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SM1303 Service Information on Dana Rear Axle

1. 1 Part number 2 Number of ring gear teeth 3 Manufacturing numbers 4 Matching gear set number 5 Number of pinion teeth 6 Date code 7 Indicates genuine Spicer parts 8 Heat code ep D 5 D D 5 So D f 5 Failure Analysis Failure analysis is the process of determining the original cause of a component failure in order to keep it from happen ing again Too often when a failed component is replaced without determining its cause there will be a recurring failure If a carrier housing is opened revealing a ring gear with a bro ken tooth it is not enough to settle on the broken tooth as the cause of the carrier failure Other parts of the carrier must be examined For a thorough understanding of the failure and possible insight into related problems the technician needs to observe the overall condition of the vehicle No one benefits when a failed component goes on the junk pile with the cause unknown Nothing is more disturbing to a customer than a repeat failure Systematically analyzing a fail ure to prevent a repeat occurrence assures quality service by avoiding unnecessary downtime and further expense to the customer The true cause of a failure can be better determined by know ing what to look for determining how a piece of the equip ment was running and learning about previous problems In the case of a rebuilt rear axle mismatched g
2. Block the vehicle Drain axle lubricant Disconnect main driveline Disconnect differential lockout air line ao fF oOo PY Disconnect lead wires to the selector switch and air line at shift cylinder 6 Remove axle shafts Diff Lock Models e For removal of the locking wheel differential carrier assembly the differential lock must be engaged and held in the engaged position This can be accom plished by one of two methods either engage via air pressure or engage manually Engage via Air Pressure e Using an auxiliary air line apply 80 120 PSI air pres sure to shift cylinder air port to engage clutch 1 Connect 80 120 PSI air line to cylinder port Engage Manually e Install a 250 18 NPTF bolt over 1 5 long in the cylinder air port to manually engage the clutches GM models require a M12 X 1 5 X 38mm bolt Note Hand tighten the bolt over torquing may cause damage to the shift unit To facilitate hand tightening coat bolt threads with axle lube 1 Hand tighten with socket 2 M12 x 1 5 x 38mm bolt GM only 250 18 NPTF all models except GM Note With either method the axle shaft may have to be rotated to permit the clutch to become engaged A WARNING Do not lie under carrier after fasteners are removed Use transmission jack to support differential carrier assembly prior to loosening fasteners 7 To remove axle shaft remove axle stud nuts If used remove lock washers
3. BLUE BIRD February 22 2013 SERVICE MEMORANDUM NO SM1303 MEMO TO All Blue Bird Dealers SUBJECT Service Information on Dana Rear Axle MODEL YEAR S 2012 2013 and 2014 MODEL S AFFECTED All American Front Engine All American Rear Engine and Blue Bird Vision Some Blue Bird All American and Vision buses have Dana Spicer rear axles To determine whether your bus has a Dana Spicer or Meritor axle see the axle identification plate on axle housing Axles shown below are for reference and the identification location may vary Service information for Meritor axles are in the Blue Bird Service Manuals Attached is an advance copy of the Spicer Drive Axle Service Manual to assist in servicing your vehicle Plans are to include this information in future Blue Bird Service Manuals BLUE BIRD BODY COMPANY P O Box 937 402 Blue Bird Blvd Fort Valley Georgia 478 825 2021 Spicer Single Drive Axles lt pana gt SPICER Drivetrain Products Service Manual Single Reduction amp Single Reduction with Differential Lock AXSM0048 September 2008 150408 23070S D 17060S D 23080S D 190508 230858 D 19055S D 23090S D 19060S D 23105S D 20060S D R 26080S D 21060S D 26085S D 21065S D 26090S D 21090S D 26105S D 22060S D R 30105S D 22065S D P20060S D R P22060S D R General Information General Information The description and specifications contained in this service Any reference to brand names in this publ
4. 35 38 47 Bracket Screw 1 5 Shift Fork Capscrew All Axles where used 12 9 M8 x 1 25 6mm 12 15 16 20 Allen Selector Switch All Models M12 x 1 5 24mm 10 12 14 16 Diff Lock Cylinder Ship All Models 250 18 Snug to Engage Clutch Teeth ping Screw Note In the previous charts axle models are listed either spe cifically or referred to by Series axles The chart below denotes the possible models being referred to in this manual and in the previous charts Note Fasteners using self locking thread Patches may be reused if not damaged but should be secured by a few drops of Loctite 277 on threaded surface Reused fas teners should be wiped clean of excess oil but do not require special cleaning Series Possible Models Note Correct tightening torque values are extremely important to assure long Spicer life and dependable 15 15040 performance Under tightening of attaching parts is 17 17060 just as harmful as over tightening 19 19050 19055 19060 21 21060 21065 21080 21090 22 22060 22065 23 23070 23080 23085 23090 23105 26 26080 26085 26090 26105 30 30080 30105 64 Note Exact compliance with recommended torque values will assure the best results Fastener Specifications Class Identification Fastener Strength Strength class is identified by num
5. Dama 3 gt me N General Information Table of Contents Visual Carrier Assembly page 8 Wheel End Seals page 49 A Inter Axle Speed Sensor page 46 Differential Assembly page 11 12 Drive Pinion page 13 Seals page 25 Wheel Differential Lock page 36 Housing Breather page 44 General Information Introduction Dana presents this publication to aid in maintenance and overhaul of Spicer single reduction drive axles Instructions 23 080 S contained cover the models listed below Their design is common with differences in load capacity Capacity GAWR x 1000 Ibs l oti i ini iaai earing variations are achieved by combining basic differential GCW x 1000 Ibs A Single Reduction with In Axle carrier assemblies with different axle housings axle shafts Speed Sensing and wheel equipment The suffix letter P in the model B Bus Specific number indicates a lube pump is standard Pump models D Single Reduction with are equipped with a gerotor pump designed to provide P ae Lock additional lubrication to the inter axle differential and eo isi p fep related parts P Planetary Double Reduction D eT R Retarder Parking Brake Ready D Model Listing ee ee S Single Reduction 5 The following models are included in this publication T 2 Speed 5 S Spicer Single Reduction Axles z With Standard With With Wheel S Wheel Differential IASS Different
6. Do not use shim stock or grind spacers These practices can lead to loss of bearing preload and gear or bearing failure Stake Pattern 8 Press pilot bearing on pinion A CAUTION To prevent bearing damage use suitable sleeve that only contacts the inner race of bearing cone 10 With pinion installed and bearing preload adjust ment complete install oil seal Use properly sized installation tool as described on the next page to pre vent distortion 1 Tool 2 Seal 3 Bearing cage 22 Z 3 D o 3 a ix D a 3 Pinion Assembly 11 Prior to installation of yoke make sure yoke is clean and dry 12 Install yoke 13 Install yoke nut using one of the following options e Install a new nut with the pre applied thread adhesive compound Tighten the nut to the specified torque as specified in the back of this publication e If anew nut with pre applied thread adhesive compound is unavailable apply Loctite 277 or 271 to the nut along two threads for at least two flats 120 of the nut midway through the thickness A IMPORTANT Follow the instructions specified by the thread adhesive manufacturer when applying thread adhesive compound Midway thru thickness of nut Note Use of a torque multiplier is recommended TIP If you can t get the correct torque on yoke nut try torquing the nut with the
7. a ieee 8 Manual engagement scew 16 Set screw 3 O ring 11 Pushrod 17 Piston Driver 4 Shift cylinder body 12 Shift fork spring pin 10 Foehirod 5 Bracket cap screw 13 Shift fork 6 Mounting bracket 14 Sliding curvic clutch 7 Fixed curvic clutch 15 Fixed curvic clutch snap ring 8 Compression spring ta Piston 3a Shift cylinder gasket 2a piston O ring 4a Shift cylinder 5a Housing cap screw 35 Wheel Differential Lock Wheel Differential Locking Axles Comparison Information on Spicer Wheel Differential Locking Axles This section covers Spicer Wheel Differential Locking axles The basic concept of Dana s Wheel Differential Locking axles are the same but the designs vary model to model When servicing your Diff Lock axle pay close attention to all NOTES TIPS and WARNING signs that will assist you while you work on your axle The Diff Lock axles listed below are grouped together by design type In this section they will be referred to as Type 1 or Type 2 Type 1 Type 1 Style Diff Lock Axles Feature A sliding curvic clutch A fixed curvic clutch The Flange Half Diff Case is externally splined Uses double spline or extended spline axle shaft 1 spline length on Flange Half Side of axle Uses standard spline axle shaft 4 spline length on plain half side of axle The Diff Lock selector switch is located on the car rier cap assembly Type 2 1 Case bolt
8. to provide improved traction under adverse road conditions The differential lock is driver controlled through an electric switch or air valve mounted in the cab The locking mecha nism is air operated to engage a mechanical clutch and lock the wheel differential It is spring operated to disengage the lock and permit the wheel differential to function normally The wheel differential lock consists of three major assemblies Shift Cylinder Assembly e Operates a shift fork and push rod assembly Shift Fork and Push Rod Assembly e Engages and disengages the differential lock curvic clutch assembly Curvic Clutch Assembly e Consists of a sliding clutch splined to a axle shaft and a fixed clutch which is splined to the differential case hub The differential lock also includes a selector switch electric which senses clutch engagement and sends an electrical sig nal to a cab mounted indicator light or an audible signal device 3 yor _ a 3b 1 Curvic clutch assembly 1a Sliding clutch 1b Fixed clutch 2 Shift fork and pushrod assembly 2a Shift fork 2b Pushrod 3 Shift cylinder assembly 3a Piston driver 3b Selector switch 57 Theory of Operation Wheel Differential Lock Operation Differential Lock Engaged Air pressure applied to the shift cylinder moves the piston push rod shift fork and the sliding curvic clutch as an assem bly Th
9. 8 Switch 2 Cover 9 Differential carrier 3 Cylinder seal 10 Switch actuator 4 O ring 11 Compression spring 5 Piston 12 Fixed cirvic clutch 6 Push rod 13 Sliding cervic clutch 7 Gasket 14 Shift fork 1 Fixed clutch 4 Piston driver 2 Sliding clutch 5 Gasket 3 Pushrod 6 Switch Type 2 Style Diff Lock Axles Feature A Sliding curvic clutch A fixed curvic clutch The Plain Half Diff Case is externally splined Uses extended spline axle shaft 11 spline length on plain half side of axle Uses standard spline axle shaft 4 spline length o flange half side of axle The Diff Lock selector switch is located on the Diff Lock shift cylinder n 36 7 3 D ix 3 v ix D a 3 Wheel Differential lock Install and Adjust Differential Lock Type 1 Axles Special Instructions Note With differential carrier completely assembled and adjusted install differential lock assembly for Type 1 axles as follows Procedure 1 Install fixed curvic clutch on splined hub of flanged differential case Type 1 2 Install Snap ring 37 3 If shift fork and sliding curvic clutch are disassem bled engage fork with clutch hub and install spring pin in end of fork long leg to hold components together See illustration for fork mounting position on clutch Install clamp screw in fork and tighten fin ger tight Long leg of shift 4 Plac
10. 8 Back off the inner nut one full turn Rotate the wheel hub 9 Retighten the inner nut to 50 ft Ibs 68 Nem while rotating the wheel hub 10 Back off the inner nut exactly 1 4 turn Note This adjustment procedure allows the wheel to rotate freely with 0 001 005 0 025 mm 0 127 mm end play 11 Install the correct lock washer for the wheel nut sys tem being used Three piece Dowel type Lock Washer System 05 1 Inner nut 2 Dowel pin 3 Dowel type lock washer 4 Outer nut a Install the Dowel type lock washer on the spindle Note If the dowel pin and washer are not aligned remove washer turn it over and reinstall If required loosen the inner nut just enough for alignment Note Never tighten the inner nut for alignment This can pre load the bearing and cause premature failure b Install the outer nut on the spindle and tighten to 350 ft lbs 475 Nem c Verify end play see Verify Wheel End Play Proce dure Wheel Adjustment Systems Three piece Tang type Lock Washer System Note If the dowel pin and washer are not aligned remove washer turn it over and reinstall If required loosen the oS N inner nut just enough for alignment Note Never tighten the inner nut for alignment This can pre 9 load the bearing and cause premature failure Q A b Install the Tang type lock washer on the spindle pa O c Install the outer nut on the spindle and tighten to 250 O 1 ft lbs 3
11. along the face width could be longer Adjust Contact Pattern If necessary adjust the contact pattern by moving the ring gear and drive pinion e Ring gear position controls the backlash This adjustment moves the contact pattern along the face width of the gear tooth e Pinion position is determined by the size of the pin ion 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 considered 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 Tooth Contact Pattern Adjust Pinion Position If the gear pattern shows incorrect tooth depth contact Adjust Ring Gear Position Backlash change drive pinion position by altering the shim pack Used gears should achieve proper contact with the same shims If the gear pattern shows incorrect face width contact change removed from the axle at disassembly ae 9 backlash by adjusting the ring gear Note Check ring gear backlash after each shim change and adjust if necessary to maintain the 006 to 018 specifi If the pattern is too close to the edge of the tooth toe move cations the ring gear away from the pinion to increase backlash If the pattern is too close to the top land of the gear tooth remove pinion shims Move pinion toward
12. and taper dowels 8 Remove axle shafts Note All models in this publication use axle shafts with unequal lengths Axle shafts may also be location spe cific with various wheel equipment Do not misplace axle shafts from their intended location Identify left and right shafts for reference during reassembly TIP If necessary loosen dowels by holding a brass drift in the center of the shaft head and strike drift a sharp blow with a hammer A CAUTION Do not strike the shaft head with a steel hammer Do not use chisels or wedges to loosen shaft or dowels 9 Remove carrier cap screws nuts and lock washers 10 Remove differential carrier assembly Differential Carrier Install Differential Carrier A IMPORTANT Before installing carrier assembly inspect and thoroughly clean interior of axle housing using an appropriate solvent and clean rag Procedure 1 Apply Spicer approved RTV compound on axle hous ing mating surface as shown in the illustration Com pletely remove all old gasket material prior to applying new material Compound will set in 20 min utes Install carrier before compound sets or reap ply 1 Apply silicone gasket in this pattern 2 Common stud locations TIP To assist in installing complete differential carrier use two pieces of threaded rod threaded into carrier cap screw holes Rod should be approximately 6 long Use these to pilot the carrier into the housing 2 Install
13. are disassem When air pressure is released or the manual bolt is bled engage fork with clutch hub and install spring removed the shift assembly should disengage freely ae ee peels HanOn for ORK 14 When adjustment is complete torque fasteners to PA gP i 28 35 ft lbs 38 47 Nem D 3 Position compression spring shift fork and clutch acs s assembly in shift opening of the carrier Align pilot 13 a wo TTS ei Tague 3 hole of shift fork with pilot hole of carrier Install ae i m pushrod engaging shift fork head and compression 16 Check selector switch operation Check switch elec S spring in carrier trically with an ohmmeter or continuity tester Switch 2 D should close show continuity when clutches are engaged and should open no continuity when 5 Lubricate piston and O ring with silicone grease and clutches are disengaged install piston assembly in cylinder Position piston with small diameter hub toward closed end of cylin der 4 Install new O ring on piston 6 Screw piston driver on pushrod 7 Tighten piston driver until shift fork clutch is approx imately 030 from the fixed clutch J LI 030 8 Push down by hand on the piston drive Both clutches must be completely engaged 9 Install set screw in piston driver and torque to 12 15 ft lbs 16 20 Nem 10 Trial fit install piston cover assembly Hand tighten cap screws 11 Screw in manual engagement
14. carrier to housing washers cap screws and nuts Torque to proper specifications See torque chart of page 66 3 Install axle shafts and axle stud nuts if used also install lock washers and tapered dowels 4 Add axle lubricant Fill to bottom of filler hole 5 Rear Only Connect inter axle driveline making sure all yokes are in phase Lubricate U joints a 3 D o wo a J o D a i 3 Differential Carrier Disassemble Carrier Assembly Rear Axles Note For models having the wheel differential lock option or a carrier thrust bolt follow the steps below These parts must be removed first before further removal of the wheel differential and or pinion can take place Procedure Remove Wheel Differential Models with Wheel Differential Lock 1 For ease of servicing mount differential carrier in stand with differential lock facing up Note To remove the pinion assembly the shift fork clutch hand wheel Diff assembly must be removed from car rier See instructions below 2 Remove shift cylinder mounting screws then lift shift cylinder piston and o ring assembly off carrier and end of push rod 1 Shift cylinder 3 To disassemble shift cylinder for inspection first remove or back off actuator switch The piston and o ring assembly can be removed by inserting a pen cil size tool through the cylinder air port 4 Grasp push rod end and pull it out of the shift fork
15. grease and DY install piston assembly in cylinder Position piston w Z Sliding with small diameter hub toward closed end of cylin D7 elute der ies Insert 3 spring Spring 6 Screw piston driver on pushrod 7 Tighten piston driver until shift fork clutch is approx imately 030 of an inch from the fixed clutch 8 Push down by hand on the piston driver both clutches must be completely engaged 9 Install set screw in piston driver and torque to 12 15 Ibs ft 16 20 Nem 10 Trial fit install piston cover assembly Hand tighten cap screws 11 Screw in manual engagement screw by hand approximately 1 inch or until snug fit light resis tance pressure is felt Both clutches must be com pletely engaged 12 Remove manual engagement screw clutches until completely disengaged e Repeat above procedure if clutches are not completely disengaged Note Fork adjustment is correct when curvic clutch teeth are fully engaged with the fork free when moved by hand When air pressure is released or the manual bolt is removed the shift assembly should disengage freely 40 Wheel Differental lock Install and Adjust Differential Lock Type 2 Axles Continued Procedure 1 Install selector switch in cylinder cover Torque switch to 10 12 Ibs ft 14 16 Nem Note Effective July 1 1996 Dana will standardize on the selector switch and wiring harness Reference Bulletin ABIB 9609 Types 1 and 2 switc
16. ment procedures end play is still not within the 001 005 025 127 mm range disassemble and inspect the compo nents If parts are found to be defective replace the defective parts reassemble and repeat wheel bearing adjustment pro cedure Verify end play with a dial indicator Lubrication Lubrication Information Note For Lubrication information see TCMT 0021 Lubrication Manual N wo gt o wo a o wo a a gt 54 Proper Vehicle Towing Towing of Axles Equipped with Wheel Dif ferential Lock 1 Engage the wheel differential lock until the indicator light is on move vehicle to verify engagement 2 Shift transmission into neutral 3 With vehicle stationary release the air pressure on the wheel differential lock shift system and apply the parking brake 4 Disconnect the air supply and fitting at the shift cyl inder 5 Install the shipping cap screw or 128274 M12 X 1 5 screw or 128642 250 X 18 NPSM screw Manu ally engage the wheel diff lock until the indicator light is on and the main differential lock is com pletely engaged 6 Remove the axle shafts Note Axle shafts are location specific Remember the double splined or extended splined axle shafts are located on the shift cylinder side of the axle 7 Install temporary cover on hub to prevent contami nation entering and also to prevent the loss of lubri cant Description The Spicer W
17. plug Drain plug 11 Housing stud 12 Hardened washer 13 Carrier capscrew 14 Nut stud Boe oo eel El Fastener Specifications Fastener Torque Specifications Fastener Axle Model Class Size Tool Size Lbs ft Nem Differential Case Cap 15040 19050 19055 10 9 M12x 18mm 70 88 95 119 screw 1 75 19060 21 22 series axles 10 9 Mi4x2 18mm 114 140 155 190 12pt 23070 23080 23085 23090 10 9 Mi6x2 24mm 177 218 240 296 26080 26085 26090 30080 23105 26105 30105 8 625 11 15 16 165 195 224 264 Ring Gear Nut 15040 17060 19060 21060 12 M14x1 5 21mm 215 255 292 346 19 21 22 series axles except 12 M16 x 1 5 24mm 215 255 292 346 21080 21080 23070 23080 23085 12 M18 x1 5 27mm 325 395 441 536 26080 26085 30080 23105 26105 30105 750 16 11 8 275 300 373 407 Pinion Bearing Cage 15 19 series axles 10 9 M14x2 21mm 114 140 155 190 Capscrew 21060 21065 21080 22060 10 9 Mi6x2 24mm 117 218 240 296 22065 23070 23080 23085 23090 26080 26085 26090 30080 23105 26105 30105 5 150 10 11 8 240 300 325 407 Diff Bearing Cap Cap 15040 12 9 M16x2 24mm 117 218 240 296 screw 19 21 22 series axles 23070 12 9 M20x2 5 30mm 350 428 475 580 23080 23085 26080 26085 30080 23105 26105 30105 8 8125 10 11 8 370 430 502 583 Diff Carrier To Housing 15040 19050 12 9 M1
18. screw by hand approximately 1 inch or until snug fit light resis tance pressure is felt both clutches must be com pletely engaged 42 Wheel Differential Lock Install and Adjust Ring Gear Thrust Bolt Procedure 1 Thread thrust screw into the carrier until firm contact with the back face of the ring gear is made 2 Loosen the thrust screw 1 4 turn to obtain the cor rect adjustment of 020 50mm clearance between gear face and screw Tighten jam nut holding thrust screw stationary with a wrench torque jam nut 150 190 ft Ibs 203 258 Nem 3 Recheck to assure minimum clearance during full rotation of ring gear 1 Rear carrier or front carrier 2 Thrust bolt 3 Thrust bolt jam nut 43 Axle Housing Install New Axle Housing Breather Metal and Plastic Spicer uses an axle housing breather that consists of a fitting Plastic only Tighten until one thread is showing hose and clamp assembly This breather design has improved resistance to water ingestion and clogging caused by dirt ice or snow buildup around the base of the breather See installation instructions below all views from rear Procedure 1 Install fitting in breather hole 4 Insert hose onto fitting long end down N wo o D v o wo z5 wo r 5 Push hose firmly against fitting Rotate hose to point 3 Using a 3 4 wrench down ss Metal only Rotate the fit
19. the chart below A CAUTION Read only the torque value after the bearing cage starts to rotate 4 If necessary adjust pinion bearing preload by chang ing the pinion bearing spacer A thicker spacer will decrease preload A thinner spacer will increase pre load Note Once correct bearing preload has been established note the spacer size used Select a spacer 001 larger for use in the final pinion bearing cage assembly The larger spacer compensates for slight growth in the bearings which occurs when they are pressed on the pinion shank A CAUTION Do not assume that all assemblies will retain proper pre load once bearings are pressed on pinion shank FINAL PRELOAD TEST MUST BE MADE IN EVERY CASE N 3 o 3 a o D a 3 Pinion Assembly Nominal Bearing Axle Model Spacer Thickness Press Loads Spring Scale Adjustments in mm Tons Metric Tons Ibs Nem 15040 19050 19055 703 17 86 12 13 11 12 4 7 17 33 17060 19060 21060 22060 638 16 21 14 15 13 14 4 8 17 35 21065 22065 720 18 29 15 16 14 15 3 7 15 30 21080 21090 23070 23080 23085 672 17 07 18 19 16 17 3 6 12 24 23090 26080 26085 26090 23105 26105 30105 527 13 40 18 19 16 17 3 6 12 24 Note Spring scale reading w o pinion seal torque to rotate bearing cage 10 20 Ibs in 1 1 2 3 Nem 19 Pinion Assembly Adjust Pinion Bearing Prel
20. the differential bearings lowering the assembly 10 Install the bearing cup and bearing adjuster to the flange half side first 11 Install the bearing cup and bearing adjuster to the plain half side Use a long screwdriver or bar to lift the differential up while installing the cup and bear ing adjuster 30 N 32 o wo a o wo 2 3 Wheel Differential Adjustments Measure and Adjust Carrier Assembly Adjust Backlash and Preload Procedure 1 Turn the flange half bearing adjuster in until the ring gear contacts the pinion zero backlash than back the adjuster out two notches of the adjuster lugs 1 Flange half 2 Plain half 2 Tighten the plain half adjuster until the bearing cup just starts to turn this is a zero bearing preload 31 Tighten the plain half adjuster two lug notches Start with the notch at the top count two notches coun terclockwise on the adjuster and turn the adjuster so the notch is facing straight up You now have a two notch preload NS A FN 1 Lugs 2 One notch Use a rubber mallet to make certain both bearing adjusters are fully seated Measure backlash Make sure it is within specifica tion of 008 018 TIP To give yourself room to adjust contact pattern set it between 010 012 Wheel Differential Adjustments Change Backlash Setting If you have too much backlash the ring gear needs to move Measure R
21. the ring gear ainparoid adIA1aS 1 Loosen the bearing adjuster on the teeth side of the ring gear several notches 2 Loosen the opposite adjuster one notch 3 Return to adjuster on teeth side of ring gear and If the pattern is too close to the root of the gear tooth add Tighten da ls er Unti M puntan We Dealing CUB pinion shims Move pinion away from the ring gear 4 Continue tightening the same adjuster 2 or 3 notches and recheck backlash e Ifthe pattern is concentrated at the heel too far up the tooth move the ring gear toward the pinion to decrease backlash 5 Loosen the bearing adjuster on the teeth side of the ring gear several notches 6 Tighten the opposite adjuster one notch 7 Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup 8 Continue tightening the same adjuster 2 or 3 notches and recheck backlash 34 Wheel Differential lock Differential Lock Shifting Parts Exploded View Type 1 Type 2 For Models 19055D 21065D 21080D 21090D 22065D For models 17060D 19060D 21060D 22060D 23070D 23080D 23085D 23090D 23105D 26080D 26090D 26105D 30105D d 11 1 Fixed curvic clutch 9 Cap screw k 2 Fixed curvic snap ring 10 Piston cover 3 Sliding curvic clutch 11 Washer 4 Shift fork spring pin 12 Switch 5 Shift fork 13 Gasket 6 Compression spring 14 O ring 7 Cap screw 15 Piston eee washier
22. 2 x 18mm 85 103 115 140 Capscrew 1 75 19055 19060 21 22 series axles 12 9 M16x2 24mm 230 270 312 366 23070 23080 23085 23090 26080 26085 26090 30080 23105 26105 30105 5 625 11 15 16 160 176 217 239 Carrier to Housing Nut All 19 21 22 23 30 series axles 12 M16x1 5 24mm 199 244 270 331 Magnetic Plug Fill All Models 13 16 7 8 40 60 54 81 wrench Oil Drain Plug All Models 1 2 drive 40 60 54 81 Thrust Screw Jam Nut All Models 4 M24x2 36mm 148 181 201 245 Pinion Nut 15040 19050 19055 M30 x 1 5 41mm 376 461 510 625 63 Fastener Specifications Fastener Axle Model Class Size Tool Size Lbs ft Nem Pinion Nut Continued 17060 19060 21 22 series axles M36 x 1 5 55mm 575 703 780 953 21080 23080 26080 30080 M42 x 1 5 55mm 840 1020 1139 1383 23070 23085 26085 M42 x 1 5 55mm 789 966 1070 1310 23105 26105 30105 1 75 12 2 1 4 840 1020 1139 1383 ABS Sensor Assy Fas All Models 1024 x 7 1 8 Allen Finger Tight 1 Turn teners 8 Axle Shaft to Wheel Hub All Models 500 20 11 16 55 71 75 96 Nut an 625 18 15 16 170 190 230 258 S w 150 16 11 8 285 345 386 468 y s w os Misc Diff Lock Only Specifications Fastener Axle Model Class Size Tool Size Lbs ft Nem Diff Lock Shift Cylinder All Models 8 8 M10 x 13mm 28
23. 39 Nem VI i 2 d Verify end play see Verify Wheel End Play Proce dure 1 Inner nut e After verifying end play secure the outer nut by bending 180 apart two opposing tangs of the ee Hane RONDO WASET TAS GR locking washer over the outer nut 3 Outer nut a Install the Tang type lock washer on the spindle 12 Install the following e New gasket at axle shaft flange Note Never tighten the inner nut for alignment This can pre e Axle shaft load the bearing and cause premature failure N wo o a gt a o wo z5 3 e Axle flange nuts and tighten to specified torque b Install the outer nut on the spindle and tighten to 250 ft lbs 839 Nem 13 Lubricate axle wheel ends c Verify end play see Verify Wheel End Play Proce dure d After verifying end play secure wheel nuts by bend ing one of the locking washer tangs over the outer wheel nut and another tang over the inner wheel nut e Goto step 12 Four piece Tang Dowel type Lock Washer System 1 Inner nut 2 Dowel pin 3 Dowel type lock washer 4 Tang type lock washer 0478 thick 5 Outer nut a Install the Dowel type lock washer on the spindle 52 Verify Wheel End Play Procedure Verify end play meets specification using a dial indicator An indicator with 001 03 mm resolution is required Wheel end play is the free movement of the tire and wheel assembly along the sp
24. Inspect the spindle and nut threads for corrosion and clean thoroughly or replace as required Note Proper assembly and adjustment is not possible if the spindle or nut threads are corroded 2 Inspect the tang type washer if used Replace the washer if the tangs are broken cracked or dam aged 3 Install the hub and drum on the spindle with care to prevent damage or distortion to the wheel seal A CAUTION A wheel dolly is recommended during installation to make sure that the wheel seal is not damaged by the weight of the hub and drum Never support the hub on the spindle with just the inner bearing and seal This c an damage the seal and cause premature failure 4 Completely fill the hub cavity between the inner and outer bearing races with the same lubricant used in the axle sump 5 Before installation lubricate the outer bearing with the same lubricant used in the axle sump Note Lubricate only with clean axle lubricant of the same type used in the axle sump Do not pack the bearings with grease before installation Grease will prevent the proper circulation of axle lubricant and may cause wheel seal failure 6 Install the outer bearing on the spindle 7 Install the inner nut on the spindle Tighten the inner nut to 200 ft lbs 271 Nem while rotating the wheel hub A CAUTION Never use an impact wrench to adjust wheel bearings A torque wrench is required to assure the nuts are properly tightened 51
25. ailure Analysis meretee an a a 5 Prepare the Parts for Inspection cccceseeseeeteeeeeees 6 MSpecHON sosie n aA 7 Differential Carrier Assembly Exploded View 8 Remove Differential Carrier c ccccscsceeseseeseeesees 9 Install Differential Carrier c cccccesesecetseeeseeeeees 10 Disassemble Carrier Assembly Rear Axles 11 Rear Axle Pinion Assembly Exploded View 13 Remove Pinion Assembly cceseeeeesssseseeeeteeeeeees 14 Disassemble and Overhaul Drive Pinion 15 Replace Pinion Bearing Cage Cups ccc 17 Adjust Pinion Bearing Preload Trial Buildup 18 Adjust Pinion Bearing Preload Final Buildup 20 Install Drive Pinion Assembly ceeeceteeesteeeeeees 24 Install Pinion Oil Seal and Yoke ccceceseseeeteeeees 25 Wheel differential Exploded View cccecseeees 26 Remove Wheel Differential All Standard Models 27 Disassemble Overhaul and Assemble Wheel Differential 0 0 c cc cccesccsscsssssecsesssecsetsreesnens 28 Overhaul and Assemble Wheel Differential 29 Measure and Adjust Carrier Assembly cccccee 31 Change Backlash Setting ccccccccccseesesseeteseeeees 32 Adjust Ring and Pinion Tooth Contact Pattern 33 Adjust Pinion Position oo ce eeeseeeeteeeeteteeteeees 34 Differential Lock Shifting Parts Exploded View 35 Wheel Differenti
26. al Locking Axles ccccceeeeeeeeees 36 Install and Adjust Differential Lock Type 1 Axles 37 Shift Fork Adjustment Type 1 Axles cccseeeeees 39 Install and Adjust Differential Lock Type 2 Axles 40 Install and Adjust Wheel Differential Lock 42 Install New Axle Housing Breather Metal and Plastic cc cceeeeeeeseeeeeeeeeeeeees 44 Axle Housing Exploded View ccscccseeeeeeeeeees 45 Inter Axle Speed Sensor Parts Exploded View 46 Disassemble and Overhaul Inter Axle Speed Sensor 47 Install Inter Axle Speed Sensor cccesseceeseeeees 48 Wheel End Seal Parts Exploded View cccc0 49 Remove and Overhaul Wheel End Seal 0000 50 Adjust Wheel Bearing cccccesessssecseecssesesseeseees 51 Verify Wheel End play Procedure ccccecceeeeeeees 53 Lubricate Information cecceeseseeeseeeeteeeseeeseeeees 54 Proper Vehicle TOWING ccssar iiie 55 Operate Wheel Differential Assembly cccee 56 Wheel Differential LOCK cccesecsecssesctseseseeeesees 57 Wheel Differential Lock Operation ccccecceeee 58 Rear Drive Axle Parts Exploded View cccee 59 Inter Axle Speed Sensor Parts Exploded View 60 61 Housing and Output Shaft Assembly Parts Exploded MiG Weve Sseieveds Mick stsbl tls Soak eek E E TS 62 Fastener Torque Specifications ccceeeee 63 65 D 3 i gt O
27. al sol vents available Kerosene and diesel fuel are accept able A WARNING Gasoline is not an acceptable solvent because of its extreme combustibility It is unsafe in the workshop envi ronment 2 Wash castings or other rough parts in solvent or clean in hot solution tanks using mild alkali solu tions Note If a hot solution tank is used make sure parts are heated thoroughly before rinsing 3 Rinse thoroughly to remove all traces of the cleaning solution 4 Dry parts immediately with clean rags 5 Oil parts e f parts are to be reused immediately Lightly oil e f parts are to be stored Coat with oil wrap in corro sion resistant paper and store in a clean dry place Inspect Axle Housing Axle housing inspection and repairs are limited to the follow ing checks or repairs e Visually inspect axle housing for cracks nicks and burrs on machined surfaces e Check carrier bolt holes and studs for foreign mate rial e Replace damaged fasteners Look for loose studs or cross threaded holes A CAUTION Any damage which affects the alignment or structural integ rity of the housing requires housing replacement Do not repair by bending or straightening This process can affect the material s properties and cause it to fail completely under load e Check all seals and gaskets Note Replace conventional gaskets with silicone rubber gas ket compound included in many repair kits The com pound pro
28. bers on the bolt head or nut face Increasing numbers represent increasing strength Axle Model Pinion Nut Washer Part Thread Size Socket Size Part No No 15040 210133 210144 M30x1 5 41mm 19050 210133 210144 M30x1 5 41mm 19055 210089 210090 M36x1 5 55mm 17060 127589 not used M36x1 5 55mm 19060 127589 not used M36x1 5 55mm 21060 127589 not used M36x1 5 55mm 21065 210089 210090 M36x1 5 55mm 21080 128049 not used M36x1 5 55mm 21090 210089 not used M36x1 5 55mm 22060 127589 not used M36x1 5 55mm 22065 210089 210090 M36x1 5 55mm 23070 210508 210509 M42x1 5 55mm 23080 128049 not used M42x1 5 55mm 23085 128049 not used M42x1 5 55mm 23090 128049 not used M42x1 5 55mm 23105 95262 not used 1 75 12 2 25 26080 128049 not used M42x1 5 55mm 26085 210508 210509 M42x1 5 55mm 26090 210508 210509 M42x1 5 55mm 26105 95262 not used 1 75 12 2 25 30080 128049 not used M42x1 5 55mm 30105 95262 not used 1 75 12 2 25 Thread Size Identification M12 X 1 75 Nominal Thread Diameter Pitch mm mm 65 Bolts and cap screws Nuts For spec ing or service assistance call 1 877 777 5360 or visit our website at www dana com Dana Commercial Vehicle Products Group 3939 Technology Drive Maumee Ohio USA 43537 lt DANA SPICER Drivetrain Products www dana com All applications must be approved by the Application Engineering Department Specifications and or design are subject to cha
29. ce two 120 3 05mm feeler gauges one on each side of the clutches between the tips of the clutch teeth Slide shift fork on push rod to set clutch clearance Working through carrier pipe plug opening tighten shift fork cap screw to 12 15 Ibs ft 16 20 Nem torque 0 120 3 05mm Two 0 120 3 05mm feeler gauges 3 Check differential lock clutch engagement by one of the following methods Air Pressure Engagement Apply air pressure 80 120 psi to shift cylinder port to engage clutches Manual Engagement Install an M12x1 5 bolt over 38mm 1 5 long in the cylinder air port to manually engage clutches Note Hand tighten the bolt Over torquing may cause damage to the shift unit To facilitate hand tightening lubricate bolt threads with axle lube 39 Correct Fork Adjustment Fork adjustment is correct when clutch curvic teeth are fully engaged with the fork free when moved by hand see illustration When air pressure is released or manual bolt is removed the shift assembly should disengage freely Recheck the 120 3 05mm clutch teeth clearance with shift cylinder fully disengaged If not correct readjust fork position see Steps 1 and 2 With differential lock correctly adjusted coat pipe plug with sealant and install plug in carrier shift box Install selector switch and plastic washer in carrier shift box Torque switch to 10 12 Ibs ft 14 16 Nem Check Selector Switch Operation Ch
30. e compression spring and switch actuator in shift box Switch actuator Compression spring Wheel Differential lock 5 Position shift fork and clutch assembly on carrier 10 Place shift cylinder assembly on end of pushrod inserting fork head in shift box on top of actuator Compress cylinder assembly by hand to keep push Install pushrod engaging fork head switch actuator rod piloted in carrier and install mounting bracket compression spring and pilot hole in carrier cap screws Torque to 28 35 Ibs ft 38 47 Nem 2 Igogo 1 Cover capscrew 4 O ring 2 Cover 5 Piston 3 Cover gasket 6 Push rod Note The shift cylinder is serviced only as an assembly How ever if the cylinder is disassembled and parts are ser viceable assemble as described in Steps 5 thru 8 N wo o a gt v o wo z5 3 6 Install new O ring on piston Note At this stage of assembly adjust shift fork position 7 Lubricate piston and O ring with silicone grease and install piston with small diameter hub toward closed end of cylinder 8 Install seal on cylinder piloting seal shoulder inside cylinder 9 Install mounting bracket on cylinder 38 Wheel Differential Lock Shift Fork Adjustment Type 1 Axles Procedure 1 With clutches disengaged adjust position of shift fork on pushrod to set a clearance of 120 3 05mm between the clutch teeth Adjust as follows Pla
31. e for forward and rear axles 1 Face width 2 Tooth Depth 3 Heel 4 Top land 5 Root 6 Toe 1 Identify if new or used gearing 2 Check tooth contact pattern new or used gearing New Gearing Correct Pattern Paint six ring gear teeth 180 apart with marking compound and roll the gear to obtain a contact pattern The correct pat tern is slightly below center on the ring gear tooth with length wise contact up off 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 The pattern could vary in length and should cover 1 2 tooth or more face width The pattern should be evenly centered between tooth top land and root and should be up off the tooth toe 33 Used Gearing Correct Pattern Used gearing will not usually display the square even contact pattern found in new gear sets The gear will normally have a pocket at the heal end of the gear tooth The more use a gear has had the more the line becomes the dominant char acteristic of the pattern Adjust used gear sets to display the same contact pattern observed before disassembly A correct pattern is up off the toe and centers evenly along the face width between the top land and root Otherwise the length and shape of the pattern are highly variable and is considered acceptable as long as it does not run off the tooth at any point FF 1 Pattern
32. e sliding curvic clutch engages the fixed curvic clutch The sliding clutch is splined to the axle shaft The fixed clutch is splined to the differential case hub Engaging the two clutches locks the wheel differential thus preventing wheel dif ferential action Differential Lock Disengaged When air pressure at the shift cylinder is released a compres sion spring mounted on the push rod moves the push rod shift fork and sliding clutch as an assembly The sliding clutch moves out of engagement with the fixed clutch The wheel dif ferential is unlocked and operates normally J MULE a7 Differential Lock Engaged 1 Spring is compressed 2 Shift Fork 3 Pushrod 4 Selector switch 5 Piston 6 Shift cylinder 7 Air pressure applied engages clutches 8 Fixed clutch splined to differential case 9 Sliding clutch splined to axle shaft Differential Lock Engagement Indicator Differential lock engagement is detected by a switch electric mounted on the differential carrier An actuator mounted in the piston cover operates the switch When the shift fork moves to engage the differential lock the switch actuator moves away from the switch allows the switch to close and sends an electrical signal to turn on a cab mounted indicator light or an audible signal When the shift fork moves to disengage the differential lock the compressio
33. ear set also punch mark bearing adjust ers for reference during assembly 1 Punch marks 27 3 Remove cap screws flat washers and bearing caps Back off bearing adjusters and remove adjusters and bearing cups 4 Using a chain hoist lift ring gear and differential assembly out of carrier Wheel Differential Disassemble Overhaul and Assemble Wheel Differential Disassemble Wheel Differential 4 Lift out spider side pinions and thrust washers A CAUTION During following procedure place differential assembly on malleable surface to prevent damage when ring gear falls off its mounting position Procedure 1 Remove nuts and bolts fastening ring gear to differ not fall tap outer diameter with soft mallet to loosen Remove bearing cones from case halves using suit able puller 7 Remove bearing cone from plain case half in two steps Z 3 D o 3 a ix D a 3 a Mount puller vertically to split bearing This action will start moving bearing off case 2 Punch mark differential cases for correct location during reassembly Remove cap screws and lift off plain differential case half b 1 Punch marks MTOM 3 Lift out side gear and thrust washer _ Ti he ee 8 Remove bearing cone from flanged case half using suitable puller 28 Overhaul and Assemble Wheel Differential Wheel Differential A CAUTION T
34. ears may have been installed The more successful shops prevent repeat equipment failures by developing good failure analysis practices Knowing how to diagnose the cause of a premature failure is one of the pre requisites of a good heavy equipment technician How to Diagnose a Failure The following five steps are an effective approach to good fail ure diagnostics Document the problem Make a preliminary investigation Prepare the parts for inspection ee Oe I Find the cause of the failure 5 Correct the cause of the problem Document the Problem Here are some guidelines for starting to learn about a failure including questions to ask e Talk to the operator of the truck e Look at the service records e Find out when the truck was last serviced e Ask In what type of service is the truck being used e Ask Has this particular failure occurred before e Ask How was the truck working prior to the failure You need to be a good listener Sometimes insignificant or unrelated symptoms can point to the cause of the failure e Ask Was the vehicle operating at normal tempera tures e Ask Were the gauges showing normal ranges of operation e Ask Was there any unusual noise or vibration After listening review the previous repair and maintenance records If there is more than one driver talk to all of them and compare their observations for consistency with the ser vice and main
35. eck switch electrically with an ohmmeter or continuity tester Switch should close show continuity when Clutches are engaged and should open no continu ity when clutches are disengaged Wheel Differental lock Install and Adjust Differential Lock Type 2 Axles Note With differential carrier completely assembled and 13 When adjustment is complete torque fasteners to adjusted install differential lock as follows 28 35 Ibs ft 38 47 Nem Procedure Pam 1 Install fixed curvic clutch on splined hub of flanged S C differential case then install snap ring SOc l 7 l l g g Capscrew 2 If shift fork and sliding curvic clutch are disassem eee og bled engage fork with clutch hub and install spring ef gA Switch pin in the long leg of the fork See illustration for fork Sa Washer mounting position on clutch RK n gt Gasket D 3 Position compression spring shift fork and clutch amp S on s assembly in shift opening of the carrier Align pilot ee D hole of shift fork with pilot hole of carrier Install Piston a pushrod engaging shift fork head and compression Setscrew S spring in carrier E Piston 2 f driver S Note The shift cylinder is serviced only as an assembly How T a ever if the cylinder is disassembled and parts are ser viceable assemble as described in Steps 4 and 5 usnog 4 Install new O ring on piston gt Clutch fork 5 Lubricate piston and O ring with silicone
36. ft installation discon nect auxiliary air line or remove bolt from cylin der air port Connect vehicle air supply to shift cylinder and electrical lead wires to selector switch 4 Check differential lock operation from driver s cab before releasing vehicle for service 5 Verify the driver caution label is in the vehicle cab and is easily visible by the driver AWARNING Steering will be adversely affected when engaged ie DISENGAGED THIS VEHICLE IS EQUIPPED WITH THE DRIVER CONTROLLED WHEEL DIFFERENTIAL LOCK Engage only when traction is poor Do not engage when tires are slipping Disengage when going down hill Disengage at speeds above 25 mph y DA DRIVE CARFULLY For further information consult your owners manual or Spicer publication AXDR 0130 128045 WHEN ENGAGED Warning Label 128045 Jam Nut Option Install and Adjust Wheel Differential Lock Note With differential carrier completely assembled and 12 Remove manual engagement screw clutches must adjusted install differential lock as follows be completely disengaged 13 Repeat above procedure if clutches not completely Procedure disengaged 1 Install fixed curvic clutch on splined hub of flanged Note Fork adjustment is correct when curvic clutch teeth are differential case then install snap ring fully engaged with the fork free when moved by hand 2 If shift fork and sliding curvic clutch
37. gs will over heat resulting in axle damage or failure If this is impossible to lift the drive wheels remove all axle shafts to prevent gear rotation and cap the wheel hubs to pre vent loss of lubricant and a possible road hazard See the pre vious section Proper Vehicle Towing with Wheel Differential Lock for removal procedure Theory of Operation Operate Wheel Differential Assembly The Spicer Wheel Differential Lock is driver controlled and Operated by a carrier mounted air actuated shift unit In operation it positively locks the wheel differential to provide improved traction under adverse road conditions Control Systems for Differential Lock Two systems may be used to control the differential lock operation Transmission Low Range Interlock Control System The wheel differential is locked manually with the transmis sion in Low Range It is unlocked by the driver or unlocked when the transmission is shifted out of Low Range Note The interlock system is preferred for vehicles equipped with an air shifted Low Range transmission It is designed to ensure the differential lock is not left engaged and to prevent accidental engagement when the transmission is in high range Direct Driver controlled System The driver manually locks and unlocks the wheel differential using a cab mounted electric switch or air valve The follow ing description assumes the system includes a cab mounted electric switch and a sole
38. heel Differential Lock is an optional feature for Spicer Axles In operation it positively locks the wheel dif ferential to provide improved traction under adverse road conditions The differential lock is driver controlled through an electric switch or air valve mounted in the cab The locking mecha nism is air operated to engage a mechanical clutch and lock the wheel differential It is spring operated to disengage the lock and permit the wheel differential to function normally The Wheel Differential Lock consists of three major assem blies e A shift cylinder assembly which operates a shift fork and push rod assembly e A shift fork and push rod assembly which engages and disengages the differential lock curvic clutch assembly e Accurvic clutch assembly which consists of a sliding clutch splined to a axle shaft and a fixed clutch which is splined to the differential case hub 55 The Differential Lock also includes a selector switch electric which senses clutch engagement and sends an electrical sig nal to a cab mounted indicator light or an audible signal device Without Wheel Differential Lock Lift the drive wheels completely off of the ground or damage will occur A WARNING Do not lift the front wheels non drive wheels This alters the oil s position in the drive axle draining it away from the drive pinion and its bearings If the pinion is rotated under these conditions for any period of time bearin
39. hes with 12 mm threads will be discontinued The selector switch and wiring har nesses are interchangeable with each other Check Selector Switch Operation Check switch electrically with an ohmmeter or continuity tester Switch should close show continuity when clutches are engaged and should open no continuity when clutches are disengaged Install Differential Carrier Assembly in Axle Housing The differential lock must be engaged and held in the engaged position for installation of carrier assembly in axle housing This can be accomplished by one of the following two meth ods Air Pressure Engagement Using an auxiliary air line apply 80 120 psi air pressure to shift cylinder air port to engage clutch Manual Engagement Install an M12x1 5 bolt over 38mm 1 5 long in the cylinder air port to manually engage the clutches With clutches engaged grasp fork long leg between thumb and forefinger Move fork back and forth to check for free movement Some GM models use a 250 x 18 NPSM 128642 manual engagement bolt 41 Note Hand tighten the bolt over torquing may cause damage to the shift unit To facilitate hand tightening lubricate bolt threads with axle lube 2 Complete the installation of the carrier following instructions for your specific axle A CAUTION When installing axle shafts make sure the long splined shaft is installed in the shift unit side of differential carrier 3 After carrier and axle sha
40. ial Lock 150408 170608 17060D 190508 190558 19055D 190608 19060A 19060D 210608 21060A 21060D 210658 21065D 210808 21080A 21080D 210908 21090A 21090D 220608 22060A 22060D 220658 22065D 230708 23070D 230808 23080A 23080D 230858 23085D 230908 23090A 23090D 231058 23105A 23105D 260808 26080A 26080D 260908 26090A 26090D 261058 26105A 26105D 301058 30105A 30105D P22060S P20060D P22060S P22060D General Information Model Identification 4 5 3 S IN CUST PART NO Spicer SPEC SERIAL NO 2 Ol 6 ies PART NO RATIO mie ao 7 1 Country of origin 2 Axle modle identification _ 3 Specification number assigned to the axle A built by Spicer Identifies all component parts of the axle including special OEM requirements such as yoke or flanges 4 OEM part number assigned to the axle build Data plate is located on the axle centerline 5 Carrier assembly serial number assigned by N the manufacturing plant x 6 Axle gear ratio pS 7 Carrier assembly production or service part number CJ aaa Rear Axle Top View Parts Identification Axle Housing Axle Shaft 1 ID Tag 2 Axle shaft part number General Information Ring Gear and Pinion Note Ring gear and drive pinion are matched parts and must be replaced in sets 2 SSE pae e Z RY SPICER N lt 1 w
41. ial carrier When checking backlash a yoke or helical gear must be installed and torqued to get an accurate reading Best results are obtained when established wear patterns are maintained in used gearing 4 Using a chain hoist lift ring gear and differential assembly out of carrier 2 If reusing gear set also punch mark bearing adjust ers for reference during assembly 1 Thrust bolt o 32 3 3e o 5 i 3 to i 5 Pinion Assembly Rear Axle Pinion Assembly Exploded View 1 Pinion pilot bearing 2 Pinion 3 Pinion bearing cone inner 4 Pinion bearing spacer 5 Pinion bearing cup inner 6 Shim 7 Pinion bearing cage 8 Cap screw 9 Pinion bearing cup outer 10 Pinion bearing cone outer 11 Oil seal 12 Yoke 13 Pinion nut 13 Pinion Assembly Remove Pinion Assembly Procedure 1 Remove pinion bearing cage cap screws Remove pinion and cage assembly from carrier Remove shim pack o 3 3 D 5 i D i 5 A WARNING Do not allow pinion to drop on hard surface lf gear set is to be reused keep pinion bearing cage shim pack intact for use in reassembly If the original shims can not be reused record the number and size of shims in the pack Pinion Assembly Disassemble and Overhaul Drive Pinion The following procedures cover both forward and rear differ ential drive carrier di
42. ication is made sim publication are current at the time of printing Dana reserves ply as an example of the types of tools and materials recom the right to discontinue or to modify its models and or mended for use and should not be considered an procedures and to change specifications at any time endorsement Equivalents if available may be used without notice Important Notice This symbol is used throughout this Failure to follow indicated manual to call attention to procedures procedures creates a high risk of personal where carelessness or failure to follow injury to the servicing technician specific instructions may result in personal y mury ancor component damage Failure to follow indicated procedures may cause component damage or malfunction Departure from the instructions choice of CL _ Amomn tools materials and recommended parts pA IMPORTANT mentioned in this publication may Sed CM di jeopardize the personal safety of the prop service technician or vehicle operator NOTE Additional service information not covered in the service procedures TIP Helpful removal and installation procedures to aid in the service of this unit Always use genuine Spicer replacement parts Table of Contents Table of Contents Table of Contents Visual ccccccceceeeesetetetseeeseeeeees 1 ItFOGUCTION an E a A A 2 Model Identification Cisean 3 Ring Gear and Pinion ou ceeeesecsescseseseececseseseseeees 4 F
43. indle axis Correct end play is 001 005 025 125 mm Adjust End Play with Tire and Wheel Assembly Procedure 1 Attach a dial indicator with its magnetic base to the hub or brake drum Aw R i S REA S4 N 2 Adjust the dial indicator so its plunger or pointer is against the end of the spindle with its line of action approximately parallel to the axis of the spindle 3 Grasp the wheel assembly at the 3 o clock and 9 o clock positions Push the wheel assembly in and out while oscillating it to seat the bearings Read bearing end play as the total indicator movement A CAUTION If end play is not within specification readjustment is required 53 Adjust End play with Wheel Hub Insufficient End play If end play is not present remove the outer nut and pull the lock washer away from the inner nut but not off the spindle Loosen the inner nut to the next adjustment hole of the dowel type washer if used Reassem ble the washer and re torque the outer nut Verify end play with a dial indicator Excessive End play lf end play is greater than 005 127 mm remove the outer nut and pull the lock washer away from the inner nut but not off the spindle Tighten the inner nut to the next alignment hole of the dowel type washer if used Reassemble the washer and re torque the outer nut Verify end play with a dial indicator Fine Tuning the End play lf after performing the readjust
44. ing Gear Runout closer to the pinion Back off the plain half adjuster and count the number of notches you backed it off Each notch equals about 003 of backlash 1 Measure ring gear total radial run out Indicator A IMPORTANT reading should not exceed 010 In order to maintain the differential bearing preload you will need to turn the flange half bearing adjuster the same amount in the same direction If you need more backlash reverse this procedure Procedure Procedure 1 Install carrier bearing caps and torque carrier cap bolts to specifications outlined in the back of this publication Z 3 D o 3 7 ix D a 3 2 Recheck Backlash If the bearing adjusters were not in straight or fully seated the backlash will change a Used Gearing Reset to backlash recorded before disassembly b New Gearing Backlash should be between 008 and 2 Measure ring gear total backface runout Indicator 018 reading should not exceed 010 3 Check ring gear tooth contact pattern Paint ring gear teeth and check tooth contact pattern Correct tooth patterns Check adjusting procedures outlined in this section 4 Install bearing adjuster cotter pins Measure Ring Gear Runout 32 Adjust Tooth Contact Pattern Adjust Ring and Pinion Tooth Contact Pattern Note Rear axle gearing is shown in the following instructions Correct tooth contact patterns and adjustments are the sam
45. ing cage 3 Cup inner 2 Clean and inspect bearing cages for damage nicks and burrs 3 Install inner and outer pinion bearing cups Use a press and an appropriate drive sleeve Make certain bearing cup is evenly and firmly seated 1 Press ram 2 Sleeve must apply pressure to back face of outer bearing cone 17 Seat cups securely to shoulder Check clearance between cup and bearing cage Must be less than 001 Pinion Assembly Adjust Pinion Bearing Preload Trial Buildup 1 Assemble pinion bearing cage bearings spacer and spacer washer without drive pinion or oil seal Cen ter bearing spacer between two bearing cones Lubricate bearing cups and cones Bearing Cone Note When new gear set or pinion bearings are used select nominal size spacer from the specification chart below If original parts are used use spacer removed during disassembly 1 Press ram 2 Sleeve must apply pressure to back face of outer bearing cone 3 Spring scale 2 With the bearings well lubricated place the assembly in the press Position sleeve so load is applied directly to the back face of the outer bearing cone 3 Rotate pinion cage while applying press load 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 within the specifica tions listed in
46. ion a sleeve or spacer so that load is applied directly to the back face of the outer bearing cone 1 Press Measure Pinion Bearing Preload Use a spring scale to test the assembly rolling torque To use the spring scale wrap flexible wire around the bearing cage attach the scale and pull Preload is correct when torque required to rotate the pinion bearing cage is within the specifications Listed in the previous chart A CAUTION Read only the torque value after the bearing cage starts to Adjust Pinion Bearing Preload If necessary adjust pinion bearing preload Disassemble the pinion bear ing cage as recommended in this manual and change the pinion bearing spacer A thicker spacer will decrease preload A thinner spacer will increase preload Pinion Assembly Axle Model Pinion Nut Torque Press Loads Spring Scale Adjustments Lbs ft Nem Tons Metric Tons Ibs Nem 15040 19050 19055 376 461 510 625 12 13 11 12 6 13 25 58 17060 19060 21060 22060 575 703 780 953 14 15 13 14 6 14 25 60 21065 22065 22080 542 664 735 900 15 16 14 15 5 11 23 52 21080 21090 23070 23080 23085 789 966 1070 1310 18 19 16 17 4 10 18 43 23090 26080 26085 26090 23105 26105 30105 840 1020 1140 1383 18 19 16 17 4 10 18 43 9 Stake pilot bearing using staking tool This is essen A CAUTION tial to retain the bearing Use the correctly sized spacer
47. n spring also moves the pushrod actuator to contact the switch The switch is opened and turns off the cab mounted indicator light or the audible signal N wo i wo v o wo z5 wo Differential Lock Disengaged 1 Spring is decompressed 2 Shift fork 3 Pushrod 4 Selector switch 5 Piston 6 Shift cylinder 7 Air pressure applied disengages clutches 8 Fixed clutch splined to differential case 9 Sliding clutch splined to axle shaft 58 Parts Identification Rear Drive Axle Parts Exploded View 1 Ring gear 2 Carrier cap bolt 3 Washer 4 Flange half carrier cap 5 Cotter pin 6 Flange half differential case 7 Flange half bearing cone 8 Flange half bearing cup 9 Flange half bearing adjuster 10 Ring gear bolt 11 Nut 12 Plain half bearing adjuster 13 Plain half bearing cup 59 14 Plain half bearing cone 15 Plain half differential case 16 Side gear thrust washer 17 Side gear 18 Wheel differential spider 19 Side pinion 20 Side pinion thrust washer 21 Side gear 22 Side gear thrust washer 23 Pinion pilot bearing 24 Pinion 25 Inner pinion bearing cone 26 Pinion bearing spacer 22 2 Inner pinion bearing cup 28 Pinion cage shim 29 Pinion cage 30 Outer pinion bearing cup 31 Outer pini
48. nge without notice or obligation Printed in USA AXSM 0048 09 08
49. noid valve as shown in the illustra tion An air valve may be substituted for these components Operation is as follows 1 With control switch in the unlock position the wheel differential functions normally 2 When the control switch is placed in the lock posi tion the air supply solenoid valve opens and air pressure activates the shift cylinder The shift fork is moved to engage the curvic clutches which in turn lock the wheel differential 3 When the control switch is placed in the unlock position air pressure supply to the shift cylinder is shut off and air pressure is released from the cylin der A compression spring moves the shift fork to disengage the curvic clutch and unlock the wheel dif ferential 1 Cab mounted control valve plunger in valve open 2 Dry air supply tank 80 120 PSI 3 Preferably equal in length 4 Power supply 5 Fuse or circuit breaker 6 Indicator light or audible signal 7 Wheel differential lock indicator switch part of axle assembly 8 Rear axle wheel differential lock air shift cylinder part of axle assembly 56 TUERI 9dIN1aS Theory of Operation Wheel Differential Lock The Spicer Wheel Differential Lock is an optional feature for Spicer Axles In operation it positively locks the wheel differential
50. o prevent bearing damage use suitable sleeve that only contacts the inner race of the cone A used bearing race would be a suitable tool This tool should have a slit cut if the ID is the same as the flange OD Procedure 29 1 2 Press new flange half bearing cones on differential case halves Press new plain half bearing cones on differential case halves 3 Place thrust washer and side gear in flanged differ ential case 4 Lubricate all differential parts 5 Assemble side pinion and thrust washers on spider Place this assembly in flanged differential case Rotate gears and check for proper mesh 6 Place side gear and thrust washer on side pinions Wheel Differential 7 Align punch marks and install plain case half Install Cap screws and tighten to proper specifications as outlined in the back of this publication Check differ ential for free rotation by turning side gear hub 1 Punch marks 8 Install ring gear Secure with bolts and nuts Note For 17060 19060 21060 22060 model axles flange half differential cases were redesigned starting with pro duction axles built in January 1997 New style ring gear bolts are also required with the new style flange case Torque bolt to proper specifications listed on page 70 9 Lower assembled differential assembly in to the car rier using a hoist and a strap Be careful not to dam age
51. oad Final Buildup Note On rear axles do not install oil seal in cage until bearing 2 Install preselected bearing spacer preload is correctly adjusted A IMPORTANT After bearing cups are installed preselect pinion bearing spacer using the trial buildup procedure Note During pinion bearing installation locate each part in same position that was used in trial buildup preload test Procedure 1 Press inner bearing cone Pinion Assemblyon pinion 3 N 32 o wo a o wo 2 3 A CAUTION To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cone 20 To prevent bearing damage spin cage while pressing outer Pinion Assembly 4 Press outer bearing cone on pinion A CAUTION bearing on Note Specifications for finial Pinion Bearing Preload Test Torque to rotate bearing cage 15 35 in Ibs 1 7 4 0 5 Apply clamp load to the pinion bearing cage assem bly Either install the yoke or helical gear and torque the pinion nut to specifications or use the press to simulate nut torque see chart below Torque nut to 840 ft lbs 1 140 Nem then continue tightening nut to align nut slot to nearest hole in pinion shank Nem Vise Method 21 a a vise clamping yoke firmly If the yoke and nut are used mount the assembly in Press Method If a press is used posit
52. on bearing cone 32 Pinion seal 33 Pinion yoke 34 Pinion nut 35 R head carrier or rear carrier 36 Thrust bolt 37 Thrust bolt jam nut Parts Identification Inter Axle Speed Sensor Parts Exploded View Inter Axle speed Sensor a 3 D ix 3 a ix D a 3 wy A Sensor or B Fastener B C Rotor assembly D Differential bearing adjuster E Sensor connector 60 Parts Identification Wheel Differential Lock Assembly Type 1 1 Seal 2 Piston 3 O ring 4 Piston cover 5 Capscrew 6 Cover retainer 7 Cervic clutch 8 Spring 9 Spring washer 10 Set Screw 11 Push rod 12 Set screw 13 Clutch fork 14 Sliding cervic clutch 15 Snap ring Type 2 xed cervic clutch gear Snap ring iding clutch gear Spring pin Shift fork ompression spring sh rod ston driver 9 Set screw 10 Piston 11 O ring 12 Switch 13 Plastic washer 14 Piston cover 15 Capscrew flange head 16 Capscrew manual engagement 17 Gasket 1 1 Y VO NVVUVTI CONDO Bw MN 61 Parts Identification Housing and Output Shaft Assembly Parts Exploded View n LA v00 PDDE a N wo o wo a o wo 2 3 61510 8 95 Axle shaft Housing Outer nut Lock washer Inner nut Housing breather tube Housing breather fitting Fill plug Oil sensor
53. or hole is on carrier mounting surface 3 6 inch long wires 4 Sensor terminals positioned near carrier mount ing surface Procedure 1 Lubricate interior rotor with axle lube or grease Check that the rotor turns freely by hand Mate the rotor and the sensor assembly Align the sensor rotor assembly with the face of the adjuster so the terminals are nearest the carrier mounting surface Orient the sensor to line up the holes in the sensor with the threaded holes in the adjuster Rotate the sensor in either direction to get the fit that keeps the terminals near the carrier mounting surface This final adjustment should only require a slight shift in sensor position Apply Loctite to the four mounting screws Install the screws and tighten in a star pattern to maintain sensor alignment Torque to 28 32 in lbs 3 2 3 6 Nem A preferred tightening approach is the turn of bolt method torque screws finger tight then tighten additional 1 4 turn Attach the two round terminals to sensor Either wire can connect to either sensor blade Make sure termi nals are not bridged and connectors are not touch ing Torque to 10 15 in Ibs 1 1 1 7 Nem Before sealing wires in place check sensor continu ity by measuring the resistance between pins on the outside of the connector Resistance between con nector pins should be 1125 to 1375 ohms Check wire routing Make sure wire is seated in the cast in channel and
54. quire replacement do not unscrew plated connector The sensor may be replaced without replacing connector and wire 3 Remove four screws from face of sensor 4 Remove sensor from differential bearing adjuster 47 Overhaul Note If plated connector was damaged during axle disassem bly or if there is indication of a wiring fault the connec tor assembly must be replaced There are two different connectors with two different lengths of terminal wires See Inter Axle Speed Sensor Service Man ual AXSM 0034 If sensor assembly is to be replaced install new sensor before finishing installation of new connector The final position of the sensor terminals must be fixed before wires can be sealed in place To install new connector 1 Clean threaded hole in carrier and wire path to allow proper seal for new connector Male threads on the new connector have microencapsulated Loctite 2 Insert connector and torque to 20 28 Ibs ft 27 38 Nem 3 Route wires to the sensor location Inter Axle Speed Sensor Install Inter Axle Speed Sensor Except for routing the wires between the sensor and the plated connector procedures for installing both drive axle speed sensors are identical The instructions which follow cover the long arm plain half side speed sensor and require careful routing of the 6 inch long connector wires to prevent pinching between the head and housing 1 Wires seated in channel 2 Connect
55. rolling torque then proceed with pinion installation in carrier Yoke Reuse Guidelines A CAUTION Do not use the yoke if it has any damage on the seal surface nicks or scratches The surface of the yoke and the lips of the seal form a critical interface which retains the axle s lubricant while sealing the axle from outside contaminants The condition of the yoke hub s surface is a very important factor in determining seal life Carefully inspect the seal surface area of the yoke hub for signs of wear and damage Do not reuse the yoke if there is noticeable wear such as heavy grooving beyond normal pol ishing from the seal lips 25 Note Do not rework the yoke with abrasives such as emery paper or crocus cloth Clean the surface of the yoke as necessary using chemical cleaners Remove all trace of the chemicals from the yoke after cleaning Note Do not use wear sleeves Wear sleeves increase the yoke hub surface diameter and cause premature seal wear and repeat seal failure Seal Replacement Seal Pinion bearing cage Note Spicer strongly recommends using seal drivers when installing new seals Use the proper driver to ensure the seal is square and installed to the proper depth A CAUTION Oil seals can be easily damaged prior to installation Use care when handling the new seal to prevent damage or con tamination Leave the seal in its package until installation On new yokes leave the protector on
56. sassembly Rear Axle Pinion Yoke 1 Remove yoke A CAUTION If pinion nut was not loosened during earlier disassembly clamp assembly in vise jaws use brass pads to prevent damage 2 Loosen and remove pinion nut and flat washer Remove yoke from pinion using an appropriate tool Forward and Rear Axle Pinion Bearing Cage 3 Press pinion out of bearing cage and bearing cone 1 Press Ram Rear Axle Pinion Oil Seal and Outer Bearing Cone 4 Remove oil seal and bearing cone from cage Dis card oil seal Remove bearing cups with suitable puller 15 b 7 Remove bearing spacer from pinion Remove pilot bearing from pinion using a split type puller Use two procedure steps to remove each bearing Mount puller vertically to separate the bearing This action will force puller halves under bearing and start moving bearing off pinion Mount puller horizontally to press pinion out of bear ing Remove inner bearing cone from pinion using a split type puller Use two procedure steps to remove each bearing Pinion Assembly Mount puller vertically to separate the bearing This action will force puller halves under bearing and start moving bearing off pinion w wD a o Mount puller horizontally to press pinion out of bear ing D 1 oe 1 Press Pinion Assembly Replace Pinion Bearing Cage Cups 1 Remove cups 1 Cup Outer 2 Bear
57. sleeve Damage to the housing may result Note Deep gouges can be repaired by filling gouge with hard ening gasket cement and smoothing with emery cloth 5 Inspect spindle journal and hub bore for scratches or burrs Recondition with an emery cloth as required 6 Clean hub cavity and bearing bores before reassem bly Be sure to remove contaminants from all recesses and corners 7 Clean bearings thoroughly with solvent and examine for damage Replace damaged or worn bearings A CAUTION Always use the seal installation tool specified by the seal manufacturer Using an improper tool can distort or dam age the seal and cause premature seal failure Install Wheel End Seal Procedure 1 Before installation lubricate the following with the same lubricant used in the axle sump e Inner bearing e Wheel seal follow the directions provided by the seal supplier 2 Place seal on installation tool 3 Drive seal with installation tool onto hub 50 Z 3 D ix 3 a ix D a 3 Wheel Adjustment Systems Adjust Wheel Bearing Do not mix spindle nuts and lock washers from different systems Mixing spindle nuts and lock washers can cause wheel separation Note The lock washer for a four piece tang dowel type wheel nut system is thinner than the lock washer for a three piece tang type wheel nut system and is not designed to bear against the inner nut Procedure 1
58. spring and carrier Note When the push rod is disengaged from the shift fork the fork and sliding curvic clutch assembly can be removed from carrier Note Do not disassemble shift fork from the sliding curvic clutch unless parts replacement is necessary To disas semble use pin punch to remove spring pin from long leg of fork The fork can now be disengaged from the clutch 5 Remove the snap ring then lift fixed curvic clutch off differential case hub spline Further disassembly of carrier is the same for axles without differential lock 11 Procedure Models with Ring Gear Thrust Bolt 1 Loosen thrust bolt jam nut Note If the carrier model has a ring gear thrust bolt installed it must be backed away from the ring gear before you can remove the wheel differential 2 Back out thrust bolt from the carrier until the end of the bolt is flush with the inside of the carrier casting This will allow enough clearance between the ring gear and the carrier pilot web 1 Thrust bolt 2 Jam nut Differential Carrier Procedure Remove Wheel Differential All Standard Mod 3 Remove cap screws flat washers and bearing caps els Loosen bearing adjusters and remove adjusters and ROE l bearing cups 1 Mount differential carrier in repair stand Note Omit this step if the gear set is to be replaced If gear set is to be reused check tooth contact pattern and ring gear backlash before disassembling different
59. tenance records Verify the chassis Vehicle Identification Number VIN number from the vehicle identifi cation plate as well as the mileage and hours on the vehicle Make a Preliminary Investigation These steps consist of external inspections and observations that will be valuable when combined with the results of the parts examination e Look for leaks cracks or other damage that can point to the cause of the failure e Make note of obvious leaks around plugs and seals A missing fill or drain plug would be an obvious cause for concern e Look for cracks in the carrier housing harder to see but sometimes visible e Does the general mechanical condition of the vehicle indicate proper maintenance or are there signs of neglect e Arethe tires in good condition and do the sizes match e f equipped with a torque limiting device is it work ing properly During the preliminary investigation write down anything out of the ordinary for later reference Items that appear insignifi cant now may take on more importance when the subassem blies are torn down Prepare the Parts for Inspection After the preliminary investigation locate the failure and pre pare the part for examination In carrier failure analysis it may be necessary to disassemble the unit e When disassembling subassemblies and parts do not clean the parts immediately since cleaning may destroy some of the evidence e When tearing down the drive a
60. the yoke until it is installed on the shaft to prevent damage or contamination Wheel Differential Wheel Differential Exploded View a 3 D ix 3 me o D a 3 1 Ring Gear 17 Side gear 2 Capscrew 18 Diff spider 3 Flat washer 19 Side pinion 4 Diff carrier bearing caps 20 Side pinion thrust washer 5 Cotter pin 6 Diff case LH flange half l TrueTrac 7 Bearing cone flange half No SPIN Differential 8 Bearing cup flange half 9 Diff brg adjuster flange half 10 Bolt 11 Nut 12 Diff bearing adjuster plain half 13 Bearing cup plain half Optional 14 Bearing cone plain half 15 Diff case RH plain half 16 Side gear thrust washer 26 Wheel Differential Remove Wheel Differential All Standard Models Note Omit this step if the gear set is to be replaced If gear set is to be reused check tooth contact pattern and ring gear backlash before disassembling differential carrier When checking backlash a yoke or helical gear must be installed and torqued to get an accurate reading Best results are obtained when established wear patterns are maintained in used gearing 1 Mount differential carrier in repair stand Note For easier disassembly loosen but do not remove pin ion self locking nut Forward axle pinion is equipped with slotted nut remove roll pin with a pin punch then loosen nut 2 If reusing g
61. ting at least 1 2 turn until nipple points to rear 44 Axle Housing Axle Housing Exploded View 61510 8 95 1 Axle Shaft 2 Axle Housing Assembly 3 Outer Nut 4 Lock Washer 5 Inner Nut 6 Housing Breather Tube 7 Housing Fitting 8 Fill Plug 9 Oil Sensor Plug 10 Drain Plug 11 Housing Stud 12 Hardened Washer 13 Carrier Capscrew 14 Nut Stud 45 Inter Axle Speed Sensor Inter Axle Speed Sensor Parts Exploded View Axle shaft Speed sensor Differential bearing adjuster Plated connector ABS Harness connector orhrwonrm 46 N 3 o 3 a o D a 3 Inter Axle Speed Sensor Disassemble and Overhaul Inter Axle Speed Sensor Disassemble The design of the drive axle sensor allows replacement of sev eral individual components without disassembling the com plete sensor system For example e The differential bearing adjuster does not need to be removed in order to replace any other component e The sensor and rotor can be replaced without removing or replacing the plated connector At every stage of drive axle service try to isolate the problem to specific components in order to avoid unnecessary disas sembly Procedure 1 Disconnect two wires from sensor terminals 2 Carefully inspect wires and connector If connector is intact and if there is no prior indication that con nectors and wires re
62. truck wheels on the ground and with the axle shafts installed 23 Pinion Assembly Install Drive Pinion Assembly Procedure Note If gear set is to be reused install same quantity and size of shims removed during disassembly When installing a 1 Place shim pack on carrier making sure lube holes new gear set use nominal shim pack indicated are Clear 2 Install pinion assembly Install bearing cage cap screws and lock washers Torque to proper specifi cations as outlined in back of this publication N wo o wo a o wo 2 a gt 1 I tha slate Nominal Shim Pack 15040 19050 19055 21065 21090 22065 23070 23080 23085 23090 26080 26085 26090 024 in 61 mm 17060 19060 21060 22060 023 in 58 mm 23105 26105 30105 021 in 53 mm 24 Seals Yokes Install Pinion Oil Seal and Yoke 1 With pinion bearing preload adjustment complete install oil seal If available use a properly sized installation tool to install the oil seal Otherwise use a press and properly sized sleeve to prevent distor tion or contact with seal lips during installation see illustration Bearing cage A Sleeve must be sized to press on seal outer flange 2 Make sure yoke is clean and dry Install yoke and nut or nut washer on some models Tighten nut to cor rect torque see torque chart Note After tightening nut recheck pinion bearing
63. vides a more effective seal against lube seepage and is easier to remove from mating surfaces when replacing parts 1 Axle housing 2 Machined surface Inspect all steel parts for e Notches visible steps or grooves created by wear e Pitting or cracking along gear contact lines e Scuffing deformation or discolorations These are signs of excessive heat in the axle and are usually related to low lubrication levels or improper lubrica tion practices In addition inspect the following for damage e Differential gearing e Bearings for loose fit on drive pinion pilot bearing and differential bearings e All fasteners for rounded heads bends cracks or damaged threads e Inspect machined surfaces of cast or malleable parts They must be free of nicks burrs cracks scoring and wear e Look for elongation of drilled holes wear on sur faces machined for bearing fits and nicks or burrs in mating surfaces Inspect Primary Gearing Before reusing a primary gear set inspect teeth for signs of excessive wear Check tooth contact pattern for evidence of incorrect adjustment Differential Carrier Assembly Parts Differential Carrier Assembly Exploded View 1 Carrier Fasteners 2 Carrier Assembly 3 Single Axle Assembly N 3 o 3 a o o D a 3 Differential Carrier Remove Differential Carrier Procedure
64. will not get pinched when the head is reassembled to the housing Seal wire in place with RTV To replace sensor on the short arm flanged half side repeat previous steps Since connector location is inside the mounting surface there is less concern for pinching of the shorter 4 inch connector wires However before final assembly check wire position and routing to make sure it is not crimped or pinched 1 Installed position of axle shaft 2 Sensor terminals positioned near connector hole 3 Axle housing 4 4 inch long wires 5 Connector hole is not on carrier mounting sur face 6 Axle carrier 48 Z 3 D o 3 m ix D a 3 o 7e 3 wi rc o Wheel End Seal Parts Exploded View 1 Installation tool 2 Seal 3 Rear hub 49 Wheel End Seal Remove and Overhaul Wheel End Seal A WARNING Never work under a vehicle supported by only a jack Always support vehicle with stands Block the wheels and make sure the vehicle will not roll before releasing the brakes A CAUTION Wheel end seals can be easily damaged during handling Leave the seal in its package until installation to prevent damage or contamination Procedure 1 Remove outer bearing and wheel 2 Remove oil seal 3 Remove inner bearing 4 Remove old wear sleeve 2 piece design only with a ball peen hammer and discard A CAUTION Do not cut through the old wear
65. xle do it in the recom mended manner Minimize any further damage to the unit e Ask more questions when examining the interior of the carrier Does the lubricant meet the manufacturer specifications regarding quality quantity and viscos ity As soon as you have located the failed part take time to analyze the data Find the Cause of the Failure Here begins the real challenge to determine the exact cause of the failure Keep in mind that there is no benefit to replacing a failed part without determining the cause of the failure For example after examining a failed part and finding that the fail ure is caused by a lack of lubrication you must determine if there was an external leak Obviously if there is an external leak just replacing the failed gear is not going to correct the situation Another important consideration here is to determine the spe cific type of failure which can be a valuable indicator for the cause of failure The following pages show different types of failures and possible causes Use this as a guide in determin ing types of failures and in correcting problems Correct the Cause of the Problem Once the cause of the problem has been determined refer to the appropriate service manual to perform the repairs a 3 D S ix 3 me ix o a i 7 Inspect Assembly Clean 1 Wash steel parts with ground or polished surfaces in solvent There are many suitable commerci

SM1303 Service Information on Dana Rear Axle

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