Spicer DS462 User Manual

Axles & Brakes

Spicer

ABIB-0207

®

Information Bulletin

Bulletin Type: Parts/Service Information

Topic: DS404 and DS462 Housing Cover Weld Repair Instructions

WARNING: It is important that you observe all of the normal safety procedures,

This document explains the recommended procedure for repairing a cracked rear cover weld. This is the

approved method for this repair. Any other method of repair may result in damage to the axle, axle

only
housing or other vehicle components and could affect performance and safety. Failure to follow all steps of
this procedure will result in a poor repair and the crack could occur again. Welding at any other locations
on the axle housing will void the warranty and can result in an early failure and unsafe operation of the
axle. DO NOT ATTEMPT ANY OTHER TYPE OF WELD REPAIR ON DANA DRIVE AXLES.

When performing this repair on certain types of vehicles, including tank trucks hauling flammable liquids,
it will be necessary to remove the axle from the vehicle before welding.

including wearing proper protection for every step in this procedure.

Welding Equipment and Specifications:

Mig (wire) Welding

Welding Gas – recommended – 80% Argon, 20% C-O2 Gas Flow Setting – 50-60 cfh.
Wire Size – ER70S-3 or ER70S-6 .035”
First and second passes cover weld, approximate settings – 30 volts, 180 amps.
Third filler pass, cover weld, approximate settings – 26 volts, 140 amps.
Apply three weld passes to the cover. The first pass should be centered over the fit-up line and penetrate the failure
area. The second pass should be placed slightly above the first. Blend the weld smoothly
(without significant cross section enlargement) with the housing and first pass. The third pass should penetrate the
lower half of the second pass to the edge of the housing cover. Avoid any significant overlap of weld or undercut.
When making the second and third passes the weld direction should be reversed. Always start the weld at one end,
never in the middle the intended weld area. See illustrations below for more information.

Arc (stick) Welding

Miller DC type stick welder set at 140 -150 amp setting.
Use E7018 1/8 inch Electrode for all three passes. Note** Remove slag between passes. E7018 rod must be stored
in heated rod oven. Apply three weld passes to the cover. The first pass should be centered over the fit-up line and
penetrate the failure area. The second pass should be placed slightly above the first. Blend the weld smoothly
(without significant cross section enlargement) with the housing and first pass. The third pass should penetrate the
lower half of the second pass to the edge of the housing cover. Avoid any significant overlap of weld or undercut.

This bulletin contains product information.

Dana Corporation is not committed or liable for canvassing existing product.

When making the second and third passes the weld direction should be reversed. Always start the weld at one end,
never in the middle the intended weld area. See illustrations below for more information.
When welding the second and third passes, reverse the direction of the weld. Never start or stop a weld close to
the 12:00 position. When using an Arc welder you may have to start the weld at the 11:00 position so that you do
not run out of electrode at the 12:00 position. You can then go back and fill in the ends of the weld area.

Second Pass Direction

12:00 Position

First Pass Direction

First Electrode

Weld Direction Never Start or Stop at 12:00

Repair Instructions:

Important: Before starting, always wear the proper safety equipment for your protection.

If Repairs are being performed on

1. Disconnect the battery grounds and oil temperature sensor wire. Caution*** If the battery ground is not
disconnected, vehicle electronic control modules may be damaged.

2. Block front and back of steer axle tires.

3. Jack-up driver’s side forward rear drive axle and support with jack stand.

4. Remove driver’s side forward rear drive axle tires and rims only.

5. Remove inter axle driveline.

6. For the repair of the cover weld crack, locate the ends of the crack, mark 2 inches either side of the crack.
These marks are ONLY for reference! You must grind until the entire crack is eliminated
additional two-inches on either side of the crack.

. Then grind an

Locate Crack Mark 2” Both Sides of Crack

This bulletin contains product information.

Dana Corporation is not committed or liable for canvassing existing product.

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