Discard seal and reTdace with new one at time ef assembly Toel 46 131 Slide Hammer REAR AXLE pote 132 Figure 132 Remove inner and outer bearing cupa from hub Tools 0 162 Bearmg Cup Remover 4171 Handic Figura 134 1019 534 Agaerpble new inner beating cup Teola C 4303 Cup installer 4171 Handle Pack with grease and assemble new beanng cone ASSEMBLY NOTE lt ia recommended that whenever hearing cups and renes are removed they ere to be replaced with pew onea
27. be taken net to damage the seal lip and bearing rollers anil that thc sbuft spline engages with splines of differentia side Bo net rotate side gears REAR AXLE 1 12 Figure 122 Figure 129 119 123 Push flange end ef axle towards center of vehicle and instali the C leck Pull out from center ef vehicle uat C lock seats into differential side gears 1978 132 Figure 124 Assemble pinion mate shale Re sure lock pin hole of the shaft is lined up with the leck pin hole of the case Assemble lock pin al Figure 125 Torque leck pin te 8 Lb Ft minimum 11 Tool C 524 A Torque Wrench t r10 125 NOTE Whenever the lock pin ia removed it is to be replaced wit a new one New lock pins beve lecking type maberial en the threads that secures the pin when in place Belere installing leck pin mako sure hole Free ef dirt and oil Figura 128 1003 08 Assemble backing plate assembly uring a torque wrench as shown torque nuts te 50 85 Lbs Ft 68115 Nm Assemble brake drums retainer wheels etc Fool 524 Torque Wrench NOTE Refer camer section fer ef cover REAR AXLE REAR AXLE FULL FLOAT DESIGN Disassembly of huda drums wheel bearings ew Figure 127 L D Remove wheel fem drum assembly ir Ses Figure 128 116 128 Remeve ox t shalt nuis and er cap screws pull axle shafts If g
28. be used on both Model 60 and Model the carrier shorn 70 asles D 120 Master Pinion Block CARRIER SECTION Figure 170 1012 176 Place ardor discs small and arbor into crosa boies of carnier ag chown Tools D 116 2 Master Discs D 11S3 Arbor Figure 17 1 Place pinion height block on top of master pinion block and agumst arbores shown 1019 171 D 116 1 Pinioo Heighi Block Figure 172 blocs Apply pr wure gaze is fim on the pinion block waDe pressure is set indicelos al zero 0 Tool amp D 116 Gage Figure 173 Sude scootor gagu over arbor As wage slides 1061917 over top of erdor it wifi travel In a clockwiso direct on When Indicator s eo center of erbor on it win Sop crevelllag ina clutwise direct sp If indicator sta te wW tovel Us 6 omuia dremion this means YOU bove passed the center top of the arbor Record only the mading when the indicator is at the goes point This reading ndicates the ameunt of shims neressary to obtain the shim pack phus or E c n e amp ching on the button end of the ET M the etching la zero 0 whe shim pack will remain unchangtd Yor example 1f the pinion iR etched 3 8 this giruop weuld require 003 4 08 mm leas shima than a pinion etched zero Iel If the pinico is etched 3 m 8 this would require 003 08 mm more sBons than a pmion etc
29. ble loch wasber tum nut 40 nearest holein asher Assemble omer locknut and torque co 50 Lb Pt 68 Nm Foal bangs adjusrment 10 be 001 010 1 03 26 mm total end play Tools D 166A Wheel Gesrlng Wrench C 512A Torque Wrench NOTE Fer atsvicing spindle and knuckle remove hub and drum as described in figures 45 Uvwugb 47 FRONT AXLE Figure 54 4018 54 Remove spindfe If necessacy tap Letitly with a tuwhide hammer te free amp feet the koucklo Check brensc spacer located betweem axle shaft joint assembly and beaclog wear is evident replace with a new one Figure 55 WO Place spindle in vise De noi becate on bearlog diameters Remeve ne cdle beanng 13 Slide Hammer CAUTION Be sure thut vise jaws are equipped with breee protectora ot aim er type to protect the machined aurfacea of any parts that are to be placed In the vige Remove axle shaft jeint assembly Remove ije red Refer te Figure 23 t6 Figure 56 1003 88 Remove feur nuts on steeriag arm Remove nuts alternately as comBtesewn spring will ferce steering arm up d Figure Remeve steering arm compressian spring and gasei D scard gasket replace with new at time of assembly 1038 54 Figure 58 Remove feu cap screws on bearing Remove wearing cap FRONT AXLE Figure 59 10 938 Remove king pm tapered bushing spring re eee eee Reoove king nin 8
30. d the brake basking piate to the ade housing Discard nuta reptace with new eneg althne of assembly Nuta of torque design Bre ta be reused Figure 78 Remove the axle shaf by pulling on the axle It may be nceessaty te free the axle shaft by prying it leose with two acr2wdrivera or pry bara as shown NOTE Bechng plate cen normally be wired to the fiame without loosening the hydraulic bralke if line connection at the wheel cylinder dealred Use cautian to avoid damage ta brake line REAR AXLE mist Figure 79 The bearing will stay in pisce whb the housing To cemove bearing cup use puller 39 shown Tool D 131 Slide Hammers Cleaning inspectiog and relubrleating wheel unit bearing Cleun bearing cup with any of tha tondard meta Ccleuning solvents Inspect cup for any posaible wenr nick etc The assembly can be clesned in place on the urle shaft Use fay standard metal cleaning solvent anda stiff bristle brush bo cemove any dirt or any other cantani nation that might be present thon use compteaaed air Air shoald be directed et tho cone that goes through the tearing foro one end of the callers to the otber It is impanna 001 to Spio the learning with comprazaed ais Spinning the dry may score tho recewoys aod rollers due to lack ef lubricant Yao standard metal Cieaning solvent to clean uut bearing bere in the
31. e bahing inta ball foke Tools 40 16 Insta ler 06 3171 Handle LL LI Figu e 32 1018 22 Assemble now felt over bul as shown Figure 33 101 33 Assemble new oil sen with the meta part of the seal tewards the end of the axle Spread split of seal just enough to alip over tbe tube of the axle FRONT AXLE Figure 34 didis Locate steering mm m vise as Aumeble camiaosl shi part to the tumle wedi Assemble knuck e to the are Assew ble the for nute nuts aheraxely and evenly Torque nuta 70 90 Lb Fs 95 122 Nm Figure 35 me Aaromblo new bearing cone 6 king Kecoge beuring with epeclbod grease F ig ure 38 1008 34 Assombk ase sheaf joint assembly into housing 2 Figure 37 mv Assemble knuctie bal yoke Sold bottcw bear ing inewl a s shown lo Qruvent it hom falling Fiqure 38 1019 34 Assemble bottom king pin bearing cap with preload shima esd four cop screws Torque sacws te 76 06 Lb Fu 185 122 N ml 1019 38 Figure 49 Place terque wrench amp eering arm nut as shawn Torque to actuate knuckle to 9 15 Ib Ft 22 20 N m When checking torque retatian of knuckle make suro Le rod and seals are ezembied to knuckle FRONT AXLE NOTE If prelead ls too tight eerrect by adding shima preload amp Loo loose ecxrrect by cemoving shams Pretasd shim pack is lasted on the botiom between the bearing
32. en beth the pinion and ling gear are ebched for verificetien if new gear sei is being used varlfy the numbers ef each pinion and ting gcas befor preeeeding h assembly The nominal distance from the centerline of the ting gear tbe end of the pinion fer the model 60 froni end reer axle ia 3 125 79 37 mmt On the button end of each pi on there ia etcbed u plus number a minua number er a zere 0 number which indicates the bes cuaning pesitton for each particular gear set This dimension ts eontretled by the ehiarming behind the iancr pinion bearing cup Fer example tf a pinion is etched plus 9 im thia pinion would requie 003 06 mm lese Aima than a pinion stched 0 This means by Figure 166 jemoving shims the mounting distance of the pinin is increased to 3 128 79 45 mm which ia just what a 3 m 8 indicates Or If a pin we etched 3 Im 3 we would maat to add 003 1 08 myil more shims than would bt required if the pinan were etched 0 By adding 05 08 mm shma the mounting distance of the pin n was decrassed bo 3 128 79 86 mm which is Just what a 3 m 8 indicated If the old ring and Pinon ect is te be reused measure the old shim pack and build a new shim pack to same dimension If a baffle is used the axle assembly itis considered as part ef the ahim pack To chauge tho pinivun adjusdmenta shima are available in thickawsaes ef 003 0
33. eochos D 1983 C 524 A C 4053 and BD 994 aro optional and cap be pur chased separately These torque wrenchet ore noL Inctuded in the BW 60 Axle Tool AXLE IDENTIFICA TION All Spicer arles are identibed hd masulee turing date and the complete pan number etam ped in the right hand tube Alse caeb axle contains gear ralio ag and if the exle ie vquipped wt a limited alip differential Jt will contain a tag apecliving ihe use of J nited alip lubricant ln thla figure the axle is identlflad wlth 1 8 43 07 mm high numbers stomped In the tube For Example The menufectining date or build date ef the axle is ste pre amp e as follows The fret number le the month second mumber is the day of the month the third oumber is the year the iether ia the shift tbe last number je the linc that built the axle Tbe act number the part of cnatevial The eir digits reading from lef to 1igbht m tho basie number for the paricular axle assembls The seventh dizit foljo w ing the dash wil doni fy ratio differcotial aod end yoke options used in the assembly NOTE the event there are two bald dates the tuer will be the date in which the brase componeaia were anuuhed The wmbect nest 40 the date is the camplete axle essem part numbez It recamenended that when referring to the axle obtain the comriete number and build date To do thla
34. f azie Lubricant Figure 111 Remove the differential pinion shaft lock ecrew Shown in Figure Figure 112 Remove the differential pinlon mate shaft Figure 113 1019718 Push flange end of axle shalis toward center of vel ele and remove the C from button eed o both shafts REAR AXLE OIL SEAL AND WHEEL BEARING REPLACEMENT Figure 114 3018 114 Figure 116 e ad Remove the backing plate nuts and beits witch heldtbe breke backing plate to the axle housing 3 pleces Discard nuts ie Noce wich new ones at lime of assembly Nuts of bergue Prevailing design are te be reused Do nA refttnve brake bactiag plaie NOTE The oii seal may be remeved and Inetalled without removing brake backing plate nuts and belta Care sheuld be taken 90 ss net to damage the besling upea removing seal C 4171 Handle B 233 Seal nstailer Figure 115 Sef Hemever screwdriver or ether similar Remove the axle chafs from iht teusing being nei bo damage the uj seals ag show in Figures 114 and 115 CAUTION When removing the axlc ebofts be cureful the differontint side Rears will tause the pubo mete feara and thrust washers te turu to the opeaing of the case and 4 ELE drop out Figure 117 338 117 Remove the wheet bearing and oil seal as shown Discard old seal and bearing Took 4D 232 1 Baanng iemover Use
35. he tickness of the ring Do not drillall the way through the ring the drill could damage the arle shaft ititi Replace witb now at time of assembly Tnsped plitte fer possiblo distortion M any portion of the retainer ple c is damaged it should be repisced inspect machined s rfaceo of the axlo ehaft euch the seal and bearun diameters Cean axle aha rcvauve eli or burrg REAR AXLE INSTALLATION OF NEW UNIT BEARING NOTE The retalner ring area cf the shaft 1 7721 46 01 mm minimum in diamaar end tho ring inside diameter is 1 7676 44 28 mmi marum and thesefore choald some 6000 tb 26683 mmimom press to seat the ring agttinst the unit bezring 1019 10 Tengo plate ahould still be assembled t tho flange of tho uxle shaft Remove bolta from flenge plots As umble new retainer plate and oil seal Tho rubber portion of the oil seal which oxtends beyond the casing has numbers nda in ihe tubbor Th Se numbers t lowerd she flanges of the axle chaft Assemble new unit whee beanog on ale ahah Side cag on axle shaft sure to locate unk wbeel bearing on the made of ibe insaliog ang Side forcing plale on arbe shalt and locale oa bistalling ring naaj bolts and washer ihrough the holes in the forcing plate and Gto flange plate Tools SP 5643 A Fiange Plaie SP 6017 Adep ter Hing SP 6440 Adapter Paare I
36. hed zero 0 CARRIER SECTION Figur 174 LIT WI Measure eech shim sevarzteby with end edi Loyotber to get estai shim pack Uckoces If dallo je required it ia o be incuded in the shim pack If slingor is used between the inner bearing and thsi face of pinion the slinger ia also to Sc minut and included ea part of the total abim p b 1000 178 Figura 176 Place be required amount of hons land beffle f used in the bearing berg dnve the Inner bearing cup the camer Meke sare cup ls seated Tools 0 001 Cup installer C 4178 Handle kh rad Figure 176 Assemble the outer pinioa bearing into camer as showo make sure CUP is seated Tools eC 1703 Cup bretallee 4171 Handle 1 m ll i j t Figure 177 b i Assemble inner bearing land alinger if ased on pinien Drive bearing an shaft until it ia cempletely seated Teol C 3095 A Beuring Insinilbr I D 1 19178 Figure 178 Aasemble pinien into camer Assemble euter pinioo bearing cone tand slinger if used and end yoke onte pining spline CARRIER SECTION NOTE Do not aesemble prelead or pinion ell seal a thia time Use yoke instullet s shewn to assemble end yoke onbo spline of pinlon locis 8718 InsteBer C 3281 Holder Figura 179 1019 178 Assemble washer and pinion nut Ter amp ue nut until it requires 10 Lb In 1 13 N ml te ro
37. im a total of 055 indicator wading was This lesves e balance 062 of ahime for tbe appaste side and adds up bo the 07 which was first ceanded Add an sdd ional 0 5 shins on the opposite side for besring prelosd backlash Ring Gear Side 055 1 40 mm Opposite Side 052 1 32 mm Opposite Side Preload 016 88 mmi gC 417 Handle 1616 188 Figure 186 Install spreader 8nd Indicator to can jeras shown Do ast spreng carrier Over 016 1 38 mm Remove 2 2 indicator CARRIER SECTION Figure 189 1013 188 Assemble differential bearing cupa to differential beanng cones Install differentia aszetobly into carrier Use a suwhtde hammer to csal differentia assexobiy into cress bore of carrier Care chould be taken te aveid nickiog tho tewth of the ring gear and pinion during assembly Remove sp 30 8 190 Figuce 190 lostall beaiing caps Mako sure the carriers Torque bearing cap screws to 89 90 Ib Fr 108 122 N mb Tool 4 524 Torque Wrench letters stamped Use Caps cercespond with Uhose on the Figure 191 1018 187 Check ting gear und pinion backlash in three equally spaccd peusts with dinl indicator as shown Wecklash toleranec is 004 mm 10 38 to 909 and ary mere thnn 062 Imm 85 between ponts checked High backlash is corrected by tho ring gear to the pinton law hacktash js oorvected by
38. ing rollers Line up the holes ef the retainer plate with the bolts push exle shaft inte the bouging es far as pessibie Figure 96 one Start nuts en hacking plate bv hand Use a speed wrench shown and ghten to snug fit REAR AXLE Figure 97 Discard and ceplace wub a sew one M lime of Use a torque wrench and torque nuts to 25 86 Lp 93979 bly FL 3441 Nan REMOVAL OF UNIT BEARING FROM AXLE SHAFT Figure 100 046 000 Pusb rttainer plate and scal tewards flange of asle shaft Inetel the Nange plate to the flange of the axle shoft Install bolla int flange plate Slide facing over the axlo shult Install the adapters 30 they eost under the cup rib ring Gradually Ughion the belta until they are located in the dimples on tho backaide of the forcing plate Tools SP 6443 A Flange Piete SP 6017 Adsp ter Ring SP 5542 D Adafteis 5 5 26 Boks Tighten bolts of tool akerna ely amt conc ts seumved from axle shaft Be carefp ol bo JAS the maxdined surfaces of the arle shaft CAUTION Do aot beet or cut the bnaring cone assembly witb a torch to remove Oumage to the ill result Remove seal and ectalner pliate Oxcard aeal To dsasempble axie shalt trot housag follow he procedures hrzrated in Agures 76 thru 2 a Figure 98 Pisce exle shaft in vise Brill a 1 4 6 35 mm hole the outside ef the retainer to a depth epproximatley three fourths t
39. m WILL a a ohm Figure 1019 88 Asser ble naw needle tearing into eyindle Tools 00 266 Installer 4C 4171 Handle Figure 66 Assemble grease seal into pindia The Hn of the seal is to be directed away from the spmdle 1019 99 FRONT AXLE Figure 72 1910 29 Pack the eres around the thrust face area of the shaft and seal full of greas Also fill the seal area ofthe splade with grow Figura 70 Some front axles oce equipped wlth YV seul whith 14 aseemblcd to the axle shaft atono shield as shown 1 seul 19 mum remove und replace with a new one i 0 74 Figure 73 Assemble axle shaft folni assembly into housing Figure 71 Figure 74 Assemble new seal abown of the seal is to new bronze acer and spindle be directed towards ihe spindle 19 REARAXLE REAR AXLE Unit wheel bearing dealgn iubricated with hypeid lub icant NOTE Unit wheel beanngs that are dependent on lub ication from the hypoid gear lube in the axle housing rather than grease are not equipped with an inner axle shaft sea aa ahoan m Ggure 75 BRAKE BACKING PLATE DL BEAL y UNIT e amp A RING BEARIN RETAINER T Figure 75 rer Unit wheel bearing I D without inner grease seal DISASSEMBLY Figure 75 4019 28 After wheel 1 resseved remove breke drut 20 figure 77 hd ad Remove backing plate tuta which hol
40. nstelloz ASP 5026 Bolts 456 2020 Waahers Tighton bolts alternately and evenly making yuro bearlny ls not cocked on axle shalt Centinue until whee beeing i seated To mabe bearing ie sealed use a 0015 0381 mmt foeler gage between Bearltig seat and b anag If gage intera ee bearing funber on the axle shaft until gage does AA enter Figure 10 26 Figure 102 wam lnsall ning on axie shak Follow ibe same preccdure9 m figue 101 to aszbk the rolainer img V3aea 0815 038 feeler gage det ween tbe bearag and retainer ring to be aure that che retainer tig s seated At least one point exis where the gage will not enter between the tet lnet ring and bearing If gage enters compleboly Oreund the diameter retsinor ring mus be ferced onto the axle hatt To assemble axle shah esscinbly inlo housing follow steps as Mlustrated in figure 52 threugh 94 LUBRICATING NEW UNIT 6EARING WITH GREASE Flgure 103 1019 40 Push ses and ietalner away from bering to allow e cavity between the seal and bearing REAR AXLE Figure 104 Fil cavity with geod Quality 42 E P Extreme Pressuret lithium 3030 wheel beartng grease 1000 100 Figure 106 109 105 After cavity ia full of wrap tape completely around nb end sea ie enclose the cavily Figure 106 1018106 Push seal tewards the bearing until contacts the vib ng This will fere the gr ase
41. othe safe veliahle operation of all mator vehicles or driving axles whether they be rept ov rear The service prucedures recommended and desc bed in thia service manual are effecti ve metheds Por pezforining serviee operatiena Same of these service ape ations tequire the usa of teols specially designed for the purpose The apecial tool ahould be used when and as recommended Tt i Impesaibie Kaew evaluate and advise the aervice t rade of all conccivalle ways in which service might he done of the possible hazardous eon sequences Of aach way Aecordingiy anyone who uaesa service precedureo rte aol which ia not recommended musi first satisfy himself thoroughly that neither his safety or safety will be jeopardized hy the service methods he selects NOTE Trov ghoul this manue reference is made ceztaic tool numbers whenever Speal teo s ere te amp uired These numbers ore oumbets of Miller Special Toels 32615 Park Lone Garden City Michigan 48185 They are used herein for customer cenventeace enly Dana makes no warranty or representation bo these tool LUBRICATION Lt is not our inecot te rerummsnd any paticular brand or make of lubricant for Spicer axles However a S A E 90 weight multipurpose gear lubricant mugting Mil Spec 1 2105 B or 80 W 90 mu vpurposas gear lub cent mwting Mil Spec 1 2105 sulteble for Service Claasificlation GL 5 is suggested nee minimum requiremeot WHEEL BEA
42. s and any periicles left by the eld gasket De wet use cleaning solvents of any type Use ef cleaning solvents may prevent the RTV ge ler from adhering tot cover plate and carrtez reaulting in leaks of xte lubricant CARRIER SECTION CAUTION Before removmeg differential case and ring gear make aure the axle abafta are pulled out far enough or clearance te remove differen tia Refer ta of manos covering the type of axle sasembiy being serviced for peecedures on removing the axle ahalta Figure 40 Renove be amp ciog caps Note Mating letters stamped on and carier This is impoctant at time of aagembly they arc to be assembled exacily as removed Jesters oc numbers sre in and horirenta pesition 1018 040 NOTE Af amp ercemoving axle shafts from the rear axle semi float shaft diag bearing umt assemble pmion mate shaft und lock pin finger light odyj into the differential Thia procedure amp netussery to prevent the crome ahaft Irem chepping out and the differentia side gears and differenti pinion mate gears from retating in the and dropping out when servicing the carter sectieo Figure 141 Pridi Mount epreader to houa ug Do noi spread carrier over 19 38 mmi Usa dia indicator shown Note This spreader can aliso be used en the Spieer Model 44 axle Toole D 167 Spreader D 128 indicater Set Figure 142 Pr
43. s lubricant meeting the MIL 1 2105C eperificstiou COLD WEATHER OPERATION Lf tbe vedelo is operated balow 0 F 18 C It advisable to use S A E 80 multipurpose gear lubticent M Spec L 2105 B end suicable fur A P 1 Service Clasxif catinn GLO IMPORTANT As special equipment Jlmlted slip differentials arepcevided in many vehicles the freedom icom ch atter e a function of the iub cant ueed and cannot be covered the above specification n 36roe applications epecial limdted slip differential lubricant may be required If required these speciz lubricants are normally availabe throngh tbe original equipimect manufacturer SUBMERSION OR DEEP WATER FORDING Lf the ia expesed to water deep enough to eover the hubs or whee bearing rotsiner plate and oll seal of either he rent or rear 2 09 it recemimended that the whoel ends be disassombled and inspuctod fer water dainpge andor centamination daily In the avent the gear carrier housiog should become submerged in water particular y if over the breathers itis that the hypoid Inbricant be drwzimad dally and mana perte be insperred or water 4 teow Clean ezamino sod TPP da maged pasts if 20606 prior to assembling the cover housing and zefililug with the abecified bypaid lubricant NOTE It is caqmpamenddJ thet whonsver baring are ruwed they are to berepisced wit oew ones cexarddee of
44. tate the pipien Retate puuen several mes hefare checking pinien pesition This is to seat the bearings and assur n more seeding pinion depth seltlng Tee C 193 In Lb Torque Wrench NOTE The reason fer net assembling preload shims and new Pinien seal at this ume ia due to the pessibility of having to t einion preload or pinion adjustment It weuld be necessary o again eeranve the seal and as mentioned whenever seals are removed they are to be replaced with new ones duc to pvaslble damage Figure 180 ree Plaso arber and discs small diameter dis for Model 08 asic and large diameter used on Medel 70 axle into cress bore of corrier Place piven beight block on button cnd of pinion Set diab Indlcater on small step of beled blesk Ih ub step ol bleck is used Model 70 axle Set diial indicator at zero B Slide scooter gage sctess er over order Ind cater will read plus er minus 1 9 at ita highest point depending en the etcAmg of the pinion NOTE Later modei pinion heigtu blocks are designed fur each individual mede azie Therefere it is possible te have a height block that does not have a step as piccured and described NOTE Indicator reading w tbin 002 05 mm f elct ing is vonsidered acceptable Pinien position is found to be within specihcatiews continue with build up tf pinion position ja not within specficetions change ahm pack thick ness under
45. to tbe pew ophaal An easy way to assemble the sida gears and pinion mace gears is to have all parts lubricated before assembly Aspomble both ade gegra and thrust washers hold them im place with band then assemble the pinion mate gears and weehere to hold the side geers in place Howe the ade geers until the holes of the washers aod pinion geers line up with the hales of the case the geers cannot be cotated by hand install one of the azie ahafta mo the mde guar and use Pipe wvench to turo the aheft Figure 159 min niat Use a dif to tne up the holes with those of the adiffersalial case Assemble pinon male Maf drive an shaft to coupe drift sure lock pin hole of shaf ia lined up wah the loch pin hole of the Figure 180 Assemble Jock pin Peen metelofcase over to lock in place NOTE The sermi flont shah riding Wesrig design uses Jock pin that is assembled with the use of wrench Use lock pi and aasemble finger light only Thie procedure is necessar to prevent differential side gear and diiforentiel pinion mete gears from rotating im the case and dropping out when servicing the carrier sectisd A new loch will be astalied aller the erle CARRIER SECTION Figure 301 Be sure Nange fece of the case is free of nite burre Aesembie ring gear to case Line up doles of the rmg gear with those of the case Use ne
46. up with tools ag ATR Tools AC 417 Handle 0 362 Cup Remover NOTE Sous are loeeted bet sun the bearing cup and cartier bore and may also mchde an ef hafile If shims and bafftce are bent or aicked they sbould be replaced at time of assembly Wire and sech tegether and mcasure each If steck has t be reptaced replace wilh sumo thickness a Figure 155 Remove pi on bearing with tools as shown Tools BD 914 P Presa 9DD 914 9 Adapter Bing 4C 293 57 Adpaters 1919 593 NOTE Roth ba fie and sling r are part of the Vin Dijustmenc shi und areto be kept intact for nili y ASSEMBLY On ell front driving exes these are exle shaft oil senis prvssed ito tho tube ends of tho carier Figure L D Carrier Seal 156 101 P1 Aa shown in figure 156 this dealg eonsists of the Intogra seal unit whereby the neal and guide ere combined On or each side CARRIER SECTION Figure 157 pue Agemble inner axle shaft seale and guides Te essenible seals use tools as shown Took B 195 lostafer When assembling the seals mako sure they are positioned etraigh and do not cocked Tum forcing screw until 1 stops seals will then be positioned Giogso lipo ef seels 1090 108 Figure 168 Meco differential case viso e shown Apply grease new side gear thrust wusbery end to bubs ond ihust face of the Aseunh e both gears Apply greuse
47. w ring gear acrews Draw up sczewe oWMerbpate ly and evebly Torque ring gear screws to 109 120 Lb Ft 1886 163 Nem Figure 162 1016283 tnsta mester differentia bearinge onto case Remove oll nicha burrs dirt esc from ta allow master bearings to rotate freely Tool 3B 117 Mester Oifte eutial Geurings Figure 183 Acemhte differential caso into carrier Qess pinoen Mount dial mditaior with bese as shewn Locate tip of indicator on flat sursee of one of thering gear spot iaces Merk location witha piece of chalk Force differentiel eese mb ae far as paen ble in the direction tewards the indicator With force stil apptled aet Indicator at zero 0 20 198 Indicator Set NOTE Dial have a m ngznum pare of 200 15 06 mm Flgure 164 Foree the differential aescmbly es fay es it will go in the opposite direction Repeet these stepo until you have obtained the sune reading the reading of the Thia will we the total ameunt of sbime required lors preload and will be calculated Inter during assembly After making sure the readings correct remove indicator and difserential assembly from DO NOT BEMOVE MASTER BEARINGS FROM DESER ENTIAL CASE AT THIS Tink CARRIER SECTION VIEW OF RING AND PINION SET Figure 165 Yang geurs and pinioms are supplied matched seta only Matching nutobers
48. y dif erentiB case from carrier with two pry birs shewn After diferential case has been remuved remove apreader Use caution to aveid damage te cing end pinien Mark or tag bearing cups indicating from which ado they were cemoved 1619142 Figure 143 Remove differential bearings with a puller shewn Wip shims bearing cup and beariog cone lezether Identify from which side they were comoved Ring gear side or oppesite side If abima mutilated witb new ones at time of assembly Shims are avatlable in thickness s of 00 005 01 and 8 imm 06 19 26 and 76 Repositien case to puller sod remove other hearing cone described abeve Toela 4DD 914P Preas DD 9146 Adcapicr BD 914 8 Adapter Ring 0122914 7 Extension Db 914 42 Button NOTE lt recemmended that whenever bearings are removed they arc dregarmesea of milage te be replaced with onts lt 9 recomraended that whenever the ring gear are removed Urey te be replaced with new onea Figure 145 i 09 66 Replace care in vise and drive out lock pin wich eecurea the Pinion mate Use small drift es zhowa NOTE The semi foet sheft iding beating design hee lock pin the ls rcmoved with a wrench The paion mae shaft 3 of the slip Bt design and can be removed by hand CARRIER SECTION ue J Figure 148 1010 15 Remove pica mate ehaft with
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