Spicer 34DS, 34RS, 38DS, 38RS, DS340 User Manual

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Spicer® Single Drive Axles

Service Manual

Spicer® Single Drive Axles

AXSM-0041 September 2007

Table of Contents

Introduction .........................................................1

Failure Analysis ...................................................7

Inspection ...........................................................9

Differential Carrier Assembly - Parts .................11

Differential Lockout ...........................................17

Power Divider

Power Divider - Parts Exploded View........................ 23

Remove Power Divider............................................. 24

Remove Power Divider from Differential Carrier

(with carrier removed from axle housing) ................ 25

Disassemble, Assemble and Overhaul

the Power Divider..................................................... 27

Install Power Divider on Differential Carrier

(with carrier assembled to axle housing) .................. 38

Install Power Divider on Differential Carrier

(with carrier removed from axle housing) ................. 40

Dissasemble Differential Carrier

(with power divider removed) ...................................54

Drive Pinion

Drive Pinion - Parts Exploded View............................ 57

Disassemble and Overhaul Drive Pinion.................... 58

Install Drive Pinion Assembly.................................... 65

Wheel Differential Assembly Wheel Differential Assembly

- Parts Exploded View ............................................... 68

Housing and Rear Cover Assembly

- Parts Exploded View ............................................... 91

Seals ..................................................................92

Housing Breather ..............................................94

Wheel End Seal - Parts Exploded View .............95

Remove and Overhaul Wheel End Seal .............96

Wheel Adjustment Systems ..............................97

Verify Wheel End-play Procedure ......................99

Lubricate Wheel End .......................................100

Lubrication ......................................................102

Lube Change Intervals ....................................103

Change Lube ...................................................104

Standpipes ......................................................105

Torque Chart ...................................................107

Appendix

Wheel Differential Lock ...........................................109

Differential Lock Theory of Operation ....................110

Control Systems ....................................................111

Dual Range Axle Shift Systems ..............................113

Troubleshooting .....................................................120

Proper Vehicle Towing ...........................................122

Axle Shift System Components ..............................124

Inter-Axle Differential Lockout

With Interlock Control Valve (straight-air type) ......126

Theory of Operation ...............................................129

Power Flow and Torque Distribution ......................130

Lubrication .............................................................132

Torque Distribution in Low Range .........................136

Table of Contents

Out of Vehicle Resetting

Introduction Dana Corporation, presents this publication to aid in maintenance and overhaul of Dana tandem drive axles. Instructions contained herein cover four basic axle models. Their design is common, with differences in load capacity. Capacity variations are achieved by combining basic differential carrier assemblies in different axle housings, axle shafts and wheel equipment.

Load Capacity Model No.

34,000 lbs. . . . . . . . . . . . . .. DS340, 341

38,000 lbs. . . . . . . . . . . . . . . DS2380(P)

38,000 lbs. . . . . . . . . . . . . .. DS381(P)*

40,000 lbs. . . . . . . . . . . . . . . . DS400-P, DS401-P, DS402(P), DS403(P)

45,000 lbs.. . . . . . . . . . . . . .. DS451-P

Some models (identified with letter “P”) are equipped with a gear-driven pump, designed to provide additional lubrication to the inter-axle differential and related parts. Instructions contained herein are applicable to all axle models, unless specified otherwise.

For brake information and axle mounting or suspension systems, refer to pertinent truck manufacturer’s literature.

Typical Dana Single Reduction Tandem Axle

Two design variations of tandem axles are included in this manual. The major difference is in the shaft spline design. Note: DS381 (P) axles manufactured after April 1985 are rated at 40,000 lbs.

Axle and Carrier Assembly Model Identification

Drive Axle

General Information

Gear i n g

D - For war d Tan dem Axle R - Rear Tan dem Axle

S - S i ngle Redu ction D - S i n gle Reduction with Wheel Differ e n tial Lock T - Du al Ran ge P - Plan etar y Dou ble Reduction

Example:

D S = For ward Tan dem Axle/Sin gle Redu ction R S = Rear Tandem Axle/S in gle Redu ction

Note: Tags that do not include all the information shown here

are older models (before May 1987).

CUST. PART NO.

SPEC. SERIAL NO.

MODEL PART NO. RATIO

MADE IN:

Spicer

L u be Pu mp

P = S tan dar d (P) = Option al

Design Level

Capacity (x 1000 lbs.)

Example: 46 = 46,000 lbs .

Service Procedure

CUST. PART NO.

Spicer

SPEC. SERIAL NO.

MODEL PART NO. RATIO

MADE IN:

Data plate is located on

the axle centerline

CUST. PART NO.

SPEC. SERIAL NO.

MODEL PART NO. RATIO

MADE IN:

Spicer

Forward Axle (Side View) Rear Axle (Top 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. 4 - OEM part number assigned to the axle build 5 - Carrier assembly serial number assigned by the manufacturing plant 6 - Axle gear ratio 7 - Carrier assembly production or service part number

General Information

Part Identification

Axle Housing Axle Shaft

T P .

SH BL GSH

OH U DAM

ecipS

O N .

. P

A C .G

N .D

E . I .. G N I

1 - ID Tag 2 - Axle shaft part number

Axle Specification Number

The complete axle is identified by the specification number stamped on the side of the axle housing. This number identifies all component parts of the axle as built by Dana, including special OEM requirements such as yoke or flange. In addition, some axles may include a metal identification tage.

Ring Gear and Pinion

Note: Ring gear and drive pinion are matched parts and must

be replaced in sets.

General Information

Service Procedure

8307L

183721

RECIPS

41-8

2LN

14-8

721

RECIPS

824721

1 - Part number 2 - Number of ring gear teeth 3 - Manufacturing numbers 4 - Matching gear set number 5 - Number of pinion teeth 6 - Date code 7 - Indicates genuine Spicer parts 8 - Heat code

6-39

J D 7 7

5 0 4 58

8 6

EATON

General Information

Power Flow and Torque Distribution

Spicer tandem drive axles described in this publication are single reduction units designed primarily for highway or turnpike. They are also for a variety of other applications. This type of axle provides a vehicle with superior load carrying and roadability characteristics by dividing its work between two axles. The complete tandem assembly consists of two axles coupled by a power divider.

Lube Pump System

Power Divider

In operation, the power divider accepts the torque from the vehicle 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. The inter-axle differential compensates for axle speed variations in the same way the wheel differential 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 mechanically prevents inter-axle differentiation for better performance under poor traction conditions.

Gearing

The gearing for each axle is of the spiral bevel design with drive pinion positioned at centerline of the ring gear. The differential and drive pinion are mounted on tapered roller bearings. The wheel differential is a 4 pinion and 2 side gear design.

Lube Pump

Tandem Axles with suffix letter "P" in Model No. are equipped with a lube pump to provide positive lubrication to the inter- axle differential and other power divider parts. This pump is operated by a drive gear engaged with the input shaft splines. When vehicle is moving in a forward direction, pressurized lube is delivered to the vital power divider parts. The pump lube system incorporates a magnetic strainer screen. To keep the system clean, the magnet traps minute particles and the screen blocks out large particles of foreign material.

General Information

Torque Distribution with Lockout Disengaged (Inter-axle Differential is Operation)

Torque (power flow) from the vehicle driveline is transmitted to the input shaft and the inter-axle differential spider. At this point, the differential distributes torque equally to both axles. For the forward axle, torque is transmitted from the helical-side gear to the pinion helical gear, drive pinion, ring gear, wheel differential and axle shafts. For the rear axle, torque is transmitted from the output shaft side gear, through the output shaft, inter-axle driveline, to the drive pinion, ring gear, wheel differential and axle shafts.

Input torque

Lockout disengaged

Inter-axle differential

operating

Torque is transmitted to both axles through inter-axle differential action.

Drive is

from differential

through output

shaft to

rear gearing

Drive is from differential through helical gears to

forward gearing

Torque Distribution with Lockout Engaged (inter-axle Differential is Not Operation)

A lockout mechanism is incorporated in the power divider to enable the vehicle driver to lock out the inter-axle differential and provide maximum traction under adverse road conditions. In operation, an air cylinder (controlled by a cab-mounted valve) shifts a sliding clutch. To lock out inter-axle differential action, the clutch engages the helical-side gear and causes this gear, the input shaft and differential to rotate as one assembly. This action provides a positive drive to both axles. With Lockout engaged, torque is distributed to both-axles without differential action. The forward axle pinion and ring gear are driven by the helical side gear. The rear axle gearing is driven from the output shaft side gear and inter-axle driveline.

Service Procedure

Note: Varied road surface conditions can result in unequal torque distribution between the two axle assemblies.

Input torque

Lockout engaged

Inter-axle differential

not operating

Torque is transmitted to both axles without inter-axle differential action.

Drive is from input shaft

through helical gears to

Drive is from

output shaft side

gear to rear

gearing

forward gearing

Spicer Single Reduction Tandem Drive Axles

Differential Carrier Assembly Exploded View

Forward Axle Carrier Assembly (Single Speed) with Diff. Lock

52 53 54 56 57 58 55 6 1 5

Other Design Variations

23 24

DIFFERENTIAL

& RING GEAR

29 31 32 35 34 38 36 37 3435 28 27 26 25

19 15

Axle Series D340, 380(P),400-P D341, 381(P), 401-P, 402(P), 403(P), 451-P

Output Shaft Splines 16 16

Side Gear End 16 16

Output End 10 34

Input Shaft Splines

Input End 15 44

Diff End 36 36

Helical Gears 7 pitch 5 pitch

Drive Pinion Splines

Forward Axle 10 41

Rear Axle 10 39

Axle Shaft Side Gear Splines

D340- 16 D341- 39

D380(P)- 16 D381(P), 402(P), 403(P)- 41

D400(P)- 33 D401-P, 451-P- 33

Spicer Single Reduction Tandem Drive Axles

Axle Series D340, 380(P), 400-P, D341, 381(P), 401-P, 402(P), 403 (P), 451-P

INTER-AXLE

64 65

DIFFERENTIAL ASSEMBLY

Service Procedure

76 77

39 31 40

79 80 81 82 83

106

43 45

LUBE PUMP

444647

84 85 86 88 89 90

105

94 97 98 99

100

101

104 103 95

Note: Before Replacing Seals, Yokes, and Slingers, refer to the Repair and Replacement Instructions for interchangeability infor-

mation.

102

Spicer Single Reduction Tandem Drive Axles

1 - Differential carrier & bearing caps 2 - Bearing capscrew 3 - Flat washer 4 - Lockwire 5 - Dowel bushing 6 - Bearing cap adjuster lock (RH) 7 - Capscrew 8 - Bearing cap adjuster lock (LH) 9 - Cotter pin (LH) 10 - Expansion plug (upper) 11 -Expansion plug (lower) 12 - Filler plug 13 - Shift fork shaft 14 - Carrier cover dowel pun

Shi

15 16 - Shift fork seal & spring assembly 17 - Flat washer 18 - Stud nut 19 - Shift fork & roller assembly 20 - Shift unit assembly 21 - Sliding clutch 22 - Differential bearing adjuster (RH) 23 - Differential bearing cup (RH) 24 - Differential bearing cone (RH) 25 - Differential bearing adjuster (LH) 2 27 - Differential bearing cone (LH) 28 - Differential case (plain half) 29 - Differential case (flanged half) 30 - Differential case capscrew 31 - Ring gear & drive pinion 32 - Bolt 33 - Nut 34 - Differential side gear 36 - Side pinion

ft unit mounting stud

6 - Differen

tial bearing cup (LH)

37 - Side pinion thrust washer 38 - Spider

t bearin

39 - Pinion pilo 40 - Pinion bearing cone 41 - Pinion bearing spacer washer 42 - Pinion bearing spacer 43 - Pinion bearing cup 44 - Pinion bearing cage 45 - Pinion bearing cage shim 46 - Lock washer 47 - Bearing cage capscrew 48 - Pinion helical gear 49 - Outer pinion support bearing (one piece) 50 - Pinion shaft end nut 51 - Pinion nut spring p 52 - Outpu 53 - Output shaft washer 54 - Rear bearing retaining washer 55 - Axle housing cover 56 - Output shaft oil seal 57 - Bearing snap ring 58 - Output shaft bearing 59 - Filler plug 60 - Output shaft 61 - Output shaft bushing 62 - Output shaft O-ring 63 - Output shaft bearing cup 64 - Output shaft bearing cone 65 - Output shaft side gear 66 - Side gear snap ring 67 - Output shaft compression spring 68 - Output shaft thrust bearing 69 - Inter-axle differential assemble 70 - Inter-axle differential case half 71 - Case bo

t shaft nut

72 - Case nut 73 - Side pinio 74 - Side pinion thrust washer 75 - Spider 76 - Helical side gear snap ring 77- Helical side gear 78 - Helical side gear bushing 79 - Helical side gear thrust washer 80 - Helical side gear “D” washer 81 - Lo 82 - Inp 83 - Input shaft bearing cone 84 - Input shaft bearing cup 85 - Input cover shim 86 - Input bearing cover 87 - Bearing cover capscrew 88 - Input shaft oil seal 89 - Input shaft nut washer 90 - Input shaft nut 91 - PDU carrier cover 92 - Carrier cover capscrew 93 - Lock 94 - Pipe plug 95 - Exp 96 - Magnetic filter screen 97 - Pump gear & shaft assembly 98 - Cover O-ring 99 - Lube pump cover 100 - Lock washer 101 - Cover capscrew 102 - Cover d 103 - Pump drive gear 104 - Drive gea 105 - Air-operated lockout assembly 106 - Shift fork & push rod assembly

ckout sliding clutch

ut shaft

washer

ansion plug

owel pin

r locknut

Spicer Single Reduction Tandem Drive Axles

Differential Carrier Assembly

Rear Axle RS340, 341, 380, 400, 401, 402, 403, 451

10 11 12 15 18 20 21 17 18 13 15 12 11 10

16 17 19 14 14

Service Procedure

243 6

6 5 1 1 22 23 24 29 31 32

1 - Differential carrier & bearing caps 2 - Bearing capscrew 3 - Flat washer 4 - Lockwire 5 - Bearing cap adjuster lock 6 - Cotter pin 7 - Dowel bushing 8 - Ring gear thrust screw 9 - Thrust screw jam nut 10 - Differential bearing adjuster 11 - Differential bearing cup

8 9 27 26 28 25 26 23 30 33

12 - Differential bearing cone 13 - Ring gear & drive pinion 14 - Bolt and nut 15 - Differential case (flanged half) 16 - Differential case capscrew 17 - Differential side gear 18 - Side gear thrust washer 19 - Side pinion 20 - Side pinion thrust washer 21 - Spider 22 - Pinion pilot bearing

23 - Pinion bearing cone 24 - Pinion bearing spacer 25 - Pinion bearing cage 26 - Pinion bearing cup 27 - Pinion bearing spacer washer 28 - Pinion bearing cage shim 29 - Bearing cage capscrew 30 - Oil seal 31 - Input yoke 32 - Flat washer 33 - Pinion nut

Lubrication

The ability of a drive axle to deliver quiet, trouble free operation over a period of years is largely dependent upon the use of good quality gear lubricant in correct quantity. The most satisfactory results can be obtained by following the directions contained in this manual. The following lubrication instructions represent the most current recommendations from Dana Corporation.

Approved Lubricants

General—Gear lubrications acceptable under military specification (MILSPEC) MIL-L-2105D (Lubricating Oils, Gear, Multipurpose) are approved for use in for multigrade oils. It supersedes both MIL-L-2105B, MIL-L-2105C and cold weather specification MlL-L-l 0324A. 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 modifiers are not approved in Dana 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 lubricants include extended change intervals, improved fuel economy, better extreme temperature operation, reduced wear and cleaner component appearance. The family of Spicer TM 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 Spicer representative. See back cover of this manual for appropriate phone number.

Spicer Drive Axles. The MIL-L-2105D specif

ication defines performance and viscosity requirements

Makeup Lube — Maximum amount of non-synthetic makeup lube is 100/o.

Viscosity / Ambient Temperature Recommendations -The following chart lists the varies 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 Roadranger 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 temperature range, must be obtained through tcontacting your local Spicer epresentative.

Grade Ambient Temperature

75W - 40 F to -150 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 - 40 F to 100 F (-40 C to -38 C)

80W-140 - 40 F and above(-40 C and above)

85W-140 - 40 F and above (-40 C and above)

Lubrication

Lube Change Intervals

This product combines the latest manufacturing and part washing technology. When filled with an Spicer approved synthetic lubricant at the factory, the initial drain is not required.

Change the lubricant within the first 5,000 miles of operation when not using 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.

Severe Service Lubrication Change Intervals-Severe service applications are those where the vehicle consistently operates at or near its maximum GCW or GVW ratings, dusty or wet environments, or consistent operation on grades greater than 8%. For these applications, the ON/OFF HIGHWAY portion of the chart should be used. Typical applications are construction, logging, mining and refuse removal. Note: Remove metallic particles from the magnetic filler plug and drain plugs. Clean or replace the breather at each lubricant

change.

Spicer approved synthetic lubricant in either a

Guide Lines - Lube Change Intervals for Drive Axles

Lubricant Type On-Highway Miles Maximum change In-

terval

Mineral Based 100,000 Yearly 40,000 Yearly

Roadranger Approved Lubricant

250,000 3 Years 100,000 Yearly

On/Off Highway Severe Service Miles

Maximum Change Interval

Changing Lube

Draining

Drain when the lube is at normal operating temperature. It will run freely and minimize the time necessary to fully drain the axle. Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container. Inspect drain plug for large quantities of metal particles. After initial oil change, these are signs of damage or extreme wear in the axle, and inspection of the entire unit may be warranted. Clean the drain plug and replace it after the lube has drained completely.

Service Procedure

Axles with Lube Pump: Remove the magnetic strainer from the power divider cover and inspect for wear material in the same manner as the drain plug. Wash the magnetic strainer in solvent and blow dry with compressed air to remove oil and metal particles.

CAUTION

Exercise care to direct compressed air into safe area. Wear safety glasses.

Lubrication

Filling

Remove the filler hole plug from the center of the axle housing cover and fill the axle with approved lubricant until level with the bottom of the hole.

Forward axles: Add two pints (0.94 liters) of lubricant through filler hole at the top of the differential carrier near the power divider cover.

Oil Filler Hole at top of Differential Carrier Magnetic Strainer for Axle with Lube Pump

Note: Lube fill capacities in the adjacent chart are good guidelines but will vary somewhat on the basis of the angle the axle is

installed in a particular chassis. Always use the filler hole as the final reference. If lube is level with the bottom of the hole, the axle is properly filled.

Axle Installation Angles

Axles installed at angles exceeding 10 degrees or operated regularly in areas of continuous and lengthy grades may require standpipes to allow proper fill levels.

For specific recommendations, contact your local

Spicer representative. See back cover of

this manual for phone numbers.

Lube Capacities, Dana Housings

Single Reduction Tandem Series Forward Axle Pints (liters) Rear Axle Pints (liters)

380(P), 381(P), 400-P, 401-P 39 (18.5) 36 (17.0)

402(P), 403(P),451-P 39 (18.5) 36 (17.0)

Forward Axle: Add an additional 2 pints divider cover.

Capacities listed are approximate. The amount of lubricant will vary with angle of axle as installed in vehicle chassis.

(0.94 liters) axle lubricant through filler hole at the top of differential carrier near the power

Lubrication

Wheel End Lubrication

IMPORTANT

Before operating the axle, the wheel hub cavities and bearings must be lubricated to prevent failure. When wheel ends are serviced, follow Spicer’s wheel end lubrication procedure before operating the axle.

Spicer axles may be equipped with either of tw

• Wheel en

ds with an oil fill hole.

o wheel end designs:

• Wheel ends without an oil fill hole.

Wheel Ends with an oil fill hole proceed as follows: (Fig. 1)

1. Rotate the wheel end hub until the oil fill hole is up.

2. Remove the oil fill plug.

3. Pour 1/2 pint of axle sump lubricant into each hub through the wheel end fill hole.

4. Install oil fill plug and tighten to specified torque.

Wheel End with Oil Fill Hole

WHEEL END

OIL FILL HOLE

Wheel End without Oil Fill Hole

Service Procedure

LUBRICANT

FLOW

FROM SUMP

PROPER

LUBRICANT

LEVEL

Fig. 1 Cutaway views of typical wheel and assemblies

PROPER

LUBRICANT

LEVEL

Lubrication

Wheel Ends without an oil fill hole proceed as follows: (Fig. 2)

1. With axle level and wheel ends assembled, add lubricant through filler hole in axle housing cover until fluid is level with the bottom of filler hole.

2. Raise the left side of the axle 6 inches or more. Hold axle in this position for one minute.

3. Lower the left side.

4. Raise the right side of the axle 6 inches or more. Hold axle in this position for one minute.

5. Lower the right side.

6. With axle on a level surface, add lubricant through housing cover oil filler hole until fluid is level with the bottom of the hole.

Note: Axles without wheel end fill holes will require approximately 2.5 additional pints of lubricant to bring the lube level even with

the bottom of fill hole.

WITH AXLE ON LEVEL

SURFACE FILL HOUSING

WITH OIL TO BOTTOM OF PLUG

TEMPERATURE SENSOR

MOUNTING HOLE

Fig. 2 Wheel end lubrication procedure

OIL WILL

RUN INTO

WHEEL END

TILT HOUSING SIDE TO SIDE, 1 MINUTE PER SIDE, THEN,

RECHECK OIL LEVEL IN AXLE

OIL WILL

RUN INTO

WHEEL END

General Information

Cleaning, Inspection, Replacement

As the drive axle is disassembled, set all parts aside for thorough cleaning and inspection. Careful inspection will help determine whether parts should be reused. In many cases, the causes of premature wear or drive axle failure will also be revealed.

Cleaning

The differential carrier assembly may be steam-cleaned while mounted in the housing as long as all openings are tightly plugged. Once removed from its housing, do not steam clean differential carrier or any components. Steam cleaning at this time could allow water to be trapped in cored passages, leading to rust, lubricant contamination, and premature component wear. The only proper way to clean the assembly is to disassemble it completely. Other methods will not be effective except as preparatory steps in the process. Wash steel parts with ground or polished surfaces in solvent. There are many suitable commercial solvents available. Kerosene and diesel fuel are acceptable.

WARNING

Gasoline is not an acceptable solvent because of its extreme combustibiliy. It is unsafe in the workshop environment.

Service Procedure

Wash castings or other rough parts in solvent or clean in hot solution tanks using mild alkali solutions. If a hot solution tank is used, make sure parts are heated thoroughly, before rinsing.

Rinse thoroughly to remove all traces of the cleaning solution. Dry parts immediately with clean rags.

Lightly oil parts if they are to be reused immediately. Otherwise, coat with oil and

wrap in corrosion-resistant paper. Store parts in a clean, dry place.

Inspection

Inspect steel parts for notches, visible steps or grooves created by wear. Look for pitting or cracking along gear contact lines. Scuffing, deformation or discoloration are signs of excessive heat in the axle, usually related to low lubricant levels or improper lubrication practices.

Before reusing a gear set, inspect teeth for signs of excessive wear. Check tooth contact pattern for evidence of incorrect adjustment (see Adjustment Section for correct pattern). Inspect machined surfaces of cast or malleable parts. They must be free of cracks, scoring, and wear. Look for elongation of drilled holes, wear on surfaces machined for bearing fits and nicks or burrs in mating surfaces.

Inspect fasteners for rounded heads, bends, cracks or damaged threads. The axle housing should be examined for cracks or leaks. Also look for loose studs or cross-threaded holes. Inspect machined surfaces for nicks and burrs.

General Information

Repair and Replacement

IMPORTANT

To achieve maximum value from an axle rebuild. Replace lower-cost parts, such as thrust washers, seals, etc. These items protect the axle from premature wear or loss of lubricants. Replacing these parts will not increase rebuild cost significantly.

It is also important to replace other parts which display signs of heavy wear even though not cracked or broken. A significant portion of such a parts useful life has been expended and the damage caused, should the part fail, is far in excess of its cost.

Steel Parts- Gear sets, input and output shafts, differential parts and bearings are not repairable. Worn or damaged parts should be discarded without hesitation. Also discard mating parts in some cases. Gear sets, for example, must be replaced in sets.

Miscellaneous Parts - Seals and washers are routinely replaced. None of these parts can be reused if damaged. Fasteners using self-locking nylon patches may be reused if not damaged, but should be secured by a few drops of Loctite #277 on the threaded surface of the hole during installation and carefully torqued during installation.

Axle Housings - Repairs are limited to removal of nicks or burrs on machined surfaces and the replacement of loose or broken studs.

CAUTION

Any damage which affects the alignment or structural integrity of the housing requires housing replacement. Repair by welding or straightening should not be attempted. This process can affect the housing heat treatment and cause it to fail completely when under load.

Silicone Rubber Gasket Compound - For more effective sealing. majority of metal-to-metal mating surfaces.

Spicer includes gasket compound and application instructions in many repair parts kits.

mmended that this

is reco

It against lube and is easier to remove from mating surfaces when replacing parts.

Seals, Yoke & Slinger Service Information

During the 4th Quarter of 1990, new seals and yoke & slingers were used on the models in this publication. The new seals and slingers are noticeably different from the current seals and will affect interchangeability.

The upgraded seals can be used on axles originally equipped with the old seals.

Dana recommends the replacement of old yoke & slinger assemblies when the new seals are installed.

The old yokes and slingers will work with the new seals, but new yoke and slinger assemblies provide maximum sealing protection and prevent premature seal wear due to poor yoke condition.

New yoke and slinger assemblies cannot be used with the old seal design on the tandem forward axles.

New yoke and slinger assemblies can be used with the old seal on the tandem rear pinions.

Yoke Assembly & Oil Seal Kits contain oil seal, yoke & slinger and instructions.

Most non-Dana aftermarket seals will not be compatible with the new Dana Yoke and Slinger assemblies.

Spcier recommends the use of special installation tools conveniently packaged in one single kit (listed below

compound be used in place of conventional gaskets. The compound will provide a more effective seal

Spicer uses silicone rubber gasket compound to seal the

Refer to Dana parts Boo

Seal Driver Installation Kit 272139

126917 Driver (Rear Axle Pinion)

127787 Adapter (use with 126917 Driver for Forward Axle Input)

127786 Driver (Forward Axle Output)

k AXIP-0089 and Eaton Bulletin 90-06 for additional information.

Adjustments

Wheel Bearing Adjustment

Special Instructions

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.

Procedure - Wheel End Seal

1. Remove:

• The outer bearing and wheel.

• The inner bearing.

• The oil seal or grease retainer and discard.

• The old wear sleeve (2-piece design only) with a ball peen hammer and discard.

IMPORTANT

Wheel end seals can be easily damaged during handling. Leave the seal in its package until installation to prevent damage or contamination.

CAUTION

Do not cut through the old wear sleeve. Damage to the housing may result.

2. Inspect:

• The spindle journal and hub bore for scratches or burns. Recondition with emery cloth as required.

Note: Deep gouges can be repaired by filling gouge with hardened gasket and smoothing with emery cloth.

3. Clean:

• The hub cavity and bearing bores before reassembly. Be sure to remove contaminants from all recesses and corners.

Service Procedure

• The bearings thoroughly with solvent and examine for damage. Replace damaged or worn bearings.

• Before installation, lubricate with the same lubricant used in the axle sump.

• The inner bearing.

• The wheel seal following the directors provided by the seal supplier.

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.

Procedure - Wheel Bearing Adjustment

1. Identify the wheel nut system being installed. Three systems are available:

• Three piece Dowel-type wheel nut system -Fig.1

• Three piece Tang-type wheel nut system - Fig.2

Adjustments

• Four piece Tang/Dowel type wheel nut system - Fig.3

WARNING

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-dowel-type wheel 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.

Fig 1

Outer nut

(P/N 119881)

Inner nut

(P/N 119882)

Dowel Pin

Dowel-type Lock

Washer (P/N 119883)

Fig 2

Outer nut

(P/N 11249)

Inner nut

(P/N 11249)

Tang-type lock washer

(P/N 119883) 0.123" thick

Fig 3

Outer nut (P/N 119881)

Tang-type lock washer (P/N 129132) .0478" thick

Inner nut (P/N 119882)

Dowel pin

Dowel-type lock washer (P/N 119883)

2. 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.

• lnspect 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.

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.

• Completely fill the hub cavity between the inner and outer bearing races with the same lubricant used in the axle sump.

4. Before installation, lubricate the outer bearing with the same lubricant used in the axle sump.

Note: Lubricate only with clean axle lubricant of the same type used in the axle sump. Do not pack the bearing with grease

before installation. Grease will prevent the proper circulation of axle lubricant and may cause wheel seal failure.

5. Install the outer bearing on the spindle.

• Install the inner nut on the spindle.

• Tighten the inner nut to 200 lbs. ft. (271 N.M.) while rotating the wheel hub.

CAUTION

Never use an impact wrench to adjust wheel bearings. A torque wrench is required to assure that the nuts are property

Adjustments

tightened.

6. Back-off the inner nut one full turn. Rotate the wheel hub.

7. Re-tighten the inner nut to 50 lbs. ft. (68 N.M.) while rotating the wheel hub.

8. Back-off the inner nut exactly 1/4 turn.

Note: This adjustment procedure allows the wheel to rotate freely with 0.001"-0.005" (0.025mm to 0.1 27mm) end-play.

9. Install the correct lock washer for the wheel nut system being used.

Procedure - Three piece tang-type lock washer system (see Fig. 2).

1. Install the Tang-type lock washer on the spindle.

IMPORTANT

Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure.

2. Install the outer nut on the spindle and tighten to 250 lbs. ft. (339 N.M.).

Service Procedure

3. Verify end-play (see End Play Verification Procedure)

4. 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 as shown in Figure 4. (below)

Bend two tangs…

one over inner nut

and one over

outer nut

Outer nut

Spindle

Inner nut

Lockwasher

Procedure - Three piece dowel-type lock washer system (see Fig. 1)

1. 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.

IMPORTANT

Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure.

Adjustments

2. Install the outer nut on the spindle and tighten to 350 lbs. ft. (475 N.M.).

3. Verify end-play (see End Play Verification Procedure)

Procedure - Four piece tang/dowel-type lock washer system (see Fig. 3)

1. First, 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.

IMPORTANT

Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure.

2. Install the Tang-type lock washer on the spindle.

3. Install the outer nut on the spindle and tighten to 250 lbs. ft. (339 N. M.)

4. Verify end-play (see End Play Verification Procedure)

5. After verifying end play, secure the outer nut by bending two opposing (180° apart) tangs of the locking washer over the outer nut as shown in Figure 5.

Figure 5

Bend two tangs

over outer nut

Spindle

Inner nut

Dowel pin

Outer nut

Lockwasher

Procedure - Install

1. Install a new gasket at axle shaft flange.

2. Install axle shaft.

3. Install axle flange nuts and tighten to specified torque.

4. Lubricate axle wheel ends (see Wheel End Lubrication Procedure)

Procedure - End Play Verification Procedure

1. Verify that end-play meets specification using a dial indicator. 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.

2. Attach a dial indicator with its magnetic base to the hub or brake drum as shown below:

Adjustments

Service Procedure

End Play Adjustment

with Tire & Wheel

Assembly

3. 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.

4. Grasp the wheel assembly at the 3 o’clock and 9 o’clock positions. Push the wheel assembly in and out while oscillating it to seat the bearings. Read bearing end play as the total indicator movement.

CAUTION

If end play is not within specification, readjustment is required.

With indicator mounted at bottom,

Push/Pull at sides of drum

End Play Adjustment

with Wheel hub

Procedure - End Play Readjustment Procedure

1. Excessive End Play - If end play is greater than.005” (.127 mm), remove the outer nut and pull the lock washer away from the inner nut, but not off the spindle. Tighten the inner nut to the next alignment hole of the dowel-type washer (if used). Reassemble the washer and torque the outer nut. Verify end play with a dial indicator.

2. 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). Reassemble the washer and re-torque the outer nut. Verify end play with a dial indicator.

3. Fine Tuning the End Play - If, after performing the readjustment procedures, end play is still not within the.001”-.005” (.025 mm to.127 mm) range, disassemble and inspect the components. If parts are found to be defective, replace the defective parts, reassemble and repeat wheel bearing adjustment procedure. Verify end play with a dial indicator.

Adjustments

Differential Carrier Adjustments

Adjustments help provide optimum axle life and performance by correctly positioning bearings and gears under load. The tandem axles covered in this manual require the following adjustments:

Bearing Preload: This adjustment is performed for both pinion and differential bearings. It maintains proper gear alignments by creating correct bearing cone and cup relationships for free rotation under load. The pinion pilot bearing does not require a preload adjustment.

Ring Gear Tooth Contact: This adjustment positions ring gear and pinion for best contact under load. Correct adjustment distributes torque evenly over gear teeth and helps maximize gear set Iife.

Input Shaft End Play (Forward Axles): This adjustment controls gear mesh in the inter-axle differential. Proper adjustment helps maximize life of all power divider parts.

Adjust Input Shaft End Play

Specifications: Input shaft end play requirements will vary with operating conditions, mileage and rebuild procedures. These vari-

ations are shown in the following chart.

Input Shaft End Play

New or Rebuild with new parts: 0.003" to 0.007".

Rebuild with reused parts: 0.013" to 0.017". Note: Because of manufacturing variations in individual parts, correctly adjusted end play could vary 0.010", after the unit is ro-

tated.

Acceptable End Play Tolerances when measuring as a regular maintenance procedure with axle in truck.

Up to 0.060" with over 100,000 miles or 1 year service off-road.

Up to 0.040" with less than 100,000 miles or 1 year service on- road.

Note: If end play exceeds limits, disassemble power divider and replace worn parts.

Procedure - Measure and Adjust End Play

IMPORTANT

In September 1988, a Spring and a Thrust Button between the input and output shafts. End play tolerances are the same for axles with or without this Spring and Button. However, end play measurement procedure is different than described below. Refer to Service Bulletin Supplement at back of this manual for procedure variances.

With power divider assembled to differential carrier, measure end play with dial indicator positioned at yoke end of input shaft. Move input shaft axially and measure end play. If end play is not correct (see chart), adjust as follows.

2. Remove input shaft nut, flat washer and yoke. Remove bearing cover cap screws and lock washers. Remove cover and shim pack.

3. To increase end play, add shims:

Desired end play: 0.003" to 0.007"

Measured endplay (Step 1): 0.001" - 0.001"

Add shims to provide desired end play : 0.002" to 0.006"

Adjustments

4. To decrease end play, remove shims:

Measured end play (Step 1): 0.015" - 0.015"

Desired end play: 0.003" to 0.007"

Remove shims to provide desired end play : 0.012" to 0.008"

5. To reassemble input shaft, install the adjusted shim pack and bearing cover. Install cap screws and lock washers. Torque screws to 75-85 ft. lbs. (101-115 N.m).

Dial indicator

U-bracket

Pry bar

Input shaft

Lift up on pry bar to compress input shaft.

Measuring End Play with Dial Indicator

Note: If difficulty is experienced in achieving correct torque on the input yoke nut, torque the nut with truck on the ground

and axle shafts installed.

6. Install yoke, flat washer and nut. Tighten nut snugly. Tap end of input shaft lightly to seat bearings.

7. Measure input shaft end play with dial indicator. If end play is still incorrect, repeat Steps 2 through 6.

8. With end play correct, seal shim pack to prevent lube leakage, then torque input shaft nut and cover cap screws (see chart).

Service Procedure

Note: When power divider has been disassembled and reassembled, it may be desirable to adjust end play by measuring bear-

ing cover clearance and calculating shim pack size. For procedures, see page 39.

Torque Chart

ft. lbs. N.m

Input Shaft Nut

1 5/8 - 18 780-960 1057 - 1301

*M42 x 1.5 840 - 1020 1140 - 1383

Bearing Cover Capscrew

1/2 - 13 75 - 85 101 - 115

*Metric Nut used on Axles produced after 1-3-95

Adjustments

Pinion Bearing Preload

Special Instructions

Most late model axles are provided with a “press-fit” outer bearing on the drive pinion. Some of the early model axles use an outer bearing which slips over the drive pinion. Procedures for adjusting both types of pinion bearing design are contained in this section.

Procedure - Adjust Pinion Bearing Preload for Axles with “Press-fit” Outer Pinion Bearings

1. Trial Build-up

Assemble pinion bearing cage, bearings and spacer (without drive pinion or oil seal). Center bearing spacer between two bearing cones.

Assemble these Parts for

Trial Build-up.

Inter

Inner

bearing

cone

Inter

Inner

bearing

cup

Bearing spacer

Bearing

(variable)

spacer (variable)

Outer

bearing

cup

Bearing cage

Outer

bearing

cone

Note: When new gear set or pinion bearings are used, select nominal size spacer from the specification chart below. If orig-

inal parts are used, use spacer removed during disassembly.

2. With the bearings well lubricated, place the assembly in the press. Position sleeve so that load is applied directly to the backface of the outer bearing cone.

Cage in Press to Check Bearing

Preload.

Press

Ram

Press ram

Sleeve Must

Sleeve must

Apply Pressure

apply pressure to

To Back Face

back face of

Of Outer

outer bearing

Bearing Cone

cone

Spring scale

Spring

Scale

Adjustments

3. Apply press load (see chart below) to the assembly and check rolling torque. Wrap soft wire around the bearing cage, attach spring scale and pull. Preload is correct when torque required to rotate the pinion bearing cage is from 10-20 in. lbs.. This specification is translated into spring scale readings in the chart below.

Specifications for Pinion Bearing Trial Build-up Preload Test (“Press-fit” Outer Pinion Bearings)

Nominal Bearing Spacer Thickness

Axle Models in. mm Tons Metric Tons lbs. Kgs.

Forward Axles

D340, 380(P), 400-P

D341, 381, (P), 401-P, 402(P), 403(P), 451-P

Rear Axles 0.638 16.21 14 - 15 127 - 136 4-8 18-

4. If necessary, Adjust Pinion Bearing Preload by changing the pinion bearing spacer. A thicker spacer will decrease preload. A thinner spacer will increase preload.

0.638 16.21 13.5 - 15.5 122- 140 3-7 2-3

0.496 12.60 17 - 19 154 - 172 3-7 1.4-

Press Loads

IMPORTANT

Spring Scale Reading (without pinion seal) (for 10-20 in. lbs. torque) (1.1-

2.3 N.m)

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 the pinion shank. The trial build-up will result in proper pinion bearing preload in three of four cases.

Service Procedure

Do not assume that all assemblies will retain proper preload once bearings are pressed on pinion shank. Final preload test must be made in every case.

Adjustments

Final Pinion Bearing Preload Test

Procedure -

1. Assemble the complete pinion bearing cage unit as recommending the assembly section of this manual.

Measuring Bearing Preload with Pinion in Vise

Note: Forward axle pinion is equipped with helical gear. For easier disassembly during bearing adjustment procedure, use a

dummy yoke (if available) in place of helical gear.

2. Apply clamp load to the pinion bearing cage assembly. Either install the yoke (or helical gear) and torque the pinion nut to specifications or use a press to simulate nut torque (see chart below).

Vise Method - If the yoke and nut are used, mount the assembly in a vise, clamping yoke firmly.

Press Method - If a press is used, position a sleeve or spacer so that load is applied directly to the back-face of the outer bearing cone.

Measuring Bearing Preload with Pinion in Press

3. Measure Pinion Bearing Preload - Use a spring scale to test the assembly rolling torque. To use the spring scale, wrap soft wire around the bearing cage, attach the scale and pull. Preload is correct when torque required to rotate the pinion bearing cage is from 15 to 35 in. lbs.. This specification is translated into spring scale readings in the chart below.

Final Pinion Bearing Preload Test

Adjustments

Axle Model Nut Torque ft. lbs. (N.m) Press Load- Tons (Metric

tons)

Forward Axle

D340, 380(P), 400-P 560 - 700 (759 - 949) Self

Locking Nut

D341, 381(P), 401-P, 402(P), 403(P), 451-P

Rear Axle (All models) 560-700 (759-949) 14-15 (12.7-13.6) 6-14 (2.7-6.4)

*Torque nut to 840 ft-lbs. (1 139 N.m), Then continue tightening nut to align nut slot to nearest hole in pinion shank.

4. Adjust Pinion Bearing Preload - If necessary, adjust pinion bearing preload. Disassemble the pinion bearing cage as recommended in this -manual and change the pinion bearing spacer. A thicker spacer will decrease preload. A thinner spacer will increase preload.

780 - 960 (1057-1301) Self Locking Nut

840-1020 (1140-1383) Metric Nut

840* (1139) Slotted Nut and role pin

13.5 - 15.5 (12.2 - 14.0) 5-12 (2.3-5.4)

17 - 19 (15.4 - 17.2) 5-12 (2.3-5.4)

IMPORTANT

Spring Seal Reading (without pinion seal)- lbs (kg)

Service Procedure

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.

Adjustments

Adjust Pinion Bearing Preload for Axles with "Slip-fit" Outer Pinion Bearings

Procedure -

1. Lubricate bearings and assemble the drive pinion, bearings, and pinion bearing cage as recommended in the assembly section of this manual. Use the pinion bearing spacer removed from the axle during disassembly. If the original spacer cannot be used, install the nominal spacer recommended in the adjacent chart.

Nominal Pinion Bearing Spacers

Axle Model Spacer Thickness in (mm)

Forward Axle

D340, 380(P), 400-P 0.638 (16.205)

D341, 381(P), 401-P, 402(P), 403(P), 451-P

Rear Axle (all models) 0.638 (16.205)

Note: Forward axle pinion is equipped with helical gear, For easier disassembly during bearing adjustment procedure, use a

dummy yoke (if available) in place of helical gear.

2. Apply clamp load to the pinion bearings. Install the yoke (or helical gear) and torque the nut to specification or use a press to simulate nut torque by applying pressure to the assembly (see chart below).

Vise Method - If the yoke and nut are used, mount the assembly in a vise, clamping yoke firmly.

Press Method - If a press is used, position a sleeve or spacer so that load is applied directly to the back-face of the outer bearing cone.

0.492 (12.497)

Measuring Bearing Preload with Pinion in Vise

3. Measure Pinion Bearing Preload - Use a spring scale to test the assembly rolling torque. To use the spring scale, wrap soft wire around the bearing cage, attach the scale and pull. Preload is correct when torque required to rotate the pinion bearing cage is from 15 to 35 in. lbs. This specification is translated into spring scale readings in the chart below.

Adjustments

Measuring Bearing Preload with Pinion in Press

4. Adjust Pinion Bearing Preload - If necessary, adjust pinion bearing preload. Disassemble the pinion bearing cage as recommended in this manual and change the pinion bearing spacer. A thicker spacer will decrease preload. A thinner spacer will increase preload.

Service Procedure

IMPORTANT

Use the correctly sized spacer, Do not use shim stock or grind spacers. These practices can lead to loss of bearing preload and gear or bearing failure.

Final Pinion Bearing Preload Test (Slip fit outer pinion bearings)

Axle Model Nut Torque ft. lbs (N.m) Press Load- Tons (Metric

tons)

Forward Axle

D340, 380(P), 400-P 560 - 700 (759 - 949) Self

Locking Nut

D341, 381(P), 401-P, 402(P), 403(P), 451-P

Rear Axle (All models) 560-700 (759-949) 14-15 (12.7-13.6) 6-14 (2.7-6.4)

*Torque nut to 840 ft-lbs. (1 139 N.m), Then continue tightening nut to align nut slot to nearest hole in pinion shank.

780 - 960 (1057-1301) Self Locking Nut

840-1020 (1140-1383) Metric Nut

840* (1139) Slotted Nut and role pin

13.5 - 15.5 (12.2 - 14.0) 5-12 (2.3-5.4)

17 - 19 (15.4 - 17.2) 5-12 (2.3-5.4)

Spring Seal Reading (without pinion seal)- lbs (kg)

Adjustments

Differential Bearing Preload and Ring Gear Backlash Adjustment

Special Instructions

Correct differential bearing preload insures proper location of these bearings under load and helps position the ring gear for proper gear tooth contact.

Procedure - Adjust Diff. Bearing Preload

1. Lubricate differential bearings.

IMPORTANT

When installing bearing caps and adjuster, exert care not to cross threads.

2. Install adjusters and bearing caps. Tighten bearing cap screws finger-tight. If this is difficult, use a hand wrench.

Note: Ring gear position for rear axle is illustrated.

3. Loosen the bearing adjuster on the same side as the ring gear teeth until its first thread is visible.

4. Tighten the bearing adjuster on the back-face side of the ring gear until there is no backlash.

This can be tested by facing the ring gear teeth and pushing the gear away from the body while gently rocking the gear from side to side. There should be no free movement.

lash.

6. Measure backlash with a dial indicator.

USED GEARING — Reset to backlash recorded before disassembly.

NEW GEARING — Backlash should be between 0.006” and 0.016”.

If backlash is incorrect, proceed as described below to readjust.

Procedure - Adjust Ring Gear Backlash

1. To add backlash: Loosen the adjuster on the teeth side of the ring gear several notches. Loosen the opposite adjuster one notch. Return to adjuster on teeth side of the ring gear and tighten adjuster until it contacts the bearing cup. Continue tightening the same adjuster 2 or 3 notches. Recheck backlash.

2. To remove backlash: Loosen the adjuster on the teeth side of the ring gear several notches. Tighten the opposite adjuster one notch. Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup. Continue tightening the same adjuster 2 or 3 notches. Recheck backlash.

One

notch

Notch

Lugs

Rotate the ring gear and check for any point where the gear may bind. If such a point exists, loosen and re-tighten the back side adjuster. Make all further adjustments from the point of tightest mesh.

5. At teeth side of ring gear, tighten adjuster until it contacts the bearing cup. Continue tightening adjuster two or three notches and this will preload bearings and provide back-

3. Moving adjuster one notch is the movement of the lead edge of one adjuster lug to the lead edge of the next lug past a preselected point.

Adjustments

Ring Gear and Pinion Tooth Contact

Note: Rear axle gearing is shown in the following instructions. Correct tooth contact patterns and adjustments are the same for

forward and rear axles.

Check Tooth Contact Pattern (NEW GEAR)

Paint twelve ring gear teeth with marking compound and roll the gear to obtain a contact pattern. The correct pattern is well-centered on the ring gear tooth with lengthwise contact clear of the toe. The length of the pattern in an unloaded condition is approximately one-half to two-thirds of the ring gear tooth in most models and ratios.

Correct Pattern New Gearing

Tooth

Could vary in length. Pattern should cover 1/2 tooth or more (face width).

Pattern should be evenly centered between tooth top land and root.

Pattern should be clear of tooth toe.

Face width

depth

Heel

Top land

Root

Toe

Service Procedure

Check Tooth Contact Pattern (USED GEAR)

Used gearing will not usually display the square, even contact pattern found in new gear sets. The gear will normally have a “pocket” at the toe-end of the gear tooth which tails into a contact line along the root of tooth. The more use a gear has had, the more the line becomes the dominant characteristic of the pattern. Adjust used gear sets to display the same contact pattern observed before disassembly. A correct pattern is clear of the toe and centers evenly along the face width between 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.

Correct Pattern Used Gearing

Pocket may be extended.

Pattern along the face width could be longer.

Adjustments

Adjust Tooth Contact Patterns

If necessary, adjust the contact pattern by moving the ring gear and drive pinion. Ring gear position controls the backlash. This adjustment moves the contact pattern along the face width of the gear tooth, Pinion position is determined by the size of the pinion bearing cage shim pack. It controls contact on the tooth depth of the gear tooth. These adjustments are interrelated. As a result, they must be considered together even though the pattern is altered by two distinct operations. When making adjustments, first adjust the pinion, then the backlash. Continue this sequence until the pattern is satisfactory.

Adjust Pinion Position

If the gear pattern shows incorrect tooth depth contact, change drive pinion position by altering the shim pack. Used gears should achieve proper contact with the same shims removed from the axle at disassembly.

INCORRECT PATTERN

Move pinion toward ring gear.

Pattern too close to tooth top land and off center.

INCORRECT PATTERN

Move pinion away from ring gear.

Pattern too close or off tooth root.

If the pattern is too close to the top land of the gear tooth, remove pinion shims. If the pattern is too close to the root of the gear tooth, add pinion shims. Check ring gear backlash after each shim change and adjust if necessary to maintain the 0.006” to 0.016” specifications.

Adjust Backlash

If the gear pattern shows incorrect face width contact, change backlash.

INCORRECT PATTERN

Move ring gear away from pinion to increase backlash.

INCORRECT PATTERN

Move ring gear toward pinion to decrease backlash.

Pattern too close to edge of tooth toe.

Pattern too far along tooth toward tooth heel.

With the pattern concentrated at the toe (too far down the tooth), add backlash by loosening the bearing adjuster on the teeth side of ring gear several notches. Loosen the opposite adjuster one notch. Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup. Continue tightening the same adjuster 2 or 3 notches. Recheck backlash.

If the pattern is concentrated at the heel (too far up-the tooth), remove backlash by loosening the bearing adjuster on the teeth side of ring gear several notches. Tighten the opposite adjuster one notch. Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup. Continue tightening the same adjuster 2 or 3 notches. Recheck backlash.

Fastener Tightening Specifications

Specifications are for all axle models unless specified otherwise.

Fastener Tightening Specifications

Service Procedure

Fastener Tightening Specifications

Dana Single Reduction Tandem Models

D340, 380(P), 400-P D341, 381 (P), 401-P, 402(P), 403(P), 451-P

Note 1: Metric Nut Used on Axles Produced After 1/3/95, Ref. Chart PG 56

• Correct tightening torque values are extremely important to assure long Dana Axle life and dependable performance. Under-tightening of attaching parts is just as harmful as over-tightening.

• Exact compliance with recommended torque values will assure the best results.

• The data includes fastener size, grade and torque tightening values. Axle models are included to pinpoint identification of fasteners for your particular axle.

• To determine bolt or cap screw grade, check for designation stamped on bolt head (see illustration).

Bolt head markings for grade identification

Grade 5

Grade 8

Forward Axle Differential Carrier Replacement

Remove Differential Carrier Assembly from Axle Housing

Special Instructions

IMPORTANT

D341, 381 (P), 401-P, 402(P), 403(P), 451-P models do NOT use and output shaft Rear Bearing Retaining Washer.

WARNING

The output shaft rear bearing retaining washer is frequently lost when the differential carrier assembly is removed. It may adhere to the yoke, to the face of the output shaft bearing, fall on the floor or into the housing. Locate this washer before continuing! If it is not reinstalled, the end of the yoke will wear the output shaft bearing very quickly. If it is left in the housing, it can be picked up by the ring gear motion and cause premature axle failure.

Procedure -

1. Drain axle lubricant

Service Procedure

2. Disconnect inner axle driveline.

3. Remove output shaft but, flat washer and yoke.

4. Disconnect differential lockout air line.

5. Disconnect main driveline. Losen inputshaft yoke nut but do not remove.

6. Remove stud nuts and axle shafts(if used, remove lockwashers and taper dowels.) If necessary, loosen dowels by holding a

Forward Axle Differential Carrier Replacement

brass drift in the center of the shaft head and striking the drift with a sharp blow from a hammer.

IMPORTANT

Do not strike the shaft head with a hammer. Do not use chisels or wedges to loosen shaft or dowels.

7. Remove nuts and lockwashers fastening the carrier to the axle housing. Remove the differentail carrier assembly.

WARNING

Do not lie under the carrier after fasteners are removed. Use transmission jack to support the differential carrier assemble during removal.

8. Axle Housing Cover and Output Shaft Bearing Parts: The bearing parts can be replaced with cover removed or installed. If

necessary, remove axle housing cover. It is fastened with cap screws, nuts and lock washers.

9. Remove oil seal and discard.

10. Remove bearing retaining washer.

IMPORTANT

D341, 381(P), 401-P, 402(P), 403(P), 451-P models do not use and output shaft rear bearing retaining washer.

11. If replacement is necessary, remove snap ring, rear bearing and bearing sleeve.

WARNING

Snap ring is spring steel and may pop off. Wear safety glasses when removing.

Forward Axle Differential Carrier Replacement

Install Differential Carrier Assembly

Special Instructions

IMPORTANT

D341, 381 (P), 401-P, 402(P), 403(P), 451-P models do NOT use and output shaft Rear Bearing Retaining Washer.

Before installing carrier assembly, inspect and thoroughly clean interior of axle housing.

WARNING

When installing differential carrier assembly, it is important to follow correct procedures to assure useful life. Failure to correctly install rear bearing and retaining washer could result in premature axle failure.

Note: Use silicone rubber gasket compound on axle housing mating surface as shown in the illustrations. Compound will set in

20 minutes. Install carrier and axle housing cover before compound sets or reapply.

Procedure -

1. Apply silicone gasket compound. Install differential carrier assembly in axle housing. Install nuts and lock washers. Tighten to correct torque. (See Chart).

SILICONE GASKET COMPOUND PATTERN DIFFERENTIAL CARRIER MATING SURFACE

SILICONE GASKET COMPOUND

PATTERN. HOUSING COVER

MATING SURFACE.

Location of hole in rear cover.

Service Procedure

Torque Chart

Size Torque- ft. lbs. (N.m)

Differential Carrier

5/8-18 (Grade 8 stud) 220-240 (298-325)

Axle Housing Cover

7/16 - 20 (Grade 8 stod) 78-86 (94 - 116)

Cap screw size

7/16 - 14 (Grade 5) 48-56 (65 - 75)

5/8 - 18 (Grade 8) 220 - 240 (298 - 325)

2. Axle Housing Cover and Output Shaft Bearing Parts. If removed, install cover and fasten with nuts, cap screws and lockwashers. Tighten to correct torque. If removed, install bearing parts (see steps 3 through 6).

Forward Axle Differential Carrier Replacement

3. Install output shaft rear bearing. Tap the outer race (with a sleeve or drift) until it is seated firmly in the machined pocket of the cover. Secure with snap ring.

4. Lubricate and install the rear bearing sleeve on the output shaft. Make certain it fits snugly against the shoulder at the forward edge of the shaft splines.

5. Install a new output shaft seal in the axle housing cover.*

Note: Check carrier date – code. on units built prior to 1988, Julian calendar date code could be found on the metal tag on

the differential.

Units built before March 13,1987 (87072), seal should be flush with bottom of chamfer. Units built after March 13,1987 (87072), seal should be installed until 3/32” deeper than bottom of chamfer. Lubricate the seal diameter to prevent damage during yoke installation.

6. Slide the rear bearing retaining washer over the splines of the outer shaft until it seats flush against the output shaft bearing.

IMPORTANT

*D341, 381(P), 401-P, 402(P), 403(P), 451-P models do NOT use an output shaft Rear Bearing Retaining Washer.

7. Install output yoke, flat washer and self-locking nut. Tighten to correct torque.

8. Install axle shafts, and stud nuts. (if used, also install lock- washers and taper dowels).

9. Connect main and inter-axle drivelines.

10. Fill axle with correct lubricant (see Lubrication Section).

11. Connect differential lockout air line.

IMPORTANT

When axle has been disassembled or housing, gears, axle shafts or wheel equipment replaced, check axle assembly for proper differential action before operating vehicle. Wheels must rotate freely and independently.

*Refer to page 13 for service information on seals, yokes & slingers.

Note: Washer not used on axles with metric threaded nuts. Reference bulletin AXIB-9409.

Power Divider Replacement

Power Divider Replacement (with differential carrier assembled to axle housing)

Special Instructions

The power divider can be replaced with the axle assembly in or out of chassis and with differential carrier assembled to axle housing.

WARNING

During removal and installation, the power divider assembly must be supported as a safety precaution. During removal or installation, the lnter-axle differential may fall from carrier. Exert caution to prevent damage or injury.

Procedure - Removing and Installing Power Divider

1. With axle out of chassis, use chain hoist. Fasten chain to input yoke to remove power divider.

Service Procedure

Removing Power Divider with Chain Hoist and Sling

Note: Lifting mechanism may create nicks and burrs on input yoke. Remove if present,

2. With axle installed in chassis, use a transmission jack or a chain hoist and a sling. Wrap sling strap around power divider and attach to chain hoist hook as shown in drawings.

Power Divider Replacement

Procedure - Remove Power Divider from Differential Carrier

1. Disconnect main driveline.

Lockout

air line

Drain

pan

2. Loosen, but do not remove input yoke nut.

3. Disconnect lockout air line.

4. Position drain pan under power divider cover.

Input

yoke nut

Main

driveline

5. To remove power divider assembly, remove cover cap screws and lock washers. Support power divider (see instructions above). Then, tap back-face of input yoke to dislodge cover from differential carrier. If cover does not dislodge easily, strike the sides of the cover near the dowel pin locations (see illustration). Drain lube.

CAUTION

During removal of power divider, the lnter-axle differential may fall from carrier. Exert caution to prevent damage or injury.

6. Pull power divider assembly forward until it is completely free of carrier, then remove the assembly.

7. With power divider removed, the inter-axle differential can be lifted off output shaft side gear .

Note: Late model axles may be equipped with a compression spring and thrust button mounted between the input shaft and

output shaft .

8. Output Shaft. If necessary, remove output shaft as follows: Disconnect inter-axle driveline. Remove nut, flat washer and output shaft yoke. Pull output shaft assembly out of carrier.

9. Axle Housing Cover and Output Shaft Bearing Parts. If necessary, remove these parts following instructions.

Dowel Pin

Socket Head

Capscrew

Dowel Pin

Install Power Divider on Differential Carrier

Special Instructions

Lubricate all parts before installation.

Power Divider Replacement

Procedure -

1. Axle Housing Cover and Output Shaft Bearing Parts. If removed, install these parts following instructions on page 27.

2. Output Shaft. If removed, lubricate "O" rings, then install shaft assembly in differential carrier and housing cover. Lubricate seal lip. Make sure yoke is clean and dry, then install yoke, flat washer* and self-locking nut. Torque nut to correct specification.

3. Inter-axle Differential- Install this assembly on output

shaft side gear (with nuts facing away from side gear).

Silicone Gasket Compound

Service Procedure

4. Power Divider Assembly- Use silicone rubber gasket

compound on differential carrier mating surface as shown in the illustration.

Note: Compound will set in 20 minutes. Install power di-

vider before compound sets or reapply.

Note: Late Model Axles may be equipped with a spring

and thrust button mounted in end of output shaft.

CAUTION

During installation of power divider, the inter-axle differential may fall from carrier. Exert caution to prevent damage or injury.

Power Divider Replacement

5. Make certain dowel pins are installed in carrier (see drawing above), then install power divider assembly.

Use a transmission jack or a chain hoist and sling (see photo).

During installation, rotate input shaft to engage input shaft splines with inter-axle differential, After installation, again rotate input shaft to check for correct assembly. Output shaft should turn when input shaft is rotated.

2. Check and Adjust Input Shaft End Play- With power divid-

er assembled to differential carrier. Check end play with dial indicator. If necessary, adjust end play. After input shaft end play is within specifications, complete assembly procedure as follows:

Dial indicator

U-bracket

Pry bar

Input sha

Lift up on pry bar to compress input shaft.

Measuring Input shaft End Play with Dial Indicator

Installing Power Divider Assembly with Chain Hoist and Sling

Procedure - Installing Power Divider Assembly with Chain Hoist and Sling.

1. Install power divider cover cap screws and lock washers. On pump models only, install socket-head cap screw in correct location (see drawing on preceding page). Torque cap screw to 110-125 ft. lbs. (149-170 N.m).

3. Measuring Input Shaft End Play with Dial Indicator.

4. Connect drivelines. Connect lockout air line.

5. Fill axle to proper lube level (see Lubrication Section).

IMPORTANT

*Washer not used on axles with metric threaded nuts.

Rear Axle Differential Carrier Replacement

Remove Differential Carrier Assembly from Axle Housing

Service Procedure

Procedure - Install Differential Carrier Assembly

1. Drain Lubricant

2. Disconnect inter-axle driveline.

Note: For easier disassembly, the drive pinion nut can be

loosened after driveline is disconnected.

3. Remove axle shaft, stud nuts, lock washers and taper dowels (if used). If necessary, loosen dowels by holding a brass drift in the center of the shaft head and striking it a sharp blow with a hammer.

IMPORTANT

Do not strike the shaft head with a hammer. Do not use chisels or wedges to loosen shaft or dowels.

4. Remove nuts and lock washers fastening carrier to axle housing. Remove differential carrier assembly.

WARNING

Do not lie under carrier after fasteners are removed. Use transmission jack to support and remove differential carrier assembly.

IMPORTANT

Before installing carrier assembly, inspect and thoroughly clean interior of axle housing.

Note: Use silicone rubber gasket compound on axle hous-

ing mating surface as shown in the illustration. Compound will set in 20 minutes. Install carrier before compound sets or reapply.

Axle Housing Silicone Gasket Compound Pattern

5. Install differential carrier assembly in axle housing. Install stud nuts and lock washers. Tighten to correct torque (see chart).

IMPORTANT

6. Install axle shafts and stud nuts.(If used, also install lock washers and taper dowels.)

7. Connect inter-axle driveline.

8. Fill axle with correct lube [size 5/8-18 Grade 8, 220-240 Ft. lbs. (298-325 N-m)].

Power Divider Overhaul

Remove Power Divider from Differential Carrier (with carrier removed from axle housing)

Special Instructions

Note: It is assumed that the differential carrier and power divider assembly have been removed from axle housing prior to starting

the following procedures:

Procedure -

1. Mount differential carrier in repair stand. Loosen input shaft nut.

2. Remove power divider cover cap screws and lock washers.

CAUTION

During removal of power divider, the lnter-axle differential may fall off input shaft from differential carrier. Exert caution to prevent damage or injury.

Power Divider Cover Dowel Pin Location

Socket Head

Capscrew

Dowel Pin

3. Attach chain hoist to input yoke and lift power divider off carrier, If power divider does not separate easily, strike the cover near the dowel pin locations with a mallet (see illustration).

Note: Lifting mechanism may create nicks or burrs on in-

put yoke. Remove if present.

Dowel Pin

4. Inter-axle Differential. Lift differential assembly off output shaft side gear.

5. Output Shaft. Tilt carrier and remove the output shaft assembly.

Power Divider Overhaul

Service Procedure

6. Output Shaft Side Gear Bearing Cup. If replacement is necessary, use puller to remove bearing cup from carrier.

Note: Late Model Axles may be equipped with a spring

and thrust button mounted between the input shaft and output shaft.

Note: For instructions on removing axle housing cover

and output shaft rear bearing parts, see page 26.

Power Divider Overhaul

Disassemble Power Divider Cover

Power Divider Cover and Input Shaft (without Lube Pump)

1 Snap ring

2 Helical side gear

3 Thrust washer

4 D washer

5 Lockout sliding clutch

6 Input shaft

7 Bearing cone

8 Lockwasher

9 Capscrew

10 Bearing cup

11 Shim

12 Oil seal

13 Yoke

14 Flat washer

17 Bearing cover

18 Lockout unit (See lockout service

instructions for design variations

19 Power divider cover

20 Shift fork and push rod

21 Bushings

15 Nut

16 Capscrew

1 Lock nut

2 Power divider cover

3 Pipe plug

4 Woodruff key*

5 O-ring

6 Pump cover

7 Capscrew

8 Lockwasher

9 Dowel pin

10 Pump gears

11 Magnetic strainer

12 Expansion plug

13 Pump drive gear

*NOTE: The drive shaft on early pump models is equipped with a woodruff key. On late pump models, the key is eliminated. The drive shaft end has two machined flats and the drive gear mounting hole is shaped to accommodate these flats.

Power Divider Overhaul

Procedure -

1. Remove snap ring from machined groove at rear of input shaft.

WARNING

Snap ring is spring steel and may pop off wear safety glasses when removing. with snap ring removed, the helical side gear may fall off shaft. Exert care to prevent damage or injury,

Slide helical-side gear off input shaft, then remove bronze thrust washer and "D" washer from shaft.

2. Axles with Lube Pump- At this point in disassembly, it is desirable to remove lube pump drive gear nut. Hold input shaft yoke to secure drive gear, then loosen and remove drive gear nut.

4. Remove cap screws lock-washers and input bearing cover and shim pack.

Service Procedure

5. Slide input shaft assembly out of cover. Remove bearing spacer from shaft (used only on D340, 380(P), 400-P).

6. Remove Lockout, Sliding Clutch and Shift Fork.. Starting with axles built early in 1991, the sliding clutch and helical slide gear curvic teeth diameter was increased to provide greater tooth engagements. For additional parts and service information, refer to Bulletin 91-01.

3. Remove nut, flat washer and yoke from input shaft. To remove the larger-diameter sliding clutch, first remove

the lockout (see pages 40-42). Then remove the sliding clutch and shift fork (with the two parts engaged). Grasp the assembly by hand and maneuver the assembly past restrictions in the power divider cover.

To remove the smaller-diameter sliding clutch, (used on earlier model axles), the clutch can be disengaged and removed without removal of the lockout and shift fork.

Power Divider Overhaul

7. Remove oil seal from input bearing cover. Remove bear-

ing cup from cover.

8. Remove input shaft bearing cone. Temporarily place lock-

out sliding clutch over rear of input shaft, teeth toward bearing cone. Place shaft in press and remove bearing cone.

10. Remove oil pump cover cap screws and lock washers. Remove pump cover and "O" ring.

11. *NOTE: When used, remove woodruff key from gear shaft. Remove pump gears from power divider cover.

9. Axles with Lube Pump: With drive gear locknut previously removed (step 2) and working through power divider cover input shaft bore, gently pry oil pump drive gear from its shaft. See steps 10 through 12 for pump disassembly.

12. Unscrew and remove magnetic screen from power divider cover.

Power Divider Overhaul

Disassemble Inter-axle Differential

Procedure -

1. Punch mark differential case halves for correct position during reassembly.

2. Remove locknuts and bolts. Separate case halves and remove thrust washers, side pinions, bushings, and spider.

Note: Side Pinion Bushings. Not used on tandems built after November 1, 1991. Use when originally equipped.

Current production Inter-Axle Differential Assemblies are only serviced as a complete assembly.

Case half

Spider

Bushing

Side pinion

Thrust washer

Non-Current Production Inter-Axle Differential

Punch

mark

Case half

Service Procedure

Power Divider Overhaul

Disassemble Output Shaft

Output Shaft Assembly

Output shaft

*Bushing

Bearing cup

(mounted in

carrier)

Side gear

Spring

O-rings

OTE:

Late Model Axles may be equipped with a spring and thrust button mounted between the input shaft and output shaft.

*Bushing removed from current production axles in Sept. 1994. Output shafts with P/N 129016 do not use bushings.

Procedure -

3. Remove bearing cone from side gear using press and

Bearing cone

split-type puller.

1. Mount shaft assembly in vise using brass vise jaw protectors. Remove outer snap ring, side gear and bearing cone assembly. If replacement is necessary, remove inner snap

Note: For instructions covering output shaft rear bearing

parts, see page 26.

ring.

Button

O-rings

WARNING

Snap ring is spring steel and may pop off, wear safety glasses when removing.

2. Remove output shaft "O" rings, If replacement is necessary, remove bushing mounted in end of output shaft. (NOTE 1) .

Removing Bearing Cone from Output Shaft Side Gear

Note: Starting in June 1993, production axles were made

with bushing less output shaft 128736. Do not attempt to install bushings in shafts with P/N's 128736 or 129194* stamped into them. Ref. bulletin AXIB-93-06 *(output shaft w/metric threads used in axles after 1-3-95).

Assemble Output Shaft

Special Instructions

Lubricate parts with gear lube during assembly.

Procedure -

1. Press bearing cone on output shaft side gear.

Power Divider Overhaul

Service Procedure

IMPORTANT

Provide protection against possible gear teeth damage during press operation.

2. Mount output shaft in vise. Lubricate and install "O" rings. If removed, install bushing in end of output shaft. (NOTE 1)

3. If removed, install inner snap ring on shaft, then install side gear and bearing cone assembly, and outer snap ring.

O-rings

WARNING

SNAP RING IS SPRING STEEL AND MAY POP OFF. WEAR SAFETY GLASSES WHEN INSTALLING.

Note: Late Model Axles may be equipped with a spring and thrust button mounted between the input shaft and output shaft

(see page 54).

Power Divider Overhaul

Assemble Inter-axle Differential

Special Instructions

Lubricate parts with gear lube during assembly

Procedure -

1. Install bushings, side pinions and thrust washers on inter-axle differential spider.

2. Install spider assembly in one differential case half, align punch marks and install other case half, secure assembly with bolts and locknuts, tighten to correct torque (17-23 ft. lbs, 23-31 N.m).

Note: Side Pinion Bushings. Not used on tandems built after November 1, 1991. Use when originally equipped.

Assembling Non-Current Production Inter-Axle Differentials

Note: Starting in June 1993, production axles were made with bushing less output shaft 128736. Do not attempt to install

bushings in shafts with P/N's 128736 or 129194* stamped into them. Ref. bulletin AXIB-93-06* (output shaft w/metric threads used in axles after 1-3-95).

Assemble Power Divider Cover

Power Divider Overhaul

Power Divider (without Lube

Cover and Input Shaft Pump)

1 Snap ring

2 Helical side gear

3 Thrust washer

4 D washer

5 Lockout sliding clutch

6 Input shaft

7 Bearing cone

8 Lockwasher

9 Capscrew

10 Bearing cup

11 Shim

12 Oil seal

13 Yoke

14 Flat washer

LOCKOUT FOR DESIGN VARIATIONS REFER TO LOCKOUT SERVICE INSTRUCTIONS

Service Procedure

17 Bearing cover

18 Lockout unit (See lockout service

instructions for design variations

19 Power divider cover

20 Shift fork and push rod

Bushings

15 Nut

16 Capscrew

Power Divider Cover with Lube Pump.

1 Lock nut

2 Power divider cover

3 Pipe plug

4 Woodruff key*

5 O-ring

6 Pump cover

7 Capscrew

8 Lockwasher

9 Dowel pin

10 Pump gears

11 Magnetic strainer

12 Expansion plug

13 Pump drive gear

Note: Axles with Lube Pump. Assemble and install lube pump and magnetic screen. See steps 1 to 4.

Power Divider Overhaul

Procedure -

1. See note on exploded view. Install pump gears in power divider cover (position gear with long shaft in opening adjacent to input shaft).

2. Install "O" ring in pump cover, making sure "O" ring is seated firmly in cover. If removed, install dowel pins. Install pump cover on power divider cover and secure with cap screws and lock washers. Tighten to correct torque (85-105 in. lbs., 10-12 N.m).

3. Install Pump Drive Gear. Install drive gear on pump shaft end.

Note: Some pump drive shafts use a woodruff key. When

key is used. place key in shaft slot. Position gear on shaft engaging key. Then install gear with driver and hammer.

Note: Install and tighten drive gear nut after input shaft is

assembled to power divider cover (see step 10).

4. Install magnetic screen in power divider cover. Tighten to correct torque (40-60 ft. lbs., 54-81 N.m).

5. Press bearing cone on input shaft.

IMPORTANT

To prevent bearing damage, be careful to use sleeve that only contacts the inner race of bearing cone.

6. SEAL INSTALLATION IMPORTANT: Before installing seal,

refer to page 13 for service information on Seals, Yokes & Slingers.

Power Divider Overhaul

Service Procedure

en correctly

talled, seal

uld be flush

h bottom of

mfer

Press oil seal in cover using a seal driver or suitable sleeve.

Note: Check carrier date code (see page 27, note before 5).

Units built before October 26, 1987 (87299), seal should be flush with bottom of chamfer. Units built after October 26, 1987 (87299), seal should be installed until 3/32" deeper than bottom of chamfer.

Press bearing cup in input bearing cover.

IMPORTANT

For correct cup installation, use appropriate sleeve. Take care to make sure cup is not cocked and is firmly seated all around.

7. Install bronze bushings in helical-side gear.

Note: Helical Gears made after 1/3/95 have a "step" at the

end of Inner Bore. Bushings must reinstalled from the Curvic Tooth side, inward towards this step. Press flush against the shoulder of the step.

1/32"

Power Divider Overhaul

Expansion plug

8. Check expansion plug in power divider cover (see photo) to make sure it is in place and firmly seated. If loose, seat by tapping with a hammer. Replace plug if necessary.

Assemble lockout shift fork and sliding clutch with clutch teeth facing the helical-side gear, then install this assembly in power divider cover.

Note: At this point in reassembly, assemble and install lock-

out (see pages 40-42).

9. Slide input shaft and bearing assembly into power divider cover from the front side. Engage shaft splines in lock-out clutch.

Install bearing spacer on input shaft (used only on D340, 380, 380-P, 400-P). Temporarily install input bearing cover assembly, cap screws and lock washers.

Note: Do not install any shims under bearing cover at this

time. Correct shim pack will be determined after the power divider is installed on differential carrier (Refer to "Adjust Input Shaft End Play" page 39).

IMPORTANT

For Axles with Spring and Thrust Button between input shaft and output shaft: For preliminary adjustment of input shaft end play, install a 0.045" (0.024 mm) shim pack under bearing cover (see Service Bulletin Supplement, page

54). Tighten bearing cover cap screws finger-tight. Install input yoke, flat washer and nut. Temporarily tighten nut snugly.

10. Axles with Lube Pump: Install and tighten lube pump drive gear locknut, holding input shaft to secure gear. Torque nut to 35-45 ft. lbs. (47-61 N.m).

11. Slide "D" washer over input shaft up to base of sliding clutch splines.

Note: Make sure flat part of washer inside diameter engages

shaft properly.

Install bronze washer. Install helical gear. Secure with snap ring.

WARNING

Power Divider Overhaul

Snap ring is spring steel and may pop off. Wear safety glasses when installing.

12. Install power divider cover assembly on differential carrier (see page 38).

Service Procedure

Power Divider Overhaul

Install Power Divider on Differential Carrier (with carrier removed from axle housing)

Special Instructions

Note: The following instructions pertain to installation of power divider on differential carrier with carrier removed from axle hous-

ing.

Note: Before installing power divider, install related parts as follows

Procedure -

1. Output Shaft Side Gear Bearing Cup. If removed, press bearing cup in carrier. Use a press and appropriate sleeve or use a brass drift and a mallet. Tap bearing cup into its' bore making certain cup is evenly and firmly seated.

Note: Late Model Axles may be equipped with a spring and

thrust button mounted between the input shaft and output shaft (see page 54).

2. Output Shaft. Lubricate "O" rings, then install output shaft assembly in carrier.

3. Inter-axle Differential. Install differential assembly on output shaft side gear (with nuts facing away from output shaft side gear).

4. Apply silicone gasket compound on carrier mating surface (see illustration).

5. Install Power Divider. Attach chain hoist to input yoke and install power divider assembly During installation, rotate input shaft to engage input shaft splines with inter-axle differential. After installation, again rotate input shaft. Output shaft should turn when input shaft is rotated if assembly is correct.

Power Divider Overhaul

Silicone Gasket Compound

Service Procedure

Note: Lifting mechanism may create nicks and burrs on in-

put yoke. Remove if present.

6. If removed, install dowel pins in carrier. Install power divider cover cap screws and lock-washers. (On pump models only, place socket-head cap screw at location shown on drawing. Torque cap screws to 110-125 ft. lbs. (149-170 N.m).

7. Adjust Input Shaft End Play. Adjust end play with the power divider assembled to the differential carrier. (See page 39.)

ower

owel

ivider

Pin L

over

ocat

ion

Socket Head

Capscrew

Dowel Pin

Power Divider Overhaul

Measure and Adjust Input Shaft End Play

Special Instructions

Note: After power divider overhaul and installation in power divider, check and adjust input shaft end play.

Correct end play when new parts are used in overhaul is 0.003" to 0.007", with reused parts 0.013" to 0.017". Refer to page 15 for other variations.

IMPORTANT

September 1988, A Spring and a Thrust Button were added between the input and output shafts. End play tolerances are the same for axles with or without this Spring and Button. However, end play measurement procedure is different than described below. Refer to Service Bulletin Supplement at back of this manual for procedure variances.

Procedure -

1. Remove input shaft nut, flat washer and yoke. Remove input bearing cover cap screws and lock washers. Remove bearing cover (and shim pack if installed).

2. Reinstall bearing cover without shims. Hold in position with hand pressure and measure clearance between power divider cover and bearing cover, using a feeler gauge.

3. The bearing cover clearance measured in Step 2 plus 0.005" will equal shim pack thickness required for desired end play (rebuild with new parts). Add 0.015" to shim pack for rebuild with used parts.

Install shim pack and bearing cover. Install cap screws and lock-washers, Torque screws to 75-85 ft. lbs. (101-115 N.m).

4. Install yoke, flat washer and nut. Tighten nut snugly. Tap end

of input shaft lightly to seat bearings.

5. Check input shaft end play with dial indicator positioned at yoke end of input shaft. Move input shaft axially and measure end play. If end play is correct, seal shim pack to prevent lube leakage then torque input shaft nut and cover cap screws (see chart).

6. If end play is incorrect, change shim pack size, as follows:

Add shims to increase end play.

Example: Desired end play (New Parts): 0.003" to 0.007"

Power Divider Overhaul

Dial indicator

U-bracket

Pry bar

Input shaft

Service Procedure

Lift up on pry bar to compress input shaft.

Measured end play (Step 6): 0.001" - 0.001"

Add shims to provide desired end play: 0.002" to 0.006"

Remove shims to decrease end play.

Example: Measured end play (Step 6): 0.015" - 0.015"

Desired end play (New Parts): 0.003" to 0.007"

Remove shims to provide desired end play: 0.012" to 0.008"

7. To add or remove shims, remove input shaft nut, flat washer and yoke. Remove cap screws, lockwashers and bearing cover. Add or remove shims as required.

8. Install bearing cover, cap screws and lockwashers. Install yoke, flat washer and nut. Seal shim pack to prevent lube leakage then torque input shaft nut and cover cap screws (see chart).

Torque Chart

Size Ft. lbs. N.m

Input Shaft Nut

1-5/8 -18 780-960 1057-1301

M42 x 1.5 840-1020 1140-1383

Bearing Cover Cap Screw

1/2-13 (Grade 5) 75-85 101-115

*Metric Nut used in Production Axles after 1/3/95

Inter-Axle Differential Lockout Overhaul.

"Standard" or "Current" Model Lockout Overhaul

Special Instructions

Three differential model lockouts are used on Dana Tandem Axles. To identify the lockout used on your axle, refer to the illustrations and related service instructions below.

“Standard” Lockouts (Current and Non-Current Models). The “current” model is an improved version of and replaces the “noncurrent” lockout. Both are air-operated to engage the lockout and spring-released to disengage the lockout.

Dana Axles may be equipped with either of these lockouts. The “current” model is interchangeable with the “non-current” model as an assembly. For service information, refer to the following page.

“Reverse-Air” Lockout. The “Reverse-Air” lockout is spring- operated to engage the lockout and air-operated to disengage the lockout. This model is similar to the “non-current” “standard” lockout. It is not available in the new “current” lockout.

Procedure - Disassemble and Remove Lockout.

1. With axle installed in vehicle, place differential lock selector valve in the disengaged (or unlocked) position. Disconnect the air line at the lockout piston housing.

Cylindrical

design

“Standard” “Current” Model Lockout

2. Remove cap screws and lock washers fastening mounting bracket to power divider cover. Remove bracket and piston housing.

3. Remove locknut, piston with “O” ring, compression spring and shoulder washer from push rod.

Note: The shift fork and push rod cannot be removed with power divider cover installed (see Power Divider instructions).

Inter-Axle Differential Lockout Overhaul.

Procedure - Assemble and Install Lockout

1. With shift fork and sliding clutch installed, place the shoulder washer (white plastic) over push rod. The large diameter side of the washer must face the power divider cover.

2. Install compression spring on push rod.

3. Lubricate “O” ring with silicone-based lubricant and install “O” ring on piston.

4. Place piston assembly on push rod. The large diameter end of piston must face power divider cover.

5. Install locknut on push rod and tighten to 13-17 lft. lbs. (l8-23 N.m).

6. Install piston housing, making sure the housing is correctly seated and piloted in the shoulder washer.

7. Place mounting bracket over housing and position on power divider cover. Install cap screws and lock washers and tighten to 48-56 ft. lbs. (65-76 N.m).

Note: If axle is installed in vehicle, apply sealant to air line fitting and connect air line. When tightening air line, hold piston

housing in mounting position using a wrench applied to the hexagon configuration at outer end of housing.

Shoulder washer

must seat properly

Note: A new style “Inter-Axle Differential Lockout” was being released as this publication was being printed. If the Inter- Axle

Differential Lockout Assembly on your axle is not shown in this publication, call your local

Spicer representative.

Service Procedure

Inter-Axle Differential Lockout Overhaul.

"Standard" or "Non-Current" Model Lockout Overhaul

Retrofit “Non-Current” to “Current” Model Lockout

The “current” model (only as an assembly) is interchangeable with the “non-current” lockout. The original shift fork and push rod can be used for either model lockout and need not be replaced. Retrofit Kits are available to convert the “non-current” model to the “current” lockout. Parts (except the shift fork), included in these kits are shown in the illustration on the preceding page. For additional information, refer to Dana Parts Books (see back cover). Retrofit as follows:

Disassemble and remove “non-current” lockout. Refer to instructions below.

Assemble and install “current” lockout following instructions on preceding page.

Note: Do not use mounting screws from “non-current” model. They are too long to use with the new “current” model.

Special Instructions

Service Parts Availability: The “non-current” lockout assembly, body, piston and body cover are no longer available. If any of these items are not serviceable, replace lockout with the new “current” model per instructions above. For other parts, a Service Parts Kit (see illustration) is available to service the “non-current” lockout.

“Standard” “Non-Current” Model Lockout

*Asterisk Identifies parts included in Service Kit 211201

Note: Axles with Lube Pumps: These axle models are equipped with a piston stop located at base of piston. It is important that

this stop be reinstalled in reassembly.

Procedure - Disassemble and Remove Lockout

1. Remove cap screws and lock washers fastening cover to the body. Remove cover and “O’’ ring.

2. Remove nut, flat washer and “O’’ ring from push rod.

3. Remove body cap screws and lock washers, then remove body and piston as an assembly. Remove “O’’ ring and felt oilers from the piston.

Note: The shift fork and push rod cannot be removed with power divider cover installed (see Power Divider instructions).

Inter-Axle Differential Lockout Overhaul.

Procedure - Assemble and Install Lockout

1. With shift fork and sliding clutch installed in power divider cover, assemble and install lockout as follows.

2. Apply silicone gasket compound to mounting surface on power divider cover. See illustration.

3. Install lockout body. Secure with cap screws and lock washers. Torque cap screws to 48-56 ft. lbs. (65-76 N.m).

Note: Before installation, soak piston felt oilers in SAE 30 engine oil and lubricate “O’’ rings with a high-viscosity silicone oil

or barium grease “O’’ ring lubricant.

4. Install felt oilers and large “O” ring on piston.

5. Axles with Lube Pump. Before installing piston, place piston stop at base of lockout body.

6. Install compression spring over shift fork push rod. Install piston in body and secure with “O” ring, flat washer and nut. Torque nut to 20-26 ft. lbs. (27-35 N.m).

7. Install “O’’ ring in lockout body cover. Install cover and secure with cap screws and lock washers. Torque cap screws to 96108 in. lbs. (10-12 N.m).

Lockout Silicone Gasket Pattern

Service Procedure

Inter-Axle Differential Lockout Overhaul.

"Reverse-Air" Lockout Overhaul

The "reverse-air" lockout unit is spring-operated to engage lockout and air-operated to disengage lockout. A clutch engages or disengages the helical-side gear to lock or unlock the inter-axle differential.

Service Parts Availability

A new design of the original "Reverse-Air" Lockout has not been released at this writing. The piston, body and cover of the original lockout are no longer available as individual parts. If these parts are not serviceable, replace the complete unit. For other parts, use a Service Parts Kit (see illustration for contents). For additional information, refer to Dana Parts Books (see back cover).

"Reverse-Air" Lockout

*Non-serviceable parts

Shift fork

and push rod

Push rod

seal ring

Lockwasher

Capscrew

Body

O-ring

Lockout

body*

Piston O-ring

Felt

oilers

Compression

Piston*

Flat

washer

spring

Nut

Cover*

Cover

O-ring

Capscrew

Lockwasher

Procedure - Disassemble Lockout.

1. Remove cap screws and lock washers fastening cover to body. Remove cover, "O" ring and compression spring.

2. Remove push rod nut and flat washer.

3. Remove body cap screws and lock washers. Then remove body, body "O" ring, and piston as an assembly. Remove seal ring from threaded end of push rod.

Inter-Axle Differential Lockout Overhaul.

Procedure - Assemble and Install Lockout

1. With shift fork and sliding clutch installed in power divider cover, assemble and install lockout as follows:

2. Install seal ring on shift fork push rod (threaded end). Install "O" ring in body.

3. Apply silicone gasket compound to lockout mounting surface (see illustration).

4. Install lockout body, cap screws and lock washers. Torque cap screws to 48-56 ft. lbs. (65-76 N.m).

Service Procedure

Lockout Silicone Gasket Pattern

5. Install felt oilers and "O" ring on piston. Install piston assembly in body and secure to push rod with flat washer and nut. Torque nut to 20-26 ft. lbs. (27-35 N.m).

Note: Before installation, soak piston felt oilers in SAE 30

engine oil and lubricate "O" rings with a high-viscosity silicone oil or barium grease "O" ring lubricant.

6. Place "O" ring on body cover. Install compression spring, cover, cap screws and lockwashers. Torque cap screws to 96-108 in. lbs. (10-12 N.m).

Differential Carrier Overhaul (Forward and Rear Axle)

Disassemble Differential Carrier (with power divider removed)

Special Instructions

If gear set is to be reused, check tooth contact pattern and ring gear backlash before disassembling differential carrier. Best results are obtained when established wear patterns are maintained in using gearing. Omit this step if the gear set is to be replaced.

Procedure -

1. Mount differential carrier in repair stand.

Note: For easier disassembly, loosen but do not remove

pinion self-locking nut. When forward axle pinion is equipped with slotted nut, remove roll pin with a pin punch then loosen nut.

2. Punch mark differential bearing caps. If reusing gear set, also punch mark bearing adjusters for reference during assembly.

3. Cut lock-wire. Remove cap screws, flat washers and bearing caps.

Differential Carrier Overhaul (Forward and Rear Axle)

4. Using a chain hoist, lift ring gear and differential assembly out of carrier.

5. Forward Axle: Remove pinion nut (see NOTE under Step 1). Remove helical drive gear, using puller if necessary.

Note: Remove outer pinion bearing cone if Slip-fit.

Service Procedure

6. Forward Axle: Remove pinion bearing cage cap screws. Remove drive pinion and cage assembly from carrier. Remove shim pack.

7. Rear Axle: Remove pinion bearing cage cap screws, then drive pinion, cage and yoke assembly out of carrier.

IMPORTANT

Do not allow pinion to drop on hard surface. Remove shim pack.

Forward and Rear Axle: If gear set is to be reused, keep pinion bearing cage shim pack intact for use in reassembly. If the original shims cannot be reused, record the number and size of shims in the pack.

Differential Carrier Overhaul (Forward and Rear Axle)

Disassembly Drive Pinion

Rear Axle Pinion Illustrated.

1 Pinion pilot bearing

2 Drive Pinion

3 Bearing cone (inner)

4 Spacer washer

5 Bearing spacer (variable)

6 Bearing cup (inner)

7 Lockwasher

8 Bearing cage shim

9 Bearing cage

10 Bearing cup (outer)

11 Cage capscrew

12 Bearing cone (outer)

13 Oil seal

14 Input yoke

15 Flat washer

16 Pinion

nut

12 13

Forward Axle Pinion Illustrated.

ïD341, 381(P), 401-P, 402(P), 403(P), 451-P use self-locking or slotted nut and roll pm. Metric self-locking nuts used as of 1-3-95. D340, 380(P), 400-P use self-locking nut only.

Note: Dana drive axles may be equipped with either slip-fit or press-fit outer pinion bearings. Procedures are contained in-this

section for disassembly of both types.

Differential Carrier Overhaul (Forward and Rear Axle)

Special Instructions

IMPORTANT

During the following yoke removal procedure, the drive pinion may fall out of bearings and cage. Do not allow pinion to drop on hard surface.

Procedure -

1. Rear Axle Pinion Yoke: Remove yoke. If pinion nut was not loosened during earlier disassembly, clamp assembly in vise jaws, use brass pads to prevent damage.

Loosen and remove pinion nut and flat washer.

2. Forward and Rear Axle Pinion Bearing Cage: For pinion with press-fit bearing cone, support cage and press pinion out of bearing cage and bearing cone.

3. For pinion with slip-fit bearing cone, the cage, outer bearing and pinion can usually be disassembled easily without a press. If difficulty is experienced, use a press.

Service Procedure

4. Removing Bearing Cage (Rear Axle illustrated).

Differential Carrier Overhaul (Forward and Rear Axle)

5. Rear Axle Pinion Oil Seal and Outer Bearing Cone: Remove oil seal and bearing cone from cage. Discard oil seal. Remove bearing cups with suitable puller.

6. Remove and retain bearing spacer from pinion.

7. Mount puller vertically to split the bearing.

8. Mount puller horizontally to press pinion out of bearing.

9. Remove pilot bearing and inner bearing cone from pinion, using a split-type puller. Use two procedure steps to remove each bearing (see photos above).

This action will force puller halves under bearing and start moving bearing off pinion.

The same procedure can be used to remove pilot bearing and pinion inner bearing cone.

Differential Carrier Overhaul (Forward and Rear Axle)

Disassemble Wheel Differential

Procedure -

Service Procedure

1. Remove nuts and bolts fastening ring gear to differential cases, allowing gear to fall free. If gear does not fall, tap outer diameter with soft mallet to loosen.

2. Punch mark differential cases for correct location during assembly. Remove cap screws and lift off plain differential case half.

3. Lift out side gear and thrust washer.

Punch

marks

Marks

Differential Carrier Overhaul (Forward and Rear Axle)

4. Lift out spider, side pinions and thrust washers.

5. Remove side gear and thrust washer.

6. Puller Mounted Vertically to Split Bearing.

7. Remove bearing cones from case halves using suitable puller (see photos).

8. Removing Bearing Cone from Flanged Case Half.

Remove bearing cone from plain case half in two steps: First, mount puller vertically to split bearing (see photo). This action will start moving bearing off case. Second, mount puller vertically to remove cone.

9. Remove bearing cone from flanged case half using suitable puller.

Differential Carrier Overhaul (Forward and Rear Axle)

Assemble Wheel Differential

Special Instructions

Lubricate differential parts with gear lube during reassembly

Procedure -

1. Press bearing cones on differential case halves (see photos).

IMPORTANT

To prevent bearing damage, use suitable sleeve that only contacts the inner race of the cone.

Fig A: Press Bearing Cone on Flanged Differential Case.

Fig B: Press Bearing Cone on Plain Differential/ Case.

2. Place thrust washer and side gear in flanged differential case.

Service Procedure

Fig A Fig B

3. Assemble side pinion and thrust washers on spider. Place this assembly in flanged differential case. Rotate gears and check for proper mesh.

Differential Carrier Overhaul (Forward and Rear Axle)

4. Place side gear and thrust washer on side pinions.

5. Align punch marks and install plain case half. Install cap screws and tighten to correct torque. Check differential for free rotation by turning side gear hub. Differential may re-

Punch Marks

quire up to 50 ft. lbs. (68 N.m) torque to rotate.

6. Install ring gear. Secure with bolts and nuts. Torque nuts to 180- 220 ft. lbs. (244-298 N.m).

Differential Carrier Overhaul (Forward and Rear Axle)

Assemble Drive Pinion ("Press-fit" outer pinion bearing)

Service Procedure

Special Instructions

Dana drive axles may be equipped with either “slip-fit” or ‘press-fit” outer pinion bearings. Procedures are contained in this section for assembly of both types.

Lubricate parts with gear lube during reassembly.

Differential Carrier Overhaul (Forward and Rear Axle)

Procedure -

Forward Axle Pinion. Press Bearing Cups in Cage.

- Cups must be firmly seated in cage Check with feeler gauge (1.0001") after installation

OTE:

PRESS

Install cups one at a time.

Rear Axle Pinion. Press Bearing Cups in Cage.

"A" - Caps must be firmly seated in cage

Check with feeler gauge (0.001") after installation.

OTE:

Install cups one at a time.

1. Using appropriate sleeve, press bearing cups in cage (see

PRESS

adjacent drawings).

Note: On rear axles, do not install oil seal in cage until bear-

ing preload is correctly adjusted.

IMPORTANT

After bearing cups are installed, preselect pinion bearing spacer using the “trial build-up” procedure described in the Adjustments Section of this manual.

2. Press pilot bearing on pinion.

IMPORTANT

To prevent bearing damage, use suitable sleeve that only contacts inner bearing race.

3. Stake pilot bearing using staking tool, this is essential to retain the bearing.

Note: During pinion bearing installation, locate each part in

same position that was used in "Trial Build-up" Preload Test.

Differential Carrier Overhaul (Forward and Rear Axle)

4. Press inner bearing cone on pinion.

IMPORTANT

To prevent bearing damage, use suitable sleeve that only contacts inner race of bearing cone.

5. Install preselected bearing spacer on pinion.

Service Procedure

6. Install bearing cage on drive pinion.

7. Press outer bearing cone on pinion.

IMPORTANT

To prevent bearing damage, use suitable sleeve that only contacts inner race of bearing cone.

At this stage of assembly, "final-check" pinion bearing preload. See Adjustment Section of this manual.

Differential Carrier Overhaul (Forward and Rear Axle)

8. Rear Axle Only. With pinion installed and bearing preload ad-

Rear Axle Pinion. Press Oil Seal in Cage (with pinion installed

justment complete, Install oil seal with a press. **

9. Rear Axle Only. Prior to installation of yoke, lubricate oil seal and make sure yoke is clean and dry. Install yoke, flat washer* and nut. Torque nut to proper specification. (see page

24).

Note: After tightening pinion nut, recheck pinion bearing

rolling torque. See Adjustment Section for "Press-fit" outer pinion bearing.

10. Forward Axle Pinion Helical Gear and Nut: These parts are installed during pinion installation (see page 53).

IMPORTANT

**Refer to page 13 for service information on Seals, Yokes & Slingers.

* Nuts used on production axles after 1/3/95 are metric and do not use flat washer.

Differential Carrier Overhaul (Forward and Rear Axle)

Assemble Drive Pinion ("Slip-fit" outer pinion bearing)

Procedure -

1. Using appropriate sleeve, press bearing cups in cage (see adjacent drawings).

2. Press pilot bearing in pinion.

IMPORTANT

To prevent bearing damage, use suitable sleeve that only contacts inner bearing race.

Forward Axle Pinion.

Press Bearing Cups

in Cage.

- Cups must be firmly seated in cage Check with feeler gauge (1.0001") after installation

OTE:

PRESS

Install cups one at a time.

Rear Axle Pinion. Press Bearing Cups in Cage.

"A" - Caps must be firmly seated in cage

Check with feeler gauge (0.001") after installation.

OTE:

Install cups one at a time.

PRESS

Service Procedure

3. Stake pilot bearing using staking tool and press. This is essential to retain the bearing.

Differential Carrier Overhaul (Forward and Rear Axle)

4. Press inner bearing cone on pinion.

IMPORTANT

To prevent bearing damage, use suitable sleeve that only contacts inner race of bearing cone.

5. Install bearing spacer on pinion.

Note: When new gear set or pinion bearings are used, select

nominal size spacer (see chart page 20). If original parts are used, use spacer removed during disassembly.

6. Install bearing cage on drive pinion.

7. Install pinion outer bearing cone.

Note: At this stage in assembly, check pinion bearing pre-

load de-scribed in Adjustment Section of this manual for "slip fit" outer pinion bearing. Rear Axle: Do not install oil seal until adjustment incomplete.

8. Rear Axle Oil Seal and Yoke: Installation of these parts is the same for "slip-fit" and "press-fit" bearings. See page 49 (step 8 and 9) for instructions.

Note: For "slip-fit" bearings, pinion may be temporarily re-

moved to simplify seal installation.

9. Forward Axle Helical Gear and Nut: See page 53 for instructions.

Inter-Axle Differential Lockout Overhaul.

Procedure - Assemble and Install Lockout

1. With shift fork and sliding clutch installed, place the shoulder washer (white plastic) over push rod. The large diameter side of the washer must face the power divider cover.

2. Install compression spring on push rod.

3. Lubricate “O” ring with silicone-based lubricant and install “O” ring on piston.

4. Place piston assembly on push rod. The large diameter end of piston must face power divider cover.

5. Install locknut on push rod and tighten to 13-17 lft. lbs. (l8-23 N.m).

6. Install piston housing, making sure the housing is correctly seated and piloted in the shoulder washer.

7. Place mounting bracket over housing and position on power divider cover. Install cap screws and lock washers and tighten to 48-56 ft. lbs. (65-76 N.m).

Note: If axle is installed in vehicle, apply sealant to air line fitting and connect air line. When tightening air line, hold piston

housing in mounting position using a wrench applied to the hexagon configuration at outer end of housing.

Shoulder washer

must seat properly

Note: A new style “Inter-Axle Differential Lockout” was being released as this publication was being printed. If the Inter- Axle

Differential Lockout Assembly on your axle is not shown in this publication, call your local

Spicer representative.

Service Procedure

Differential Carrier Overhaul (Forward and Rear Axle)

4. Rear Axle Drive Pinion: Install pinion assembly. Install bearing cage cap screws and lock washers. Torque cap screws to 110-125 ft. lbs. (149-170 N.m).

5. Place ring gear and differential assembly in carrier. During installation, tilt carrier to allow differential case pilot to mesh properly with edge of bearing cap pedestal (see photo above).

6. Install bearing cups at both sides of differential case.

Install bearing adjusters and caps.

Differential Carrier Overhaul (Forward and Rear Axle)

7. Install and tighten bearing cap screws finger tight. If this is difficult, use hand wrench. The assembly is now read-y foradjustment of differential bearing preload, ring gear backlash and gear tooth contact.

8. At the teeth-side of ring gear, position bearing adjuster until its first thread is visible.

9. At the back-face side of ring gear, tighten adjuster until there is no backlash.

10. At the teeth-side of ring gear, tighten adjuster until it contacts the bearing cup. Continue tightening adjuster two or three notches. This will preload bearings and provide backlash.

Service Procedure

11. Check Ring Gear Backlash. Measure backlash with a dial indicator. Specifications are listed below. Refer to page 21 for detailed instructions on adjusting backlash.

Ring Gear Backlash Specifications

USED GEARING - Reset to backlash recorded before disassembly.

NEW GEARING - Backlash should be between 0.006" and

0.016".

Differential Carrier Overhaul (Forward and Rear Axle)

12. Check Ring Gear Tooth Contact. Paint ring gear teeth and

Correct Pattern Used Gearing

check tooth contact pattern. Correct tooth patterns are illustrated below. For checking and adjusting procedures, see page 22.

Pocket may be extended.

Pattern along the face width could be longer.

Correct Pattern New Gearing

Could vary in length. Pattern should cover 1/2 tooth or more (face width).

Pattern should be evenly centered between tooth top land and root.

Pattern should be clear of tooth toe.

13. With ring gear and pinion adjusted correctly, align adjusters and locks, then tighten differential bearing cap screws to correct torque (360-440 ft. lbs., 488-596 N.m). Install adjuster locks and cotter pins. Lock-wire differential bearing cap screws.

14. Forward Axle Helical Gear. If dummy yoke was used, remove nut and yoke. Install helical gear on pinion, positioned as shown in the illustration. Install nut and tighten to correct torque (see chart)

Torque Chart

Size Ft. lbs N.m

Forward Axle Pinion Nut

(D340, 380(P), 400-P) 1 1/2-18

(D341, 381(P), 401-P, 402(P), 451-P) 1 5/8-18

(D341, 402(P) 403(P), 451-P) M42 x 1.5

560-700 759-949

780-960 1057-1301

840-1020 1140-1383

Pinion Helical Gear

Mounting Position

NOTE:

Pinion Nut Variations

See Torque Chart for

Slotted Nut and Roll Pin

(D-341, 381(P),

840 1139 401-P, 402(P), 451-P only ) 1 5/818

IMPORTANT

*Torque to 840 ft. lbs. (1139 N.m), then continue tightening nut to align slot with the nearest hole in pinion shank. Install roll pin.

15. Installing Pinion Helical Gear.

Note: See Torque Chart for Pinion Nut Variations

Appendix

Service Bulletin Supplement

Input Shaft End Play for Axle Models equipped with an Input Shaft Axial Spring and Thrust Button.

In September 1988, an Axial Spring and Thrust Button were added between the input and output shafts. The addition of these parts reduces shaft end play movement by loading the shafts axially in the direction of the yoke.

Service Procedure

Location of Axial Spring and Thrust Button.

End play tolerances are the same for axles with or without the new Spring and Thrust Button. However, end play measurement procedure is different as described below.

Input Shaft End Play:

New or Rebuild with new parts 0.003” to 0.007”

Rebuild with reused parts 0.013” to 0.017” Note: Because of manufacturing variations in individual parts, correctly adjusted end play could vary 0.010,” after the unit is ro-

tated.

Acceptable End Play Tolerances when measuring as a regular maintenance procedure with axle in truck.

Up to 0.060” with over 100,000 miles or 1 year service off-road

Up to 0.040” with less than 100,000 miles or 1 year service on-road Note: If end play exceeds limits, disassemble power divider and replace worn parts.

Appendix

Special Instructions

The addition of the Spring and Thrust Button between the input and output shafts necessitates the fabrication of a “U” bracket to assist in measuring the shaft end play. Proceed as follows:

Procedure - Measure and Adjust Input Shaft End Play

1. Fabricate a “U” bracket from 1“ flat stock (minimum thickness 0.125”) as specified in the illustration.

2. If axle is disassembled, build up a 0.045” (0.024 mm) thick shim pack and place shim pack and bearing cover on power divider cover. Then proceed with Step 3.

If axle is assembled, remove input shaft nut, flat washer and yoke. (NOTE: Axles built with metric threaded nuts do NOT use flat washers) Then proceed with Step 3.

Note: Bushing removed from current production output shafts, See notes on page 35.

Appendix

3. Install the “U” bracket on bearing cover, using two bearing cover cap screws (see illustration). In- tall all other cover cap screws and torque to 75-85 ft. lbs. (101-115 N.m).

Bearing cover

capscrew

Lockwasher

Fabricated U-bracket

Inner bearing

cover

Input bearing

cover shim(s)

Input shaft

Service Procedure

4. Position a dial indicator on the end of the input shaft (see illustration).

Dial indicator

U-bracket

Pry bar

Input shaft

Lift up on pry bar to compress input shaft.

5. Insert a pry bar through the “U” bracket with the end of the bar resting on the end of the input shaft. (see illustration).

6. Zero the dial indicator and lift up on the pry bar to move the input shaft axially until it bottoms out within the bearing cover. Measure the end play.

Appendix

7. If end play is acceptable (see chart), remove “U” bracket and bearing cover. Seal shim pack to prevent lube leak age. Reinstall bearing cover and cap screws. Torque cap screws to 75-85 ft. lbs. (101-115 N.m). Continue axle assembly as necessary.

8. If end play is incorrect, change shim pack size as follows:

Add shims to increase end play.

Desired end play 0.003” to 0.007”

Measured end play (Step 6) 0.001 “ — 0.001“

Add shims to provide desired end play 0.002” to 0.006”

Remove shims to decrease end play.

Measured end play (Step 6) 0.015” — 0.015”

Desired end play 0.003” to 0.007”

Remove shims to provide desired end play 0.01 2“ to 0.008”

9. Recheck end play and adjust as necessary until end play is within acceptable tolerance.

10. When end play is correct, remove “U” bracket and bearing cover. Seal shim pack to prevent lube leakage. Reinstall bearing cover and cap screws. Torque cap screws to 75-85 ft. lbs. (101-115 N.m). Continue axle assembly as necessary.

Gear Pinion Nut Fastening Chart:

Gear Pinion Nut Fastening Chart

Style Model Size Ft-lbs N.m

Self Locking Pinion Nut D340; 380(P); 400-P 1-1/2 - 18 560-700 759-949

D341;381 (P); 401(P); 402(P); 403(P); 451-P

R-All Modles 1 1/2 - 18 560-700 759-949

Slotted Nut and Roll Pin D341; 381(P); 401-P;

402(P); 403-(P); 451-P

Metric self locking Pinion Nut

D341; 402(P); 403(P); 451-P

R- All models M36 x 1.5 575-703 780-953

1 5/8 - 18 780-960 1057-1301

1 5/8 - 18 840 1139

Note: Torque to 840 ft. lbs. (1139 N.m) then continue tightening nut to align

slot with the nearest hole in pinion shank)

M42 x 1.5 840-1020 1140-1383

Metric nuts produced after 4/95 incorporate a pre applied thread locking compund

Nut Torques

Nut Part number Threads Nut Size Socket Size Location

95206 English 1 1/2 - 18 2.25” R-Pinion

118806 English 1 5/8 - 18 2.50” D-Pinion

127589 Metric M36 x 1.5 55mm R-Pinion

126182 Metric M42 x 1.5 65mm D-Pinion

Service Procedure

Gear Pinion Nut Fastening Chart:

Note: Reference Bulletin AXIB-9409 and AXIB-9503 for more information.

CAUTION

Metric nuts have an integral flange washer built into them. Do not use separate washer in conjunction with these nuts.

English (Inch) Style Nut

Metric Style Nut

Related Publications

Parts Book

Model Publication

Single Reduction Tandem Drive Axles

34,000 — 45,000 lbs. (340, 380, 400, 341, 381, 401, 402, 403, 451) AXIP-0089

34,000 — 45,000 lbs. (344, 404, 454) AXIP-0200

34,000 — 52,000 lbs. (With Controlled Traction Differentials) AXIP-0084

Appendix

Dual Range, Planetary Double Reduction Tandem Drive Axles

34,000 — 45,000 lbs AXIP-0087

Single Reduction, Dual Range, Planetary Double Reduction (Tandem Drive Axles)

46,000 — 65,000 lbs. (Axle Series 461,521,581, 601, 651, 652) AXIP-0085

(Diff. Lock Models 461,521, 581) AXIP-0085A

Spicer ® Brakes

All Models BRIP-0065

Spicer ® Steer Axles

All Models AXIP-0074

Service Manual

Model Publication

Single Reduction Tandem Drive Axles

34,000 -- 45,000 lbs. (Axle Series 340 — 402, 451) AXSM-0041

34,000 — 45,000 lbs. (Axle Series 344, 404, 454) .AXSM-0046

44,000 — 58,000 lbs. (Axle Series 440, 460 — 651) AXSM-0042

Dual Range and Planetary Double Reduction Tandem Drive Axles

Service Procedure

34,000 — 45,000 lbs. (Axles Series 340 — 402, 451) .AXSM-0045

44,000 — 65,000 lbs. (Axle Series 440, 460 — 651) AXSM-0044

Spicer ® Brakes

EB& ES Brakes .AXSM-0033

Spicer ® Steer Axles

E-1000I, E-1200I, E-1320I, E-1460I AXSM-0038

EFA12F3, 12F4, 13F3, 13F5, 20F4, 22 T2/T5, 24T2/T5 AXSM-0037

These publications may all be ordered through www.spicerparts.com

If additional help is needed, call 1-800-826-HELP (4357).

Dana Aftermarket Group

For spec‘ing or service assistance, call 1.800.621.8084 or visit our website at www.spicerparts.com

PO Box 321 Toledo, Ohio 43697-0321

Warehouse Distributor: 1.800.621.8084

Dana Commercial Vehicle Products Group

OE Dealers: 1.877.777.5360

3939 Technology Drive Maumee, Ohio, USA 43537

www.spicerparts.com

www.dana.com

Spicer 34DS, 34RS, 38DS, 38RS, DS340 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Axle and Carrier Assembly Model Identification

Power Flow and Torque Distribution

Differential Carrier Assembly Exploded View

Differential Carrier Assembly

Lubrication

Wheel End Lubrication

Cleaning, Inspection, Replacement

Wheel Bearing Adjustment

Differential Carrier Adjustments

Pinion Bearing Preload

Final Pinion Bearing Preload Test

Adjust Pinion Bearing Preload for Axles with "Slip-fit" Outer Pinion Bearings

Differential Bearing Preload and Ring Gear Backlash Adjustment

Ring Gear and Pinion Tooth Contact

Fastener Tightening Specifications

Dana Single Reduction Tandem Models

Remove Differential Carrier Assembly from Axle Housing

Install Differential Carrier Assembly

Power Divider Replacement (with differential carrier assembled to axle housing)

Install Power Divider on Differential Carrier

Remove Differential Carrier Assembly from Axle Housing

Remove Power Divider from Differential Carrier (with carrier removed from axle housing)

Disassemble Power Divider Cover

Disassemble Inter-axle Differential

Disassemble Output Shaft

Assemble Output Shaft

Assemble Inter-axle Differential

Assemble Power Divider Cover

Install Power Divider on Differential Carrier (with carrier removed from axle housing)

Measure and Adjust Input Shaft End Play

"Standard" or "Current" Model Lockout Overhaul

"Standard" or "Non-Current" Model Lockout Overhaul

"Reverse-Air" Lockout Overhaul

Disassemble Differential Carrier (with power divider removed)

Disassembly Drive Pinion

Disassemble Wheel Differential

Assemble Wheel Differential

Assemble Drive Pinion ("Press-fit" outer pinion bearing)

Assemble Drive Pinion ("Slip-fit" outer pinion bearing)

Service Bulletin Supplement

Gear Pinion Nut Fastening Chart

Related Publications