Spicer® Tandem Drive Axles
Service Manual
Spicer® Tandem Drive Axles
AXSM-1951
September 1997
S400-S
TABLE OF CONTENTS
Axle Identification.................................................................. 1
Model Identification Numbering System ......................... 2
Gear Set Identification ......................................................... 2
Axle Lubricant Recommendations...................................... 3
General Precautions .............................................................. 4
Components
Power Divider ............................................................... 5
Forward Rear ................................................................ 6
Rear Rear....................................................................... 7
Removal of Differential Carrier from Axle Housing ........ 8
Removal of Differential from Carrier ................................. 9
Disassembly
Inter-axle Differential.................................................. 10
Output Shaft ................................................................ 12
Differential .................................................................... 13
Pinion ............................................................................. 14
Cleaning and Inspection ...................................................... 15
Assembly
Pinion ............................................................................. 16
Differential .................................................................... 19
Assembly
Differential Installation ......................................................... 23
Ring Gear and Tooth Contact Pattern .............................. 24
Installation of Inter-axle Differential Into Carrier ........... 25
Yoke Removal and Seal Replacement ................................ 25
Shift Cylinder Service ........................................................... 26
Installation of Differential Carrier Into Axle Housing .... 27
Axle/Torque Specifications.................................................. 28
Recommended Service Tools .............................................. 29
(Continued)
Output Shaft ................................................................ 20
Inter-axle Differential.................................................. 21
GENUINE SPICER SERVICE PARTS
Should an axle assembly require replacement component
parts, it is recommended that Spicer Heavy Axle Service
Parts be used. Spicer Heavy Axle Service Parts are
manufactured under the same rigid specification as are
original equipment axle components. This assures the
customer who uses genuine Spicer service parts, maximum reliability for a Spicer Heavy Axle assembly. They
may be obtained through your vehicle manufacturer.
The use of non-original Spicer service parts may cause
premature component failure and may void the warranty.
The items included in this book are currently being
offered as service parts at the time of printing. The part
numbers and illustrations are provided specifically for
reference purposes only. Therefore, Spicer reserves the
right to update this manual without notice or liability.
i
All axle assemblies are identified with two tags. One
located on the differential carrier, and the other located
on the right hand side of the axle housing.
The differential carrier tag contains the following: Dana
part number, julian date code, and ratio. Optional items
include customer part number, line set number, and the
last six digits of the vehicle serial number.
The axle assembly tag contains the following items:
Dana part number, julian date code, axle model, and
ratio. Optional items include customer part number, line
set number, and the last six digits of the vehicle serial
number.
MODEL YEARMODEL YEAR
MODEL YEAR
MODEL YEARMODEL YEAR
DD
ANA PANA P
D
ANA P
DD
ANA PANA P
NUMBERNUMBER
NUMBER
NUMBERNUMBER
ARAR
AR
ARAR
AXLE IDENTIFICATION
TT
T
TT
JULIAN DJULIAN D
JULIAN D
JULIAN DJULIAN D
99
9
99
CUSCUS
CUS
CUSCUS
PP
ARAR
T NUMBERT NUMBER
P
AR
T NUMBER
PP
ARAR
T NUMBERT NUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
7 17 1
7 1
7 17 1
TT
OMEROMER
T
OMER
TT
OMEROMER
AA
TE CODETE CODE
A
TE CODE
AA
TE CODETE CODE
77
00
7
0
77
00
DD
AA
D
A
DD
AA
Y OF YEARY OF YEAR
Y OF YEAR
Y OF YEARY OF YEAR
DD
ANA PANA P
D
ANA P
DD
ANA PANA P
NUMBERNUMBER
NUMBER
NUMBERNUMBER
ARAR
AR
ARAR
TT
T
TT
CUSCUS
TT
OMEROMER
CUS
T
OMER
CUSCUS
TT
OMEROMER
PP
ARAR
T NUMBERT NUMBER
P
AR
T NUMBER
PP
ARAR
T NUMBERT NUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
MODELMODEL
MODEL
MODELMODEL
Carrier TCarrier T
Carrier T
Carrier TCarrier T
LASLAS
T SIX DIGITS OFT SIX DIGITS OF
LAS
T SIX DIGITS OF
LASLAS
T SIX DIGITS OFT SIX DIGITS OF
VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER
VEHICLE SERIAL NUMBER
VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
agag
ag
agag
LINE SETLINE SET
LINE SET
LINE SETLINE SET
NUMBERNUMBER
NUMBER
NUMBERNUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
JULIAN DJULIAN D
JULIAN D
JULIAN DJULIAN D
CODECODE
CODE
CODECODE
AA
TETE
A
TE
AA
TETE
Axle AAxle A
ssemblssembl
Axle A
ssembl
Axle AAxle A
ssemblssembl
LASLAS
T SIX DIGITS OFT SIX DIGITS OF
LAS
T SIX DIGITS OF
LASLAS
T SIX DIGITS OFT SIX DIGITS OF
VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER
VEHICLE SERIAL NUMBER
VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
y Ty T
y T
y Ty T
agag
ag
agag
LINE SETLINE SET
LINE SET
LINE SETLINE SET
NUMBERNUMBER
NUMBER
NUMBERNUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
JULIAN DJULIAN D
JULIAN D
JULIAN DJULIAN D
CODECODE
CODE
CODECODE
AA
TETE
A
TE
AA
TETE
1
MODEL IDENTIFICATION NUMBERING SYSTEM
S 400 S N
FF
amilamil
yy
F
amil
y
FF
amilamil
yy
(S = Spicer)(S = Spicer)
(S = Spicer)
(S = Spicer)(S = Spicer)
Nominal LoadNominal Load
Nominal Load
Nominal LoadNominal Load
CarrCarr
ying Capacitying Capacit
Carr
ying Capacit
CarrCarr
ying Capacitying Capacit
(400 = 40,000 Lbs.)(400 = 40,000 Lbs.)
(400 = 40,000 Lbs.)
(400 = 40,000 Lbs.)(400 = 40,000 Lbs.)
yy
y
yy
Gearing TGearing T
Gearing T
Gearing TGearing T
(S = Single R(S = Single R
(S = Single R
(S = Single R(S = Single R
ypeype
ype
ypeype
educeduc
educ
educeduc
tion)tion)
tion)
tion)tion)
OpOp
tionstions
Op
tions
OpOp
tionstions
(N = *No-SPIN(N = *No-SPIN
(N = *No-SPIN
(N = *No-SPIN(N = *No-SPIN
* No-SPIN® is a registered trademark of Tractech
® ®
®
® ®
DifferDiffer
Differ
DifferDiffer
ential)ential)
ential)
ential)ential)
GEAR SET IDENTIFICATION
Manufacturer's Date- Date gear set was made.
Spicer Trademark- Company logo and location of
manufacturing facility.
Part number of pinion- 390GP100 (TYPICAL)
Tooth Combination(i.e. 41-11)- Indicates the pinion
has 11 teeth and the ring gear has 41 teeth which
results in a 3:73:1 ratio.
Matched Set Number- Spicer ring gears and pinions
are manufactured as matched sets. Both ring gear and
pinion are marked with a corresponding number (i.e.
260), which identifies them as a matched set.
A gear set that does not have the same match set
numbers should not be run together. If either ring gear
or pinion require replacement, a new matched set must
be used.
41-11
TOOTH
COMBINATION
TRADEMARK
PART
NUMBER
SPICER
HEAT
CODE
SPICER
TRADEMARK
PINION ETCH
+15
260
MFG.
DATE
BACKLASH ETCH
MATCHED
SET NUMBER
L10
260
Backlash etch- Indicates backlash setting for assembly.
2
AXLE LUBRICANT RECOMMENDATIONS
To ensure proper lubrication and operating temperature,
correct lubricants and lubricant levels must be obtained.
RECOMMENDED LUBRICANTS
Petroleum based or synthetic based hypoid gear lubricants that meet or exceed military specification MIL-L2105D, and API service classification GL-5, are the
minimum requirements for use in Spicer Medium and
Heavy Duty Drive Axles.
The table below indicates which SAE viscosities are
recommended for various temperature ranges the vehicle
will encounter.
AMBIENT AIR TEMPERATURE
SERVICE
Recommended lubricant change intervals are dependent
on the application and operating environment. The
following chart should be used to establish proper
change intervals.
APPLICATION
On Highway 100,000 1 Year 250,000 3 Year
* Severe Service
and 50,000 1 Year 100,000 1 Year
On-Off Highway
PETROLEUM BASED SYNTHETIC BASED**
MILES INTERVAL MILES INTERVAL
* Severe service includes any applications operating
at or near maximum GVW or GCW ratings. This
includes normally wet or dusty environment, or
consistent high load and low speed applications.
** Includes Semi-Synthetic blends that meet
MIL-L-2105D specifications.
AFTER OVERHAUL OR CHANGE INTERVALS
Fill the axle assembly to the bottom of housing fill hole
as shown in the illustration below. It is recommended
that following an overhaul, each side of the axle be
jacked up separately to approximately six inches and
held into position for one minute. This procedure will
allow adequate lubricant to flow into the wheel ends and
help eliminate the possibility of premature damage to
wheel bearings and seals. Lower the vehicle to the floor
and allow ten minutes for lube to return to normal level.
Check and refill assembly to bottom of fill hole to
replace the lubricant that was directed into the wheel
ends.
SUBMERSION OR DEEP WATER FORDING
In the event the axle assembly should become submerged in water, particularly if over the vent or breather,
it is recommended that the lubricant be drained to
prevent water damage and/or contamination. The axle
assembly should then be refilled with specified lubricant.
3
NOTE: Lubricant close enough to the bottom of the fill hole to be seen or
touched is not sufficient. Lubricant must be level with the fill hole.
GENERAL PRECAUTIONS
IMPORTANT
IMPORTANT
READ THIS SECTION BEFORE STARTING
ANY SERVICE PROCEDURES
GENERAL AXLE DESCRIPTION
The Spicer tandem rear axle assemblies consist of two
heavy duty, hypoid, single reduction differential carrier
assemblies. The forward axle contains a power divider,
which does exactly what its name implies. It divides
power between the forward rear and rear rear axle
assemblies.
The forward axle receives power through a set of helical
gears within the power divider. The rear rear axle
receives power from the power divider output shaft that
extends through the forward axle housing. The complete
forward axle differential carrier assembly and power
divider can be removed from the axle housing as a unit.
Follow the sections of this manual that cover individual
service needs.
Accordingly, anyone who uses a service procedure or
tool different than shown must first thoroughly satisfy
themselves that their safety, nor the vehicle safety, will
be jeopardized by the service method selected.
END YOKES AND FLANGES
CAUTION: Hammering on end yokes could
damage the bearing bores or misalign yoke lugs and
result in early failures of journal needle bearings or
other driveline components. Serious damage can
also be done internally to the ring and pinion set or
pinion bearings by hammering on external parts. End
yokes or companion flanges should be removed or
installed using the recommended method such as
that described herein.
Safety glasses should be worn
at all times when assembling
or disassembling axles.
SAFTEY PRECAUTIONS
Proper service and repair of vehicle components is
important to the safe and reliable operation of all motor
vehicles. This applies particularly to driving axles such as
the ones described in this manual. The procedures
recommended and described in this manual are tested,
and effective methods for performing service operations.
Follow each procedure closely, making use of both the
text and illustrations. Some of these service procedures
show the use of certain tools designed specifically for
the operation being performed. They are shown as a
preferred means of performing the operation. It is not
practical to anticipate and advise the service trade of all
possible alternative methods, and of all possible hazardous consequences that could result from any particular
method.
CLEANLINESS
Axle components should be steam cleaned prior to
removal from the vehicle. Dirt is abrasive and can cause
premature wear of otherwise serviceable parts. Service
personnel should use a wash tank for thorough cleaning
of parts just prior to reassembly.
CAUTION
BRAKE LININGS CONTAIN NON-ASBESTOS FIBERS
BREATHING BRAKE DUST MAY BE HAZARDOUS TO YOUR HEALTH AND
MAY CAUSE SERIOUS RESPITORY OR OTHER BODILY HARM.
AVOID CREATING DUS T
DO NOT REMOVE BRAKE DRUM WITHOUT PROPER PROTECTIVE EQUIPMENT.
DO NOT WORK ON LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT.
DO NOT REPLACE LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT.
DO NOT ATTEMPT TO SAND, GRIND, CHISEL, FILE, HAMMER OR ALTER BRAKE
LININGS IN ANY MANNER WITHOUT PROPER PROTECTIVE EQUIPMENT.
FOLLOW 0.S.H.A. STANDARDS FOR PROPER PROTECTIVE DEVICES TO BE USED
WHEN WORKING WITH BRAKE MATERIALS.
4
POWER DIVIDER COMPONENTS
Flange Hex Bolt
(160-180 Lb-Ft)
(217-244 N-m)
Fill Plug (35- 45 Lb-Ft)
Magnetic Drain Plug
(35- 45 Lb-Ft)
(47-61 N-m)
Lube Retainer
Hex Bolt (20-25 Lb-Ft)
(27-34 N-m)
Compression Spring
(47-61 N-m)
Inter-axle Differential Case
Inter-axle Differential Bearing Cup
Inter-axle Differential Bearing Cone
Inter-axle Differential Side Gear
Washer
Shift Fork
Inter-axle Differential Assembly
Helical Drive Gear
Needle Bearing
Needle Thrust
Bearing Assembly
Input Shaft
Clutch Collar
Input Bearing Cone
Input Bearing Cup
Input Shaft Bearing
Shim (Selective)
Input Shaft
Bearing Retainer
Input Oil Seal
Yoke Spacer
Shift Shaft
Piston Assembly
Shift Cover O-ring
Shift Cover
Washer
Shift Cover Bolt
(15 - 20 Lb-Ft)
(20-27 N-m)
5
Input Shaft Bearing
Retainer Bolt
(100-120 Lb-Ft)
(136-163 N-m)
Input Yoke Assembly
Flanged Hex Nut
(900-1,200 Lb-Ft)
(1,220-1,627 N-m)
FORWARD REAR COMPONENTS
Flanged Hex Nut
(900-1,200 Lb-Ft)
(1,220-1,627 N-m)
Output Yoke Assembly
Output Oil Seal
Beveled Retaining Ring
Output Shaft Bearing
Output Shaft
Fill Plug
(35-45 Lb-Ft)
(47-61 N-m)
Temperature Sensor Plug
(35-45 Lb-Ft)
(47-61 N-m)
Vent Plug
Axle Shaft
( Roadside )
Differential Side Bearing Cap
Axle Housing
Dowel Pin
Differential Gear
Thrust Washer
Differential
Bearing Cap Bolt
(295-340 Lb-Ft)
(400-461 N-m)
Flat Washer
Adjusting
RingLock
Adjusting Ring Lock Bolt
(30-40 Lb-Ft)
(41-54 N-m)
Magnetic
Drain Plug
(35-45 Lb-Ft)
(47-61 N-m)
Differential Case Flange Half
Flat Washer
Nut
(300-320 Lb-Ft)
(407-434 N-m)
Differential
Bearing Cone
Differential
Bearing Cup
Adjusting Ring
Ring Gear Bolt
Ring Gear
Inner Pinion Bearing Cone
Inner PinionBearing Cup
Pinion Bearing Spacer
(selective)
Differential Case Bolt
(180-200 Lb-Ft)
(244-271 N-m)
Differential Case Cap Half
Differential Side Gear
Differential Cross Shaft
Differential Pinion Mate
Differential Pinion Mate
Thrust Washer
Hex Bolt (150 Max. Lb-Ft)
(203 Max. N-m)
Pinion Pilot Bearing Cap
Pinion Pilot Bearing
Pinion
Dowel Pin
Outer Pinion
Bearing Cup
Axle Shaft
( Curbside )
Carrier Housing
6
Carrier Mounting Bolt
(240-260 Lb-Ft)
(325-353 N-m)
Outer Pinion Bearing Cone
Helical Driven Gear
Flanged Hex Nut
(900- 1200 Lb-Ft)
(1,220-1,627 N-m)
Housing
REAR REAR COMPONENTS
Temperature Sensor Plug
Differential
Bearing Cap Bolt
(295-340 Lb-Ft)
(400-461 N-m)
Differential Bearing
Cap Washer
Adjusting
Ring Lock
Adjusting Ring Lock Bolt
(30-40 Lb-Ft)
(41-54 N-m)
Differntial Pinion Mate Thrust Washer
Differential
Bearing Cone
Fill Plug
(35-45 Lb-Ft)
(47-61 N-m)
(35-45 Lb-Ft)
(47-61 N-m)
Differential Pinion Mate
Differential Cross Shaft
Differential Side Gear
Differential Case
Cap Half
Differential Bearing Cup
Adjusting Ring
Vent Plug
Magnetic Drain Plug
(35-45 Lb-Ft)
(47-61 N-m)
Differential
Gear Thrust Washer
Differential Case Bolt
(180-200 Lb-Ft)
(244-271 N-m)
Hex Bolt
(150 Max. Lb-Ft)
(203 Max. N-m)
Pinion Pilot
Bearing Cap
Dowel Pin
Ring Gear
Ring Gear Bolt
Pinion Pilot Bearing
Pinion
Axle Shaft
( Roadside )
Differential Bearing Cap
Nut
(300-320 Lb-Ft)
(407-434 N-m)
Ring Gear
Flat Washer
Differential Case Flange Half
Inner PinionBearing Cone
Inner Pinion Bearing Cup
Axle Shaft
( Curbside )
Carrier Housing
Carrier Mounting Bolt
(240-260 Lb-Ft)
(325-353 N-m)
7
Pinion Bearing
Preload Spacer
(Selective)
Outer Pinion
Bearing Cup
Outer Pinion
Bearing Cone
Pinion Oil Seal
End Yoke Assembly
Flanged Hex Nut
(900-1,200 Lb-Ft)
(1,220-1,627 N-m)
REMOVAL OF DIFFERENTIAL
CARRIERS FROM AXLE HOUSINGS
NOTE: Steam clean axle assembly.
1. Block wheels.
2. Remove axle housing and power divider drain plugs
and drain lubricant.
3. Disconnect drive shaft at the rear U-joint.
NOTE: If end yoke and/or seal is to be replaced,
loosen yoke nut at this time.
4. Match mark each axle shaft flange to its mating
wheel end and remove axle shaft flange nuts.
IMPORTANT: Axle shafts are of different lengths and
should be marked accordingly for proper reassembly.
5. Hold a large brass drift or a brass hammer against
the center of the axle shaft flange. Strike the drift
with sharp blows from a large hammer or sledge
until the axle shaft separates from the hub.
CAUTION: Do not strike the flange directly with
a steel hammer or sledge. This may crack and
splinter material, possibly causing serious or fatal
injury. Do not pry or chisel axle flange away from hub
or damage to sealing surfaces could occur.
10 . Separate differential carrier from the housing using
removal slots. See Figures 1 and 2. Be certaindifferential carrier clears dowel pins and is balanced
properly on jack. Remove top two carrier mounting
bolts, and remove differential carrier assembly from
the axle housing.
Removal slot
Dowel Pin
FF
F
FF
igurigur
igur
igurigur
e 1e 1
e 1
e 1e 1
Power Divider
Drain Plug
Dowel Pin
Removal slot
6. Remove axle shafts. Remember due to different
length axle shafts, each shaft should be marked
to mating wheel end for proper reassembly.
7. Disconnect air line from power divider shift cover on
forward rear assembly.
8. Support the differential carrier assembly on a roller
jack. Secure as necessary to prevent it from
falling off the jack when removed from the housing.
9. Loosen the differential carrier-to-housing
mounting bolts. Remove all bolts except top two.
These two bolts will prevent the carrier assembly
from falling.
IMPORTANT: Thread two guide pins into axle housing
to relieve weight from output shaft bearing assembly
of forward rear during differential carrier removal.
Removal slot
Removal slot
FF
igurigur
e 2e 2
F
igur
e 2
FF
igurigur
e 2e 2
11 . Mount carrier assembly in a suitable rebuild stand.
(Refer to RECOMMENDED SERVICE TOOLS, pgs.
29-30)
Differential Carrier Removal Complete
8
REMOVAL OF DIFFERENTIAL FROM CARRIER
The following service procedures apply for both forward
rear and rear rear axles, unless otherwise noted.
IMPORTANT: If the ring and pinion is to be reused,
ring gear backlash should be checked and recorded
before disassembly. Backlash should be reset to this
specification after completion of repairs. For backlash
specifications refer to DIFFERENTIAL INSTALLATION.
1. Remove adjusting ring bolts and locks from bearing
caps.
2. One differential bearing cap and leg of the carrier is
match marked to aid during reassembly.
See Figure 3.
3. Loosen four bearing cap retaining bolts.
4. Loosen adjusting rings, to relieve bearing preload.
5. Remove four bearing cap retaining bolts and
washers.
FF
F
FF
igurigur
igur
igurigur
e 3e 3
e 3
e 3e 3
6. Remove bearing caps.
7. Remove adjusting rings and bearing cups.
NOTE: If bearings are to be reused, cups must stay
with mated cones. They can not be interchanged.
8. Carefully lift the ring gear and differential subassem-
bly out of carrier.
NOTE: The ring gear side of subassembly must be
tipped up for the ring gear to clear the pinion pilot
bearing cap.
Removal of Differential Complete
9
INTER-AXLE DIFFERENTIAL DISASSEMBLY
Fill Plug
(35-45 Lb-Ft)
(47-61 N-m)
Bolt
(160-180 Lb-Ft)
(217-244 N-m)
Drain Plug
(35-45 Lb-Ft)
(47-61 N-m)
Lube Retainer
Inter-axle Differential Case
Bearing Cup
Bearing Cone
Inter-axle Differential Side Gear
Inter-axle Differential Assembly
Helical Drive Gear
Needle Bearing
Washer
Bolt
(20-25 Lb-Ft)
(27-34 N-m)
Shift Fork
Needle Bearing
Thrust Washer Assembly
Input Shaft
Clutch Collar
Bearing Cone
Bearing Cup
Shim (Selective)
Input Shaft
Bearing Retainer
Spring
Shift Shaft
Piston Assembly
Shift Cover O-ring
Shift Cover
1. Remove intermediate case to carrier bolts. Use
removal slots to seperate inter-axle differential
case from carrier. See Figure 4.
2. With inter-axle differential assembly removed,
remove four bolts and washers of shift cylinder.
3. Remove shift cylinder cap and piston.
NOTE: It may be necessary to tap piston lightly with
soft mallet to remove.
4. Remove shift cylinder shaft.
5. Remove flanged hex nut.
Washer
Shift Cover Bolt
(15 - 20 Lb-Ft)
(20-27 N-m)
Spacer
Removal slot
Bolt
(100-120 Lb-Ft)
(136-163 N-m)
Input Yoke Assembly
Flanged Hex Nut
(900-1,200 Lb-Ft)
(1,220-1,627 N-m)
FF
igurigur
e 4e 4
F
igur
e 4
FF
igurigur
e 4e 4
Seal
Removal slot
10
INTER-AXLE DIFFERENTIAL DISASSEMBLY
NOTE: Use of a torque multiplier is recommended as
torque specification on input flanged hex nut is 9001,200 Lb-Ft (1,220-1,627 N-m). (Refer to RECOMMENDED SERVICE TOOLS, pgs. 29-30)
6. Remove input yoke using a suitable puller.
See Figure 5.
Yoke
Remover
8. Remove input oil seal
9. Press out input shaft bearing cup from bearing
retainer. Retain shims for possible use during
reassembly. Early models were not a press fit.
10 . Remove input shaft assembly. Remove input yoke
spacer from input shaft.
11 . Remove front bearing cone from input shaft using
suitable puller.
12 . Remove clutch collar, shift fork, and spring from
assembly.
13 . Remove needle thrust bearing assembly from top of
drive gear.
14 . Remove drive gear from inter-axle differential case.
15 . Remove two lube retainer bolts.
16 . Remove lube retainer.
FF
igurigur
e 5e 5
F
igur
e 5
FF
igurigur
e 5e 5
7. Remove bolts from input shaft bearing retainer. Use
removal slots (See Figure 6) to seperate bearing
retainer from inter-axle differential case, and remove
retainer.
Removal slot
Removal slot
17. Remove inter-axle differential assembly from case.
18 . Remove rear Diff-gear from inter-axle differential
case.
19 . Remove rear bearing cup from intermediate case.
20. Remove bearing cone from rear differential gearus-
ing a suitable puller.
21 . Clean and inspect all components for excessive
wear, scoring, or cracks. Replace damaged components with original equipment replacement parts
and prepare for reassembly.
Inter-Axle Differential Disassembly Complete
FF
F
FF
igurigur
igur
igurigur
e 6e 6
e 6
e 6e 6
11
OUTPUT SHAFT DISASSEMBLY
Flanged Hex Nut
(900-1,200 Lb-Ft)
(1,220-1,627 N-m)
End Yoke
Output Oil Seal
Beveled Retaining Ring
1. Remove the inter-axle drive shaft.
NOTE: Power divider must be engaged so shaft will
not rotate.
2. Remove output flanged hex nut.
NOTE: Use of torque multiplier is recommended as
torque specification on output nut is 900-1,200 LbFt (1,220-1,627 N-m).
3. Remove output yoke using a suitable puller.
Output Shaft
Housing
Output Shaft Bearing
6. Place output shaft remover adapter into housing
bore.
7. Thread yoke installer service tool onto output shaft.
See Figure 7.
8. Tighten nut on yoke installer to pull output shaft
bearing assembly out of housing.
9. If output shaft bearing is to be replaced, remove old
bearing using a suitable puller or press.
4. Remove oil seal.
5. Remove beveled retaining ring.
Yoke Installer
Service Tool
# DST1007
Output Shaft
Remover Adapter
w/Shoulder Facing Out
FF
igurigur
F
igur
FF
igurigur
NOTE: It is important to place the Output Shaft
Remover Adapter on with the shoulder to the outside.
See Figure 7.
Output Shaft Removal Complete
Housing
Output Shaft
Bearing Assembly
e 7e 7
e 7
e 7e 7
12
Pinion Mate Thrust Washer
Differential Cross Shaft
DIFFERENTIAL DISASSEMBLY
Bearing Cup
Bearing Cone
Bolt
Ring Gear
Flange Half
Differential Case
Flat Washer
Nut
(300-320 Lb-Ft)
(407-434 N-m)
Bearing Cup
Bearing Cone
1. Match mark differential case halves with a punch or
chisel for correct alignment in reassembly. See
Figure 8.
Differential Case Bolt
(180-200 Lb-Ft)
(244-271 N-m)
Plain Half
Differential Case
Differential Gear
Differential Pinion Mate
Gear Thrust Washer
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2. Remove differential case bolts and lift off the
differential case half.
3. Remove thrust washer and differential gear.
4. Lift out cross shaft, pinion mates and pinion mate
thrust washers.
5. Remove second differential gear and thrust washer.
6. If differential bearings are to be replaced, remove
old bearings using a suitable puller. See Figure 9.
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NOTE: Inspect all parts including the machined
surfaces of the case itself.
IMPORTANT: If any gears are to be replaced, they
must be replaced in sets. Inspect thrust washers for
scoring and excessive wear. Replace all worn or
damaged parts.
7. When it is necessary to remove ring gear from
differential case, carefully loosen ring gear nuts with
breaker bar in an alternating pattern and remove.
IMPORTANT: Do not damage ring gear when loosening
ring gear nuts.
8. Inspect ring gear, ring gear bolts, and ring gear bolt
holes for nicks, excessive wear, and irregularities.
13
Differential Disassembly Complete
PINION DISASSEMBLY
1. Remove flanged hex nut.
NOTE: Use of a torque multiplier is recommended.
Torque flanged hex nut to 900-1,200 Lb-Ft (1,2201,627 N-m).
2. Remove end yoke on the rear rear axle using a
suitable puller. Refer to RECOMMENDED
SERVICE TOOLS, pgs. 29-30).
3. Remove the oil seal on the rear rear axle and
discard.
4. Remove the four pinion pilot bearing support bolts.
5. Remove the pinion pilot bearing support.
6. Place carrier in press with threaded end of pinion
Press
face up. See Figure 10 and 10A.
7. Place a wooden block under pinion to avoid damage
of gear teeth during removal.
8. Pinion removal -
• On the Forward Rear, press the pinion through
the helical driven gear and inner and outer
bearing cones. See Figure 10.
• On the Rear Rear, press the pinion through the
inner and outer bearing cones. See Figure 10A.
9. Remove the pinion from the bottom of the carrier.
10 . Remove bearing preload spacer and save for use in
reassembly.
11 . If the gearset is to be reused, remove inner pinion
bearing with a suitable puller at this time. If the
gear set is to be replaced new bearings must be
installed.
Pinion
Wood Block
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Driven Gear
12 . If bearings are to be replaced, press bearing cups
out of carrier casting at this time.
13 . Remove pinion pilot bearing with a suitable puller.
Pinion Disassembly Complete
Press
Pinion
Wood Block
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14
CLEANING AND INSPECTION
CLEANING
1. Parts should be cleaned with emulsion cleaners or
petroleum base cleaning solvent.
NOTE: Alkaline type solutions may cause damage to
machined surfaces and should be avoided.
2. Make sure interior of axle housing is clean prior to
reassembly.
3. Clean all gasket surfaces of old material.
DRYING
Use soft, clean, lintless towels or rags to dry
not
components after cleaning. Bearings should
be
dried by spinning with compressed air. This can
damage mating surfaces due to the lack of lubrication.
After drying, parts should be coated with a light
coat of lubricant or rust inhibitor to prevent damage
from corrosion. If parts are to be stored for a
prolonged period, they should be wrapped in wax
paper.
GEARS
Inspect gears for excessive wear or damage. Replace
gears that are pitted, scored, broken, or worn.
SHAFTS
INSPECTION
Prior to reassembly, inspect parts for signs of
excessive wear or damage. Replacement of these
parts can prevent premature failure and costly
downtime.
BEARINGS
Bearing surfaces should be inspected for pitting,
excessive wear, or overheating.
Inspect shafts for nicks or scoring.
SPLINES
Inspect all splines for excessive wear, distortion from
twisting, and cracking.
HOUSINGS
THRUST WASHERS
Inspect thrust washers for scoring and cracking.
Inspect housing for stripped threads and bending
fatigue.
15
PINION ASSEMBLY
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1. Press inner bearing cone onto pinion. See
Figure 11.
2. Press pinion pilot bearing onto the pinion. See
Figure 12.
NOTE: Alkaline type solutions may cause
damage to machined surfaces and should be avoided.
3. Stake pilot bearing in nine places using a center
punch or equivalent tool. See Figure 13.
4. Press inner and outer bearing cups into the carrier
Feeler Gauge
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Press
Pinion Pilot Bearing
Pinion
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NOTE: Chamfer side of bearing faces the pinion head.
until seated. Use a feeler gauge (.0015 inch) to
make sure that bearing cups are fully seated in
bearing bores. Apply hypoid gear lubricant to both
cup and cone. See Figure 14.
Press
Outer Pinion
Bearing
Wood Block
Bearing Preload Spacer
Pinion
FF
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NOTE: After installing pinion bearing and or helical
gear, pinion shaft should be turned at least 8 rotations
to assure proper alignment of bearing rollers.
33
3
33
16
5. Place carrier housing in press with the pinion
supported by wood block (6"X6"X6"), so the inner
pinion bearing is mated to the cup. See Figure 15.
6. Insert original preload spacer and outer pinion
bearing onto pinion.
7. Press outer pinion bearing onto pinion until
completely seated.
8. On forward rear, press driven gear onto pinion.
See Figure 16.
IMPORTANT: The old style driven gear on the 3.21
and 3.42 ratios will have FRONT stamped on the
face of the gear. This gear must be installed with the
word FRONT facing away from the carrier assembly.
If you do not have this driven gear no special instructions apply to the installation of the gear.
9. On rear rear carrier, inspect end yoke or companion
flange, for grooves in seal surface. If grooves can be
Press
Driven Gear
PINION ASSEMBLY
Yoke Installer
Service Tool
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900-1,200 Lb-Ft (1,220-1,627 N-m).
12 . Install pinion pilot bearing cap. Tighten and torque
four bolts to 150 Lb-Ft (203 N-m).
13 . Measure torque to rotate with an inch-pound torque
wrench. Make eight revolutions, taking a torque
measurement every fourth revolution. It should read
between 10-40 lb-in of bearing preload. See Figure
18 .
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.
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detected with finger-nail, then end yoke must be
repaired with a C/R approved repair sleeve or
replaced.
10 . Use yoke installer service tool and install yoke
without seal. See Figure 17.
11 . Use torque multiplier and torque flanged hex nut to
.001 inch change in preload spacer will change torque to
rotate approximately 30 lb-in.
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PINION ASSEMBLY
NOTE: Individual carriers may vary slighty.
Pinion bearing preload spacers are available in the
following thicknesses:
inch mm inch mm
.718 18.24 .731 18.57
.719 18.26 .732 18.60
.720 18.29 .733 18.62
.721 18.31 .734 18.64
.722 18.34 .735 18.67
.723 18.36 .736 18.69
.724 18.39 .737 18.72
.725 18.41 .738 18.75
.726 18.44 .739 18.77
.727 18.47 .740 18.80
.728 18.49 .741 18.82
.729 18.52 .742 18.85
.730 18.54
Always measure each spacer before assembly to ensure
correct thickness.
NOTE: Closer adjustment can be made by sanding the
next thicker spacer to desired thickness using emery
cloth on a flat surface.
CAUTION: Wash spacer thoroughly of emery cuttings
before installing on pinion.
14 . Repeat process until torque to rotate is between
10-40 lb-in after preload is achieved, remove yoke
and install new seal with proper service tool.
NOTE: Acceptable torque to rotate with seal installed
is 15-45 lb-in.
15 . Install yoke using yoke installer (See RECOM-
MENDED SERVICE TOOLS, pgs. 29-30)
NOTE: Spicer recommends that new flanged hex nuts
be used.
16 . Apply Loctite #680 (green) to threads.
17. Use torque multiplier and torque flanged hex nut to
900-1,200 Lb-ft (1,220-1,627 N-m).
Pinion Assembly Complete
18
Pinion Mate Thrust Washer
Differential Cross Shaft
DIFFERENTIAL ASSEMBLY
Bearing Cup
Bearing Cone
Ring Gear
Bolt
Flange Half
Differential Case
Flat Washer
Nut
(300-320 Lb-Ft)
(407-434 N-m)
Bearing Cup
Bearing Cone
1. If ring gear was removed from the differential case,
reinstall it at this time.
• Clean the differential case and ring gear
mounting surface.
• Position the differential case on a work bench
with the machine surface down.
• Place the ring gear on the case with the
teeth facing up.
• Install bolts into the tooth side of the ring gear
and install the flat washer and nut onto the
differential case side.
NOTE: Bolts have a clearance fit in the differential
case and the ring gear mounting holes. Bolts require
correct torque to ensure proper clamp.
• When all bolts have been installed, tighten
opposite one another until one half the prescribed torque is obtained. 150-160 Lb-Ft
(204-217N-m)
NOTE: Bolt heads must be held flat against ring gear
while torque is being applied.
• Repeat the process to full torque specifications.
300-320 Lb-Ft (407-434 N-m)
Differential Case Bolt
(180-200 Lb-Ft)
(244-271 N-m)
Plain Half
Differential Case
Differential Side Gear
Differential Pinion Mate
Gear Thrust Washer
2. Press bearing cones onto differential case
halves. Place bearing cups on cones during
remainder of assembly to prevent damage of
bearings.
3. Apply a small amount of hypoid axle lubricant to all
mating surfaces. This will aid in assembly by
keeping parts together and providing initial lubrication.
4. Place gear thrust washer and differential side gear in
differential case flange half.
5. Assemble pinion mates and pinion mate thrust
washers onto differential cross shaft. Place assembly into flange half differential case.
6. Place remaining differential side gear and thrust
washer in position on differential pinion mates.
7. Assemble case halves, making sure match marks are
lined up.
8. Install differential case bolts. Tighten alternately
and torque evenly to 180-200 Lb-Ft (244-27N-m).
NOTE: If old bolts are used, coat threads with Loctite
#277 before installing.
Differential Assembly Complete
19
OUTPUT SHAFT ASSEMBLY
Flanged Hex Nut
(900-1,200 Lb-Ft)
(1,220-1,627 N-m)
End Yoke
Output Oil Seal
Beveled Retaining Ring
1. Press new bearing onto shaft using output shaft
bearing installer service tool. See Figure 19.
NOTE: Clean bore of housing to remove old Loctite
and oil.
Bearing Installer
Service Tool
Output Shaft
Housing
Output Shaft Bearing
3. Install output shaft and bearing assembly into
housing using bearing installer service tool withadequate 2 jaw puller. See Figure 20.
4. Seat bearing completely in housing and remove
excess Loctite.
5. Install beveled retaining ring in housing with bevel
facing to the rear of the axle. Be certain the
retainer ring is fully seated. Clean and dry threads
on output shaft.
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2. Apply a thin layer of Loctite #620 to the outside
diameter of the bearing before assembly into
housing.
NOTE: Care must be taken to keep Loctite out of
bearing.
2-Jaw Puller
6. Lubricate bearing with hypoid axle lube.
7. Install oil seal using proper service tools.
8. Install end yoke using yoke installer service tool.
9. Apply Loctite #680 to threads before installing new
flanged hex nut.
10 . Use torque multiplier and torque flanged hex nut to
900-1,200 Lb-Ft (1,220-1,627 N-m).
Output Shaft Installation Complete
Bearing Installer
Service Tool
Housing
F F
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INTER-AXLE DIFFERENTIAL ASSEMBLY
1. Position inter-axle differential case on two 4" x 4"
blocks for reassembly
2. Install new rear differential bearing cup into case.
3. Press new bearing cone onto rear differential gear.
NOTE: Be certain that both cup and cone are seated
properly or false reading on end play of inter-axle may
occur.
4. Apply a light coating of gear lube to rear diff-gear
bearing, hub surface, and interior bore, then install..
5. Lubricate and place inter-axle differential assembly
inside of plastic lube retainer and install into case.
6. Align the bolt holes of the plastic lube retainer with
the case and install the two bolts and washers.
Tighten and torque lube retainer bolts to 20-25
Lb-Ft (27-34 N-m).
7. Press new needle bearing into I.D. of drive gear.
8. Lubricate needle bearing and carefully lower drive
gear into intermediate case until differential gear is
seated in inter-axle differential.
Tap nut lightly with soft hammer.
15 . Position dial indicator onto end of input shaft. See
Figure 21.
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Using suitable pry bar and spacer, pry input shaft
out and record end play.
16 . Proper end play for inter-axle is .001 to .003 inch
(.025 to .076 mm). Subtract .003 inch (.076 mm)
from recorded end play and assemble combination
of shims that total proper thickness to establish
correct end play.
9. Press input shaft front bearing cone onto shaft until
seated completely against shoulder.
10 . Lube the needle thrust bearing lightly and place on
front drive gear. Ensure that thin bearing race is
seated against drive gear and the thrust bearing is
seated between the two spacers.
NOTE: To establish proper end play, input shaft will be
installed into inter-axle differential prior to installing
shift collar, fork , and shift shaft.
11 . Lube and install input shaft, turning slightly to
engage splines.
12 . Install new input shaft front bearing cup into input
shaft bearing retainer without shims.
13 . Install bearing retainer onto intermediate housing
and bolt into place.
14 . Thread input flanged hex nut onto input shaft until
resistance is felt from locking compound.
EXAMPLE:
Measurement with dial indicator. .080in. (2.032 mm)
Preferred end play. .003in. (0.076 mm)
Required shims. .077in. (1.956 mm)
17. Remove input shaft bearing retainer and install shim
pack between bearing retainer and input shaft
bearing cup. Remove input shaft.
18 . Install shift spring into the bottom of the shift well.
19 . Check shift fork for excessive wear. Replace if
necessary.
20. Check clutch collar for wear or damage in groove,
on drive lugs, and splines. Replace if necessary.
21 . Apply a thin coat of grease on the clutch collar
riding surface area of shift fork.
21
INTER-AXLE DIFFERENTIAL ASSEMBLY
22. Assemble the shift collar onto the shift fork with
flat side of collar up. The fork bushing must also
face up. Install the fork and collar into the case and
align the hole of the shift fork over the opening of
the spring.
23. Apply a thin coat of grease to the small diameter of
the shift shaft.
24. Insert shift shaft into cylinder and install through
the shift fork hole and the spring. Make sure shaft is
seated into the bottom of the shift cylinder.
25. Apply a thin coat of grease to the O-ring of the shift
piston.
NOTE: Visually inspect the composite shift piston to
insure the steel spacer is present on the bottom of the
piston. See page 26 for more piston information.
26. Lubricate and place piston/O-ring assembly into
shift cylinder with detailed side facing front for the
composite piston and the flat face on the aluminum
piston. See Figure 27 on page 26. Seat piston
firmly against shift shaft.
32 . Install new oil seal into input shaft bearing retainer.
33. Clean the mating surfaces of the bearing retainer
and the case. Apply a 1/16 in. bead of Loctite
#518 Gasket Eliminator to cover mounting surface
of case and around each bolt hole. See Figure 22.
34. Install bearing retainer and tighten bolts alternately.
Torque bolts 100-120 Lb-Ft (135-163 N-m).
35. Inspect input yoke seal surface for grooves. If
grooves can be detected with fingernail, it must be
®
repaired with a CR SPEEDI-SLEEVE
or replaced.
36. Clean and dry threads on input shaft.
37. Install end yoke using installer service tool.
NOTE: Spicer recommends that new flanged hex nuts
be used.
38. Apply Loctite #680 (green) to threads.
39. Use torque multiplier and torque input flanged hex
nut to 900-1,200 Lb-Ft (1,220-1,627 N-m).
Inter-axle Assembly Complete
27. Install onto the shift cover.
28. Clean the shift cover sealing area and the intermedi-
ate case and apply a 1/16 in. bead of Loctite #518
Gasket Eliminator. See Figure 22.
NOTE: Care must be taken to keep Loctite off of
piston assembly.
29. Install shift cover.
NOTE: If old bolts are used, coat threads with Loctite
#277 before installing.
30. Install four washers and cover bolts. Tighten and
torque bolts alternately to 15-20 Lb-Ft (20-27 Nm) until cover is seated properly.
31 . Lube bearing and bearing journals then Install the
input shaft into the shift collar and lube input shaft
bearing.
Loctite #518
Gasket Eliminator
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22
DIFFERENTIAL INSTALLATION
1. Install ring gear and differential assembly into carrier
housing. Tilt differential slightly so ring gear clears
pinion pilot bearing support.
NOTE: Care should be used when installing ring gear
and differential into carrier housing so damage to ring
gear, pinion, bearings, or bearing bores does not
occur.
2. Differential bearings should be lubricated and
bearing cups should be cleaned and #620 loctite
applied to the O.D. of the bearings.
3. Be sure side bearing cups are seated on bearing
cones. Assemble differential bearing caps with
match marks in proper location. Clean bearing cap
bolts and washers and coat threads with Loctite
#277(red).
4. Install bearing cap bolts and tighten enough to
eliminate visible space between differential bearing
cap and carrier. Do not torque bolts at this time.
6. Loosen adjusting ring on tooth side of ring gear 1
notch and tighten adjusting ring on flange side of
ring gear 1 notch. Repeat process until backlash is
elminated. Tighten adjusting ring on tooth side of
ring gear until the ring gear and pinion backlash
matches the backlash etched on the ring gear. This
adjustment sets both the backlash and the bearing
preload.
7. Check ring gear and pinion backlash in four equally
spaced positions aound the ring gear with a dial
indicator as shown.
Acceptable backlash tolerance is +/- .002" from
backlash etched on ring gear. (See Figure 24.)
NOTE: Differential assembly must be aligned within
bearing bores before preload is applied or damage to
bearings can occur.
5. Install adjusting rings. Tighten both adjusting rings
until end play is eliminated, and there is backlash
between the ring gear and pinion. See Figure 23.
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NOTE: If the backlash tolerance varies more than
.003" (.080mm) between the four positions, remove
the differential and determine the cause.
8. Once the backlash is set, torque the differential
bearing cap bolts to 295-340 Lb-Ft (400-461 Nm). Check backlash after torquing cap bolts.
Differential Installation Complete
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23
RING GEAR AND PINION
TOOTH CONTACT PATTERN
The procedures to the right are to be used to establish
proper gear tooth pattern after assembly of the carrier is
complete.
NOTE: If matched sets are being reused, measure and
record backlash before disassembly, and reas-
STEP 1. Paint 1/4 ring gear with marking compound on
both the drive and coast side.
STEP 2. Rotate ring gear at least one complete
revolution in both directions while load is
being applied.
semble to the same backlash. This will match ring
and pinion gears to the established wear patterns.
TOE
Hand rolled patterns will cover less area than the
gear pattern established by previous service.
HEEL
PROFILE
The GLEASON gear set is identified by a 390GA10 0
series part number. The ORLIKON is identified by a
390GA200 series part number. (See Gear Set Identifi-
cation section.)
DRIVE SIDE
(CONVEX)
ROOT
CORRECT GEAR PATTERNS FOR GLEASON CUT GEARS
TOP LAND
COAST SIDE
(CONCAVE)
LIGHTLY LOADED
HEAVILY LOADED
CORRECT GEAR PATTERNS FOR ORLIKON CUT GEARS
LIGHTLY LOADED
HEAVILY LOADED
NOTE: Tooth contact pattern, on this axle model, can be moved only by adjusting backlash. The contact
pattern can be moved in the direction of heel-to-toe, and toe-to-heel; Depth of the pattern cannot be
adjusted. If an acceptable tooth contact pattern cannot be established within limits of backlash, contact
Spicer Service at 1-800-666-8688.
24
INSTALLATION OF INTER-AXLE DIFFERNETIAL TO CARRIER
1. Thoroughly clean mating face of carrier and apply
an 1/8 inch bead of Loctite #518 Gasket Eliminator. See Figure 19 for correct bead pattern.
2. Align inter-axle differential case with carrier housing
and insert bolts and torque to 160-180 Lb-Ft
(217-244 N-m).
#518 Gasket Eliminator Bead Pattern
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YOKE REMOVAL AND SEAL REPLACEMENT
1. Disconnect drive shaft at the rear U-joint.
2. Remove yoke nut.
NOTE: Use of torque multiplier is recommended as
torque specification on input flanged hex nut is 9001,200 Lb-Ft (1,220-1,627 N-m).
3. Remove end yoke using the yoke remover tool. See
Figure 25.
4. Remove oil seal.
5. Inspect end yoke seal surface for grooves. If grooves
can be detected with fingernail, it should be repaired
®
with a CR SPEEDI-SLEEVE
6. Clean and dry threads on input/ouput shaft or
pinion. Install oil seal using proper tools.
7. Install end yoke using yoke installer. See Figure 17
on page 17.
NOTE: Spicer recommends that new flanged hex nuts
be used.
or replaced.
Yoke Remover
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8. Apply Loctite #680 (green) to threads.
9. Use torque multiplier and torque flanged hex nut to
900-1,200 Lb-Ft (1,220-1,627 N-m).
Yoke Removal and Seal Replacement Complete
25
SHIFT CYLINDER SERVICE
DISASSEMBLY
1. Disconnect air line from power divider.
2. Remove shift cylinder cover bolts and washers.
3. Remove cover and O-ring seal.
4. Pull shift cylinder piston assembly from carrier.
5. Inspect all components for wear.
NOTE: Do not remove shift fork shaft from assembly.
Disassembly Complete
ASSEMBLY
NOTE: Visually inspect the composite shift piston to
insure the steel spacer is present on the bottom of the
piston.
1. Inspect all new components.
2. Lubricate and place piston/O-ring assembly into
shift cylinder with detailed side facing front for the
composite piston and the flat face on the aluminum
piston. See Figure 27. Seat piston firmly against
shift shaft.
Composite Shift Piston AluminumShift Piston
Piston Assembly
Seal, "O"-ring
Shift Cover
Washer
Shift Cover Bolt
(15-20 Lb-Ft)
(20-27 N-m)
Loctite 518
Gasket Eliminator
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3. Clean the shift cover sealing area and the intermedi-
ate case and apply a 1/16 in. bead of Loctite #518
Gasket Eliminator. See Figure 28.
4. Install shift cover and tighten bolts to precribed
torque. 15-20 Lb-Ft(20-27N-m)
Detail Faces Front
(Found on early production models)
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NOTE: Care must be taken to keep Loctite off of
piston assembly.
NOTE: If old bolts are to be used, coat threads with
Loctite #277 before installing.
5. Install washers and cover bolts. Tighten bolts
alternately to 15-20 Lb-Ft (20-27 N-m) until
shift cover is seated properly.
6. Connect air line to power divider.
26
Assembly Complete
INSTALLATION OF DIFFERENTIAL
CARRIER INTO AXLE HOUSING
1. Thoroughly clean the inside of the carrier housing
and inspect the housing mounting surface for nicks
and general cleanliness. Stone the surface if necessary to remove burrs or nicks.
Loctite #518
Gasket Eliminator
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2. Apply an 1/8 inch bead of Loctite #518 Gasket
Eliminator onto the axle housing mounting flange
and around each bolt hole. See Figure 29.
7. Install the new axle flange gasket.
8. Install the axle shafts in proper location. Torque
the axle flange nuts to vehicle manufacturers
specifications.
9. Clean drain plug and fill unit to proper level with
hypoid gear lubricant.
10 . Apply Loctite #565, or its equivalent, to drain plug
threads. Insert and torque to 35-45Lb-Ft (4761N-m).
Differential Installation Complete
3. Thread 2 studs or guide pins into the axle housing
0
apart. This will eliminate rotation of the carrier
18 0
assembly after it makes contact with the gasket
material.
NOTE: Use guide pins to install forward carrier
assembly with output shaft in housing. Align splines of
output shaft and rear gear of inter-axle differential.
This will help align carrier and output shaft during
installation and prevent any unnecessary weight on
output shaft bearing.
4. Install the carrier assembly into the axle housing.
Clean the mounting bolts and coat with Loctite
#277 (red), or its equivalent , and install Tighten
bolts evenly in cross pattern. Torque bolts
240-260 Lb-Ft (330-338 N-m).
5. Allow one hour cure time for gasket material before
adding hypoid gear lubricant.
NOTE : Lubricant close enough to bottom of fill hole to be seen
or touched is not sufficient. Lubricant must be level with the fill
hole.
CAPACITIES (Approximate):
Axle Pints Liters
Forward Rear * 30 14
Rear Rear ** 25 11.7
* Lube capacity is based on a 40 installation angle
** Lube capacity is based on a 110 installation angle
6. Remove the old axle flange gasket and clean mating
surfaces of the hub and axle flange.
27
AXLE / TORQUE SPECIFICATIONS
S400-S Specifications
PP
ositionosition
P
osition
PP
ositionosition
Pinion Torque
Bearing Preload (Torque Wrench)*
Differential
U.S.U.S.
U.S.
U.S.U.S.
10 - 40 Lb-in
MeMe
trictric
Me
tric
MeMe
trictric
1.1 - 4.5 N-m
Ring Gear to Pinion Backlash
Lubrication (Approx.**)
Forward Rear
Rear Rear
* Pinion bearing preload is established prior to installation of pinion seal.
** Capacity will vary depending on the housing angle in each vehicle. Fill to lower edge of fill hole in rear of axle
housing as shown on Page 27.
.008 - .012 in.
.30 - .40 mm
14 Liters 30 Pts.
11.7 Liters 25 Pts.
Forward Rear Fasteners
PP
ositionosition
P
osition
PP
ositionosition
Flanged Hex Nut
Carrier Mounting Bolts
Fill Plugs
Temperature Sensor Plug
Magnetic Drain Plug
Shift Cylinder Cap Bolts
Inter-Axle Differential Case Bolts
ThrThr
ead sizeead size
Thr
ead size
ThrThr
ead sizeead size
1 3/4 12
5/8 11
3/4 14
3/4 14
1/2 14
3/4 14
5/16 18
9/16 12
GrGr
Gr
GrGr
adeade
ade
adeade
8
8
8
Lb-FtLb-Ft
Lb-Ft
Lb-FtLb-Ft
900 - 1,200
240 - 260
35 - 45
35 - 45
35 - 45
15 - 2 0
160 - 180
N-mN-m
N-m
N-mN-m
1,220 - 1,627
330 - 358
47 - 61
47 - 61
47 - 61
20 - 27
217 - 244
Lube RetainerBolts
3/8 16
8
20 - 25
27 - 34
Rear Rear Fasteners
PP
ositionosition
P
osition
PP
ositionosition
Flanged Hex Nut
Carrier Mounting Bolts
Fill Plug
Temperature Sensor Plug
Magnetic Drain Plug
NOTE: Refer to vehicle manufactures specifications for Axle Flange - Wheel Nut fastener torque
requirements.
ThrThr
ead sizeead size
Thr
ead size
ThrThr
ead sizeead size
1 3/4 12
5/8 11
3/4 14
1/2 14
3/4 14
28
GrGr
Gr
GrGr
adeade
ade
adeade
8
Lb-FtLb-Ft
Lb-Ft
Lb-FtLb-Ft
900 - 1,200
240 - 260
35 - 45
35 - 45
35 - 45 47 - 61
N-mN-m
N-m
N-mN-m
1,220 - 1,627
330 - 358
47 - 61
47 - 61
RECOMMENDED SERVICE TOOLS
DESCRIPTION ILLUSTRA TION ORDER NUMBER
DST1001 CARRIER STAND
TORQUE MULTIPLIERS
DST1002 Maximum 1,000 Lb-Ft
Maximum 2,000 Lb-FtDST1003
Maximum 4,000 Lb-FtDST1004
DST1005 Maximum 12,000 Lb-Ft
DST1006
YOKE REMOVER, BAR TYPE
YOKE INSTALLER (1-3/4"-12)DST1007
LONG, 2-JAW, PULLERDST1008
29
RECOMMENDED SERVICE TOOLS
DS DS
DS
DS DS
T1T1
T1
T1T1
000000
000
000000
S400 SER S400 SER
S400 SER
S400 SER S400 SER
ORDER NUMBER
DST1000-1
DST1000-2 INPUT SHAFT SEAL INSTALLER
DST1000-3 PINION SEAL INSTALLER
VICE KITVICE KIT
VICE KIT
VICE KITVICE KIT
SEAL INSTALLATION HANDLE
(To be used with seal installers listed below)
OUTPUT SHAFT SEAL INSTALLER
DESCRIPTIONILLUSTRATION
DST1000-4 OUTPUT SHAFT BEARING/
BEARING ASSEMBLY INSTALLER
(To be used with 2-jaw puller)
DST1000-5 OUTPUT SHAFT REMOVER ADAPTER
(To be used with yoke installer DST 1007)
ALL SERVICE TOOLS AVAILABLE FROM OTC DIVISION:
30
Service Tools
655 Eisenhower Drive
Owatonna, MN 55060
Telephone: 1-800-533-0492
Fax Number: 1-800-578-7375
Dana Aftermarket Group
For spec‘ing or service assistance, call 1.800.621.8084 or visit our website at www.spicerparts.com
PO Box 321
Toledo, Ohio 43697-0321
Warehouse Distributor: 1.800.621.8084
Dana Commercial Vehicle Products Group
OE Dealers: 1.877.777.5360
3939 Technology Drive
Maumee, Ohio, USA 43537
www.spicerparts.com
www.dana.com
AXSM-1951 Printed in U.S.A.
Copyright Dana Limited, 2012.
All rights reserved. Dana Limited.
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