SERVICE MANUAL - The Expert
Contents
1. Figure 57 4 Put the spline holder tool in a vise Figure 58 Set the case on the splined shaft being careful to align the splines while slipping the case over the shaft Figure 58 R X5001 CVSP spice 5 Remove the pinion mate shaft lock pin and 7 Install the spreader with a load to hold the use a punch to remove the pinion mate shaft side gears in place Figure 61 Figures 59 and 60 Figure 61 Figure 59 8 Use a yoke holder to turn the case so the pinion mate gears and thrust washers can be removed Figure 62 Take the case off the splined shaft and remove the side gear spreader Remove the side gears and thrust washers Figure 60 6 Inspect the holes in the case where the shaft was removed The two holes must be round and not oblong NOTE If they are oblong the case is damaged Figure 62 and must be replaced Use the side gear spreader to hold the side gears while the pinion mates and thrust washers are removed If this is too tight the case will not turn 19 Figure 63 NOTE Be sure to keep track of which side each disc and plate stack is removed from either the flange or button side Figure 63 9 Measure each plate and disc from the flange side gear Remember that the plate has the ears and the disc is round Figure 64 Figure 64 10 Write down the thickness of each plate and disc Eight numbers should be written down and then added to determine the total2. 3 Use a ball peen hammer and drift punch to knock the gear off the case being careful not to hit the case Figure 42 Figure 42 4 Ona standard axle first remove the pinion mate shaft lock pin Figure 43 14 X5001 CVSP Figure 43 NOTE This lock pin should be replaced with a new one during the rebuild procedure NOTE The pinion mate shaft should slide out of the hole If it is tight you may have to use a punch to knock it out Look for excessive wear or grooves where the pinion mates ride on the shaft Figure 44 There may be some minor discolora tion on the shaft which is the result of friction and heat This should not prevent the pinion mate shaft from being reused Figure 44 5 Rotate both pinion mate gears so they come to the windows on the case and remove them X5001 CVSP NOTE On the pinion mate gear look for nicks chips or visible damage to the gear teeth Inspect the back gear face for a groove or other visible signs of damage Figure 45 This is where the pinion mate thrust washer rides The surface will be shiny and smooth if there is no damage Check the thrust washers for grooves or damage on both sides of the washer Also look to see if the washer is bent or part of the washer is missing at the spot where the pinion mate shaft passes through the washer Figure 45 If the shaft took out part of the washer during assembly the hole will look distorted and not round If
3. 26 Align the parts using a drift punch to line them up pR 27 Look in both holes to be sure the thrust washers stayed in place NOTE If the washers have moved and the pinion mate shaft is installed a side of the washer will get punched out and it must be replaced 28 Install the pinion mate shaft using a hammer to tap it Figure 75 Figure 75 29 Make sure that the hole in the pinion mate shaft will align with the hole in the differential case 30 Install the pinion mate shaft retaining pin and start a few threads Do not torque until the total torque to rotate has been checked 31 Use the same procedure described earlier to check the total torque to rotate NOTE If the total is within specification torque the pinion mate shaft retaining pin to 8 to 16 ft Ibs or 11 to nm E i f ONEN S RAIN COMP vet pR Differential Case Reassembly Hydra Lok The WJ44 4 axle also may be equipped with the Spicer Hydra Lok differential assembly The Hydra Lok unit itself is not field serviceable Figure 76 However care must be taken when removing the differential case and reinstalling it in the carrier to avoid damaging the plenum Figure 76 1 Carefully remove the Hydra Lok differential assembly from the carrier Figure 77 a Figure 77 2 Remove the bearing from the case using Miller tool adapters 8353 Figure 78 24 X5001 CVSP Figure 78 AXCAUTION Be sure th
4. SERVICE MANUAL Jeep Grand Cherokee WJ 44 4 X5001 CVSP August 2002 fecole Finding 4 Botti May R spice X5001 CVSP TADIE OF Coments sorrera a a E A EE E E E T E EA EEE EA EA 1 Cetine Star CS hoses sca E E T A E E E E E ES 2 15 CeT DE e Dy eren E E E E ns 2 Carrier Inspection and Reassembly essessessessessessessessessessessesseeseeseeseeseeseeseessessessessesseosesstoseoseoseseoseoseoseeseeseeseesees 7 Differential Case Disassembly ss ssssessssssesssssssssssssesssssseessesssoseessesseeseessroseessreseesseesteseesstessesstosestesrtoseessreseeseesseesee 12 Differential Case Reassembly eeoeeoeeoseoseooesossosessssossossossssssossossesesossossosscssssssossossessssssossoses 15 25 SE 1 E E E E A ONTE E A AAT 15 MaLo a E E E A E EAE T E R 16 Hydra LOk sarae n E EE E E E E E E 23 Carrier and Differential Case Reassembly cccscccsscccscccsscccscccscccsscccscccscccssccessccsccesseees 26 31 Jemne ETE S DICES gerrian E E E E E EO 27 Sau ee ee A E ee E A E teneheaaeas 29 Seting Dikerental PN acess space Eo i eea eaa eE ee 29 Checkmig Gear Patetere E Ea Eoee ae ses eE e eadi eater teeter 30 EE E E E E O EA O O O E A A N 31 34 BELEANE E EE AAAA AE OE S A A S A TE A 55 Lubrication SS CEC ANIONS cece cc casera etei a oE E rA ENEE T cade caucus e AEE TEE a a a 54 Hee X5001 CVSP Axle Teardown and Rebuild Getting Started Under no circumstances should individuals attempt to perform axle service and
5. Install the cover plate on the carrier Before installing the cover plate be sure to inspect both mating surfaces for nicks or dings on either part If either part is damaged the cover plate may leak oil leading to premature failure of the ring and pinion It is also important that both surfaces are cleaned with a solvent to remove any oil film remaining on the surfaces If oil is not removed the sealant will not adhere and may cause oil to leak from the cover plate and carrier 5 Apply a thin line of RTV silicone to the carrier Figure 111 Use a continuous line around the carrier surface connecting the end point to the starting point Figure 111 NOTE The Traction Technologies Group recom mends using RTV Silicone gasket maker Spicer part number 38615 ina 70 milliliter tube SP EI i oNEN RAIN come vET pR 6 Lay the cover plate on top of the carrier being careful not to slide the cover against the other surface Figure 112 Figure 112 7 Install the cover bolts and tighten to 28 to 33 ft Ibs Lubrication Option 1 Use this method before installing the axle in the vehicle 1 Measure the correct amount of oil 2 Remove the fill plug in the cover plate and pour the oil into the axle using a funnel Figure 113 Figure 115 3 Install a new fill plug X5001 CVSP Option 2 Use this method if the axle is already installed in the vehicle 1 Remove the fill plug 2 Pour
6. the more the pattern will shift toward the heel Once the gear pattern is set and backlash and preload are within specification the axle shafts and wheel ends can be installed Figure 106 32 X5001 CVSP Figure 106 Axle Reassembly Before installing the axle shafts into the carrier be sure to check for damage to the splines and wheel studs Check the spline for nicks and dings that could prevent the axle shaft from sliding into the side gear Also look for threads on the studs that are bent and could cause the nut to cross thread The studs should be replaced if the studs are bad The shaft must be replaced as well if the spline is bad 1 Slide the axle shaft through the backing plate and into the tube Figure 107 Figure 107 X5001 CVSP 2 Line up the splines of the differential case and the axle shaft and slide the shaft into place Figure 108 Do not force the axle shaft into the side gear This could cause damage to the splines on the axle shaft or in the side gear Figure 108 NOTE Be sure that the correct shaft is in the correct tube An easy trick is to remember that the long axle shaft goes in the left hand tube remember left is long right is short Figure 109 It is important to always use new nuts when putting the assembly together Then torque the nuts to 35 to 55 ft lbs Figure 109 3 Install the rotor assembly on each axle shaft Figure 110 Figure 110 4
7. to 70 ft Ibs Figure 98 ar f rr PFT mt Figure 98 29 E i PIC R oNEN ET pRIV Setting Backlash Backlash is the measurement of movement be tween the pinion and ring gear With this axle backlash must be 004 to 006 To adjust backlash it must be measured first using a dial indicator attached to the cover face of the carrier 24 Align the dial indicator plunger with the ring tooth that is parallel to the cover face to measure backlash Figure 99 Figure 99 NOTE If the measurement is over 006 it is too high 25 To tighten backlash subtract shims from the button side and place them on the flange side NOTE For example the flange shim may be 180 and the button shim 160 with an 008 backlash To achieve 004 backlash take 004 from the button shim making it 156 Then add 004 to the flange shim making it 184 To move the shims follow the same steps used for removing the differential case and installing it 160 180 004 004 156 186 26 Change shims and check backlash again NOTE It should be 004 005 which is within the specification for backlash on the WJ44 4 aluminum axle 30 X5001 CVSP Setting Differential Preload Differential preload is the amount of pressure that we put on the bearing with the cup For this axle an increase of 5 to 13 in lbs over the pinion torque to rotate is required 27 To meas
8. Figure 24 8 Slide the height block 6734 over the threaded rod and position it on top of the bearing Screw the measuring block 6739 on the threaded rod until it is snug Figure 25 Figure 25 NOTE This set up should rotate freely in the pinion bores 9 Zero the scooter gauge to the top of the measuring block Figure 26 Figure 26 ER pic ONEN ET pRIV 10 Place the metal rod D 115 2 through the arbor disk 6927 and place the assembly in the differential bore Put the other disk into the bore and slide the metal rod through the disk Figure 27 Figure 27 NOTE Be sure the arbor disks are flat against the differential backup to ensure an accurate reading 11 Place the bearing caps over the disk and tighten the bolts to no more than half of the original torque specification Figure 28 Figure 28 X5001 CVSP NOTE If the procedure is done correctly the metal bar should slide freely back and forth inside the disk If the bar does not move freely check on the bearing cap to make sure the disks are seated in the bore Retighten the bearing cap bolts 12 Snug the threaded rod assembly NOTE DO NOT tighten the assembly to the point it cannot be turned but so it turns with slight resistance This puts a preload on the pinion bearing for a more accurate reading at the gauge 13 Slide the gauge to the top of the bar and look for the lowest reading This is the first number needed
9. bearing and seals on both sides of the axle R spice X5001 CVSP Carrier Inspection and Reassembly 1 Inspect the housing for signs of stress cracks that are the results of overloading the axle Figure 19 Figure 21 NOTE Spicer recommends replacing the yoke any time the pinion and bearings are replaced Perform a visual inspection inside the housing to check for damage or wear Figure 19 3 Apply liquid graphite to the inner and outer pinion cup bores before installing new bearing cups Figure 22 2 Check the axle housing spring seats and shock brackets for cracks or elongated holes Figure 20 ae Ee Figure 22 Figure 20 4 Measure pinion position using the Miller pinion height gauge To use this tooling first install both pinion cups using installer D 129 for the outer pinion cup and C 4308 for the inner pinion cup Use handle C 4171 If wear is detected DO NOT reuse the housing After cleaning the axle inspect the unit for damage Look for damage in the pinion bores the pinion yoke and the differ ential bores Figure 21 X5001 CVSP 5 To install the pinion height tooling use the threaded rod 6741 Figure 23 Figure 23 6 With the outer pinion adapter threaded onto the rod slide the rod through the outer pinion bearing and cup 7 Turn the carrier and put the inner cone in the cup and slide the threaded rod through the carrier and through the inner bearing Figure 24
10. or maintenance procedures for which they have not been trained or do not have the proper tools and equipment 1 ALWAYS wear safety glasses that meet OSHA requirements when performing maintenance or service Failure to wear safety glasses can result in personal injury and or partial or complete vision loss 2 ALWAYS be careful handling gears or other sharp components so you do not cut your hands 3 ALWAYS be sure to follow torque specifications carefully Failure to do so may lead to prema ture component failure or damage to other vehicle components Introduction Figure 1 Proper care during the teardown and rebuild of the W 44 4 Figure 1 is critical to improved service as well as customer satisfaction In addition failure analysis is an important compo A f oNEN S RAIN COMP ET pRIV This will help determine what parts can be saved and how the axle should be rebuilt Carrier Disassembly 1 Remove the cover bolts and use a rubber mallet to remove the cover plate Figure 2 Figure 2 2 Turn the axle over and drain the oil Figure 3 NOTE During drainage strain the oil to see if it contains metal shavings Figure 3 Be sure to place a bucket under the stand to catch the oil so it can be disposed of properly If the axle is being rebuilt because of a major problem such as gear set breakage or excessive bearing wear a sample of the oil should be sent to a lab for spectral analysis to h
11. stack height NOTE Do not measure the Belleville washer which is the dished plate sitting on the side gear 20 X5001 CVSP 11 Repeat the procedure for the button side gear If all eight plates and discs are measured as a stack it should be nearly equal to the total of the individual measurements Figure 65 NOTE If the stacks are being reused be sure to keep the plates and discs in the same order and reinstall them in the same sequence as they were removed Figure 65 To help identify the various components the plates have ears and can be found in three thicknesses 060 064 and 068 Discs are round and come in one standard thickness 060 Each stack contains four plates and four discs NOTE The Belleville washer is not measured It sits on the side gear with the ears up When the stack is compressed the bellville flattens out to keep constant pressure on the stack X5001 CVSP During rebuilding it is critical that the plates and discs are measured accurately When measuring it is important that the new stack height is not less than the original stack height Spicer offers service kits with the pre measured stack included Figure 66 Be careful not to mix stacks when rebuilding the case Figure 68 13 Place a disc on top of the bellville washer then a plate on the disc until there are four plates and four discs on the side gear Figure 68 When the process is finished a pla
12. the bearing onto the button side of the 12 Attach a dial indicator to the carrier again and hub using a Miller tool C 4340 Figure 94 put the tip of the indicator on thetop edge of the ring gear tooth Figure 93 7 93 13 Set the dial indicator to zero Slide the case to the right so that the root of the ring gear tooth meets with the root of the pinion tooth 14 Repeat this procedure one or two times to be sure the reading is correct 180 for example 28 X5001 CVSP 17 Turn the case over to install the flange side bearing Be sure to use a plug or other type of support on the button side to prevent the case from being damaged when the second bearing is being installed Figure 95 ares Figure 95 18 Place the spreader on the carrier and spread the carrier to no more than 015 Figure 96 Figure 96 If the carrier is spread past this limit the carrier will yield and the axle housing will have to be replaced 19 Fit the bearing spacers in the carrier bores using a light coating of grease 20 Tap the case into the bore using a rubber mallet 21 Remove the spreader Once the differential case is seated the bearing caps may be installed ER pics ONEN ET pRIV 22 Verify that the letters stamped on the bearing cap are stamped on the cover face One will be horizontal while the other will be vertical Figure 97 Figure 97 23 Snug the bearing cap bolts and torque to 55
13. this is the case the thrust washer is damaged and must be replaced If any of these parts look damaged they should be replaced as well All damaged parts must be replaced in sets 6 Take the side gears out of the case and look for nicks chips or other signs of damage to the teeth on the side gears Figure 46 Check the back face of the side gear for a groove or visible damage Figure 46 NOTE This surface will be shiny and smooth if there is no damage Look at the side gear thrust washer for grooves or visible damage If any damage to the side gear or thrust washer is noted they must be replaced NOTE Also be sure to check for damage in the following areas the ring gear mounting surface for nicks and high spots the bearing trunnion for grooves or damage caused by the bearing spinning on the trunnion 7 Surface nicks can be stoned or filed off NOTE If the bearing fell off the trunnion and did not need to be pressed off the differential case must be replaced 8 Check the machined areas where the pinion mate and side gear thrust washers sit Figure 47 Figure 47 SP EI i oNEN RAIN come vet pR Look for grooves or visible damage to these areas If damage is detected the differential case must be replaced 9 Inspect the pinion mate shaft holes Be sure to check both holes making sure they are still round If one or both holes are oblong the case is damaged and must be replaced 10 C
14. Place the slinger on top of the bearing and 19 Slide the collapsible spacer on the pinion place the seal in the bore and use seal driver stem and slide the pinion through the carrier C 3972 A to install the seal Figure 33 Figure 35 Figure 33 Figure 35 18 Tap the driver to install the seal 20 Match up the pinion splines with the end yoke NOTE Tap the driver a few times to be sure the 21 Use the pinion installer C 3718 to pull the end seal is seated in the bore and the sealant flat yoke tight to the pinion Figure 36 tened in the bore Look through the pinion seal hole to see if the garter spring on the seal fell off Figure 34 Installing the seal with a hammer does work but occasionally the shock from hitting the tooling may knock the spring off the seal If a press is available it should be used Figure 36 pe Figure 34 NOTE Do not grease the inner pinion bearing during installation X5001 CVSP 22 Place a pinion nut on the pinion torque the pinion nut to a minimum of 200 ft Ibs Figure 57 Figure 37 NOTE There is no set maximum torque because each spacer collapses differently Once the spacer starts to collapse continue checking for 25 to 35 in Ibs torque to rotate using a 50 in Ib wrench 23 Turn the torque wrench four revolutions taking a reading while the wrench is moving on the fourth turn Figure 38 24 Tighten the pinion nut slowly checking the torque to
15. Remove the bearing caps using an air gun or hand ratchet with the appropriate socket Figure 9 Figure 9 10 Use a pry bar to remove the differential case Figure 10 Figure 10 11 Set the outboard spacers by the proper bearing cap 12 Measure and record both outboard spacers including the case side or gear side location Figure 11 Figure 11 13 Check your pinion torque to rotate This must be done 14 Remove the pinion nut and use the yoke puller to remove the end yoke Figure 12 Inspect the yoke for signs of damage such as a groove that is cut into the end yoke by the pinion seal Deep scratches and nicks are causes to replace the end yoke Figure 13 Figure 12 X5001 CVSP Figure 13 Figure 15 15 After inspecting the end yoke grab the pinion 17 Remove the slinger and outer pinion bearing head and hit the top of the pinion with a soft and set it aside Figure 16 faced mallet to remove the pinion from the carrier Figure 16 Figure 14 16 Pull the bearing off the pinion using Miller tool C 293 Figure 14 Inspect it for signs of damage NOTE If there is no oil leakage from the pinion seal during use there will be no damage now If there was leakage look for a cut in the rubber where the seal ran on the end yoke or check to see if the garter spring on the seal fell off Figure 15 Other leakage could be the result of a seal that was not properly installed and the seal
16. ant on the outside lip did not seal Following this inspection remove the seal and discard it X5001 CVSP 18 Remove the inner pinion cup using a Miller tool C 4307 and handle C 4171 Figure 17 Figure 17 NOTE Be careful not to damage the pinion cup bore when removing the cup Figure 18 Figure 18 ER pic ONEN ET pRIV DO NOT use a punch to pound out the cup This will damage the bore where the cup sits making it impossible to reseat the new cup during installation Eventually poor seating can lead to improper loading on the seal and bearing leading to premature axle failure NOTE If the axle doesn t have too many miles the axle shaft bearings may be reused If the axle has high mileage on it the bearings and seals should be replaced To determine if the seal and bearing should be replaced inspect the following At the oil seal check for E signs of leakage prior to teardown W tears in the rubber at the sealing surface W the garter spring in the proper location and W improper installation that resulted in leakage At the wheel bearing check for MH complaints dealing with wheel noise WE pitting on the rollers caused by particles rolling through the bearing and WE spalling on the rollers caused by excessive load and poor lubrication If there is any doubt whether the seal or bearing can be reused it is best to be safe and replace these components Always replace the
17. e tab on each adapter fits in the plenum windows around the bearing on the flange side 3 Remove the bearing from the button side of the case using the same tooling NOTE To order a new Hydra Lok differential or other Spicer components the bill of material number must be checked This number may be found on a bar code label on the carrier snout behind the pinion flange yoke on a strip tag between the bolts on the cover plate or stamped on the right axle tube when looking at the cover plate Figure 79 Figure 79 R X5001 CVSP spice 4 Press the ring gear onto the case Figure 80 9 Lubricate the outer and inner lip seals on the plenum using the same lube as required for filling the unit Figure 82 Figure 80 5 Start all of the ring gear bolts and then press Figure 82 the ring gear onto the case 10 Install the plenum by rotating it around the Do not use the ring gear bolts hub Figure 83 Press downward to seal the to pull the ring gear onto the case This will plenum against the sealing surfaces on the stretch the bolt threads and the bolts may not case and to prevent damaging the seal hold their required torque 6 Tighten the bolts and torque them to 70 to 90 ft Ibs 7 Drive the bearing onto the button side of the hub using a Miller tool C 4340 Figure 81 Figure 85 Figure 81 8 Turn the case over to install the flange side bearing NOTE Be sure to use a plug or other type of
18. elp determine the root nent of the entire procedure First a thorough failure cause of the failure analysis of the axle and axle components must be completed to determine the cause of failure P El q ONEN S RAIN COMP T RIVE D 3 After the axle is drained remove the axle shaft 5i retainer nuts using a swivel adapter Figure 4 Figure 4 4 Remove the brake drum rotor unit and pull the axle shafts from the assembly Figure 5 Figure 5 NOTE It may be necessary to carefully pry them loose using a pry bar or slide hammer Figure 6 Figure 6 7 8 X5001 CVSP Inspect the seal and bearing then set the shaft aside Check the total torque to rotate using a 50 in Ib torque wrench and a 1 1 8 socket Figure 7 With the nose of the axle pointing up turn the end yoke by hand in a clockwise rotation four or five revolutions Using the torque wrench turn the pinion nut clockwise and take a reading while spinning the end yoke This torque reading will be used only as reference if bearings and cups can be reused Figure 7 Check the backlash using a 001 dial indica tor and a magnetic base with the plunger set on the ring gear tooth Figure 8 The dial indicator should be facing towards the O D of the ring gear Figure 8 Move the ring gear back and forth in a smooth motion Look at the indicator and take a reading Then take three equally spaced readings X5001 CVSP 9
19. he shim thickness The other uses the existing differential outboard spacer Both of these methods will be explained however keep in mind that using the existing shims can save a lot of time and reduces the number of times the differential case is installed and then removed from the carrier The more times the process is repeated the greater the risk for damaging the carrier the case the differential bearings or the gear set NOTE When using dummy bearings the differ ential case must not have any bearings or the ring gear attached 1 Slide the dummy bearing with the deep chamfer towards the case onto the trunnion Figure 89 Figure 89 2 Slide the differential case with the dummy bearing into the carrier The case should slide back and forth 3 Push the case as far to one side as possible 4 Attach a dial indicator to the carrier so that the tip of the indicator is against the flange side of the case Set the dial indicator to zero Figure 90 5 Slide the differential case to the right and take a reading Figure 90 Do this a couple of times to make sure that the same reading 340 for example is obtained NOTE This is called the total travel of the differential case Total travel means that the case did not touch the pinion and is measured from shoulder to shoulder of the differential case in the differential bore Be sure to write down this number for later reference 6 Pull the case from the carr
20. heck for grooves caused by metal shavings or contamination in the oil that got into the gears or under the thrust washers NOTE If any parts in the differential case are damaged or if there is any uncertainty regarding the extent of damage to a component replace the parts or the entire differential case Differential Case Reassembly Standard Case To rebuild the standard differential case be sure to have the following components available Figure 48 E One empty differential case Mi Two side gears Mi Two side gear thrust washers WE Two pinion mate gears WE Two pinion mate thrust washers E One pinion mate shaft E One pinion mate shaft lock pin Figure 48 X5001 CVSP 1 Put the side gears and thrust washers in the differential case Then hold the top gear with one hand while placing one pinion mate gear and thrust washer in the window with the other hand Figure 49 Figure 49 2 Install the other pinion mate gear and thrust washer in the other window directly across from the other gear Figure 50 Figure 50 3 Turn the pinion mate gears until they align with the pinion mate shaft hole R X5001 CVSP spice pR 4 Slide the pinion mate shaft through the thrust Differential Case Reassembly Trac Lok washers and pinion mate gears Figure 51 If the unit has no visible damage check the total torque to rotate before rebuilding the unit The torque to rotate spec for the 44 4 Jeep Trac L
21. ier and remove the dummy bearings 8 To install the ring gear on the case start all of the ring gear bolts 9 Press the ring gear onto the case Figure 91 Figure 91 Do not use the ring gear bolts to pull the ring gear onto the case This will stretch the bolt threads and the bolts may not hold their required torque Zi spice X5001 CVSP 10 Tighten the bolts and torque them to 70 to NOTE This is the root to root reading Write 90 ft Ibs Figure 92 this number under the total travel number With the total travel and the root to root reading the starting differential spacers can be determined The root to root reading is always the flange side differential spacer The remainder is always the button side spacer To calculate this number subtract the root to root travel from the total travel taken earlier Using the previous examples 340 180 160 The flange side spacer is 180 and the button side spacer is 160 With these starting numbers there should be zero backlash and zero differential preload Figure 92 11 Put the dummy bearing back on the case and slide it into the differential bores Keep the flange side of the case to the left Existing Spacers 15 Measure the spacers before installing them in the carrier Write down the numbers for later reference Do not drop the case and ring gear into the carrier because it could damage the ring gear or pinion 16 Drive
22. ok is 320 to 400 ft Ibs Figure 53 Figure 51 5 Align the hole in the pinion mate shaft with the hole in the case and install the lock pin and torque to 8 to 16 foot pounds or 11 to Figure 53 22 nm Figure 52 1 Put the Trac Lok in a vise with the windows of the case facing the jaws of the vise Figure 54 Tighten the vise until it is snug making sure that the side gears are not hitting the jaws Figure 52 6 Spin the side gears to make sure that they spin freely Figure 54 P E i oNEN S RAIN COMP vet DR 2 Put the splined tooling in the gear Figure 55 Figure 55 NOTE You will need a 500 ft Ib torque wrench Put the torque wrench in the splined tooling and pull the torque wrench slowly to exercise the case in one direction After pulling the case five times a reading can be taken 3 Pull the torque wrench slowly looking at the indicator Check the reading a couple of times to be sure it is accurate Figure 56 Figure 56 NOTE Remember that if the assembly was full of metal shavings and contamination so is the differential case If all new parts are installed in the rebuilt axle all new parts should be used when rebuilding the Trac Lok 18 X5001 CVSP To teardown and rebuild the Trac Lok differential case some special tooling will be required Figure 57 This includes E An OTC splined holder W Miller Special Tool Trac Lok tool set and E Drift punch
23. rotate often Figure 38 NOTE It is important that the maximum pinion torque to rotate is not exceeded However a minimum torque to rotate of 25 in Ibs must be met The pinion preload is now set Be sure to write down this number because it will be needed later 13 El f ONEN S RAIN COMP ET pRIV NOTE If the bearings are being reused follow the same process as above except the pinion torque to rotate must be set at 1 to 2 in Ibs over the pinion torque to rotate obtained during teardown The bearings are already broken in so setting a used bearing to a torque meant for a new bearing will cause the old bearing to fail prematurely Differential Case Disassembly 1 Remove the differential bearings using a Miller puller set number C 293 PA and inserts 8353 Figure 39 Figure 39 NOTE Be sure to inspect the bearings for damage that could cause bearing failure Also look at the differential case bearing trun nions for signs of damage Figure 40 Figure 40 If a bearing falls off the trun nion or if visible damage to the case is noted the case must be replaced If a bearing falls off the case it means that the bearing has spun and either the bearing inside diameter is oversize or the trunnion is undersize If a new bearing still slips on the case the trunnion is undersize and the case must be replaced 2 Place the case in a vise to remove the ring gear bolts Figure 41 Figure 41
24. side gear assem bly into the case 18 Hold the assembly with one hand and use the side gear spreader tool to hold the side gears and stacks in place NOTE To use the spreader tooling place the flat disc in the hole where the axle shaft rides Take the disc with the hole in it and put it in the button side gear Slide the threaded shaft through the button side of the case and through the threaded disc until the flat disc is reached Figure 71 If this is tightened too much it will be difficult to turn the differential case to install the pinion mate gears X5001 CVSP Figure 71 19 Put the splined shaft tooling in the vise and set the differential case on it with the flange side down Figure 72 Figure 72 20 Tighten the threaded rod until it is tight and then back off the threaded rod until the case can be turned using the yoke holder 22 X5001 CVSP 21 Put the pinion mate gears in the windows directly across from each other and use the yoke holder to turn the case Figure 73 The pinion mate gears should roll into their pockets Figure 73 22 Look through the pinion mate shaft hole and make sure the pinion mates are aligned with the holes 23 Tighten the threaded rod until the bellville washer is collapsed 24 Take each pinion mate thrust washer and slide it behind the pinion mate Align the holes Figure 74 A Ee Figure 74 25 Loosen the threaded rod and remove the spreader
25. support on the button side to prevent the case from being damaged when the second bearing is installed 25 SP El i oNEN RAIN come vET D l 11 Assemble the new differential bearing using the proper tooling and use a 0015 feeler gauge to check between the bearing and case to be sure that the bearing is properly seated Figure 84 Figure 54 NOTE If the feeler gauge can be inserted the bearing is not properly seated NOTE After completing these steps the differ ential case assembly is ready to place in the carrier Note that the tabs on the plenum are offset and must be installed in the carrier with the oil pick up pointing to the bottom or sump of the carrier Figure 85 Figure 85 12 Attach the spreader to the carrier and spread the carrier a maximum of 015 or 038 mm Figure 86 X5001 CVSP Figure 86 13 Fit the bearing spacers in the carrier bores using a light coating of grease Figure 87 Figure 87 14 Install the differential case assembly with the oil pick up in the proper position Figure 88 Figure 88 Be extremely careful not to bend the ears on the plenum or the oil will not flow properly to the pump and the bearing caps cannot be installed correctly 26 X5001 CVSP Carrier and Differential Case Reassembly To install the differential case into the carrier two different methods may be used One method uses the dummy differential bearing to figure t
26. te should be on the top of the stack Figure 66 14 Place one clip over each side of the disc and plate stack to hold the plates together Figure 12 To put the first disc and plate stack together 69 Repeat this procedure for the other side use a side gear with the teeth facing down Put gear the Belleville washer over the hub of the side gear with the convex side contacting the side gear the ears facing up Figure 67 Figure 69 15 Take the differential case and put it on the Figure 67 table with the flange side facing up A friction modifier must be placed on all plates and discs at the time of the assembly Spicer part number 43161 is recom mended 21 ER pic ONEN ET pRIV 16 Slide the side gear and disc and plate stack assembly through the window of the case making sure that the clips and ears slide in the grooves in the case Figure 70 This is the only way the side gear assembly can be put together Figure 70 The flange side must be as sembled first or it will be impossible to assemble the case correctly It is also important that the disc and plate stack and the side gear stay together during assembly If the top disc sepa rates from the spline on the side gear further assembly could damage the disc by bending the teeth and the disc must be replaced 17 Hold the flange side gear and stack assembly in place and turn the case over so the button is facing up Install the other
27. the correct amount of oil into the axle using a hose Figure 114 Figure 114 NOTE If the correct amount has been used oil should be at the bottom of the fill hole 3 Install a new fill plug NOTE The type and amount of lubricant re quired depends upon the type of the axle See specifications below Lube Specs Standard differential case Use 80W90 thermal stable lube For a standard differential use 76 ounces of lubricant for the best protection Trac Lok differential Use 80W90 thermal stable lube For this axle use 72 ounces of lubricant plus four ounces of friction modifier This is Dana part number 43161 The total amount of lubricant used should equal 76 ounces Hydra Lok differential Use a synthetic lubricant Again use 72 ounces of lube plus four ounces of friction modifier which is Spicer part number 43161 SPICER Rang Dana Corporation Commercial Vehicle Service Parts P O Box 321 Toledo Ohio 43697 0321 1 800 SAY DANA 729 3262 www dana com www2 dana com expert Dana Corporation Commercial Vehicle Service Parts Canada 5095 South Service Road Beamsville Ontario LOR 1BO Tech Service 905 563 4991 X5001 CVSP Copyright Dana Corporation 2002 8 02 All rights reserved Printed in U S A Dana Corporation Commercial Vehicle Service Parts International 10800 NW 103rd Street Suite 11 Miami Florida 33178 305 499 5100
28. to determine pinion position NOTE Check this reading a few times to be sure it is accurate When the number is confirmed and written down the setup can be disassembled X5001 CVSP NOTE All Dana gear sets are marked with a set number and an etch number The etch number may look something like plus 1 minus 3 or O for example Figure 29 This number tells what is required to build the axle at zero the ideal running position for the gear If for example the etch number is plus 2 it means to subtract 002 If the pinion height gauge measures 040 for example subtract 002 and install a 038 shim Figure 29 14 Place the correct pinion position shim on the pinion stem Figure 30 Figure 30 15 Slide the inner pinion bearing cone on the pinion stem and press the bearing tight to the shim using the bearing installer 6448 Figure 51 Figure 51 NOTE This can be done by tapping the installer with a steel hammer until the bearing is seated on the pinion If a press is available use it to seat the bearing To be sure the bearing is seated properly try to turn the position shim Also try to slide a 0015 shim between the bearing and the shim If the shim does not fit the bearing is properly seated 16 Rotate the axle unit so that the pinion nose is facing up and put the outer pinion bearing in the cup Figure 32 Do not put grease on the bearing Figure 32 R spice X5001 CVSP 17
29. ure not to use too much paint or the gears will show a false reading of interference 2 Apply a load to the ring gear while the pinion is turning Figure 103 The ring gear must spin in both directions to get patterns on the coast and drive sides of the gear 31 Figure 103 3 Look for a centered toe pattern on both the drive and the coast sides Figure 104 pies Ps Figure 104 NOTE It is very important that the gear pattern on the drive side of the ring gear is in the correct position There are a few terms that must be understood to determine if the gear pattern is correct OE a LENGTHWISE Figure 105 These terms include the following Figure 105 WE Root is the inside radius of the tooth E Top Land refers to the outside edge of the tooth E E Toe is the bottom of the ring gear I D Heel is the top of the ring gear tooth closest to the carrier O D The Central portion is the middle of the tooth Flank In means the gear pattern is close to the root of the tooth and the picture starts at the toe Flank Out means the gear pattern is close to the top land of the gear tooth The picture will be central to heel Backlash is the amount of movement between the ring gear and the pinion and the amount of backlash can move the gear pattern from toe to heel and heel to toe With a tight backlash the pattern will shift toward the toe With a looser backlash
30. ure preload use a 50 or 100 in Ib torque wrench With the end yoke up turn the end yoke in one direction about four or five revolutions This will help seat all of the bearings in the cups 28 Turn the wrench the same direction that the yoke was turned to seat the bearings Be sure the turn is steady and not too fast or a false reading may occur Take a reading while the wrench is moving Figure 100 Figure 100 NOTE If the pinion torque to rotate is 30 in Ibs and the total torque to rotate is 34 in Ibs there is not enough preload on the differential bearings 29 To adjust the preload disassemble the differ ential case as described previously and add a slight thickness to the outboard spacers NOTE The current flange side is 184 and the button side is 156 By adding 002 to each shim they will change to 186 and 158 respec tively This small adjustment should not effect backlash 184 156 002 002 186 158 X5001 CVSP 30 Reassemble the differential case to the carrier as described earlier and take another backlash and total torque to rotate reading The backlash and the preload should both be within specification Checking Gear Pattern Checking the gear pattern will help determine if the pinion position and backlash are correct Figure 101 Figure 10 1 Coat the entire ring gear with a thin coat of gear paint Figure 102 Figure 102 NOTE Be s
Download Pdf Manuals
Related Search