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1. 61 Drive Pinion A IMPORTANT Torque to 840 Ibs ft 1 140 Nem then continue tightening nut to align slot with the nearest hole in pinion shank Install roll pin 1 Roll pin 2 Slotted nut 62 Wheel Differential Assembly Wheel Differential Parts Exploded View Flange Half LH 4 jenuarayig laauM 9 STD ds 1 Ring gear 11 Nut 2 Capscrew 12 Diff brg adjuster plain half 3 Flat washer 13 Bearing cup plain half 4 Diff carrier bearing caps 14 Bearing cone plain half 5 Cotter pin 15 Diff case RH plain half 6 Diff case LH flange half 16 Side gear thrust washer 7 Bearing cone flange half 17 Side gear 8 Bearing cup flange half 18 Diff spider 9 Diff brg adjuster flange half 19 Side pinion 10 Bolt 20 Side pinion thrust 63 Wheel Differential Assembly Disassemble Overhaul and Assemble Wheel Differential Forward and Rear Axles Disassemble Wheel Differential 4 Lift out spider side pinions and thrust washers A IMPORTANT During following procedure place differential assembly on malleable surface to prevent damage when ring gear falls off its mounting position 1 Remove nuts and bolts fastening ring gear to differ ential cases allowing gear to fall free If gear does not fall tap outer diameter with soft mallet to loosen 5 Remove remaining side gear and thrust washer finan 6
2. N EE rd 7 Mn kow oo aas ED El les D i lt i O T 3 D i 5 4 1 Input torque 4 Rear axle torque is transmitted from the output shaft side 2 Lockout engaged gear through the output shaft inter axle driveline drive pin 3 Forward axle torque is transmitted from the helical side ion ring gear wheel differential and axle shafts gear through the pinion helical gear drive pinion ring gear 5 Input torque power flow from the vehicle driveline is wheel differential and axle shafts transmitted directly to the helical side gear and the output shaft A positive drive is provided to both axles for maximum traction under adverse road conditions 99 Theory of Operation Operate Wheel Differential Assembly The Spicer wheel differential lock is driver controlled and oper ated 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 oper ation 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 pref
3. 126917 1 Interchangeability of Parts A cross reference chart of OLD axle housing to NEW axle housings with welded on covers will be published in a sepa rate bulletin The bolt on D Housing covers will remain avail able for service Inter Axle Speed Sensor Parts Exploded View 1 Axle shaft 2 Speed sensor 3 Differential bearing adjuster 4 Plated connector 5 ABS Harness connector 81 Disassemble Inter Axle Speed Sensor 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 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 require 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 82 Overhaul Inter Axle Speed Sensor Note If plated connector was damaged during axle disass
4. c0000 85 Remove and Overhaul Wheel End Seal 86 Wheel Adjustment Systems Adjust Wheel Bearing ee ee ee ee AR Re 87 Wheel End Verify Wheel End play Procedure ee esse 89 Lubricate Wheel End Ge RR Ge ER Ge Re 90 Wheel Ends Without Oil Fill Hole esse se ee ee 91 Lubrication General Lubrication Information ees see ee 92 Lube Change Intervals ees see ee ee ee ee ee ee 93 Change Lube ees es ee ee ek ee Ge Ge ER AR Re Ak AE Ee Be AR AE 94 SLANADIPES Este eis DEE ER Bi ee eg ees 95 Towing Proper Vehicle TOWING ee ee ee ee ee Re Re Re 97 Theory of Operation Power Divider Operation Power Flow and Torque Distribution 98 Operate Wheel Differential Assembly esse ees 100 Wheel Differential LOCK ee ee ee RR RR eeen 101 Parts Identification Power Divider Parts Exploded View 0008 103 Front Drive Axle Parts Exploded View 000 104 Rear Drive Axle Parts Exploded View 00 105 Inter Axle Speed Sensor Parts Exploded View 106 Housing and Output Shaft Assembly Parts Exploded View ee ee ee ee Ge Re Ge 107 Torgue Chart Fastener Torque Specifications esse ee se ees 108 General Information Introduction D Dana presents this publication to aid in maintenance and The suffix letter P in the model number indicates a lube D overhaul of Spicer single reduction drive
5. 77 Housing and Output Shaft Assembly Measure and Adjust Note Use bearing cup driver to insure seating of snap ring after installation with snap ring pliers See illustration for steps 1 4 1 2 3 4 Assemble cover assembly to axle housing Position dial indicator at yoke end of output shaft Push in on output shaft and zero the dial indicator Using a pry bar move output shaft axially and mea sure record end play 78 Correct end play for a new assembly is 001 to 015 The maximum end play for a used assembly is no more than 015 If end play is incorrect contact Dana Install oil seal Follow seal replacement procedures on page 72 of this manual Install yoke Install yoke nut One of the following options may be utilized a Install a new nut with the pre applied thread adhesive compound Tighten the nut to the specified torque 680 832 Ibs ft 920 1130 Nem If a new nut with pre applied thread adhesive compound is unavailable apply Loctite 277 or 271 available in 5 ml tube P N 129293 to the nut along two threads for at least two flats 120 of the nut midway through the thickness See illustration Tighten the nut to the specified torque 680 832 Ibs ft 920 1130 Nem Replace Seal Dana strongly recommends using seal drivers when installing new seals Use the proper driver to make sure that the seal is square and installed to the proper depth A CAUT
6. A IMPORTANT If you can t get the correct torque on yoke nut try torquing the nut with the truck wheels on the ground and with the axle shafts installed I Oo 2 2 z i 3 a de 1 _ ma 13 Install axle shafts and axle stud nuts If used also install lock washers and taper dowels 14 Connect inter axle driveline Make sure driveline is properly phased Lubricate U joints 15 Add axle lubricant Fill to bottom of filler hole 1 Apply silicon gasket in this pattern A IMPORTANT 2 Stud locations When axle has been disassembled or housing axle shafts or wheel equipment replaced check axle assembly for 12 Install yoke nut using one of the following options proper differential actions before operating vehicle Wheels must rotate freely and independently 11 Install output yoke a Install a new nut with the pre applied thread adhesive compound Tighten the nut to the 16 Road test vehicle to bring axle lubricant up to tem specified torque 680 832 Ibs ft 920 1 130 perature Recheck joints drain and fill plugs for leak Nem age Retighten as necessary b Ifa new nut with pre applied thread adhesive compound is unavailable apply Loctite 277 or 271 available in 5 ml tube P N 129293 to the nut along two threads for at least two flats 120 of the nut midway through the thickness Tighten the nut to the specified torque 680 832 lbs ft 530 1 130 Nem
7. Pilot plate 10 Hex head capscrew with flange 3 O ring 11 O ring 4 0 ring 12 Push rod 5 Snap ring 13 Compression spring 6 Piston 14 Shift fork 7 O ring 15 Snap ring 8 Snap ring 13 Differential Lockout Remove Lockout External Type Lockout 1 With axle installed in vehicle place differential lock selector valve in the disengaged or unlocked posi tion 2 Disconnect differential lockout air line 3 Remove capscrews 4 Remove shift cylinder body or cast iron cover o ring and piston A IMPORTANT Do not remove push rod Removal of push rod will result in shift fork and compression spring falling into power divider unit If this occurs disassembly of the power divider assembly will be necessary 5 Remove shoulder washer in cylindrical design lock outs Cast iron cover lockout designs do not use a shoulder washer Note Cylindrical design lockout and cast iron cover lockout are interchangeable only as complete assemblies Integral Type Lockout 1 With axle installed in vehicle place differential lock selector valve in the disengaged or unlocked posi tion 2 Disconnect differential lockout air line 3 Remove piston cover and o ring 4 Remove piston and o ring assembly with pliers Note To remove shift fork and push rod parts the power divider must be removed See power divider section Install Lockout External Type Lockout 1 Assemble o rings onto piston
8. Wheel Differential Assembly Wheel Differential Parts Exploded View 0 Disassemble Overhaul and Assemble Wheel Differential Forward and Rear Axles 5 Overhaul and Assemble Wheel Differential Measure and Adjust Carrier Assembly 000000e Change Backlash Setting ee ee se ee ee ee se ee ee Adjust Tooth Contact Pattern Adjust Ring and Pinion Tooth contact Pattern Adjust Pinion Position ee ee ee ke Re Re ER Wheel Differential Lock Wheel Differential Lock Parts Exploded View Install and Adjust Wheel Differential Lock Housing and Output Shaft Assembly Remove Output Shaft Assembly ou eek ee Housing and Output Shaft Assembly Parts Exploded VieW ceceessseesseeseeeesseeeees Overhaul and Assemble Output Shaft Assembly Measure and Adjust ee ee ee ee AR RA RE Seals Replace Seall di ese es AE ER ER EE se ese Service Kit 217414 esse ee se se ek ee Ge ee ek ee ee IASS Inter Axle Speed Sensor Parts Exploded View Disassemble Inter Axle Speed Sensor 0c0ee Install Inter Axle Speed Sensor ee ee ee ee 74 75 78 79 80 D o 3 i gt O o a 3 Fi 7c Table of Contents Housing Breather Install New Axle Housing Breather Metaland Plastic amp iss EE EER Ri geeet 84 Wheel End Seal Wheel End Seal Parts Exploded View
9. 11 Sump screen 12 Seal manifold feed tube 13 Output side gear bearing cup 14 Output side gear bearing cone 15 Pump locking Pin 16 Output side gear 17 Pump 17A Old style pump 17B Output side gear bearing cup 18 Snapping ring 19 Inter axle differnential 20 Helical side gear 21 Sliding clutch 22 Push rod spring 23 Shift fork assembly 24 Input shaft 25 Input shaft oil retainer 26 Input shaft bearing cone 27 Power divider cover integral 28 Lube trough 29 Capscrew 30 Shift fork 31 Power divider cover Old style 32 Push rod 33 Input bearing cup 34 Input cage shim 35 Input cage V ring 36 Input cage 37 Capscrew 38 Oil seal 39 Input yoke 40 Input nut 15 5 o 3 a 3 Power Divider Remove Power Divider Assemblies built BEFORE 11 02 98 Power Divider Interchangeability D344 404 405 454 Models Only Note Due to the 11 02 98 redesign of the power divider inte gral air lockout and lube trough the ability to inter change parts will vary by build e Pre 11 02 98 carriers cannot be rebuilt with current design power divider unit s parts that have the inte gral air lockout design and lube trough e 11 02 98 current models can be rebuilt using pre 11 02 98 power divider parts For more information refer to Spicer Bulletin ABIB 9901 The power divider can be replace
10. Apply silicone grease to o ring 2 Install piston and o ring assembly into cylinder body or cast iron cover 3 Attach shift cylinder body or cast iron cover to power divider while aligning piston with push rod Make sure shoulder washer or gasket is in place 4 For stamped steel style lockouts attach mounting bracket to cylinder body and secure capscrews 5 Tighten capscrews to 28 35 lbs ft 38 47 Nem 6 Connect differential lockout air line 7 Cycle the lockout unit to insure there are no leaks and system shifts freely Integral Type Lockout 1 Assemble o rings onto piston and piston cover Apply silicone grease to o rings 2 Gently push piston and o ring assembly into lockout cylinder recess Make sure piston is pushed all the way in 3 Install piston cover and o ring assembly Start by hand tightening clockwise A CAUTION Do not to strip threads or use excessive force damage to part may occur 4 Tighten piston cover to 25 35 Ibs ft 35 47 Nem 5 Connect differential lockout air line 6 Cycle the lockout unit to make sure there are no leaks and the system shifts freely Power Divider Power Divider Parts Exploded View 1 Output shaft nut 2 Output yoke 3 Output seal 4 Output shaft bearing snap ring 5 Outer bearing cup 6 Outer bearing cone 7 Inner bearing cone 8 Inner bearing cup 9 Output shaft 10 Seal manifold assembly
11. Failure to follow indicated procedures may cause component damage or malfunction IMPORTANT Highly recommended procedures for proper service of this unit 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 General Information General Information oo ccesescsstecsesesesesetseeeseeseees i IntrOAUGHON adaa EE EE EE ee ee ela 1 Model Identification 00 ee ee ee ee ee Ge Re Ge Re Ge Re Ge ek 2 Ring Gear and Pinion ou ee ee ee ek ee ee ee 3 Inspection Failure AnalysiS ee ee n Re Ge Re Ge Re Ge A ek Ge Re Ge 4 Prepare the Parts for Inspection ee se se ee ee 5 INSPOCUOMN ER ER Ee Pe dati Ge ee ee se eg 6 Check Input Shaft End play Forward Axle 7 Remove Differential Carrier Differential Carrier Assembly Parts cccceceeeee 8 Remove Differential Carrier Forward and Rear 9 Install Differential Carrier Install Differential Carrier Forward and Rear 10 Differential Lockout Inter Axle Lockout Types snenie 11 REMOVE LOCKOUL e i n Re Re Ge Re Ge 14 Power Divider Power Divider Parts Exploded View cceee 15 Remove Power Divider eie ee ee ee ee ee ee ee ee ee 16 Disassemble Assemble and Overhaul the Power Divider oniiir a Met nnn 17 Remove Lube
12. Install output side gear bearing cup if removed reusing the IAD assembly install in the same direc Press bearing cup in carrier Use a press and an tion as removed appropriate sleeve Make certain bearing cup is evenly and firmly seated If a press is not available use a Sleeve or a bearing driver tool and a hammer to install the cup Oo Note For lube pump models see page 30 er eie O rings 6 Out of the vehicle on a bench install lockout slid bearing cup ing clutch onto the input shaft 3 Lubricate o rings 33 y o 3 a 3 7 8 34 9 Power Divider Install thrust washer 10 Install shift fork compression spring and shift rod A CAUTION During installation of power divider components a part may fall from the carrier Use caution to prevent injury or damage 11 Install plastic trough in power divider cover 12 Install power divider cover to carrier Use Spicer approved RTV compound on the carrier mating sur face Torque capscrews to 114 140 Ibs ft 155 190 Nem Note Gasket compound will harden in 20 minutes Install power divider quickly as possible to avoid future leaks 13 Install input cage shim and input cage assembly 14 Install input cage capscrews and tighten until snug 15 Measure and adjust input shaft end play see page 40 16 Torque input cage capscrews to 114 140 Ibs ft 155 190 Nem 17 Install NEW
13. Lubrication General Lubrication Information The ability of a drive axle to deliver quiet trouble free opera tion over a period of years is largely dependent upon the use of good quality gear lubrication in the correct quantity The most satisfactory results can be obtained by following the directions contained in this manual The following lubrication instructions represent the most cur rent recommendations from Dana Approved Lubricants General Gear lubrications acceptable under military specifi cation MILSPEC MIL L 2105D Lubricating Oils Gear Mul tipurpose are approved for use in Spicer Drive Axles The MIL L 2105D specification defines performance and viscosity requirements for multigrade oils It supersedes both MIL L 2105B MIL L 2105C and cold weather specification MIL L 10324A This specification applies to both petroleum based and synthetic based gear lubricants if they appear on the most current Qualified Products List QPL 2105 for MIL L 2105D Note The use of separate oil additives and or friction modifi ers are not approved in Spicer Drive Axles Synthetic based Synthetic based gear lubricants exhibit superior thermal and oxidation stability and generally degrade at a lower rate when compared to petroleum based lubricants The performance characteristics of these lubri cants include extended change intervals improved fuel econ omy better extreme temperature operation reduced wear and c
14. 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 13 When adjustment is complete torque fasteners to 28 35 Ibs ft 38 47 Nem 14 Install selector switch in cylinder cover Torque switch to 10 12 Ibs ft 14 16 Nem Wheel Differential Lock 15 Check selector switch operation Check switch elec Install and Adjust Ring Gear Thrust Bolt trically with an ohmmeter or continuity tester Switch should close show continuity when clutches are 1 Thread thrust screw into the carrier until firm contact engaged and should open no continuity when with the back face of the ring gear is made clutches are disengaged 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 Ibs ft 203 258 Nem 3 Recheck to assure minimum clearance during full rotation of ring gear 17 1 i CD 17 o9 m i i xr 1 D head carrier or front carrier 2 Thrust bolt 3 Thrust bolt jam nut 1 Piston engagement bolt 2 Capscrew 3 Switch 4 Washer 5 O ring 6 Piston 7 Setscrew 8 Piston driver 9 Pushrod 10 Clutch fork 11 Spring 12 Sliding cl
15. Verify end play see page 81 87 gt D ae a gt SS jn 2 3 D 5 Wheel Adjustment Systems Three piece Tang type Lock Washer System GO 2 3 1 Inner nut P N 11249 2 Tang type lock washer P N 11245 123 thick 3 Outer nut P N 11249 a Install the Tang type lock washer on the spindle A IMPORTANT Never tighten the inner nut for alignment This can preload the bearing and cause premature failure b Install the outer nut on the spindle and tighten to 250 Ibs ft 339 Nem c Verify end play see page 81 d After verifying end play secure wheel nuts by bending one of the locking washer tangs over the outer wheel nut and another tang over the inner wheel nut e Goto step 12 88 Four piece Tang Dowel type Lock Washer System 1 Inner nut P N 119882 2 Dowel pin 3 Dowel type lock washer P N 119883 4 Tang type lock washer P N 129132 0478 thick 5 Outer nut P N 119881 a Install the Dowel type lock washer on the spin dle 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 A IMPORTANT Never tighten the inner nut for alignment This can preload the bearing and cause premature failure b Install the Tang type lock washer on the spindle c Install the outer nut on the spindle and tighten to 250 Ibs ft 339 Nem d Verify end play
16. ure recor play Adjustment Adjustment Correct end play for a new assembly is 003 to 007 The Correct end play for a new assembly is 001 to 015 The maximum end play for a used assembly is no more than maximum end play for a used assembly is no more than 014 If end play is incorrect determine shim pack changes 015 If end play is incorrect contact Dana as follows Add shims to increase end play Desired end play New Parts 0 003 to 0 007 Measured end play Step 3 0 001 0 001 Add shims to provide desired end play 0 002 to 0 006 Remove shim to decreased end play Measured end play Step 3 0 015 0 015 Desired end play New Parts 0 003 to 0 007 Remove shims to provide desired end play 0 012 to 0 008 Remove Differential Carrier Forward and Rear Differential Carrier Assembly Parts a SS 0 7 pw j sw 1 Garrier fasteners 2 Carrier assembly 3 Forward axle assembly 4 Inter axle differential lockout 5 Rear axle assembly Remove Differential Carrier Forward and Rear Remove Differential Carrier Forward and Rear Note The removal of the forward carrier does not require dis Note Hand tighten the bolt over torquing may cause damage connecting of the inter axle driveline and removal of the to the shift unit To facilitate hand tightening coat bolt output shaft yoke assembly as most other Spicer tan threads with axle lube de
17. 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 Ibs ft 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 that the nuts are prop erly tightened 8 Back off the inner nut one full turn Rotate the wheel hub 9 Retighten the inner nut to 50 Ibs ft 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 0 005 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 ees 1 Inner nut P N 119882 2 Dowel pin 3 Dowel type lock washer P N 119883 4 Outer nut P N 119881 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 A IMPORTANT Never tighten the inner nut for alignment This can preload the bearing and cause premature failure b Install the outer nut on the spindle and tighten to 350 lbs ft 475 Nem c
18. vent injury or damage 1 ol N BE EO Mm Disconnect the main driveline Disconnect the lockout air line Remove input yoke Remove input seal Position a drain pan under the power divider unit Remove PDU capscrews Remove power divider cover 24 8 9 Remove shift fork compression spring and shift rod Power Divider 11 Remove helical side gear and snap ring Note Remove lube pump if you have one See page 30 5 Inspect output side gear o rings for nicks and cuts Replace if necessary v i 1 1 1 Press 2 Bearing 3 Oil retainer 4 Input shaft 16 Install new bearing cup 17 Remove input shaft bearing cone and oil retainer if necessary 18 Press new oil retainer on input shaft 14 Remove the output side gear A CAUTION It is not recommended to reuse the oil retainer due to possi ble damage that may occur while removing the input shaft bearing cone While pressing on new oil retainer make sure not to over press and or press with the retainer at an angle If the retainer is bent or distorted it may rub on the input cage or not seal properly to the v ring 25 Power Divider 19 Press input bearing cone on input shaft 21 Press bearing cup in input bearing cover 22 Install new oil v ring on input bearing cage cover 2 3 CON KJ An Y 1 Bearing cup press 2 V ring 5 CES 23 If bushing removal is needed th
19. For non pump manifold installation it is important to line up the oil inlet path hole in the manifold with the oil path opening in the carrier manifold casting a 2 1 Manifold Oil Inlet Hole y o 3 a 3 1 Barbed Nipple 2 Install the hose clamp on the hose push the hose onto the barbed fitting and slide the clamp over the barbed nipple 3 Route the suction end of the hose through the holes in the carrier casting to the bottom of the carrier 4 Fully press the manifold assembly into position Note Use care when pressing the manifold assembly to avoid damaging the seals and barbed nipple Do not over press plastic 43 Power Divider Hose Filter Assembly 1 Look to see that the hose guide collar is installed and 3 not damaged If damaged or not present replace with new 2 Now with the collar installed push the hose through the back side of the collar and install the filter to the end of the hose 4 44 Next push the filter and hose down into the collar so that the filter is fully seated Because of the increased diameter of the hose after the filter is installed the hose should fit snugly in the collar Fully seated position Know hose should be showing and filter will contact the collar Power Divider Install Power Divider to Carrier Assembly Assemblies built AFTER 11 02 98 Out of Vehicle Non pump Models Note Parts inspectio
20. above 26 C and above 85W 140 10 F and above 12 C and above Available in the Spicer family of synthetic gear lubricants Lubrication Lube Change Intervals This product combines the latest manufacturing and part Severe Service Lubrication Change Intervals Severe ser washing technology When filled with a Spicer approved vice applications are those where the vehicle consistently synthetic lubricant at the factory the initial drain is operates at or near its maximum GCW or GVW ratings dusty not required or wet environments or consistent operation on grades greater than 8 For these applications the ON OFF HIGH Change the lubricant within the first 5 000 miles of opera WAY portion of the chart should be used Typical applications tion when not using a Spicer approved synthetic lubricant are construction logging mining and refuse removal in either a new axle or after a carrier head replacement Base subsequent lubricant changes on a combination of the following chart and user assessment of the application and operating environment Note Clean metallic particles from the magnetic filler plug and drain plugs Clean or replace the breather yearly to avoid lube contamination due to water ingestion Synthetic or Lubricant SAE Change Interval for Line Haul Change Interval for Voca Mineral tional Synthetic SHAES 256 SAE 75W 90 500 000 miles 800 000 Km or 120 000 mile
21. axles pump is standard Pump models are equipped with a gerotor 5 i l pump designed to provide additional lubrication to the inter Q Instructions contained cover the models listed below Their axle differential and related parts 3 design is common with differences in load capacity Capacity variations are achieved by combining basic differential carrier nee assemblies with different axle housings axle shafts and wheel Model Listing equipment The following models are included in this publication FORWARD AXLE REAR AXLE FORWARD AXLE REAR AXLE LOAD CAPACITY DS344 RS344 34 000 Ibs DA344 RA344 DS404 P RS404 DSP41 RSP41 40 000 Ibs DA404 P RA404 DSH40 RSH40 DD404 P RD404 DDH40 RDH40 DS405 P RS405 DSH44 RSH44 DS405 P RA405 DDH44 RDH44 DD405 P RD405 DST40 P RST40 DSP40 RSP40 DST41 P RSDT41 DDT41 P DS454 P RS454 DD454 P RD454 45 000 Ibs DA454 P RA454 P Model Information DS 404 P DSH 40 P Gearing L Lube Pump j eed Lube Pump Forward Tandem Axle P Standard D Tandem Forward Axle Rear Tandem Axle P Optional with Inter Axle Differential Capacity x 1000 Ibs R Tandem Rear Axle Example 40 40 000 Ibs Single Reduction Design Level Dual Range F Gearing H High Performance 40 Planetary Double Reduction ea nt Me S Single Reduction T Torsionally Tuned Single Reduction with Wheel Differential Lock xample MOE AD S D Driver Controlled Differential Lock P Premium Single R
22. dif ferential is unlocked and operates normally Bure po UI El Pe ao 9 Differential Lock Engaged 1 Spring is compressed 2 Shift fork 3 Push rod 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 102 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 push rod actuator moves away from the switch allows the switch to close and send 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 compression spring also moves the push rod actuator to contact the switch The switch is opened and turns off the cab mounted indicator light or the audible signal TZ a va joes EI Differential Lock Disengaged 1 Spring is decompressed 2 Shift fork 3 Push rod 4 Selector switch 5 Piston 6 Shift cylinder 7 Air pressure applied disengages clutches 8 Fixed clutch
23. drive wheels and possible lubrication damage 1 Engage the wheel differential lock indicator light is on move vehicle to verify engagement Shift transmission into neutral With vehicle stationary release the air pressure on the wheel differential lock shift system and apply the parking brake Disconnect the air supply and fitting at the shift cyl inder Install the shipping capscrew 128642 250 X 18 X 1 5 NPSM screw GM models require part number 128274 M12 X 1 5 X 38mm screw Tighten cap screw to manually engage the wheel differential lock until the indicator light is on and the differential lock is completely engaged Remove the axle shafts Install temporary cover on hub to prevent contami nation entering and also to prevent the loss of lubri cant 97 Theory of Operation Power Divider Operation Power Flow and Torque Distribution In operation the power divider accepts torque from the vehi cle driveline and distributes it equally to the two axles This assembly is of the two gear design consisting of an input shaft inter axle differential output shaft and two constant mesh helical gears With Lockout Engaged Inter Axle Differential is Operating SEE m7 1 Input torque 2 Lockout disengaged 3 Forward axle torque is transmitted from the helical side gear through the pinion helical gear drive pinion ring gear wheel differential and axle shaf
24. eal ke cones from case halves using suit 7 Remove bearing cone from plain case half in two steps 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 capscrews and lift off plain differential case half b 1 Punch marks 3 Lift out side gear and thrust washer GAAN dee 8 Remove bearing cone from flanged case half using suitable puller 64 Wheel Differential Assembly Overhaul and Assemble Wheel Differential A IMPORTANT To prevent bearing damage use suitable sleeve that only 4 Lubricate all differential parts 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 5 Assemble side pinion and thrust washers on spider Place this assembly in flanged differential case Rotate gears and check for proper mesh 1 Press new flange half bearing cones on differential case halves pey CD i a mel CD CD gt 2 6 Place side gear and thrust washer on side pinions Ca SS QS S BAR RIP Be RD ORAL 2 Press new plain half bearing cones on differential case halves 7 Align punch marks and install plain case half Install capscrews and tighten to 114 140 Ibs ft 155 190 Nem Check differential
25. input seal see page 72 18 Reinstall input yoke U0 i 1 z5 1 35 Power Divider Disassemble Assemble and Overhaul Power Divider Assemblies built AFTER 11 02 98 Out of Vehicle 8 Remove shift fork compression spring and shift rod The power divider cover comes off as a unit followed by the input shaft and then the helical side gear S ree le aie dale oo se GUY oth in or out of the chassis and with the differential carrier VM assembled to the axle housing S A CAUTION During removal of power divider cover the inter axle differ ential IAD input shaft assembly or IAD shift system parts may fall from the carrier if not careful Use caution to pre vent injury or damage 9 Remove input shaft and helical thrust washer from 1 Disconnect the main driveline shocarier Disconnect the lockout air line Remove input yoke Remove input seal Position a drain pan under the power divider unit Remove PDU capscrews noo eS oO NS Remove power divider cover 36 Power Divider 11 Remove the IAD assembly from the output side gear 12 Remove the output side gear Note Remove lube pump if you have one 13 Inspect output side gear o rings for nicks and cuts Replace if necessary 14 Install new bearing cup 15 Remove input shaft bearing cone and oil retainer if necessary J aly N 1 Press 2 Bearing 3 Oil retainer 4 Input sh
26. of the adjuster so that the terminals are nearest the carrier mounting surface 4 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 5 Apply Loctite to the four mounting screws Install the screws and tighten in a star pattern to maintain sensor alignment Torque to 28 32 lbs in 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 6 Attach the two round terminals to sensor Either wire can connect to either sensor blade Make sure that terminals are not bridged and that connectors are not touching Torque to 10 15 Ibs in 1 1 1 7 Nem 7 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 8 Check wire routing Make sure wire is seated in the cast in channel and 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 mount ing surface there is less concern for pinching of the shorter 4 inch connector wir
27. pinion seal scale wrap flexible wire around the bearing cage 42 Ibs in 2 0 4 7 Nem attach the scale and pull Preload is correct when Forward Axles Rear Axles torque required to rotate the pinion bearing cage is from 5 13 Ibs This specification is translated into Spring Scale 5 13 Ibs 2 5 6 0 kgs lbs in readings in the previous chart Reading Press Loads 17 19 Tons 14 15 Tons CAUTION 15 4 17 2 12 7 13 6 Metric Tons Metric Tons Read only the torque value after the bearing cage starts to Nut Torque 840 Ibs ft 575 708 lbs ft oer 1 140 Nem 780 953 Nem 7 Adjust Pinion Bearing Preload If necessary adjust pinion bearing preload Disassemble the pinion bear Torque nut to 840 Ibs ft 1 140 Nem then continue tighten bette EE thig ae and ing nut to align nut slot to nearest hole in pinion shank enange Li PLEIN Deal ig Spacer lexer Spacer will decrease preload A thinner spacer will increase Vise Method preload a if the yoke and nut are used mount the assem A IMPORTANT bly in a vise clamping yoke firmly Use the correctly sized spacer Do not use shim stock or grind spacers These practices can lead to loss of bearing preload and gear or bearing failure 8 Press pilot bearing on pinion A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts the inner race of bearing cone 1 Vise Press Method a fa press is used position a sleeve or spacer so that load is app
28. press to shoulder 4 Shoulder 5 Sleeve 6 Second bronze bushing recess 1 32 38 Power Divider Lube Pump Removal Lube Pump Installation Assemblies Built Before June 15 2008 Assemblies Built Before June 15 2008 1 Remove inter axle differential IAD and pump collar 1 Install lube pump assembly onto output side gear TIP The output shaft side gear and pump will be Note The lube pump assembly is a slip fit on the output shaft removed as an assembly The lube pump assembly side gear behind the press fit of the output shaft side is located on the back side of the output shaft side gear bearing The output shaft side gear bearing cone gear between the output shaft side gear and bearing positions the pump assembly into the carrier cone 2 Install bearing cone on output side gear Note If the IAD assembly is to be reused install in same 3 direction removed Press bearing using proper tools until fully seated y o 3 a 3 4 Reinstall output side gear pump and bearing assem bly into carrier 2 Remove the three pump retaining screws and 5 Tighten lube pump retaining screws to 17 21 Ibs ft remove the pump and output shaft side gear as an 23 38 Nem assembly TIP The lube pump assembly is orientated in such a way that the three mounting locating tabs will only line up one way Note The lube pump is driven off the IAD assembly through a drive coupling The drive couplin
29. sure that the seal is mounted properly 7 Use a rubber mallet to drive the seal tool in until the flange bottoms on the housing cover bore face The flange will locate the seal at the proper depth Guidelines for Reusing Yoke 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 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 A CAUTION Do not use wear sleeves Wear sleeves increase the yoke hub surface diameter and cause premature seal wear and repeat seal failure 79 Service Kit 217414 Location 126917 New Welded D Housing Cover Lube Quantity Difference 0 zero Standout of Output Shaft Yoke Length increased by 6mm 25 this should not have any significant impact on inter axle driveline length or drive line angles 80
30. the outer bearing cup into the housing assembly over the out put shaft bearing cone 8 Using snap ring pliers install the snap ring that fas tens the outer bearing cup into the welded on cover assembly 9 Check the end play of the output shaft New assem blies should measure 001 to 015 76 Note Use the bearing cup driver to insure seating of snap ring after installation with snap ring pliers 1 CS ED 3 4 1 Press 5 Press bearing on first 2 Plate 6 Output shaft 3 Sleeve 7 Plate 4 Press bearing on second 1 Snap ring 2 Bearing cup 3 Output shaft assembly 4 Inner bearing cup 5 Rear cover assembly Housing and Output Shaft Assembly 10 Bolted rear cover only If removed install cover and A IMPORTANT fasten with nuts capscrews and lock washers Tighten to proper torque specifications Follow the instructions specified by the thread adhesive Note Use Spicer approved RTV compound on axle housing manufacturer when applying thread adhesive compound mating surface as shown in illustration Completely remove all old gasket material prior to applying new material Compound will set in 20 minutes Install axle housing cover and output shaft assembly before com pound sets or reapply TT 2 Flats Cover Side of Axle Housing o 120 Midway thru thickness of nut Note Use of a torque multiplier is recommended
31. the unit does not have a pump go to the Power Divider Assembly section Note Keep work area clean Dirt is an abrasive and will cause premature wear of the otherwise serviceable parts Note For non pump models see page 17 for output side gear seal manifold installation Note Only service the power divider if the differential carrier is secured in a stand or while the axle is still attached to the housing JAapIAig 1AMOd A CAUTION During installation of power divider cover the inter axle dif ferential IAD input shaft assembly or IAD shift system parts may fall from the carrier if not careful Use caution to prevent injury or damage 1 Install the pump into the output side gear so that the pump shaft is facing toward the teeth end of the side 1 Machined Slot ear j 2 Pin 41 Power Divider Lube Manifold Removal 1 Disconnect the hose from the lube manifold 2 Remove the manifold assembly by prying it out around the inner diameter A IMPORTANT Once removed the seal manifold assembly cannot be reused This component should always be replaced with new Use the same removal procedure for the output side gear seal removal on the non pump models 1 Barbed Nipple 42 Power Divider Manifold Installation 1 Install the manifold assembly into the output side gear bore in the carrier Make sure the barbed nipple is lined up with the opening in the carrier casting Note
32. 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 If parts are to be stored Coat with oil wrap in corrosion 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 provides 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 Components Inspect all steel parts for e Notches visible steps or grooves created by wear e Pitting or crackin
33. with slotted nut remove roll pin with a pin punch then loosen nut 2 If reusing gear set also punch mark bearing adjust ers for reference during assembly oO D zZ 1 gt an 72 1 3 lt 1 Punch marks 51 Carrier Assembly Remove Pinion Assembly 1 Remove pinion bearing cage capscrews Remove pinion and cage assembly from carrier Remove shim pack 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 52 2 Remove pinion bearing cage capscrews Remove pinion and cage assembly from carrier Remove shim pack A IMPORTANT Do not allow pinion to drop on hard surface If 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 Drive Pinion Front Axle Pinion Assembly Parts Exploded View 1 i em xy So 1 Pinion pilot brg 8 Capscrew 2 Pinion 9 Pinion brg cup outer 3 Pinion brg cone inner 10 Pinion brg cone outer 4 Pinion brg spacer 11 Pinion helical gear 5 Pinion brg cup inner 12 Roll pin 6 Shim 13 Slotted pinion nut 7 Pinion brg cage Before 3 01 95 two spacers were used instead of the one shown Rear Axle Pinion Assembly Parts Explod
34. 26219 12 M16 X 1 5 24 mm 215 255 292 346 Ring gear nut with bolt 129686 11 9 M16 X 1 5 24 mm 260 280 352 380 Bolt 129686 Torque Turn Angle Initial Torque 125 Nm 92 ft Ibs Plus 65 Turn Angle Wheel diff case capscrew 10 9 M14 X 2 16mm12pt 114 140 155 190 Carrier Class Size Tool Ibs ft Nem ABS sensor assembly fasteners 1024 X 7 8 1 8 Allen Finger tight 1 turn Carrier to housing capscrew 12 9 M16 X 2 24mm 230 270 312 366 Carrier to housing nut 12 M16 X 1 5 24 mm 199 244 270 331 Diff brg capscrew 12 9 M20 X 2 5 30 mm 350 428 475 580 Filter assembly pump model NPTF 150 14 11 16 40 60 54 81 Lube pump attachment screw 8 8 M8 X 1 25 6 mm Allen 17 21 23 28 Thrust bolt jam nut 4 M24 X 2 36 mm 148 181 201 245 Housing Class Size Tool Ibs ft Nem Axle cover capscrew 12 9 M12 X 1 75 18mm 85 103 115 140 900 20 11 16 55 71 75 96 Axle shaft to wheel hub nuts 625 18 15 16 170 190 230 258 150 16 11 8 285 345 386 468 Breather old design NPSF 375 18 750 Hex 20 26 27 35 Breather fitting u tube design 375 18 750 Hex 20 26 27 35 Housing cover nut 12 M12 X 1 25 18mm 85 103 115 140 Magnetic plug fill NPSF 1X 11 5 13 16 40 60 54 81 108 Torque Chart Power Divider Class Size Tool Ibs ft Nem 3 2 Oil drain plug NPTF 150 14 1 2 Drive 40 60 54 81 5 Temperature sender plug 40 60 54 81 S a Note Fasteners using self locking thread patches may be reused if not damag
35. 5 Remove the snap ring then lift fixed curvic clutch off 2 Back out thrust bolt from the carrier until the end of differential case hub spline Further disassembly of the bolt is flush with the inside of the carrier casting carrier is the same for axles without differential lock This will allow enough clearance between the ring Models with Ring Gear Thrust Bolt EE 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 1 D head carrier or front carrier 2 Thrust bolt 3 Thrust bolt jam nut 1 Back off thrust bolt jam nut 50 Carrier Assembly Remove Wheel Differential All Standard Models 3 Remove capscrews flat washers and bearing caps Back off bearing adjusters and remove adjusters and Note Omit this step if the gear set is to be replaced If gear bearing cups 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 4 Using a chain hoist lift ring gear and differential assembly out of carrier Note For easier disassembly loosen but do not remove pin ion self locking nut Forward axle pinion is equipped
36. Dana Spicer Tandem Drive Axles lt ana gt SPICER Drivetrain Products Service Manual Single Reduction amp Single Reduction with Wheel Differential Lock AXSM0046 November 2013 DS RS344 DSP RSP40 DS RS404 P DSP RSP41 DS RS405 P DSH RSH40 DS RS454 P DSH RSH44 DD RD404 DDH RDH40 DD RD405 DDH RDH44 DD RD454 DST40 P DDT41 P DST41 P DA RA344 DA RA404 P DA RA405 P General Information General Information The description and specifications contained in this service publication are current at the time of printing Dana reserves the right to discontinue or to modify its models and or procedures and to change specifications at any time without notice Important Notice This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and or component damage Departure from the instructions choice of tools materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator Any reference to brand names in this publication is made sim ply as an example of the types of tools and materials recom mended for use and should not be considered an endorsement Equivalents if available may be used WARNING Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician CAUTION
37. IAD shift system parts may fall from the carrier if not careful Use caution to prevent injury or damage 7 During installation rotate input shaft to engage input shaft splines with inter axle differential After instal lation the output shaft should turn when the input shaft is rotated and output shaft should turn inde pendently from the input shaft Note Gasket compound will harden in 20 minutes Install power divider as quickly as possible to avoid future leaks 8 Install power divider capscrews Torque to 114 140 Ibs ft 155 190 Nem 9 Reinstall input yoke if removed All yokes have a slip to interference fit on spline Yokes should always be installed with a press on tool to ensure they are fully seated 10 Even though you may have checked the input shaft end play before you must check and adjust it again now 23 v i 1 z5 1 Power Divider Disassemble Assemble and Overhaul Power Divider Assemblies built AFTER 11 02 98 In Vehicle The power divider cover comes off as a unit followed by the input shaft and then the helical side gear The power divider can be replaced with the axle assembly both in or out of the chassis and with the differential carrier assembled to the axle housing A CAUTION During removal of power divider cover the inter axle differ ential IAD input shaft assembly or IAD shift system parts may fall from the carrier if not careful Use caution to pre
38. ION 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 the yoke until it is installed on the shaft to prevent damage or contamination 1 Inspect axle end play at the yoke see page 10 Ser vice if beyond specified limit 2 Remove the old yoke using appropriate tool A yoke puller tool may be made from the center section of most gear puller tools or may be purchased from your local tool distributor 1 Yoke puller tool 3 Remove seal Use care when removing the old seal to prevent damage to the housing seal bore 4 Inspect the seal bore area for any damage nicks gouges corrosion Carefully remove any slight damage with a crocus cloth Clean the bore area to remove any loose debris A CAUTION Do not use any silicone or permatex type bore sealant with this seal 5 Remove the new seal from its package and install with the proper driver Service kit 217414 D Input Use driver 126917 only D Output Use insert 128706 with driver 126917 R Pinion Use driver 126917 only A CAUTION Due to the resiliency of the plastic driver hammer rebound may occur when the seal is seated Keep clear of the ham mer rebound path 6 Handle the seal by its outside diameter avoiding any contact with the seal lips During installation use the proper driver to make
39. 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 IMPORTANT Wheel end seals can be easily damaged during handling Leave the seal in its package until installation to prevent damage or contamination 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 sleeve Damage to the housing may result 5 Inspect spindle journal and hub bore for scratches or burrs Recondition with an emery cloth as required 86 Note Deep gouges can be repaired by filling gouge with hard ening gasket cement and smoothing with emery cloth 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 IMPORTANT Always use the seal installation tool specified by the seal manufacturer Using an improper tool can distort or damage the seal and cause premature seal failure Install Wheel End Seal 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 se
40. PUMP e ee se ee ee Re Ee GR Ge 21 Install Power Divider to Carrier Assembly 22 Disassemble Assemble and Overhaul Power DIVIdEF ZA aana 24 Remove Lube Pump Assemblies Built Before June 15 2008 ir EER a EE AE EDE GE Ede 27 Pump Removal Assemblies Built After June 15 2008 ee ee ee ee 28 Lube Pump Installation Assemblies Built Before June 2008 29 Manifold Installation e ee ee ee ee ee ee ee ee ee 31 Hose Filter Assembly ese ev ve EG ana Gee 32 Install Power Divider to Carrier Assembly 33 Disassemble Assemble and Overhaul Power DIVIDED issie sie ae Ee Se ee dorset de see 36 Lube Pump Removal Assemblies Built Before June 15 2008 ee ee 39 Lube Pump Removal Assemblies Built After June 2008 ee 40 Lube Pump Installation Assemblies Built After June 2008 eee Manifold AssemDly oeiee eeen ee ee ee Re Ge a Hose Filter Assembly ee ee ee ee ee Re Install Power Divider to Carrier Assembly Measure and Adjust Input Shaft End Play Carrier Assembly Carrier Assembly Parts Exploded View 0 Drive Pinion Front Axle Pinion Assembly Parts Exploded View Disassemble and Overhaul Drive Pinion 04 Replace Pinion Bearing Cage Cups i ese ese ee ee Adjust Pinion Bearing Preload ee ee ee ee Final Bun dUp SES Ge IR SEG EG EI ee ee Install Drive Pinion Assembly ee ee ek ee ek ee
41. Remove inner bearing cone from pinion using a split type puller Use two procedure steps to remove each bearing a Mount puller vertically to separate the bearing This action will force puller halves under bearing and start moving bearing off pinion i em xy So b Mount puller horizontally to press pinion out of bearing 1 Press 55 Drive Pinion Replace Pinion Bearing Cage Cups 4 Seat cups securely to shoulder Check clearance between cup and bearing cage Must be less than 001 1 Cup outer 2 Bearing cage 3 Cup inner 1 Remove cups 2 Clean and inspect bearing cages for damage nicks and burrs x 1 Press ram 2 Sleeve must apply pressure to back face of outer bearing cone 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 56 Drive Pinion 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 1 Bearing 6 Bearing Note When new gear set or pinion bearings are used select nominal size spacer from the specification chart If origi nal parts are used use spacer removed during disas sembly 2 With the bearings well lubricated place the assembly
42. Z CD D Oo 5 1 Output shaft nut 11 Rear cover capscrew 21 Breather 2 Output yoke 12 Fill plug 22 Breather hose 3 Output seal 13 Rear cover nut 23 Carriage capscrew 4 Snap ring 14 Lock washer 24 Lock washer 5 Outer bearing cup 15 Stud 25 Nut 6 Outer bearing cone 16 Dowel 26 Lock washer 7 Inner bearing cone 17 Jam nut 27 Stud 8 Inner bearing cup 18 Locking ring 28 Drain plug 9 Output shaft 19 Spindle nut 29 Axle shaft 10 Rear cover 20 Axle housing 107 Fastener Torque Specifications Torque Chart Power Divider Class Size Tool Ibs ft Nem Diff lock cover to carrier 8 8 M10X 1 5 13 mm 28 35 38 47 Diff lock switch 8 8 M12 X 1 5 10 12 14 16 IAD lock cover capscrew 8 8 M10 X 1 5 13 mm 28 35 38 47 IAD lock cover capscrews 2pcs M10 X 1 5 17 mm 28 35 38 47 Input brg cage capscrew 10 9 M14 X2 21mm 114 140 155 190 Input shaft nut M42 X 1 5 55 mm 840 1020 1140 1383 Power divider cover capscrew 10 9 M14 X2 21mm 114 140 155 190 Power divider pipe plug NPTF 150 14 1 2 Drive 40 60 51 81 Diff and Gearing Class Size Tool lbs ft Nem Front pinion helical nut Grade 8 M42 X 1 5 65 mm 840 1020 1140 1383 Output shaft nut M39 X 1 5 55 mm 680 832 920 1130 Rear pinion nut 8 8 M36 X 1 5 55 mm 575 703 780 953 Ring gear nut with bolt 1
43. aft 16 Press new oil retainer on input shaft A CAUTION It is not recommended to reuse the oil retainer due to possi ble damage that may occur while removing the input shaft bearing cone While pressing on new oil retainer make sure not to over press and or press with the retainer at an angle If the retainer is bent or distorted it may rub on the input cage or not seal properly to the v ring 37 v i 1 1 Power Divider 17 Press input bearing cone on input shaft 19 Press bearing cup in input bearing cover 20 Install new oil v ring on input bearing cage cover 2 3 es gew W Bearing cup press dan 2 V ring ay ye 21 If bushing removal is needed the bushings must exit from the thrust washer side of the helical gear 1 Press 4 Input shaft bearing cone 2 Plate 5 Oil retainer 3 Drive sleeve 6 Input shaft 1 Tap out bronze bushings 22 Install bronze bushing in helical side gear Bushings must be installed from thrust washer side of gear See illustration for dimensional tolerances 18 If input shaft bearing cup needs replacement use either of the following recommended practices e Weld a bead around the cup when the weld cools the cup will fall out e Drilla 1 4 size hole through the bearing cover to the back side of the cup and use a punch to remove the bearing cup 1 2 1 32 1 Press 2 Sleeve 3 1st bronze bushing
44. al supplier 2 Place seal on installation tool 3 Drive seal with installation tool onto hub 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 1 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 damaged 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 can 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
45. al thrust washer over input shaft Snap ring is spring steel and may pop off Wear safety 25 Install helical side gear glasses when installing 1 Helical side gear 2 Helical side gear thrust washer 3 PDU cover before 11 02 98 20 Power Divider Remove Lube Pump 1 Remove inter axle differential IAD and pump collar Install Lube Pump TIP The output shaft side gear and pump will be removedas an assembly The libe pump deed 1 Install lube pump assembly onto output side gear is located on the back side of the output shaft side Note The lube pump assembly is a slip fit on the output shaft gear between the output shaft side gear and bearing side gear behind the press fit of the output shaft side cone gear bearing The output shaft side gear bearing cone ositions the pump assembly into the carrier Note If the IAD assembly is to be reused install in same k alle y direction as removed 2 Install bearing cone on output side gear 3 Press bearing using proper tools until fully seated v i 1 1 4 Reinstall output side gear pump and bearing assem bly into carrier el 5 Tighten lube pump retaining screws to 17 21 Ibs ft 2 Remove the three pump retaining screws and 23 38 Nem remove the pump and output shaft side gear as an assembly TIP The lube pump assembly is orientated in such a way that the three mounting locating tabs will only line up one way Note The lu
46. anism may create nicks and burrs on input yoke Remove nicks and burrs if present 5 Tap the sides of the cover at the dowel pin location with a mallet to loosen cover 1 Carrier assembly stand Power Divider Disassemble Assemble and Overhaul the Power Divider Assemblies built BEFORE 11 02 98 2 If replacement of the output shaft side gear bearing The power divider may be serviced with the carrier assembly Cup is necessary use either of the following meth in or out of the axle housing ods Note The following procedure assumes that the differential Weld Place a weld bead around the inside of the carrier has been removed from the axle housing and that cup when the weld cools the cup will fall out the ee divider has been removed from the carrier Hammer Use slipper to get under the cup and witha desefDy hammer and drift from the back side of carrier tap 1 Remove output shaft side gear from differential car out bearing cup rier 5 o 3 a 7 Note On pump models it will be necessary to remove three pump retaining screws and remove the pump and out put shaft side gear as an assembly 3 Remove snap ring from machined groove at rear of input shaft 17 Power Divider 4 Slide helical side gear off input shaft 5 Remove helical side gear thrust washer 1 Helical side gear 2 Thrust washer 3 PDU Cover after 11 02 98 6 Remove input shaft nut 7 Remove yoke f
47. ar Bushings must be installed from thrust washer side of gear See illustration for dimensional tolerances 1 Press 2 Plate 3 Drive sleeve 4 Input shaft bearing cone 5 Oil retainer 6 Input shaft 1 Press a 2 Sleeve 14 Press bearing cup in input bearing cover 3 1st bronze bushing press to shoulder 15 Install oil v ring on input bearing cage cover 4 Shoulder 5 Sleeve 6 Second bronze bushing recess 1 32 18 Install shift fork spring and push rod in cover assembly if removed 19 Units with reverse air install snap ring fork spring and push rod in cover assembly if removed 1 Bearing cup press 2 V ring 19 v i 1 1 Power Divider 20 Install lockout cylinder assembly if removed Some 26 Install snap ring models may have a one piece cover Refer to pages 14 17 Tighten capscrews to 28 35 Ibs ft 38 47 Nem 21 Place sliding clutch in power divider cover engaging clutch with shift fork Position clutch teeth toward helical side gear 22 Slide input shaft into power divider cover Engage shaft splines in lockout sliding clutch 23 Install input bearing cover and shims Note Input shaft end play must be adjusted after power divider is assembled to differential carrier For easier adjustment temporally install input bearing cage cover and tighten capscrews finger tight A WARNING 24 Install helic
48. arrier cap 5 Flange half differential case 6 Nut 7 Ring gear 8 Side gear thrust washer 9 Side gear 10 Wheel differential spider 11 Side pinion 12 Side pinion thrust washer 13 Carrier cap bolt 14 Lock washer 15 Plain half carrier cap 16 Side gear 104 17 Side gear thrust washer 16 Plain half differential case 19 Plain half bearing cone 20 Plain half bearing cup 21 Plain half bearing adjuster 22 D head carrier with pump 23 Core plugs 24 Pump filter 25 Core plugs 26 D head carrier or front carrier with a pump 27 1 inch core plug 28 Dowel 29 D head carrier or front carrier 30 O ring 31 Dowel 32 D head carrier or front carrier with thrust bolt 33 Thrust bolt jam nut 34 Thrust bolt 35 Pinion pilot bearing 36 Pinion 37 Inner pinion bearing cone 38 Pinion bearing spacer 39 Inner pinion bearing cup 40 Pinion cage shim 41 Pinion cage 42 Outer pinion bearing cup 43 Outer pinion bearing cone 44 Helical gear 45 Pinion roll pin 46 Pinion nut Parts Identification Rear Drive Axle Parts Exploded View 1 Ring gear 2 Carrier cap bolt 3 Flange half carrier cap 4 Flange half differential case 5 Flange half bearing cone 6 Flange half bearing cup 7 Flange half bearing adjuster 8 Plain half bearing adjuster 9 Plain half bearing cup 10 Pla
49. ash 1 Measure ring gear total radial run out Indicator 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 1 Install carrier bearings caps and torque carrier cap bolts to 350 428 Ibs ft 475 580 Nem 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 2 Measure ring gear total back face run out Indicator 0 006 and 0 018 reading should not exceed 010 3 Check ring gear tooth contact pattern Paint ring gear teeth and check tooth contact pattern Correct tooth patterns Checking and adjusting procedures are on pages 61 62 4 Install bearing adjuster cotter pins 68 Adjust Tooth Contact Pattern Adjust Ring and Pinion Tooth Contact Pattern 1 Face width 2 Tooth Depth 3 Heel 4 Top land 5 Root 6 Toe Note Rear axle gearing is shown in the following instructions Correct tooth contact patterns and adjustments are the same for forward and rear axles 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
50. be pump is driven off the IAD assembly through a drive coupling The drive coupling has drive tangs to both the IAD assembly and the lube pump The IAD has 1 Magnetic strainer notches that will accept the drive coupling on either 3 Inspect the lube pump if metal particles are found in lee axle assembly 6 Install pump drive coupling 4 Remove the magnetic strainer from the carrier and Note If reusing the IAD assembly install in same direction as inspect for wear material in the same manner as the removed drain plug Wash the magnetic strainer in solvent and blow dry with compressed air to remove oil and 7 Reinstall IAD metal particles A CAUTION Note The pump assembly must turn freely by hand The pump is non serviceable and must be replaced as a Exercise care to direct compressed air into a safe area complete assembly Wear safety glasses 21 Power Divider Install Power Divider to Carrier Assembly Assemblies built BEFORE 11 02 98 In vehicle installations shown Note Cleanliness in your work area is important as dirt is an abrasive and will cause premature wear of the otherwise serviceable parts Note It is assumed that the differential carrier is secured in a stand or the power divider only is being serviced while the axle is still attached to the housing A CAUTION During installation of power divider cover the inter axle dif ferential IAD input shaft assembly or IAD shift system parts may fall f
51. d with the axle assembly both in or out of the chassis and with the differential carrier assembled to the axle housing A CAUTION During removal of power divider cover the inter axle differ ential IAD input shaft assembly or IAD shift system parts may fall from the carrier if not careful Use caution to pre vent injury or damage 1 Disconnect the main driveline 2 Disconnect the lockout air line 3 If overhauling the power divider loosen but do not remove input nut 4 Position a drain pan under the unit 5 Remove PDU capscrews Method A With Carrier Installed in Chassis 1 Use a transmission jack or a chain hoist and a sling 2 Wrap sling strap around power divider and attach to chain hoist hook 3 Tap on the sides of the cover at the dowel pins with a mallet to create a space large enough to finish free ing the cover from the dowel pins 4 Pull the power divider forward until the input shaft stub end is free of the output side gear then remove the assembly Method B With Carrier Out of Chassis 1 Use a chain hoist 2 Mount carrier assembly in carrier assembly stand 3 Remove PDU capscrews 4 Fasten chain or strap to input yoke to remove power divider A CAUTION During removal of power divider cover the inter axle differ ential IAD input shaft assembly or IAD shift system parts may fall from the carrier if not careful Use caution to pre vent injury or damage Note Lifting mech
52. ding 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 determine refer to the appropriate service manual to perform the repairs Inspection Clean 1 Wash steel parts with ground or polished surfaces in solvent There are many suitable commercial 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
53. e bushings must exit from the thrust washer side of the helical gear BEES 1 Press 4 Input shaft bearing cone 2 Plate 5 Oil retainer 3 Drive Sleeve 6 Input shaft 1 Tap out bronze bushings 20 If input shaft bearing cup needs replacement use 24 Install bronze bushing in helical side gear Bushings either of the following recommended practices must be installed from thrust washer side of gear See illustration for dimensional tolerances e Weld a bead around the cup when the weld cools the cup will fall out e Drill a 1 4 size hole through the bearing cover to the back side of the cup and use a punch to remove the bearing cup 2 Sleeve 3 Ist bronze bushing press to shoulder 4 Shoulder 5 Sleeve 6 Second bronze bushing recess 1 32 26 Power Divider Lube Pump Removal Install Lube Pump Assemblies Assemblies Built Before June 2008 Assemblies Built Before June 2008 1 Remove inter axle differential IAD and pump collar 1 Install lube pump assembly onto output side gear TIP The output shaft side gear and pump will be Note The lube pump assembly is a slip fit on the output shaft removed as an assembly The lube pump assembly side gear behind the press fit of the output shaft side is located on the back side of the output shaft side gear bearing The output shaft side gear bearing cone gear between the output shaft side gear and bearing positions the pump ass
54. e plug from the axle housing cover and fill the axle with the approved lubricant until level with the bottom of the hole b If wheel ends were removed follow instructions in wheel end servicing pages 81 83 l Correct lube level at bottom of filler hole 94 Always use the filler hole as the final reference If lube is level with the bottom of the hole the axle is properly filled Note Lube fill capacities see chart are basic guidelines and will vary based on the angle the axle is installed in a particular chassis Torque fill plug to 40 60 Ibs ft 54 82 Nem TIP The axle can be filled through the axle housing breather hole Fill until lube level is even with the bottom of filler hole in axle housing rear cover 1 With axle on level surface fill housing with oil to bottom of plug 2 Temperature sensor mounting hole Lubrication Standpipes Drive axles are lubricated with oil drawn from a large sump integral to the assembly Most axle designs attempt to posi tion vital components such as pinion bearings in close prox Tandem Forward Axles imity to this sump keeping them bathed in a generous supply Installation 5 10 10 15 15 20 of oil at all times Angle Grade Grade Grade When drive axles are installed at severe angles in vehicle 0 7 chassis the position of these c
55. ed 5 Install helical side gear 45 Power Divider 6 Install thrust washer 10 Install power divider cover to carrier Use Spicer approved RTV compound on the carrier mating sur face Torque capscrews to 114 140 lbs ft 155 190 Nem Note Gasket compound will harden in 20 minutes Install power divider as quickly as possible to avoid future leaks 7 Install compression spring shift fork push rod and lockout sliding clutch 8 Install input shaft assembly Note The input shaft snap ring is not used in this buildup 13 Measure and adjust input shaft end play see page 9 14 Torque input cage capscrews to 114 140 lbs ft 9 Install plastic oil trough in power divider cover 155 190 Nem 15 Install NEW input seal see page 71 16 Reinstall input yoke 46 Power Divider Measure and Adjust Input Shaft End Play Note After power divider overhaul and installation on carrier 4 Install shim pack and bearing cover Install cap check and adjust input shaft end play screws Torque screws to 114 140 Ibs ft 155 190 Nem Make sure shims are flat with no kinks or The correct end play when new parts are used in overhaul is bends 0 003 to 0 007 with reused parts the maximum is 0 014 1 Remove input shaft nut Remove input bearing cover capscrews Remove bearing cover and shim pack if installed 2 Reinstall bearing cover without shims Hold in posi ti
56. ed but should be secured by a few drops of Loctite 277 on threaded surface Reused fasteners should be wiped clean of excess oil but do not require special cleaning In June 1997 lube fill plug size was changed See bulletin ABIB 9709 Ring gear bolt design changed 1 2 97 See bulletin ABIB 9701 Torque nut to 840 Ibs ft 1140 Nem then continue tightening to align nut slot with nearest hole in pinion shank Correct torque values are extremely important to assure long Spicer life and dependable performance Under tightening of parts is just as harmful as over tightening Exact compliance with recommended torque values will assure the best results The data includes class and torque tightening values 109 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 Dri N lt at gt SPICER Drivetrain Products www dana com All applications must be approved by the Application Engineering Department Specifications and or design are subject to change without notice or obligation Printed in USA AXSM 0046 11 13
57. ed View 14 Pa CA lt gt 19 o 20 14 Pinion pilot brg 21 Capscrew 15 Pinion 22 Pinion brg cup outer 16 Pinion brg cone inner 23 Pinion brg cone outer 17 Pinion brg spacer 24 Oil seal 18 Pinion brg cup inner 25 Yoke 19 Shim 26 Pinion nut 20 Pinion brg cage 53 Drive Pinion Disassemble and Overhaul Drive Pinion The following procedures cover both forward and rear differ 6 Remove pilot bearing from pinion using a split type ential drive carrier disassembly puller Use two procedure steps to remove each bearing 1 Rear Axle Pinion Yoke Remove yoke a Mount puller vertically to separate the bearing A CAUTION This action will force puller halves under bearing and start moving bearing off pinion 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 3 Forward and Rear Axle Pinion Bearing Cage Press pinion out of bearing cage and bearing cone b Mount puller horizontally to press pinion out of bearing 1 Press ram 4 Rear Axle Pinion Oil Seal and Outer Bearing Cone Remove oil seal and bearing cone from cage Dis card oil seal Remove bearing cups with suitable puller 5 Remove bearing spacer from pinion 54 Drive Pinion 7
58. eduction with In Axle Speed Sensors IASS avo n rov Example DS Forward Tandem Axle Single Reduction or RS Rear Tandem Axle Single Reduction General Information Model Identification Drive Axle 4 B E dil pd AF pii Forward Axle Side View 1 Country or origin 2 Axle model identification 3 Specification number assigned to the axle built by Spicer Identifies all component parts of the axle including special OEM requirements such as yokes or flanges Parts Identification Axle Housing 1 ID Tag N cust PARTNO Jp Data plate is located on 7 the axle centerline Spice SERIAL NO O 6 RATIO T 7 W Rear Axle Top View 4 OEM part number assigned to the axle build 5 Carrier assembly serial number assigned by the manufac turing plant 6 Axle gear ratio 7 Carrier assembly production or service part number Axle Shaft 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 ep D 5 D 2 s 53 So 3 D o 5 1 Part number 2 Number of ring gear teeth 3 Manufacturing numbers 4 Matching gear set numbe
59. em 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 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 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 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 Connector hole is on carrier mounting surface 3 6 inch long wires 4 Sensor terminals positioned near carrier mounting surface 1 Lubricate interior rotor with axle lube or grease Check that the rotor turns freely by hand 2 Mate the rotor and the sensor assembly 3 Align the sensor rotor assembly with the face
60. embly into the carrier cone 2 Install bearing cone on output side gear Note If the IAD assembly is to be reused install in same 3 p E ET E E E direction as removed Fress bearing using prop until fully y o 3 a 3 4 Reinstall output side gear pump and bearing assem bly into carrier 5 Tighten lube pump retaining screws to 17 21 Ibs ft 2 Remove the three pump retaining screws and 23 38 Nem remove the pump and output shaft side gear as an assembly TIP The lube pump assembly is orientated in such a way that the three mounting locating tabs will only line up one way Note The lube pump is driven off the IAD assembly through a drive coupling The drive coupling has drive tangs to both the IAD assembly and the lube pump The IAD has Ne r l 5 VEER 1 Magnetic strainer notches that will accept the drive coupling on either face 3 Inspect the lube pump if metal particles are found in ace axle assembly 6 Install pump drive coupling 4 Remove the magnetic strainer from the carrier and Note If reusing the IAD assembly install in same direction as inspect for wear material in the same manner as the removed drain plug Wash the magnetic strainer in solvent and blow dry with compressed air to remove oil and 7 Reinstall IAD metal particles A CAUTION ee esi ee must Turi ee by Hand THe Exercise care to direct compressed air into a safe area pump is non serviceable and m
61. ent e Redesigned shift system recessed into PDU cover e Integral 1 2 l Q eN 4 eS N d 5 6 1 Compression spring 4 Piston 2 Shift fork 5 O ring 3 O ring 6 Piston Cover Integral Shift Cylinder November 2 1998 to February 2 2000 e Redesigned shift system recessed into PDU cover e Integral Lady Sv 1 Compression spring 5 O ring 2 Shift fork 6 Piston 3 Snap ring 7 O ring 4 Push rod 8 Piston Cover 11 oO a 1 1 pr D m iar x Differential Lockout Cast Iron Cover Lockout February 1996 to November 1998 e External type lockout e Cast iron piston cover 1 Compression spring 5 O ring 2 Shift fork 6 Gasket 3 Push rod 7 Piston cover 4 Piston 8 Hex head capscrew with flange Cylindrical Design Lockout November 1992 to February 1996 e External type lockout e Stamped steel piston cover e Interchangeable with the cast style cover only as a complete assembly Se ES 1 2 MNA 1 Compression spring 5 Piston 2 Shift fork 6 O ring 3 Push rod 7 Shift cylinder 4 Shoulder washer 8 Mounting bracket 9 Mounting bracket capscrews Differential Lockout Reverse Air Lockout Navistar before November 1 1996 e External type lockout e Cast iron piston cover j h 1 CD gt pr 9 Oo iar o OT 14 1 O ring 9 Piston cover 2
62. eps consist of external inspections and observations that will be valuable when combine 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 If equipped with a torgue 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 axle 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 regar
63. erential can take place i 4 Remove Wheel Differential Models with Wheel Differential Lock l 5 or 1 For ease of servicing mount differential carrier in stand with differential lock facing up l DN EN Note To overhaul and reassemble the wheel differential the 8 shift fork and clutch assembly must be removed from carrier See instructions below 13 2 Remove shift cylinder mounting screws then lift x 9 shift cylinder piston and o ring assembly off carrier ES N s and end of push rod ye aN See 11 oO t 3 1 Piston engagement bolt gt 2 Capscrew j 3 Switch 3 4 Washer 5 O ring 6 Piston 7 Setscrew 8 Piston driver 9 Pushrod 1 Shift cylinder Ve eel as 3 To disassemble shift cylinder for inspection first 12 Sliding clutch remove or back off actuator switch The piston and 13 Pin o ring assembly can be removed by inserting a pen cil size tool through the cylinder air port 14 Piston cover 4 Grasp push rod end and pull it out of the shift fork 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 49 Carrier Assembly
64. erred 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 transmission is in high range Direct Driver controlled System 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 100 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 solenoid 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 t
65. es However before final assembly check wire position and routing to make sure that 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 surface 6 Axle carrier 83 Housing Breather Install New Axle Housing Breather Metal and Plastic Spicer Truck Components has released a new axle housing 5 Plastic only tighten until one thread is showing breather kit part number 507162 This kit contains a fitting hose and clamp assembly and instructions This new breather kit will replace the current breather P N 809560 and snap cap P N 126980 on the models listed above for both production and service This newly designed breather has improved resistance to water ingestion clogging caused by dirt ice or snow buildup around the base of the breather See installation instructions below all views from rear 1 Install fitting in breather hole 6 Insert hose onto fitting long end down 7 Push hose firmly against fitting Rotate hose to point down 3 Using a 3 4 wrench 4 Metal only rotate the fitting at least 1 2 turn until ad nipple points to rear ja 84 o ie 3 wi o Wheel End Seal Parts Exploded View Wheel End Seal 1 nstallation tool 2 Seal 3 Rear hub 85 Wheel End Seal Remove and
66. f axle sump lubricant into each hub through the wheel end fill hole 4 Install oil fill plug and tighten to specified torque 90 Wheel End with Oil Fill Hole ral foo Ht HHS EA Oo T ZZ AE ON Wheel End without Oil Fill Hole L t ont uz H iS 1 Wheel end oil fill hole 2 Proper lubricant level 3 Lubricant flow from sump Wheel Ends Without Oil Fill Hole 1 With axle level and wheel ends assembled add lubri 5 Lower the left side cant through filler hole in axle housing cover until fluid is level with the bottom of filler hole 6 With axle on a level surface add lubricant through housing cover oil filler hole until fluid is level with the 2 Raise the right side of the axle 6 inches or more bottom of the hole Hold axle in thi ition for one minute l i aman S POSION TON ANE di Note Axles without wheel end fill holes will require approxi 3 Lower the right side mately 2 5 additional pints of lubricant to bring the lube level even with the bottom of fill hole 4 Raise the left side of the axle 6 inches or more Hold axle in this position for one minute 1 With axle on level surface fill housing with oil to bottom of plug 2 Temperature sensor mounting hole 38 Oil will run into wheel end 4 Oil will run into wheel end 5 Tilt housing side to side 1 minute per side 6 Recheck oil level in axle 91
67. for free rotation by turning side gear hub 3 Place thrust washer and side gear in flanged differ ential case 1 Punch marks 65 Wheel Differential Assembly 8 Install ring gear Secure with bolts and nuts Note Flange half differential cases were redesigned starting with production axles built in January 1997 New style ring gear bolts are also required with the new style flange case the torque specification for this bolt is different than the old 126219 bolt See chart Bolt No Torque Specs 129686 260 280 Ibs ft Nem 352 380 126219 215 255 Ibs ft Nem 292 346 Ring Gear Bolt Torque Turn Specification Bolt No Torque Turn Angle 129686 125 Nm 92 ft Ibs 65 A With a calibrated torque wrench torque each ring gear bolts to 125 Nm in a crisscross pattern B With a torque wrench that reads torque turn angle tighten each fastener clockwise 65 degrees IMPORTANT NOTE If the torque exceeds 447 Nm 330 ft Ibs when the 65 turn angle is achieved the bolt and nut need to be replaced 66 Reference Spicer Bulletin ABIB 9701 for more details 9 Lower assembled differential assembly in to the carrier using a hoist and a strap Be careful not to damage the differential bearings lowering the assembly 10 Install the bearing cup and bearing adjuster to the flange half side first 11 Install the bearing c
68. g 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 Check Input Shaft End play Forward Axle Note Before disassembling the power divider measure and Check Output Shaft End play record input shaft end play Forward Axle See illustration for steps 1 3 TEE ee See illustration for steps 1 3 1 Position dial indicator at yoke end of input shaft as 1 Position dial indicator at yoke end of output shaft 2 Push in on input shaft and zero the dial indicator 2 Push in on output shaft and zero the dial indicator 3 Using a pry bar move input shaft axially and mea sure record end play 3 de ae sa input shaft axially and mea
69. g has drive tangs to both the IAD assembly and the lube pump The IAD has Magnon saler notches that will accept the drive coupling on either 3 Inspect the lube pump if metal particles are found in face axle assembly 6 Install pump drive coupling 4 Remove the magnetic strainer from the carrier and Note If reusing the IAD assembly install in same direction as inspect for wear material in the same manner as the removed drain plug Wash the magnetic strainer in solvent and blow dry with compressed air to remove oil and 7 Reinstall IAD metal particles A CAUTION Note The pump assembly must turn freely by hand The pump is non serviceable and must be replaced as a complete assembly Exercise care to direct compressed air into a safe area Wear safety glasses 39 Power Divider Lube Pump Removal Assemblies Built After June 2008 For output side gear and or pump replacement follow the 3 Remove pump from the output side gear procedure below 1 Remove the output side gear bearing cone if required 1 Press 2 Press Tool 2 Remove pump locking dowel pin from the hole in the output side gear hub 40 Power Divider Lube Pump Installation Assemblies Built After June 2008 Use these instructions with the carrier assembly in or out of 2 Install the pump locking dowel pin into the hole in the vehicle the output side gear hub Make sure the pin is lined up with the machined slot in the pump body If
70. 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 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 characteris tic 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 ad 1 Pattern 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
71. he 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 9 Forward rear axle wheel differential lock air shift cylinder part of axle assembly 10 Wheel differential lock indicator switch part of axle assembly 11 Indicator light of audible signal 12 Fuse or circuit breaker 13 Power supply 14 66468 Quick release valve optional located on frame rail and within 10 feet of tubing from control valve 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 differen tial to provide improved traction under adverse road condi tions 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 e Shift Cylinder Assembly Operates a shift fork and push rod assembly e Shift Fork and Push Rod Assembly Engages and d
72. ier into the housing 2 Install carrier to housing lock washers capscrews and nuts Torque to proper specification Torque to 230 270 Ibs ft 312 366 Nem After 11 02 98 axle housing covers are welded in place If you have a bolt on cover install rear hous ing cover output shaft assembly see page 69 Torque all fasteners to proper specifications Torque to 85 103 Ibs ft 115 140 Nem Install inter axle driveline making sure yokes are in phase Install axle shafts and axle stud nuts if used also install lock washers and tapered dowels Add axle lubricant Fill to bottom of filler hole Rear Only Connect inter axle driveline making sure all yokes are in phase Lubricate U joints Front Only Connect main driveline making sure all yokes are in phase Lubricate U joints Front Only Connect differential lockout air line Differential Lockout Inter Axle Lockout Types Since 1992 there have been 5 different power divider air lock All are air operated to engage the lockout and spring released out designs that are identified for service as either to disengage the lockout with the exception of the Reverse _ Air lockout The Reverse Air lockout is spring released to External all models produced BEFORE 11 02 98 engage the lockout and air operated to disengage the lockout e Integral all models produced AFTER 11 02 98 Integral Shift Cylinder with Welded Push Rod Assembly February 2 2000 to Pres
73. in half bearing cone 11 Plain half differential case 12 Side gear thrust washer 13 Plain half carrier cap 14 Side gear 15 Side pinion 16 Side pinion thrust washer 17 Wheel differential spider 18 Side gear 19 Side gear thrust washer 20 R head carrier or rear carrier 21 Thrust bolt 22 Thrust bolt jam nut 23 Pinion pilot bearing 24 Pinion 25 Inner pinion bearing cone 26 Pinion bearing spacer 27 Inner pinion bearing cup 28 Pinion cage shim 29 Pinion cage 30 Outer pinion bearing cup 31 Outer pinion bearing cone 32 Pinion seal 33 Pinion yoke 34 Pinion nut 35 R head carrier with thrust bolt 105 y D Z CD 53 D D Parts Identification Inter Axle Speed Sensor Parts Exploded View Wheel Differential Lock Assembly Parts Exploded View 1 Sensor assembly 2 Fastener 3 Rotor assembly 4 Differential bearing adjuster 1 Fixed curvic clutch gear 10 Piston 2 Snap ring 11 O ring 5 Sensor connector 3 Curvic clutch gear 12 Switch 4 Spring pin 13 Plastic washer 5 Shift fork 14 Piston cover 6 Compression spring 15 Capscrew 7 Push rod flange head 8 Piston driver 16 Capscrew 9 Set screw manual engagement 17 Gasket 106 Parts Identification Housing and Output Shaft Assembly Parts Exploded View Welded Rear Cover y D
74. in the press Position sleeve so that load is applied directly to the backface of the outer bearing cone 1 Press ram 2 Sleeve must apply pressure to back face of outer bearing cone 3 Spring scale 3 Rotate pinion cage while applying press load see chart below to the assembly and check rolling torque Wrap soft wire around the bearing cage attach spring scale and pull Preload is correct when torque required to rotate the pinion bearing cage is from 5 13 Ibs 2 5 6 0 kgs Specifications for Pinion Bearing Trial Buildup Preload Test Torque to Rotate Bearing Cage w o pinion seal 18 42 in Ibs 2 0 4 7 Nem Forward Axles Rear Axles Spring Scale 5 13 Ibs 2 5 6 0 kgs Reading Press Loads 17 19 Tons 14 15 Tons 15 4 17 2 12 7 13 6 Metric Tons Metric Tons Nominal Bearing 0 496 in 0 638 in Thickness Spacer 12 60 mm 16 21 mm 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 A IMPORTANT Once correct bearing preload has been established note the spacer size used Select a spacer 0 001 larger for use in the final pinion bearing cage assembly The larger spacer compensates for slight growth in the bearings which occurs when they are pressed on
75. isengages the differential lock curvic clutch assem bly e Curvic Clutch Assembly 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 age ox 3a V 4 oa ad 3b 1 Curvic clutch assembly 1a Sliding clutch 1b Fixed clutch 2 Shift fork and push rod assembly 2a Shift fork 2b Pushrod 3 Shift cylinder assembly 3a Piston driver 3b Selector switch 101 o i lt i O cs 3 D i 5 Theory of Operation Differential Lock Engaged Air pressure applied to the shift cylinder moves the piston push rod shift fork and the 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
76. leaner component appearance The family of Spicer gear lubricants represents a premium quality synthetic lube which fully meets or exceeds the requirements of MIL L 2105D These products available in both 75W 90 and 80 W 140 have demonstrated superior performance in comparison to others qualified under the MILSPEC as demonstrated by extensive laboratory and field testing For a complete list of Spicer approved synthetic lubricants contact your local Dana representative See back cover of this manual for appropriate phone number Makeup Lube Maximum amount of non synthetic makeup lube is 10 92 Recommendations for Viscosity Ambient Temperature The following chart lists the various SAE Grades covered by MIL L 2105D and the associated ambient temperature range from each Those SAE grades shown with an asterisk are available in the Spicer family of synthetic gear lubricants The lowest ambient temperatures covered by this chart are 40 F and 40 C Lubrication recommendations for those applications which consistently operate below this tempera ture range must be obtained through Dana by contacting your local Dana Spicer representative Grade Ambient Temperature Range 75W 40 F to 15 F 40 C to 26 C 75W 80 40 F to 80 F 40 C to 21 C 75W 90 40 F to 100 F 40 C to 38 C 75W 140 40 F and above 40 C and above 80W 90 15 F to 100 F 26 C to 38 C 80W 140 15 F and
77. lied directly to the backface of the outer bearing cone a D 1 Press 59 i em xy So Drive Pinion 9 Stake pilot bearing using staking tool This is essen 11 Rear Axle Only Prior to installation of yoke make tial to retain the bearing sure yoke is clean and dry S Stake Pattern 1 o 12 Install yoke 13 Install yoke nut using one of the following options 10 Rear Axle Only With pinion installed and bearing a Install a new nut with the pre applied thread preload adjustment complete install oil seal Use adhesive compound Tighten the nut to the properly sized installation tool as described on page specified torque 71 to prevent distortion e 575 703 Ibs ft 780 953 Nem for rear pinion nut e 840 1020 Ibs ft 1140 1383 Nem for front pinion nut b fa new nut with pre applied thread adhesive compound is unavailable apply Loctite 277 or 271 available in 5 ml tube P N 129293 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 1 Tool Z 2 Seal Ed 20 3 Bearing cage 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 torqu ing the nut with the truck wheels
78. ll bearing cover and capscrews Seal shim pack with Spicer approved RTV compound to prevent lube leakage then torque input shaft capscrews 150 165 Ibs ft 204 224 Nem 10 Install yoke 11 Install yoke nut One of the following options may be used a Install a new nut with the pre applied thread adhesive compound Tighten the nut to the specified torque 840 1020 Ibs ft 1148 1383 Nem b If anew nut with pre applied thread adhesive compound is unavailable apply Loctite 277 or 271 available in 5 ml tube P N 129293 to the nut along two threads for at least two flats 120 of the nut midway through the thickness Tighten the nut to the specified torque 840 1020 lbs ft 1148 1383 Nem ein W Midway thru thickness of nut Note Use of a torque multiplier is recommended If difficulty is experienced in achieving correct torque torque the nut with the truck wheels on the ground and with the axle shaft installed A IMPORTANT Follow the instructions specified by the thread adhesive manufacture when applying thread adhesive compound Carrier Assembly Carrier Assembly Parts Exploded View Disassemble Carrier Assembly All Forward and Rear Axles 1 A 2 Note For models having the wheel differential lock option ora g carrier thrust bolt follow the steps below These parts EP must be removed first before further removal of the ad A wheel diff
79. mp shaft is facing toward the teeth end of the side 1 Machined Slot 2 Pin gear 29 Power Divider Lube Manifold Removal 1 Disconnect the hose from the lube manifold 2 Remove the manifold assembly by prying it out around the inner diameter A IMPORTANT IMPORTANT Once removed the seal manifold assembly can not be reused This component should always be replaced with new Use the same removal procedure for the output side gear seal removal on the non pump models 1 Barbed Nipple 30 Power Divider Manifold Installation 1 Install the manifold assembly into the output side gear bore in the carrier Make sure the barbed nipple is lined up with the opening in the carrier casting Note For non pump manifold installation it is important to line up the oil inlet path hole in the manifold with the oil path opening in the carrier manifold casting 1 Manifold Oil Inlet Hole y o 3 a 3 If the unit does not have a pump go to the Power Divider Assembly section If the unit contains a pump go to the Pump Assembly section 1 Barbed Nipple 2 Install the hose clamp on the hose push the hose onto the barbed fitting and slide the clamp over the barbed nipple 3 Route the suction end of the hose through the holes in the carrier casting to the bottom of the carrier 4 Fully press the manifold assembly into position Note Use care when pressi
80. ms require Standard Differentials 1 Block the vehicle Drain axle lubricant Rear Only Disconnect inter axle driveline Front Only Disconnect main driveline Front Only Disconnect differential lockout air line D OU Co P Disconnect lead wires to the selector switch and air line at shift cylinder 7 Remove axle shafts Diff Lock Models 1 Hand tighten with socket For removal of the locking wheel differential carrier assembly 2 M12 x 1 5 x 38mm bolt GM only 250 18 NPTF all the differential lock must be engaged and held in the engaged models except GM position This can be accomplished by one of two methods either engage via air pressure or engage manually Note With either method the axle shaft may have to be ie is rotated to permit the clutch to become engaged Engage via Air Pressure p gag a Using an auxiliary air line apply 80 120 PSI air pressure to shift cylinder air port to engage clutch Do not lie under carrier after fasteners are removed Use transmission jack to support differential carrier assembly prior to loosening fasteners i ET 3 D tS iq 2 3 8 To remove axle shaft remove axle stud nuts If used remove lock washers and taper dowels 9 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 f
81. n and cleaning procedures are important a Install output side gear and should be adhered to Cleanliness oe work area b Install the IAD assembly to the output side gear If is important as dirt is an abrasive and will cause prema reusing the IAD assembly install the same direction ture wear of the otherwise serviceable parts as removed Note It is assumed that the different carrier is secured in a stand A CAUTION During installation of power divider components parts may fall from the carrier if not careful Use caution to prevent injury or damage 1 Make sure dowel pins are installed in carrier 5 o 3 a 3 2 Output side gear bearing cup If removed press bearing cup in carrier Use a press and an appropri ate sleeve Make certain bearing cup is evenly and firmly seated If a press is not available use a sleeve or a bearing driver tool and a hammer to install the cup Lube Pump Models 3 Lubricate o rings a Install output side gear pump assembly into carrier 4 Install the output side gear using one of the follow The lube pump mounting holes are oriented in such ing instructions non pump models or lube pump a way that it can be installed only in one position models b Lube pump coupling Line up the drive couplings tangs with the pump and IAD notches The spacing of the tangs are the same one side to the other If reusing the IAD assembly install the same direction as it was remov
82. nd install spring pin in the long leg of the fork See illustration for fork mounting position on clutch 3 Position compression spring shift fork and clutch assembly in shift opening of the carrier Align pilot hole of shift fork with pilot hole of carrier Install pushrod engaging shift fork head and compression spring in carrier 4 Install new o ring on piston 5 Lubricate piston and o ring with silicone grease and install piston assembly in cylinder Position piston with small diameter hub toward closed end of cylin der 6 Screw piston driver on push rod 7 Tighten piston driver until shift fork clutch is approx imately 030 of an inch from the fixed clutch 72 8 Push down by hand on the piston driver both clutches must be completely engaged 9 Install set screw in piston driver torque to 12 15 Ibs ft 16 20 Nem A CAUTION On 3 90 ratio models only a washer P N 210288 must be used between the piston driver and piston Failure to install the washer will cause engagement and disengagement problems in the differential lock 10 Trial fit install piston cover assembly Hand tighten capscrews 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 must completely disengaged Repeat above procedure if clutches not completely disengaged
83. ng the manifold assembly to avoid damaging the seals and barbed nipple Do not over press plastic 31 Power Divider Hose Filter Assembly 1 Look to see that the hose guide collar is installed and 3 Next push the filter and hose down into the collar so not damaged If damaged or not present replace that the filter is fully seated Because of the with new increased diameter of the hose after the filter is installed the hose should fit snugly in the collar 2 Now with the collar installed push the hose through l the back side of the collar and install the filter to the 4 Fully seated position Know hose should be showing end of the hose and filter will contact the collar 32 Power Divider Install Power Divider to Carrier Assembly Assemblies built AFTER 11 02 98 In Vehicle Fe Install the output side gear if removed Note See page 34 for out of vehicle Note Parts inspection and cleaning procedures are important and should be adhered to Cleanliness in your work area is important as dirt is an abrasive and will cause prema ture wear of the otherwise serviceable parts A CAUTION During installation of power divider components the inter axle differential input shaft assembly or IAD shift system parts may fall from the carrier if not careful Use caution to prevent injury or damage Be Make Burg dowel pints are installed ii aner Install the IAD assembly to the output side gear If 2
84. ock 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 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 Fine Tuning the End play lf after performing the readjust 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 89 Lubricate Wheel End A IMPORTANT Before operating the axle the wheel hub cavities and bear ings must be lubricated to prevent failure When wheel ends are serviced follow Spicer s wheel end lubri cation procedure before operating the axle Spicer axles may be equipped with either of two wheel end designs e Wheel ends with an oil fill hole e Wheel ends without an oil fill hole Wheel Ends with an Oil Fill Hole 1 Rotate the wheel end hub until the oil fill hole is up 2 Remove the oil fill plug 3 Pour 1 2 pint o
85. 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 69 gt N _ z e e O o Fed D iv Cana Adjust Tooth Contact Pattern Adjust Pinion Position If the gear pattern shows incorrect tooth depth contact change drive pinion position by altering the shim pack Used gears should achieve proper contact with the same shims removed from the axle at disassembly Note Check ring gear backlash after each shim change and adjust if necessary to maintain the 0 006 to 0 018 specifications If the pattern is too close to the top land of the gear tooth remove pinion shims Move pinion toward the ring gear If the pattern is too close to the root of the gear tooth add pinion shims Move pinion away from the ring gear 70 Adjust Ring Gear Position Backlash If the gear pattern shows incorrect face width contact change backlash by adjusting the ring gear If the pattern is too close to the edge of the tooth toe move the ring gear away from the pinion to increase backlash 1 Loosen the bearing adjuster on the teeth side of the ring gear several notches 2 Loosen the opposite adj
86. 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 s 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 maintenance 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 st
87. omponents is changed relative 3 m 2 00 to the oil sump The same effect is present when the vehicle gt i travels up a Steep grade Oil in the sump remains level while 5 if 1 00 2 25 the axle itself tilts up or down This makes it possible for bear 7 1 25 2 50 ings and gears located well forward in the assembly to gt starve for lubrication even though the axle is filled to the 10 1 50 1 75 2 75 base of the fill plug hole as recommended by the manufac 13 1 75 2 00 3 00 turer 15 2 50 2 50 3 25 Axles should be modified with standpipes to raise lube levels whenever chassis installation angles exceed 10 and when the Pinion pointing upward vehicle must negotiate continuous or lengthy grades on a rou tine basis Tandem Rear Axles The chart gives standpipe recommendations for vehicles Installation 5 10 10 15 15 20 operating in consistently mountainous areas Angle Grade Grade Grade Axle Installation Axle Location Quantity 0 5 Angle pints 3 1 00 o D 12 Rear 19 5 1 00 1 75 S 10 Rear 21 70 z 175 7 00 8 Rear 22 5 10 a 900 995 6 Forward 24 5 13 1 00 995 975 j Ed 15 2 00 2 50 3 05 4 Forward 27 4 Rear 25 Pinion pointing upward 2 Forward 29 2 Rear 26 0 Forward 31 0 Rear 28 Does not allow for standpipe Capacities do not include wheel equipment requirements An additional 1 2 pints is required in each wheel hub 95 L
88. on the ground and with the axle shafts installed Note Forward axle pinion helical gear and bearing These parts are installed after pinion installation in carrier see page 54 60 Drive Pinion Install Drive Pinion Assembly 1 Forward Axle Only Place shim pack on carrier mak 3 Install drive pinion assembly Install bearing cage ing sure holes are properly aligned Make sure shims capscrews and lock washers Torque capscrews to S are flat with no kinks or bends 114 140 Ibs ft 155 190 Nem I Note Use a dummy yoke if available in place of helical gear 9 This will result in easier disassembly and reassembly during carrier adjustments 2 Rear Axle Only Place shim pack on carrier making sure lube holes are clear Note Do not install cotter pin until carrier adjustments are completed 4 Rear Axle Drive Pinion Install pinion assembly Install bearing cage capscrews and lock washers Torque capscrews to 114 140 Ibs ft 155 190 Nem 5 Forward Axle Helical Gear Only If dummy yoke was used remove nut and yoke Install helical gear on pinion Install M42 X 1 5 nut and torque to 840 1 020 Ibs ft 1 140 1 383 Nem 1 Lube slots Note If gear set is to be reused install same quantity and size of shims removed during disassembly When installing a new gear set use nominal shim pack indicated Nominal Shim Pack Axle in mm Forward 0 025 0 635 Rear 0 023 0 584
89. on with hand pressure and measure clearance between power divider cover and bearing cover using a feeler gauge i 1 Push in and zero indicator read and record 2 Pry down 5 Install yoke using installation tool and nut Tighten nut snugly Tap end of input shaft lightly to seat bear ings 6 Check input shaft end play with dial indicator posi tioned at yoke end of input shaft Move input shaft axially and measure end play If end play is correct seal shim pack with Spicer approved RTV compound to prevent lube leakage Then torque input shaft nut 3 The bearing cover clearance measured in Step 2 plus 7 If end play is incorrect change shim pack size as fol 0 005 will equal shim pack thickness required for lows desired end play rebuild with new parts Add 0 015 to shim pack for rebuild with used parts Add shims to increase end play Desired end play New Parts 0 003 to 0 007 Measured end play Step 6 0 001 0 001 Add shims to provide desired end play 0 002 to 0 006 Remove shim to decreased end play Measured end play Step 6 0 015 0 015 Desired end play New Parts 0 003 to 0 007 Remove shims to provide desired end 0 012 to 0 008 play 47 ae i 1 1 48 Power Divider 8 To add or remove shims remove input shaft nut and yoke Remove capscrews lock washers and bearing cover Add or remove shims as required 9 Insta
90. r 5 Number of pinion teeth 6 Date code 7 Indicates genuine Spicer parts 8 Heat Code 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 gears 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
91. rom input shaft using a puller tool TIP A yoke puller tool may be made from the center section of most gear puller tools or may be pur chased from your local tool distributor 8 Remove capscrews input bearing cover and shim pack 9 lf input shaft bearing cup needs replacement use either of the following recommended practices e Weld a bead around the cup when the weld cools the cup will fall out e Drill a 1 4 size hole through the bearing cover to the back side of the cup and use a punch to remove the bearing cup 10 Slide input shaft assembly out of cover 1 Press 2 Bearing 3 Oil retainer 4 Input shaft Note Shift fork cannot be removed until lockout cover is removed and push rod is removed from shift fork See Differential Lockout Section 12 Press new oil retainer on input shaft A CAUTION It is not recommended to reuse the oil retainer due to possi ble damage that may occur while removing the input shaft bearing cone While pressing on new oil retainer make sure not to over press and or press with the retainer at an angle If the retainer is bent or distorted it may rub on the input cage or not seal properly to the v ring Power Divider 16 If bushing removal is needed the bushings must exit 13 Press input bearing cone on input shaft from the thrust washer side of the helical gear 1 Tap out bronze bushings 17 Install bronze bushing in helical side ge
92. rom the carrier if not careful Use caution to prevent injury or damage 1 Make sure dowel pins are installed in carrier 2 Install output side gear bearing cup if removed Press bearing cup in carrier Use a press and an appropriate sleeve Make certain bearing cup is evenly and firmly seated If a press is not available use a sleeve or a bearing driver tool and a hammer to install the cup 3 Lubricate o rings 1 O rings 2 Bearing cup 4 Install the output side gear if removed 22 5 Install the IAD assembly to the output side gear If reusing the IAD assembly install in the same direc tion as removed Note For lube pump models see instructions on page 24 A IMPORTANT If power divider was manufactured before 11 02 98 the complete power divider assembly can be installed as one unit It can be lifted or lowered into place with the input cage input shaft thrust washer helical side gear and snap ring assembled to the PDU cover TIP The use of two guide pins in the carrier mating surface will help align the PDU cover and aid in installation Guide pins may be made from M14 X 2 bolts approximately 4 inches long with the heads removed 6 Install power divider assembly to carrier assembly Use Spicer approved RTV compound on the carrier mating surface Power Divider A CAUTION During installation of power divider cover the inter axle dif ferential IAD input shaft assembly or
93. rom their intended location Identify left and right shafts for reference during reassembly TIP If necessary loosen dowels by holding a brass drift in the 1 Connect 80 120 PSI air line to cylinder port center of the shaft head and striking drift a sharp blow with a hammer Engage Manually A CAUTION a Install a 250 18 NPTF bolt over 1 5 long in the cyl inder air port to manually engage the clutches GM models require a M12 X 1 5 X 38mm bolt Do not strike the shaft head with a steel hammer Do not use chisels or wedges to loosen shaft or dowels 10 Remove carrier capscrews nuts and lock washers 11 Remove differential carrier assembly Install Differential Carrier Forward and Rear Install Differential Carrier Forward and Rear A IMPORTANT Before installing carrier assembly inspect and thoroughly clean interior of axle housing using an appropriate solvent and clean rag 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 reapply 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 M16 X 1 5 threaded into carrier cap screw holes Rod should be approximately 6 long Use these to pilot the carr
94. s 193 000 Km 5 years or lyear Synthetic SHAES 256 SAE 75W 90 250 000 miles 400 000 Km or 60 000 miles 96 500 Km or 1 75W 140 3 years year Mineral MIL L 2105E J02360 75W 75W 90 120 000 miles 193 000 Km or 60 000 miles 96 500 Km or Base API GL 5 Gear Oil 75W 140 80W 1 year 1 year MIL PRF 2105E 90 85W 140 Axles using LMS wheel end system Axles using adjustable wheel bearing system m 5 T D Oo Ss 93 Lubrication Change Lube Drain Drain when the lube is at normal operating temperature 150 200 F It will run freely and minimize the time neces sary to fully drain the axle this insures the axle is flushed Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container Note Dispose of all used lubricants properly by following dis posal methods approved for mineral or synthetic based oils After initial oil change inspect drain plug for large quantities of metal particles These are signs of damage or extreme wear in the axle Clean the drain plug and replace it after the lube has drained completely Inspect breather for clogging or cor rosion Clean or replace as necessary Fill Front Axle a With vehicle on level ground remove the filler hole plug from the axle housing cover and fill the axle with approved lubricant until level with the bottom of the hole Rear Axle a Remove the filler hol
95. see page 81 e After verifying end play secure the outer nut by bending 180 apart two opposing tangs of the locking washer over the outer nut 12 Install the following e New gasket at axle shaft flange e Axle shaft e Axle flange nuts and tighten to specified torque 13 Lubricate axle wheel ends Verify Wheel End play Procedure Verify that end play meets specification using a dial indicator Adjust End play with Wheel Hub An indicator with 0 001 0 03 mm resolution is required Wheel end play is the free movement of the tire and wheel assembly along the spindle axis Correct end play is 001 005 0 025 0 125 mm 1 Attach a dial indicator with its magnetic base to the hub or brake drum as shown below 2 Adjust the dial indicator so that 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 With indicator mounted at bottom bearing end play as the total indicator movement Push Pull at sides of drum A CAUTION Readjust Wheel End play Procedure If end play is not within specification readjustment is required Excessive End play If end play is greater than 005 Adjust End play with Tire and Wheel Assembly 127 mm remove the outer nut and pull the l
96. splined to differential case 9 Sliding clutch splined to axle shaft Parts Identification Power Divider Parts Exploded View 1 Output shaft nut 2 Output yoke 3 Output seal 4 Output shaft bearing snap ring 5 Outer bearing cup 6 Outer bearing cone 7 Inner bearing cone 8 Inner bearing cup 9 Output shaft 10 Seal manifold assembly 11 Sump screen 12 Seal manifold feed tube 13 Output side gear bearing cup 14 Output side gear bearing cone 15 Pump locking Pin 16 Output side gear 17 Pump 17A Old style pump 17B Output side gear bearing cup 18 Snapping ring 19 Inter axle differnential 20 Helical side gear 21 Sliding clutch 22 Push rod spring 23 Shift fork assembly 24 Input shaft 25 Input shaft oil retainer 26 Input shaft bearing cone 27 Power divider cover integral 28 Lube trough 29 Capscrew 30 Shift fork 31 Power divider cover Old style 32 Push rod 33 Input bearing cup 34 Input cage shim 35 Input cage V ring 36 Input cage 37 Capscrew 38 Oil seal 39 Input yoke 40 Input nut 103 y rt D e Z 2 D 5 d D Parts Identification Front Drive Axle Parts Exploded View BR OT 1 Flange half bearing adjuster 2 Flange half bearing cup 3 Flange half bearing cone 4 Flange half c
97. the pinion shank 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 57 i em xy So Drive Pinion Final Buildup Note On rear axles do not install oil seal in cage until bearing 3 Install bearing cage on drive pinion 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 1 Press inner bearing cone on pinion 4 Press outer bearing cone on pinion A IMPORTANT To prevent bearing damage spin cage while pressing outer bearing on A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cone 2 Install preselected bearing spacer 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 on next page 58 Drive Pinion Specifications for Pinion Bearing Final Buildup Preload Test 6 Measure Pinion Bearing Preload Use a spring scale or to test the assembly rolling torque To use the spring pe A Toe ra w o
98. ts 98 The inter axle differential compensates for minor variations in speed between the two axles the same way the wheel differ ential works between the two wheels of a single drive axle This unit also acts as a central point in distribution of torque to the two axles The power divider also includes a driver controlled air operated lockout When lockout is engaged it mechani cally prevents inter axle differentiation for better performance under poor traction conditions 4 Rear axle torque is transmitted from the output shaft side gear through the output shaft inter axle driveline drive pin ion ring gear wheel differential and axle shafts 5 Input torque power flow from the vehicle driveline is transmitted to the input shaft and the inter axle differential spider The differential distributes torque equally to both axles Theory of Operation With Lockout Engaged Note Varied road surface conditions can result in unequal Inter Axle Differential is Not Operating torque distribution between the two axle assemblies Lockout should only be engaged when both axles are rotating at the same speed Operation should be limited to low traction A CAUTION situations and should be disengaged when normal traction returns Failure to do so will result in poor handling and dam Prolonged operation with the lockout engaged can damage age to the axle components axle and driveline components
99. ubrication Horizontal Mounting iM 12 Installation 12 Installation with Standpipe 1 Oil filler hole 2 Lost oil capacity 3 Additional oil capacity Note Grades must be continuous or lengthy in nature Moni tor oil temperatures before installing standpipes Axles should operate at approximately 100 F 38 C over ambient temperature and not exceed 240 F 116 C 96 Final Check Prior to putting vehicle back into service run the vehicle to bring axle lube up to temperature Check filler and drain plugs and axle joint for leakage Re tighten to specifications as nec essary Proper Vehicle Towing 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 bearings 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 fol lowing section Proper Vehicle Towing with Wheel Differential Lock for removal procedure With Wheel Differential Lock Follow this procedure to remove all axle shafts preventing gear rotation with the
100. up and bearing adjuster to the plain half side Use a long screwdriver or bar to lift the differential up while installing the cup and bearing adjuster Wheel Differential Assembly Measure and Adjust Carrier Assembly Adjust Backlash and Preload 3 Tighten the plain half adjuster two lug notches Start with the notch at the top count two notches coun terclockwise on the adjuster turn the adjuster so that the notch is facing straight up You now have a two notch preload N A AN 1 Flange half 2 Plain half 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 pey CD i a mel CD CD gt 2 4 Use a rubber mallet to make certain that both bear ing adjusters are fully seated 1 Flange half 2 Plain half 5 Measure backlash Make sure it is within specifica 2 Tighten the plain half adjuster until the bearing cup tion of 006 018 just starts to turn this is a zero bearing preload TIP To give yourself room to adjust contact pattern set it between 010 012 67 Wheel Differential Assembly Change Backlash Setting If you have too much backlash the ring gear needs to move Measure Ring Gear Runout closer to the pinion Back off the plain half adjuster count the number of notches you back it off each notch equals about Measure Ring Gear Total 003 of backl
101. ust be replaced as a complete assembly Wear safety glasses 27 Lube Pump Removal Assemblies Built After June 15 2008 For output side gear and or pump replacement follow the 3 Remove pump from the output side gear procedure below 1 Remove the output side gear bearing cone if required 1 Press 2 Press Tool 2 Remove pump locking dowel pin from the hole in the output side gear hub 28 Power Divider Lube Pump Installation Assemblies Built After June 2008 Use these instructions with the carrier assembly in or out of 2 Install the pump locking dowel pin into the hole in the vehicle the output side gear hub Make sure the pin is lined up with the machined slot in the pump body If the unit does not have a pump go to the Power Divider Assembly section Note Keep work area clean Dirt is an abrasive and will cause premature wear of the otherwise serviceable parts Note For non pump models see output side gear seal mani fold installation Note Only service the power divider if the differential carrier oe is secured in a stand or while the axle is still attached to the housing 2 CAUTION D A CAUTION CAUTION During installation of power divider cover the inter axle differential IAD input shaft assembly or IAD shift sys tem parts may fall from the carrier if not careful Use caution to prevent injury or damage 1 Install the pump into the output side gear so that the pu
102. uster one notch 3 Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup 4 Continue tightening the same adjuster 2 or 3 notches and recheck backlash If the 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 Wheel Differential Lock Wheel Differential Lock Parts Exploded View DE Ka la X ae D di co wa DO wo o 3 i 3 hd 3 p D m o vr 1 Piston engagement bolt 8 Piston driver 2 Capscrew 9 Pushrod 3 Switch 10 Clutch fork 4 Washer 11 Spring 5 O ing 12 Sliding clutch 6 Piston 13 Pin 7 Setscrew 14 Piston cover 71 Wheel Differential Lock Install and Adjust Wheel Differential Lock Note With differential carrier completely assembled and adjusted install differential lock as follows 1 Install fixed curvic clutch on splined hub of flanged differential case then install snap ring 2 If shift fork and sliding curvic clutch are disassem bled engage fork with clutch hub a
103. utch 13 Pin 14 Piston cover 73 Housing and Output Shaft Assembly Remove Output Shaft Assembly Note For forward axle rear covers that are removable the out TIP It may be helpful to loosely reinstall the yoke put shaft may be removed when the cover is in or out of and shoulder nut giving the technician more of an the axle assembly area to grip when removing the output shaft 1 Disconnect the inter axle driveline at the forward 7 Remove the inner bearing cup from rear cover axle rear cover position assembly This may be removed from inside the axle housing when the carrier is removed or by removal 2 Remove yoke nut shoulder nut of the forward axle rear cover 3 Remove yoke from output shaft using appropriate 8 Remove both inner and outer bearing from output tool shaft 1 Yoke puller tool TIP A yoke puller tool may be made from the center 1 Press section of most gear puller tools or may be pur chased from your tool distributor 9 Remove output shaft inner bearing cup 4 Remove oil seal Note On 11 02 98 a design change was made to the forward 5 Remove snap ring axle housing in the 404 family axles The rear axle hous l ing cover is now a welded assembly To replace the 6 Remove output shaft and outer bearing cup as an inner output shaft bearing cup on axle housings that assembly have the welded on D Cover follow the steps outlined below 1 DT Note Components such as the inter axle driveline
104. utput shaft bearings are assembled with both bearing cones back to back Use a press and a sleeve to install one bearing at a time A CAUTION To prevent bearing damage use a suitable sleeve that only contacts the bearing race 2 Apply pressure until the inner bearing cone touches the shoulder of the output shaft 3 Apply pressure until the back of the outer bearing cone touches the back of the inner bearing Note Axle housings with welded on covers procured through service will include the inner bearing cup as part of the service axle housing assembly Go to Step 6 if the inner cup has already been installed 4 Lightly coat the output bore of the axle housing cover with a 9 5 38 wide application of Loctite 680 where the bore contacts the inner bearing cup Do not apply Loctite outside of this area to the bearing rollers or outboard of the inner cup bore Improper application of the Loctite could lock the rollers or cause excessive pre load A CAUTION Add loctite adhesive to the inner bearing surface of the housing and NOT to the bearing race itself If added to the race excessive adhesive could get on the surface of the outer bearing race journal during installation and cure the outer cap in place with excessive pre load 5 Using a sleeve and driver hammer install the inner bearing cup 6 Put the output shaft and bearing assembly into the axle housing assembly 7 Using a sleeve and driver hammer install
105. yoke oil seal and output shaft assembly should have been removed according to normal service procedures Removing the differential assembly from the axle hous ing is not necessary but would ease the removal pro cess of the inner bearing cup from the cover bore vd a Using a bearing puller tool remove the inner 5 bearing cup b Visually inspect the inner machined bore sur face of the welded on cover for nicks and burrs Repair if necessary 1 Snap ring 4 Inner bearing cup 2 Outer bearing cup 5 Rear cover assembly 3 Output shaft assembly 74 Housing and Output Shaft Assembly Housing and Output Shaft Assembly Parts Exploded View Welded Rear Cover Oo 2 2 3 z O 3 m N 2 h 1 Output shaft nut 11 Rear cover capscrew 21 Breather 2 Output yoke 12 Fill plug 22 Breather hose 3 Output seal 13 Rear cover nut 23 Carriage capscrew 4 Snap ring 14 Lock washer 24 Lock washer 5 Outer bearing cup 15 Stud 25 Nut 6 Outer bearing cone 16 Dowel 26 Lock washer 7 Inner bearing cone 17 Jam nut 27 Stud 8 Inner bearing cup 18 Locking ring 28 Drain plug 9 Output shaft 19 Spindle nut 29 Axle shaft 10 Rear cover 20 Axle housing 75 Housing and Output Shaft Assembly Overhaul and Assemble Output Shaft Assembly Note Lubricate the parts with gear lube during assembly 1 The o

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