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

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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

Power Divider

Disassemble, Assemble and Overhaul the Power Divider

The power divider may be serviced with the carrier assembly in or out of the axle housing.

Note: The following procedure assumes that the differential

carrier has been removed from the axle housing and that the power divider has been removed from the carrier assembly.

1. Late model axles may be equipped with a spring and thrust button mounted between the input and output shafts, remove these parts.

2. Remove output shaft and output side gear

Hammer: Use slipper to get under the cup and with a hammer and drift from the back side of carrier tap out bearing cup.

Power Divider

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

3. If replacement of the output shaft side gear bearing cup is necessary, use either of the following methods:

Weld: Place a weld bead around the inside of the cup, when the weld cools the cup will fall out.

5. Slide helical side gear off input shaft.

6. Remove helical side gear thrust washer, and “D” washer from shaft.

Power Divider

7. 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.

8. Remove input shaft nut and flat washer.

Note: Some models do not use flat washer as it is built into the

nut.

9. Remove yoke from input shaft using a puller tool.

TIP: A yoke puller tool may be made from the center section of most gear puller tools, or may be purchased from your local tool distributor.

10. Remove input bearing cage, capscrews, input bearing cover and shim pack.

Note: Shift fork cannot be removed until lockout unit is disas-

sembled (see Differential Lockout Overhaul on page 20). Shift fork push rod is secured to the lockout piston with a nut.

12. Slide input shaft assembly out of cover.

13. Remove sliding clutch.

11. If input shaft bearing cup needs replacement, use either of the following recommended practices:

Weld: Place a weld bead around the cup, when the weld cools the cup will fall out.

Drill: Drill a 1/4 inch size hole through the bearing cover to the back side of the cup and use a punch to remove the bearing cup.

1 - Sliding clutch

14. Remove input shaft bearing cone. Temporarily place lockout sliding clutch over rear of input shaft, teeth toward bearing cone. Place shaft in press and remove.

Power Divider

Disassemble Power Divider Cover (For Axles with Input Shaft Tapered Roller Bearing)

Note: The drive on early pump models is equipped with a woo-

druff 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.

1 - Lock nut 2 - Power divider cover 3 - Pipe plug 4 - Woodruff key 5 - O-ring 6 - Pump cover 7 - Capscrew

Power Divider

8 - Lock washer 9 - Dowel pin 10 - Pump gears 11 - Magnetic strainer 12 - Expansion plug 13 - Pump drive gear

Power Divider

1. With drive gear locknut previously removed and working through input shaft bore, gently pry oil pump drive gear from its shaft. See steps 5 and 6 for pump disassembly.

2. For models built before February 1, 2000, remove snap ring securing pinion outer support bearing race. For models built after February 1, 2000, a design change to a one piece roller bearing was implemented. Reference Dana Bulletin ABIB-0102 for more information.

WARNING

4. Unscrew and remove magnetic strainer from power divider cover.

5. Remove oil pump cover capscrews and lock washers. Remove pump cover and o-ring.

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

3. Remove pinion outer support bearing race with suitable puller.

6. When woodruff key is used, remove key from gear shaft. Remove pump gears from power divider cover.

Power Divider

Assemble Power Divider Cover (For Axles with Input Shaft Tapered Roller Bearing)

1. Install pinion outer bearing race in power divider cover using a driver and a hammer.

2. For models built before February 1, 2000, install snap ring to secure bearing race. For models built after February 1, 2000, a design change to a one piece roller bearing was implemented. Reference Dana Bulletin ABIB-0102 for more information.

WARNING

4. Install o-ring in pump cover, making sure o-ring is seated firmly in body. If removed, install dowel pins. Install pump cover on power divider cover and secure with capscrews and lock washers. (See Torque Chart on page 107).

Power Divider

5. Install pump drive gear. Install drive gear on pump shaft end. Hand tighten drive gear nut.

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

3. Install pump gears in power divider cover (position gear with long shaft in opening adjacent to input shaft).

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.

Power Divider

6. Press input bearing cone on input shaft.

1 - Press 2 - Plate 3 - Drive Seal 4 - Input shaft bearing cone 5 - Input shaft

8. If bushing removal is needed, the bushings must exit from the thrust washer side of the helical gear.

1 - Remove bearing from helical gear

9. Install bushings in helical side gear. Bushings must

be installed from thrust washer side of gear. See illustration for dimensional tolerances.

Note: Starting in March 1995, helical side gears are designed

with a shoulder step that helps prevent bushing walkout. The inner bushing must be installed from the thrust washer side of the helical gear against the shoulder step.

1 - Press 2 - Plate 3 - Drive sleeve 4 - Input shaft bearing cone 5 - Input shaft

7. Press bearing cup in input bearing cover.

1 - Input bearing cage

1 - Step added

1/32"

1 - Press 2 - Sleeve 3 - First bushing (press to shoulder step) 4 - Shoulder 5 - Sleeve 6 - Second bushing (recess 1/32”)

Power Divider

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

1 - Expansions plug

11. Install shift fork in power divider cover.

12. Install lockout cylinder assembly if removed. See Differential Lockout on page 20.

13. Place sliding clutch in power divider cover, engaging clutch with shift fork. Position clutch teeth toward helical side gear.

14. Slide input shaft into power divider cover. Engage shaft splines in lockout sliding clutch. Install bearing spacer on input shaft. Use only on DS440-P, DS460P, DS480-P.

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

Power Divider

16. Install magnetic strainer in power divider cover. Torque to 40-60 lbs. ft. (54-81N•m).

15. Install input bearing cover and shims.

Note: Input shaft end-play must be adjusted after power divid-

er is assembled to differential carrier. For easier adjustment, temporally install input bearing cage cover and tighten capscrews finger tight. See page 10 for End-play Adjustment.

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 Axial Spring and Spring Button Adjustment Section.

WARNING

Slide “D” washer over input shaft up to base of sliding clutch splines. Install bronze thrust washer. Install helical side gear. Secure with snap ring.

Inter-axle Differential

Power Divider

1 - Case half 2 - Spider 3 - Bushing (use on models built before November 1, 1991) 4 - Side pinion

5 - Thrust washer 6 - Bolt 7 - Case half 8 - Lock nut

Power Divider

Disassemble Inter-axle Differential

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

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

Note: Side pinion bushings are not used on tandem models

equipped with lube pumps built after November 1, 1991. Use when originally equipped.

Assemble Inter-axle Differential

1. Install bushings, side pinions and thrust washers on inter-axle differential spider. Pre-lube all components at time of assembly.

Power Divider

1 - Punch marks

2. Install spider assembly in one differential case half, align punch marks and install other case half. Secure assembly with bolts and lock nuts. Torque to 17-23 lbs. ft. (23-31 N•m).

Note: Side pinion bushings are not used on tandem models

equipped with lube pumps built after November 1, 1991. Use when originally equipped.

Power Divider

Output Shaft Assembly

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

1 - Output shaft 2 - Bushing 3 - O-rings 4 - Bearing cup (mounted in carrier) 5 - Bearing cone

6 - Side gear 7 - Axial spring 8 - Thrust button 9 - Snap ring

Power Divider

Disassemble Output Shaft

WARNING

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

1. Mount shaft assembly in vise, using brass vise jaw protectors. Remove snap ring, side gear and bearing cone assembly.

2. Remove output shaft o-rings. If replacement is necessary, remove bushing mounted in end of output shaft.

Assemble Output Shaft

Note: Lubricate parts with gear lube during assembly.

1. Press bearing cone on output shaft side gear.

Power Divider

CAUTION

Provide protection against possible gear teeth damage during press operation.

2. Mount output shaft in a vise. Lubricate and install orings. If removed, install bushing in end of output shaft.

Note: Output Shaft Bushings: In September 1994, a bushing-

less output shaft design change was implemented on production 461, 521 and 581 model axles. Replace bushings only if originally equipped.

3. Remove bearing cone from side gear using press and split-type puller.

Note: Tandem Axles built after September 1994 are equipped

with bushingless output shafts. Verify output shaft design before attempting to install a bushing.

WARNING

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

3. Install side gear and bearing cone assembly. Install snap ring, be careful not to over stretch the snap ring when installing it into the shaft.

Power Divider

Install Power Divider on Differential Carrier (with carrier assembled to axle housing)

Note: Lubricate all parts before installation.

1. If removed, install axle housing cover and output shaft bearing. For instructions, see Installation of Forward Axle Housing Cover and Output Shaft Bearing Parts on page 14.

2. If output shaft was 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 and self-locking nut. Torque nut to 840-1020 lbs. ft. (1139-1383 N•m).

3. Insert axial spring and thrust button in the end of the output shaft

4. Install inter-axle differential on output shaft side gear (with nuts facing away from side gear).

5. Use silicone rubber gasket compound on differential carrier mating surface.

1 - Input shaft 2 - Thrust button (Part #51228) 3 - Axial spring (Part #51238) 4 - Output shaft

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

thrust button mounted between input and output shafts. See page 43.

1 - Dowel pin

Note: Gasket compound will set in 20 minutes. Install power

divider before compound sets or reapply.

CAUTION

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

Power Divider

6. Make certain dowel pins are installed in carrier, then install power divider assembly.

1 - Dowel pin

TIP: During installation, rotate input shaft to engage input shaft splines with inter-axle differential. After assembly output shaft should turn when input shaft is rotated, and output shaft should turn independently from the input shaft.

8. Check and adjust input shaft end play. With power divider assembled to differential carrier, check end play with dial indicator. End play should be 0.003" to

0.007". If necessary, adjust (see page 43). After end play is within specifications, complete assembly procedures as follows:

Power Divider

9. Connect main driveline and inter-axle driveline.

10. Connect all applicable lines:

• IAD lockout

• Differential lock shift unit

11. Fill axle to proper lube level (see Lube Fill Capacities on page 104).

IMPORTANT

TIP: The use of two guide pins in the carrier mating surface will help align the PDU cover and aid in installation. Guide pins may be made from 9/16"-12 UNC bolts approximately four inches long with the heads removed.

7. Install power divider capscrews. Torque hex head capscrew to 110-125 lbs. ft. (149-169 N•m) and socket head capscrew to 115-125 lbs. ft. (155-169 N•m).

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

Power Divider

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

The following instructions pertain to installation of power divider on differential carrier with carrier removed from axle housing.

1. If output shaft side gear bearing cup was 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.

2. Lubricate o-rings, then install output shaft assembly in carrier.

3. Insert axial spring and thrust button in the end of the output shaft.

4. Install inter-axle differential assembly on output shaft side gear (with nuts facing away from output shaft side gear).

5. Apply silicone gasket compound on carrier mating surface.

1 - Input Shaft 2 - Thrust button (Part #51228) 3 - Axial spring (Part #51238) 4 - Output shaft

Note: Early model axles may not be equipped with axial spring

and thrust button. If your axle was not equipped with these parts, go to step 4.

Note: Gasket compound will set in 20 minutes. Install power

divider before compound sets or reapply.

6. 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, rotate input shaft again. Output shaft should turn when input shaft is rotated if assembly is correct.

Power Divider

Note: Lifting mechanism may create nicks and burrs on input

yoke. Remove if present.

7. If removed, install dowel pins in carrier. Install power divider cover capscrews and lock washers placing sockethead capscrew at location shown on drawing. Torque capscrews to appropriate specification. (See Torque Chart on page 107).

1 - Socket head capscrew 2 - Dowel pin

Note: For power dividers equipped with an input shaft tapered

roller bearing, adjust shaft end play after power divider cover is assembled to differential carrier. Refer to page

43.

Power Divider

Measure and Adjust Input Shaft End-Play

Note: After power divider overhaul and installation on carrier,

check and adjust input shaft end-play.

Input Shaft End Play Chart

New or Rebuild with new parts

0.003" to 0.007"

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: Because of manufacturing variations in individual parts, correctly adjusted end-play could vary 0.010", after the unit is rotated.

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

Without Input Shaft Axial Spring Thrust Button

CAUTION

In September 1988, a axial spring and 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 here. Refer to page 44 of this manual for procedure variances.

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.

4. Install shim pack and bearing cover. Install capscrews. Torque screws to 75–85 lbs. ft. (101–115 N•m). Make sure shims are flat with no kinks or bends.

5. Install yoke. Tighten nut snugly. Tap end of input shaft lightly to seat bearings.

6. 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 with Dana approved RTV compound to prevent lube leakage. Then torque input shaft nut.

The correct end-play when new parts are used in overhaul is

0.003" to 0.007", with reused parts the maximum is 0.14".

1. Remove input shaft nut, flat washer and yoke. Remove input bearing cover capscrews. Remove bearing cover (and shim pack if installed).

Power Divider

With Input Shaft Axial Spring Thrust Button

In September 1988, Spicer added an axial spring and thrust button 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. End play tolerances are the same for axles with or with out the new spring and thrust button. However, end play measurement procedure is different as described below.

Note: As of September 1994, production and service output

shafts for the D461, 521 and 581 models are no longer produced with a bushing in the end of the shaft. The shafts can be identified by part number, see Output Shaft Assembly on page 38 for more information.

2 3

3. Build up a 0.045" (0.024 mm) thick shim pack and place shim pack and bearing cover on power divider cover.

Power Divider

4. Install the U-bracket on bearing cover, using two bearing cover capscrews. Install all other cover capscrews and torque to 75-85 lbs. ft. (101-115 N•m).

1 - Thrust button 2 - Axial spring 3 - Output shaft 4 - Input shaft

Input Shaft Axial Spring

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

2. If axle is assembled, first remove input shaft nut, flat washer and yoke.

1 - Bearing cover capscrew 2 - Lock washer 3 - Fabricated U-bracket 4 - Inner bearing cover 5 - Input bearing cover shim(s) 6 - Input shaft

Power Divider

5. Position a dial indicator on the end of the input shaft.

1 - Pry bar 2 - U-bracket 3 - Dial indicator 4 - Input shaft

Remove shim to decrease end-play

Measured end-play (Step 6) 0.015" – 0.015"

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

Remove shims to provide desired end-

0.012” to 0.008”

play

11. To add or remove shims, remove input shaft nut, flat washer and yoke. Remove capscrews, lock washers and bearing cover. Add or remove shims as required.

12. Install bearing cover and capscrews. Seal shim pack with Dana approved RTV compound to prevent lube leakage then torque input shaft capscrews 75–85 lbs. ft. (101–115 N•m).

13. Install yoke.

14. Install new yoke nut with the pre-applied thread adhesive compound. Tighten the nut to the specified torque 840–1020 lbs. ft. (1148–1383 N•m).

6. Lift up on pry bar to compress input shaft.

7. Insert a pry bar through the U-bracket with the end of the bar resting on the end of the input shaft.

8. 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.

9. If the end-play is acceptable, remove U-bracket and bearing cover. Seal shim pack to prevent lube leakage. Reinstall bearing cover and capscrews. Torque capscrews to 75-85 lbs. ft. (101-115 N•m). Continue axle assembly as necessary.

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

Add shims to increase end-play

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

Measured end-play (Step 6) 0.001” – 0.001”

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

Carrier Assembly

Forward Axle Carrier Assembly (Single Speed) with Diff. Lock - Parts Exploded View

52 53 54 56 57 58 55 6 1 5

DIFFERENTIAL

& RING GEAR

19 15

Carrier Assembly

23 24

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

Carrier Assembly

76 77

79 80 81 82 83

106

64 65

INTER-AXLE DIFFERENTIAL ASSEMBLY

84 85 86 88 8990

105

39 31 40

43 45

LUBE PUMP

104 103 95

444647

94 97 98 99

100

101

102

Carrier Assembly

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 15 - Shift unit mounting stud 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) 26 - Differential bearing cup (LH) 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

37 - Side pinion thrust washer 38 - Spider 39 - Pinion pilot bearing 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 pin 52 - Output shaft nut 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 bolt

72 - Case nut 73 - Side pinion 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 - Lockout sliding clutch 82 - Input shaft 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 washer 94 - Pipe plug 95 - Expansion plug 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 dowel pin 103 - Pump drive gear 104 - Drive gear locknut 105 - Air-operated lockout assembly 106 - Shift fork & push rod assembly

Carrier Assembly

Rear Axle (Single Speed) - Parts Exploded View

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

16 17 19 14 14

243 6

6 5 1 1 22 23 24 29 31 32

8 9272628 25 26 23 30 33

Carrier Assembly

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

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

Carrier Assembly

Forward Axle (Two Speed) - Parts Exploded View

3031

Dual Range Axles

Planetary Double

Reduction Axles

Planetary Double

Reduction Axles

Carrier Assembly

1 - Nut 2 - Washer (used on DT461-P, DT652P, DP461-P, DP652-P) 3 - Yoke 4 - Bearing retainer washer (used on DT440-P, DT485-P, DP440-P, DP650-P) 5 - Oil seal 6 - Snap ring 7 - Bearing & sleeve 8 - Filler plug 9 - Capscrew 10 - Lockwire 11 - Dowel bushing 12 - Adjuster lock 13 - Bearing cap 14 - Dowel bushing 15 - Capscrew 16 - Lockwire 17 - Flat washer 18 - Bearing cap 19 - Cotter pin 20 - Adjuster lock

21 - Expansion plug 22 - Shift fork shaft 23 - Filler plug 24 - Differential carrier 25 - Dowel pin 26 - Expansion plug 27 - Nut 28 - Lock washer 29 -Seal spring 30 - Seal 31 - Stud 32 - Shift fork 33 - Shift fork cover 34 - Lock washer 35 - Capscrew 36 - Differential & ring gear 37 - Sliding clutch (dual range only) 38 - Retainer 39 - Sun gear 40 - Bearing adjuster 41 - Bearing cup 42 - Bearing cone 43 - Ring gear nut

44 - Gear support case 45 - Ring gear 46 - Thrust washer 47 - High-speed clutch plate 48 - Idler pinion pin 49 - Idler pinion 50 - Differential assembly 51 - Differential case with pins 52 - Thrust washer 53 - Side gear 54 - Spider 55 - Thrust washer 56 - Side pinion 57 - Plain differential assembly 58 - Capscrew 59 - Thrust washer 60 - Gear support case 61 - Washer 62 - Ring gear bolt 63 - Bearing cone 64 - Bearing cup 65 - Bearing adjuster

Carrier Assembly

Rear Axle (Two Speed) - Parts Exploded View

Dual Range RT440, RT460, RT480, RT485

Planetary Double Reduction RP440, RP460, RP480, RP485, RP580, RP650

Dual Range RT461, RT521, RT601, RT651

Planetary Double Reduction RP461, RP521, RP581, RP601, RP651, RP652

Planetary Double

Reduction Axles

Carrier Assembly

1 - Cotter pin 2 - Adjusting lock 3 - Bearing cap 4 - Capscrew 5 - Flat washer 6 - Dowel bushing 7 - Lockwire 8 - Bearing cap 9 - Adjusting lock 10 - Dowel bushing 11 - Lockwire 12 - Capscrew 13 - Differential carrier 14 - Expansion plug 15 - Shift fork shaft 16 - Shift fork 17 - Stud 18 - Seal 19 - Seal spring 20 - Shift unit 21 - Shift fork cover 22 - Lock washer 23 - Capscrew 24 - Retainer 25 - Sun gear

26 - Sliding clutch (dual range) 27 - Bearing adjuster 28 - Bearing cup 29 - Bearing cone 30 - Ring gear nut 31 - Gear support case (LH) 32 - Ring gear 33 - Thrust washer 34 - High-speed clutch plate 35 - Idler pinion 36 - Idler pinion pin 37 - Differential assembly 38 - Differential case with pins (LH) 39 -Thrust washer 40 - Side gear 41 - Spider 42 - Side pinion 43 - Thrust washer 44 - Side gear 45 - Thrust washer 46 - Plain differential case (RH) 47 - Capscrew 48 - Thrust washer 49 - Gear support case (RH) 50 - Washer

51 - Ring gear bolt 52 - Bearing cone 53 - Bearing cup 54 - Bearing adjuster 55 - Lock washer 56 - Nut 57 - Expansion plug 58 - Pilot bearing 59 - Drive pinion 60 - Bearing cone 61 - Spacer washer 62 - Bearing spacer (variable) 63 - Bearing cup 64 - Bearing cage shim 65 - Bearing cage 66 - Lock washer 67 - Capscrew 68 - Bearing cup 69 - Bearing cone 70 - Oil seal 71 - Yoke 72 - Flat washer (use on RT461, RT651, RP461, RP652) 73 - Pinion nut

Carrier Assembly

Disassemble Differential Carrier (with power divider removed)

Carrier Assembly

Dual range axles only

1. Remove shift fork seal and spring.

2. Remove expansion plugs.

3. Working at the lower (or small) plug hole, drive out the shift fork shaft.

4. Disengage shift fork yoke from sliding collars.

5. Remove clutch and shift fork.

Planetary double reduction axles

A sun gear is used in place of sliding clutch gear. To remove sun gear:

1. Remove capscrews and the retainer which holds gear in position.

2. Remove sun gear.

Models with Ring Gear Thrust Bolt

Note: If the carrier model has a ring gear thrust bolt installed,

it must be backed away from the ring gear before you can remove the wheel differential.

1. Back off thrust bolt jam nut.

2. Back out thrust bolt from the carrier until the end of the bolt is flush with the inside of the carrier casting. This will allow enough clearance between the ring gear and the carrier pilot web.

1 - D-head carrier or front carrier 2 - Thrust bolt 3 - Thrust bolt jam nut

Carrier Assembly

Remove Wheel Differential (All Standard Models)

Note: If gear set is to be reused, check tooth contact pattern

and ring gear backlash before disassembling differential carrier. When checking backlash, a yoke or helical gear must be installed and torqued to get an accurate reading. Best results are obtained when established wear patterns are maintained in used gearing. Omit this step if the gear set is to be replaced.

1. Mount differential carrier in repair stand.

3. Cut lockwire. Remove capscrews, flat washers and bearing caps. Back off bearing adjusters and remove adjusters and bearing cups.

Carrier Assembly

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

Note: For easier disassembly, loosen but do not remove pinion

(self-locking) nut. Forward axle pinion is equipped with slotted nut, remove roll pin with a pin punch then loosen nut.

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

1 - Punch marks

Carrier Assembly

Remove Pinion Assembly

1. Forward Axle: Remove pinion nut. Remove helical drive gear using puller. Remove helical gear spacer (D440-P and D560-P only).

Note: For easier disassembly, loosen but do not remove pinion

(self-locking) nut. Forward axle pinion is equipped with slotted nut, remove roll pin with a pin punch then loosen nut.

2. Remove pinion bearing cage capscrews. Remove pinion and cage assembly from carrier. Remove shim pack.

IMPORTANT

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.

Do not allow pinion to drop on hard surface.

3. Forward Axle: Pilot Bearing Sleeve (Early Models Only): If replacement is necessary, remove capscrews, locks and pilot bearing sleeve from carrier.

Drive Pinion - Parts Exploded View

Front Axle Pinion Assembly

Drive Pinion

1 - Pinion pilot bearing 2 - Pinion 3 - Pinion bearing cone - inner 4 - Pinion bearing spacer 5 - Bearing spacer variable 6 - Pinion bearing cup - inner 7 - Shim 8 - Pinion bearing cage 9 - Pinion bearing cup - outer

Rear Axle Pinion Assembly

10 - Capscrew 11 - Pinion bearing cup - outer 12 - Helical gear spacer 13 - Pinion helical gear 14 - One piece bearing 15 - Slotted pinion nut 16 - Roll pin 17 - Pinion self locking nut

18 - Pinion pilot bearing 19 - Pinion 20 - Pinion bearing cone - inner 21 - Pinion bearing spacer 22 - Bearing spacer variable 23 - Pinion bearing cup - inner 24 - Shim 25 - Pinion bearing cage

26 - Lock washer 27 - Capscrew 28 - Pinion bearing cup - outer 29 - Pinion bearing cone - outer 30 - Oil seal 31 - Yoke 32 - Flat washer 33 - Pinion nut

Disassemble and Overhaul Drive Pinion

Drive Pinion

The following procedures cover both forward and rear differential drive carrier assembly.

Note: Dana drive axles may be equipped with either “press-fit”

or “slip-fit” outer pinion bearings. Procedures are contained in this section for assembly of both types.

1. Rear Axle Pinion Yoke: Remove yoke.

2. 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. Remove yoke from pinion.

CAUTION

If pinion nut was not loosened during earlier disassembly, clamp assembly in vise jaws, use brass pads to prevent damage.

3. Loosen and remove pinion nut and flat washer. Remove yoke from pinion using an appropriate tool.

4. Forward and Rear Axle Pinion Bearing Cage:

• Press-fit. Press pinion out of bearing cage and

bearing cone.

6. Remove bearing spacer and spacer washers from pinion.

7. Remove pilot bearing from pinion using a split-type puller. Use two procedure steps to remove each bearing.

a. Mount puller vertically to separate the bearing.

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

1 - Press ram

• Slip-fit. 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.

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.

b. Mount puller horizontally to press pinion out of

bearing.

Drive Pinion

8. Remove inner bearing cone from pinion using a splittype puller. Use two procedure steps to remove each bearing.

a. Mount puller vertically to separate the bearing.

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

b. Mount puller horizontally to press pinion out of

bearing.

Replace Pinion Bearing Cage Cups

Front

1 - Cup (outer) 2 - Bearing cage 3 - Cup (inner)

1. Remove cups.

Rear

Drive Pinion

1 - Press

2. Clean and inspect bearing cages for damage, nicks and burrs.

1 - Press ram 2 - Sleeve must apply pressure to back face of outer bearing cone

Drive Pinion

3. Install inner and outer pinion bearing cups. Use a press and an appropriate drive sleeve. Make certain bearing cup is evenly and firmly seated.

4. Seat cups securely to shoulder. Check clearance between cup and bearing cage. Must be less than .001".

Adjust Pinion Bearing Preload

Trial Buildup

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

1 - Bearing 2 - Cup 3 - Spacer washer 4 - Bearing spacer (variable size) 5 - Cage 6 - Cup 7 - Bearing

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

nominal size spacer from the specification chart. If original parts are used, use spacer removed during disassembly.

Drive Pinion

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.

1 - Press ram 2 - Sleeve must apply pressure to back face of outer bearing cone 3 - Spring scale

3. Rotate pinion cage while applying press load (see chart below) to the assembly and check rolling torque. Wrap soft wire around the bearing cage, attach spring scale and pull. Preload is correct when torque required to rotate the pinion bearing cage is from 3–7 lbs. (2–3 kgs.).

Specifications for Pinion Bearing Trial Buildup Preload Test

Torque to Rotate Bearing Cage (w/o pinion seal) 10–20 lbs. in. (1.1–2.3 N•m)

Forward Axles and Rear Axles

Spring Scale Reading 3 - 7 lbs.

(2 - 3 Kgs.)

Press Loads 18.5 - 19.5 tons

(16.8 - 17.7 metric tons)

Nominal Bearing Thickness spacer

CAUTION

0.185”

(4.699 mm)

Read only the torque value after the bearing cage starts to rotate.

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.

IMPORTANT

Once correct bearing preload has been established, note the spacer size used. Select a spacer 0.001” larger for use in the final pinion bearing case assembly. The larger spacer compensates for slight “growth” in the bearings which occurs when they are pressed on the pinion shank.

Drive Pinion

Do not assume that all assemblies will retain proper preload once bearing are pressed on pinion shank. FINAL PRELOAD TEST MUST BE MADE IN EVERY CASE.

Drive Pinion

Final Buildup

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

preload is correctly adjusted.

IMPORTANT

After bearing cups are installed, preselect pinion bearing spacer using the “trial buildup” procedure.

Note: During pinion bearing installation, locate each part in

same position that was used in “trial buildup” preload test.

1. Press inner bearing cone on pinion.

3. Install bearing cage on drive pinion.

4. Press outer bearing cone on pinion.

IMPORTANT

To prevent bearing damage, spin cage while pressing outer bearing on.

IMPORTANT

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

2. Install preselected bearing spacer.

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

Drive Pinion

Specifications for Pinion Bearing Final Buildup Preload Test

Torque to Rotate Bearing Cage (w/o pinion seal) 15-35 lbs. in.(1.7–4.0 N•m)

Forward Axles Rear Axles

Spring Scale Reading

5 - 12 lbs.

(2 - 5 kgs.)

Press Loads 18 - 21 tons

(16.3 - 18 metric tons)

Nut Torque 980 lbs. ft.*

(1,329 N•m)

840 - 1,020 lbs. ft. (1,139 - 1,383 N•m)

*Torque nut to 980 lbs. ft. (1,329 N•m), then continue tightening nut to align nut slot to nearest hole in pinion shank.

Vise Method

a. If the yoke and nut are used, mount the assembly

in a vise, clamping yoke firmly.

6. Measure Pinion Bearing Preload: Use a spring scale to test the assembly rolling torque. To use the spring scale, wrap flexible wire around the bearing cage, attach the scale and pull. Preload is correct when torque required to rotate the pinion bearing cage is from 5–12 lbs.

CAUTION

Read only the torque value after the bearing cage starts to rotate.

7. 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.

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.

Drive Pinion

1 - Vise

Press Method

a. If a press is used, position a sleeve or spacer so

that load is applied directly to the backface of the outer bearing cone.

8. Press pilot bearing on pinion.

IMPORTANT

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

1 - Press

Drive Pinion

9. Stake pilot bearing using staking tool. This is essential to retain the bearing.

10. Rear Axle Only: With pinion installed and bearing preload adjustment complete, install oil seal. Use properly sized installation tool as described on page 92 to prevent distortion.

Specification for Final Pinion Bearing Preload Test

(“Press-fit” Outer Pinion Bearings)

Nut Torque

Axle Models lbs. ft. N•m

Forward Axles

Self-Locking Nut 840 - 1020 1139 - 1383

Slotted Nut & Roll Pin

Rear Axles 840 - 1020 1139 - 1383

* Torque nut to 980 lbs. ft.. (1329 N•m), then continue tightening nut to align nut slot to nearest hole in pinion shank.

11. Rear Axle Only: Prior to installation of yoke, make sure yoke is clean and dry.

980* 1329*

1 - Tool 2 - Seal 3 - Bearing cage

12. Install yoke.

13. Install and tighten the nut to the specified torque: 840–1020 lbs. ft. (1140–1383 N•m).

Note: Use of a torque multiplier is recommended.

TIP: If you can't get the correct torque on yoke nut,

try torquing the nut with the truck wheels on the ground and with the axle shafts installed.

Note: Forward axle pinion helical gear and bearing: These

parts are installed after pinion installation in carrier (see Install Helical Gear and Pinion Outer Support BearingForward Axle Only on page 65).

Install Drive Pinion Assembly

Drive Pinion

1. Forward Axle Only: Place shim pack on carrier making sure holes are properly aligned. Make sure shims are flat with no kinks or bends.

2. Rear Axle Only: Place shim pack on carrier making sure lube holes are clear.

Note: Use a dummy yoke (if available) in place of helical gear.

This will result in easier disassembly and reassembly during carrier adjustments.

Drive Pinion

Note: Do not install cotter pin until carrier adjustments are

completed.

4. Rear Axle Drive Pinion: Install pinion assembly. Install bearing cage capscrews and lock washers. Torque capscrews to 160–176 lbs. ft. (217–239 N•m).

1 - Lube slots

Note: If gear set is to be reused, install same quantity and size

of shims removed during disassembly. When installing a new gear set, use nominal shim pack indicated.

Nominal Shim Pack

Axle in mm

Forward 0.024 0.610

Rear 0.023 0.584

3. Forward Axle Drive Pinion Only: Install drive pinion assembly. Install bearing cage capscrews and lock washers. Torque capscrews to 155–175 lbs. ft. (210–237 N•m).

Drive Pinion

Install Helical Gear and Pinion Outer Support Bearing - Forward Axle Only

After February, 2000

Note: After differential adjustment is complete or if dummy

yoke was used, remove nut and yoke. Then continue to assemble pinion as follows:

1. On D440-P and D460-P only, install helical gear spacer. Install helical gear on pinion using driver and hammer.

One Piece Support Bearing 1 - Slotted nut and roll pin 2 - Support bearing race 3 - Helical gear 4 - Helical gear spacer

Before February, 2000

Two Piece Support Bearing 1 - Support bearing race 2 - Snap ring 3 - Slotted nut and roll pin 4 - Self locking nut 5 - Pinion outer support bearing 6 - Helical gear 7 - Helical gear spacer (D440-P, D460-P only)

2. Install pinion outer support bearing using driver and hammer.

3. Install self-locking nut or slotted nut. Torque nut

properly (see chart), using a suitable fixture to hold helical gear.

Note: On axles equipped with slotted nut and roll pin, do not

install roll pin until carrier adjustments are completed.

If the power divider was built before February 2000, continue with Step 4.

Drive Pinion

4. If removed, install bearing race in power divider cover, using driver and hammer.

5. Install snap ring to secure bearing race.

Drive Pinion

WARNING

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

IMPORTANT

Torque to 980 lbs. ft. (1329 N•m), then continue tightening nut to align slow with the nearest hole in pinion shank. Install roll pin.

Torque Chart

Pinion Self-Locking Nut

Size lbs. ft. N•m

1-3/4 - 12 840 - 1020 1139 - 1383

Pinion Slotted Nut and Roll Pin

Size lbs. ft. N•m

1-3/4 - 12 980* 1329*

* Torque nut to 980 lbs. ft. (1,329 N•m), then continue tightening nut to align nut slot to nearest hole in pinion shank.

Wheel Differential Assembly

Wheel Differential Assembly - Parts Exploded View

Single Reduction Differential

73458

12 3 45

Differential Lock

1 - Sliding clutch 2 - Diff. lock differential bearing adjuster 3 - Differential bearing cup 4 - Differential bearing cone 5 - Nut (ring gear) 6 - Diff. lock differential case (flanged half) 7 - Differential bearing adjuster 8 - Differential case flange half 9 - Ring gear

9101112131415 1211 16 17 4 3 7

10 - Bolt 11 - Side gear thrust gear 12 - Differential side gear 13 - Side pinion thrust washer 14 - Spider 15 - Side pinion 16 - Differential case (plain half) 17 - Differential case capscrew

Wheel Differential Assembly

Planetary and 2 - Speed Differential

2 3 4 5 6 7 8 9 10 11 12 13 14 15 4 3 2

1 - Sliding clutch (dual range only) 2 - Differential bearing adjuster 3 - Differential bearing cup 4 - Differential bearing cone 5 - Ring gear nut 6 - Gear support case 7 - Ring gear 8 - Thrust washer

18 19 20 21 22 23 24 25 26

9 - High speed clutch plate 10 - Idler pinion pin 11 - Idler pinion 12 - Differential assembly 13 - Thrust washer 14 - Gear support case 15 - Ring gear bolt and washer 16 - Retainer

Wheel Differential

Assembl

17 - Sun gear 18 - Differential case with pins 19 - Side gear thrust washer 20 - Differential side gear 21 - Side pinion 22 - Spider 23 - Side pinion thrust washer 24 - Plain differential case

Wheel Differential Assembly

Disassemble, Overhaul and Assemble Wheel Differential (Forward and Rear Axles)

For Single Reduction Differential Case Disassemble Wheel Differential

Note: For Dual Reduction Differential Case see page 73.

IMPORTANT

During following procedure, place differential assembly on malleable surface to prevent damage when ring gear falls off its mounting position.

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

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

5. Remove remaining side gear and thrust washer.

6. Remove bearing cones from case halves using suitable puller.

7. Remove bearing cone from plain case half in two steps:

a. Mount puller vertically to split bearing. This ac-

tion will start moving bearing off case.

2. Punch mark differential cases for correct location during reassembly. Remove capscrews and lift off plain differential case half.

1 - Punch marks

3. Lift out side gear and thrust washer.

b. Mount puller horizontally to remove cone.

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

Wheel Differential Assembly

Overhaul and Assemble Wheel Differential

IMPORTANT

To prevent bearing damage, use suitable sleeve that only contacts the inner race of the cone. A used bearing race would be a suitable tool. This tool should have a slit cut if the ID is the same as the flange OD.

1. Press new flange half bearing cones on differential case halves.

2. Press new plain half bearing cones on differential case halves.

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

7. Align punch marks and install plain case half. Install capscrews and tighten. See Torque Chart on page

106. Check differential for free rotation by turning side gear hub.

1 - Punch marks

8. Install ring gear. Secure with bolts and nuts. Torque nuts to 180-220 lbs. ft. (224-298 N•m)

Wheel Differential

Assembl

Note: Flange half differential cases were redesigned starting

with production axles built in January 1997. New style ring gear bolts are also required with the new style flange case, the torque specification for this bolt is different

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

4. Lubricate all differential parts.

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

than the old 126219 bolt.

9. Lower assembled differential assembly into the carrier using a hoist and a strap. Be careful not to damage the differential bearings lowering the assembly.

10. Install the bearing cup and bearing adjuster to the flange half side first.

11. Install the bearing cup and bearing adjuster to the plain half side. Use a long screwdriver or bar to lift the differential up while installing the cup and bearing adjuster.

Wheel Differential Assembly

Planetary and 2-Speed Models (Forward and Rear Axles)

2 3 4 5 6 7 4 3 8

109

1 - Differential case capscrew 2 - Differential case (plain) 3 - Side gear thrust washer 4 - Differential side gear 5 - Side pinion thrust washer 6 - Side pinion 7 - Spider 8 - Differential case with pins

9 - Differential bearing adjuster 10 - Differential bearing cup 11 - Differential bearing cone 12 - Ring gear bolt 13 - Gear support case (large) 14 - Support case thrust washer 15 - Idler pinion pin 16 - Idler pinion

18 19

LHRH

17 - High speed clutch plate 18 - Ring gear 19 - Gear support case (small) 20 - Ring gear nut 21 - Sliding clutch (dual range axles) 22 - Sun gear 23 - Sun gear retainer

11 10 9 21 22 2314171615141311

Wheel Differential Assembly

Disassemble Dual Reduction Differential Case

Note: For Single Reduction Differential Case see page 68.

1. Remove nuts and bolts fastening ring gear and support cases.

2. Remove small support case and thrust washer.

6. Invert differential assembly to remove idler pins, then remove idler pinions.

Wheel Differential

Assembl

7. Punch mark differential cases for correct location in reassembly. Remove capscrews and separate case halves.

8. Lift out thrust washer and side gear.

3. Remove ring gear.

Note: A soft-faced hammer or mallet may be required to dis-

lodge gear from its mounting.

4. To remove differential assembly, place support case assembly on a bench or on the floor. Position case on its side, then slowly roll the case and slide differential assembly out of the case.

5. Remove thrust washer from support case.

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

Wheel Differential Assembly

10. Remove inner side gear and thrust washer.

11. First, try to lift off high-speed clutch plate by hand. If it cannot be removed easily, press off plate as follows:

Note: Holes are provided in case to enable removal of bearing

cone with a pin punch. Tap alternately through each hole until cone is removed.

WARNING

When using a drift, punch or similar tool, wear safety glasses.

a. Insert properly sized adapters (round metal

stock) into two idler pin holes and invert the case assembly in a press. The clutch plate should be down. The adapter length should provide space for removal of the plate.

b. Use bar stock to block the center hole in the

clutch plate and press against it with the press ram.

c. Continue to press until the plate breaks loose

from the plate dowel pins.

12. Remove bearing cones from support cases using suitable puller.

Wheel Differential Assembly

Assemble Dual Reduction Differential Case

Note: Lubricate internal parts with gear lube during reassem-

bly.

1. Press bearing cones on support cases.

IMPORTANT

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

Pressing Bearing Cone on Large Support Case

2. Position high-speed clutch plate with chamfered end of clutch teeth toward idler pinions. Press clutch plate on case.

Wheel Differential

Assembl

IMPORTANT

It is important that the ends of the dowel pins are recessed 1/8 inch below surface of the clutch plate. If pins extend beyond plate surface, press pins to proper depth. Don’t press them in too far.

Pressing Bearing Cone on Small Support Case

15 DEGREE

CHAMFER

35 DEGREE

CHAMFER

POSITION

35 DEGREE

SIDE OF

PLATE

TOWARD

CASE

HIGH-SPEED

CLUTCH PLATE

DOWEL

CASE

THRU-

HOLE

RECESS

1/8 in.

Wheel Differential Assembly

3. Place thrust washer and side gear in differential case.

4. Assemble side pinions and thrust washers on spider. Place this assembly in differential case.

5. Place side gear and thrust washer in position on side pinions.

6. Align punch marks and place plain case on case (with pins). Install capscrews. Torque screws to 116-130 lbs. ft. (157-176 N•m).

Note: Turn side gear hub to check for free differential rotation.

Rotation may require up to 50 lbs. ft. (65 N•m).

7. Install idler pins and pinions.

Wheel Differential Assembly

8. Place thrust washer in support case.

9. During installation of ring gear, temporarily use two bolts in mounting holes to assure bolt hole alignment. Place ring gear on support case, then remove two bolts.

11. Install thrust washer and small support case over differential assembly.

Wheel Differential

Assembl

12. Carefully install ring gear bolts, making certain flat on bolt head is seated against the outside diameter of the support case. Install nuts and torque to 110-130 lbs. ft. (149-176 N•m).

10. To install differential assembly, place support case and ring gear assembly on bench or the floor. Position case on its side. Carefully lift and slide differential assembly into case. Engage idler pinions with ring gear teeth to complete the installation.

Note: During differential installation, be sure thrust washer

stays in its proper mounting position.

Note: Temporarily install sliding clutch (or sun gear) and

check planetary for free rotation.

Wheel Differential Assembly

Install Differential–Forward and Rear Axles

Note: Lubricate bearings during the following assembly proce-

dures.

1. Place ring gear and differential assembly in carrier. Carefully lower the assembly until bearing cones rest on carrier.

2. Install bearing cup and bearing adjuster to the flange half side first.

3. Lubricate the differential bearings. Install bearing cup and bearing adjuster to the plain half side. Use a long screwdriver or bar to lift the differential up while installing the cup and bearing adjuster.

4. With bearing adjusters and cups assembled to carrier, the carrier assembly is now ready for adjustment of bearing preload, ring gear backlash and gear tooth contact (see page 79).

Wheel Differential Assembly

Measure and Adjust Carrier Assembly

Adjust Backlash and Preload

1. Turn the flange half bearing adjuster in until the ring gear contacts the pinion (zero backlash) then back the adjuster out two notches of the adjuster lugs.

1 - Flange half 2 - Plain half

2. Tighten the plain half adjuster until the bearing cup just starts to turn, this is a zero bearing preload.

3. Tighten the plain half adjuster two lug notches. Start with the notch at the top, count two notches counterclockwise on the adjuster, turn the adjuster so that the notch is facing straight up. You now have a two notch preload.

Wheel Differential

Assembl

1 - Lugs 2 - One notch

4. Use a rubber mallet to make certain that both bearing adjusters are fully seated.

5. Measure backlash. Make sure it is within specification of .006"–.018".

TIP: To give yourself room to adjust contact pattern, set it between .010"–.012".

Wheel Differential Assembly

Change Backlash Setting

If you have too much backlash the ring gear needs to move closer to the pinion. Back off the plain half adjuster, count the number of notches you back it off, each notch equals about .003" of backlash.

IMPORTANT

In order to maintain the differential bearing preload you will need to turn the flange half bearing adjuster the same amount in the same direction. If you need more backlash reverse this procedure.

1. Install carrier bearings caps and torque carrier cap bolts to 370–430 lbs. ft. (501–583 N•m)

2. Recheck backlash: if the bearing adjusters were not in straight or fully seated the backlash will change.

a. Used Gearing: Reset to backlash recorded be-

fore disassembly.

b. New Gearing: Backlash should be between

0.006 and 0.018".

Measure Ring Gear Runout

Measure Ring Gear Total

1. Measure ring gear total radial runout. (Indicator reading should not exceed .010").

2. Measure ring gear total backface runout (Indicator reading should not exceed .010").

3. Check ring gear tooth contact pattern. Paint ring gear teeth and check tooth contact pattern. Correct tooth patterns. Checking and adjusting procedures are on page 80.

4. Install bearing adjuster cotter pins.

5. Install retainer.

Wheel Differential Assembly

Adjust Tooth Contact Pattern

Adjust Ring and Pinion Tooth Contact Pattern

1 - Face width 2 - Tooth depth 3 - Heel 4 - Top land 5 - Root 6 - Toe

Note: Rear axle gearing is shown in the following instructions.

Correct tooth contact patterns and adjustments are the same for forward and rear axles.

1. Identify if new or used gearing.

2. Check tooth contact pattern (new or used gearing).

New Gearing - Correct Pattern

Paint six ring gear teeth 180° apart with marking compound and roll the gear to obtain a contact pattern. The correct pattern is slightly below center on the ring gear tooth with lengthwise contact up off the toe. The length of the pattern in an unloaded condition is approximately one-half to two-thirds of the ring gear tooth in most models and ratios.

The pattern could vary in length and should cover 1/2 tooth or more (face width). The pattern should be evenly centered between tooth top land and root and should be up off the tooth toe.

4 5 6

Used Gearing - Correct Pattern

Used gearing will not usually display the square, even contact pattern found in new gear sets. The gear will normally have a “pocket” at the heal end of the gear tooth. The more use a gear has had, the more the line becomes the dominant characteristic of the pattern.

Adjust used gear sets to display the same contact pattern observed before disassembly. A correct pattern is up off the toe and centers evenly along the face width between the top land and root. Otherwise, the length and shape of the pattern are highly variable and is considered acceptable as long as it does not run off the tooth at any point.

Pattern along the face width could be longer

Adjust Contact Pattern

If necessary, adjust the contact pattern by moving the ring gear and drive pinion.

• 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.

Wheel Differential

Assembl

Wheel Differential Assembly

Adjust Pinion Position

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

Note: Check ring gear backlash after each shim change and

adjust if necessary to maintain the 0.006" to 0.018" specifications.

If the pattern is too close to the top land of the gear tooth, remove pinion shims. Move pinion toward the ring gear.

If the pattern is too close to the root of the gear tooth, add pinion shims. Move pinion away from the ring gear.

3. Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup.

4. Continue tightening the same adjuster 2 or 3 notches and recheck backlash.

If the pattern is concentrated at the heel (too far up the tooth), move the ring gear toward the pinion to decrease backlash.

5. Loosen the bearing adjuster on the teeth side of the ring gear several notches.

6. Tighten the opposite adjuster one notch.

7. Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup.

8. Continue tightening the same adjuster 2 or 3 notches and recheck backlash.

Adjust Ring Gear Position (Backlash)

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

If the pattern is too close to the edge of the tooth toe, move the ring gear away from the pinion to increase backlash

1. Loosen the bearing adjuster on the teeth side of the ring gear several notches.

2. Loosen the opposite adjuster one notch.

Wheel Differential Lock

Wheel Differential Lock - Parts Exploded View

1 - Shift fork seal and spring assembly 2 - Shift fork and roller assembly 3 - Sliding clutch 4 - Differential bearing adjuster 5 - Differential case (flanged half)

4 5 4

Wheel Differential Lock

Install and Adjust Wheel Differential Lock, Dual Range Shifters

1. For planetary double reduction axles (on backface side of ring gear), install sun gear and retainer, then install capscrews that fasten both retainer and adjuster lock capscrews. Tighten screws to correct torque (see chart), and lockwire all capscrews.

Differential Bearing Capscrew Size

13/16-10 (8) 370 - 430 501 - 583

Bearing Adjuster Lock and Sun Gear Retainer Capscrew Size

Torque Chart Cap

Grade lbs. ft. N•m

Planetary Double Reduction Axle

1 - Capscrew

2 - Sun gear retainer 3 - Bearing adjuster 4 - Sun gear 5 - Lock wire

2. For dual range axles and differential lock: Position shift fork in carrier opening, then install sliding clutch

3. With clutch installed, engage shift fork yoke with clutch collar. Then install shift fork shaft. Install expansion plugs to seal openings.

5/8-11 (5) 160 - 176 216 - 238

Install and Adjust Ring Gear Thrust Bolt

1. Thread thrust screw into the carrier until firm contact with the backface of the ring gear is made.

2. Loosen the thrust screw 1/4 turn to obtain the correct adjustment of .020" (.50 mm) clearance between gear face and screw. Tighten jam nut, holding thrust screw stationary with a wrench, torque jam nut 150–190. lbs. ft. (203–258 N•m).

3. Recheck to assure minimum clearance during full rotation of ring gear.

Installing Shift Fork Shaft

4. Install shift unit seal and spring.

1 - D-head carrier or front carrier 2 - Thrust bolt 3 - Thrust bolt jam nut

Piston Air Shift Unit

Wheel Differential Lock

13 14

Wheel Differential Lock

35 1 4 2 6 8 23

24 25

1 - Cover assembly 2 - Cover bearing 3 - Screw and washer assembly 4 - Cover gasket 5 - Cover plug 6 - Actuating lever 7 - Clevis pin 8 - Actuating lever, pin, and block assembly 9 - Shift housing cover 10 - Seal ring 11 - Cover bolt 12 - Lock nut 13 - Lock nut

14 - Washer 15 - Piston 16 - Felt piston oiler (strip) 17 - Piston o-ring 18 - Grommet 19 - Push rod 20 - Compression spring 21 - Piston stop 22 - Housing assembly 23 - Housing bearing 24 - Switch 25 - Nylon washer 26 - Wiring harness

Air Shift Unit Replacement

Wheel Differential Lock

Removal of Shift Unit

1. Disconnect air lines at shift unit cover.

2. Disconnect the wiring harness and remove selector switch from the housing cover.

3. Remove nuts, flat washers and piston air shift unit from the differential carrier.

Note: When shift unit is removed, provide container to catch

oil that escapes from reservoir.

4. Remove shift fork seal and spring assembly.

Note: Dana Service Manual AXSM-0029 for overhaul proce-

dures on air shift units is available.

Air Shift Unit Installation

1. Lubricate shift fork.

2. Slide shift fork seal and spring assembly over fork and seal onto the shift unit carrier studs.

3. Place shift unit on mounting studs and make certain shift fork actuating lever engages slot in shift fork.

4. Install flat washers and stud nuts.

• Torque 55-61 lbs. ft. (74-82 N•m)

Note: When axle is installed in vehicle, fill shift unit housing to

level of filler plug with SAE 10 oil [1.5 oz. (50 ml)]. Coat threads of filler plug with sealer and install plug.

5. Thread selector switch in air shift unit and reconnect wiring harness

6. Connect air lines to shift unit cover.

Air Shift Unit Overhaul

Wheel Differential Lock

Disassemble Unit

1. Remove capscrews, lock washers, cover and gasket from housing. Drain lubricant.

2. Remove bolts, lock nuts, cover at piston end of housing. Remove o-ring.

CAUTION

During the following procedure, the piston will pop out of housing under spring pressure. Exercise caution to prevent possible injury.

3. Remove lock nut, flat washer, and piston from push rod. Remove o-ring and felt oilers from piston.

1 - O-ring 2 - Actuating lever assembly 3 - Piston 4 - Felt oilers 5 - Compression spring 6 - Shift unit housing 7 - Piston rod 8 - Clevis pin

4. Remove compression spring and piston stop from bore of shift unit housing.

1 - Compression spring 2 - Piston 3 - O-ring

5. Remove clevis pin, then remove push rod from shift unit housing. Remove o-ring from push rod.

6. Remove actuating lever and pin from shift unit housing. Do not disassemble actuating lever.

Wheel Differential Lock

1- Actuating lever 2 - Shift fork swivel pin 3 - O-ring 4 - Actuating lever pin 5 - Bearing

Wheel Differential Lock

Parts Inspection

Shift Fork Seal: Inspect shift fork seal for defects and tight fit

on shift fork. A spring is used to assure a closer fit of seal around shift fork. If this spring is not present on axle being serviced, install one when reassembling unit.

O-rings, Felt Oilers and Gasket: Replace o-rings, felt oilers and cover gasket when piston air shift unit is disassembled for repair.

Compression Spring: Inspect spring for distortion, cracks or other visual defects. Replace a faulty spring.

Actuating Lever and Pins: Inspect lever pins and bearings for worn or grooved condition. Inspect actuating lever and push rod for worn or elongated holes at point where they are connected. Replace faulty parts.

Piston: Inspect piston friction surface for worn, grooved or damaged condition which will affect the piston movement in cylinder. Replace a faulty piston.

Wheel Differential Lock

Assemble Unit

Note: Prior to assembly, the piston felt oilers should be soaked

in SAE 10 oil for one hour. Lubricate o-rings with a highviscosity silicone oil or barium grease o-ring lubricant.

1. Assemble pin to actuating lever and install this assembly in shift lever unit housing.

2. Assemble o-ring and piston to push rod and fasten with flat washer and lock nut. Tighten nut to a torque of 120-150 lbs. in. (14-17 N•m). Install felt oilers and o-ring in piston.

CAUTION

During the following procedure using a press, make certain components are properly aligned in press to prevent possible personal injury or damage to parts.

3. Insert piston stop and compression spring in shift unit housing. Place piston and push rod assembly in housing. Position housing assembly in arbor press.

4. Apply pressure to piston until actuating lever is in alignment with push rod end. Install clevis pin. Release press.

1 - Actuating lever assembly 2 - Press 3 - Shift unit housing 4 - Push rod 5 - Clevis pin

5. Place cover gasket in position on shift unit housing then install cover and bearing assembly and fasten with capscrew and lock washers. If necessary, use a sealer on threads of capscrews to prevent any leaking. Tighten screws to a torque of 90-110 lbs. in. (1012 N•m).

6. Place o-ring in groove of shift unit housing, then install housing cover and secure with bolts and lock nuts. Tighten lock nuts evenly to a torque of 108-132 lbs. in. (12-15 N•m).

Wheel Differential Lock

1 - Press 2 - Piston 3 - Piston lock nut 4 - Compression spring 5 - Actuating lever assembly

7. Fill shift unit with SAE 10 oil or automatic transmission fluid (see Lubrication) when axle is installed in vehicle.

Wheel Differential Lock

Lubrication

Lubricant: Use SAE 10 motor oil* for temperature above 0°F

(–18°C). For temperatures below 0°F (–18°C), mix three parts of SAE 10 motor oil with one part of kerosene. This cold weather mixture can be safely used up to 32°F (0°C).

Note: Commercially available automatic transmission fluid

may be used in place of SAE 10 motor oil. Automatic transmission fluid can be used for all temperatures. Do not mix kerosene with automatic transmission fluid.

Lubricant Check and Level: Each 20,000 miles or six months, remove pipe plug in shift unit housing cover to check lubricant level. Lube should be level with bottom of filler hole [1.5 oz. (50 ml)].

Lubricant Change: At least once a year remove shift unit housing cover and drain old lubricant. Wash parts thoroughly and air dry. Reinstall cover. Remove pipe plug in cover. Fill through pipe plug opening until lube is level with bottom of filler hole.

Housing and Rear Cover Assembly

Housing and Rear Cover Assembly - Parts Exploded View

1 - Rear cover 2 - Rear cover capscrew 3 - Fill plug 4 - Rear cover nut 5 - Lock washer 6 - Stud 7 - Dowel 8 - Jam nut - outer 9 - Locking ring 10 - Jam nut (inner)

Housing and Rear Cover

Assembl

Bolt on Rear Cover

11 - Axle housing 12 - Breather 13 - Breather hose 14 - Carrier capscrew 15 - Lock washer 16 - Nut 17 - Lock washer 18 - Stud 19 - Drain plug 20 - Axle shaft

Seals

Replace Seal

Dana strongly recommends using seal drivers when installing new seals. Use the proper driver to make sure that the seal is square and installed to the proper depth.

Seals

WARNING

Due to the resiliency of the plastic driver, hammer rebound may occur when the seal is seated. Keep clear of the hammer rebound path!

CAUTION

Oil seals can be easily damaged prior to installation. Use care when handling the new seal to prevent damage or contamination. Leave the seal in its package until installation. On new yokes, leave the protector on the yoke until it is installed on the shaft to prevent damage or contamination.

1. Inspect axle end-play at the yoke (see page 10). Service if beyond specified limit.

2. Remove the old yoke using appropriate tool. A yoke puller tool may be made from the center section of most gear puller tools, or may be purchased from your local tool distributor.

1 - Yoke puller tool

6. Handle the seal by its outside diameter avoiding any contact with the seal lips. During installation, use the proper driver to make sure that the seal is mounted properly.

7. Use a rubber mallet to drive the seal tool in until the flange bottoms on the housing cover bore face. The flange will locate the seal at the proper depth.

Guidelines for Reusing Yoke

CAUTION

Do not use the yoke if it has any damage on the seal surface (nicks or scratches).

3. Remove seal. Use care when removing the old seal to prevent damage to the housing seal bore.

4. Inspect the seal bore area for any damage (nicks, gouges, corrosion). Carefully remove any slight damage with a crocus cloth. Clean the bore area to remove any loose debris.

CAUTION

Do not use any silicone or permatex-type bore sealant with this seal.

5. Remove the new seal from its package and install with the proper driver:

Service kit #217590

D-Input-Use driver #210749 with inert 210750 only

D-Output-Use insert #210751

R-Pinion-Use driver #210749 only

The surface of the yoke and the lips of the seal form a critical interface which retains the axle's lubricant while sealing the axle from outside contaminants. The condition of the yoke hub's surface is a very important factor in determining seal life.

Carefully inspect the seal surface area of the yoke hub for signs of wear and damage. Do not reuse the yoke if there is noticeable wear, such as heavy grooving, beyond normal polishing from the seal lips.

Note: Do not rework the yoke with abrasives such as emery

paper or crocus cloth. Clean the surface of the yoke as necessary using chemical cleaners. Remove all trace of the chemicals from the yoke after cleaning.

CAUTION

Do not use wear sleeves. Wear sleeves increase the yoke hub surface diameter and cause premature seal wear and repeat seal failure.

Seals

New Welded D-Housing Cover

Lube Quantity Difference

0 (zero)

Standout of Output Shaft Yoke

Length increased by 6 mm (.25"), this should not have any significant impact on inter-axle driveline length or drive line angles.

Service Kit 217414

D - Input D - Output R - Pinion

Location

Interchangeability of Parts

A cross reference chart of “OLD” axle housing to “NEW” axle housings with welded on covers will be published in a separate bulletin. The bolt on D-Housing covers will remain available for service.

Seals

126917

Tool

Old Seal

New Seal

126917

128706

D - Input D - Output R - Pinion

126917

Housing Breather

Install New Axle Housing Breather (Metal and Plastic)

Dana uses an axle housing breather that consists of a fitting, hose and clamp assembly. This breather design has improved resistance to water ingestion, clogging caused by dirt, ice or snow buildup around the base of the breather. See installation instructions below (all views from rear).

1. Install fitting in breather hole.

2. Tighten fitting finger tight.

• Plastic only: tighten until one thread is showing.

4. Insert hose onto fitting, long end down.

3. Using a 3/4" wrench:

• Metal only: rotate the fitting at least 1/2 turn until nipple points to rear. Torque to 5 lbs. ft.

5. Push hose firmly against fitting. Rotate hose to point down.

Wheel End Seal - Parts Exploded View

Wheel End Seal

1 - Installation tool 2 - Seal 3 - Rear hub

Remove and Overhaul Wheel End Seal

WARNING

Wheel End Seal

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.

IMPORTANT

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

1. Remove outer bearing and wheel.

2. Remove oil seal.

3. Remove inner bearing.

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

CAUTION

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

5. Inspect spindle journal and hub bore for scratches or burrs. Recondition with an emery cloth as required.

Install Wheel End Seal

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

• Inner bearing

• Wheel seal (follow the directions provided by the

seal supplier)

2. Place seal on installation tool.

3. Drive seal with installation tool onto hub.

Note: Deep gouges can be repaired by filling gouge with hard-

ening gasket cement and smoothing with emery cloth.

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

7. Clean bearings thoroughly with solvent and examine for damage. Replace damaged or worn bearings.

CAUTION

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.

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

Specifications and Main Features

Frequently Asked Questions

User Manual

Warnings and Caution

Table of Contents - Visual

Introduction

Failure Analysis

Inspection

Differential Carrier Assembly - Parts

Forward Axle Differential Carrier Removal and Installation

Installation of Forward Differential Carrier

Installation of Forward Axle Housing Cover and Output Shaft Bearing Parts

Rear Axle Differential Carrier Removal and Installation

Rear Differential Carrier “Installation”

Differential Lockout

Differential Lockout Overhaul

Original Design Lockout Overhaul

Cylindrical Design Lockout - Overhaul

Power Divider - Parts Exploded View

Remove Power Divider

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

Disassemble, Assemble and Overhaul the Power Divider

Disassemble Power Divider Cover (For Axles with Input Shaft Tapered Roller Bearing)

Assemble Power Divider Cover (For Axles with Input Shaft Tapered Roller Bearing)

Inter-axle Differential

Output Shaft Assembly

Install Power Divider on Differential Carrier (with carrier assembled to axle housing)

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

Measure and Adjust Input Shaft End-Play

Forward Axle Carrier Assembly (Single Speed) with Diff. Lock - Parts Exploded View

Rear Axle (Single Speed) - Parts Exploded View

Forward Axle (Two Speed) - Parts Exploded View

Rear Axle (Two Speed) - Parts Exploded View

Disassemble Differential Carrier (with power divider removed)

Drive Pinion - Parts Exploded View

Disassemble and Overhaul Drive Pinion

Install Drive Pinion Assembly

Install Helical Gear and Pinion Outer Support Bearing - Forward Axle Only

Wheel Differential Assembly - Parts Exploded View

Disassemble, Overhaul and Assemble Wheel Differential (Forward and Rear Axles)

Planetary and 2-Speed Models (Forward and Rear Axles)

Disassemble Dual Reduction Differential Case

Assemble Dual Reduction Differential Case

Measure and Adjust Carrier Assembly

Wheel Differential Lock - Parts Exploded View

Install and Adjust Wheel Differential Lock, Dual Range Shifters

Piston Air Shift Unit

Air Shift Unit Replacement

Air Shift Unit Overhaul

Housing and Rear Cover Assembly - Parts Exploded View

Seals

Housing Breather

Wheel End Seal - Parts Exploded View

Remove and Overhaul Wheel End Seal