Spicer Pro-40 User Manual

Spicer

Tandem Drive Axles

Servic

PRO-40 Single Reduction & Single Reduction with Wheel Differential Lock

AXSM0058 September 2013

D40-145D

R40-145S

D40-145X

e Manual

Table of Contents

Introduction

Model Listing ..............................................................1

Model Information ......................................................1

Model Identiﬁcation ....................................................2

Part Identiﬁcation .......................................................2

Ring Gear and Pinion ..................................................3

General Information ................................................4

Important Notice .........................................................4

Inspection

Failure Analysis .......................................................5

How to Diagnose a Failure ......................................5

Prepare the Parts for Inspection ..............................6

Find the Cause of the Failure ...................................6

Correct the Cause of the Problem ...........................6

Inspect Axle Housing ..................................................7

Inspect Components ...................................................7

Inspect Primary Gearing .............................................8

Check:

Input Shaft End-play (Forward Axle) Adjust .............8

Output Shaft End-play (Forward Axle) Adjust ..........8

Tandem Axle Assemblies ......................................9

Differential Carrier Assembly - Forward .......10

Disassemble Carrier Assembly - Forward

Standard Differentials ........................................... 10

Diff-Lock Models ..................................................10

Engage via Air Pressure ........................................10

Engage Manually ..................................................10

Install Differential Carrier - Forward ....................11

Inter-Axle Lockout Types - Forward

Parts Exploded View ............................................. 12

Disassemble Lockout ........................................ 13

External Type Lockout ......................................13

Integral Type Lockout .......................................13

Install Lockout .................................................. 13

External Type Lockout ......................................13

Integral Type Lockout .......................................13

Power Divider - Forward

Parts Exploded View .............................................14

Disassemble, Assemble & Overhaul

In Vehicle ......................................................15

Install Power Divider to Carrier Assembly

In Vehicle ......................................................18

Disassemble, Assemble & Overhaul

Out of Vehicle ............................................... 20

Install Power Divider to Carrier Assembly

Out of Vehicle ................................................23

Lube Pump

Disassembly .........................................................25

Installation ............................................................25

Lube Manifold

Disassembly ........................................................ 26

Installation ........................................................... 26

Measure and Adjust Input Shaft End-Play ............28

Carrier Assembly - Forward

Parts Exploded View ........................................ 30

Disassemble Carrier Assembly ......................31

Disassemble Wheel Differential

Models w/ Wheel Differential Lock....................31

Models with Ring Gear Thrust Bolt ................31

Disassemble Wheel Differential .....................32

Disassemble Pinion Assembly ...................... 33

Front Axle Pinion Assembly - Forward

Parts Exploded View ........................................ 34

Disassemble and Overhaul Drive Pinion........ 35

Replace Pinion Bearing Cage Cups ............... 36

Adjust Pinion Bearing Preload .......................37

Trial Buildup ..................................................37

Final Buildup ................................................ 38

Install Drive Pinion Assembly ........................41

Wheel Differential - Forward

Parts Exploded View .........................................42

Disassemble, Overhaul, and Assemble

Wheel Differential - Forward ............................ 43

Disassemble Wheel Differential .................... 43

Overhaul & Assemble Wheel Differential ...... 44

Measure and Adjust Carrier Assembly .......... 46

Adjust Backlash and Preload ........................ 46

Change Backlash Setting ..............................47

Measure Ring Gear Runout ...........................47

Measure Ring Gear Total ...............................47

Adjust Ring & Pinion Tooth Contact Pattern .. 48

Adjust Contact Pattern ................................. 48

Adjust Pinion Position ................................... 49

Adjust Ring Gear Position (Backlash) ........... 49

Wheel Differential Lock - Forward

Parts Exploded View ........................................ 50

Install and Adjust Wheel Differential Lock .....51

Install and Adjust Ring Gear Thrust Bolt ........52

Housing & Output Shaft Assembly - Forward

Parts Exploded View ............................................ 53

Disassemble Output Shaft Assembly .................... 54

Overhaul & Assemble Output Shaft Assembly ...... 55

Measure and Adjust ..............................................57

Replace Seal .........................................................57

Guidelines for Reusing Yoke ................................. 58

Table of Contents

Differential Carrier - Rear ...........................................59

Parts Exploded View ................................................ 60

Install Differential Carrier - Rear .......................61

Drive Pinion .................................................................62

Rear Axle Pinion Assembly

Parts Exploded View .............................................62

Pinion Disassembly .......................................... 63

Pinion Installation ............................................ 64

Final Buildup .................................................... 64

Wheel Differential Assembly

Parts Exploded View ................................................ 66

Disassemble, Overhaul, & Assem. Wheel Diff ........67

Assemble Wheel Differential .................................73

Measure and Adjust Carrier Assembly ...................73

Adjust Backlash and Preload ................................. 74

Change Backlash Setting ...................................... 74

Measure Ring Gear Runout ...................................74

Measure Ring Gear Total ....................................... 74

Adjust Contact Pattern ..........................................75

Adjust Ring Gear Position (Backlash) ....................75

Seals

Service Kit 217414 ................................................... 77

General Lubrication Information ................................78

Approved Lubricants .............................................78

Recommendations for Visc./Ambient Temp ...........78

Lube Change Intervals ..........................................79

Change Lube........................................................ 80

Drain .................................................................... 80

Fill.... .................................................................... 80

Towing

Proper Vehicle Towing .............................................. 85

Without Wheel Differential Lock ............................... 85

Theory of Operation

Power Divider Operation .......................................... 86

With Lockout Engaged ............................................. 86

With Lockout Engaged ..............................................87

Operate Wheel Differential Assembly ....................... 88

Control Systems for Differential Lock ....................... 88

Transmission Low-Range Interlock Control System.. 88

Direct Driver-controlled System ............................... 88

Wheel Differential Lock ............................................ 89

Lock Engaged .......................................................... 90

Lock Disengaged ..................................................... 90

Differential Lock Engagement Indicator ................... 90

Parts Identiﬁcation

Power Divider

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

Front Drive Axle

Parts Exploded View ............................................ 92

Wheel Differential Lock Assembly

Parts Exploded View ............................................ 93

Parts Exploded View ............................................ 94

Housing and Output Shaft Assembly

Parts Exploded View ............................................ 95

Fastener Torque Speciﬁcations ................................ 96

Torque Chart - Rear Carrier ......................................97

Wheel Ends

Wheel End Seal

Parts Exploded View .............................................81

Disassemble & Overhaul Wheel End Seal ..........82

Install Wheel End Seal ......................................82

Verify Wheel End-play Procedure ..................... 83

Adjust End-play w/ Tire & Wheel Assem .......... 83

Adjust End-play with Wheel Hub ...................... 83

Readjust Wheel End-play Procedure ................ 83

Lubricate Wheel End ........................................ 84

Wheel Ends with an Oil Fill Hole ....................... 84

Introduction

Dana Spicer Corporation, Commercial Vehicle Division, presents this publication to aid in maintenance and overhaul of Dana Spicer single 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.

Model Listing

Tandem Axles Load Capacity

D40-145 40,000 Lbs [18,144 kg]

Model Information

D - Dual Drive Forward Axle

with Inter-Axle Differential

R - Dual Drive Rear Axle

GAW Rating x 1000 lbs.

Gear Type 1 - Standard Single Reduction

Introduction

D 40 - 1 4 5 X

Options

D - Wheel Differential Lock

(forward unit only)

H - Heavy Wall Housing P - Lube Pump S - SelectTrack X - Without Inter-Axle

Design Level

Head Assembly Series

Model Identification

Drive Axle

Introduction

picer

T. PART NO. S

ERIAL NO.

S PEC. S

MODEL PART NO. RATIO

MADE IN:

Rear Carrier

1 - Country of origin 2 - Axle model identification 3 - Specification number assigned to the axle built by Dana Spicer. Identifies all component parts of the axle including special OEM requirements such as yokes or flanges

Part Identification

CU ST. PART NO.

SPEC. SERIAL NO.

MODEL PART NO. RATIO

MADE IN:

Spice r

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

Forward Carrier

Axle Housing Axle Shaft

Spicer

T. NO.

P. LBS.

P HSG. CA

. I.D. NO.

HSG HOUSING M ADE IN

1 - ID Tag 2 - Axle shaft part number

Introduction

Ring Gear and Pinion

Note: Ring gear and drive pinion are matched parts and must be replaced in sets.

127381

SPICER

Forward Axle

NL2

41-8

Rear Axle

L7038

127381

SPICER

41-8

NL2

L7038

Introduction

8-41

127

SPICER

127428

1 - Part number 2 - Number of ring gear teeth 3 - Manufacturing numbers

6-39

JD77

85405

4 - Matching gear set number 5 - Number of pinion teeth 6 - Date code

7 - Indicates genuine Dana Spicer parts 8 - Heat Code

General Information

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

Dana Spicer 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.

Any reference to brand name 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.

Always use genuine Dana Spicer replacement parts.

TIP: Helpful removal and installation

procedures to aid in the service of this unit.

Refer to the OEM vehicle specifications

OEM

Inspection

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.

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

5. Ask: Has this particular failure occurred before?

6. Ask: How was the truck working prior to the failure?

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

7. Ask: Was the vehicle operating at normal temperatures?

8. Ask: Were the gauges showing normal ranges of operation?

9. 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.

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.

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

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

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

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

5. Are the tires in good condition and do the sizes match?

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

Document the Problem

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

1. Talk to the operator of the truck.

2. Look at the service records.

3. Find out when the truck was last serviced.

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.

Inspection

Prepare the Parts for Inspection

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

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

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

9. 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.

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 ure is caused by a lack of lubrication, you must determine if there was an external leak. Obviously, if there is an external leak, just replacing the failed gear is not going to correct the situation.

Another important consideration 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.

the fail -

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.

Clean

10. Wash steel parts with ground or polished surfaces in solvent. There are many suitable commercial sol vents available. Kerosene and diesel fuel are accept able.

WARNING

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

11. Wash castings or other r 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.

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

13. Dry parts immediately with clean rags.

14. 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.

ough parts in solvent or

Inspection

Inspect Axle Housing

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

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

• Check carrier bolt holes and studs for foreign mate -

rial.

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

CAUTION

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

• Check all seals and gaskets.

Note: Replace conventional gaskets with silicone rubber gas -

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

when replacing parts.

Inspect Components

Inspection

Inspect all steel parts for:

• Notches, visible steps or grooves created by wear

• 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 lubrica tion 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 surf aces of cast or malleable parts. They must be free of nicks, burrs, cracks, scoring, and wear.

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

1 - Axle housing 2 - Machined surface

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 0.003" to 0.007". The maximum end-play for a used assembly is no more than

0.014". 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"

Adjus

tment

Correct end-play for a new assembly is 0.001" to 0.005". The maximum end-play for a used assembly is no more than

0.005". If end-play is incorrect, contact Dana.

Tandem Axle

Tandem Axle Assemblies

Tandam Axle

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

Forward Assembly

Differential Carrier Assembly - Forward

Disassemble Carrier - Forward

Note: The removal of the forward carrier does not require dis-

connecting of the inter-axle driveline and removal of the output shaft yoke assembly as most other Dana tandems require.

Standard Differentials

1. Block the vehicle.

2. Drain axle lubricant.

3. Disconnect main driveline.

4. Disconnect differential lockout air line.

5. Disconnect lead wires to the selector switch and air line at shift cylinder.

6. Remove axle shafts.

Diff-Lock Models

For removal of the locking wheel differential carrier assembly, the differential lock must be engaged and held in the engaged position. This can be accomplished by one of two methods; either engage via air pressure or engage manually.

Engage via Air Pressure

Note: Hand-tighten the bolt, over-torquing may cause damage

to the shift unit. To facilitate hand-tightening, coat bolt threads with axle lube.

1—Hand tighten with socket 2—M12 x 1.5 x 38mm bolt – GM only 0.250 – 18 NPTF –

all models except GM

Note: With either method, the axle shaft may have to be

rotated to permit the clutch to become engaged.

WARNING

a. Using an auxiliary air line, apply 80–120 PSI air

pressure to shift cylinder air port to engage clutch.

1—Connect 80-120 PSI air line to cylinder port

Engage Manually

a. Install a 0.250 – 18 NPTF bolt over

cylinder air port to manually engage the clutches. GM models require a M12 X 1.5 X 38mm bolt.

1.5" long in the

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

7. To remove axle shaft, remove axle stud nuts. (If used, remove lock washers and taper dowels.)

8. Remove axle shafts.

Note: All models in this publication use axle shafts with

unequal lengths. Axle shafts may also be location specific with various wheel equipment. Do not misplace axle shafts from their intended location. Identify left and right shafts for reference during reassembly.

P: If necessary, loosen dowels by holding a brass drift in the

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

CAUTION

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

9. Remove carrier cap screws, nuts and lock washers.

10. Remove differential carrier assembly.

Forward Assembly

Install Differential Carrier - Forward

IMPORTANT

Note: Before installing carrier assembly, inspect and thor-

oughly clean interior of axle housing using an appropriate solvent and clean rag.

1. Apply Dana approved RTV 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 min-

utes. Install carrier before compound sets or reapply.

6. Connect main driveline, making sure all yokes are in phase. Lubricate U-joints.

7. Connect differential lockout air line.

1— Apply silicone gasket in this pattern 2— Common stud locations

TIP: To assist in installing complete differential carrier use two pieces of threaded rod (M16 X 1.5) threaded into carrier cap screw holes. Rod should be approximately 6" long. Use these to pilot the carrier into the housing.

2. Install carrier to housing, lock washers, cap screws and nuts. Torque to proper specification. Torque to 230–270 lb-ft. (312–366 N•m).

3. After 11/02/98, axle housing covers are welded in

If you have a bolt-on cover, install rear hous-

place. ing cover/output shaft assembly (see page 53). Torque all fasteners to proper specifications. Torque to 85–103 lb-ft. (115–140 N•m). Install inter-axle driveline making sure yokes are in phase.

Forward Assembly

4. Install axle shafts and axle stud nuts (if used, also install lock washers and tapered dowels).

5. Add axle lubricant. Fill to bottom of filler hole.

Inter-Axle Lockout Types - Forward

Parts Exploded View

Forward Assembly

1 - Compression spring 2 - Shift fork 3 - O-ring

Air-operated to engage the lockout and spring-released to disengage the lockout.

4 - Piston 5 - O-ring 6 - Piston Cover

Forward Assembly

Disassemble Lockout

External Type Lockout

8. With axle installed in vehicle, place differential lock selector valve in the disengaged (or unlocked) position.

9. Disconnect differential lockout air line.

10. Remove cap screws.

11. Remove shift cylinder body or cast iron cover, o-ring and piston.

IMPORTANT

Do not remove push rod. Removal of push rod will result in shift fork and compression spring falling into power divider unit. If this occurs, disassembly of the power divider assembly will be necessary.

12. Remove shoulder washer in cylindrical design lockouts. Cast iron cover lockout designs do not use a shoulder washer.

Note: Cylindrical design lockout and cast iron cover lockout

are interchangeable only as complete assemblies.

Integral Type Lockout

1. With axle installed in vehicle, place differential lock selector valve in the disengaged (or unlocked) position.

2. Disconnect differential lockout air line.

Install Lockout

External Type Lockout

1. Assemble o-rings onto piston. Apply silicone grease to o-ring.

2. Install piston and o-ring assembly into cylinder body or cast iron cover.

3. Attach shift cylinder body or cast iron cover to power divider while aligning piston with push rod. Make sure shoulder washer or gasket is in place.

4. For stamped steel style lockouts, attach mounting bracket to cylinder body and secure cap screws.

5. Tighten cap screws to 28–35 lb-ft. (38–47 N•m).

6. Connect differential lockout air line.

7. Cycle the lockout unit to insure there are no leaks and system shifts freely.

Integral Type Lockout

1. Assemble o-rings onto piston and piston cover. Apply silicone grease to o-rings.

2. Gently push piston and o-ring assembly into lockout cylinder recess. Make way in.

3. Install piston cover and o-ring assembly. Start by hand tightening clockwise.

sure piston is pushed all the

CAUTION

Forward Assembly

3. Remove piston cover and o-ring.

4. Remove piston and o-ring assembly with pliers.

Note: To remove shift fork and push rod parts, the power

divider must be removed. See power divider section.

Do not to strip threads or use excessive force, damage to part may occur.

4. Tighten piston cover to 25-35 lb-ft. (35-47 N•m).

5. Connect differential lockout air line.

6. Cycle the lockout unit to make sure there are no leaks and the system shifts freely.

Power Divider - Forward

Parts Exploded View

Forward Assembly

1 2

1 0

2 42 1

3 6

2 5

2 6

2 7

1 5

1 6

1 7

2 9

3 0

1 8

2 0

3 2

2 2

3 3

3 4 3 5

1 9

2 3

3 1

2 4

1 3

1 1

1 4

1 —Output shaft nut 2 —Output yoke 3 —Output seal 4 —Output shaft bearing snap ring 5 —Outer bearing cup 6 —Outer bearing cone 7 —Inner bearing cone 8 —Inner bearing cup 9 —Output shaft 10 —Seal manifold assembly 11 —Sump screen 12 —Seal manifold feed tube 13 —Output side gear bearing cup

14 —Output side gear bearing cone 15 —Pump locking Pin 16 —Output side gear 17 —Pump 18—Snapping ring 19 —Inter-axle differential 20 —Helical side gear 21 —Sliding clutch 22 —Shift fork assembly 23 —Spring 24 —Input shaft 25 —Input shaft oil retainer 26 —Input shaft bearing cone

27 —Power divider cover 28 —Lube trough 29 —Cap screw 30 —Input bearing cup 31 —Input cage shim 32 —Input cage V-ring 33 —Input cage 34 —Cap screw 35 —Oil Seal 36 —Input yoke 37 —Input nut

Forward Assembly

Disassemble, Assemble and Overhaul Power Divider - In Vehicle

The power divider cover comes off as a unit followed by the input shaft and then the helical side gear.

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

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.

7. Disconnect the main driveline.

8. Disconnect the lockout air line.

9. Remove input yoke.

10. Remove input seal.

11. Position a drain pan under the power divider unit.

12. Remove PDU cap screws.

13. Remove power divider cover.

14. Remove shift fork, compression spring and shift rod.

15. Remove input shaft drive assembly from the carrier.

Forward Assembly

16. Remove the IAD

assembly from the output side gear.

Forward Assembly

17. Remove helical side gear and snap ring.

18. Remove thrust washer.

Note: Remove lube pump if you have one. See page 30.

21. Inspect output side gear o-rings for nicks and cuts. Replace if necessary.

19. Remove lockout sliding clutch from the input shaft.

20. Remove the output side gear.

1—Press 2—Bearing 3—Oil retainer 4—Input shaft

22. Install new bearing cup.

23. Remove input shaft bearing cone and oil retainer, if necessary.

24. Press new oil retainer on input shaft.

CAUTION

It is not recommended to reuse the oil retainer due to possible damage that may occur while removing the input shaft bearing cone. While pressing on new oil retainer, make sure not to over press, and/or press with the retainer at an angle. If the retainer is bent or distorted it may rub on the input cage or not

seal properly to the v-ring.

Forward Assembly

25. Press input bearing cone on input shaft.

27. Press bearing cup in input bearing cover.

28. Install new oil v-ring on input bearing cage cover.

1—Bearing cup (press) 2—V-ring

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

Forward Assembly

1 - Press 2 - Plate 3 - Drive Sleeve

- Input shaft bearing cone

4 5 - Oil retainer 6 - Input shaft

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

• Weld a bead around the cup, when the weld

cools the cup will fall out.

• Drill a 1/4 size hole through the bearing cover to

the back side of the cup and use a punch to remove the bearing cup.

1—Tap out bronze bushings

30. Install bronze bushing in helical side gear. Bushings

must be installed from thrust washer side of gear.

See illustration for dimensional tolerances.

1/32"

1—Press 2—Sleeve 3—1st bronze bushing (press to shoulder) 4—Shoulder 5—Sleeve 6—Second bronze bushing (recess 1/32")

Forward Assembly

Install Power Divider to Carrier Assembly - In Vehicle

Note: See page 20 for out of vehicle.

Note: Parts inspection and cleaning procedures are important

and should be adhered to. Cleanliness in your work area is important as dirt is an abrasive and will cause premature wear of the otherwise serviceable parts.

CAUTION

During installation of power divider components, the interaxle differential, input shaft assembly or IAD shift system parts may fall from the carrier if not careful. Use caution to prevent injury or damage.

1. Make sure dowel pins are installed in carrier.

2. Install output side gear bearing cup, if removed. Press bearing cup in carrier. Use a press and an appropriate sleeve. Make certain bearing cup is evenly and firmly seated. If a press is not available, use a sleeve or a bearing driver tool and a hammer to install the cup.

5. Install the IAD assembly to the output side gear. If reusing the IAD assembly, install in the same direction as removed.

Note: For lube pump models, see page 23.

6. Out of the vehicle—on a bench, install lockout sliding clutch onto the input shaft.

1—Lubricate o-rings 2—Bearing cup

3. Lubricate o-rings.

4. Install the output side gear, if removed

7. Install thrust washer.

Forward Assembly

8. Install helical side gear and snap ring.

9. Install input shaft drive assembly into the carrier.

11. Install plastic trough in power divider cover.

12. Install power divider cover to carrier. Use Dana approved RTV compound on the carrier mating surface. Torque cap screws to 114–140 lb-ft. (155–190 N•m).

Note: Gasket compound will harden in 20 minutes. Install

power divider quickly as possible to avoid future leaks.

13. Install input cage shim and input cage assembly.

Forward Assembly

10. Install shift fork, compression spring and shift rod.

CAUTION

During installation of power divider components, a part may fall from the carrier. Use caution to prevent injury or damage.

14. Install input cage cap screws and tighten until snug.

15. Measure and adjust input shaft end-play,

16. Torque input cage cap screws to 114–140 lb-ft. (155–190 N•m).

17. Install NEW input seal.

18. Reinstall input yoke.

see page 28.

Forward Assembly

Disassemble, Assemble and Overhaul Power Divider - Out of Vehicle

The power divider cover comes off as a unit followed by the input shaft and then the helical side gear.

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

CAUTION

1. Disconnect the main driveline.

2. Disconnect the lockout air line.

3. Remove input yoke.

4. Remove input seal.

5. Position a drain pan under the power divider unit.

6. Remove PDU cap screws.

7. Remove power divider cover.

8. Remove shift fork, compression spring and shift rod.

9. Remove input shaft and helical thrust washer from the carrier.

10. Remove helical side gear.

Forward Assembly

11. Remove the IAD assembly from the output side gear.

12. Remove the output side gear.

Note: Remove lube pump if you have one.

16. Press new oil retainer on input shaft.

CAUTION

17. Press input bearing cone on input shaft.

Forward Assembly

13. Inspect output side gear o-rings for nicks and cuts. Replace if necessary.

14. Install new bearing cup.

15. Remove input shaft bearing cone and oil retainer, if necessary.

1—Press 2—Bearing 3—Oil retainer 4—Input shaft

1—Press 2—Plate 3—Drive sleeve

4—Input shaft bearing cone 5—Oil retainer 6—Input shaft

Forward Assembly

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

• Weld a bead around the cup, when the weld

cools the cup will fall out.

• Drill a 1/4 size hole through the bearing cover to

the back side of the cup and use a punch to remove the bearing cup.

19. Press bearing cup in input bearing cover.

20. Install new oil v-ring on input bearing cage cover.

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

1—Tap out bronze bushings

22. Install bronze bushing in helical side gear. Bushings must be installed from thrust washer side of gear.

See illustration for dimensional tolerances.

1/32"

1—Bearing cup (press) 2—V-ring

1—Press 2—Sleeve 3—1st bronze bushing (press to shoulder) 4—Shoulder 5—Sleeve 6—Second bronze bushing (recess 1/32”)

Forward Assembly

Install Power Divider to Carrier Assembly - Out of Vehicle

Note: Parts inspection and cleaning procedures are important

and should be adhered to. Cleanliness in your work area is important as dirt is an abrasive and will cause premature wear of the otherwise serviceable parts.

Note: It is assumed that the different carrier is secured in a

stand.

CAUTION

During installation of power divider components, parts may fall from the carrier if not careful. Use caution to prevent injury or damage.

1. Make sure dowel pins are installed in carrier.

2. Output side gear bearing cup. If removed, press bearing cup in carrier. Use a press and an appropriate sleeve. Make certain bearing cup is evenly and firmly seated. If a press is not available, use a sleeve or a bearing driver tool and a hammer to install the cup.

3. Lubricate o-rings.

4. Install the output side gear using one of the fo ing instructions (non-pump models or lube pump models).

llow-

Lube Pump Models

a. Install output side gear /pump assembly into carrier.

The lube pump mounting holes are oriented in such a way that it can be installed only in one position.

b. Lube pump coupling—Line up the drive couplings

tangs with the pump and IAD notches. The spacing of the tangs are the same, one side to the other. If reusing the IAD assembly, install the same direction as it was removed.

5. Install helical side gear.

6. Install thrust washer.

Forward Assembly

Non-pump Models

a. Install output side gear.

b. Install the IAD assembly to the output side gear. If

reusing the IAD assembly, install the same direction as removed.

7. Install compression spring, shift fork, push rod and lockout sliding clutch.

8. Install input shaft assembly.

Forward Assembly

Note: The input shaft snap ring is not used in this buildup.

9. Install plastic oil trough in power divider cover.

10. Install power divider cover to carrier. Use Dana approved RTV compound on the carrier mating surface. Torque cap screws to 114–140 lb-ft. (155–190 N•m).

Note: Gasket compound will harden in 20 minutes. Install

power divider as quickly as possible to avoid future leaks.

12. Install input cage cap screws and tighten until snug.

13. Measure and adjust input shaft end-play, see page 28.

14. Torque input cage cap screws to 114–140 lb-ft. (155–190 N•m)

15. Install NEW input seal, see page 71.

16. Reinstall input yoke.

11. Install input cage shim and input cage assembly.

Forward Assembly

Lube Pump Disassembly

For output side gear and/or pump replacement, follow the procedure below.

1. Remove the output side gear bearing cone, if required.

1 - Press 2 - Press Tool

2. Remove pump locking dowel pin from the hole in the output side gear hub.

Lube Pump Installation

Use these instructions with the carrier assembly in or out of the vehicle.

If the unit does not have a pump, go to the Power Divider Assembly section.

Note: Keep work area clean. Dirt is an abrasive and will cause

premature wear of the otherwise serviceable parts.

Note: For non-pump models, see page 17 for output side gear

seal manifold installation.

Note: Only service the power divider if the differential carrier

is secured in a stand or while the axle is still attached to the housing.

CAUTION:

CAUTION

CAUTION: During installation of power divider cover, the interaxle differential (IAD), input shaft assembly or IAD shift system parts may fall from the carrier if to prevent injury or damage.

1. Install the pump into the output side gear so that the pump shaft is facing toward the teeth end of the side gear.

not careful. Use caution

Forward Assembly

3. Remove pump from the output side gear.

2. Install the pump locking dowel pin into the hole in the output side gear hub. Make sure the pin is lined up with the machined slot in the pump body.

1 - Machined Slot 2 - Pin

Forward Assembly

Lube Manifold Disassembly

1. Disconnect the hose from the lube manifold.

2. Remove the manifold assembly by prying it out around the inner diameter.

IMPORTANT:

IMPORTANT

IMPORTANT: Once removed, the seal manifold assembly cannot be reused. This component should always be replaced with new. Use the same removal procedure for the output side gear seal removal on the non-pump models.

Lube Manifold Installation

1. Install the manifold assembly into the output side gear bore in the carrier. Make sure the barbed nipple is lined up with the opening in the carrier casting.

Note: Seals are not sold separately from the manifold.

1 - Barbed Nipple

2. Install the hose clamp on the hose, push the hose onto the barbed fitting and slide the clamp over the barbed nipple.

3. Route the suction end of the hose through the holes in the carrier casting to the bottom of the carrier.

4. Fully press the manifold assembly into position.

Note: Use care when pressing

damaging the seals and barbed nipple. Do not overpress plastic.

the manifold assembly to avoid

Forward Assembly

Note: For non-pump manifold installation, it is important to

line up the oil inlet path hole in the manifold with the oil path opening in the carrier manifold casting.

1 - Manifold Oil Inlet Hole

Forward Assembly

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