Spicer D-R440, 460, 480, D_R461, D-R462 User Manual

...

Spicer® Tandem Drive Axles

Sevice Manual

Spicer® Tandem Drive Axles

AXSM-0042 September 2007

Models: D/R440 D/R460 D/R480 D/R485 D/R461 D/R462 D/R463 D/R521 D/R581 D/R601 D/R651 D/R652 D/R653

Warnings and Caution

Warning

The description and specifications contained in this service publication are current and the time of printing.

Dana Corporation reserves the right to discontinue or to modify its models and/or procedures and to change specifications at any time without notice.

Important Notice

This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and/or component damage.

Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator.

Always use genuine Dana replacement parts.

Any reference to brand names in this publication is made simply as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents, if available, may be used.

WARNING

Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician.

CAUTION

Failure to follow indicated procedures may cause component damage or malfunction.

IMPORTANT

Highly recommended procedures for proper service of this unit.

NOTE: Additional service information not covered in the service procedures.

TIP: Helpful removal and installation procedures to aid in the service of this unit.

Table of Contents

Table of Contents - Visual

Wheel Differential Assembly Page 68-82

Carrier Assembly Page 45-56

Drive Pinion Page 57-67

Wheel End Page 99-101

Power Divider Page 24-44

Seals Page 92-93

Table of Contents

Ring Gear Page 82-83

Wheel End Seal Page 95-96

Wheel Adjustment Systems Page 97-98

Wheel Differential Lock Page 83-90

Housing and Rear Cover Assembly Page 91

Housing Breather Page 94

Differential Lockout Page 17-22

Differential Carrier Assembly Page 11-16

Lubrication Page 102-106

Torque Chart Page 107-108

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

iii

Introduction

General Information

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

The suffix letter “P” in the model number indicates lube pump is standard. Pump models are equipped with a gerotor pump, designed to provide additional lubrication to the inter-axle differential and related parts.

Carrier Design and Identification

(DT440-P, DT460-P, DT480-P and DP440-P through DP650P)

On August 1, 1981, these axles were converted to a new configuration which includes redesign of the axle differential carrier; input shaft bearing, involute side gear and axle shaft spline configuration. For carrier identification, see illustrations:

Axles built after August 1, 1981 with Carrier Casting No. 110500

Note: Refer to Dana Parts Book AXIP-0108 for parts informa-

tion.

Input Shaft

Input shaft with Carrier Casting 110500 is equipped with a tapered roller bearing. Casting 103530 uses a ball bearing.

Input Shaft Bearing Spacer

Used only with Carrier Casting 110500.

Pinion Bearing Sleeve

Used only with Carrier Casting 103530.

Pinion Helical Gear Spacer

Used only on DT/DP440-P and DT/DP460-P (ratios 3.90-6.17).

Output Shaft Rear Bearing Retaining Washer

Used only on DT440-P - DT485-P and DP440-P - DP650-P.

Lube Pump Drive Shaft

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

General Information

Axles built before August 1, 1981 with Carrier Casting No. 103530

Model Listing

General Information

The following models are included in this publication:

Forward Axle Rear Axle Load Capacity

DP440-P 44,000 lbs.

DS440-P RS440

DT440-P

DP460-P 46,000 lbs.

DS460-P RS460

DT460-P

DD461-P RD461

DP461-P

DS461-P RS461

DT461-P

DP480-P 48,000 lbs.

DS480-P RS480

DT480-P

DP485-P

The suffix letter "P" in the model number indicates the axle is equipped with a lube pump which provides positive lubrication in the inter-axle differential and other power divider parts.

Model variations and parts identification information is included throughout this manual. For more detailed parts information, refer to your Dana parts books.

DT485-P

DD521-P RD521 52,000 lbs.

DP521-P

DS521-P RS521

DT521-P

DP580-P 58,000 lbs.

DD581-P RD581

DS581-P RS581

DP581-P

DP601-P 60,000 lbs

DT601-P

DP650-P 65,000 lbs

DP651-P

DT461-P

DP652-P

Model Information

General Information

Gearing

D - Forward Tandem Axle R - Rear Tandem Axle

S - Single Reduction D - Single Reduction with Wheel Differential Lock T - Dual Range P - Planetary Double Reduction

Example:

DS = Forward Tandem Axle/Single Reduction RS = Rear Tandem Axle/Single Reduction

Lube Pump

P = Standard (P) = Optional

Design Level

Capacity (x 1000 lbs.)

Example: 46 = 46,000 lbs.

General Information

Model Identification

Drive Axle

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

are older models (before May 1987).

CUST. PART NO.

Spicer

SPEC. SERIAL NO.

MODEL PART NO. RATIO

CUST. PART NO.

Spicer

SPEC. SERIAL NO.

MODEL PART NO. RATIO

MADE IN:

Data plate is located on

the axle centerline

CUST. PART NO.

Spicer

SPEC. SERIAL NO.

MODEL PART NO. RATIO

MADE IN:

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

Spicer

PT. NO.

HSG. CAP. LBS.

E IN HSG. I.D. N HOUSING MAD

1 - ID Tag 2 - Axle shaft part number

General Information

Ring Gear and Pinion

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

be replaced in sets.

127381

SPICER

127

41-8

8-41

127428

NL2

L7038

127

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

JD77

85405

Failure Analysis

Failure analysis is the process of determining the original cause of a component failure in order to keep it from happening again. Too often, when a failed component is replaced without determining its cause, there will be a recurring failure. If a carrier housing is opened, revealing a ring gear with a broken tooth, it is not enough to settle on the broken tooth as the cause of the carrier failure. Other parts of the carrier must be examined. For a thorough understanding of the failure and possible insight into related problems, the technician needs to observe the overall condition of the vehicle.

No one benefits when a failed component goes on the junk pile with the cause unknown. Nothing is more disturbing to a customer than a repeat failure. Systematically analyzing a failure to prevent a repeat occurrence assures quality service by avoiding unnecessary downtime and further expense to the customer.

The true cause of a failure can be better determined by knowing what to look for, determining how a piece of the equipment was running and learning about previous problems. In the case of a rebuilt rear axle, mismatched gears may have been installed. The more successful shops prevent repeat equipment failures by developing good failure analysis practices. Knowing how to diagnose the cause of a premature failure is one of the prerequisites of a good heavy-equipment technician.

How to Diagnose a Failure

The following five steps are an effective approach to good failure diagnostics.

1. Document the problem.

2. Make a preliminary investigation.

3. Prepare the parts for inspection.

4. Find the cause of the failure.

5. Correct the cause of the problem.

Document the Problem

Here are some guidelines for starting to learn about a failure, including questions to ask:

• Talk to the operator of the truck.

• Look at the service records.

• Find out when the truck was last serviced.

• Ask: In what type of service is the truck being used?

• Ask: Has this particular failure occurred before?

• Ask: How was the truck working prior to the failure?

Failure Analysis

You need to be a good listener. Sometimes, insignificant or unrelated symptoms can point to the cause of the failure.

• Ask: Was the vehicle operating at normal temperatures?

• Ask: Were the gauges showing normal ranges of operation?

• Ask: Was there any unusual noise or vibration?

After listening, review the previous repair and maintenance records. If there is more than one driver, talk to all of them and compare their observations for consistency with the service and maintenance records. Verify the chassis Vehicle Identification Number (VIN) number from the vehicle identification plate, as well as the mileage and hours on the vehicle.

Failure Analysis

Make a Preliminary Investigation

These steps consist of external inspections and observations that will be valuable when combined with the results of the parts examination.

• Look for leaks, cracks or other damage that can point to the cause of the failure.

• Make note of obvious leaks around plugs and seals. A missing fill or drain plug would be an obvious cause for concern.

• Look for cracks in the carrier housing (harder to see, but sometimes visible).

• Does the general mechanical condition of the vehicle indicate proper maintenance or are there signs of neglect?

• Are the tires in good condition and do the sizes match?

• If equipped with a torque-limiting device, is it working properly?

During the preliminary investigation, write down anything out of the ordinary for later reference. Items that appear insignificant now may take on more importance when the subassemblies are torn down.

Find the Cause of the Failure

Here begins the real challenge to determine the exact cause of the failure. Keep in mind that there is no benefit to replacing a failed part without determining the cause of the failure. For example, after examining a failed part and finding that the failure is caused by a lack of lubrication, you must determine if there was an external leak. Obviously, if there is an external leak, just replacing the failed gear is not going to correct the situation.

Another important consideration here is to determine the specific type of failure which can be a valuable indicator for the cause of failure. The following pages show different types of failures and possible causes. Use this as a guide in determining types of failures and in correcting problems.

Correct the Cause of the Problem

Once the cause of the problem has been determined, refer to the appropriate service manual to perform the repairs.

Prepare the Parts for Inspection

After the preliminary investigation, locate the failure and prepare the part for examination. In carrier failure analysis, it may be necessary to disassemble the unit.

• When disassembling subassemblies and parts, do not clean the parts immediately since cleaning may destroy some of the evidence.

• When tearing down the drive axle, do it in the recommended manner. Minimize any further damage to the unit.

• Ask more questions when examining the interior of the carrier. Does the lubricant meet the manufacturer specifications regarding quality, quantity and viscosity? As soon as you have located the failed part, take time to analyze the data.

Inspection

Clean

1. 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 combustibility. It is unsafe in the workshop environment.

2. Wash castings or other rough parts in solvent or clean in hot solution tanks using mild alkali solutions.

Note: If a hot solution tank is used, make sure parts are heated

thoroughly before rinsing.

3. Rinse thoroughly to remove all traces of the cleaning solution.

4. Dry parts immediately with clean rags.

5. Oil parts.

• If parts are to be reused immediately: Lightly oil.

• If parts are to be stored: Coat with oil, wrap in

corrosion resistant paper and store in a clean, dry place.

Note: Replace conventional gaskets with silicone rubber gas-

ket compound (included in many repair kits). The compound provides a more effective seal against lube seepage and is easier to remove from mating surfaces when replacing parts.

Inspection

1 - Axle housing 2 - Machined surface

Inspect Components

Inspect all steel parts for:

• Notches, visible steps or grooves created by wear

Inspect Axle Housing

Axle housing inspection and repairs are limited to the following checks or repairs:

• Visually inspect axle housing for cracks, nicks and burrs on machined surfaces.

• Check carrier bolt holes and studs for foreign material.

• Replace damaged fasteners. Look for loose studs or cross threaded holes.

CAUTION

Any damage which affects the alignment or structural integrity of the housing requires housing replacement. Do not repair by bending or straightening . This process can affect the material's properties and cause it to fail completely under load.

• Check all seals and gaskets.

• Pitting or cracking along gear contact lines

• Scuffing, deformation or discolorations. These are signs of excessive heat in the axle and are usually related to low lubrication levels or improper lubrication practices.

In addition, inspect the following for damage:

• Differential gearing

• Bearings for loose fit on drive pinion, pilot bearing, and differential bearings

• All fasteners for rounded heads, bends, cracks or damaged threads.

• Inspect machined surfaces of cast or malleable parts. They must be free of nicks, burrs, cracks, scoring, and wear.

• Look for elongation of drilled holes, wear on surfaces machined for bearing fits and nicks or burrs in mating surfaces.

Inspection

Inspect Primary Gearing

Before reusing a primary gear set, inspect teeth for signs of excessive wear. Check tooth contact pattern for evidence of incorrect adjustment.

Check Input Shaft End-play (Forward Axle)

Note: Before disassembling the power divider, measure and

record input shaft end-play.

See illustration for steps 1-3.

1. Position dial indicator at yoke end of input shaft.

2. Push in on input shaft and zero the dial indicator.

3. Using a pry bar, move input shaft axially and measure/record end-play.

Check Output Shaft End-play (Forward Axle)

See illustration for steps 1-3.

1. Position dial indicator at yoke end of output shaft.

2. Push in on output shaft and zero the dial indicator.

3. Using a pry bar, move input shaft axially and measure/record end-play.

Adjustment

Correct end-play for a new assembly is .003" to .007". The maximum end-play for a used assembly is no more than .014". If end-play is incorrect, determine shim pack changes as follows:

Add shims to increase end-play

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

Measured end-play (Step 3) 0.001”-0.001”

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

Remove shim to decrease end-play

Measured end-play (Step 3) 0.015" – 0.015"

Desired end-play (New Parts) 0.003” to 0.007”

Remove shims to provide desired endplay

0.012” to 0.008”

Adjustment

Correct end-play for a new assembly is .001" to .005". The maximum end-play for a used assembly is no more than .005". If end-play is incorrect, contact Dana.

Differential Carrier Assembly

Differential Carrier Assembly - Parts

1 - Carrier fasteners 2 - Carrier assembly 3 - Forward axle assembly 4 - Inter-axle differential lockout 5 - Rear axle assembly

Differential Carrier

Assembl

Differential Carrier Assembly

Forward Axle Differential Carrier Removal and Installation

Removal of Forward Differential Carrier

Note: The removal of the forward carrier requires disconnect-

ing of the inter-axle driveline and removal of the output shaft yoke assembly.

1. Block the vehicle.

2. Drain axle lubricant.

3. Disconnect all air lines to the axle.

4. Disconnect inter-axle and main drivelines.

5. Remove axle stud nuts and axle shafts (If used, remove lock washers and taper dowels).

WARNING

The differential lock 461/521/581 models use axle shafts with different spline length (4" or 11"). Axle shafts may also be location specific with various wheel equipment. Do not misplace axle shafts from their intended location.

TIP: To loosen dowels, hold a brass drift in the center of the

shaft head and strike drift with a sharp blow using a hammer.

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

6. Remove carrier capscrews, nuts and lock washers.

7. Forward Models Only: Remove output shaft shoulder nut and yoke.

8. Remove differential carrier assembly.

Removal of Forward Axle Housing Cover

Tip: The bearing parts can be serviced separately

without removing the housing cover form the axle housing

1. Block the vehicle.

2. Drain axle lubricant.

3. Disconnect inter-axle driveline.

4. Remove output shaft shoulder nut and yoke.

5. Remove capscrews, nuts, and lock washers fastening cover to axle housing.

6. Remove oil seal and discard.

7. Remove bearing retaining washer, if used.

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

WARNING

CAUTION

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

1 - Carrier fasteners 2 - Carrier assembly 3 - Forward axle assembly 4 - Axle shaft

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

5 - Nut 6 - Lock washer 7 - Lift and support

Inspection

Installation of Forward Differential Carrier

IMPORTANT

Before installing carrier assembly, inspect and thoroughly clean interior of axle housing using an appropriate solvent and clean rag.

IMPORTANT

1. Use silicone rubber gasket compound on axle housing mating surface as shown in the illustration. Completely remove all old gasket material prior to applying new material. Compound will set in 20 minutes. Install carrier before compound sets or reapply.

TIP: To assist in installing complete differential carrier, use two pieces of threaded rod (5/8"- 11 UNS) threaded into carrier capscrew holes. Rod should be approximately 6" long. Use these to pilot the carrier into the housing.

2. Install differential carrier assembly to axle housing using lockwashers, capscrews and nuts. Torque to proper specification (see Torque Chart on page 107).

3. With the forward axle now assembled to the housing, proceed with Installation of Forward Axle Housing Cover and Output Shaft Bearing Parts, on next page.

4. Install output yoke and self-locking nut. Tighten to specified torque (see Torque Chart on page 107). Reference Yoke Installation Section page 92.

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

WARNING

When axle has been disassembled or housing, axle shafts or wheel equipment re placed, check axle assembly for proper differen- tial action before operating vehicle. Wheels must rotate freely and independently.

Road test vehicle to bring axle lubricant up to temperature. Recheck joints, drain and fill plugs for leakage. Re-tighten as necessary.

Differential Carrier Side of Axle Housing

Inspection

6. Connect main and inter-axle driveline. Ensure drivelines are properly phased. Lubricate U-joints.

7. Add axle lubricant. See Lube Fill Capacities on page 104 for correct amount.

Note: Oil fill plug removed from D461/462/463 Differential

Carriers. The oil fill plug hole located in the differential carrier was removed. Lube capacity is not affected, customers to fill axle with lube through rear cover fill hole or through the breather hole in housing. February 1, 2000.

8. Connect air lines to differential.

Axle Housing Silicone Gasket Compound Pattern

1 - Apply silicone gasket in this pattern 2 - Typical stud locations

Differential Carrier Assembly

Installation of Forward Axle Housing Cover and Output Shaft Bearing Parts

Note: Forward axle should be assembled to the axle housing

before proceeding with the following procedure.

1. If removed, install housing cover and fasten with nuts, capscrews and lock washers. Tighten to proper torque specifications (see Torque Chart on page

107).

Note: Use silicone rubber gasket compound on axle housing

mating surface as shown in illustration. Completely remove all old gasket material prior to applying new material. Compound will set in 20 minutes. Install axle housing cover and output shaft assembly before compound sets or reapply.

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

IMPORTANT

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

Road test vehicle to bring axle lubricant up to temperature. Recheck joints, drain and fill plugs for leakage. Re-tighten as necessary.

Cover Side of Axle Housing

3. 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.

4. Install the output shaft seal in the axle housing cover.

Note: Some axles require the use of a rear bearing retaining

washer. Install the washer over the splines of the output shaft flush against the output shaft bearing.

5. Install output yoke and self-locking nut. Tighten to specified torque (see Torque Chart on page 107). Reference Yoke Installation Section page 92.

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

WARNING

7. Connect main and inter-axle driveline. Ensure drivelines are properly phased. Lubricate U-joints.

8. Add axle lubricant. See Lube Fill Capactities on page 104 for correct amount.

1 - Apply silicone gasket in this pattern 2 - Stud locations (varies by model)

Note: Oil fill plug removed from D461/462/463 Differential

9. Connect air lines to differential.

Differential Carrier Assembly

Rear Axle Differential Carrier Removal and Installation

Removal of Rear Differential Carrier

Perform the following steps:

1. Block the vehicle.

2. Drain axle lubricant.

3. Disconnect air line if working on a differential lock axle. (See Differential Lockout Section).

4. Disconnect inter-axle driveline.

5. Remove axle stud nuts and axle shafts (If used, remove lock washers and taper dowels).

WARNING

TIP: To loosen dowels, hold a brass drift in the center of the shaft head and strike drift with a sharp blow using a hammer.

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

CAUTION

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

6. Remove capscrews, nuts and lock washers.

7. Remove differential carrier assembly.

Differential Carrier

Assembl

1 - Carrier fasteners 2 - Carrier assembly 3 - Rear axle assembly

4 - Axle shaft 5 - Nut 6 - Lock washer

Differential Carrier Assembly

Rear Differential Carrier “Installation”

IMPORTANT

Before installing carrier assembly, inspect and thoroughly clean interior of axle housing using an appropriate solvent and clean rag.

Note: Note:

Note: Apply silicone rubber gasket compound on axle housing

mating surface as shown in illustration. Completely remove all old gasket material prior to applying new material. Compound will set in 20 minutes. Install carrier before compound sets or reapply.

1. Install differential carrier assembly.

TIP: To assist in installing complete differential carrier use two pieces of threaded rod (5/8"- 11 UNS) threaded into carrier capscrew holes. Rod should be approximately 6" long. Use these to pilot the carrier into the housing.

2. Install carrier to axle housing lock washers, capscrews and nuts. Torque to proper specification. See “Torque Chart” on page 107.

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

WARNING

Road test vehicle to bring axle lubricant up to temperature. Recheck joints, drain and fill plugs for leakage. Re-tighten as necessary.

1 - Apply silicone gasket in this pattern 2 - Typical stud locations

4. Connect inter-axle driveline, making sure driveline is in phase. Lubricate U-joints.

5. Add axle lubricant. Fill to bottom of filler hole. See “Change Lube” on page 104. Reference Lube Fill Capacities for correct amount.

6. Connect air line to differential if working on a differential lock model axle.

IMPORTANT

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

Differential Lockout

Inter-Axle Lockout Types

All are air-operated to engage the lockout and spring-released to disengage the lockout with the exception of the “ReverseAir” lockout. The “Reverse-Air” lockout is spring-released to engage the lockout and air-operated to disengage the lockout.

Cast Iron Cover Lockout - February 1996 to Present (Single Reduction Models)

• External type lockout

• Cast iron piston cover

3 4

6 7

Differential Lockout

1 - Shift fork assembly 2 - Compression spring 3 - Piston driver 4 - O-ring

5 - Piston 6 - Lock nut 7 - Cast iron piston housing 8 - Capscrew

Differential Lockout

Original Design Lockout - 1948 to Present (*Optional design for use with all dual range tandem axles)

• Die cast body

• Square Top

Original

design

• Interchangeable with cast iron lockout*

“In 1985, a “Protective Shift System” was released into production axles. Dana bulletin 85-03 explains this popular OEM option. This option can only work with the “original” design lockouts.

1514

1 - Shift fork assembly 2 - Push rod o-ring 3 - Body o-ring 4 - Lock washer 5 - Cap screw 6 - Original design lockout body 7 - Piston o-ring 8 - Piston

9 - Felt oilers 10 - O-ring 11 - Flat washer 12 - Lock nut 13 - Compression spring 14 - Cover o-ring 15 - Cover 16 - Lock washer 17 - Capscrew

Differential Lockout

Cylindrical Design Lockout - October 1989 to February 1996

• External type lockout

• Stamped steel piston cover

• Interchangeable with the cast style cover only as a complete assembly

8 9

Differential Lockout

1 - Shift fork assembly 2 - Shoulder washer 3 - Compression spring 4 - O-ring 5 - Piston

6 - Lock nut 7 - Cylindrical design piston housing 8 - Mounting bracket 9 - Lock washer 10 - Capscrew

Differential Lockout Overhaul

Differential Lockout

Instructions for the three different designs are on the following pages:

Cast Iron Cover Lockout - Overhaul on page 20

Original Design Lockout - Overhaul on page 21

Cylindrical Design Lockout - Overhaul on page 22

Cast Iron Cover Lockout - Overhaul

Disassemble and Remove Lockout

Note: With axle installed in vehicle, place differential lock se-

lector valve in the disengaged (or unlocked) position. Disconnect the air line at the lockout piston cover.

1. Remove capscrews and lock washers fastening piston housing to power divider cover. Remove the cast iron piston housing.

2. Remove lock nut, piston with o-ring, piston driver and compression spring from push rod.

Assemble and Install Lockout - Cast Iron Cover Design

1. With shift fork and sliding clutch installed, install compression spring on push rod.

2. Place piston driver on push rod against compression spring. The large diameter end of piston driver must face power divider cover.

3. Lubricate o-ring with silicone-based lubricant and install o-ring on piston.

4. Place piston assembly on push rod against piston driver.

5. Install lock nut on push rod and tighten to 13-17 lbs. ft. (18-23 N•m).

6. Apply silicone gasket compound to mounting surface on power divider cover.

Note: The shift fork and push rod cannot be removed with power divider cover installed (see Remove Power Divider on page 24).

Lockout Interchangeability

The cast iron design lockout assembly is interchangeable with previously designed lockouts, only as a complete assembly. The original shift fork and push rod can be used for all three design type lockouts and need not be replaced.

Retrofit kits are available to convert the non-current design lockouts to the current cast iron cover design lockout. For additional information, refer to Dana Parts Books AXIP-0085.

Retrofit as follows:

1. Disassemble and remove the old design lockout.

2. Assemble and install the cast iron cover lock-out.

CAUTION

Mounting screws are not interchangeable between the various design style lockouts. They are a different length and size.

1 - Lockout silicone gasket pattern

7. Install piston housing cover.

8. Install capscrews and tighten to 48-56 lbs. ft. (65-76 N•m).

9. If axle is installed in vehicle, apply sealant to air line fitting and connect air line.

Original Design Lockout Overhaul

Differential Lockout

Note: Find instructions for:

Cast Iron Cover Lockout - Overhaul on page 20 Cylindrical Design Lockout - Overhaul on page 22

Disassemble and Remove Lockout

Note: With axle installed in vehicle, place differential lock se-

lector valve in the disengaged (or unlocked) position. Disconnect the air line at the lockout piston cover.

1. Remove capscrews 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 capscrews and lock washers, then remove body and piston as an assembly. Remove oring and felt oilers from the piston.

Note: The shift fork and push rod cannot be removed with power divider cover installed (see Remove Power Divider on page 24).

Retrofit Original Design to Cast Iron Cover Design Lockout

Assemble and Install Original Design Lockout

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

1. Apply silicone gasket compound to mounting surface on power divider cover.

Differential Lockout

1 - Lockout silicone gasket pattern

The cast iron cover design lockout assembly is interchangeable with the original design lockout, only as a complete assembly. 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 design lockouts to the current cast iron cover design lockout. For additional information, refer to Dana Parts Books AXIP-0085.

Retrofit as follows:

1. Disassemble and remove the original design lockout.

2. Assemble and install the cast iron cover lockout.

CAUTION

Mounting screws are not interchangeable between the various design style lockouts. They are a different length and size.

2. Install lockout body. Secure with capscrews and lock washers. Torque capscrews to 48-56 lbs. ft. (65-76 N•m).

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

gine oil and lubricate o-rings with a high-viscosity silicone oil or barium grease o-ring lubricant.

3. Install felt oilers and large o-ring on piston.

4. Install compression spring over shift fork push rod. Install piston over end of shift fork into lockout body. Secure with lock washers and lock nut. Torque locknut (see Torque Chart on page 107).

5. Install o-ring in lockout body cover. Install cover and secure with capscrews and lock washers. Torque capscrews to 96-108 lbs. in. (10-13 N•m).

Differential Lockout

Cylindrical Design Lockout - Overhaul

Note: Find instructions for:

Cast Iron Cover Lockout - Overhaul on page 20

Original Design Lockout - Overhaul on page 21

Disassemble and Remove Lockout

Note: With axle installed in vehicle, place differential lock se-

lector valve in the disengaged (or unlocked) position. Disconnect the air line at the lockout piston cover.

1. Remove capscrews and lock washers fastening mounting bracket to power divider cover. Remove bracket and piston housing.

2. Remove lock nut, 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 Remove Power Divider on page 24).

Retrofit Cylindrical Design to Cast Iron Cover Design Lockout

Assemble and Install Lockout-Cylindrical Design

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 lock nut on push rod and tighten to 13-17 lbs. ft. (18-23 N•m).

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

The cast iron cover design lockout assembly is interchangeable with the cylindrical design lockout, only as a complete assembly. The original shift fork and push rod can be used for either type lockout and need not be replaced.

Retrofit kits are available to convert the non-current design lockouts to the current cast iron cover design lockout. For additional information, refer to Dana Parts Books AXIP-0085.

Retrofit as follows:

1. Disassemble and remove the cylindrical design lockout.

2. Assemble and install the cast iron cover lockout.

CAUTION

Mounting screws are not interchangeable between various design style lockouts. They are a different length and size.

1 - Shoulder washer must seat properly

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

Note: If axle is installed in vehicle, apply sealant to air line fit-

ting 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.

Power Divider - Parts Exploded View

2* 3 4 5

Inspection

678 910

19 21 22 23 24 25 27 28 29 31 32 33 35

42 44 45 47 48

36 37 38

4643

1517 16

Inspection

1 - Output shaft 2 - Bushings* 3 - O-rings 4 - Bearing cup 5 - Bearing cone 6 - Side gear 7 - Snap ring 8 - Spring 9 - Button 10 - Inter-axle differential assembly 11 - Capscrew 12 - Case half 13 - Spider 14 - Nut * Removed in September 1994

15 - Case half 16 - Side pinion 17 - Thrust washer 18 - Snap ring 19 - Helical gear 20 - Bushings 21 - Thrust washer 22 - “D” washer 23 - Lockout sliding clutch 24 - Input shaft 25 - Bearing cone 25 - Shift fork and push rod 27 - Power divider cover 28 - Lock washer 29 - Capscrew

30 - Lockout unit 31 - Bearing cup 32 - Shim 33 - Bearing cover 34 - Capscrew 35 - Oil seal 36 - Yoke 37 - Flat washer 38 - Nut

Lube Pump Parts

39 - Lock nut 40 - Pump drive gear 41 - Expansion plug 42 - Pipe plug 43 - Magnetic screen 44 - Pump gears 45 - O-ring 46 - Dowel pin 47 - Pump cover 48 - Lock washer 49 - Capscrew

Remove Power Divider

Power Divider

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

CAUTION

During removal of power divider cover, the inter-axle differential (IAD), input shaft assembly or IAD shift system parts may fall from the carrier if not careful. Use caution to prevent injury or damage.

1. Disconnect the main driveline.

2. Disconnect the lockout air line.

3. If overhauling the power divider, loosen but do not remove input nut.

4. Position a drain pan under the unit.

5. Remove PDU capscrews.

Method A - With Carrier Installed in Chassis

1. Use a transmission jack or a chain hoist and a sling.

Method B - With Carrier Out of Chassis

1. Use a chain hoist.

2. Mount carrier assembly in carrier assembly stand.

3. Remove PDU capscrews.

4. Fasten chain or strap to input yoke to remove power divider.

CAUTION

Note: Lifting mechanism may create nicks and burrs on input

yoke. Remove nicks and burrs if present.

5. Tap the sides of the cover at the dowel pin location with a mallet to loosen cover.

6. Remove PDU assembly.

7. Remove IAD assembly.

2. Wrap sling strap around power divider and attach to chain hoist hook.

3. Tap on the sides of the cover at the dowel pins with a mallet to create a space large enough to finish freeing the cover from the dowel pins.

4. Pull the power divider forward until the input shaft stub end is free of the output side gear, then remove the assembly.

5. Remove IAD assembly.

1 - Carrier assembly stand

Power Divider

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

Note: It is assumed that the differential carrier assembly has

been removed from axle housing prior to starting the following procedures:

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

2. Remove power divider cover capscrews and lock washers.

3. Fasten chain or strap to input yoke to remove power divider.

Note: Power divider may not separate easily, strike the cover

near the dowel pin location with a mallet.

CAUTION

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

5. With chain hoist attached to input yoke, lift power divider off carrier.

Power Divider

Note: Lifting mechanism may create nicks or burrs on input

yoke. Remove if present.

6. Lift inter-axle differential assembly out of carrier or off of output shaft side gear.

4. Tap the sides of the cover at the dowel pin location with a mallet to loosen cover.

Note: Late model axles may be equipped with a spring and

thrust button mounted between the input and output shafts, remove these parts.

Power Divider

7. Tilt carrier and remove the output shaft assembly.

8. If removal of the output shaft side gear bearing cup is necessary, use puller to remove bearing cup from carrier

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