Spicer Tandem Drive Axles ® Sevice Manual Spicer® Tandem Drive Axles AXSM-0042 September 2007 Models: D/R440 D/R480 D/R461 D/R463 D/R581 D/R651 D/R653 D/R460 D/R485 D/R462 D/R521 D/R601 D/R652
Warning Warnings and Caution The description and specifications contained in this service publication are current and the time of printing. Dana Corporation reserves the right to discontinue or to modify its models and/or procedures and to change specifications at any time without notice. Any reference to brand names in this publication is made simply as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents, if available, may be used.
Table of Contents Table of Contents - Visual Wheel End Page 99-101 Carrier Assembly Page 45-56 Power Divider Page 24-44 Table of Contents Drive Pinion Page 57-67 Wheel Differential Assembly Page 68-82 Seals Page 92-93 Differential Lockout Page 17-22 Ring Gear Page 82-83 Differential Carrier Assembly Page 11-16 Wheel Differential Lock Page 83-90 Housing Breather Page 94 Wheel End Seal Page 95-96 Wheel Adjustment Systems Page 97-98 Housing and Rear Cover Assembly Page 91 Lubrication Page 102-10
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 .............................................
General Information Introduction Dana Corporation, Axle & Brake Division, presents this publication to aid in maintenance and overhaul of Dana tandem drive axles. Instructions contained cover the models listed. Their design is common, with differences in load capacity. Capacity variations are achieved by combining basic differential carrier assemblies with different axle housings, axle shafts and wheel equipment.
General Information Model Listing The following models are included in this publication: Forward Axle Rear Axle DP440-P DS440-P Load Capacity 44,000 lbs. RS440 DT440-P DP460-P DS460-P 46,000 lbs. RS460 DT460-P DD461-P RD461 DP461-P DS461-P RS461 DT461-P DP480-P DS480-P 48,000 lbs. RS480 DT480-P DP485-P DT485-P DD521-P RD521 52,000 lbs. DP521-P DS521-P RS521 DT521-P DP580-P 58,000 lbs.
General Information Model Information Lube Pump P = Standard (P) = Optional S - Single Reduction D - Single Reduction with Wheel Differential Lock T - Dual Range P - Planetary Double Reduction Design Level General Information Gearing D - Forward Tandem Axle R - Rear Tandem Axle Capacity (x 1000 lbs.) Example: 46 = 46,000 lbs.
General Information Model Identification Drive Axle Note: Tags that do not include all the information shown here are older models (before May 1987). 4 3 5 Spicer® CUST. PART NO. SPEC. SERIAL NO. 2 MODEL PART NO. 1 ®recipS .ON TRAP .TSUC .ON LAIRES OITAR .CEPS .ON TRAP LEDOM :NI EDAM Forward Axle (Side View) 6 RATIO MADE IN: 7 Data plate is located on the axle centerline Spicer® CUST. PART NO. SPEC. MODEL PART NO. SERIAL NO.
General Information Part Identification Axle Housing Axle Shaft 2 ® erS. Spic LB . NO PT. CAP. . G. HS I.D. NO DE IN G.
General Information Ring Gear and Pinion Note: Ring gear and drive pinion are matched parts and must be replaced in sets.
Failure Analysis Failure Analysis Failure analysis is the process of determining the original cause of a component failure in order to keep it from happening again. Too often, when a failed component is replaced without determining its cause, there will be a recurring failure. If a carrier housing is opened, revealing a ring gear with a broken tooth, it is not enough to settle on the broken tooth as the cause of the carrier failure. Other parts of the carrier must be examined.
Failure Analysis Make a Preliminary Investigation Find the Cause of the Failure These steps consist of external inspections and observations that will be valuable when combined with the results of the parts examination. Here begins the real challenge to determine the exact cause of the failure. Keep in mind that there is no benefit to replacing a failed part without determining the cause of the failure.
Inspection Inspection Clean 1. Wash steel parts with ground or polished surfaces in solvent. There are many suitable commercial solvents available. Kerosene and diesel fuel are acceptable. Note: Replace conventional gaskets with silicone rubber gasket compound (included in many repair kits). The compound provides a more effective seal against lube seepage and is easier to remove from mating surfaces when replacing parts.
Inspection Inspect Primary Gearing Before reusing a primary gear set, inspect teeth for signs of excessive wear. Check tooth contact pattern for evidence of incorrect adjustment. Check Output Shaft End-play (Forward Axle) See illustration for steps 1-3. Check Input Shaft End-play (Forward Axle) Note: Before disassembling the power divider, measure and record input shaft end-play. 1. Position dial indicator at yoke end of output shaft. 2. Push in on output shaft and zero the dial indicator. 3.
Differential Carrier Assembly Differential Carrier Assembly - Parts 5 1 2 3 Differential Carrier Assembly 4 1 - Carrier fasteners 2 - Carrier assembly 3 - Forward axle assembly 4 - Inter-axle differential lockout 5 - Rear axle assembly 11
Differential Carrier Assembly Forward Axle Differential Carrier Removal and Installation Removal of Forward Differential Carrier Note: The removal of the forward carrier requires disconnecting of the inter-axle driveline and removal of the output shaft yoke assembly. 1. Block the vehicle. 2. Drain axle lubricant. 3. Disconnect all air lines to the axle. 4. Disconnect inter-axle and main drivelines. 5. Remove axle stud nuts and axle shafts (If used, remove lock washers and taper dowels). 6.
Inspection Installation of Forward Differential Carrier IMPORTANT Before installing carrier assembly, inspect and thoroughly clean interior of axle housing using an appropriate solvent and clean rag. 1. Use silicone rubber gasket compound on axle housing mating surface as shown in the illustration. Completely remove all old gasket material prior to applying new material. Compound will set in 20 minutes. Install carrier before compound sets or reapply. 2.
Differential Carrier Assembly Installation of Forward Axle Housing Cover and Output Shaft Bearing Parts Note: Forward axle should be assembled to the axle housing before proceeding with the following procedure. 1. If removed, install housing cover and fasten with nuts, capscrews and lock washers. Tighten to proper torque specifications (see Torque Chart on page 107). Note: Use silicone rubber gasket compound on axle housing mating surface as shown in illustration.
Differential Carrier Assembly Rear Axle Differential Carrier Removal and Installation Removal of Rear Differential Carrier Perform the following steps: TIP: To loosen dowels, hold a brass drift in the center of the shaft head and strike drift with a sharp blow using a hammer. 1. Block the vehicle. 2. Drain axle lubricant. 3. Disconnect air line if working on a differential lock axle. (See Differential Lockout Section). Disconnect inter-axle driveline. 5.
Differential Carrier Assembly Rear Differential Carrier “Installation” IMPORTANT Before installing carrier assembly, inspect and thoroughly clean interior of axle housing using an appropriate solvent and clean rag. Road test vehicle to bring axle lubricant up to temperature. Recheck joints, drain and fill plugs for leakage. Re-tighten as necessary. Note: Note: Note: Apply silicone rubber gasket compound on axle housing mating surface as shown in illustration.
Differential Lockout Differential Lockout Inter-Axle Lockout Types All are air-operated to engage the lockout and spring-released to disengage the lockout with the exception of the “ReverseAir” lockout. The “Reverse-Air” lockout is spring-released to engage the lockout and air-operated to disengage the lockout.
Differential Lockout Original Design Lockout - 1948 to Present (*Optional design for use with all dual range tandem axles) • Die cast body • Square Top • Interchangeable with cast iron lockout* “In 1985, a “Protective Shift System” was released into production axles. Dana bulletin 85-03 explains this popular OEM option. This option can only work with the “original” design lockouts.
Differential Lockout Cylindrical Design Lockout - October 1989 to February 1996 • • Stamped steel piston cover • Interchangeable with the cast style cover only as a complete assembly External type lockout 4 1 - Shift fork assembly 2 - Shoulder washer 3 - Compression spring 4 - O-ring 5 - Piston 2 3 6 10 Differential Lockout 1 8 9 5 7 6 - Lock nut 7 - Cylindrical design piston housing 8 - Mounting bracket 9 - Lock washer 10 - Capscrew 19
Differential Lockout Differential Lockout Overhaul Instructions for the three different designs are on the following pages: Assemble and Install Lockout - Cast Iron Cover Design Cast Iron Cover Lockout - Overhaul on page 20 1. With shift fork and sliding clutch installed, install compression spring on push rod. 2. Place piston driver on push rod against compression spring. The large diameter end of piston driver must face power divider cover. 3.
Differential Lockout Original Design Lockout Overhaul Note: Find instructions for: Cast Iron Cover Lockout - Overhaul on page 20 Cylindrical Design Lockout - Overhaul on page 22 Assemble and Install Original Design Lockout With shift fork and sliding clutch installed in power divider cover, assemble and install lockout as follows: Disassemble and Remove Lockout 1. 1. Remove capscrews and lock washers fastening cover to the body. Remove cover and o-ring. 2.
Differential Lockout Cylindrical Design Lockout - Overhaul Note: Find instructions for: Cast Iron Cover Lockout - Overhaul on page 20 Original Design Lockout - Overhaul on page 21 Assemble and Install Lockout-Cylindrical Design 1. With shift fork and sliding clutch installed, place the shoulder washer (white plastic) over push rod. The large diameter side of the washer must face the power divider cover. 2. Install compression spring on push rod. 3.
Inspection Power Divider - Parts Exploded View 12 11 1 2* 3 4 5 6 7 8 9 13 10 18 19 21 22 23 24 25 27 28 29 31 32 33 36 37 38 34 20 30 26 40 39 1 - Output shaft 2 - Bushings* 3 - O-rings 4 - Bearing cup 5 - Bearing cone 6 - Side gear 7 - Snap ring 8 - Spring 9 - Button 10 - Inter-axle differential assembly 11 - Capscrew 12 - Case half 13 - Spider 14 - Nut * Removed in September 1994 35 15 14 Inspection 17 16 15 - Case half 16 - Side pinion 17 - Thrust washer 18 - Snap ring 19
Power Divider Remove Power Divider The power divider can be replaced with the axle assembly both in or out of the chassis and with the differential carrier assembled to the axle housing. CAUTION During removal of power divider cover, the inter-axle differential (IAD), input shaft assembly or IAD shift system parts may fall from the carrier if not careful. Use caution to prevent injury or damage. 1. Disconnect the main driveline. 2. Disconnect the lockout air line. 3.
Power Divider Remove Power Divider from Differential Carrier (with carrier removed from axle housing) Note: It is assumed that the differential carrier assembly has been removed from axle housing prior to starting the following procedures: Mount differential carrier in repair stand. Loosen input shaft nut. 2. Remove power divider cover capscrews and lock washers. 3. Fasten chain or strap to input yoke to remove power divider. With chain hoist attached to input yoke, lift power divider off carrier.
Power Divider 26 7. Tilt carrier and remove the output shaft assembly. 8.
Power Divider Disassemble, Assemble and Overhaul the Power Divider The power divider may be serviced with the carrier assembly in or out of the axle housing. Hammer: Use slipper to get under the cup and with a hammer and drift from the back side of carrier tap out bearing cup. Note: The following procedure assumes that the differential carrier has been removed from the axle housing and that the power divider has been removed from the carrier assembly.
Power Divider 7. At this point in disassembly, it is desirable to remove lube pump drive gear nut. Hold input shaft yoke to secure drive gear, then loosen and remove drive gear nut. 8. Remove input shaft nut and flat washer. Note: Shift fork cannot be removed until lockout unit is disassembled (see Differential Lockout Overhaul on page 20). Shift fork push rod is secured to the lockout piston with a nut. 12. Slide input shaft assembly out of cover.
Power Divider Disassemble Power Divider Cover (For Axles with Input Shaft Tapered Roller Bearing) Note: The drive on early pump models is equipped with a woodruff key. On late pump models the key is eliminated. The drive shaft end has two machined flats and the drive gear mounting hole is shaped to accommodate these flats.
Power Divider 1. With drive gear locknut previously removed and working through input shaft bore, gently pry oil pump drive gear from its shaft. See steps 5 and 6 for pump disassembly. 2. For models built before February 1, 2000, remove snap ring securing pinion outer support bearing race. For models built after February 1, 2000, a design change to a one piece roller bearing was implemented. Reference Dana Bulletin ABIB-0102 for more information. 4.
Power Divider Assemble Power Divider Cover (For Axles with Input Shaft Tapered Roller Bearing) Install pinion outer bearing race in power divider cover using a driver and a hammer. 2. For models built before February 1, 2000, install snap ring to secure bearing race. For models built after February 1, 2000, a design change to a one piece roller bearing was implemented. Reference Dana Bulletin ABIB-0102 for more information. WARNING Snap ring is spring steel and may pop out.
Power Divider 6. Press input bearing cone on input shaft. 8. If bushing removal is needed, the bushings must exit from the thrust washer side of the helical gear. 1 1 2 3 4 1 - Remove bearing from helical gear 9. 1 - Press 2 - Plate 3 - Drive Seal 4 - Input shaft bearing cone 5 - Input shaft 5 Install bushings in helical side gear. Bushings must be installed from thrust washer side of gear. See illustration for dimensional tolerances.
Power Divider 10. Check expansion plug in power divider cover to make sure it is in place and firmly seated. If loose, seat by tapping with a hammer. Replace plug if necessary. Snap ring is spring steel and may pop off. Wear safety glasses when installing. Power Divider 1 1 - Expansions plug 11. Install shift fork in power divider cover. 12. Install lockout cylinder assembly if removed. See Differential Lockout on page 20. 13.
Power Divider Inter-axle Differential 1 7 2 3 6 8 4 5 1 - Case half 2 - Spider 3 - Bushing (use on models built before November 1, 1991) 4 - Side pinion 34 5 - Thrust washer 6 - Bolt 7 - Case half 8 - Lock nut
Power Divider Disassemble Inter-axle Differential 1. Punch mark differential case halves for correct position during reassembly. 2. Remove lock nuts and bolts. Separate case halves and remove thrust washers, side pinions, bushings and spider. Assemble Inter-axle Differential 1. Install bushings, side pinions and thrust washers on inter-axle differential spider. Pre-lube all components at time of assembly.
Power Divider Output Shaft Assembly *Bushing removed from production axles in September 1994. Output shafts with P/N 129016 do not use bushings.
Power Divider Disassemble Output Shaft WARNING Assemble Output Shaft Note: Lubricate parts with gear lube during assembly. 1. Press bearing cone on output shaft side gear. Snap ring is spring steel and may pop off. Wear safety glasses when removing. 1. Mount shaft assembly in vise, using brass vise jaw protectors. Remove snap ring, side gear and bearing cone assembly. Provide protection against possible gear teeth damage during press operation. 2. 2. Remove output shaft o-rings.
Power Divider Install Power Divider on Differential Carrier (with carrier assembled to axle housing) Note: Lubricate all parts before installation. 1. If removed, install axle housing cover and output shaft bearing. For instructions, see Installation of Forward Axle Housing Cover and Output Shaft Bearing Parts on page 14. 2. If output shaft was removed, lubricate o-rings, then install shaft assembly in differential carrier and housing cover. Lubricate seal lip.
Power Divider 6. Make certain dowel pins are installed in carrier, then install power divider assembly. 8. Check and adjust input shaft end play. With power divider assembled to differential carrier, check end play with dial indicator. End play should be 0.003" to 0.007". If necessary, adjust (see page 43). After end play is within specifications, complete assembly procedures as follows: 9. Connect main driveline and inter-axle driveline. 1 Power Divider 10.
Power Divider Install Power Divider on Differential Carrier (with carrier removed from axle housing) The following instructions pertain to installation of power divider on differential carrier with carrier removed from axle housing. 1. If output shaft side gear bearing cup was removed, press bearing cup in carrier. Use a press and appropriate sleeve or use a brass drift and a mallet. Tap bearing cup into its bore making certain cup is evenly and firmly seated. 2.
Power Divider Note: Lifting mechanism may create nicks and burrs on input yoke. Remove if present. 7. If removed, install dowel pins in carrier. Install power divider cover capscrews and lock washers placing sockethead capscrew at location shown on drawing. Torque capscrews to appropriate specification. (See Torque Chart on page 107).
Power Divider Measure and Adjust Input Shaft End-Play Note: After power divider overhaul and installation on carrier, check and adjust input shaft end-play. 2. Reinstall bearing cover without shims. Hold in position with hand pressure and measure clearance between power divider cover and bearing cover, using a feeler gauge. 3. The bearing cover clearance measured in Step 2 plus 0.005" will equal shim pack thickness required for desired end-play (rebuild with new parts). Add 0.
Power Divider With Input Shaft Axial Spring Thrust Button Build up a 0.045" (0.024 mm) thick shim pack and place shim pack and bearing cover on power divider cover. 4. Install the U-bracket on bearing cover, using two bearing cover capscrews. Install all other cover capscrews and torque to 75-85 lbs. ft. (101-115 N•m). In September 1988, Spicer added an axial spring and thrust button between the input and output shafts.
Power Divider 5. Position a dial indicator on the end of the input shaft. 3 Remove shim to decrease end-play Measured end-play (Step 6) 0.015" – 0.015" Desired end-play (New Parts) 0.003” to 0.007” Remove shims to provide desired end- 0.012” to 0.008” play 2 1 4 11. To add or remove shims, remove input shaft nut, flat washer and yoke. Remove capscrews, lock washers and bearing cover. Add or remove shims as required. 12. Install bearing cover and capscrews.
Carrier Assembly Forward Axle Carrier Assembly (Single Speed) with Diff.
Carrier Assembly 61 60 62 63 64 65 INTER-AXLE DIFFERENTIAL ASSEMBLY 66 67 68 70 71 69 75 74 73 76 77 78 91 79 80 81 82 93 70 72 92 83 84 85 86 88 89 90 87 106 105 39 31 40 41 42 43 45 46 44 43 47 40 48 50 49 51 LUBE PUMP 94 104 103 95 46 91 97 96 98 99 102 100 101
Carrier Assembly 37 - Side pinion thrust washer 38 - Spider 39 - Pinion pilot bearing 40 - Pinion bearing cone 41 - Pinion bearing spacer washer 42 - Pinion bearing spacer 43 - Pinion bearing cup 44 - Pinion bearing cage 45 - Pinion bearing cage shim 46 - Lock washer 47 - Bearing cage capscrew 48 - Pinion helical gear 49 - Outer pinion support bearing (one piece) 50 - Pinion shaft end nut 51 - Pinion nut spring pin 52 - Output shaft nut 53 - Output shaft washer 54 - Rear bearing retaining washer 55 - Axle
Carrier Assembly Rear Axle (Single Speed) - Parts Exploded View 10 2 11 4 12 3 15 18 20 16 17 6 8 21 17 18 19 13 15 14 9 27 12 11 10 14 26 28 25 26 23 30 33 5 6 48 5 1 1 22 13 23 24 29 31 32
Carrier Assembly 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
Carrier Assembly Forward Axle (Two Speed) - Parts Exploded View 19 20 18 16 1 3 4 5 2 24 21 22 23 25 15 7 6 17 13 14 8 11 9 12 26 10 32 31 30 29 28 27 Dual Range Axles 34 33 36 35 Planetary Double Reduction Axles 40 46 43 62 64 61 59 49 48 37 41 42 47 44 63 60 50 45 38 39 Planetary Double Reduction Axles 50 54 51 52 53 55 56 57 58 65
Carrier Assembly 21 - Expansion plug 22 - Shift fork shaft 23 - Filler plug 24 - Differential carrier 25 - Dowel pin 26 - Expansion plug 27 - Nut 28 - Lock washer 29 -Seal spring 30 - Seal 31 - Stud 32 - Shift fork 33 - Shift fork cover 34 - Lock washer 35 - Capscrew 36 - Differential & ring gear 37 - Sliding clutch (dual range only) 38 - Retainer 39 - Sun gear 40 - Bearing adjuster 41 - Bearing cup 42 - Bearing cone 43 - Ring gear nut 44 - Gear support case 45 - Ring gear 46 - Thrust washer 47 - High-spe
Carrier Assembly Rear Axle (Two Speed) - Parts Exploded View Dual Range RT440, RT460, RT480, RT485 Planetary Double Reduction RP440, RP460, RP480, RP485, RP580, RP650 44 47 49 53 42 Dual Range RT461, RT521, RT601, RT651 41 Planetary Double Reduction RP461, RP521, RP581, RP601, RP651, RP652 43 45 46 52 38 32 37 48 39 40 31 34 27 29 28 36 35 51 50 26 30 33 25 Planetary Double Reduction Axles 24 14 11 15 12 10 9 21 13 19 16 17 18 8 64 65 68 69 71 4 6 58 3 2 52 23
Carrier Assembly 26 - Sliding clutch (dual range) 27 - Bearing adjuster 28 - Bearing cup 29 - Bearing cone 30 - Ring gear nut 31 - Gear support case (LH) 32 - Ring gear 33 - Thrust washer 34 - High-speed clutch plate 35 - Idler pinion 36 - Idler pinion pin 37 - Differential assembly 38 - Differential case with pins (LH) 39 -Thrust washer 40 - Side gear 41 - Spider 42 - Side pinion 43 - Thrust washer 44 - Side gear 45 - Thrust washer 46 - Plain differential case (RH) 47 - Capscrew 48 - Thrust washer 49 - Ge
Carrier Assembly Disassemble Differential Carrier (with power divider removed) Dual range axles only Planetary double reduction axles 1. Remove shift fork seal and spring. 2. Remove expansion plugs. 3. Working at the lower (or small) plug hole, drive out the shift fork shaft. 1. Remove capscrews and the retainer which holds gear in position. 4. Disengage shift fork yoke from sliding collars. 2. Remove sun gear. 5. Remove clutch and shift fork.
Carrier Assembly Remove Wheel Differential (All Standard Models) 3. Cut lockwire. Remove capscrews, flat washers and bearing caps. Back off bearing adjusters and remove adjusters and bearing cups. 4. Using a chain hoist, lift ring gear and differential assembly out of carrier. Note: If gear set is to be reused, check tooth contact pattern and ring gear backlash before disassembling differential carrier.
Carrier Assembly Remove Pinion Assembly 1. Forward Axle: Remove pinion nut. Remove helical drive gear using puller. Remove helical gear spacer (D440-P and D560-P only). Note: For easier disassembly, loosen but do not remove pinion (self-locking) nut. Forward axle pinion is equipped with slotted nut, remove roll pin with a pin punch then loosen nut. 2. Remove pinion bearing cage capscrews. Remove pinion and cage assembly from carrier. Remove shim pack.
Drive Pinion Drive Pinion - Parts Exploded View Front Axle Pinion Assembly 1 2 3 4 5 6 7 10 8 9 11 12 14 15 Drive Pinion 13 16 17 1 - Pinion pilot bearing 2 - Pinion 3 - Pinion bearing cone - inner 4 - Pinion bearing spacer 5 - Bearing spacer variable 6 - Pinion bearing cup - inner 7 - Shim 8 - Pinion bearing cage 9 - Pinion bearing cup - outer 10 - Capscrew 11 - Pinion bearing cup - outer 12 - Helical gear spacer 13 - Pinion helical gear 14 - One piece bearing 15 - Slotted pinion nut 16 -
Drive Pinion Disassemble and Overhaul Drive Pinion The following procedures cover both forward and rear differential drive carrier assembly. 6. Remove bearing spacer and spacer washers from pinion. 7. Remove pilot bearing from pinion using a split-type puller. Use two procedure steps to remove each bearing. Note: Dana drive axles may be equipped with either “press-fit” or “slip-fit” outer pinion bearings. Procedures are contained in this section for assembly of both types. 1.
Drive Pinion 8. Remove inner bearing cone from pinion using a splittype puller. Use two procedure steps to remove each bearing. a. Replace Pinion Bearing Cage Cups Mount puller vertically to separate the bearing. This action will force puller halves under bearing and start moving bearing off pinion. 1 Front Rear 2 2 Drive Pinion 3 1 - Cup (outer) 2 - Bearing cage 3 - Cup (inner) b. Mount puller horizontally to press pinion out of bearing. 1. Remove cups. 2.
Drive Pinion 3. 4. Install inner and outer pinion bearing cups. Use a press and an appropriate drive sleeve. Make certain bearing cup is evenly and firmly seated. Seat cups securely to shoulder. Check clearance between cup and bearing cage. Must be less than .001". Adjust Pinion Bearing Preload Trial Buildup 1. Assemble pinion bearing cage, bearings, spacer and spacer washer (without drive pinion or oil seal). Center bearing spacer between two bearing cones. Lubricate bearing cups and cones.
Drive Pinion 2. With the bearings well lubricated, place the assembly in the press. Position sleeve so that load is applied directly to the backface of the outer bearing cone. Specifications for Pinion Bearing Trial Buildup Preload Test Torque to Rotate Bearing Cage (w/o pinion seal) 10–20 lbs. in. (1.1–2.3 N•m) Forward Axles and Rear Axles 1 Spring Scale Reading 3 - 7 lbs. (2 - 3 Kgs.) 2 Press Loads 18.5 - 19.5 tons (16.8 - 17.7 metric tons) Nominal Bearing Thickness spacer 0.185” (4.
Drive Pinion Final Buildup 3. Install bearing cage on drive pinion. 4. Press outer bearing cone on pinion. Note: On rear axles, do not install oil seal in cage until bearing preload is correctly adjusted. IMPORTANT After bearing cups are installed, preselect pinion bearing spacer using the “trial buildup” procedure. Note: During pinion bearing installation, locate each part in same position that was used in “trial buildup” preload test. 1. Press inner bearing cone on pinion.
Drive Pinion Specifications for Pinion Bearing Final Buildup Preload Test 6. Torque to Rotate Bearing Cage (w/o pinion seal) 15-35 lbs. in.(1.7–4.0 N•m) Forward Axles Rear Axles Spring Scale Reading 5 - 12 lbs. (2 - 5 kgs.) Press Loads 18 - 21 tons (16.3 - 18 metric tons) Nut Torque 840 - 1,020 lbs. ft. (1,139 - 1,383 N•m) CAUTION Read only the torque value after the bearing cage starts to rotate. 7. *Torque nut to 980 lbs. ft.
Drive Pinion 9. Stake pilot bearing using staking tool. This is essential to retain the bearing. Specification for Final Pinion Bearing Preload Test (“Press-fit” Outer Pinion Bearings) Nut Torque Axle Models lbs. ft. N•m Forward Axles Self-Locking Nut 840 - 1020 1139 - 1383 Slotted Nut & Roll Pin 980* 1329* 840 - 1020 1139 - 1383 Rear Axles * Torque nut to 980 lbs. ft.. (1329 N•m), then continue tightening nut to align nut slot to nearest hole in pinion shank. 11.
Drive Pinion Install Drive Pinion Assembly 1. Rear Axle Only: Place shim pack on carrier making sure lube holes are clear. Note: Use a dummy yoke (if available) in place of helical gear. This will result in easier disassembly and reassembly during carrier adjustments. Note: Do not install cotter pin until carrier adjustments are completed. 4. Rear Axle Drive Pinion: Install pinion assembly. Install bearing cage capscrews and lock washers. Torque capscrews to 160–176 lbs. ft. (217–239 N•m).
Drive Pinion Install Helical Gear and Pinion Outer Support Bearing - Forward Axle Only Note: After differential adjustment is complete or if dummy yoke was used, remove nut and yoke. Then continue to assemble pinion as follows: After February, 2000 1 1. On D440-P and D460-P only, install helical gear spacer. Install helical gear on pinion using driver and hammer. 2. Install pinion outer support bearing using driver and hammer. 3. Install self-locking nut or slotted nut.
Drive Pinion If removed, install bearing race in power divider cover, using driver and hammer. 5. Install snap ring to secure bearing race. Drive Pinion 4. WARNING Snap ring is spring steel and may pop out. Wear safety glasses when installing. IMPORTANT Torque to 980 lbs. ft. (1329 N•m), then continue tightening nut to align slow with the nearest hole in pinion shank. Install roll pin. Torque Chart Pinion Self-Locking Nut Size lbs. ft.
Wheel Differential Assembly Wheel Differential Assembly - Parts Exploded View Single Reduction Differential 7 3 4 5 1 8 2 9 3 4 10 11 12 13 14 15 5 12 11 16 6 Differential Lock 1 - Sliding clutch 2 - Diff. lock differential bearing adjuster 3 - Differential bearing cup 4 - Differential bearing cone 5 - Nut (ring gear) 6 - Diff.
Wheel Differential Assembly Planetary and 2 - Speed Differential 1 2 4 5 6 7 8 9 10 11 12 13 14 15 4 3 2 Wheel Differential Assembly 16 3 17 18 1 - Sliding clutch (dual range only) 2 - Differential bearing adjuster 3 - Differential bearing cup 4 - Differential bearing cone 5 - Ring gear nut 6 - Gear support case 7 - Ring gear 8 - Thrust washer 19 20 21 22 23 24 25 9 - High speed clutch plate 10 - Idler pinion pin 11 - Idler pinion 12 - Differential assembly 13 - Thrust washer 14 - Gear
Wheel Differential Assembly Disassemble, Overhaul and Assemble Wheel Differential (Forward and Rear Axles) For Single Reduction Differential Case Disassemble Wheel Differential 4. Lift out spider, side pinions and thrust washers. 5. Remove remaining side gear and thrust washer. 6. Remove bearing cones from case halves using suitable puller. 7. Remove bearing cone from plain case half in two steps: Note: For Dual Reduction Differential Case see page 73.
Wheel Differential Assembly Overhaul and Assemble Wheel Differential 6. Place side gear and thrust washer on side pinions. 7. Align punch marks and install plain case half. Install capscrews and tighten. See Torque Chart on page 106. Check differential for free rotation by turning side gear hub. IMPORTANT To prevent bearing damage, use suitable sleeve that only contacts the inner race of the cone. A used bearing race would be a suitable tool.
Wheel Differential Assembly Planetary and 2-Speed Models (Forward and Rear Axles) 1 9 10 11 13 12 14 3 4 5 6 15 16 17 7 14 4 3 8 18 RH 1 - Differential case capscrew 2 - Differential case (plain) 3 - Side gear thrust washer 4 - Differential side gear 5 - Side pinion thrust washer 6 - Side pinion 7 - Spider 8 - Differential case with pins 72 2 19 LH 9 - Differential bearing adjuster 10 - Differential bearing cup 11 - Differential bearing cone 12 - Ring gear bolt 13 - Gear support cas
Wheel Differential Assembly Disassemble Dual Reduction Differential Case Note: For Single Reduction Differential Case see page 68. 1. 3. Invert differential assembly to remove idler pins, then remove idler pinions. 7. Punch mark differential cases for correct location in reassembly. Remove capscrews and separate case halves. 8. Lift out thrust washer and side gear. 9. Lift out spider, side pinions and side thrust washers. Remove nuts and bolts fastening ring gear and support cases.
Wheel Differential Assembly 10. Remove inner side gear and thrust washer. Note: Holes are provided in case to enable removal of bearing cone with a pin punch. Tap alternately through each hole until cone is removed. 11. First, try to lift off high-speed clutch plate by hand. If it cannot be removed easily, press off plate as follows: WARNING When using a drift, punch or similar tool, wear safety glasses. a.
Wheel Differential Assembly Assemble Dual Reduction Differential Case Note: Lubricate internal parts with gear lube during reassembly. 1. Press bearing cones on support cases. 2. Position high-speed clutch plate with chamfered end of clutch teeth toward idler pinions. Press clutch plate on case. IMPORTANT To prevent bearing cone damage, use suitable sleeve that only contacts the inner race of the cone.
Wheel Differential Assembly 3. Place thrust washer and side gear in differential case. 5. Place side gear and thrust washer in position on side pinions. 4. Assemble side pinions and thrust washers on spider. Place this assembly in differential case. 6. Align punch marks and place plain case on case (with pins). Install capscrews. Torque screws to 116-130 lbs. ft. (157-176 N•m). Note: Turn side gear hub to check for free differential rotation. Rotation may require up to 50 lbs. ft. (65 N•m). 7.
Wheel Differential Assembly Place thrust washer in support case. 9. During installation of ring gear, temporarily use two bolts in mounting holes to assure bolt hole alignment. Place ring gear on support case, then remove two bolts. 10. To install differential assembly, place support case and ring gear assembly on bench or the floor. Position case on its side. Carefully lift and slide differential assembly into case. Engage idler pinions with ring gear teeth to complete the installation. 11.
Wheel Differential Assembly Install Differential–Forward and Rear Axles Note: Lubricate bearings during the following assembly procedures. 78 1. Place ring gear and differential assembly in carrier. Carefully lower the assembly until bearing cones rest on carrier. 2. Install bearing cup and bearing adjuster to the flange half side first. 3. Lubricate the differential bearings. Install bearing cup and bearing adjuster to the plain half side.
Wheel Differential Assembly Measure and Adjust Carrier Assembly 3. Adjust Backlash and Preload 1. Turn the flange half bearing adjuster in until the ring gear contacts the pinion (zero backlash) then back the adjuster out two notches of the adjuster lugs. Tighten the plain half adjuster two lug notches. Start with the notch at the top, count two notches counterclockwise on the adjuster, turn the adjuster so that the notch is facing straight up. You now have a two notch preload.
Wheel Differential Assembly Change Backlash Setting If you have too much backlash the ring gear needs to move closer to the pinion. Back off the plain half adjuster, count the number of notches you back it off, each notch equals about .003" of backlash. Measure Ring Gear Runout Measure Ring Gear Total 1. Measure ring gear total radial runout. (Indicator reading should not exceed .010"). 2. Measure ring gear total backface runout (Indicator reading should not exceed .010").
Wheel Differential Assembly Adjust Tooth Contact Pattern Used Gearing - Correct Pattern Used gearing will not usually display the square, even contact pattern found in new gear sets. The gear will normally have a “pocket” at the heal end of the gear tooth. The more use a gear has had, the more the line becomes the dominant characteristic of the pattern.
Wheel Differential Assembly Adjust Pinion Position If the gear pattern shows incorrect tooth depth contact, change drive pinion position by altering the shim pack. Used gears should achieve proper contact with the same shims removed from the axle at disassembly. 3. Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup. 4. Continue tightening the same adjuster 2 or 3 notches and recheck backlash.
Wheel Differential Lock Wheel Differential Lock - Parts Exploded View 1 3 4 5 4 2 Wheel Differential Lock 1 - Shift fork seal and spring assembly 2 - Shift fork and roller assembly 3 - Sliding clutch 4 - Differential bearing adjuster 5 - Differential case (flanged half) 83
Wheel Differential Lock Install and Adjust Wheel Differential Lock, Dual Range Shifters 1. For planetary double reduction axles (on backface side of ring gear), install sun gear and retainer, then install capscrews that fasten both retainer and adjuster lock capscrews. Tighten screws to correct torque (see chart), and lockwire all capscrews. Torque Chart Cap Differential Bearing Capscrew Size 13/16-10 1 2 3 Bearing Adjuster Lock and Sun Gear Retainer Capscrew Size 4 5 5/8-11 Grade lbs. ft.
Wheel Differential Lock Piston Air Shift Unit 18 19 12 9 10 Wheel Differential Lock 13 14 15 20 17 16 21 11 22 3 5 24 25 1 4 2 6 7 8 23 26 1 - Cover assembly 2 - Cover bearing 3 - Screw and washer assembly 4 - Cover gasket 5 - Cover plug 6 - Actuating lever 7 - Clevis pin 8 - Actuating lever, pin, and block assembly 9 - Shift housing cover 10 - Seal ring 11 - Cover bolt 12 - Lock nut 13 - Lock nut 14 - Washer 15 - Piston 16 - Felt piston oiler (strip) 17 - Piston o-ring 18 - Grommet 19 - Pus
Wheel Differential Lock Air Shift Unit Replacement Removal of Shift Unit Air Shift Unit Installation 1. Disconnect air lines at shift unit cover. 1. Lubricate shift fork. 2. Disconnect the wiring harness and remove selector switch from the housing cover. 2. Slide shift fork seal and spring assembly over fork and seal onto the shift unit carrier studs. 3. Remove nuts, flat washers and piston air shift unit from the differential carrier. 3.
Wheel Differential Lock Air Shift Unit Overhaul Disassemble Unit 4. 1. Remove capscrews, lock washers, cover and gasket from housing. Drain lubricant. 2. Remove bolts, lock nuts, cover at piston end of housing. Remove o-ring. Remove compression spring and piston stop from bore of shift unit housing. 1 CAUTION Wheel Differential Lock 2 During the following procedure, the piston will pop out of housing under spring pressure. Exercise caution to prevent possible injury. 3.
Wheel Differential Lock Parts Inspection Shift Fork Seal: Inspect shift fork seal for defects and tight fit on shift fork. A spring is used to assure a closer fit of seal around shift fork. If this spring is not present on axle being serviced, install one when reassembling unit. O-rings, Felt Oilers and Gasket: Replace o-rings, felt oilers and cover gasket when piston air shift unit is disassembled for repair. Compression Spring: Inspect spring for distortion, cracks or other visual defects.
Wheel Differential Lock Assemble Unit 4. Note: Prior to assembly, the piston felt oilers should be soaked in SAE 10 oil for one hour. Lubricate o-rings with a highviscosity silicone oil or barium grease o-ring lubricant. Assemble pin to actuating lever and install this assembly in shift lever unit housing. 2. Assemble o-ring and piston to push rod and fasten with flat washer and lock nut. Tighten nut to a torque of 120-150 lbs. in. (14-17 N•m). Install felt oilers and o-ring in piston.
Wheel Differential Lock Lubrication Lubricant: Use SAE 10 motor oil* for temperature above 0°F (–18°C). For temperatures below 0°F (–18°C), mix three parts of SAE 10 motor oil with one part of kerosene. This cold weather mixture can be safely used up to 32°F (0°C). Note: Commercially available automatic transmission fluid may be used in place of SAE 10 motor oil. Automatic transmission fluid can be used for all temperatures. Do not mix kerosene with automatic transmission fluid.
Housing and Rear Cover Assembly Housing and Rear Cover Assembly - Parts Exploded View 1 7 2 3 13 Bolt on Rear Cover 11 Housing and Rear Cover Assembly 4 12 5 6 15 8 9 10 18 19 17 14 16 20 1 - Rear cover 2 - Rear cover capscrew 3 - Fill plug 4 - Rear cover nut 5 - Lock washer 6 - Stud 7 - Dowel 8 - Jam nut - outer 9 - Locking ring 10 - Jam nut (inner) 11 - Axle housing 12 - Breather 13 - Breather hose 14 - Carrier capscrew 15 - Lock washer 16 - Nut 17 - Lock washer 18 - Stud 19 - Drain p
Seals Seals Replace Seal WARNING Dana strongly recommends using seal drivers when installing new seals. Use the proper driver to make sure that the seal is square and installed to the proper depth. CAUTION Oil seals can be easily damaged prior to installation. Use care when handling the new seal to prevent damage or contamination. Leave the seal in its package until installation. On new yokes, leave the protector on the yoke until it is installed on the shaft to prevent damage or contamination. 1.
Seals New Welded D-Housing Cover Lube Quantity Difference 0 (zero) Standout of Output Shaft Yoke Length increased by 6 mm (.25"), this should not have any significant impact on inter-axle driveline length or drive line angles. Interchangeability of Parts A cross reference chart of “OLD” axle housing to “NEW” axle housings with welded on covers will be published in a separate bulletin. The bolt on D-Housing covers will remain available for service.
Housing Breather Housing Breather Install New Axle Housing Breather (Metal and Plastic) • Plastic only: tighten until one thread is showing. 4. Insert hose onto fitting, long end down. 5. Push hose firmly against fitting. Rotate hose to point down. Dana uses an axle housing breather that consists of a fitting, hose and clamp assembly. This breather design has improved resistance to water ingestion, clogging caused by dirt, ice or snow buildup around the base of the breather.
Wheel End Seal Wheel End Seal - Parts Exploded View Wheel End Seal 1 2 3 1 - Installation tool 2 - Seal 3 - Rear hub 95
Wheel End Seal Remove and Overhaul Wheel End Seal WARNING Never work under a vehicle supported by only a jack. Always support vehicle with stands. Block the wheels and make sure the vehicle will not roll before releasing the brakes. Install Wheel End Seal 1. IMPORTANT Wheel end seals can be easily damaged during handling. Leave the seal in its package until installation to prevent damage or contamination. 1. Remove outer bearing and wheel. 2. Remove oil seal. 3. Remove inner bearing. 4.
Wheel Adjustment Systems Wheel Adjustment Systems Adjust Wheel Bearing WARNING Do not mix spindle nuts and lock washers from different systems. Mixing spindle nuts and lock washers can cause wheel separation. 1. 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. 2. Inspect the tang-type washer (if used).
Wheel Adjustment Systems Three-piece Tang-type Lock Washer System Four-piece Tang/Dowel-type Lock Washer System 3 4 5 1 2 2 1 3 1 - Inner nut (P/N 11249) 2 - Tang-type lock washer (P/N 11245) .123” thick 3 - Outer nut (P/N 11249) a. Install the Tang-type lock washer on the spindle. IMPORTANT Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure. b. Install the outer nut on the spindle and tighten to 250 lbs. ft. (339 N•m) c. Verify end-play.
Wheel End Verify Wheel End-play Procedure Verify that end-play meets specification using a dial indicator. An indicator with 0.001" (0.03 mm) resolution is required. Wheel end-play is the free movement of the tire and wheel assembly along the spindle axis. Adjust End-play with Wheel Hub Correct end-play is .001"–.005" (0.025–0.125 mm). Attach a dial indicator with its magnetic base to the hub or brake drum as shown below. 2.
Wheel End Lubricate Wheel End IMPORTANT Before operating the axle, the wheel hub cavities and bearings must be lubricated to prevent failure. When wheel ends are serviced, follow Dana’s wheel end lubrication procedure before operating the axle. Wheel End with Oil Fill Hole 1 Dana axles may be equipped with either of two wheel end designs: • Wheel ends with an oil fill hole. • Wheel ends without an oil fill hole. Wheel Ends with an Oil Fill Hole 1.
Wheel End Wheel Ends Without Oil Fill Hole 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 right side of the axle 6 inches or more. Hold axle in this position for one minute. 3. Lower the right side. Raise the left side of the axle 6 inches or more. Hold axle in this position for one minute. 5. Lower the left side. 6.
Lubrication Lubrication The ability of a drive axle to deliver quiet, trouble-free operation over a period of years is largely dependent upon the use of good quality gear lubrication in the correct quantity. The most satisfactory results can be obtained by following the directions contained in this manual. The following lubrication instructions represent the most current recommendations from the Axle & Brake Division of Dana Corporation.
Lubrication Lube Change Intervals This product combines the latest manufacturing and part washing technology. When filled with a Dana 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.
Lubrication Change Lube Drain Drain when the lube is at normal operating temperature (150°– 200°F). It will run freely and minimize the time necessary to fully drain the axle, this insures the axle is flushed. Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container. Note: Lube fill capacities (see chart) are basic guidelines and will vary based on the angle the axle is installed in a particular chassis. Torque fill plug to 40–60 lbs. ft.
Lubrication Standpipes Drive axles are lubricated with oil drawn from a large sump integral to the assembly. Most axle designs attempt to position vital components such as pinion bearings in close proximity to this sump, keeping them bathed in a generous supply of oil at all times. Tandem Forward Axles Installation Angle* 5-10% Grade 10-15% Grade 15-20% Grade 0 - - - 3 - - 2.00” 5 - 1.00” 2.25” 7 - 1.25” 2.50” 10 1.50” 1.75” 2.75” 13 1.75” 2.00” 3.
Lubrication Final Check Horizontal Mounting Prior to putting vehicle back into service, run the vehicle to bring axle lube up to temperature. Check filler and drain plugs and axle joint for leakage. Re-tighten to specifications as necessary. 1 12° Installation 2 1 12° Installation with Standpipe 3 1 1 - Oil filller hole 2 - Lost oil capacity 3 - Additional oil capacity Note: Grades must be continuous or lengthy in nature. Monitor oil temperatures before installing standpipes.
Torque Chart Torque Chart Fastener Carrier & Cap-Misc. Parts Ring Gear Nut/Bolt Pinion Bearing Cage Capscrew Input Shaft Nut Input Shaft Brg. Cover Capscrew Axle Housing Misc. Related Parts Class 8 5 5 4 5 8 8 8 Size 13/16 - 10 5/8 - 11 5/16 - 18 M24 7/16 - 14 5/8 - 18 9/16 - 18 9/16 - 12 Tool Size 1-1/8 1-1/8 --36mm --15/16 ----- Lbs.-ft.
Torque Chart Fastener Cast Iron Cover Style Class Size Tool Size Lbs.-ft. N-m 5 7/16 - 14 5/8 48-56 65-76 --3/8 - 24 5/8 13-17 18-23 Wheel End-Misc. Parts --1/2 - 20 1 1/16 55-71 75-96 --5/8 - 18 1 5/16 170-190 230-258 --3/4 - 16 1 1/8 285-345 386-468 Diff. Lock-Misc. Parts Shift Cylinder Cover Capscrew 8.8 M10 X 1.4 12mm 28-34 38-46 Shift Fork Capscrew 12.9 M8 X 1.25 6mm Allen 12-15 16-20 Selector Switch --M14 X 1.5 24mm 10-12 14-16 Diff.
Wheel Differential Lock Wheel Differential Lock Comparison Information on Dana Wheel Differential Locking Axles Note: Information for Type 1 and 2 differential lock axles are not covered in this manual, refer to AXSM-0048 and AXSM-0046 for information pertaining to those axles.
Wheel Differential Lock Differential Lock Theory of Operation The Dana Wheel Differential Lock is an optional feature for Dana axles. In operation, it positively locks the wheel differential, power flows to the tires without any differential action, providing improved traction under adverse road conditions.
Control Systems Control Systems Two types of systems may be used to control the Differential Lock operation: • Transmission low-range interlock control system • Direct driver-controlled system Transmission Low Range Interlock Control System (preferred system) The wheel differential is locked manually with the transmission in low range. It is unlocked by the driver or unlocked when the transmission is shifted out of low range. 2.
Control Systems Direct Driver-Controlled System The driver manually locks and unlocks the wheel differential, using a cab-mounted air valve. The following description assumes the system includes a cab-mounted air valve and a solenoid valve as shown in the illustration. Operation is as follows: 1. 2. When the control valve is placed in the lock position, the air supply solenoid valve opens and air pressure activates the shift unit.
Dual Range Axle Shift Systems Dual Range Axle Shift Systems There are two shift system designs predominantly used to select range of an Dana dual range tandem axle. 1. Standard System. For range selection, a cab-mounted air shifter valve operates two air shift units mounted on the axles.
Dual Range Axle Shift Systems Standard System for Axle Range Selection and Inter-Axle Differential Lockout (straight air type) 1 - Circuit breaker †‡ 2 - Speedometer adapter† 3 - Air pressure 4 - Axle range shifter valve (open in high range) 5 - Solenoid valve‡ (exhaust system when de-energized) 6 - Inter-axle differential lockout shifter 7 - Air pressure 8 - Forward axle shift unit 9 - Inter-axle differential lockout cylinder 10 - Rear axle shift unit 11 - Ignition switch†‡ 12 - Pressure switch† (normal
Dual Range Axle Shift Systems For vehicles equipped with transmission-drive speedometers, the system includes a speedometer adapter which compensates speedometer readings when axle is in Low Range. The adapter is operated by an electrical switch mounted on or near the quick-release valve. The switch is normally-closed and is opened by air pressure.
Dual Range Axle Shift Systems “Standard” Lockout (straight-air type) Description:The “standard” lockout unit is of the straight-air type and is air-operated to engage lockout and spring-released to disengage lockout. The piston is mechanically connected to the shift fork and sliding clutch. The clutch engages or disengages the helical-side gear to lock or unlock the inter-axle differential.
Dual Range Axle Shift Systems Axle Range Selection and Inter-Axle Differential Lockout System Dual Range Axle Shift Systems 1 - Circuit breaker †‡ 2 - Speedometer adapter † 3 - Air pressure 4 - Interlock pin assembly (mounted in cover) (blocks lever with lockout engaged) 5 - Axle range shifter valve (open in high range) 6 - Solenoid valve ‡ (exhaust system when de-energized) 7 - Inter-axle differential lockout shifter valve (open in “lock” position) 8- Air pressure 9 - Interlock control valve (open when
Dual Range Axle Shift Systems Axle Range Interlock Operation Engage Lockout (Lock Differential) (Axle in High or Low Range) 1 - Reservoir air pressure 2 - Air pressure 3 -Air pressure (from lockout shifter valve) moves piston to engaged lockout 4- Lockkout cylinder piston movement allows interlock control valve to open 118 5 - Air pressure is applied to the interlock 10 - Lockout cylinder pin. Pin moves to block shifter valve le- 11 - Interlock control valve ver. Axle range cannot be changed.
Dual Range Axle Shift Systems Disengage Lockout (Unlock Differential) (Axle in High or Low Range) Dual Range Axle Shift Systems 1 - Reservoir air pressure 2 - Air exhaust 3 - Air pressure at piston is released. Return spring moves piston to disengage lockout. 4 - Lockout cylinder piston movement closes interlock control valve 5 - Air pressure to interlock pin is exhausted through control valve port.
Troubleshooting Troubleshooting Check for Air Pressure and Air Leaks A simple method for quickly locating troubles in a shift system can be accomplished by listening for possible air leaks and for sound which would indicate mechanical shifting. Axle Shift System 1. When system includes a solenoid valve, turn ignition “ON” to energize and open the solenoid valve. If electrical system is functioning, air pressure should be present at valve outlet connection.
Troubleshooting Check Electrical System Check Solenoid Valve When ignition switch is “ON,” solenoid valve is energized and air pressure is available to operate the system. When ignition switch is “OFF,” solenoid valve is de-energized and exhausts the system which downshifts axle to low range. Check wiring and circuit breaker for defects that would cause shorts or open circuits. 2. Make sure valve has a good ground connection to the frame.
Proper Vehicle Towing Proper Vehicle Towing Without Wheel Differential Lock With Wheel Differential Lock (Type 3 Only) Lift the drive wheels completely off of the ground or damage will occur. Follow these listed procedures for vehicle towing when the drive axles are equipped with Type 3 wheel differential lock. WARNING Do not lift the front wheels (non-drive wheels). This alters the oil’s position in the drive axle, draining it away from the drive pinion and its bearings.
Proper Vehicle Towing 7. Install temporary cover on hub to prevent contamination from entering and also to prevent the loss of lubricant. Proper Vehicle Towing Parts unique to type 3 differential lock axles.
Air Shift System Components Axle Shift System Components Air Shifter Valves (Standard System) Note: For air shifter valve repair instruction, refer to pertinent manufacturer’s literature. See instructions below for Interlock Pin Assembly repair. Axle Range Selector Name Plate (Stan- Inter-Axle Differential Lockout Name Typical Air Shifter Valve for Standard Plate Systems, Axle Range Selection and Inter- dard System) axle Differential Lockout.
Air Shift System Components Axle Range Shifter Valve Interlock Pin Assembly Air Shift System Components 1 - Mounting screw 2 - Interlock pin and piston 3 - Piston stop 4 - Snap ring 5 - O-rings 6 - Compression spring 7 - Piston housing 8 - Air shifter valve assembly Note: Before reassembly, lubricate o-rings with a high-viscosity silicone oil or barium grease o-ring lubricant. Assembly Pin. Install o-rings on piston and piston stop.
Inter-Axle Differential Lockout Inter-Axle Differential Lockout With Interlock Control Valve (straight-air type) Lockout Cylinder Interlock Control Valve Disassemble cylinder by performing the following steps: Repair and Replacement Replace faulty valve as an assembly. 1. Remove capscrews, Iock washers, cover assembly and o-ring. 2. Remove hex-nut piston and o-rings. 3. Remove body capscrews and lock washers, then remove body and piston as an assembly.
Inter-Axle Differential Lockout Inter-Axle Differential Lockout 1 - Shift fork and push rod 2 - Lock washer 3 - Capscrew 4 - O-ring 5 - Cover 6 - Lock washer 7 - Control valve button 8 - Interlock control valve Speedometer Adapter 9 - Lock nut 10 - Capscrew 11 - Lock washer 12 - Hex-nut piston 13 - Felt oilers 14 - Compression spring 15 - Lockout body Solenoid Valve The speedometer adapters are lubricated and sealed for life of the unit. No maintenance is required. Replace a faulty unit.
Inter-Axle Differential Lockout Quick Release Valve Pressure Switch Replace pressure switch as an assembly. If quick release valve fails to operate properly, it may be repaired as follows: 128 1. Disassemble valve. 2. Inspect valve body, valve seat and spring (if used) for evidence of faulty operation. 3. Replace faulty parts, then reassemble valve.
Theory of Operation Theory of Operation Spicer tandem drive axles described in this publication are single reduction units designed primarily for heavy-duty hauling on and on/off highway. This type axle assembly provides a vehicle with superior load carrying and roadability characteristics by dividing its work between two axles. The complete tandem assembly consists of two axle units coupled by a power divider.
Theory of Operation Power Flow and Torque Distribution Torque Distribution with Lockout Disengaged (Inter-axle Differential is Operating) For the forward axle, torque is transmitted from the helicalside gear to the pinion helical gear, drive pinion, ring gear, wheel differential and axle shafts. 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.
Theory of Operation Torque Distribution with Lockout Engaged (Inter-axle Differential is Not Operating) 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. Note: Varied road surface conditions can result in unequal torque distribution between the two axle assemblies. CAUTION Prolonged operation with the lockout engaged can damage axle and driveline components.
Inspection Lubrication The ability of a drive axle to deliver quiet, trouble-free operation over a period of years is largely dependent upon the use of good quality gear lubrication in the correct quantity. The most satisfactory results can be obtained by following the directions contained in this manual. The following lubrication instructions represent the most current recommendations from the Axle & Brake Division of Dana Corporation.
Inspection Lube Change Intervals Note: When filled with an Spicer approved synthetic lubricant at the factory, the initial drain is not required. Severe Service Lubrication Change Intervals: Severe service applications are those where the vehicle consistently operates at or near its maximum GCW or GVW ratings, dusty or wet environments, or consistent operation on grades greater than 8%. For these applications, the On/Off Highway portion of the chart should be used.
Inspection Changing Lube Rear Axle • Remove the filler hole plug from the center of the axle housing cover and fill the axle with the approved lubricant until level with the bottom of the hole. • If wheel ends were removed. Draining Drain when the lube is at normal operating temperature (150°200°F). It will run freely and minimize the time necessary to fully drain the axle, insuring the axle is flushed. Always use the filler hole as the final reference.
Inspection Standpipes *Pinion Pointing Upward Drive axles are lubricated with oil drawn from a large sump integral to the assembly. Most axle designs attempt to position vital components such as pinion bearings in close proximity to this sump, keeping them bathed in a generous supply of oil at all times.
Theory of Operation Torque Distribution in Low Range Torque is transmitted to both axles through inter-axle differential action. 1 - Input torque 2 - Drive is from differential through helical gears to forward axle gearing. 3 - In low range, the planetary gearing is introduced in the drive system, between the ring gear and wheel differential (both axles). 4 - Drive is from differential through output shaft to rear axle gearing. 5 - Inter-axle differential operating.
Theory of Operation Dual Range Tandem Shift System Range selection is accomplished by an air shift system and is driver-controlled through a cab-mounted air control valve. The control valve operates two shift units (one for each axle) which mechanically engages or disengages the planetary gearing. For operation description, refer to Shift System section in this manual.
Theory of Operation Dual Range Gearing The gearing for each axle is a combination of a spiral bevel ring gear and pinion and a planetary unit. First reduction (High Range) is provided by the spiral bevel gearing. Second reduction (Low Range) is through the planetary gearing. Four planetary idler pinions are confined within the ring gear and mesh with the ring gear internal teeth. The planetary gears rotate around a sliding clutch gear.
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Aftermarket Group ForDana spec‘ing or service assistance, call 1.800.621.8084 or visit our website at www.spicerparts.com PO Box 321 Toledo, Ohio 43697-0321 Warehouse Distributor: Dana Commercial Vehicle1.800.621.8084 Products Group OE Technology Dealers: 1.877.777.5360 3939 Drive Maumee, Ohio, USA 43537 www.spicerparts.com www.dana.com AXSM-0042 Printed in U.S.A. Copyright Dana Limited, 2012. All rights reserved. Dana Limited.
