SPICER SINGLE DRIVE AXLES SERVICE MANUAL AXSM-0041 SEPTEMBER 2007

Công Nghệ Thông Tin, it, phầm mềm, website, web, mobile app, trí tuệ nhân tạo, blockchain, AI, machine learning - Công Nghệ Thông Tin, it, phầm mềm, website, web, mobile app, trí tuệ nhân tạo, blockchain, AI, machine learning - Chứng khoán Spicer Single Drive Axles Service Manual AXSM-0041 September 2007 Spicer Single Drive Axles i Table of Contents Table of Contents Introduction .........................................................1 Failure Analysis ...................................................7 Inspection ...........................................................9 Differential Carrier Assembly - Parts .................11 Differential Lockout ...........................................17 Power Divider Power Divider - Parts Exploded View........................ 23 Remove Power Divider............................................. 24 Remove Power Divider from Differential Carrier (with carrier removed from axle housing) ................ 25 Disassemble, Assemble and Overhaul the Power Divider..................................................... 27 Install Power Divider on Differential Carrier (with carrier assembled to axle housing) .................. 38 Install Power Divider on Differential Carrier (with carrier removed from axle housing) ................. 40 Dissasemble Differential Carrier (with power divider removed) ................................... 54 Drive Pinion Drive Pinion - Parts Exploded View ............................ 57 Disassemble and Overhaul Drive Pinion .................... 58 Install Drive Pinion Assembly.................................... 65 Wheel Differential Assembly Wheel Differential Assembly - Parts Exploded View ............................................... 68 Housing and Rear Cover Assembly - Parts Exploded View ............................................... 91 Seals ..................................................................92 Housing Breather ..............................................94 Wheel End Seal - Parts Exploded View .............95 Remove and Overhaul Wheel End Seal .............96 Wheel Adjustment Systems ..............................97 Verify Wheel End-play Procedure ......................99 Lubricate Wheel End .......................................100 Lubrication ......................................................102 Lube Change Intervals ....................................103 Change Lube ...................................................104 Standpipes ......................................................105 Torque Chart ...................................................107 Appendix Wheel Differential Lock ...........................................109 Differential Lock Theory of Operation ....................110 Control Systems ....................................................111 Dual Range Axle Shift Systems ..............................113 Troubleshooting .....................................................120 Proper Vehicle Towing ...........................................122 Axle Shift System Components ..............................124 Inter-Axle Differential Lockout With Interlock Control Valve (straight-air type) ......126 Theory of Operation ...............................................129 Power Flow and Torque Distribution ......................130 Lubrication .............................................................132 Torque Distribution in Low Range .........................136 1 Out of Vehicle Resetting Introduction Dana Corporation, presents this publication to aid in maintenance and overhaul of Dana tandem drive axles. Instructions con- tained herein cover four basic axle models. Their design is common, with differences in load capacity. Capacity variations are achieved by combining basic differential carrier assemblies in different axle housings, axle shafts and wheel equipment. Load Capacity Model No. 34,000 lbs. . . . . . . . . . . . . .. DS340, 341 38,000 lbs. . . . . . . . . . . . . . . DS2380(P) 38,000 lbs. . . . . . . . . . . . . .. DS381(P) 40,000 lbs. . . . . . . . . . . . . . . . DS400-P, DS401-P, DS402(P), DS403(P) 45,000 lbs.. . . . . . . . . . . . . .. DS451-P Some models (identified with letter “P”) are equipped with a gear-driven pump, designed to provide additional lubrication to the inter-axle differential and related parts. Instructions contained herein are applicable to all axle models, unless specified otherwise. For brake information and axle mounting or suspension systems, refer to pertinent truck manufacturer’s literature. Typical Dana Single Reduction Tandem Axle Two design variations of tandem axles are included in this manual. The major difference is in the shaft spline design. Note: DS381 (P) axles manufactured after April 1985 are rated at 40,000 lbs. General Information 2 Service Procedure Axle and Carrier Assembly Model Identification Note: Tags that do not include all the information shown her e are older models (befor e May 1987). 1 - Country or origin 2 - Axle model identification 3 - Specification number assigned to the axle built by Spicer. Identifies all component parts of the axle including special OEM requirements such as yokes or flanges . 4 - OEM part number assigned to the axle bu ild 5 - Carrier assembly serial number assigned by the manufacturing plan t 6 - Axle gear r atio 7 - Carrier assembly production or service part number Data plate is located on the axle centerlin e Forward Axle (Side View) Rear Axle (Top View) 4 6 5 1 3 2 7 Spicer MODEL PART NO. RATIO MADE IN: SPEC. S ERIAL NO. CUST. PART NO. Spicer MODEL PART NO. RATIO MADE IN: SPEC. S ERIAL NO. CUST. PART NO. Spicer MODEL PART NO. RATIO MADE IN: SPEC. S ERIAL NO. CUST. PART NO. G e a r i n g C a p a c i t y ( x 1 0 0 0 l b s . ) D e s i g n L e v e l L u b e P u m p D - F o r w a r d T a n d e m A x l e R - R e a r T a n d e m A x l e S - S i n g l e R e d u c t i o n D - S i n g l e R e d u c t i o n w i t h W h e e l D i f f e r e n t i a l L o c k T - D u a l R a n g e P - P l a n e t a r y D o u b l e R e d u c t i o n E x a m p l e : E x a m p l e : 4 6 = 4 6 , 0 0 0 l b s . P = S t a n d a r d ( P ) = O p t i o n a l D S = F o r w a r d T a n d e m A x l e S i n g l e R e d u c t i o n R S = R e a r T a n d e m A x l e S i n g l e R e d u c t i o n Drive Axle General Information 3 Part Identification Axle Housing Axle S haft 1 - ID Tag 2 - Axle shaft part number 1 N . T P . O . P A C .G S H B L .S G S H N .D.I . . O O H U D A M G NIS N I E recipS 2 Axle Specification Number The complete axle is identified by the specification number stamped on the side of the axle housing. This number identifies all component parts of the axle as built by Dana, including special OEM requirements such as yoke or flange. In addition, s ome axles may include a metal identification tage. General Information 4 Service Procedure Ring Gear and Pinion Note: Ring gear and drive pinion are matched parts and mus t be replaced in sets . 1 - Part number 2 - Number of ring gear teeth 3 - Manufacturing numbers 4 - Matching gear set number 5 - Number of pinion teeth 6 - Date code 7 - Indicates genuine Spicer parts 8 - Heat code 41-8 RECIPS 18372 1 F O 2L N 7 1 72 1 14- 8 82472 1 RECIPS 7 1 G 6-39 7 7 D J 5045 8 EATON 6 8 5 2 3 1 7 8 L 7 0 3 8 1 4 8307 L 4 7 G 3 72 1 H 0 6 8 6 General Information 5 Power Flow and Torque Distribution Spicer tandem drive axles described in this publication are single reduction units designed primarily for highway or turnpike. They are also for a variety of other applications. This type of axle provides a vehicle with superior load carrying and roadability characteristics by dividing its work between two axles. The complete tandem assembly consists of two axles coupled by a power divider. Power Divider In operation, the power divider accepts the torque from the vehicle driveline and distributes it equally to the two axles. This as- sembly is of the two-gear design consisting of an input shaft, inter-axle differential, output shaft and two constant-mesh helical gears. The inter-axle differential compensates for axle speed variations in 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, air-operated lockout. When lockout is engaged, it mechanically prevents inter-axle differentiation for better performance under poor traction conditions. Gearing The gearing for each axle is of the spiral bevel design with drive pinion positioned at centerline of the ring gear. The differential and drive pinion are mounted on tapered roller bearings. The wheel differential is a 4 pinion and 2 side gear design. Lube Pump Tandem Axles with suffix letter "P" in Model No. are equipped with a lube pump to provide positive lubrication to the inter- axle differential and other power divider parts. This pump is operated by a drive gear engaged with the input shaft splines. When vehicle is moving in a forward direction, pressurized lube is delivered to the vital power divider parts. The pump lube system incorporates a magnetic strainer screen. To keep the system clean, the magnet traps minute particles and the screen blocks out large particles of foreign material. Lube Pump System General Information 6 Service Procedure Torque Distribution with Lockout Disengaged (Inter-axle Differential is Operation) Torque (power flow) from the vehicle driveline is transmitted to the input shaft and the inter-axle differential spider. At this point, the differential distributes torque equally to both axles. For the forward axle, torque is transmitted from the helical-side gear to the pinion helical gear, drive pinion, ring gear, wheel differential and axle shafts. For the rear axle, torque is transmitted from the output shaft side gear, through the output shaft, inter-axle driveline, to the drive pinion, ring gear, wheel differential and axle shafts. Torque Distribution with Lockout Engaged (inter-axle Differential is Not Operation) A lockout mechanism is incorporated in the power divider to enable the vehicle driver to lock out the inter-axle differential and provide maximum traction under adverse road conditions. In operation, an air cylinder (controlled by a cab-mounted valve) shifts a sliding clutch. To lock out inter-axle differential action, the clutch engages the helical-side gear and causes this gear, the input shaft and differential to rotate as one assembly. This action provides a positive drive to both axles. With Lockout engaged, torque is distributed to both-axles without differential action. The forward axle pinion and ring gear are driven by the helical side gear. The rear axle gearing is driven from the output shaft side gear and inter-axle driveline. Note: Varied road surface conditions can result in unequal torque distribution between the two axle assemblies. Input torque Lockout disengaged Drive is from differential through helical gears to forward gearing Drive is from differential through output shaft to rear gearing Torque is transmitted to both axles through inter-axle differential action. Inter-axle differential operating Input torque Lockout engaged Drive is from input shaft through helical gears to forward gearing Drive is from output shaft side gear to rear gearing Torque is transmitted to both axles without inter-axle differential action. Inter-axle differential not operating Spicer Single Reduction Tandem Drive Axles 7 Differential Carrier Assembly Exploded View Forward Axle Carrier Assembly (Single Speed) with Diff. Lock Other Design Variations Axle Series D340, 380(P),400-P D341, 381(P), 401-P, 402(P), 403(P), 451-P Output Shaft Splines 16 16 Side Gear End 16 16 Output End 10 34 Input Shaft Splines Input End 15 44 Diff End 36 36 Helical Gears 7 pitch 5 pitch Drive Pinion Splines Forward Axle 10 41 Rear Axle 10 39 Axle Shaft Side Gear Splines D340- 16 D341- 39 D380(P)- 16 D381(P), 402(P), 403(P)- 41 D400(P)- 33 D401-P, 451-P- 33 52 53 54 56 57 58 55 6 1 5 59 7 4 2 3 1 9 8 30 DIFFERENTIAL RING GEAR 21 22 23 24 33 29 31 32 35 34 38 36 37 34 35 28 27 26 25 RH LH 10 13 12 1 14 11 19 15 16 17 18 20 Spicer Single Reduction Tandem Drive Axles 8 Service Procedure Axle Series D340, 380(P), 400-P, D341, 381(P), 401-P, 402(P), 403 (P), 451-P Note: Before Replacing Seals, Yokes, and Slingers, refer to the Repair and Replacement Instructions for interchangeability infor- mation. 60 61 62 63 64 65 66 INTER-AXLE DIFFERENTIAL ASS EMBLY 67 68 69 71 70 74 73 75 72 70 76 77 78 79 80 81 82 83 91 93 92 84 85 86 88 89 90 87 105 106 39 31 40 41 42 43 45 44 46 47 43 40 48 49 50 51 94 97 98 99 100 101 104 103 95 91 96 102 LUBE PUMP Spicer Single Reduction Tandem Drive Axles 9 1 - Differential carrier bearing caps 2 - Bearing capscr ew 3 - Flat washer 4 - Lockwir e 5 - Dowel bushin g 6 - Bearing cap adjuster lock (RH) 7 - Capscr ew 8 - Bearing cap adjuster lock (LH) 9 - Cotter pin (LH) 10 - Expansion plug (upper ) 11 -Expansion plug (lower ) 12 - Filler plu g 13 - Shift fork s haft 14 - Carrier cover dowel pun 15 - Shift unit mounting stu d 16 - Shift fork seal spring ass embly 17 - Flat washer 18 - Stud nu t 19 - Shift fork roller ass embly 20 - Shift unit ass embly 21 - Sliding clu tch 22 - Differential bearing adjuster (RH) 23 - Differential bearing cu p (RH) 24 - Differential bearing con e (RH) 25 - Differential bearing adjuster (LH) 26 - Differential bearing cu p (LH) 27 - Differential bearing con e (LH) 28 - Differential case (plain half) 29 - Differential case (flan ged half) 30 - Differential case capscr ew 31 - Ring gear drive pinion 32 - Bolt 33 - Nu t 34 - Differential side gear 36 - Side pinion 37 - Side pinion thrust washer 38 - Spider 39 - Pinion pilot bearin g 40 - Pinion bearing con e 41 - Pinion bearing spacer washer 42 - Pinion bearing spacer 43 - Pinion bearing cu p 44 - Pinion bearin g cage 45 - Pinion bearing cage s him 46 - Lock washer 47 - Bearing cage capscr ew 48 - Pinion helical gear 49 - Outer pinion support bearing (on e piece) 50 - Pinion shaft end nu t 51 - Pinion nut spring pin 52 - Output shaft nu t 53 - Output shaft washer 54 - Rear bearing retaining washer 55 - Axle housing cover 56 - Output shaft oil s eal 57 - Bearing snap rin g 58 - Output shaft bearin g 59 - Filler plu g 60 - Output s haft 61 - Output shaft bushin g 62 - Output shaft O-rin g 63 - Output shaft bearing cu p 64 - Output shaft bearing con e 65 - Output shaft side gear 66 - Side gear snap rin g 67 - Output shaft compression sprin g 68 - Output shaft thrust bearin g 69 - Inter-axle differential ass emble 70 - Inter-axle differential cas e half 71 - Cas e bolt 72 - Case nu t 73 - Side pinion 74 - Side pinion thrust washer 75 - Spider 76 - Helical side gear snap rin g 77- Helical side gear 78 - Helical side gear bushin g 79 - Helical side gear thrust washer 80 - Helical side gear “D” washer 81 - Lockout sliding clu tch 82 - Input s haft 83 - Input shaft bearing con e 84 - Input shaft bearing cu p 85 - Input cover s him 86 - Input bearing cover 87 - Bearing cover capscr ew 88 - Input shaft oil s eal 89 - Input shaft nut washer 90 - Input shaft nu t 91 - PDU carrier cover 92 - Carrier cover capscr ew 93 - Lock washer 94 - Pipe plu g 95 - Expansion plu g 96 - Magnetic filter screen 97 - Pump gear shaft ass embly 98 - Cover O-rin g 99 - Lube pump cover 100 - Lock washer 101 - Cover capscr ew 102 - Cover dowel pin 103 - Pump drive gear 104 - Drive gear locknu t 105 - Air-operated lockout ass embly 106 - Shift fork push rod assembly Spicer Single Reduction Tandem Drive Axles 10 Service Procedure Differential Carrier Assembly Rear Axle RS340, 341, 380, 400, 401, 402, 403, 451 1 - Differential carrier bearing caps 2 - Bearing capscrew 3 - Flat washer 4 - Lockwire 5 - Bearing cap adjuster lock 6 - Cotter pin 7 - Dowel bushing 8 - Ring gear thrust screw 9 - Thrust screw jam nut 10 - Differential bearing adjuster 11 - Differential bearing cup 12 - Differential bearing cone 13 - Ring gear drive pinion 14 - Bolt and nut 15 - Differential case (flanged half) 16 - Differential case capscrew 17 - Differential side gear 18 - Side gear thrust washer 19 - Side pinion 20 - Side pinion thrust washer 21 - Spider 22 - Pinion pilot bearing 23 - Pinion bearing cone 24 - Pinion bearing spacer 25 - Pinion bearing cage 26 - Pinion bearing cup 27 - Pinion bearing spacer washer 28 - Pinion bearing cage shim 29 - Bearing cage capscrew 30 - Oil seal 31 - Input yoke 32 - Flat washer 33 - Pinion nut 6 5 1 1 22 23 24 29 31 32 2 4 3 6 5 8 9 27 26 28 25 26 23 30 33 16 17 19 14 14 10 11 12 15 18 20 21 17 18 13 15 12 11 10 13 Lubrication 11 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 lubricant in 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 Corporation. Approved Lubricants General—Gear lubrications acceptable under military specification (MILSPEC) MIL-L-2105D (Lubricating Oils, Gear, Multipur- pose) 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 MlL-L-l 0324A. This specification applies to both petroleum-based 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 andor friction modifiers are not approved in Dana 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 appear- ance. The family of Spicer TM 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 perfor- mance 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 Spicer representative. See back cover of this manual for appropriate phone number. Makeup Lube — Maximum amount of non-synthetic makeup lube is 100o. Viscosity Ambient Temperature Recommendations -The following chart lists the varies 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 Roadranger 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 tcontacting your local Spic er epresen- tative. Grade Ambient Temperature 75W - 40 F to -150 F (-40 C to -26 C) 75W-80 - 40 F to 80 F (-40 C to 21 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 - 40 F to 100 F (-40 C to -38 C) 80W-140 - 40 F and above(-40 C and above) 85W-140 - 40 F and above (-40 C and above) Lubrication 12 Service Procedure Lube Change Intervals This product combines the latest manufacturing and part washing technology. When filled with an 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. 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 ONOFF HIGHWAY portion of the chart should be used. Typical applications are construction, logging, mining and refuse removal. Note: Remove metallic particles from the magnetic filler plug and drain plugs. Clean or replace the breather at each lubricant change. Changing Lube Draining Drain when the lube is at normal operating temperature. It will run freely and minimize the time necessary to fully drain the axle. Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container. Inspect drain plug for large quantities of metal particles. After initial oil change, these are signs of damage or extreme wear in the axle, and inspection of the entire unit may be warranted. Clean the drain plug and replace it after the lube has drained completely. Axles with Lube Pump: Remove the magnetic strainer from the power divider cover and inspect for wear material in the same manner as the drain plug. Wash the magnetic strainer in solvent and blow dry with compressed air to remove oil and metal parti- cles. Exercise care to direct compressed air into safe area. Wear safety glasses. Guide Lines - Lube Change Intervals for Drive Axles Lubricant Type On-Highway Miles Maximum change In- terval OnOff Highway Severe Service Miles Maximum Change In- terval Mineral Based 100,000 Yearly 40,000 Yearly Roadranger Approved Lubricant 250,000 3 Years 100,000 Yearly CAUTION Lubrication 13 Filling Remove the filler hole plug from the center of the axle housing cover and fill the axle with approved lubricant until level with the bottom of the hole. Forward axles: Add two pints (0.94 liters) of lubricant through filler hole at the top of the differential carrier near the power divider cover. Note: Lube fill capacities in the adjacent chart are good guidelines but will vary somewhat on the basis of the angle the axle is installed in a particular chassis. Always use the filler hole as the final reference. If lube is level with the bottom of the hole, the axle is properly filled. Axle Installation Angles Axles installed at angles exceeding 10 degrees or operated regularly in areas of continuous and lengthy grades may require stand- pipes to allow proper fill levels. For specific recommendations, contact your local Spicer representative. See back cover of this manual for phone numbers. Forward Axle: Add an additional 2 pints (0.94 liters) axle lubricant through filler hole at the top of differential carrier near the power divider cover. Capacities listed are approximate. The amount of lubricant will vary with angle of axle as installed in vehicle chassis. Oil Filler Hole at top of Differential Carrier Magnetic Strainer for Axle with Lube Pump Lube Capacities, Dana Housings Single Reduction Tandem Series Forward Axle Pints (liters) Rear Axle Pints (liters) 380(P), 381(P), 400-P, 401-P 39 (18.5) 36 (17.0) 402(P), 403(P),451-P 39 (18.5) 36 (17.0) Lubrication 14 Service Procedure Wheel End Lubrication Before operating the axle, the wheel hub cavities and bearings must be lubricated to prevent failure. When wheel ends are serviced, follow Spicer’s wheel end lubrication procedure before operating the axle. Spicer 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 proceed as follows: (Fig. 1) 1. Rotate the wheel end hub until the oil fill hole is up. 2. Remove the oil fill plug. 3. Pour 12 pint of axle sump lubricant into each hub through the wheel end fill hole. 4. Install oil fill plug and tighten to specified torque. Fig. 1 Cutaway views of typical wheel and assemblies IMPORTANT LUBRICANT FLOW FROM SUMP WHEEL END OIL FILL HOLE PROPER LUBRICANT LEVEL PROPER LUBRICANT LEVEL Wheel End with Oil Fill Hole Wheel End without Oil Fill Hole Lubrication 15 Wheel Ends without an oil fill hole proceed as follows: (Fig. 2) 1. With axle level and wheel ends assembled, add lubricant through filler hole in axle housing cover until fluid is level with the bottom of filler hole. 2. Raise the left side of the axle 6 inches or more. Hold axle in this position for one minute. 3. Lower the left side. 4. Raise the right side of the axle 6 inches or more. Hold axle in this position for one minute. 5. Lower the right side. 6. With axle on a level surface, add lubricant through housing cover oil filler hole until fluid is level with the bottom of the hole. Note: Axles without wheel end fill holes will require approximately 2.5 additional pints of lubricant to bring the lube level even with the bottom of fill hole. Fig. 2 Wheel end lubrication procedure TEMPERATURE SENSOR MOUNTING HOLE WITH AXLE ON LEVEL SURFACE FILL HOUSING WITH OIL TO BOTTOM OF PLUG TILT HOUSING SIDE TO SIDE, 1 MINUTE PER SIDE, THEN, RECHECK OIL LEVEL IN AXLE OIL WILL RUN INTO WHEEL END OIL WILL RUN INTO WHEEL END General Information 16 Service Procedure Cleaning, Inspection, Replacement As the drive axle is disassembled, set all parts aside for thorough cleaning and inspection. Careful inspection will help determine whether parts should be reused. In many cases, the causes of premature wear or drive axle failure will also be revealed. Cleaning The differential carrier assembly may be steam-cleaned while mounted in the housing as long as all openings are tightly plugged. Once removed from its hous- ing, do not steam clean differential carrier or any components. Steam cleaning at this time could allow water to be trapped in cored passages, leading to rust, lubri- cant contamination, and premature component wear. The only proper way to clean the assembly is to disassemble it completely. Other methods will not be effective except as preparatory steps in the process. Wash steel parts with ground or pol- ished surfaces in solvent. There are many suitable commercial solvents available. Kerosene and diesel fuel are acceptable. Gasoline is not an acceptable solvent because of its extreme combustibiliy. It is unsafe in the workshop environment. Wash castings or other rough parts in solvent or clean in hot solution tanks using mild alkali solutions. If a hot solution tank is used, make sure parts are heated thor- oughly, before rinsing. Rinse thoroughly to remove all traces of the cleaning solution. Dry parts immedi- ately with clean rags. Lightly oil parts if they are to be reused immediately. Otherwise, coat with oil and wrap in corrosion-resistant paper. Store parts in a clean, dry place. Inspection Inspect steel parts for notches, visible steps or grooves created by wear. Look for pitting or cracking along gear contact lines. Scuffing, deformation or discoloration are signs of excessive heat in the axle, usually related to low lubricant levels or im- proper lubrication practices. Before reusing a gear set, inspect teeth for signs of excessive wear. Check tooth contact pattern for evidence of incorrect adjustment (see Adjustment Section for correct pattern). Inspect machined surfaces of cast or malleable parts. They must be free of cracks, scoring, and wear. Look for elongation of drilled holes, wear on surfaces machined for bearing fits and nicks or burrs in mating surfaces. Inspect fasteners for rounded heads, bends, cracks or damaged threads. The axle housing should be examined for cracks or leaks. Also look for loose studs or cross-threaded holes. Inspect machined surfaces for nicks and burrs. WARNING General Information 17 Repair and Replacement To achieve maximum value from an axle rebuild. Replace lower-cost parts, such as thrust washers, seals, etc. These items protect the axle from premature wear or loss of lubricants. Replacing these parts will not increase rebuild cost significantly. It is also important to replace other parts which display signs of heavy wear even though not cracked or broken. A significant portion of such a parts useful life has been expended and the damage caused, should the part fail, is far in excess of its cost. Steel Parts- Gear sets, input and output shafts, differential parts and bearings are not repairable. Worn or damaged parts should be discarded without hesitation. Also discard mating parts in some cases. Gear sets, for example, must be replaced in sets. Miscellaneous Parts - Seals and washers are routinely replaced. None of these parts can be reused if damaged. Fasteners using self-locking nylon patches may be reused if not damaged, but should be secured by a few drops of Loctite 277 on the threaded surface of the hole during installation and carefully torqued during installation. Axle Housings - Repairs are limited to removal of nicks or burrs on machined surfaces and the replacement of loose or broken studs. Any damage which affects the alignment or structural integrity of the housing requires housing replacement. Repair by weld- ing or straightening should not be attempted. This process can affect the housing heat treatment and cause it to fail complete- ly when under load. Silicone Rubber Gasket Compound - For more effective sealing. Spicer uses silicone rubber gasket compound to seal the majority of metal-to-metal mating surfaces. Spicer includes gasket compound and application instructions in many repair parts kits. It is recommended that this compound be used in place of conventional gaskets. The compound will provide a more effective seal against lube and is easier to remove from mating surfaces when replacing parts. Seals, Yoke Slinger Service Information During the 4th Quarter of 1990, new seals and yoke slingers were used on the models in this publication. The new seals and slingers are noticeably different from the current seals and will affect interchangeability. The upgraded seals can be used on axles originally equipped with the old seals. Dana recommends the replacement of old yoke slinger assemblies when the new seals are installed. The old yokes and slingers will work with the new seals, but new yoke and slinger assemblies provide maximum sealing protection and prevent premature seal wear due to poor yoke condition. New yoke and slinger assemblies cannot be used with the old seal design on the tandem forward axles. New yoke and slinger assemblies can be used with the old seal on the tandem rear pinions. Yoke Assembly Oil Seal Kits contain oil seal, yoke slinger and instructions. Most non-Dana aftermarket seals will not be compatible with the new Dana Yoke and Slinger assemblies. Spcier recommends the use of special installation tools conveniently packaged in one single kit (listed below). Refer to Dana parts Book AXIP-0089 and Eaton Bulletin 90-06 for additional information. Seal Driver Installation Kit 272139 126917 Driver (Rear Axle Pinion) 127787 Adapter (use with 126917 Driver for Forward Axle Input) 127786 Driver (Forward Axle Output) IMPORTANT CAUTION Adjustments 18 Service Procedure Wheel Bearing Adjustment Special Instructions 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. Procedure - Wheel End Seal 1. Remove: The outer bearing and wheel. The inner bearing. The oil seal or grease retainer and discard. The old wear sleeve (2-piece design only) with a ball peen hammer and discard. Wheel end seals can be easily damaged during handling. Leave the seal in its package until installation to prevent dam- age or contamination. Do not cut through the old wear sleeve. Damage to the housing may result. 2. Inspect: The spindle journal and hub bore for scratches or burns. Recondition with emery cloth as required. Note: Deep gouges can be repaired by filling gouge with hardened gasket and smoothing with emery cloth. 3. Clean: The hub cavity and bearing bores before reassembly. Be sure to remove contaminants from all recesses and corners. The bearings thoroughly with solvent and examine for damage. Replace damaged or worn bearings. Before installation, lubricate with the same lubricant used in the axle sump. The inner bearing. The wheel seal following the directors provided by the seal supplier. 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. Procedure - Wheel Bearing Adjustment 1. Identify the wheel nut system being installed. Three systems are available: Three piece Dowel-type wheel nut system -Fig.1 Three piece Tang-type wheel nut system - Fig.2 WARNING IMPORTANT CAUTION IMPORTANT Adjustments 19 Four piece TangDowel type wheel nut system - Fig.3 Do not mix spindle nuts and lock washers from different systems. Mixing spindle nuts and lock washers can cause wheel separation. Note: The lock washer for a four piece-dowel-type wheel system is thinner than the lock washer for a three piece tang-type wheel nut system and is not designed to bear against the inner nut. 2. Inspect the spindle and nut threads for corrosion and clean thoroughly or replace as required. Note: Proper assembly and adjustment is not possible if the spindle or nut threads are corroded. lnspect the tang-type washer (if used). Replace the washer if the tangs are broken, cracked, or damaged. 3. Install the hub and drum on the spindle with care to prevent damage or distortion to the wheel seal. A wheel dolly is recommended during installation to make sure that the wheel seal is not damaged by the weight of the hub and drum. Never support the hub on the spindle with just the inner bearing and seal. This can damage the seal and cause premature failure. Completely fill the hub cavity between the inner and outer bearing races with the same lubricant used in the axle sump. 4. Before installation, lubricate the outer bearing with the same lubricant used in the axle sump. Note: Lubricate only with clean axle lubricant of the same type used in the axle sump. Do not pack the bearing with grease before installation. Grease will prevent the proper circulation of axle lubricant and may cause wheel seal failure. 5. Install the outer bearing on the spindle. Install the inner nut on the spindle. Tighten the inner nut to 200 lbs. ft. (271 N.M.) while rotating the wheel hub. Never use an impact wrench to adjust wheel bearings. A torque wrench is required to assure that the nuts are property WARNING Outer nut (PN 11249) Inner nut (PN 11249) Tang-type lock washer (PN 11988 3) 0.123" thick Fig 2 Outer nut (PN 11988 1) Inner nut (PN 11988 2) Dowel Pin Dowel-type Lock Washer (PN 11988 3) Fig 1 Outer nut (PN 11988 1) Inner nut (PN 11988 2) Dowel pin Dowel-type lock washer (PN 11988 3) Tang-type lock washer (PN 129132) .0478 " thick Fig 3 CAUTION CAUTION Adjustments 20 Service Procedure tightened. 6. Back-off the inner nut one full turn. Rotate the wheel hub. 7. Re-tighten the inner nut to 50 lbs. ft. (68 N.M.) while rotating the wheel hub. 8. Back-off the inner nut exactly 14 turn. Note: This adjustment procedure allows the wheel to rotate freely with 0.001"-0.005" (0.025mm to 0.1 27mm) end-play. 9. Install the correct lock washer for the wheel nut system being used. Procedure - Three piece tang-type lock washer system (see Fig. 2). 1. Install the Tang-type lock washer on the spindle. Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure. 2. Install the outer nut on the spindle and tighten to 250 lbs. ft. (339 N.M.). 3. Verify end-play (see End Play Verification Procedure) 4. After verifying end play, secure wheel nuts by bending one of the locking washer tangs over the outer wheel nut and another tang over the inner wheel nut as shown in Figure 4. (below) Procedure - Three piece dowel-type lock washer system (see Fig. 1) 1. Install the Dowel-type lock washer on the spindle. Note: If the dowel pin and washer are not aligned, remove washer, turn it over and reinstall. If required, loosen the inner nut just enough for alignment. Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure. IMPORTANT Spindle Inner nut Lockwasher Bend two tangs… one over inner nut and one over outer nut Outer nut IMPORTANT Adjustments 21 2. Install the outer nut on the spindle and tighten to 350 lbs. ft. (475 N.M.). 3. Verify end-play (see End Play Verification Procedure) Procedure - Four piece tangdowel-type lock washer system (see Fig. 3) 1. First, install the Dowel-type lock washer on the spindle. Note: If the dowel pin and washer are not aligned, remove washer, turn it over and reinstall. If required loosen the inner nut just enough for alignment. Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure. 2. Install the Tang-type lock washer on the spindle. 3. Install the outer nut on the spindle and tighten to 250 lbs. ft. (339 N. M.) 4. Verify end-play (see End Play Verification Procedure) 5. After verifying end play, secure the outer nut by bending two opposing (180° apart) tangs of the locking washer over the outer nut as shown in Figure 5. Procedure - Install 1. Install a new gasket at axle shaft flange. 2. Install axle shaft. 3. Install axle flange nuts and tighten to specified torque. 4. Lubricate axle wheel ends (see Wheel End Lubrication Procedure) Procedure - End Play Verification Procedure 1. Verify that end-play meets specification using a dial indicator. An indicator with 0.001” (0.03 mm) resolution is required. IMPORTANT Figure 5 Spindle Inner nut Lockwasher Bend two tangs over outer nut Outer nut Dowel pin Adjustments 22 Service Procedure Wheel end play is the free movement of the tire and wheel assembly along the spindle axis. 2. Attach a dial indicator with its magnetic base to the hub or brake drum as shown below: 3. 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. 4. 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. If end play is not within specification, readjustment is required. Procedure - End Play Readjustment Procedure 1. Excessive End Play - If end play is greater than.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 torque the outer nut. Verify end play with a dial indicator. 2. 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 wash- er and re-torque the outer nut. Verify end play with a dial indicator. 3. Fine Tuning the End Play - If, after performing the readjustment procedures, end play is still not within the.001”-.005” (.025 mm to.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. End Play Adjustment with Tire Wheel Assembly With indicator mounted at bottom, PushPull at sides of drum End Play Adjustment with Wheel hub CAUTION Adjustments 23 Differential Carrier Adjustments Adjustments help provide optimum axle life and performance by correctly positioning bearings and gears under load. The tandem axles covered in this manual require the following adjustments: Bearing Preload: This adjustment is performed for both pinion and differential bearings. It maintains proper gear alignments by creating correct bearing cone and cup relationships for free rotation under load. The pinion pilot bearing does not require a preload adjustment. Ring Gear Tooth Contact: This adjustment positions ring gear and pinion for best contact under load. Correct adjustment distrib- utes torque evenly over gear teeth and helps maximize gear set Iife. Input Shaft End Play (Forward Axles): This adjustment controls gear mesh in the inter-axle differential. Proper adjustment helps maximize life of all power divider parts. Adjust Input Shaft End Play Specifications: Input shaft end play requirements will vary with operating conditions, mileage and rebuild procedures. These vari- ations are shown in the following chart. Input Shaft End Play New or Rebuild with new parts: 0.003" to 0.007". Rebuild with reused parts: 0.013" to 0.017". Note: Because of manufacturing variations in individual parts, correctly adjusted end play could vary 0.010", after the unit is ro- tated. Acceptable End Play Tolerances when measuring as a regular maintenance procedure with axle in truck. Up to 0.060" with over 100,000 miles or 1 year service off-road. Up to 0.040" with less than 100,000 miles or 1 year service on- road. Note: If end play exceeds limits, disassemble power divider and replace worn parts. Procedure - Measure and Adjust End Play 1. In September 1988, a Spring and a Thrust Button between the input and output shafts. End play tolerances are the same for axles with or without this Spring and Button. However, end play measurement procedure is different than described below. Refer to Service Bulletin Supplement at back of this manual for procedure variances. With power divider assembled to differential carrier, measure end play with dial indicator positioned at yoke end of input shaft. Move input shaft axially and measure end play. If end play is not correct (see chart), adjust as follows. 2. Remove input shaft nut, flat washer and yoke. Remove bearing cover cap screws and lock washers. Remove cover and shim pack. 3. To increase end play, add shims: Desired end play: 0.003" to 0.007" Measured endplay (Step 1): 0.001" - 0.001" Add shims to provide desired end play : 0.002" to 0.006" IMPORTANT Adjustments 24 Service Procedure 4. To decrease end play, remove shims: Measured end play (Step 1): 0.015" - 0.015" Desired end play: 0.003" to 0.007" Remove shims to provide desired end play : 0.012" to 0.008" 5. To reassemble input shaft, install the adjusted shim pack and bearing cover. Install cap screws and lock washers. Torque screws to 75-85 ft. lbs. (101-115 N.m). Note: If difficulty is experienced in achieving correct torque on the input yoke nut, torque the nut with truck on the ground and axle shafts installed. 6. Install yoke, flat washer and nut. Tighten nut snugly. Tap end of input shaft lightly to seat bearings. 7. Measure input shaft end play with dial indicator. If end play is still incorrect, repeat Steps 2 through 6. 8. With end play correct, seal shim pack to prevent lube leakage, then torque input shaft nut and cover cap screws (see chart). Note: When power divider has been disassembled and reassembled, it may be desirable to adjust end play by measuring bear- ing cover clearance and calculating shim pack size. For procedures, see page 39. Metric Nut used on Axles produced after 1-3-95 Measuring End Play with Dial Indicator Torque Chart ft. lbs. N.m Input Shaft Nut 1 58 - 18 780-960 1057 - 1301 M42 x 1.5 840 - 1020 1140 - 1383 Bearing Cover Capscrew 12 - 13 75 - 85 101 - 115 Pry bar U-bracket Dial indicator Input shaft Lift up on pry bar to compress input shaft. Adjustments 25 Pinion Bearing Preload Special Instructions Most late model axles are provided with a “press-fit” outer bearing on the drive pinion. Some of the early model axles use an outer bearing which slips over the drive pinion. Procedures for adjusting both types of pinion bearing design are contained in this sec- tion. Procedure - Adjust Pinion Bearing Preload for Axles with “Press-fit” Outer Pinion Bearings 1. Trial Build-up Assemble pinion bearing cage, bearings and spacer (without drive pinion or oil seal). Center bearing spacer between two bear- ing cones. Note: When new gear set or pinion bearings are used, select nominal size spacer from the specification chart below. If orig- inal 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. Inter bearing cone Inter bearing cup Bearing spacer (variable) Bearing cage Outer bearing cup Outer bearing cone Inner bearing cone Inner bearing cup Bearing spacer (variable) Bearing cage Outer bearing cup Outer bearing cone Assemble these Parts for Trial Build-up. Cage in Press to Check Bearing Preload. Spring Scale Press Ram Sleeve Must Apply Pressure To Back Face Of Outer Bearing Cone Press ram Sleeve must apply pressure to back face of outer bearing cone Spring scale Adjustments 26 Service Procedure 3. Apply 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 10-20 in. lbs.. This specification is translated into spring scale readings in the chart below. 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. Once correct bearing preload has been established, note the spacer size used. Select a spacer 0.001” larger for use in the final pinion bearing cage assembly. The larger spacer compensates for slight “growth” in the bearings which occurs when they are pressed on the pinion shank. The trial build-up will result in proper pinion bearing preload in three of four cases. Do not assume that all assemblies will retain proper preload once bearings are pressed on pinion shank. Final preload test must be made in every case. Specifications for Pinion Bearing Trial Build-up Preload Test (“Press-fit” Outer Pinion Bearings) Nominal Bearing Spacer Thickness Press Loads Spring Scale Reading (without pinion seal) (for 10-20 in. lbs. torque) (1.1- 2.3 N.m) Axle Models in. mm Tons Metric Tons lbs. Kgs. Forward Axles D340, 380(P), 400-P 0.638 16.21 13.5 - 15.5 122- 140 3-7 2-3 D341, 381, (P), 401-P, 402(P), 403(P), 451-P 0.496 12.60 17 - 19 154 - 172 3-7 1.4- 32 Rear Axles 0.638 16.21 14 - 15 127 - 136 4-8 18- 36 IMPORTANT Adjustments 27 Final Pinion Bearing Preload Test Procedure - 1. Assemble the complete pinion bearing cage unit as recommending the assembly section of this manual. Note: Forward axle pinion is equipped with helical gear. For easier disassembly during bearing adjustment procedure, use a dummy yoke (if available) in place of helical gear. 2. 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 a press to simulate nut torque (see chart below). Vise Method - If the yoke and nut are used, mount the assembly in a vise, clamping yoke firmly. Press Method - If a press is used, position a sleeve or spacer so that load is applied directly to the back-face of the outer bearing cone. 3. Measure Pinion Bearing Preload - Use a spring scale to test the assembly rolling torque. To use the spring scale, wrap soft wire around the bearing cage, attach the scale and pull. Preload is correct when torque required to rotate the pinion bearing cage is from 15 to 35 in. lbs.. This specification is translated into spring scale readings in the chart below. Measuring Bearing Preload with Pinion in Vise Measuring Bearing Preload with Pinion in Press Adjustments 28 Service Procedure Torque nut to 840 ft-lbs. (1 139 N.m), Then continue tightening nut to align nut slot to nearest hole in pinion shank. 4. Adjust Pinion Bearing Preload - If necessary, adjust pinion bearing preload. Disassemble the pinion bearing cage as recom- mended in this -manual and change the pinion bearing spacer. A thicker spacer will decrease preload. A thinner spacer will increase preload. 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. Final Pinion Bearing Preload Test Axle Model Nut Torque ft. lbs. (N.m) Press Load- Tons (Metric tons) Spring Seal Reading (without pinion seal)- lbs (kg) Forward Axle D340, 380(P), 400-P 560 - 700 (759 - 949) Self Locking Nut 13.5 - 15.5 (12.2 - 14.0) 5-12 (2.3-5.4) D341, 381(P), 401-P, 402(P), 403(P), 451-P 780 - 960 (1057-1301) Self Locking Nut 17 - 19 (15.4 - 17.2) 5-12 (2.3-5.4) 840-1020 (1140-1383) Metric Nut 17 - 19 (15.4 - 17.2) 5-12 (2.3-5.4) 840 (1139) Slotted Nut and role pin 17 - 19 (15.4 - 17.2) 5-12 (2.3-5.4) Rear Axle (All models) 560-700 (759-949) 14-15 (12.7-13.6) 6-14 (2.7-6.4) IMPORTANT Adjustments 29 Adjust Pinion Bearing Preload for Axles with "Slip-fit" Outer Pinion Bearings Procedure - 1. Lubricate bearings and assemble the drive pinion, bearings, and pinion bearing cage as recommended in the assembly section of this manual. Use the pinion bearing spacer removed from the axle during disassembly. If the original spacer cannot be used, install the nominal spacer recommended in the adjacent chart. Note: Forward axle pinion is equipped with helical gear, For easier disassembly during bearing adjustment procedure, use a dummy yoke (if available) in place of helical gear. 2. Apply clamp load to the pinion bearings. Install the yoke (or helical gear) and torque the nut to specification or use a press to simulate nut torque by applying pressure to the assembly (see chart below). Vise Method - If the yoke and nut are used, mount the assembly in a vise, clamping yoke firmly. Press Method - If a press is used, position a sleeve or spacer so that load is applied directly to the back-face of the outer bearing cone. 3. Measure Pinion Bearing Preload - Use a spring scale to test the assembly rolling torque. To use the spring scale, wrap soft wire around the bearing cage, attach the scale and pull. Preload is correct when torque required to rotate the pinion bearing cage is from 15 to 35 in. lbs. This specification is translated into spring scale readings in the chart below. Nominal Pinion Bearing Spacers Axle Model Spacer Thickness in (mm) Forward Axle D340, 380(P), 400-P 0.638 (16.205) D341, 381(P), 401-P, 402(P), 403(P), 451-P 0.492 (12.497) Rear Axle (all models) 0.638 (16.205) Measuring Bearing Preload with Pinion in Vise Adjustments 30 Service Procedure 4. Adjust Pinion Bearing Preload - If necessary, adjust pinion bearing preload. Disassemble the pinion bearing cage as recom- mended in this manual and change the pinion bearing spacer. A thicker spacer will decrease preload. A thinner spacer will increase preload. 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. Torque nut to 840 ft-lbs. (1 139 N.m), Then continue tightening nut to align nut slot to nearest hole in pinion shank. Measuring Bearing Preload with Pinion in Press Final Pinion Bearing Preload Test (Slip fit outer pinion bearings) Axle Model Nut Torque ft. lbs (N.m) Press Load- Tons (Metric tons) Spring Seal Reading (without pinion seal)- lbs (kg) Forward Axle D340, 380(P), 400-P 560 - 700 (759 - 949) Self Locking Nut 13.5 - 15.5 (12.2 - 14.0) 5-12 (2.3-5.4) D341, 381(P), 401-P, 402(P), 403(P), 451-P 780 - 960 (1057-1301) Self Locking Nut 17 - 19 (15.4 - 17.2) 5-12 (2.3-5.4) 840-1020 (1140-1383) Metric Nut 17 - 19 (15.4 - 17.2) 5-12 (2.3-5.4) 840 (1139) Slotted Nut and role pin 17 - 19 (15.4 - 17.2) 5-12 (2.3-5.4) Rear Axle (All models) 560-700 (759-949) 14-15 (12.7-13.6) 6-14 (2.7-6.4) IMPORTANT Adjustments 31 Differential Bearing Preload and Ring Gear Backlash Adjustment Special Instructions Correct differential bearing preload insures proper location of these bearings under load and helps position the ring gear for proper gear tooth contact. Procedure - Adjust Diff. Bearing Preload 1. Lubricate differential bearings. When installing bearing caps and adjuster, ex- ert care not to cross threads. 2. Install adjusters and bearing caps. Tighten bearing cap screws finger-tight. If this is difficult, use a hand wrench. Note: Ring gear position for rear axle is illustrated. 3. Loosen the bearing adjuster on the same side as the ring gear teeth until its first thread is visible. 4. Tighten the bearing adjuster on the back-face side of the ring gear until there is no backlash. This can be tested by facing the ring gear teeth and push- ing the gear away from the body while gently rocking the gear from side to side. There should be no free movement. Rotate the ring gear and check for any point where the gear may bind. If such a point exists, loosen and re-tight- en the back side adjuster. Make all further adjustments from the point of tightest mesh. 5. At teeth side of ring gear, tighten adjuster until it contacts the bearing cup. Continue tightening adjuster two or three notches and this will preload bearings and provide back- lash. 6. Measure backlash with a dial indicator. USED GEARING — Reset to backlash recorded before dis- assembly. NEW GEARING — Backlash should be between 0.006” and 0.016”. If backlash is incorrect, proceed as described below to re- adjust. Procedure - Adjust Ring Gear Backlash 1. To add backlash: Loosen the adjuster on the teeth side of the ring gear several notches. Loosen the opposite adjust- er one notch. Return to adjuster on teeth side of the ring gear and tighten adjuster until it contacts the bearing cup. Continue tightening the same adjuster 2 or 3 notches. Re- check backlash. 2. To remove backlash: Loosen the adjuster on the teeth side of the ring gear several notches. Tighten the opposite ad- juster one notch. Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup. Continue tightening the same adjuster 2 or 3 notches. Re- check backlash. 3. Moving adjuster one notch is the movement of the lead edge of one adjuster lug to the lead edge of the next lug past a preselected point. IMPORTANT One Notch Lugs Lugs One notch Adjustments 32 Service Procedure Ring Gear and Pinion Tooth Contact Note: Rear axle gearing is shown in the following instructions. Correct tooth contact patterns and adjustments are the same for forward and rear axles. Check Tooth Contact Pattern (NEW GEAR) Paint twelve ring gear teeth with marking compound and roll the gear to obtain a contact pattern. The correct pattern is well-cen- tered on the ring gear tooth with lengthwise contact clear of the toe. The length of the pattern in an unloaded condition is approx- imately one-half to two-thirds of the ring gear tooth in most models and ratios. Check Tooth Contact Pattern (USED GEAR) Used gearing will not usually display the square, even contact pattern found in new gear sets. The gear wi...

Service Manual

AXSM-0041 September 2007

Remove Power Divider 24

Remove Power Divider from Differential Carrier (with carrier removed from axle housing) 25

Disassemble, Assemble and Overhaul the Power Divider 27

Install Power Divider on Differential Carrier (with carrier assembled to axle housing) 38

Install Power Divider on Differential Carrier (with carrier removed from axle housing) 40

Dissasemble Differential Carrier (with power divider removed) 54

Drive Pinion Drive Pinion - Parts Exploded View 57

Disassemble and Overhaul Drive Pinion 58

Install Drive Pinion Assembly 65

Wheel Differential Assembly Wheel Differential Assembly - Parts Exploded View 68

Housing and Rear Cover Assembly - Parts Exploded View 91

Seals 92

Housing Breather .94

Wheel End Seal - Parts Exploded View .95

Remove and Overhaul Wheel End Seal .96

Wheel Adjustment Systems .97

Verify Wheel End-play Procedure 99

Lubricate Wheel End .100

Differential Lock Theory of Operation .110

Control Systems .111

Dual Range Axle Shift Systems 113

Troubleshooting 120

Proper Vehicle Towing .122

Axle Shift System Components 124

Inter-Axle Differential Lockout With Interlock Control Valve (straight-air type) 126

Dana Corporation, presents this publication to aid in maintenance and overhaul of Dana tandem drive axles Instructions tained herein cover four basic axle models Their design is common, with differences in load capacity Capacity variations are achieved by combining basic differential carrier assemblies in different axle housings, axle shafts and wheel equipment.

con-Load Capacity Model No

34,000 lbs DS340, 34138,000 lbs DS2380(P)38,000 lbs DS381(P)*

40,000 lbs DS400-P, DS401-P, DS402(P), DS403(P)45,000 lbs DS451-P

Some models (identified with letter “P”) are equipped with a gear-driven pump, designed to provide additional lubrication to the inter-axle differential and related parts Instructions contained herein are applicable to all axle models, unless specified otherwise.

For brake information and axle mounting or suspension systems, refer to pertinent truck manufacturer’s literature.

Typical Dana Single Reduction Tandem Axle

Two design variations of tandem axles are included in this manual The major difference is in the shaft spline design

Note: DS381 (P) axles manufactured after April 1985 are rated at 40,000 lbs.

Axle and Carrier Assembly Model Identification

Note: Tags that do not include all the information shown here

are older models (before May 1987).

1 - Country or origin2 - Axle model identification

3 - Specification number assigned to the axle built by Spicer Identifies all component parts of the axle including special OEMrequirements such as yokes or flanges

4 - OEM part number assigned to the axle build

5 - Carrier assembly serial number assigned by the manufacturing plant 6 - Axle gear ratio

7 - Carrier assembly production or service part number

Data plate is located onthe axle centerline

G e a r i n g

C a p a c i t y ( x 1 0 0 0 l b s )D e s i g n L e v e l

L u b e P u m p

D - F o r w a r d T a n d e m A x l eR - R e a r T a n d e m A x l eS - S i n g l e R e d u c t i o n

D - S i n g l e R e d u c t i o n w i t h W h e e l D i f f e r e n t i a l L o c k

T - D u a l R a n g e

P - P l a n e t a r y D o u b l e R e d u c t i o nE x a m p l e :

E x a m p l e : 4 6 = 4 6 , 0 0 0 l b s P = S t a n d a r d

( P ) = O p t i o n a l

D S = F o r w a r d T a n d e m A x l e / S i n g l e R e d u c t i o nR S = R e a r T a n d e m A x l e / S i n g l e R e d u c t i o n

Drive Axle

Part Identification

T.O.P

B SG D.I O

Axle Specification Number

The complete axle is identified by the specification number stamped on the side of the axle housing This number identifies all component parts of the axle as built by Dana, including special OEM requirements such as yoke or flange In addition, some axles may include a metal identification tage.

Ring Gear and Pinion

Note: Ring gear and drive pinion are matched parts and must

be replaced in sets.

1 - Part number

2 - Number of ring gear teeth3 - Manufacturing numbers4 - Matching gear set number5 - Number of pinion teeth6 - Date code

7 - Indicates genuine Spicer parts8 - Heat code

6

Power Flow and Torque Distribution

Spicer tandem drive axles described in this publication are single reduction units designed primarily for highway or turnpike.They are also for a variety of other applications This type of axle provides a vehicle with superior load carrying and roadabilitycharacteristics by dividing its work between two axles The complete tandem assembly consists of two axles coupled by a powerdivider.

Power Divider

In operation, the power divider accepts the torque from the vehicle driveline and distributes it equally to the two axles This sembly is of the two-gear design consisting of an input shaft, inter-axle differential, output shaft and two constant-mesh helicalgears The inter-axle differential compensates for axle speed variations in the same way the wheel differential works between thetwo wheels of a single drive axle This unit also acts as a central point in distribution of torque to the two axles The power divideralso includes a driver-controlled, air-operated lockout When lockout is engaged, it mechanically prevents inter-axle differentiationfor better performance under poor traction conditions.

Lube Pump System

Torque Distribution with Lockout Disengaged (Inter-axle Differential is Operation)

Torque (power flow) from the vehicle driveline is transmitted to the input shaft and the inter-axle differential spider At this point,the differential distributes torque equally to both axles For the forward axle, torque is transmitted from the helical-side gear to thepinion helical gear, drive pinion, ring gear, wheel differential and axle shafts For the rear axle, torque is transmitted from the outputshaft side gear, through the output shaft, inter-axle driveline, to the drive pinion, ring gear, wheel differential and axle shafts.

Torque Distribution with Lockout Engaged (inter-axle Differential is Not Operation)

A lockout mechanism is incorporated in the power divider to enable the vehicle driver to lock out the inter-axle differential andprovide maximum traction under adverse road conditions In operation, an air cylinder (controlled by a cab-mounted valve) shiftsa sliding clutch To lock out inter-axle differential action, the clutch engages the helical-side gear and causes this gear, the inputshaft and differential to rotate as one assembly This action provides a positive drive to both axles With Lockout engaged, torqueis distributed to both-axles without differential action The forward axle pinion and ring gear are driven by the helical side gear.The rear axle gearing is driven from the output shaft side gear and inter-axle driveline

Note: Varied road surface conditions can result in unequal torque distribution between the two axle assemblies.

Input torque

Lockout disengagedDrive is from differentialthrough helical gears toforward gearing

Drive isfrom differential

through outputshaft to rear gearing

Torque is transmitted to both axles through inter-axle differential action.

Inter-axle differential operating

Input torque

Lockout engaged Drive is from input shaftforward gearing

Drive is fromoutput shaft side

gear to rear gearingInter-axle differential

not operating

Differential Carrier Assembly Exploded View

Forward Axle Carrier Assembly (Single Speed) with Diff Lock

Other Design Variations

Axle Series D340, 380(P),400-P D341, 381(P), 401-P, 402(P), 403(P), 451-POutput Shaft Splines 16 16

52 535456575855615

2 3 1 9 8

& RING GEAR

212223243329313235 343836 3734 3528272625

12 114

1915 16 17 18

20

63 64 65 66

67 6869

74 73 75727076 77 78 79 80 81 82 83

91 93 92

84 85 86 88 89 90

39 31 40 41

42 43 45 44 46474340 48 4950

94 97 98 99100

104 103 95 91 96 102LUBE PUMP

1 - Differential carrier & bearing caps2 - Bearing capscrew

3 - Flat washer4 - Lockwire5 - Dowel bushing

6 - Bearing cap adjuster lock (RH)7 - Capscrew

8 - Bearing cap adjuster lock (LH)9 - Cotter pin (LH)

10 - Expansion plug (upper)11 -Expansion plug (lower)12 - Filler plug

13 - Shift fork shaft

14 - Carrier cover dowel pun15 - Shift unit mounting stud

16 - Shift fork seal & spring assembly17 - Flat washer

47 - Bearing cage capscrew48 - Pinion helical gear

49 - Outer pinion support bearing (onepiece)

50 - Pinion shaft end nut51 - Pinion nut spring pin52 - Output shaft nut53 - Output shaft washer

54 - Rear bearing retaining washer55 - Axle housing cover

56 - Output shaft oil seal57 - Bearing snap ring58 - Output shaft bearing59 - Filler plug

60 - Output shaft

61 - Output shaft bushing62 - Output shaft O-ring63 - Output shaft bearing cup64 - Output shaft bearing cone65 - Output shaft side gear66 - Side gear snap ring

67 - Output shaft compression spring68 - Output shaft thrust bearing69 - Inter-axle differential assemble70 - Inter-axle differential case half71 - Case bolt

72 - Case nut73 - Side pinion

74 - Side pinion thrust washer75 - Spider

76 - Helical side gear snap ring77- Helical side gear

78 - Helical side gear bushing79 - Helical side gear thrust washer80 - Helical side gear “D” washer81 - Lockout sliding clutch82 - Input shaft

83 - Input shaft bearing cone84 - Input shaft bearing cup85 - Input cover shim86 - Input bearing cover87 - Bearing cover capscrew88 - Input shaft oil seal89 - Input shaft nut washer90 - Input shaft nut91 - PDU carrier cover92 - Carrier cover capscrew93 - Lock washer

94 - Pipe plug95 - Expansion plug96 - Magnetic filter screen97 - Pump gear & shaft assembly98 - Cover O-ring

99 - Lube pump cover100 - Lock washer101 - Cover capscrew102 - Cover dowel pin103 - Pump drive gear104 - Drive gear locknut

105 - Air-operated lockout assembly106 - Shift fork & push rod assembly

5 - Bearing cap adjuster lock6 - Cotter pin

7 - Dowel bushing8 - Ring gear thrust screw9 - Thrust screw jam nut10 - Differential bearing adjuster

12 - Differential bearing cone13 - Ring gear & drive pinion14 - Bolt and nut

15 - Differential case (flanged half)16 - Differential case capscrew17 - Differential side gear18 - Side gear thrust washer19 - Side pinion

20 - Side pinion thrust washer21 - Spider

23 - Pinion bearing cone24 - Pinion bearing spacer25 - Pinion bearing cage26 - Pinion bearing cup

27 - Pinion bearing spacer washer28 - Pinion bearing cage shim29 - Bearing cage capscrew30 - Oil seal

31 - Input yoke32 - Flat washer

The ability of a drive axle to deliver quiet, trouble free operation over a period of years is largely dependent upon the use of goodquality gear lubricant in correct quantity The most satisfactory results can be obtained by following the directions contained inthis manual The following lubrication instructions represent the most current recommendations from Dana Corporation.

Approved Lubricants

General—Gear lubrications acceptable under military specification (MILSPEC) MIL-L-2105D (Lubricating Oils, Gear, pose) 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 MlL-L-l 0324A Thisspecification applies to both petroleum-based and synthetic based gear lubricants if they appear on the most current “QualifiedProducts List” (QPL-2105) for MIL-L-2105D.

Multipur-Note: The use of separate oil additives and/or friction modifiers are not approved in Dana Drive Axles.

Synthetic based — Synthetic-based gear lubricants exhibit superior thermal and oxidation stability, and generally degrade at alower rate when compared to petroleum-based lubricants The performance characteristics of these lubricants include extendedchange intervals, improved fuel economy, better extreme temperature operation, reduced wear and cleaner component appear-ance The family of Spicer TM gear lubricants represents a premium quality synthetic lube which fully meets or exceeds therequirements of MIL-L-2105D These products, available in both 75W-90 and 80 W-140, have demonstrated superior perfor-mance in comparison to others qualified under the MILSPEC, as demonstrated by extensive laboratory and field testing For acomplete list of Spicer ® approved synthetic lubricants contact your local Spicer representative See back cover of this

manual for appropriate phone number.

Makeup Lube — Maximum amount of non-synthetic makeup lube is 100/o.

Viscosity / Ambient Temperature Recommendations -The following chart lists the varies SAE Grades covered by MIL-L- 2105Dand the associated ambient temperature range from each Those SAE grades shown with an asterisk (*) are available in theRoadranger family of synthetic gear lubricants

The lowest ambient temperatures covered by this chart are -40°F and -40°C Lubrication recommendations for those applicationswhich consistently operate below this temperature range, must be obtained through tcontacting your local Spicer epresen-tative.

75W - 40 F to -150 F (-40 C to -26 C)75W-80 - 40 F to 80 F (-40 C to 21 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 - 40 F to 100 F (-40 C to -38 C)80W-140 - 40 F and above(-40 C and above)85W-140 - 40 F and above (-40 C and above)

Lube Change Intervals

This product combines the latest manufacturing and part washing technology When filled with an Spicer approved syntheticlubricant 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 anduser assessment of the application and operating environment

Severe Service Lubrication Change Intervals-Severe service applications are those where the vehicle consistently operates at ornear its maximum GCW or GVW ratings, dusty or wet environments, or consistent operation on grades greater than 8% For theseapplications, the ON/OFF HIGHWAY portion of the chart should be used Typical applications are construction, logging, miningand refuse removal.

Note: Remove metallic particles from the magnetic filler plug and drain plugs Clean or replace the breather at each lubricant

Changing LubeDraining

Drain when the lube is at normal operating temperature It will run freely and minimize the time necessary to fully drain the axle.Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container Inspectdrain plug for large quantities of metal particles After initial oil change, these are signs of damage or extreme wear in the axle,and inspection of the entire unit may be warranted Clean the drain plug and replace it after the lube has drained completely Axles with Lube Pump: Remove the magnetic strainer from the power divider cover and inspect for wear material in the samemanner as the drain plug Wash the magnetic strainer in solvent and blow dry with compressed air to remove oil and metal parti-cles.

Exercise care to direct compressed air into safe area Wear safety glasses.

Guide Lines - Lube Change Intervals for Drive Axles

Lubricant Type On-Highway Miles Maximum change terval

In-On/Off Highway SevereService Miles

Maximum Change terval

In-Mineral Based 100,000 Yearly 40,000 YearlyRoadranger Approved

250,000 3 Years 100,000 Yearly

CAUTION

Note: Lube fill capacities in the adjacent chart are good guidelines but will vary somewhat on the basis of the angle the axle is

installed in a particular chassis Always use the filler hole as the final reference If lube is level with the bottom of the hole,the axle is properly filled.

Axle Installation Angles

Axles installed at angles exceeding 10 degrees or operated regularly in areas of continuous and lengthy grades may require pipes to allow proper fill levels

stand-For specific recommendations, contact your local Spicer representative See back cover of this manual for phone numbers.

Forward Axle: Add an additional 2 pints (0.94 liters) axle lubricant through filler hole at the top of differential carrier near the power

divider cover.

Capacities listed are approximate The amount of lubricant will vary with angle of axle as installed in vehicle chassis.

Oil Filler Hole at top of Differential CarrierMagnetic Strainer for Axle with Lube Pump

Lube Capacities, Dana Housings

Single Reduction Tandem Series Forward Axle Pints (liters) Rear Axle Pints (liters)380(P), 381(P), 400-P, 401-P 39 (18.5) 36 (17.0)

402(P), 403(P),451-P 39 (18.5) 36 (17.0)

Wheel End Lubrication

Before operating the axle, the wheel hub cavities and bearings must be lubricated to prevent failure When wheel ends areserviced, follow Spicer’s wheel end lubrication procedure before operating the axle.

Spicer 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 proceed as follows: (Fig 1)

1 Rotate the wheel end hub until the oil fill hole is up.2 Remove the oil fill plug.

3 Pour 1/2 pint of axle sump lubricant into each hub through the wheel end fill hole.4 Install oil fill plug and tighten to specified torque.

Fig 1 Cutaway views of typical wheel and assemblies

LUBRICANTFLOWFROM SUMPWHEEL END

OIL FILL HOLE

LUBRICANTLEVEL

Wheel Ends without an oil fill hole proceed as follows: (Fig 2)

1 With axle level and wheel ends assembled, add lubricant through filler hole in axle housing cover until fluid is level withthe bottom of filler hole.

2 Raise the left side of the axle 6 inches or more Hold axle in this position for one minute.3 Lower the left side.

4 Raise the right side of the axle 6 inches or more Hold axle in this position for one minute.5 Lower the right side.

6 With axle on a level surface, add lubricant through housing cover oil filler hole until fluid is level with the bottom of thehole.

Note: Axles without wheel end fill holes will require approximately 2.5 additional pints of lubricant to bring the lube level even with

the bottom of fill hole.

Fig 2 Wheel end lubrication procedure

TEMPERATURE SENSOR MOUNTING HOLEWITH AXLE ON LEVEL SURFACE FILL HOUSING WITH OIL TO BOTTOM OF PLUG

TILT HOUSING SIDE TO SIDE, 1 MINUTE PER SIDE, THEN, RECHECK OIL LEVEL IN AXLE

OIL WILL RUN INTO WHEEL ENDOIL WILL

RUN INTO WHEEL END

Cleaning, Inspection, Replacement

As the drive axle is disassembled, set all parts aside for thorough cleaning and inspection Careful inspection will help determinewhether parts should be reused In many cases, the causes of premature wear or drive axle failure will also be revealed.

The differential carrier assembly may be steam-cleaned while mounted in thehousing as long as all openings are tightly plugged Once removed from its hous-ing, do not steam clean differential carrier or any components Steam cleaning atthis time could allow water to be trapped in cored passages, leading to rust, lubri-cant contamination, and premature component wear The only proper way to cleanthe assembly is to disassemble it completely Other methods will not be effectiveexcept as preparatory steps in the process Wash steel parts with ground or pol-ished surfaces in solvent There are many suitable commercial solvents available.Kerosene and diesel fuel are acceptable.

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

Wash castings or other rough parts in solvent or clean in hot solution tanks usingmild alkali solutions If a hot solution tank is used, make sure parts are heated thor-oughly, before rinsing

Rinse thoroughly to remove all traces of the cleaning solution Dry parts ately with clean rags

immedi-Lightly oil parts if they are to be reused immediately Otherwise, coat with oil andwrap in corrosion-resistant paper Store parts in a clean, dry place.

Inspect steel parts for notches, visible steps or grooves created by wear Look forpitting or cracking along gear contact lines Scuffing, deformation or discolorationare signs of excessive heat in the axle, usually related to low lubricant levels or im-proper lubrication practices

Before reusing a gear set, inspect teeth for signs of excessive wear Check toothcontact pattern for evidence of incorrect adjustment (see Adjustment Section forcorrect pattern) Inspect machined surfaces of cast or malleable parts They mustbe free of cracks, scoring, and wear Look for elongation of drilled holes, wear onsurfaces machined for bearing fits and nicks or burrs in mating surfaces Inspect fasteners for rounded heads, bends, cracks or damaged threads The axlehousing should be examined for cracks or leaks Also look for loose studs orcross-threaded holes Inspect machined surfaces for nicks and burrs.

WARNING

Repair and Replacement

To achieve maximum value from an axle rebuild Replace lower-cost parts, such as thrust washers, seals, etc These itemsprotect the axle from premature wear or loss of lubricants Replacing these parts will not increase rebuild cost significantly It is also important to replace other parts which display signs of heavy wear even though not cracked or broken A significantportion of such a parts useful life has been expended and the damage caused, should the part fail, is far in excess of its cost

Steel Parts- Gear sets, input and output shafts, differential parts and bearings are not repairable Worn or damaged parts shouldbe discarded without hesitation Also discard mating parts in some cases Gear sets, for example, must be replaced in sets Miscellaneous Parts - Seals and washers are routinely replaced None of these parts can be reused if damaged Fasteners usingself-locking nylon patches may be reused if not damaged, but should be secured by a few drops of Loctite #277 on the threadedsurface of the hole during installation and carefully torqued during installation

Axle Housings - Repairs are limited to removal of nicks or burrs on machined surfaces and the replacement of loose or brokenstuds.

Any damage which affects the alignment or structural integrity of the housing requires housing replacement Repair by ing or straightening should not be attempted This process can affect the housing heat treatment and cause it to fail complete-ly when under load.

weld-Silicone Rubber Gasket Compound - For more effective sealing Spicer uses silicone rubber gasket compound to seal themajority of metal-to-metal mating surfaces

Spicer includes gasket compound and application instructions in many repair parts kits.

It is recommended that this compound be used in place of conventional gaskets The compound will provide a more effective sealagainst lube and is easier to remove from mating surfaces when replacing parts.

Seals, Yoke & Slinger Service Information

During the 4th Quarter of 1990, new seals and yoke & slingers were used on the models in this publication The new seals andslingers are noticeably different from the current seals and will affect interchangeability.

The upgraded seals can be used on axles originally equipped with the old seals.

Dana recommends the replacement of old yoke & slinger assemblies when the new seals are installed.

The old yokes and slingers will work with the new seals, but new yoke and slinger assemblies provide maximum sealing protectionand prevent premature seal wear due to poor yoke condition.

New yoke and slinger assemblies cannot be used with the old seal design on the tandem forward axles.New yoke and slinger assemblies can be used with the old seal on the tandem rear pinions.

Yoke Assembly & Oil Seal Kits contain oil seal, yoke & slinger and instructions.

Most non-Dana aftermarket seals will not be compatible with the new Dana Yoke and Slinger assemblies.Spcier recommends the use of special installation tools conveniently packaged in one single kit (listed below).Refer to Dana parts Book AXIP-0089 and Eaton Bulletin 90-06 for additional information.

Seal Driver Installation Kit 272139

126917 Driver (Rear Axle Pinion)

127787 Adapter (use with 126917 Driver for Forward Axle Input)127786 Driver (Forward Axle Output)

CAUTION

• The oil seal or grease retainer and discard.

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

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

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

2 Inspect:

• The spindle journal and hub bore for scratches or burns Recondition with emery cloth as required.

Note: Deep gouges can be repaired by filling gouge with hardened gasket and smoothing with emery cloth.

• The wheel seal following the directors provided by the seal supplier.

Always use the seal installation tool specified by the seal manufacturer Using an improper tool can distort or damagethe seal and cause premature seal failure.

Procedure - Wheel Bearing Adjustment

1 Identify the wheel nut system being installed Three systems are available:• Three piece Dowel-type wheel nut system -Fig.1

IMPORTANT

• Four piece Tang/Dowel type wheel nut system - Fig.3

Do not mix spindle nuts and lock washers from different systems Mixing spindle nuts and lock washers can cause wheelseparation.

Note: The lock washer for a four piece-dowel-type wheel system is thinner than the lock washer for a three piece tang-type

wheel nut system and is not designed to bear against the inner nut.

2 Inspect the spindle and nut threads for corrosion and clean thoroughly or replace as required.

Note: Proper assembly and adjustment is not possible if the spindle or nut threads are corroded.

• lnspect the tang-type washer (if used) Replace the washer if the tangs are broken, cracked, or damaged.3 Install the hub and drum on the spindle with care to prevent damage or distortion to the wheel seal.

A wheel dolly is recommended during installation to make sure that the wheel seal is not damaged by the weight of thehub and drum Never support the hub on the spindle with just the inner bearing and seal This can damage the seal andcause premature failure.

• Completely fill the hub cavity between the inner and outer bearing races with the same lubricant used in the axle sump.4 Before installation, lubricate the outer bearing with the same lubricant used in the axle sump.

Note: Lubricate only with clean axle lubricant of the same type used in the axle sump Do not pack the bearing with grease

before installation Grease will prevent the proper circulation of axle lubricant and may cause wheel seal failure.5 Install the outer bearing on the spindle.

• Install the inner nut on the spindle.

• Tighten the inner nut to 200 lbs ft (271 N.M.) while rotating the wheel hub.

Never use an impact wrench to adjust wheel bearings A torque wrench is required to assure that the nuts are property

Outer nut(P/N 11249)

Inner nut(P/N 11249)Tang-type lock washer (P/N 119883) 0.123" thickFig 2

Outer nut(P/N 119881)

Inner nut(P/N 119882)Dowel PinDowel-type LockWasher (P/N 119883)Fig 1

Outer nut(P/N 119881)

Inner nut(P/N 119882)

Dowel pinDowel-type lock

washer (P/N 119883)Tang-type lock

washer (P/N 129132).0478" thickFig 3

CAUTION

6 Back-off the inner nut one full turn Rotate the wheel hub.

7 Re-tighten the inner nut to 50 lbs ft (68 N.M.) while rotating the wheel hub.8 Back-off the inner nut exactly 1/4 turn.

Note: This adjustment procedure allows the wheel to rotate freely with 0.001"-0.005" (0.025mm to 0.1 27mm) end-play.

9 Install the correct lock washer for the wheel nut system being used.

Procedure - Three piece tang-type lock washer system (see Fig 2).

1 Install the Tang-type lock washer on the spindle.

Never tighten the inner nut for alignment This can preload the bearing and cause premature failure.

2 Install the outer nut on the spindle and tighten to 250 lbs ft (339 N.M.).3 Verify end-play (see End Play Verification Procedure)

4 After verifying end play, secure wheel nuts by bending one of the locking washer tangs over the outer wheel nut and anothertang over the inner wheel nut as shown in Figure 4 (below)

Procedure - Three piece dowel-type lock washer system (see Fig 1)

1 Install the Dowel-type lock washer on the spindle.

Note: If the dowel pin and washer are not aligned, remove washer, turn it over and reinstall If required, loosen the inner nut

just enough for alignment.

Never tighten the inner nut for alignment This can preload the bearing and cause premature failure.

SpindleInner nutLockwasher

Bend two tangs…one over inner nut

and one overouter nutOuter nut

IMPORTANT

2 Install the outer nut on the spindle and tighten to 350 lbs ft (475 N.M.).3 Verify end-play (see End Play Verification Procedure)

Procedure - Four piece tang/dowel-type lock washer system (see Fig 3)

1 First, install the Dowel-type lock washer on the spindle.

Note: If the dowel pin and washer are not aligned, remove washer, turn it over and reinstall If required loosen the inner nut

just enough for alignment.

Never tighten the inner nut for alignment This can preload the bearing and cause premature failure.

2 Install the Tang-type lock washer on the spindle.

3 Install the outer nut on the spindle and tighten to 250 lbs ft (339 N M.)4 Verify end-play (see End Play Verification Procedure)

5 After verifying end play, secure the outer nut by bending two opposing (180° apart) tangs of the locking washer over the outernut as shown in Figure 5

Procedure - Install

1 Install a new gasket at axle shaft flange.2 Install axle shaft.

3 Install axle flange nuts and tighten to specified torque.

4 Lubricate axle wheel ends (see Wheel End Lubrication Procedure)

Procedure - End Play Verification Procedure

1 Verify that end-play meets specification using a dial indicator An indicator with 0.001” (0.03 mm) resolution is required.

Figure 5

SpindleInner nut

LockwasherBend two tangs

over outer nut

Outer nut

Dowel pin

If end play is not within specification, readjustment is required.

Procedure - End Play Readjustment Procedure

1 Excessive End Play - If end play is greater than.005” (.127 mm), remove the outer nut and pull the lock washer away fromthe 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 torque the outer nut Verify end play with a dial indicator

2 Insufficient End Play - If end play is not present, remove the outer nut and pull the lock washer away from the inner nut, butnot off the spindle Loosen the inner nut to the next adjustment hole of the dowel-type washer (if used) Reassemble the wash-er and re-torque the outer nut Verify end play with a dial indicator

3 Fine Tuning the End Play - If, after performing the readjustment procedures, end play is still not within the.001”-.005” (.025mm to.127 mm) range, disassemble and inspect the components If parts are found to be defective, replace the defectiveparts, reassemble and repeat wheel bearing adjustment procedure Verify end play with a dial indicator.

End Play Adjustmentwith Tire & Wheel

With indicator mounted at bottom,

Push/Pull at sides of drum End Play Adjustmentwith Wheel hub

CAUTION

Differential Carrier Adjustments

Adjustments help provide optimum axle life and performance by correctly positioning bearings and gears under load The tandemaxles covered in this manual require the following adjustments:

Bearing Preload: This adjustment is performed for both pinion and differential bearings It maintains proper gear alignments by

creating correct bearing cone and cup relationships for free rotation under load The pinion pilot bearing does not require a preloadadjustment.

Ring Gear Tooth Contact: This adjustment positions ring gear and pinion for best contact under load Correct adjustment

distrib-utes torque evenly over gear teeth and helps maximize gear set Iife.

Input Shaft End Play (Forward Axles): This adjustment controls gear mesh in the inter-axle differential Proper adjustment helps

maximize life of all power divider parts.

Adjust Input Shaft End Play

Specifications: Input shaft end play requirements will vary with operating conditions, mileage and rebuild procedures These

vari-ations are shown in the following chart.

Input Shaft End Play

New or Rebuild with new parts: 0.003" to 0.007".Rebuild with reused parts: 0.013" to 0.017".

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

Acceptable End Play Tolerances when measuring as a regular maintenance procedure with axle in truck.Up to 0.060" with over 100,000 miles or 1 year service off-road

Up to 0.040" with less than 100,000 miles or 1 year service on- road.

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

Procedure - Measure and Adjust End Play

In September 1988, a Spring and a Thrust Button between the input and output shafts End play tolerances are the samefor axles with or without this Spring and Button However, end play measurement procedure is different than describedbelow Refer to Service Bulletin Supplement at back of this manual for procedure variances

With power divider assembled to differential carrier, measure end play with dial indicator positioned at yoke end of input shaft.Move input shaft axially and measure end play If end play is not correct (see chart), adjust as follows.

2 Remove input shaft nut, flat washer and yoke Remove bearing cover cap screws and lock washers Remove cover and shimpack.

3 To increase end play, add shims: Desired end play: 0.003" to 0.007"

Measured endplay (Step 1): 0.001" - 0.001"

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

IMPORTANT

4 To decrease end play, remove shims:

Measured end play (Step 1): 0.015" - 0.015"Desired end play: 0.003" to 0.007"

Remove shims to provide desired end play : 0.012" to 0.008"

5 To reassemble input shaft, install the adjusted shim pack and bearing cover Install cap screws and lock washers Torquescrews to 75-85 ft lbs (101-115 N.m).

Note: If difficulty is experienced in achieving correct torque on the input yoke nut, torque the nut with truck on the ground

and axle shafts installed.

6 Install yoke, flat washer and nut Tighten nut snugly Tap end of input shaft lightly to seat bearings.7 Measure input shaft end play with dial indicator If end play is still incorrect, repeat Steps 2 through 6.

8 With end play correct, seal shim pack to prevent lube leakage, then torque input shaft nut and cover cap screws (see chart).

Note: When power divider has been disassembled and reassembled, it may be desirable to adjust end play by measuring

bear-ing cover clearance and calculatbear-ing shim pack size For procedures, see page 39.

*Metric Nut used on Axles produced after 1-3-95

Measuring End Play with Dial Indicator

Torque Chart

ft lbs N.mInput Shaft Nut

1 5/8 - 18 780-960 1057 - 1301*M42 x 1.5 840 - 1020 1140 - 1383Bearing Cover Capscrew

1/2 - 13 75 - 85 101 - 115

Pry barU-bracket

Dial indicator

Input shaft

Lift up onpry bar to compressinput shaft.

Pinion Bearing Preload

Special Instructions

Most late model axles are provided with a “press-fit” outer bearing on the drive pinion Some of the early model axles use an outerbearing which slips over the drive pinion Procedures for adjusting both types of pinion bearing design are contained in this sec-tion.

Procedure - Adjust Pinion Bearing Preload for Axles with “Press-fit” Outer Pinion Bearings

1 Trial Build-up

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

bear-Note: When new gear set or pinion bearings are used, select nominal size spacer from the specification chart below If

orig-inal 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 face of the outer bearing cone.

Assemble these Parts forTrial Build-up.

Cage in Pressto Check BearingPreload.

Sleeve MustApply Pressure

To Back FaceOf OuterBearing Cone

apply pressure toback face ofouter bearingcone

Spring scale

3 Apply press load (see chart below) to the assembly and check rolling torque Wrap soft wire around the bearing cage, attachspring scale and pull Preload is correct when torque required to rotate the pinion bearing cage is from 10-20 in lbs Thisspecification is translated into spring scale readings in the chart below.

4 If necessary, Adjust Pinion Bearing Preload by changing the pinion bearing spacer A thicker spacer will decrease preload Athinner spacer will increase preload.

Once correct bearing preload has been established, note the spacer size used Select a spacer0.001” larger for use in the final pinion bearing cage assembly The larger spacer compensates forslight “growth” in the bearings which occurs when they are pressed on the pinion shank The trialbuild-up will result in proper pinion bearing preload in three of four cases.

Do not assume that all assemblies will retain proper preload once bearings are pressed on pinionshank Final preload test must be made in every case.

Specifications for Pinion Bearing Trial Build-up Preload Test (“Press-fit” Outer Pinion Bearings)

Nominal Bearing SpacerThickness

Spring Scale Reading (without pinionseal) (for 10-20 in lbs torque) (1.1-2.3 N.m)

Axle Models in mm Tons Metric Tons lbs Kgs.Forward Axles

D340, 380(P),400-P

0.638 16.21 13.5 - 15.5 122- 140 3-7 2-3

D341, 381, (P),401-P, 402(P),403(P), 451-P

0.496 12.60 17 - 19 154 - 172 3-7 32

1.4-Rear Axles 0.638 16.21 14 - 15 127 - 136 4-8 36

18-IMPORTANT

Final Pinion Bearing Preload Test

Procedure -

1 Assemble the complete pinion bearing cage unit as recommending the assembly section of this manual.

Note: Forward axle pinion is equipped with helical gear For easier disassembly during bearing adjustment procedure, use a

dummy yoke (if available) in place of helical gear.

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

Vise Method - If the yoke and nut are used, mount the assembly in a vise, clamping yoke firmly

Press Method - If a press is used, position a sleeve or spacer so that load is applied directly to the back-face of the outerbearing cone.

3 Measure Pinion Bearing Preload - Use a spring scale to test the assembly rolling torque To use the spring scale, wrap softwire around the bearing cage, attach the scale and pull Preload is correct when torque required to rotate the pinion bearingcage is from 15 to 35 in lbs This specification is translated into spring scale readings in the chart below.

Measuring Bearing Preload with Pinion in Vise

Measuring Bearing Preload with Pinion in Press

Final Pinion Bearing Preload Test

Axle Model Nut Torque ft lbs (N.m) Press Load- Tons (Metrictons)

Spring Seal Reading (withoutpinion seal)- lbs (kg)

Forward Axle

D340, 380(P), 400-P 560 - 700 (759 - 949) SelfLocking Nut

13.5 - 15.5 (12.2 - 14.0) 5-12 (2.3-5.4)

D341, 381(P), 401-P, 402(P),403(P), 451-P

780 - 960 (1057-1301) SelfLocking Nut

17 - 19 (15.4 - 17.2) 5-12 (2.3-5.4)

840-1020 (1140-1383) MetricNut

Adjust Pinion Bearing Preload for Axles with "Slip-fit" Outer Pinion Bearings

Procedure -

1 Lubricate bearings and assemble the drive pinion, bearings, and pinion bearing cage as recommended in the assembly sectionof this manual Use the pinion bearing spacer removed from the axle during disassembly If the original spacer cannot beused, install the nominal spacer recommended in the adjacent chart.

Note: Forward axle pinion is equipped with helical gear, For easier disassembly during bearing adjustment procedure, use a

dummy yoke (if available) in place of helical gear.

2 Apply clamp load to the pinion bearings Install the yoke (or helical gear) and torque the nut to specification or use a press tosimulate nut torque by applying pressure to the assembly (see chart below)

Vise Method - If the yoke and nut are used, mount the assembly in a vise, clamping yoke firmly

Press Method - If a press is used, position a sleeve or spacer so that load is applied directly to the back-face of the outerbearing cone.

3 Measure Pinion Bearing Preload - Use a spring scale to test the assembly rolling torque To use the spring scale, wrap softwire around the bearing cage, attach the scale and pull Preload is correct when torque required to rotate the pinion bearingcage is from 15 to 35 in lbs This specification is translated into spring scale readings in the chart below.

Nominal Pinion Bearing Spacers

Axle Model Spacer Thickness in (mm)Forward Axle

D340, 380(P), 400-P 0.638 (16.205)D341, 381(P), 401-P, 402(P), 403(P),

0.492 (12.497)

Rear Axle (all models) 0.638 (16.205)

Measuring Bearing Preload with Pinion in Vise

4 Adjust Pinion Bearing Preload - If necessary, adjust pinion bearing preload Disassemble the pinion bearing cage as mended in this manual and change the pinion bearing spacer A thicker spacer will decrease preload A thinner spacer willincrease preload.

recom-Use the correctly sized spacer, Do not use shim stock or grind spacers These practices can lead toloss of bearing preload and gear or bearing failure.

*Torque nut to 840 ft-lbs (1 139 N.m), Then continue tightening nut to align nut slot to nearest hole in pinion shank.

Measuring Bearing Preload with Pinion in Press

Final Pinion Bearing Preload Test (Slip fit outer pinion bearings)

Axle Model Nut Torque ft lbs (N.m) Press Load- Tons (Metrictons)

Spring Seal Reading (withoutpinion seal)- lbs (kg)

Forward Axle

D340, 380(P), 400-P 560 - 700 (759 - 949) SelfLocking Nut

13.5 - 15.5 (12.2 - 14.0) 5-12 (2.3-5.4)

D341, 381(P), 401-P, 402(P),403(P), 451-P

780 - 960 (1057-1301) SelfLocking Nut

17 - 19 (15.4 - 17.2) 5-12 (2.3-5.4)

840-1020 (1140-1383) MetricNut

Differential Bearing Preload and Ring Gear Backlash Adjustment

Special Instructions

Correct differential bearing preload insures proper location of these bearings under load and helps position the ring gear for propergear tooth contact

Procedure - Adjust Diff Bearing Preload

1 Lubricate differential bearings

When installing bearing caps and adjuster, ert care not to cross threads.

ex-2 Install adjusters and bearing caps Tighten bearing capscrews finger-tight If this is difficult, use a hand wrench.

Note: Ring gear position for rear axle is illustrated.

3 Loosen the bearing adjuster on the same side as the ringgear teeth until its first thread is visible.

4 Tighten the bearing adjuster on the back-face side of thering gear until there is no backlash.

This can be tested by facing the ring gear teeth and ing the gear away from the body while gently rocking thegear from side to side There should be no free movement Rotate the ring gear and check for any point where thegear may bind If such a point exists, loosen and re-tight-en the back side adjuster Make all further adjustmentsfrom the point of tightest mesh.

push-5 At teeth side of ring gear, tighten adjuster until it contactsthe bearing cup Continue tightening adjuster two or threenotches and this will preload bearings and provide back-

6 Measure backlash with a dial indicator.

USED GEARING — Reset to backlash recorded before assembly.

dis-NEW GEARING — Backlash should be between 0.006”and 0.016”.

If backlash is incorrect, proceed as described below to adjust.

re-Procedure - Adjust Ring Gear Backlash

1 To add backlash: Loosen the adjuster on the teeth side ofthe ring gear several notches Loosen the opposite adjust-er one notch Return to adjuster on teeth side of the ringgear and tighten adjuster until it contacts the bearing cup.Continue tightening the same adjuster 2 or 3 notches Re-check backlash.

2 To remove backlash: Loosen the adjuster on the teeth sideof the ring gear several notches Tighten the opposite ad-juster one notch Return to adjuster on teeth side of ringgear and tighten adjuster until it contacts the bearing cup.Continue tightening the same adjuster 2 or 3 notches Re-check backlash.

3 Moving adjuster one notch is the movement of the leadedge of one adjuster lug to the lead edge of the next lugpast a preselected point.

Onenotch

Ring Gear and Pinion Tooth Contact

Note: Rear axle gearing is shown in the following instructions Correct tooth contact patterns and adjustments are the same for

forward and rear axles.

Check Tooth Contact Pattern (NEW GEAR)

Paint twelve ring gear teeth with marking compound and roll the gear to obtain a contact pattern The correct pattern is tered on the ring gear tooth with lengthwise contact clear of the toe The length of the pattern in an unloaded condition is approx-imately one-half to two-thirds of the ring gear tooth in most models and ratios.

well-cen-Check Tooth Contact Pattern (USED GEAR)

Used gearing will not usually display the square, even contact pattern found in new gear sets The gear will normally have a et” at the toe-end of the gear tooth which tails into a contact line along the root of tooth The more use a gear has had, the morethe line becomes the dominant characteristic of the pattern Adjust used gear sets to display the same contact pattern observedbefore disassembly A correct pattern is clear of 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 thetooth at any point.

ToeRootTop landHeelTooth

Pattern should cover 1/2 tooth or more (face width) Pattern should be evenly centered between tooth top land and root.

Pattern should be clear of tooth toe.Correct Pattern New Gearing

Pocket may be extended Pattern along the face width could be longer.Correct Pattern Used Gearing

Adjust Tooth Contact Patterns

If necessary, adjust the contact pattern by moving the ring gear and drive pinion Ring gear position controls the backlash Thisadjustment moves the contact pattern along the face width of the gear tooth, Pinion position is determined by the size of the pinionbearing cage shim pack It controls contact on the tooth depth of the gear tooth These adjustments are interrelated As a result,they must be considered together even though the pattern is altered by two distinct operations When making adjustments, firstadjust the pinion, then the backlash Continue this sequence until the pattern is satisfactory

Adjust Pinion Position

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

If the pattern is too close to the top land of the gear tooth, remove pinion shims If the pattern is too close to the root of the geartooth, add pinion shims Check ring gear backlash after each shim change and adjust if necessary to maintain the 0.006” to 0.016”specifications.

Adjust Backlash

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

With the pattern concentrated at the toe (too far down the tooth), add backlash by loosening the bearing adjuster on the teeth sideof ring gear several notches Loosen the opposite adjuster one notch Return to adjuster on teeth side of ring gear and tightenadjuster until it contacts the bearing cup Continue tightening the same adjuster 2 or 3 notches Recheck backlash.

If the pattern is concentrated at the heel (too far up-the tooth), remove backlash by loosening the bearing adjuster on the teethside of ring gear several notches Tighten the opposite adjuster one notch Return to adjuster on teeth side of ring gear and tightenadjuster until it contacts the bearing cup Continue tightening the same adjuster 2 or 3 notches Recheck backlash.

Pattern too close or off tooth root.

INCORRECT PATTERN

Move ring gear away from pinion to increase backlash.

Pattern too close to edge of tooth toe.

INCORRECT PATTERN

Move ring gear toward pinion to decrease backlash.

Pattern too far along tooth toward tooth heel.

Fastener Tightening Specifications

Specifications are for all axle models unless specified otherwise.

Dana Single Reduction Tandem Models

D340, 380(P), 400-P D341, 381 (P), 401-P, 402(P), 403(P), 451-P

• Correct tightening torque values are extremely important to assure long Dana Axle life and dependable performance der-tightening of attaching parts is just as harmful as over-tightening.

Un-• Exact compliance with recommended torque values will assure the best results.

• The data includes fastener size, grade and torque tightening values Axle models are included to pinpoint identificationof fasteners for your particular axle.

• To determine bolt or cap screw grade, check for designation stamped on bolt head (see illustration).

Note 1: Metric Nut Used on Axles Produced After 1/3/95, Ref Chart PG 56

Bolt head markingsfor grade identification

Grade 5Grade 8

Remove Differential Carrier Assembly from Axle Housing

Special Instructions

D341, 381 (P), 401-P, 402(P), 403(P), 451-P models do NOT use and output shaft Rear Bearing Retaining Washer.

The output shaft rear bearing retaining washer is frequently lost when the differential carrier assembly is removed It mayadhere to the yoke, to the face of the output shaft bearing, fall on the floor or into the housing Locate this washer beforecontinuing! If it is not reinstalled, the end of the yoke will wear the output shaft bearing very quickly If it is left in the housing,it can be picked up by the ring gear motion and cause premature axle failure.

Procedure -

1 Drain axle lubricant

2 Disconnect inner axle driveline.

3 Remove output shaft but, flat washer and yoke.4 Disconnect differential lockout air line.

5 Disconnect main driveline Losen inputshaft yoke nut but do not remove.

7

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

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

7 Remove nuts and lockwashers fastening the carrier to the axle housing Remove the differentail carrier assembly.

Do not lie under the carrier after fasteners are removed Use transmission jack to support the differential carrier ble during removal.

assem-8 Axle Housing Cover and Output Shaft Bearing Parts: The bearing parts can be replaced with cover removed or installed If

necessary, remove axle housing cover It is fastened with cap screws, nuts and lock washers.

9 Remove oil seal and discard.10 Remove bearing retaining washer

D341, 381(P), 401-P, 402(P), 403(P), 451-P models do not use and output shaft rear bearing ing washer.

retain-11 If replacement is necessary, remove snap ring, rear bearing and bearing sleeve.

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

WARNING