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
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
1
Model Identification
Drive Axle
Introduction
3
2
®
picer
S
T. PART NO.
S
CU
ERIAL NO.
S
PEC.
S
MODEL PART NO. RATIO
MADE IN:
1
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
4
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
5
®
6
7
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
2
1
2
Introduction
Ring Gear and Pinion
Note: Ring gear and drive pinion are matched parts and must be replaced in sets.
127381
1
SPICER
7
Forward Axle
NL2
41-8
OF
Rear Axle
8
3
L7038
G
17
4
6
127381
SPICER
1
7
41-8
8
OF
NL2
3
L7038
G
17
Introduction
4
6
2
5
8
8-41
127
127
7
SPICER
127428
6
0H
17
G
3
1
1 - Part number
2 - Number of ring gear teeth
3 - Manufacturing numbers
6-39
JD77
85405
86
4 - Matching gear set number
5 - Number of pinion teeth
6 - Date code
4
7 - Indicates genuine Dana Spicer parts
8 - Heat Code
3
General Information
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
4
Inspection
Inspection
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.
5
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
6
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.
2
1 - Axle housing
2 - Machined surface
1
7
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.
3
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.
3
2
1
2
1
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.
8
Tandem Axle
Tandem Axle Assemblies
Tandam Axle
5
1
2
3
4
1 - Carrier fasteners
2 - Carrier assembly
3 - Front axle assembly
4 - Rear axle assembly
5 - Inter-axle differential lockout
9
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
2
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
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
TI
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
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.
2
1
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.
11
Inter-Axle Lockout Types - Forward
1
2
Parts Exploded View
Forward Assembly
3
4
5
6
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
12
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.
13
Power Divider - Forward
Parts Exploded View
Forward Assembly
1 2
1 0
9
2 42 1
3 6
2 5
2 6
37
2 7
1 5
3
1 6
1 7
28
2 9
5
3 0
1 8
7
2 0
3 2
2 2
8
3 3
3 4 3 5
6
1 9
2 3
3 1
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
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.
15
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.
1
2
3
19. Remove lockout sliding clutch from the input shaft.
20. Remove the output side gear.
4
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.
16
Forward Assembly
25. Press input bearing cone on input shaft.
1
2
3
4
5
6
27. Press bearing cup in input bearing cover.
28. Install new oil v-ring on input bearing cage cover.
1
2
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.
1
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
2
3
4
1
5
6
1/32"
1—Press
2—Sleeve
3—1st bronze bushing (press to shoulder)
4—Shoulder
5—Sleeve
6—Second bronze bushing (recess 1/32")
17
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.
1
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
2
7. Install thrust washer.
.
18
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.
19
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
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. 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.
20
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
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.
17. Press input bearing cone on input shaft.
1
2
3
4
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
5
6
1
2
3
4
1—Press
2—Plate
3—Drive sleeve
4—Input shaft bearing cone
5—Oil retainer
6—Input shaft
21
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
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
2
3
4
1
5
6
1/32"
1—Bearing cup (press)
2—V-ring
22
1
2
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.
23
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.
24
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
2
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
2
1 - Machined Slot
2 - Pin
25
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.
1
Note: Seals are not sold separately from the manifold.
1
1 - Barbed Nipple
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.
26
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
1 - Manifold Oil Inlet Hole
Forward Assembly
27
Forward Assembly
Measure and Adjust Input Shaft End-Play
Note: After power divider overhaul and installation on carrier,
check and adjust input shaft end-play.
The correct end-play when new parts are used in overhaul is
0.003" to 0.007", with reused parts the maximum is 0.014".
1. Remove input shaft nut. Remove input bearing cover
cap screws. Remove bearing cover (and shim pack if
installed).
2. Reinstall bearing cover without shims. Hold in position with hand pressure and measure clearance
between power divider cover and bearing cover,
using a feeler gauge.
4. Install shim pack and bearing cover. Install cap
screws. Torque screws to 114–140 lb-ft. (155–190
N•m). Make sure shims are flat with no kinks or
bends.
1
2
1—Push in and zero indicator, read and record
2—Pry down
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.
5. Install yoke using installation tool and nut. 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.
7. If end-play is incorrect, change shim pack size as follows:
Add shims to increase end-play.
Desired end-play (New Parts
Measured end-play (Step 6)
Add shims to provide desired end-play
Disassemble shim to decreased end-play.
Measured end-play (Step 6) 0.015" – 0.015"
Desired end-play (New Parts)
Remove shims to provide desired endplay
0.003" to 0.007"
0.001" – 0.001"
0.002" to 0.006"
0.003" to 0.007"
0.012" to 0.008"
28
Forward Assembly
8. To add or remove shims, remove input shaft nut and
yoke. Remove cap screws, lock washers and bearing
cover. Add or remove shims as required.
9. Install bearing cover and cap screws. Seal shim pack
with Dana approved RTV compound to prevent lube
leakage then torque input shaft cap screws 150–165
lb-ft. (204–224 N•m).
10. Install yoke.
11. Install yoke nut. One of the following options may be
used.
a. Install a new nut with the pre-applied thread
adhesive compound. Tighten the nut to the
specified torque 840–1020 lb-ft. (1148–1383
N•m).
If difficulty is experienced in achieving correct torque, torque
the nut with the truck wheels on the ground and with the axle
shaft installed.
IMPORTANT
Follow the instructions specified by the thread adhesive
manufacture when applying thread adhesive compound.
Forward Assembly
b. If a new nut with pre-applied thread adhesive
compound is unavailable, apply “Loctite 277” or
“271” (available in 0.5 ml tube – Dana P/N
129293) to the nut along two threads, for at
least two flats (120°) of the nut midway through
the thickness. Tighten the nut to the specified
torque 840–1020
Note: Use of a torque multiplier is recommended.
lb-ft. (1148–1383 N•m).
2 Flats
(120˚)
Midway thru
thickness of nut
29
Carrier Assembly - Forward
Parts Exploded View
Forward Assembly
1
2
1 — Piston engagement bolt
2 — Cap screw
3 — Switch
4 — Washer
5 — O-ring
6 — Piston
7 — Setscrew
8 — Piston driver
9 — Push rod
10 — Clutch fork
11 — Spring
12 — Sliding clutch
13 — Pin
14 — Piston cover
13
12
14
3
4
5
6
7
8
9
10
11
30
Disassemble Carrier Assembly
Forward Assembly
Note: For models having the wheel differential lock option or a
carrier thrust bolt follow the steps below. These parts
must be removed first before further removal of the
wheel differential can take place.
Disassemble Wheel Differential – Models with Wheel
Differential Lock
1. For ease of servicing, mount differential carrier in
stand with differential lock facing up.
Note: To overhaul and reassemble the wheel differential, the
shift fork and clutch assembly must be removed from
carrier. See instructions below.
2. Remove shift cylinder mounting screws, then lift
shift cylinder, piston and o-ring assembly off carrier
and end of push rod.
1
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.
Forward Assembly
—Shift cylinder
1
3. To disassemble shift cylinder for inspection, first
remove or back off actuator switch. The piston and
o-ring assembly can be removed by inserting a pencil-size tool through the cylinder air port.
4. Grasp push rod end and pull it out of the shift fork,
spring and carrier.
Note: When the push
the fork and sliding curvic clutch assembly can be
removed from carrier.
Note: Do not disassemble shift fork from the sliding curvic
clutch unless parts replacement is necessary. To disassemble, use pin punch to remove spring pin from long
leg of fork. The fork can now be disengaged from the
clutch.
5. Remove the snap ring, then lift fixed curvic clutch off
differential case hub spline. Further disassembly of
carrier is the same for axles without differential lock.
rod is disengaged from the shift fork,
1
2
3
1—D-head carrier or front carrier
2—Thrust bolt
3—Thrust bolt jam nut
31
Forward Assembly
Disassemble Wheel Differential (All Standard Models)
Note: Omit this step if the gear set is to be replaced. 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.
1. Mount differential carrier in repair stand.
Note: For easier disassembly, loosen but do not remove pin-
ion (self-locking) nut. Forward axle pinion is equipped
with slotted nut, remove roll pin with a pin punch then
loosen nut.
3. Remove cap screws, flat washers and bearing caps.
Back off bearing adjusters and remove adjusters and
bearing cups.
4. Using a chain hoist, lift ring gear and differential
assembly out of carrier.
2. If reusing gear set, also punch mark bearing adjusters for reference during assembly.
1
1—Punch marks
32
Disassemble Pinion Assembly
1. Remove pinion bearing cage cap screws. Remove
pinion and cage assembly from carrier. Remove
shim pack.
Forward Assembly
Note: For easier disassembly, loosen but do not remove pin-
ion (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 cap screws. Remove
pinion and cage assembly from carrier. Remove
shim pack.
Forward Assembly
IMPORTANT
Do not allow pinion to drop on hard surface.
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.
33
Front Axle Pinion Assembly - Forward
Parts Exploded View
1
2
3
Forward Assembly
4*
5
6
7
8
1—Pinion pilot bearing
2—Pinion
3—Pinion bearing cone - inner
4—Pinion bearing spacer*
5—Pinion bearing cup - inner
6—Shim
7—Pinion bearing cage
* Before 3/01/95 two spacers were used instead of the one shown.
9
10
11
12
13
8—Cap screw
9—Pinion bearing cup - outer
10—Pinion bearing cone - outer
11—Pinion helical gear
12—Roll pin
13—Slotted pinion nut
34
Forward Assembly
Disassemble and Overhaul Drive Pinion
The following procedures cover both forward and rear differential drive carrier disassembly.
3. Remove the pinion nut roll pin.
4. Loosen and remove the pinion nut.
5. Remove the helical gear with the proper puller tool.
6. Press pinion out of bearing cage and bearing cone.
1
1 - Press ram
7. Remove bearing cups with proper puller tool.
9. 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.
Forward Assembly
b. Mount puller horizontally to press pinion out of
bearing.
8. Remove bearing spacer from pinion.
35
Forward Assembly
10. Remove inner bearing cone 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.
b. Mount puller horizontally to press pinion out of
bearing.
1
Replace Pinion Bearing Cage Cups
1
Front
2
1 - Cup (outer)
2 - Bearing cage
3 - Cup (inner)
1. Remove cups.
2. Clean and inspect bearing cages for damage, nicks
and burrs.
1
Rear
3
2
1 - Press
2
1 - Press ram
2 - Sleeve must apply pressure to back face of outer bearing
cone
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.
36
Forward Assembly
4. Seat cups securely to shoulder. Check clearance
between cup and bearing cage. Must be less than
0.001".
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
2
3
4
1 - Bearing
2 - Cup
3 - Spacer
4 - Cage
5 - Cup
6 - Bearing
5
6
Forward Assembly
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.
2. With the bearings well lubricated, place the assembly
in the press. Position sleeve so that load is applied
directly to the back face of the outer bearing cone.
1
2
3
1 - Press ram
2 - Sleeve must apply pressure to back face of outer bearing
cone
3 - Spring scale
37
Forward Assembly
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 5–13 lbs. (2.5–6.0 kg.).
Specifications for Pinion Bearing Trial Buildup Preload Test
Torque to Rotate Bearing Cage (w/o pinion seal)
18 - 42 in. lbs (2.0 - 4.7 N•m)
Forward Axles Rear Axles
Spring Scale
Reading
Press Loads 17-19 Tons
Nominal Bearing
Thickness Spacer
5 - 13 lbs. (2.5 - 6.0 kg)
(15.4 - 17.2
Metric Tons)
0.496 in.
(12.60 mm)
CAUTION
14-15 Tons
(12.7-13
Metric Tons)
0.638 in.
(16.21 mm)
.6
Final Buildup
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.
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
spacer compensates for slight “growth” in the bearings
which occurs when they are pressed on the pinion shank.
Do not assume that all assemblies will retain proper pre-
load once bearings are pressed on pinion shank. FINAL
PRELOAD TEST MUST BE MADE IN EVERY CASE.
bearing cage assembly. The larger
IMPORTANT
To prevent bearing damage, use suitable sleeve that only
contacts inner race of bearing cone.
2. Install preselected bearing spacer.
38
Forward Assembly
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.
Specifications for Pinion Bearing Final
Buildup Preload Test
Torque to Rotate Bearing Cage (w/o pinion seal)
18 - 42 lbs. in. (2.0 - 4.7 N•m)
Forward Axles Rear Axles
Spring Scale
Reading
Press Loads 17–19 Tons
Nut Torque 840 lbs. ft.*
*Torque nut to 840 lbs. ft. (1,140 N•m), then continue tighten-
ing nut to align nut slot to nearest hole in pinion shank.
Vise Method
a. if the yoke and nut are used, mount the assem-
bly in a vise, clamping yoke firmly.
5 - 13 lbs. (2.5 - 6.0 kgs.)
14–15 Tons
(15.4–17.2
Metric Tons)
(1,140 N•m*)
(12.7–13.6
Metric Tons)
575–703 lbs. ft.
(780–953 N•m)
Forward Assembly
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 at right).
1
1 - Vise
39
Press Method
a. If a press is used, position a sleeve or spacer so
1 - Press
Forward Assembly
that load is applied directly to the back face of
the outer bearing cone.
1
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 5–13 lbs. This specification is translated into
lbs. in. readings in the previous chart.
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
9. Stake pilot bearing using staking tool. This is essential to retain the bearing.
Stake Pattern
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.
8. Press pilot bearing on pinion.
IMPORTANT
To prevent bearing damage, use suitable sleeve that only
contacts the inner race of bearing cone.
40
Install Drive Pinion Assembly
Forward Assembly
1. Place shim pack on carrier making sure holes are
properly aligned. Make sure shims are flat with no
kinks or bends
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
Rear 0.023 0.584
3. If dummy yoke was used, remove nut and yoke.
Install helical gear on pinion. Install M42 X 1.5 nut
and torque to 840-1,020 lb-ft. (1,140-1,383 N•m).
IMPORTANT
Torque to 840 lbs. ft. (1,140 N•m), then continue tightening
t to align slot with the nearest hole in pinion shank.
nu
Install roll pin.
Forward Assembly
2. Install drive pinion assembly. Install bearing cage
cap screws and lock washers. Torque cap screws to
114-140 lb-ft. (155-190 N•m).
Note: Use a dummy yoke (if available) in place of helical gear.
This will result in easier disassembly and reassembly
during carrier adjustments.
Note: Do not install cotter roll until carrier adjustments are
completed.
1
1—Roll pin
2—Slotted nut
2
41
Wheel Differential - Forward
Parts Exploded View
2
Forward Assembly
3
4
5
76
9
8
1
12
1 - Ring gear
2 - Cap screw
3 - Flat washer
4 - Diff. carrier bearing caps
5 - Cotter pin
6 - Diff. case - LH (flange half)
7 - Bearing cone - flange half
8 - Bearing cup - flange half
9 - Diff. bearing adjuster - flange half
10 - Bolt
10
13
14
11
Flange Half (LH)
4
16
11 - Nut
12 - Diff. bearing adjuster - plain half
13 - Bearing cup - plain half
14 - Bearing cone - plain half
15 - Diff. case - RH (plain half)
16 - Side gear thrust washer
17 - Side gear
18 - Diff. spider
19 - Side pinion
20 - Side pinion thrust
17
20
19
18
16
17
15
42
Forward Assembly
Disassemble, Overhaul, and Assemble Wheel Differential - Forward
Disassemble Wheel Differential
4. Lift out spider, side pinions and thrust washers.
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.
5. Remove remaining side gear and thrust washer.
6. Remove bearing cones from case halves using suitable puller.
2. Punch mark differential cases for correct location
during reassembly. Remove cap screws and lift off
plain differential case half.
1
1 - Punch marks
3. Lift out side gear and thrust washer.
7. Remove bearing cone from plain case half in two
steps:
a. Mount puller vertically to split bearing. This
will start moving bearing off case.
action
b. Mount puller horizontally to remove cone.
Forward Assembly
8. Remove bearing cone from flanged case half using
suitable puller.
43
Forward 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.
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.
2. Press new plain half bearing cones on differential
case halves.
6. Place side gear and thrust washer on side pinions.
44
Forward Assembly
7. Align punch marks and install plain case half. Install
cap screws and tighten to 114–140 lb-ft. (155–190
N•m). Check differential for free rotation by turning
side gear hub.
1
1 - Punch marks
8. Install ring gear. Secure with bolts and nuts.
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 than the old 126219 bolt. (See chart).
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.
Forward Assembly
Bolt No. Torque Specs.
129686 180-220 lb-ft. (N•m 224-298)
126219 215-255 l
Note: Reference Dana Bulletin ABIB-9701 for more details.
9. Lower assembled differential assembly in to the carrier using a hoist and a strap. Be careful not to damage the differential bearings lowering the assembly.
b-ft. (N•m 292-346)
45
Measure and Adjust Carrier Assembly
Forward Assembly
Adjust Backlash and Preload
1. Turn the flange half bearing adjuster in until the ring
gear contacts the pinion (zero backlash) than back
the adjuster out two notches of the adjuster lugs.
1
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.
2
2
1—Flange half
2—Plain half
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 0.006"– 0.018".
TIP: To give yourself room to adjust contact pattern,
set it between 0.010"–0.012".
1
46
Forward 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
0.003" 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 350–428 lbs. ft. (475–580 N•m).
2. Recheck backlash: if the bearing adjusters were not
in straight or fully seated the backlash will change.
c. Used Gearing: Reset to backlash recorded
before disassembly.
d. 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 run out. (Indicator
reading should not exceed 0.010").
2. Measure ring gear total back face run out (Indicator
reading should not exceed 0.010").
Forward Assembly
3. Check ring gear tooth contact pattern. Paint ring gear
teeth and check tooth
patterns. Checking and adjusting procedures are on
pages 61-62.
4. Install bearing adjuster cotter pins.
contact pattern. Correct tooth
47
Forward Assembly
Adjust Ring and Pinion Tooth Contact Pattern
2
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.
1
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
tooth toe.
and should be up off the
3
4
5
6
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.
1 - 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.
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.
This
48
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.
Forward 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.
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.
3. Loosen the bearing adjuster on the teeth side of the
ring gear several notches.
4. Loosen the opposite
5. Return to adjuster on teeth side of ring gear and
tighten adjuster until it contacts the bearing cup.
6. Continue tightening the same adjuster 2 or 3 notches
and recheck backlash.
adjuster one notch.
Forward Assembly
If the pattern is concentrated at the heel (too far up the tooth),
move the ring gear toward the pinion to decrease backlash.
7. Loosen the bearing adjuster on the teeth side of the
ring gear several notches.
8. Tighten the opposite adjuster one notch.
9. Return to adjuster on teeth side of ring gear and
tighten adjuster until it contacts the bearing cup.
10. Continue tightening the same adjuster 2 or 3 notches
and recheck backlash.
49
Wheel Differential Lock - Forward
Parts Exploded View
Forward Assembly
13
14
1
2
3
4
5
6
7
8
9
1—Piston engagement bolt
2—Cap screw
3 —Switch
4—Washer
5 —O-ring
6 —Piston
7—Setscrew
10
12
11
8 —Piston driver
9—Push rod
10—Clutch fork
11—Spring
12—Sliding clutch
13—Pin
14—Piston cover
50
Forward Assembly
Install and Adjust Wheel Differential Lock
Note: With differential carrier completely assembled and
adjusted, install differential lock as follows:
1. Install fixed curvic clutch on splined hub of flanged
differential case, then install snap ring.
2. If shift fork and sliding curvic clutch are disassembled, engage fork with clutch hub and install spring
pin in the long leg of the fork. See illustration for fork
mounting position on clutch.
3. Position compression spring, shift fork and clutch
assembly in shift opening of the carrier. Align pilot
hole of shift fork with pilot hole of carrier. Install
pushrod, engaging shift fork head, and compression
spring in carrier.
4. Install new o-ring on piston.
5. Lubricate piston and o-ring with silicone grease and
install piston assembly in cylinder. Position piston
with small diameter hub toward closed end of cylinder.
6. Screw piston driver on push
7. Tighten piston driver until shift fork clutch is approximately 0.030 of an inch from the fixed clutch.
rod.
11. Screw in manual engagement screw, by hand
approximately 1 inch or until snug fit (light resistance pressure is felt) both clutches must be completely engaged.
12. Remove manual engagement screw, clutches
completely disengaged. Repeat above procedure if
clutches not completely disengaged.
Note: Fork adjustment is correct when curvic clutch teeth are
fully engaged with the fork free when moved by hand.
When air pressure is released or the manual bolt is
removed, the shift assembly should disengage freely.
13. When adjustment is complete, torque fasteners to
28–35 lb-ft. (38–47 N•m).
14. Install selector switch in cylinder cover. Torque
switch to 10–12 lb-ft. (14–16 N•m).
15. Check selector switch operation. Check switch electrically with an ohmmeter or continuity tester. Switch
should close (show continuity) when clutches are
engaged and should open (no continuity) when
clutches are disengaged.
must
Forward Assembly
.030"
8. Push down by hand on the piston driver, both
clutches must be completely engaged.
9. Install set screw in piston driver, torque to 12–15 lbft. (16–20 N•m).
CAUTION
On 3.90 ratio models only, a washer (P/N 210288) must be
used between the piston driver and piston. Failure to install
the washer will cause engagement and disengagement
problems in the differential lock.
10. Trial fit, install piston cover assembly. Hand tighten
cap screws.
51
Forward Assembly
Install and Adjust Ring Gear Thrust Bolt
1. Thread thrust screw into the carrier until firm contact
with the back face of the ring gear is made.
2. Loosen the thrust screw 1/4 turn to obtain the correct adjustment of 0.020" (.50mm) 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.
1
2
3
1 - D-head carrier or front carrier
2 - Thrust bolt
3 - Thrust bolt jam nut
52
Forward Assembly
Housing and Output Shaft Assembly - Forward
Parts Exploded View
1
2
3
4
5
6
7
8
11
12
13
10
23
9
14
16
15
Forward Assembly
18
17
21
20
19
22
1— Output shaft nut
2— Output yoke
3— Output seal
4— Snap ring
5— Outer bearing cup
6— Outer bearing cone
7— Inner bearing cone
8— Inner bearing cup
9— Output shaft
10— Fill Plug
11— Jam nut
12— Locking ring
13— Spindle nut
14— Axle housing
15— Breather
16— Breather hose
17— Carriage cap screw
18— Lock washer
19— Nut
20— Lock washer
21— Stud
22— Drain plug
23— Axle shaft
53
Disassemble Output Shaft Assembly
Forward Assembly
Note: For forward axle rear covers that are removable the out-
put shaft may be removed when the cover is in or out of
the axle assembly.
1. Disconnect the inter-axle driveline at the forward
axle rear cover position.
2. Remove yoke nut (shoulder nut).
3. Remove yoke from output shaft using appropriate
tool.
1
1 - Yoke 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 tool distributor.
TIP: It may be helpful to loosely reinstall the yoke
and shoulder nut giving the technician more of an
area to grip when removing the output shaft.
7. Remove the inner bearing cup from rear cover
assembly. This may be removed from inside the axle
housing when the carrier is removed, or by removal
of the forward axle rear cover.
. Remove both inner and outer bearing from output
8
shaft.
1
1 - Press
9. Remove output shaft inner bearing cup.
4. Remove oil seal.
5. Remove snap ring.
6. Remove output shaft and outer bearing cup as an
assembly.
1
2
3
4
5
1 - Snap ring
2 - Outer bearing cup
4 - Inner bearing cup
5 - Rear cover assembly
3 - Output shaft assembly
Note: Components such as the inter-axle driveline, yoke, oil
seal and output shaft assembly should have been
removed according to normal service procedures.
Removing the differential assembly from the axle housing is not necessary, but would ease the removal process of the inner bearing cup from the cover bore.
e. Using a bearing puller tool, remove the inner
bearing cup.
f. Visually inspect the inner-machined bore sur-
face of the welded-on cover for nicks and burrs.
Repair if necessary.
54
Forward Assembly
Overhaul and Assemble Output Shaft
Assembly
Note: Lubricate the parts with gear lube during assembly.
1. The output shaft bearings are assembled with both
bearing cones back to back. Use a press and a sleeve
to install one bearing at a time.
CAUTION
To prevent bearing damage, use a suitable sleeve that only
contacts the bearing race.
2. Apply pressure until the inner bearing cone touches
the shoulder of the output shaft.
3. Apply pressure until the back of the outer bearing
cone touches the back of the inner bearing.
Note: Axle housings with welded-on covers procured through
service will include the inner bearing cup as part of the
“service” axle housing assembly. Go to Step 6 if the
inner cup has already been installed.
4. Lightly coat the output bore of the axle housing
cover with a 9.5 (.38) wide application of Loctite 680
where the bore contacts the
not apply Loctite outside of this area—to the bearing
rollers or outboard of the inner cup bore. Improper
application of the Loctite could lock the rollers or
cause excessive pre-load.
inner bearing cup. Do
Note: Use the bearing cup driver to insure seating of snap
ring after installation with snap ring pliers.
1
2
3
4
5
6
7
1—Press
2—Plate
3—Sleeve
5—Press bearing on first
6—Output shaft
7—Plate
4—Press bearing on second
Forward Assembly
CAUTION
Add loctite adhesive to the inner bearing surface of the
housing and NOT to the bearing race itself. If added to the
race, excessive adhesive could get on the surface of the
outer bearing race journal during installation and cure the
outer cap in place with excessive pre-load.
5. Using a sleeve and driver (hammer), install the inner
bearing cup.
6. Put the output shaft and bearing assembly into the
axle housing assembly.
7. Using a sleeve and driver (hammer), install the outer
bearing cup into the housing assembly over the output shaft bearing cone.
8. Using snap ring pliers,
install the snap ring that fastens the outer bearing cup into the welded-on cover
assembly.
9. Check the end-play of the output shaft. New assemblies should measure 0.001" to 0.015".
1
2
3
4
5
1—Snap ring
2—Bearing cup
3 —Output shaft assembly
4—Inner bearing cup
5—Rear cover assembly
10. Install output yoke.
55
Forward Assembly
11. Install yoke nut using one of the following options:
g. Install a new nut with the pre-applied thread
adhesive compound. Tighten the nut to the
specified torque 680–832 lbs. ft. (920–1,130
N•m).
h. If a new nut with pre-applied thread adhesive
compound is unavailable, apply “Loctite 277" or
“271” (available in 0.5 ml tube—Dana P/N
129293) to the nut along two threads, for at
least two flats (120°) of the nut midway through
the thickness. Tighten the nut to the specified
torque 680–832 lb-ft. (530–1,130 N•m).
IMPORTANT
Follow the instructions specified by the thread adhesive
manufacturer when applying thread adhesive compound.
When axle has been disassembled or housing, axle shafts
or wheel equipment replaced, check axle assembly for
proper differential actions before operating vehicle. Wheels
must rotate freely and independently.
15. Road test vehicle to bring axle lubricant up to temperature. Recheck joints, drain and fill plugs for leakage. Retighten as necessary.
2 Flats
(120˚)
Midway thru
thickness of nut
Note: Use of a torque multiplier is recommended.
IMPORTANT
If you can't get the correct torque on yoke nut, try torquing
the nut with the truck wheels on the grou
axle shafts installed.
12. Install axle shafts and axle stud nuts (If used, also
install lock washers and taper dowels).
13. Connect inter-axle driveline. Make sure driveline is
properly phased. Lubricate U-joints.
14. Add axle lubricant. Fill to bottom of filler hole.
nd and with the
56
IMPORTANT
Forward Assembly
Measure and Adjust
Note: Use bearing cup driver to insure seating of snap ring
after installation with snap ring pliers.
See illustration for steps 1–4.
1. Assemble cover assembly to axle housing.
2. Position dial indicator at yoke end of output shaft.
3. Push in on output shaft and zero the dial indicator.
4. Using a pry bar, move output shaft axially and measure/record end-play.
4
3
2
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.
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 da
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.
mage or contamination.
Forward Assembly
1
Correct end-play for a new assembly is 0.001" to 0.015". The
maximum end-play for a used assembly is no more than
0.015". If end-play is incorrect, contact Dana.
5. Install oil seal. Follow seal replacement procedures
on page 72 of this manual.
6. Install yoke.
7. Install yoke nut. One of the following options may be
utilized:
i. Install a new nut with the pre-applied thread
adhesive compound. Tighten the nut to the
specified torque 680–832 lbs. ft. (920–1130
N•m).
j. If a new nut with pre-applied thread adhesive
compound
“271” (available in 0.5 ml tube—Dana P/N
129293) to the nut along two threads, for at
least two flats (120°) of the nut midway through
the thickness (See illustration). Tighten the nut
to the specified torque 680–832 lbs. ft. (920–
1130 N•m).
is unavailable, apply “Loctite 277" or
1
1 - Yoke puller tool
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 #217414
D-Input-Use driver #126917 only
D-Output-Use insert #128706 with driver #126917
R-Pinion-Use driver
#126917 only
57
CAUTION
Forward Assembly
Guidelines for Reusing Yoke
CAUTION
Due to the resiliency of the plastic driver, hammer rebound
may occur when the seal is seated. Keep clear of the hammer rebound path!
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.
Do not use the yoke if it has any damage on the seal surface
(nicks or scratches).
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
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
Do not use wear sleeves. Wear sleeves increase the yoke
hub surface diameter and cause premature seal wear and
repeat seal failure.
inspect the seal surface area of the yoke hub for
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
58
Rear Assembly
Differential Carrier Assembly - Rear
1 - Carrier fastener
2 - Carrier assembly Rear Assembly
Rear Assembly
1
2
59
Differential Carrier - Rear
Parts Exploded View
Rear Assembly
31
30
29
28
19
20B
27
20A
22
17
26
25
18
21
23
32
24
16
15
14
11
9
10
8
7
6
5
4
3
13
12
1 - Pi nion N u t
2 - End Y o ke and Slinger
3 - Oil Seal
4 - Ou ter Pi nion Bearing Co ne
5 - Ou ter Pi nion Bearing C up
6 - Pi nion Sp a cer
7 - I nner Pinion Bearing Cu p
8 - I nner Pinion Bea ring Co ne
9 - Drive Pinion
10 - Carrier Ho using
Diff Case Dowels
11 12 - Ri ng Gea r
13 - Ring Gea r Bolts
14 - Flange Half Bearing Cone
15 - Flange Half Bearing Cup
16 - Flange Half Bea ring Adjuster
17 - Side Pinio n Thrus t Washer
2
1
18 - Side Pinio n
19 - Side Gea r
20A - Differential
Shaft
20B - Differential Shaft
21 - Pi n
22 - Cap screw
23 - Flat Washer
24 - Flange Half Cap
25 - Plai n Half Cap
26 - Cotter Pin
27 - Side Gear Thrust Washer
28 - Plain Half Diff Case
29 - Plain Half Bearing Cone
30 - Plain Half Bearing Cup
31 - Plain Half Bearing Adjuster
32 - Pipe Plug
60
Rear Assembly
Install Differential Carrier - Rear
IMPORTANT
IMPORTANT:
Before installing carrier assembly, inspect and thoroughly
clean interior of axle housing using an appropriate solvent and
clean rag.
1. Apply Dana Spicer 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 minutes. Install carrier before compound sets or reapply.
Rear Assembly
1
1 - Apply RTV gasket in this pattern
Note: To assist in installing complete differential carrier use
two pieces of threaded rod (M14 X 2) threaded into carrier cap screw holes. Rod should be approximately 4"
(102 mm) long. Use these to pilot the carrier into the
housing.
2. Install carrier to housing, lock washers and cap
screws. Torque to proper specification. Torque to
142–158 lb-ft. (193–214 N•m).
3. Install axle shafts and axle stud nuts.
4. Add axle lubricant. Fill to bottom of filler hole in
carrier.
5. Connect main driveline and lubricate joints.
61
Drive Pinion
Rear Axle Pinion Assembly Parts Exploded View
11
Rear Assembly
1 - Pinion Nut
2 - End Yoke
3 - Slinger
4 - Oil Seal
5 - Outer Pinion Bearing Cone
6 - Outer Pinion Bearing Cup
10
9
8
7
6
5
4
3
2
1
7 - Pinion Spacer
8 - Inner Pinion Bearing Cup
9 - Inner Pinion Bearing
10 - Drive Pinion
11 - Carrier
62
Rear Assembly
Pinion Disassembly
1. Remove yoke nut.
2. Remove yoke using a yoke puller service tool.
1
1 - Yoke puller
3. Remove oil seal.
4. Place carrier in a press with threaded end of pinion
face up.
5. Place a wood block under pinion to avoid damage to
gear teeth.
7. Remove bearing preload spacer and save for use in
reassembly.
8. Remove inner bearing cone 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.
b. Mount puller horizontally to press pinion out of bear-
ing.
Rear Assembly
1
2
3
6
5
4
1 - Press
2 - Outer bearing
3 - Inner bearing
4 - Wood block
5 - Drive pinion
6 - Bearing preload spacer
6. Press pinion through outer bearing and out of carrier
casting.
1
1 - Press
9. If bearings are to be replaced, remove bearing cups
from carrier casting at this time. Pinion removal
complete.
63
Rear Assembly
Pinion Installation
Final Buildup
Note: Do not install oil seal in carrier until bearing preload is
correctly adjusted.
1. Press inner bearing cone on pinion.
3. Press inner and outer bearing cups into the carrier
until seated. Use a feeler gage (0.0015" [0.038 mm]
approximately) to make sure that bearing cups are
fully seated in bearing bores. Apply lubricant to both
cup and cone.
4. Place carrier housing in press with the pinion supported by wood block (6" x 6" x 6" [152 x 152 x 152
mm]), so the inner pinion bearing is mated to the
cone.
1
2
5
4
3
IMPORTANTIMPORTANT
IMPORTANT:
To prevent bearing damage, use suitable sleeve that only contacts inner race of bearing cone.
2. Install preselected bearing spacer.
1 - Press
2 - Outer pinion bearing
3 - Wood block
4 - Drive pinion
5 - Bearing preload spacer
5. Press outer bearing onto pinion until completely
seated. Rotate carrier during seating process.
6. Use tor
que multiplier and torque pinion nut to 710-
1040 lbs. ft. (848-1410 N•m).
64
Rear Assembly
7. Measure torque to rotate the pinion with an inchpound torque wrench. Torque measurements should
be taken every fourth (4th) revolution and should
read between 34-42 in.lbs. of bearing preload.
Note: If bearing preload does not fall within allowed limits,
preload can be increased by using a thinner spacer and
decreased by using a thicker spacer.
Always measure each spacer before assembly to
ensure correct thickness.
8. Repeat process until torque to rotate is between 3442 in. lbs. After proper preload is achieved, remove
yoke and install new seal with proper service tool.
11. 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.
1
2
3
12. Install end yoke.
Note: Dana Spicer recommends that new torque prevailing
nuts be used.
13. Use torque multiplier and torque pinion nut to 7101040 lbs. ft. (848-1410 N•m).
Rear Assembly
CAUTIONCAUTION
CAUTION:
Do not use any silicone or permatex-type bore sealant with
this seal.
9. Remove the new seal from its package and install
with the proper driver:
R-Pinion-Use drive #126917 only
WARNINGWARNING
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!
10. 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.
1 - Seal Driver
2 - Oil Seal
3 - Pinion Cage
65
Wheel Differential Assembly
Parts Exploded View
Wheel Differential
9
8
10
9
1
1 - Diff. Case Bearing Adjuster
2 - Diff. Bearing Cup
3 - Diff. Case Bearing Cone
4 - Differential Case
5 - Side Gear Thrust Washer
6 - Side Gear
7 - Differential Shaft
8 - Side Pinion
7
6
6
10
5
9
9
13
14
15
12
16
3
4
11
2
9 - Side Pinion Thrust Washer
10 - Pin
11 - Ring Gear
12 - Ring Gear Bolt
13 - Ring Gear Bearing Cone
14 - Ring Gear Bearing Cup
15 - Ring Gear Bearing Adjuster
16 - Locating Dowels
66
Wheel Differential
Disassemble, Overhaul, and Assemble Wheel Differential
Disassemble Wheel Differential
IMPORTANTIMPORTANT
CAUTION:
IMPORTANT:
Do not press on the wheel differential shaft to free the ring
gear from the case. Pressing on the wheel differential shaft
may cause it to bend and/or fatigue.
1. Remove cap screws fastening ring gear to differential case.
The differential case and gears will fall after separation. Support the case so that it will not cause damage to the differential or bodily injury.
3. Remove the outer side gear.
Wheel Differential
CAUTIONCAUTION
2. The ring gear to differential case interface is a press
fit. Place the assembly in a press with the case facing downward. Support the assembly on either side
of the ring gear. Thread a cap screw back into one of
the case holes by hand. Press down on the head of
the cap screw, you may need to press in more than
one position to free the ring gear from the case.
4. Remove the differential shaft locking pins by turning
differential case opening facing down. Use a
the
hammer to lightly tap on the side of the case to free
the locking pins.
67
Wheel Differential
5. The locking pins are slip fit and should fall from the
case easily.
6. Remove the half shafts first and then remove their
side pinions and thrust washers.
9. Remove bearing cones from ring gear and differential case in two steps:
a. Mount puller vertically to split bearing. This
action will start moving the bearing off case and
gear.
b. Mount puller horizontally to remove cone.
Half
Differential
Shaft
7. Remove the full shaft, side pinions and thrust washers.
8. Remove inner side gear and thrust washer.
68
Wheel Differential
Assemble Wheel Differential
10. Press new bearing cone on the differential case.
11. Place thrust washer on the side gear. Lubricate both
sides of the thrust washer before installing.
13. Start the full differential shaft into the shaft bores in
the case that does not have a locking pin hole.
Side Pinion
and Thrust
Washer
Full
Differential
Shaft
Locking
Pin Holes
14. Install a side pinion and thrust washer and push the
shaft through the side pinion.
Side Pinion
and Thrust
Washer
Wheel Differential
12. Install the side gear and thrust washer in the differential case.
15. Install the side pinion and thrust washer to the other
side of the full shaft.
69
Wheel Differential
16. Install a side pinion and thrust washer on the half
shaft side.
Side Pinion
and Thrust
Washer
17. Install the half shaft so that the pin is facing upward
and push it in until it stops.
Half
Differential
Shaft
Pin Hole
Facing
Upward
19. Install the locking pins to both sides of the differential case.
Locking
Pin
20. Install outer side gear.
Note: No thrust washer is used at this location.
18. The end of the half shaft should fit into the slot of
the full shaft at the same time as the hole in the case
lines up with the hole in the half shaft.
Align Pin
Holes
Fit End
Into Slot
70
21. Lower the ring gear onto the case assembly aligning
the locking dowels.
Wheel Differential
22. Install and hand-tighten all new ring gear cap screws
23. The interface of the ring gear to differential case is a
press fit. Put the assembly in a press with the ring
gear facing upward. Make certain that the ring gear
is flush and square to the differential case before
pressing. Press until ring gear bottoms out on the
case.
IMPORTANTIMPORTANT
IMPORTANT:
DO NOT use the cap screws to draw the ring gear into place.
Only use a press.
24. Press new ring gear bearing cone.
IMPORTANTIMPORTANT
IMPORTANT:
When pressing differential case bearing cones, note that the
bearing is beyond flush with the top of the case. The cone
must be fully seated. 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 bearing boss OD.
Wheel Differential
25. Tighten and torque ring gear cap screws in an alternating pattern.
435-465 lbs. ft. (589-630 N•m).
71
Wheel Differential
26. Install differential case assembly into carrier. Be
careful not to damage the differential bearings lowering the assembly.
27. Lubricate the differential bearings and install bearing
cups and differential bearing adjusters.
72
Wheel Differential
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 (2) notches from the adjuster
lugs.
1
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.
Wheel Differential
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 0.008"– 0.018" (0.
TIP: To give yourself room to adjust contact pattern, set it
between 0.012"– 0.014" (0.30-0.36 mm).
2
15-0.46 mm).
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 twonotch preload.
2
1
1 - Lugs
2 - One notch
73
Wheel Differential
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, counting
the number of notches you back it off (each notch equals
about 0.003" [0.08 mm] of backlash).
IMPORTANTIMPORTANT
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 bearing caps and torque carrier cap
bolts to 330-360 ft. lbs. (447-488 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
before disassembly.
b. New Gearing: Backlash should be between
0.008" and 0.018" (0.15- 0.46 mm).
Measure Ring Gear Runout
Measure Ring Gear Total
1. Measure ring gear total radial runout. (Indicator
reading should not exceed 0.010" [0.25 mm]).
2. Measure ring gear total backface runout. (Indicator
reading should not exceed 0.010" [0.25 mm]).
3. Check ring gear tooth contact pattern. Paint ring gear
teeth and check tooth contact pattern. Correct tooth
patterns, see “Adjust Tooth Contact
4. Install bearing adjuster cotter pins.
74
Pattern.”
Wheel Differential
Adjust Ring and Pinion Tooth Contact Pattern
2
1
1 - Face width
2 - Tooth depth
3 - Heel
4 - Top land
5 - Root
6 - Toe
3. Identify if new or used gearing.
4. Check tooth contact pattern (new or used gearing).
New Gearing - Correct Pattern
3
4
5
6
Used Gearing - Correct Pattern
• Used geari
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.
ng will not usually display the square,
Wheel Differential
• Paint six ring gear teeth 180° apart 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 (1/2) to two-thirds (2/3) of the ring gear tooth
in most models and ratios.
• The pattern could vary in length and should cover
half (1/2) of the 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.
Adjust Ring Gear Position (Backlash)
If the ring gear pattern shows incorrect face width contact,
change backlash by adjusting the ring gear.
1 - Pattern along the face width could be longer
If the pattern is too close to the edge of the tooth toe, move the
ring gear away from the pinion to increase backlash.
75
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.
3. Return to adjuster on teeth side of the ring gear and
tighten adjuster until it contacts the bearing cup.
4. Continue tightening the same adjuster two (2) or
three (3) notches and recheck backlash.
Wheel Differential
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 two (2) or
three (3) notches and recheck backlash.
76
Service Kit 217414
Location
Seals
D-Input D-Output R-Pinion
Seals
126917
Tool
126917
New Welded D-Housing Cover
Lube Quantity Difference
0 (zero)
Standout of Output Shaft Yoke
Length increased by 6mm (.25"), this should not have any
significant impact on inter-axle driveline length or drive line
angles.
+
126917
128706
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.
77
General Lubrication Information
Lubrication
The ability of a drive axle to deliver quiet, trouble-free operation
over a period of years is largely dependent upon the use
of good quality gear lubrication in the correct quantity. The
most satisfactory results can be obtained by following the
directions contained in this manual.
The following lubrication instructions represent the most current
recommendations from Dana.
Approved Lubricants
General—Gear lubrications acceptable under military specification (MILSPEC) MIL-L-2105D (Lubricating Oils, Gear,
Multipurpose) are approved for use in Spicer Drive Axles.
The MIL-L-2105D specification defines performance and
viscosity requirements for multigrade oils. It supersedes both
MIL-L-2105B, MIL-L-2105C and cold weather specification
MIL-L-10324A. This specification applies to both petroleumbased and synthetic based gear lubricants if they appear on
the most current “Qualified Products List” (QPL-2105) for
MIL-L-2105D.
Note: The use of separate oil additives and/or friction modifiers
are not approved in Spicer Drive Axles.
Synthetic based—Synthetic-based gear lubricants exhibit
superior thermal and oxidation stability, and generally
degrade at a lower rate when compared to petroleum-based
lubricants. The performance characteristics of these lubricants
include extended change intervals, improved fuel economy,
better extreme temperature operation, reduced wear and
cleaner component appearance. The family of Spicer gear
lubricants represents a premium quality synthetic lube
which fully meets or exceeds the requirements of
MIL-L-2105D. These products, available in both 75W-90
and 80/W-140, have demonstrated superior performance in
comparison to others qualified under the MILSPEC, as demonstrated
by extensive laboratory and field testing. For a complete
list of Spicer approved synthetic lubricants contact
your local Dana representative. See back cover of this
manual for appropriate phone number.
Recommendations for Viscosity/Ambient
Temperature
The following chart lists the various SAE grades covered by
MIL-L-2105D and the associated ambient temperature range
from each. Those SAE grades shown with an asterisk (*) are
available in the Spicer family of synthetic gear lubricants.
The lowest ambient temperatures covered by this chart are
-40°F and -40°C. Lubrication recommendations for those
applications which consistently operate below this temperature
range, must be obtained through Dana by contacting
your local Dana representative.
Grade Ambient Temperature Range
75W -40°F to -15°F (- 40°C to -26°C)
75W-80 -40°F to 80°F (-40°C
75W-90* -40°F to 100°F (-40°C to 38°C)
75W-140 -40°F and above (-40°C and above)
80W-90 -15°F to 100°F (-26°C to 38°C)
80W-140* -15°F and above (-26°C and above)
85W-140 10°F and above (-12°C and above)
* Available in the Spicer family of synthetic gear lubricants.
to 21°C)
Makeup Lube—Maximum amount of non-synthetic makeup
lube is 10%.
78
Lube Change Intervals
Lubrication
This product combines the latest manufacturing and part
washing technology. When filled with a Spicer approved
synthetic lubricant at the factory, the initial drain is not
required.
Change the lubricant within the first 5,000 miles of operation
when not using a Spicer approved synthetic lubricant
in either a new axle or after a carrier head replacement.
Base subsequent lubricant changes on a combination of
the following chart and user assessment of the application
and operating environment.
Synthetic or Lubricant SAE Change Interval for Line Haul Change Interval for Vocational
Mineral
Synthetic* SHAES-256 SAE 75W-90 500,000 miles (800,000 Km) 120,000 miles (193,000 Km)
or 5 years or 1year
Synthetic** SHAES-256 SAE 75W-90, 250,000 miles (400,000 Km) 60,000 miles (96,500 Km)
75W-140 or 3 years or 1 year
Mineral MIL-L-2105E/J02360, 75W, 75W-90, 120,000 miles (193,000 Km) 60,000 miles (96,500 Km)
Base API GL-5 Gear Oil, 75W-140, 80W- or 1 year or 1 year
MIL-PRF-2105E 90, 85W-140
Severe Service Lubrication Change Intervals – Severe service
applications are those where the vehicle consistently
operates at or near its maximum GCW or GVW ratings, dusty
or wet environments, or consistent operation on grades
greater than 8%. For these applications, the ON/OFF HIGHWAY
portion of the chart should be used. Typical applications
are construction, logging, mining and refuse removal.
Note: Clean metallic particles from the magnetic filler plug
and drain plugs. Clean or replace the breather yearly to
avoid lube contamination due to water ingestion.
Lubrication
* Axles using LMS wheel end system
** Axles using adjustable wheel bearing system
79
Change Lube
Lubrication
Drain
Drain when the lube is at normal operating temperature
(150°–200°F). It will run freely and minimize the time necessary to fully drain the axle, this insures the axle is flushed.
Unscrew the magnetic drain plug on the underside of the axle
housing and allow the lube to drain into a suitable container.
Note: Dispose of all used lubricants properly by following dis-
posal methods approved for mineral or synthetic based
oils.
After initial oil change, inspect drain plug for large quantities
of metal particles. These are signs of damage or extreme wear
in the axle. Clean the drain plug and replace it after the lube
has drained completely. Inspect breather for clogging or corrosion. Clean or replace as necessary.
Fill
Front Axle
a. With vehicle on level ground, remove the filler hole
plug from the axle housing cover and fill the axle
with approved lubricant until level with the bottom of
the hole.
Note: Lube fill capacities (see chart) are basic guidelines and
will vary based on the angle the axle is installed in a particular chassis. Torque fill plug to 40–60 lbs. ft.
(54–82 N•m).
TIP: The axle can be filled through the axle housing breather
hole. Fill until lube level is even with the bottom of filler hole in
axle housing rear cover.
1 - With axle on level surface, fill housing with oil to bottom
of plug
2 - Temperature sensor mounting hole
Rear Axle
a. Remove the fill
cover and fill the axle with the approved lubricant
until level with the bottom of the hole.
b. If wheel ends were removed, follow instructions in
wheel end servicing page 40.
Correct lube level at bottom of filler hole.
Always use the filler hole as the final reference. If lube is level
with the bottom of the hole, the axle is properly filled.
er hole plug from the axle housing
80
Wheel End Seal
Wheel End Seal - Parts Exploded View
Wheel End Seal
1
1 - Installation tool
2 - Seal
3 - Rear hub
2
3
81
Wheel End Seal
Disassemble and Overhaul Wheel End Seal
WARNING
Never work under a vehicle supported by only a jack.
Always support vehicle with stands. Block the wheels and
make sure the vehicle will not roll before releasing the
brakes.
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.
IMPORTANT
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.
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.
Note: Deep gouges can be repaired by filling gouge with hard-
ening gasket cement and smoothing with emer
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.
IMPORTANT
Always use the seal installation tool specified by the seal
manufacturer. Using an improper tool can distort or damage
the seal and cause premature seal failure.
y cloth.
82
Wheel End Seal
Verify Wheel End-play Procedure
Verify that end-play meets specification using a dial indicator.
An indicator with 0.001" (0.03 mm) resolution is required.
Wheel end play is the free movement of the tire and wheel
assembly along the spindle axis.
Correct end-play is 0.001"– 0.005" (0.025– 0.125 mm).
4. Attach a dial indicator with its magnetic base to the
hub or brake drum as shown below:
5. Adjust the dial indicator so that its plunger or pointer
is against the end of the spindle with its line of action
approximately parallel to the axis of the spindle.
6. Grasp the wheel assembly at the 3 o’clock and 9
o’clock positions. Push the wheel assembly in and
out while oscillating it to seat the bearings. Read
bearing end-play as the total indicator movement.
CAUTION
If end-play is not within specification, readjustment is
required.
Adjust End-play with Tire and Wheel Assembly
Adjust End-play wi
th Wheel Hub
With indicator mounted at bottom,
Push / Pull at sides of drum
Readjust Wheel End-play Procedure
Excessive End-play—If end-play is greater than 0.005"
(.127 mm), remove the outer nut and pull the lock washer
away from the inner nut, but not off the spindle. Tighten the
inner nut to the next alignment hole of the dowel-type washer
(if used). Reassemble the washer and re-torque the outer nut.
Verify end-play with a dial indicator.
Wheel End Seal
Insufficient End-play— If end-play is not present, remove the
outer nut and pull the lock washer away from the inner nut,
but not off the spindle. Loosen the inner nut to the next
adjustment hole of the dowel-type washer (if used). Reassemble the washer and re-torque the outer nut. Verify end-play
with a dial indicator.
Fine Tuning the End-play— If, after performing the readjustment procedures, end-play is still n
0.005" (0.025 – 0.127 mm) range, disassemble and inspect
the components. If parts are found to be defective, replace the
defective parts, reassemble and repeat wheel bearing adjustment procedure. Verify end-play with a dial indicator.
ot within the 0.001" –
83
Lubricate Wheel End
Wheel End Seal
IMPORTANT
Before operating the axle, the wheel hub cavities and bear-
ings must be lubricated to prevent failure.
When wheel ends are serviced, follow Dana’s wheel end lubrication procedure before operating the axle.
Dana axles may be equipped with either of two wheel end
designs:
• Wheel ends with an oil fill hole.
• Wheel ends without an oil fill hole.
Wheel Ends with an Oil Fill Hole
7. Rotate the wheel end hub until the oil fill hole is up.
8. Remove the oil fill plug.
9. Pour 1/2 pint of axle sump lubricant into each hub
through the wheel end fill hole.
10. Install oil fill plug and tighten to specified torque.
Wheel End with Oil Fill Hole
1
2
Wheel End without Oil Fill Hole
1—Wheel end oil fill hole
2—Proper lubricant level
3—Lubricant flow from sump
3
84
Proper Vehicle Towing
Proper Vehicle Towing
Without Wheel Differential Lock
Lift the drive wheels completely off of the ground or damage
will occur.
WARNING
Do not lift the front wheels (non-drive wheels). This alters
the oil’s position in the drive axle, draining it away from the
drive pinion and its bearings. If the pinion is rotated under
these conditions for any period of time, bearings will overheat
resulting in axle damage or failure.
If this is impossible to lift the drive wheels, remove all axle
shafts to prevent gear rotation and cap the wheel hubs to prevent
loss of lubricant and a possible road hazard. See the following
section Proper Vehicle Towing with Wheel Differential
Lock for removal procedure.
Proper Vehicle Towing
85
Theory of Operation
Power Divider Operation (Power Flow and Torque Distribution)
In operation, the power divider accepts torque from the
vehicle driveline and distributes it equally to the two axles.
This assembly is of the two-gear design consisting of an
input shaft, inter-axle differential, output shaft and two constant-mesh helical gears.
With Lockout Engaged
(Inter-Axle Differential is Operating)
5
The inter-axle differential compensates for minor variations
in speed between the two axles, the same way the wheel
differential works between the two wheels of a single drive
axle. This unit also acts as a central point in distribution of
torque to the two axles.
The power divider also includes a driver-controlled, airoperated lockout. When lockout is engaged, it mechanically
prevents inter-axle differentiation for better performance
under poor traction conditions.
1
2
3
1 - Input torque
2 - Lockout disengaged
3 - Forward axle torque is transmitted from the helical side
gear through the pinion helical gear, drive pinion, ring gear,
wheel differential and axle shafts.
86
4
4 - Rear axle torque is transmitted from the output shaft side
gear through the output shaft, inter-axle driveline, drive
pinion, ring gear, wheel differential and axle shafts.
5 - Input torque (power flow) from the vehicle driveline is
transmitted to the input shaft and the inter-axle differential
spider. The differential distributes torque equally to both axles.
Theory of Operation
With Lockout Engaged
(Inter-Axle Differential is Not Operating)
Lockout should only be engaged when both axles are rotating at the same speed. Operation should be limited to lowtraction situations and should be disengaged when normal
traction returns. Failure to do so will result in poor handling
and damage to the axle components.
5
Note: Varied road surface conditions can result in unequal
torque distribution between the two axle assemblies.
CAUTIONCAUTION
Prolonged operation with the lockout engaged can damage axle and driveline components.
1
2
3
Theory of Operation
1 - Input torque
2 - Lockout engaged
3 - Forward axle torque is transmitted from the helical side
gear through the pinion helical gear, drive pinion, ring gear,
wheel differential and axle shafts.
4
4 - Rear axle torque is transmitted from the output shaft side
gear through the output shaft, inter-axle driveline, drive
pinion, ring gear, wheel differential and axle shafts.
5 - Input torque (power flow) from the vehicle driveline is
transmitted directly to the helical side gear and the output
shaft. A positive drive is provided to both axles for
maximum traction under adverse road conditions.
87
Theory of Operation
Operate Wheel Differential Assembly
The Dana wheel differential lock is driver-controlled and operated by a carrier mounted air-actuated shift unit. In operation,
it positively locks the wheel differential to provide improved
traction under adverse road conditions.
Control Systems for Differential Lock
Two systems may be used to control the differential lock
operation.
Transmission Low-Range Interlock Control System
The wheel differential is locked manually with the transmission in Low-Range. It is unlocked by the driver or unlocked
when the transmission is shifted out of Low-Range.
Note: The interlock system is preferred for vehicles equipped
with an air-shifted, Low-Range transmission. It is
designed to ensure the differential lock is not left
engaged (and to prevent accidental engagement) when
transmission is in high range.
Direct Driver-controlled System
Direct Driver-controlled System
The driver manually locks and unlocks the wheel differential,
using a cab-mounted electric switch (or air valve). The following description assum
es the system includes a cab-mounted
electric switch and a solenoid valve as shown in the illustration. An air valve may be substituted for these components.
Operation is as follows:
1. With control switch in the “unlock” position, the
wheel differential functions normally.
2. When the control switch is placed in the “lock”
position, the air supply solenoid valve opens and air
pressure activates the shift cylinder. The shift fork is
moved to engage the curvic clutches, which, in turn,
lock the wheel differential.
3. When the control switch is placed in the “unlock”
position, air pressure supply to the shift cylinder is
shut off and air pressure is released from the cylinder. A compression spring moves the shift fork to
disengage the curvic clutch and unlock the wheel
differential.
12
11
10
9
1— Cab-mounted control valve (plunger in—valve open)
2— Dry air supply tank 80–120 PSI
3— Preferably equal in length
4— Power supply
5— Fuse or circuit breaker
6— Indicator light or audible signal
7— Wheel differential lock indicator switch (part of axle
assembly)
8— Rear axle wheel differential lock air shift cylinder (part
of axle assembly)
13
1
2
14
5
3
4
6
7
8
9— Forward rear axle wheel differential lock air shift cylinder
(part of axle assembly)
10— Wheel differential lock in dicator switch (part of axle
assembly)
11— Indicator light of audible signal
12— Fuse or circuit breaker
13— Power supply
14— 66468 Quick release valve (optional) located on frame
rail and within 10 feet of tubing from control valve
88
Wheel Differential Lock
Theory of Operation
The Dana Wheel Differential Lock is an optional feature for
Dana Axles. In operation, it positively locks the wheel differential, to provide improved traction under adverse road conditions.
The differential lock is driver-controlled through an electric
switch or air valve mounted in the cab. The locking mechanism is air-operated to engage a mechanical clutch and lock
the wheel differential. It is spring-operated to disengage the
lock and permit the wheel differential to function normally.
The wheel differential lock consists of three major assemblies.
1
1a
1b
• Shift Cylinder Assembly: Operates a shift fork and
push rod assembly.
• Shift Fork and Push Rod Assembly: Engages and
disengages the differential lock curvic clutch assembly
• Curvic Clutch Assembly: Consists of a sliding clutch
splined to a axle
shaft and a fixed clutch which is
splined to the differential case hub.
The differential lock also includes a selector switch (electric)
which senses clutch engagement and sends an electrical signal to a cab mounted indicator light (or an audible signal
device).
Theory of Operation
3
1— Curvic clutch assembly
1a—Sliding clutch
1b—Fixed clutch
2— Shift fork and push rod assembly
2a—Shift fork
2b—Pushrod
3— Shift cylinder assembly
3a—Piston driver
3b—Selector switch
2a
2b
3a
2
3b
89
Theory of Operation
Differential Lock Engaged
Air pressure applied to the shift cylinder moves the piston,
push rod, shift fork and the sliding curvic clutch engages the
fixed curvic clutch.
The sliding clutch is splined to the axle shaft. The fixed clutch
is splined to the differential case hub. Engaging the two
clutches locks the wheel differential thus preventing wheel
differential action.
Differential Lock Disengaged
When air pressure at the shift cylinder is released, a compression spring (mounted on the push rod) moves the push rod,
shift fork and sliding clutch as an assembly. The sliding clutch
moves out of engagement with the fixed clutch. The wheel differential is unlocked and operates normally.
2
1
3
4
5
6
7
Differential Lock Engagement Indicator
Differential lock engagement is detected by a switch (electric)
mounted on the differential carrier. An actuator, mounted in
the piston cover, operates the switch.
When the shift fork moves to engage the differential lock, the
push rod actuator moves away from the switch, allows the
switch to close and send an electrical signal to turn on a cabmounted indicator light (or an audible signal).
When the shift fork moves to disengage the differential lock,
the compression spring also moves the push rod actuator to
contact the switch. The switch is opened and turns off the
cab-mounted indicator light (or the audible signal).
2
1
3
4
5
6
7
8
9
Differential Lock Engaged
1— Spring is compressed
2— Shift fork
3— Push rod
4— Selector switch
5— Piston
6— Shift cylinder
7— Air pressure applied engages clutches
8— Fixed clutch splined to differential case
9— Sliding clutch splined to axle shaft
90
8
9
Differential Lock Disengaged
1— Spring is decompressed
2— Shift fork
3— Push rod
4— Selector switch
5— Piston
6— Shift cylinder
7— Air pressure applied disengages clutches
8— Fixed clutch splined to differential case
9— Sliding clutch splined to axle shaft
Power Divider - Forward
Parts Exploded View
Parts Identification
1 2
1 0
9
2 42 1
3 6
2 5
37
2 6
Parts Identification
2 7
1 5
3
1 6
1 7
28
2 9
5
3 0
1 8
7
2 0
3 2
2 2
8
3 3
3 4 3 5
6
1 9
2 3
3 1
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
91
Front Drive Axle
Parts Exploded View
Parts Identification
4
12
5
1
2
3
6
13
14
15
7
8
22
9
10
11
16
1— Flange half bearing adjuster
2— Flange half bearing cup
3— Flange half bearing cone
4— Flange half carrier cap
5— Flange half differential case
6— Nut
7— Ring gear
8— Side gear thrust washer
9— Side gear
10— Wheel differential spider
11— Side pinion
12— Side pinion thrust washer
24
17
20
19
18
25
26
27
28
29
13— Carrier cap bolt
14— Lock washer
15— Plain half carrier cap
16— Side gear
17— Side gear thrust washer
18— Plain half differential case
19— Plain half bearing cone
20— Plain half bearing cup
21— Plain half bearing adjuster
22— D-head carrier or front carrier
23— Dowel
24— Pinion pilot bearing
21
30
23
32
33
34
35
31
25— Pinion
26— Inner pinion bearing cone
27— Pinion bearing spacer
28— Inner pinion bearing cup
29— Pinion cage shim
30— Pinion cage
31— Outer pinion bearing cup
32— Outer pinion bearing cone
33— Helical gear
34— Pinion roll pin
35— Pinion
nut
92
Wheel Differential Lock Assembly
Parts Exploded View
Parts Identification
1
2
3
4
1— Fixed curvic clutch gear
2— Snap ring
3— Curvic clutch gear
4— Spring pin
5— Shift fork
6— Compression spring
5
16
7— Push rod
8— Piston driver
9— Set screw
10— Piston
11— O-ring
12— Switch
17
15
14
13
12
11
10
6
7
8
9
13— Plastic washer
14— Piston cover
15— Cap screw- flange head
16— Cap screw- manual engagement
17— Gasket
Parts Identification
93
Parts Exploded View
Parts Identification
31
30
29
28
19
20B
27
20A
22
17
26
25
18
21
23
32
24
16
15
14
11
9
10
8
7
6
5
4
3
13
12
1 - Pinion Nut
2 - End Yoke and Slinger
3 - Oil Seal
4 - Outer Pinion Bearing Cone
5 - Outer Pinion Bearing Cup
6 - Pinion Spacer
7 - Inner Pinion Bearing Cup
8 - Inner Pinion Bearing Cone
9 - Drive Pinion
10 - Carrier Housing
11 - Diff Case Dowels
12 - Ring Gear
13 - Ring Gear Bolts
14 - Flange Half Bearing Cone
15 - Flange Half Bearing Cup
2
1
16 - Flange Half Bearing Adjuster
17 - Side Pinion Thrust Washer
18 - Side Pinion
19 - Side Gear
20 - A, B - Differential Shaft
21 - Pin
22 - Capscrew
23 - Flat Washer
24 - Flange Half Cap
25 - Plain Half Cap
26 - Cotter Pin
27 - Side Gear Thrust Washer
28 - Plain Half Diff Case
29 - Plain Half Bearing Cone
30 - Plain Half Bearing Cup
31 - Plain Half Bearing Adjuster
32 - Pipe Plug
94
Housing and Output Shaft Assembly
Parts Exploded View
1
2
Parts Identification
3
4
5
6
7
8
1— Output shaft nut
2— Output yoke
3— Output seal
4— Snap ring
5— Outer bearing cup
6— Outer bearing cone
7— Inner bearing cone
8— Inner bearing cup
19
20
21
22
9— Output shaft
10— Axle housing
11— Breather hose
12— Breather
13— Lock washer
14— Carriage cap screw
15— Nut
16— Lock washer
23
9
10
18
17— Stud
18— Drain plug
19— Spindle nut
20— Locking ring
21— Jam nut
22— Axle shaft
23— Fill plug
17
16
15
11
12
13
14
Parts Identification
95
Parts Identification
Fastener Torque Specifications
Forward Carrier
Power Divider Class Size Tool lbs. ft. N•m
Diff. lock cover to carrier 8.8 M10 X 1.5 13 mm 28-35 38-47
Diff. lock switch 8.8 M12 X 1.5 10-12 14-16
IAD lock cover cap screw 8.8 M10 X 1.5 13 mm 28-35 38-47
Input bearing cage cap screw 10.9 M14 X 2 21 mm 114-140 155-190
Input shaft nut M42 X 1.5 55 mm 840-1020 1140-1383
Power divider cover cap screw 10.9 M14 X 2 21 mm 114-140 155-190
Diff and Gearing
Front pinion helical nut Grade 8 M42 X 1.5 65 mm 840-1020* 1140-1383*
Output shaft nut M39 X 1.5 55 mm 680-832 920-1130
Rear pinion nut 8.8 M36 X 1.5 55 mm 575-703 780-953
Ring gear nut with bolt 126219 12 M16 X 1.5 24 mm 215-255 292-346
Wheel diff. case cap screw 10.9 M14 X 2 16 mm12 pt 114-140 155-190
Carrier
Carrier to housing cap screw 12.9 M16 X 2 24 mm 230-270 312-366
Carrier to housing nut 12 M 16 X 1.5 24 mm 199-244 270-331
Differential bearing cap screw 12.9 M20 X 2.5 30 mm 350-428 475-580
Thrust bolt jam nut 4 M24 X 2 36 mm 148-181 201-245
Housing
Axle cover cap screw 12.9 M12 X 1.75 18 mm 85-103 115-140
.500-20 11/16 55-71 75-96
Axle shaft to wheel hub nuts .625-18 15/16 170-190 230-258
.750-16 1 1/8 285-345 386-468
Breather fitting - u-tube design .375-18 .750 Hex 20-26 27-35
Magnetic plug (fill) NPSF 1 X 11.5 13/16 40-60 54-81
Oil drain plug NPTF .750-14 1/2 Drive 40-60 54-81
Temperature sender/plug 40-60 54-81
Note: Fasteners using self-locking thread “patches” may be reused if not damaged, but should be secured by a few drops of
Loctite #277 on threaded surface. Reused fasteners should be wiped clean of excess oil, special cleaning not required.
* Torque nut to 840 lb-ft. (1140 N•m), then continue tightening to align nut slot with nearest hole in pinion shank.
Correct torque values are extremely important to assure long Dana life and dependable performance. Under-tightening of parts
is just as harmful as over-tightening.
Exact compliance with recommended torque values will assure the best results.
The data includes class and torque tightening values.
96
Parts Identification
Torque Chart
Rear Carrier
Location Thread Size Class/Grade Torque Specification
Pinion End Nut M36 x 1.5 10.9 625-1040 lbs. ft. (848-1410 N•m)
Ring Gear to Diff Case Cap Screw M20 x 1.5 10.9 435-465 lbs. ft. (589-630 N•m)
Carrier Cap Screw M20 x 2 10.9 330-360 lbs. ft. (447-488 N•m)
Fill Plug 1 x 1.11.5 – 40-60 lbs. ft. (54-81 N•m)
Carrier to Housing Cap Screw M14 x 2 10.9 142-158 lbs. ft. (193-214 N•m)
Parking Brake Cap Screws M16 x 1.5 10.9 180-220 lbs. ft. (244-298 N•m)
Parts Identification
97
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