Service Manual: Spicer Tandem Drive Axles

Spicer Tandem Drive Axles
Service Manual
Single Reduction & Single Reduction with
Wheel Differential Lock
AXSM-0046
July 2016
DDH/RDH40 DA/RA344
DSH/RSH40 DS/RS344
DSP/RSP40 DA/RA404(P)
DST40(P) DD/RD404
DDT41(P) DS/RS404(P)
DSP/RSP41 DA/EA405(P)
DST41(P) DD/RD405
DDH/RDH44 DS/RS405(P)
DSH/RSH44 DD/RD454
DS/RS454(P)
General Information
The description and specifications contained in this ser- Any reference to brand names in this publication is made
vice publication are current at the time of printing. Dana simply as an example of the types of tools and materials
reserves the right to discontinue or to modify its models recommended for use and should not be considered an
and/or procedures and to change specifications at any endorsement. Equivalents, if available, may be used.
time without notice.
Important Notice
This symbol is used throughout this manual WARNING: Failure to follow indicated proce-
to call attention to procedures where care- dures creates a high risk of personal injury
lessness or failure to follow specific instruc- to the servicing technician.
tions may result in personal injury and/or
component damage. CAUTION: Failure to follow indicated pro-
cedures may cause component damage or
Departure from the instructions, choice of malfunction.
tools, materials and recommended parts
mentioned in this publication mayjeopardize IMPORTANT: Highly recommended proce-
the personal safety of the service technician dures for proper service of this unit.
or vehicle operator.
NOTE: Additional service information not
covered in the service procedures.
TIP: Helpful removal and installation proce-

dures to aid in the service of this unit.
Always use genuine Spicer replacement parts.

Table of Contents
General Information Install Power Divider to Carrier Assembly

General Information ......................................................... i (In Vehicle) ........................................................ 33
Introduction .................................................................... 1 Disassemble, Assemble, and Overhaul
Model Listing ................................................................. 1 Power Divider (Out of Vehicle) ......................... 36
Model Information........................................................... 1 Lube Pump Removal:
Model Identification ........................................................ 2 Assemblies Built Before June 15, 2008 .............. 40
Part Identification............................................................ 2 Lube Pump Installation:
Ring Gear and Pinion ...................................................... 3 Assemblies Built Before June 15, 2008 ............. 40
Lube Pump Removal:
Inspection Assemblies Built After June 15, 2008 .............. 41
Failure Analysis ............................................................... 4 Lube Pump Installation:
Prepare the Parts for Inspection ..................................... 5 Assemblies Built After June 15, 2008 ................ 42
Inspection .... .................................................................. 6 Lube Manifold Removal ...............................................43
Check Input Shaft End-play (Forward Axle) .................. 7 Manifold Installation .....................................................43
Check Output Shaft End-play (Forward Axle)...................7 Hose/ Filter Assembly ...................................................44
Install Power Divider to Carrier Assembly
Remove Differential Carrier (Out of Vehicle) .................................................... 45
Differential Carrier Assembly - Parts................................ 8 Measure and Adjust Input Shaft End-Play.....................47
Remove Differential Carrier (Forward and Rear).............. 9
Carrier Assembly
Table of Contents
Install Differential Carrier Carrier Assembly - Parts Exploded View ......................49
Disassemble Carrier Assembly ....................................49
Install Differential Carrier (Forward and Rear) ............... 10
Drive Pinion
Differential Lockout Front Axle Pinion Assembly-Parts Exploded View........ 53
Inter-Axle Lockout Types ............................................... 11
Rear Axle Pinion Assembly-Parts Exploded View......... 53
Remove Lockout ........................................................... 14
Disassemble and Overhaul Drive Pinion ..................... 54
Install Lockout .............................................................. 14
Replace Pinion Bearing Cage Cups ........................... 56
Adjust Pinion Bearing Preload .................................... 57
Power Divider Final Buildup ............................................................... 58
Power Divider - Parts Exploded View ............................ 15
Install Drive Pinion Assembly ...................................... 61
UNITS BUILT BEFORE 11/2/1998 ................................. 16
Remove Power Divider .................................................. 16
Wheel Differential Assembly
Disassemble, Assemble, and Overhaul
Wheel Differential - Parts Exploded View .....................63
Power Divider .......................................................... 17
Disassemble, Overhaul and Assemble Wheel
Remove Lube Pump ..................................................... 21
Differential (Forward and Rear Axles) .....................64
Install Lube Pump ........................................................ 21
Overhaul and Assemble Wheel Differential ..................65
Install Power Divider to Carrier Assembly .................... 22
Measure and Adjust Carrier Assembly .........................67
UNITS BUILT AFTER 11/2/1998 ................................... 24
Change Backlash Setting .............................................68
Disassemble, Assemble, and Overhaul
Measure Ring Gear Runout ..........................................68
Power Divider (In Vehicle) ........................................ 24
Lube Pump Removal:
Adjust Tooth Contact Pattern
Assemblies Built Before June 15, 2008 ................. 27
Adjust Ring and Pinion Tooth Contact Pattern .............69
Lube Pump Installation:
Adjust Pinion Position ...................................................70
Assemblies Before June 15, 2008 ........................... 27
Adjust Ring Gear Position (Backlash) ............................70
Lube Pump Removal:
Assemblies Built After June 15, 2008 .................. 28
Lube Pump Installation:
Wheel Differential Lock - Parts Exploded View ............71
Assemblies After June 15, 2008 .............................29
Install and Adjust Wheel Differential Lock ....................72
Lube Manifold Removal ................................................. 31
Install and Adjust Ring Gear Thrust Bolt .......................73
Manifold Installation ...................................................... 31
Hose/ Filter Assembly ................................................... 32
Table of Contents
Housing and Output Shaft Assembly Theory of Operation

Remove Output Shaft Assembly ...................................74 Power Divider Operation
Housing and Output Shaft Assembly - (Power Flow and Torque Distribution) .................... 98
Parts Exploded View ................................................75 Operate Wheel Differential Assembly ......................... 100
Overhaul and Assemble Output Shaft Assembly .........76 Control Systems for Differential Lock ......................... 100
Measure and Adjust .....................................................78 Wheel Differential Lock ............................................... 101
Seals Parts Identification

Replace Seal .................................................................79 Power Divider - Parts Exploded View ......................... 103
Guidelines for Reusing Yoke .........................................79 Front Drive Axle - Parts Exploded View ......................104
Service Kit 217414 ........................................................80 Rear Drive Axle - Parts Exploded View ....................... 105
New Welded D-Housing Cover .....................................80 Inter-Axle Speed Sensor - Parts Exploded View............106
Wheel Differential Lock Assy - Parts Exploded View......106
IASS Housing and Output Shaft Assembly -
Inter-Axle Speed Sensor - Parts Exploded View ..........81 Parts Exploded View ............................................ 107
Disassemble Inter-Axle Speed Sensor .........................82
Overhaul Inter-Axle Speed Sensor ...............................82 Torque Chart
Install Inter-Axle Speed Sensor ....................................83 Fastener Torque Specifications .................................. 108
Housing Breather
Install New Axle Housing Breather
(Metal and Plastic) ................................................. 84
Wheel End Seal

Wheel End Seal - Parts Exploded View ........................ 85
Remove and Overhaul Wheel End Seal .........................86
Install Wheel End Seal .................................................86
Wheel Adjustment Systems

Adjust Wheel Bearing .................................................. 87
Wheel End
Verify Wheel End-play Procedure ................................ 89
Readjust Wheel End-play Procedure ............................ 89
Lubricate Wheel End .................................................... 90
Wheel Ends Without Oil Fill Hole .................................. 91
Lubrication
General Lubrication Information ................................... 92
Approved Lubricants ................................................... 92
Recommendations for Viscosity / Ambient Temp. ....... 92
Lube Change Intervals ................................................. 93
Change Lube ................................................................ 94
Standpipes ................................................................... 95
Final Check .................................................................. 96
Towing
Proper Vehicle Towing ................................................... 97
General Information
Introduction
General Information
Dana presents this publication to aid in maintenance and The suffix letter “P” in the model number indicates a lube
overhaul of Spicer single reduction drive axles. pump is standard. Pump models are equipped with a gerotor
pump, designed to provide additional lubrication to the inter-
Instructions contained cover the models listed below. Their axle differential and related parts.
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 Model Listing
equipment.
The following models are included in this publication.
FORWARD AXLE REAR AXLE FORWARD AXLE REAR AXLE LOAD CAPACITY
DS344 R S3 44 34,000 lbs.
DA344 RA344
DS404(P) RS404 DSP41 RSP41 40,000 lbs.
DA404(P) RA404 DSH40 RSH40
DD404(P) RD404 DDH40 RDH40
DS405(P) RS405 DSH44 RSH44
DS405(P) RA405 DDH44 RDH44
DD405(P) RD405 DST40(P) RST40
DSP40 RSP40 DST41(P) RSDT41
DDT41(P)
DS454(P) RS454 DD454(P) RD454 45,000 lbs.
DA454(P) RA454(P)
Model Information
Gearing Lube Pump (P) = Optional Lube Pump

D - Forward Tandem Axle P = Standard D - Tandem Forward Axle
R - Rear Tandem Axle (P) = Optional with Inter-Axle Differential Capacity (x 1000 lbs.)
R - Tandem Rear Axle Example: 40 = 40,000 lbs.
S - Single Reduction Design Level
T - Dual Range Gearing H= High Performance-40ª
P - Planetary Double Reduction Capacity (x 1000 lbs.) T= Torsionally Tuned
S - Single Reduction
D - Single Reduction with Wheel Differential Lock Example: 40 = 40,000 lbs. P= Premium
D - Driver Controlled Differential Lock
A - Single Reduction with In-Axle Speed Sensors (IASS)
Example:
DS = Forward Tandem Axle/Single Reduction
or
RS = Rear Tandem Axle/Single Reduction
1
General Information
Model Identification
Drive Axle
4
5
3
CUST. PART NO. Spicer®
SPEC. SERIAL NO.
2 6
MODEL PART NO. RATIO
MADE IN:
1 7
®recipS
.ON LAIRES
.ON TRAP .TSUC
.CEPS Data plate is located on CUST. PART NO.
SPEC.
Spicer®
SERIAL NO.
the axle centerline

OITAR .ON TRAP LEDOM MODEL PART NO. RATIO
:NI EDAM MADE IN:
Forward Axle (Side View) Rear Axle (Top View)
1 - Country or origin 4 - OEM part number assigned to the axle build

2 - Axle model identification 5 - Carrier assembly serial number assigned by the manufac-
3 - Specification number assigned to the axle built by Spicer. turing plant
Identifies all component parts of the axle including special 6 - Axle gear ratio
OEM requirements such as yokes or flanges. 7 - Carrier assembly production or service part number
Parts Identification Axle Shaft
Axle Housing
®
erLBS.
Spic
.
. NO
PT CAP. .
G. NO IN
HS I.D. DE
G. MA
HS ING
US
HO
2 - Axle shaft part number
1 - ID Tag
2
General Information
Ring Gear and Pinion
General Information
Note: Ring gear and drive pinion are matched parts and must be replaced in sets.
8 3
38
L70
127381 OF 17 G
SPICER 41-8 NL2
4
1 6
7
5 2
8
8-41
127
12
6
7
SPICER
0H
17
7
G
428
127
3
1
L7038
6-39
JD77
85405
86
NA
DA
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
3
Inspection
Failure Analysis
Failure analysis is the process of determining the original You need to be a good listener. Sometimes, insignificant or
cause of a component failure in order to keep it from happen- unrelated symptoms can point to the cause of the failure.
ing again. Too often, when a failed component is replaced
• Ask: Was the vehicle operating at normal tempera-
without determining its cause, there will be a recurring failure.
tures?
If a carrier housing is opened, revealing a ring gear with a bro-
ken tooth, it is not enough to settle on the broken tooth as the • Ask: Were the gauges showing normal ranges of
cause of the carrier failure. Other parts of the carrier must be operation?
examined. For a thorough understanding of the failure and
• Ask: Was there any unusual noise or vibration?
possible insight into related problems, the technician needs to
observe the overall condition of the vehicle.
After listening, review the previous repair and maintenance
records. If there is more than one driver, talk to all of them
No one benefits when a failed component goes on the junk
and compare their observations for consistency with the ser-
pile with the cause unknown. Nothing is more disturbing to a
vice and maintenance records. Verify the chassis Vehicle
customer than a repeat failure. Systematically analyzing a fail-
Identification Number (VIN) number from the vehicle identifi-
ure to prevent a repeat occurrence assures quality service by
cation plate, as well as the mileage and hours on the vehicle.
avoiding unnecessary downtime and further expense to the
customer. Make a Preliminary Investigation
These steps consist of external inspections and observations
The true cause of a failure can be better determined by know- that will be valuable when combine with the results of the
ing what to look for, determining how a piece of the equip- parts examination.
ment was running and learning about previous problems. In
the case of a rebuilt rear axle, mismatched gears may have • Look for leaks, cracks or other damage that can
been installed. point to the cause of the failure.
• Make note of obvious leaks around plugs and seals.
The more successful shops prevent repeat equipment failures A missing fill or drain plug would be an obvious
by developing good failure analysis practices. Knowing how cause for concern.
to diagnose the cause of a premature failure is one of the pre-
requisites of a good heavy-equipment technician. • Look for cracks in the carrier housing (harder to see,
but sometimes visible).
How to Diagnose a Failure
• Does the general mechanical condition of the vehicle
The following five steps are an effective approach to good fail-
indicate proper maintenance or are there signs of
ure diagnostics.
neglect?
1. Document the problem.
• Are the tires in good condition and do the sizes
2. Make a preliminary investigation. match?
3. Prepare the parts for inspection. • If equipped with a torque-limiting device, is it work-
ing properly?
4. Find the cause of the failure
5. Correct the cause of the problem. During the preliminary investigation, write down anything out
of the ordinary for later reference. Items that appear insignifi-
Document the Problem
cant now may take on more importance when the subassem-
Here are some guidelines for starting to learn about a failure,
blies are torn down.
including questions to ask:
• Talk to the operator of the truck.
• Look at the service records.
• Find out when the truck was last serviced.
• Ask: In what type of service is the truck being used?
• Ask: Has this particular failure occurred before?
• Ask: How was the truck working prior to the failure?
4
Inspection
Prepare the Parts for Inspection

After the preliminary investigation, locate the failure and pre- Find the Cause of the Failure
pare the part for examination. In carrier failure analysis, it may Here begins the real challenge to determine the exact cause of
be necessary to disassemble the unit. the failure. Keep in mind that there is no benefit to replacing a
failed part without determining the cause of the failure. For
• When disassembling subassemblies and parts, do
example, after examining a failed part and finding that the fail-
not clean the parts immediately since cleaning may
ure is caused by a lack of lubrication, you must determine if
destroy some of the evidence.
there was an external leak. Obviously, if there is an external
• When tearing down the drive axle, do it in the recom- leak, just replacing the failed gear is not going to correct the
mended manner. Minimize any further damage to the situation.
unit.
Another important consideration here is to determine the spe-
• Ask more questions when examining the interior of
cific type of failure which can be a valuable indicator for the
Inspection
the carrier. Does the lubricant meet the manufacturer
cause of failure. The following pages show different types of
specifications regarding quality, quantity and viscos-
failures and possible causes. Use this as a guide in determin-
ity? As soon as you have located the failed part, take
ing types of failures and in correcting problems.
time to analyze the data.
Correct the Cause of the Problem
Once the cause of the problem has been determine, refer to
the appropriate service manual to perform the repairs.
5
Inspection
Inspection
Clean Note: Replace conventional gaskets with silicone rubber gas-
ket compound (included in many repair kits). The com-
1. Wash steel parts with ground or polished surfaces in
pound provides a more effective seal against lube
solvent. There are many suitable commercial sol-
seepage and is easier to remove from mating surfaces
vents available. Kerosene and diesel fuel are accept-
when replacing parts.
able.
WARNING
1
Gasoline is not an acceptable solvent because of its
extreme combustibility. It is unsafe in the workshop envi-
ronment.
2. Wash castings or other rough parts in solvent or
clean in hot solution tanks using mild alkali solu-
tions.
Note: If a hot solution tank is used, make sure parts are
heated thoroughly before rinsing. 2
3. Rinse thoroughly to remove all traces of the cleaning 1 - Axle Housing
solution. 2 - Machined surface
4. Dry parts immediately with clean rags. Inspect Components
5. Oil parts. Inspect all steel parts for:
• If parts are to be reused immediately: Lightly oil. • Notches, visible steps or grooves created by wear
• If parts are to be stored: Coat with oil, wrap in • Pitting or cracking along gear contact lines
corrosion resistant paper and store in a clean, • Scuffing, deformation or discolorations. These are
dry place. signs of excessive heat in the axle and are usually
Inspect Axle Housing related to low lubrication levels or improper lubrica-
Axle housing inspection and repairs are limited to the follow- tion practices.
ing checks or repairs.
In addition, inspect the following for damage:
• Visually inspect axle housing for cracks, nicks and
burrs on machined surfaces. • Differential gearing
• Check carrier bolt holes and studs for foreign mate- • Bearings for loose fit on drive pinion, pilot bearing,
rial. and differential bearings
• Replace damaged fasteners. Look for loose studs or • All fasteners for rounded heads, bends, cracks or
cross threaded holes. damaged threads.
• Inspect machined surfaces of cast or malleable
CAUTION
parts. They must be free of nicks, burrs, cracks,
scoring, and wear.
Any damage which affects the alignment or structural integ-
• Look for elongation of drilled holes, wear on sur-
rity of the housing requires housing replacement. Do not
faces machined for bearing fits and nicks or burrs in
repair by bending or straightening. This process can affect
mating surfaces.
the material's properties and cause it to fail completely
under load. Inspect Primary Gearing
• Check all seals and gaskets. Before reusing a primary gear set, inspect teeth for signs of
excessive wear. Check tooth contact pattern for evidence of
incorrect adjustment.
6
Inspection
Check Input Shaft End-play (Forward Axle)

Note: Before disassembling the power divider, measure and Check Output Shaft End-play
record input shaft end-play.
(Forward Axle)
See illustration for steps 1–3.
1. Position dial indicator at yoke end of input shaft.
1. Position dial indicator at yoke end of output shaft.
2. Push in on input shaft and zero the dial indicator.
2. Push in on output shaft and zero the dial indicator.
3. Using a pry bar, move input shaft axially and mea-
sure/record end-play. 3. Using a pry bar, move input shaft axially and mea-
sure/record end-play.
3
3
Inspection
2
2
1
1
Adjustment Adjustment
Correct end-play for a new assembly is .003" to .007". The Correct end-play for a new assembly is .001" to .015". The
maximum end-play for a used assembly is no more than maximum end-play for a used assembly is no more than
.014". If end-play is incorrect, determine shim pack changes .015". If end-play is incorrect, contact Dana.
as follows:
Add shims to increase end-play.
Desired end-play (New Parts) 0.003” to 0.007”

Measured end-play (Step 3) 0.001” – 0.001”
Add shims to provide desired end-play 0.002” to 0.006”
Remove shim to decreased end-play.

Remove shims to provide desired end-play 0.012” to 0.008”
7
Remove Differential Carrier
(Forward and Rear)
Differential Carrier Assembly - Parts
1
2
3
1—Carrier fasteners
2—Carrier assembly
3—Forward axle assembly
4—Inter-axle differential lockout
5—Rear axle assembly
8
Remove Differential Carrier
(Forward and Rear)
Remove Differential Carrier (Forward and Rear)

Note: The removal of the forward carrier does not require dis- Note: Hand-tighten the bolt, over-torquing may cause damage
connecting of the inter-axle driveline and removal of the to the shift unit. To facilitate hand-tightening, coat bolt
output shaft yoke assembly as most other Spicer tan- threads with axle lube.
dems require.
Standard Differentials 1
1. Block the vehicle.

2
2. Drain axle lubricant.
3. Rear Only: Disconnect inter-axle driveline.
4. Front Only: Disconnect main driveline.
5. Front Only: Disconnect differential lockout air line.
6. Disconnect lead wires to the selector switch and air
line at shift cylinder.
7. Remove axle shafts.
Diff-Lock Models 1—Hand tighten with socket
For removal of the locking wheel differential carrier assembly, 2—M12 x 1.5 x 38mm bolt – GM only .250 – 18 NPTF – all
the differential lock must be engaged and held in the engaged models except GM
position. This can be accomplished by one of two methods;
either engage via air pressure or engage manually. Note: With either method, the axle shaft may have to be
Differential Carrier
rotated to permit the clutch to become engaged.
Engage via Air Pressure
Assembly
a. Using an auxiliary air line, apply 80–120 PSI air WARNING
pressure to shift cylinder air port to engage clutch.
Do not lie under carrier after fasteners are removed. Use
transmission jack to support differential carrier assembly
1 prior to loosening fasteners.
8. To remove axle shaft, remove axle stud nuts. (If
used, remove lock washers and taper dowels.)
9. Remove axle shafts.
Note: All models in this publication use axle shafts with
unequal lengths. Axle shafts may also be location spe-
cific with various wheel equipment. Do not misplace axle
shafts from their intended location. Identify left and right
shafts for reference during reassembly.
TIP: If necessary, loosen dowels by holding a brass drift in the

1—Connect 80-120 PSI air line to cylinder port center of the shaft head and striking drift a sharp blow with a
hammer.
Engage Manually
CAUTION
a. Install a .250 – 18 NPTF bolt over 1.5" long in the cyl-
inder air port to manually engage the clutches. GM
Do not strike the shaft head with a steel hammer. Do not
models require a M12 X 1.5 X 38mm bolt.
use chisels or wedges to loosen shaft or dowels.
10. Remove carrier capscrews, nuts and lock washers.
11. Remove differential carrier assembly.
9
Install Differential Carrier
(Forward and Rear)
Install Differential Carrier (Forward and Rear)

IMPORTANT
Before installing carrier assembly, inspect and thoroughly TIP:To assist in installing complete differential carrier use two
clean interior of axle housing using an appropriate solvent pieces of threaded rod (M16 X 1.5) threaded into carrier cap-
and clean rag. screw holes. Rod should be approximately 6" long. Use these
to pilot the carrier into the housing.
1. Apply Spicer approved RTV compound on axle hous-
ing mating surface as shown in the illustration. Com- 2. Install carrier to housing, lock washers, capscrews
pletely remove all old gasket material prior to and nuts. Torque to proper specification. Torque to
applying new material. Compound will set in 20 min- 230–270 lbs. ft. (312–366 N•m).
utes. Install carrier before compound sets or reapply. 3. After 11/02/98, axle housing covers are welded in
place. If you have a bolt-on cover, install rear hous-
ing cover/output shaft assembly (see page 69).
Torque all fasteners to proper specifications. Torque
to 85–103 lbs. ft. (115–140 N•m). Install inter-axle
driveline making sure yokes are in phase.
4. Install axle shafts and axle stud nuts (if used, also
install lock washers and tapered dowels).
5. Add axle lubricant. Fill to bottom of filler hole.
6. Rear Only: Connect inter-axle driveline, making sure
all yokes are in phase. Lubricate U-joints.
7. Front Only: Connect main driveline, making sure all
yokes are in phase. Lubricate U-joints.
8. Front Only: Connect differential lockout air line.
1— Apply silicone gasket in this pattern

2— Common stud locations
10
Differential Lockout
Inter-Axle Lockout Types
Since 1992, there have been 5 different power divider air lock- All are air-operated to engage the lockout and spring-released
out designs that are identified for service as either: to disengage the lockout with the exception of the "Reverse-
Air" lockout. The "Reverse-Air" lockout is spring-released to
• External - all models produced BEFORE 11/02/98
engage the lockout and air-operated to disengage the lockout.
• Integral - all models produced AFTER 11/02/98
Integral Shift Cylinder with Welded Push Rod Assembly—

February 2, 2000 to Present
• Redesigned shift system recessed into PDU cover.
• Integral
1 2
3
4
5
6
1 - Compression spring 4 - Piston

2 - Shift fork 5 - O-ring
3 - O-ring 6 - Piston Cover
Integral Shift Cylinder—

November 2, 1998 to February 2, 2000
• Redesigned shift system recessed into PDU cover.
• Integral
1 2
5
6
7
8
4
3
1 - Compression spring 5 - O-ring

2 - Shift fork 6 - Piston
3 - Snap ring 7 - O-ring
4 - Push rod 8 - Piston Cover
11
Cast Iron Cover Lockout—February 1996 to November 1998

• External type lockout.
• Cast iron piston cover.
4
5
6
7
8
1 - Compression spring 5 - O-ring

2 - Shift fork 6 - Gasket
3 - Push rod 7 - Piston cover
4 - Piston 8 - Hex head capscrew with flange
Cylindrical Design Lockout—

November 1992 to February 1996
• External type lockout
• Stamped steel piston cover.
• Interchangeable with the cast style cover only as a
complete assembly.
4 9
5
6
7
8
1 - Compression spring 5 - Piston

2 - Shift fork 6 - O-ring
3 - Push rod 7 - Shift cylinder
4 - Shoulder washer 8 - Mounting bracket
9 - Mounting bracket capscrews
12
“Reverse-Air” Lockout—Navistar before November 1, 1996
• External type lockout.
• Cast iron piston cover.
1
2
3
4
15 5
6
7
8
9
14
10
13
12
11
1—O-ring 9—Piston cover

2—Pilot plate 10— Hex head capscrew with flange
3—O-ring 11— O-ring
4—O-ring 12— Push rod
5—Snap ring 13— Compression spring
6—Piston 14— Shift fork
7—O-ring 15— Snap ring
8—Snap ring
13
Remove Lockout
External Type Lockout Install Lockout
1. With axle installed in vehicle, place differential lock
External Type Lockout
selector valve in the disengaged (or unlocked) posi-
tion. 1. Assemble o-rings onto piston. Apply silicone grease
to o-ring.
2. Disconnect differential lockout air line.
2. Install piston and o-ring assembly into cylinder body
3. Remove capscrews.
or cast iron cover.
4. Remove shift cylinder body or cast iron cover, o-ring
3. Attach shift cylinder body or cast iron cover to power
and piston.
divider while aligning piston with push rod. Make
IMPORTANT sure shoulder washer or gasket is in place.
4. For stamped steel style lockouts, attach mounting
Do not remove push rod. Removal of push rod will result in bracket to cylinder body and secure capscrews.
shift fork and compression spring falling into power divider 5. Tighten capscrews to 28–35 lbs. ft. (38–47 N•m).
unit. If this occurs, disassembly of the power divider
assembly will be necessary. 6. Connect differential lockout air line.
5. Remove shoulder washer in cylindrical design lock- 7. Cycle the lockout unit to insure there are no leaks
outs. Cast iron cover lockout designs do not use a and system shifts freely.
shoulder washer.
Integral Type Lockout
Note: Cylindrical design lockout and cast iron cover lockout 1. Assemble o-rings onto piston and piston cover.
are interchangeable only as complete assemblies. Apply silicone grease to o-rings.
Integral Type Lockout 2. Gently push piston and o-ring assembly into lockout
1. With axle installed in vehicle, place differential lock cylinder recess. Make sure piston is pushed all the
selector valve in the disengaged (or unlocked) posi- way in.
tion. 3. Install piston cover and o-ring assembly. Start by
2. Disconnect differential lockout air line. hand tightening clockwise.
3. Remove piston cover and o-ring. CAUTION
4. Remove piston and o-ring assembly with pliers.

Do not to strip threads or use excessive force, damage to
Note: To remove shift fork and push rod parts, the power part may occur.
divider must be removed. See power divider section.
4. Tighten piston cover to 25-35 lbs. ft. (35-47 N•m).
5. Connect differential lockout air line.
6. Cycle the lockout unit to make sure there are no
leaks and the system shifts freely.
14
Power Divider
Power Divider - Parts Exploded View
1 2 3 4 5 6 7 8 9
14 16 19 20
13 ! " 15
17
10 18
Power Divider
12
28
11
21 24 25 26 27 31
29
30
22
32
23
33 34 35 36

1 —Output shaft nut 13 —Output side gear bearing cup 26 —Input shaft bearing cone
2 —Output yoke 14 —Output side gear bearing cone 27 —Power divider cover (integral)
3 —Output seal 15 —Pump locking Pin 28 —Lube trough
4 —Output shaft bearing snap ring 16 —Output side gear 29 —Capscrew
5 —Outer bearing cup 17 —Pump 30 ---Shift fork
6 —Outer bearing cone 17A ---Old style pump 31 —Power divider cover (Old style)
7 —Inner bearing cone 17B—Output side gear bearing cup 32 —Push rod
8 —Inner bearing cup 18—Snapping ring 33 —Input bearing cup
9 —Output shaft 19 —Inter-axle differnential 34 —Input cage shim
10 —Seal manifold assembly 20 —Helical side gear 35 —Input cage V-ring
11 —Sump screen 21 —Sliding clutch 36 —Input cage
12 —Seal manifold feed tube 22 ---Push rod spring 37 —Capscrew
23—Shift fork assembly 38 —Oil seal
24 —Input shaft 39 —Input yoke
25 —Input shaft oil retainer 40 —Input nut
15
Power Divider
Remove Power Divider

Assemblies built BEFORE 11/02/98 3. Tap on the sides of the cover at the dowel pins with a
mallet to create a space large enough to finish free-
Power Divider Interchangeability ing the cover from the dowel pins.
(D344/404/405/454 Models Only)
4. Pull the power divider forward until the input shaft
Note: Due to the 11/02/98 redesign of the power divider (inte- stub end is free of the output side gear, then remove
gral air lockout and lube trough), the ability to inter- the assembly.
change parts will vary by build.
Method B
• Pre-11/02/98 carriers cannot be rebuilt with current With Carrier Out of Chassis
design power divider unit’s parts that have the inte-
gral air lockout design and lube trough. 1. Use a chain hoist.
• 11/02/98-current models can be rebuilt using pre- 2. Mount carrier assembly in carrier assembly stand.
11/02/98 power divider parts. 3. Remove PDU capscrews.
For more information refer to Spicer Bulletin ABIB-9901. 4. Fasten chain or strap to input yoke to remove power
divider.
The power divider can be replaced with the axle assembly CAUTION
both in or out of the chassis and with the differential carrier
assembled to the axle housing. During removal of power divider cover, the inter-axle differ-
CAUTION ential (IAD), input shaft assembly or IAD shift system parts
may fall from the carrier if not careful. Use caution to pre-
During removal of power divider cover, the inter-axle differ- vent injury or damage.
ential (IAD), input shaft assembly or IAD shift system parts Note: Lifting mechanism may create nicks and burrs on input
may fall from the carrier if not careful. Use caution to pre- yoke. Remove nicks and burrs if present.
vent injury or damage.
5. Tap the sides of the cover at the dowel pin location
1. Disconnect the main driveline. with a mallet to loosen cover.
2. Disconnect the lockout air line.
3. If overhauling the power divider, loosen but do not
remove input nut.
4. Position a drain pan under the unit.
5. Remove PDU capscrews.
Method A
With Carrier Installed in Chassis
1. Use a transmission jack or a chain hoist and a sling.
2. Wrap sling strap around power divider and attach to
chain hoist hook.
1 - Carrier assembly stand
16
Power Divider
Disassemble, Assemble and Overhaul the Power Divider

Assemblies built BEFORE 11/02/98 2. If replacement of the output shaft side gear bearing
The power divider may be serviced with the carrier assembly cup is necessary, use either of the following meth-
in or out of the axle housing. ods:
Note: The following procedure assumes that the differential Weld: Place a weld bead around the inside of the
carrier has been removed from the axle housing and that cup, when the weld cools the cup will fall out.
the power divider has been removed from the carrier
Hammer: Use slipper to get under the cup and with a
assembly.
hammer and drift from the back side of carrier tap
1. Remove output shaft side gear from differential car- out bearing cup.
rier.
Power Divider
Note: On pump models it will be necessary to remove three
pump retaining screws and remove the pump and out-
put shaft side gear as an assembly.
3. Remove snap ring from machined groove at rear of

input shaft.
17
Power Divider
4. Slide helical side gear off input shaft. 10. Slide input shaft assembly out of cover.
5. Remove helical side gear thrust washer.
1
2
11. Remove input shaft bearing cone and oil retainer.
1—Helical side gear 1

2—Thrust washer
3—PDU Cover (after 11/02/98) 2
6. Remove input shaft nut.

3
7. Remove yoke from input shaft using a puller tool.
TIP: A yoke puller tool may be made from the center
section of most gear puller tools, or may be pur-
chased from your local tool distributor.
4
8. Remove capscrews, input bearing cover and shim
pack.
9. If input shaft bearing cup needs replacement, use
either of the following recommended practices:
• Weld a bead around the cup, when the weld 1—Press
cools the cup will fall out. 2—Bearing
• Drill a 1/4 size hole through the bearing cover to 3—Oil retainer
the back side of the cup and use a punch to 4—Input shaft
remove the bearing cup.
Note: Shift fork cannot be removed until lockout cover is
removed and push rod is removed from shift fork. See
Differential Lockout Section.
12. Press new oil retainer on input shaft.
CAUTION
It is not recommended to reuse the oil retainer due to possi-

ble damage that may occur while removing the input shaft
bearing cone. While pressing on new oil retainer, make
sure not to over press, and/or press with the retainer at an
angle. If the retainer is bent or distorted it may rub on the
input cage or not seal properly to the v-ring.
18
Power Divider
13. Press input bearing cone on input shaft. 16. If bushing removal is needed the bushings must exit
from the thrust washer side of the helical gear. Press
out bronze bushings.
17. Install bronze bushing in helical side gear. Bushings

must be installed from thrust washer side of gear.
Power Divider
18. The bushing installation depth is 1/8” below the thrust
washer surface. The top of the outer bushing should be
1 - Press just below the machined staking groove.
2 - Plate
3 - Drive sleeve
4 - Input shaft bearing cone
5 - Oil retainer
6 - Input shaft
14. Press bearing cup in input bearing cover.

19. With the bushings installed to the proper depth, clamp
15. Install oil v-ring on input bearing cage cover.
the assembly in a vice for the staking process. Place a
rag between the gear and vice to protect against
damage to the gear.
1 - Bearing cup (press)

2 - V-ring
19
Power Divider
20. With a round, flat-tipped drift, stake the bushing flush 28. Install helical side gear.
to the machined groove.
NOTE: It is important that the angle of the staking tool is at
the same angle as the machined groove.
21. The depth of the stake is correct when the bushing

material is fully seated in the machined groove. 1 - Helical side gear
2 - Helical side gear thrust washer
3 - PDU cover (before 11/02/98)
29. Install snap ring.
22. The bushing must be staked in four positions 90° apart,

as shown in the illustration below.
WARNING
Snap ring is spring steel and may pop off.
Wear safety glasses when installing.
23. Install lockout cylinder assembly if removed. Some

models may have a one piece cover. Refer to pages
14-17. Tighten capscrews to 28–35 lbs. ft. (38–47
N•m).
24. Place sliding clutch in power divider cover, engag
ing clutch with shift fork. Position clutch teeth
toward helical side gear.
25. Slide input shaft into power divider cover. Engage
shaft splines in lockout sliding clutch.
26. Install input bearing cover and shims.
Note: Input shaft end-play must be adjusted after power

divider is assembled to differential carrier. For easier
adjustment, temporally install input bearing cage
cover and tighten capscrews finger tight.
27. Install helical thrust washer over input shaft.
20
Power Divider
Remove Lube Pump

1. Remove inter-axle differential (IAD) and pump collar. Install Lube Pump
TIP: The output shaft side gear and pump will be
1. Install lube pump assembly onto output side gear.
removed as an assembly. The lube pump assembly
is located on the back side of the output shaft side Note: The lube pump assembly is a slip-fit on the output shaft
gear, between the output shaft side gear and bearing side gear, behind the press fit of the output shaft side
cone. gear bearing. The output shaft side gear bearing cone
positions the pump assembly into the carrier.
Note: If the IAD assembly is to be reused, install in same
direction as removed. 2. Install bearing cone on output side gear.
3. Press bearing using proper tools until fully seated.
Power Divider
4. Reinstall output side gear pump and bearing assem-
bly into carrier.
5. Tighten lube pump retaining screws to 17-21 lbs. ft.
2. Remove the three pump retaining screws and (23-38 N•m).
remove the pump and output shaft side gear as an
assembly. TIP: The lube pump assembly is orientated in such a
way that the three mounting/locating tabs will only
1 line up one way.
Note: The lube pump is driven off the IAD assembly through a
drive coupling. The drive coupling has drive tangs to
both the IAD assembly and the lube pump. The IAD has
1—Magnetic strainer notches that will accept the drive coupling on either
face.
3. Inspect the lube pump if metal particles are found in
axle assembly. 6. Install pump drive coupling.
4. Remove the magnetic strainer from the carrier and Note: If reusing the IAD assembly, install in same direction as
inspect for wear material in the same manner as the removed.
drain plug. Wash the magnetic strainer in solvent
and blow dry with compressed air to remove oil and 7. Reinstall IAD.
metal particles.
CAUTION
Note: The pump assembly must turn freely by hand. The
pump is non-serviceable and must be replaced as a Exercise care to direct compressed air into a safe area.
complete assembly. Wear safety glasses.
21
Power Divider

Assemblies built BEFORE 11/02/98 5. Install the IAD assembly to the output side gear. If
(In vehicle installations shown) reusing the IAD assembly, install in the same direc-
tion as removed.
Note: Cleanliness in your work area is important as dirt is an
abrasive and will cause premature wear of the otherwise
serviceable parts.
Note: It is assumed that the differential carrier is secured in a
stand, or the power divider only is being serviced while
the axle is still attached to the housing.
CAUTION
During installation of power divider cover, the inter-axle dif-

ferential (IAD), input shaft assembly or IAD shift system
parts may fall from the carrier if not careful. Use caution to
prevent injury or damage. Note: For lube pump models, see instructions on page 24.
1. Make sure dowel pins are installed in carrier. IMPORTANT
2. Install output side gear bearing cup, if removed.
Press bearing cup in carrier. Use a press and an If power divider was manufactured before 11/02/98, the
appropriate sleeve. Make certain bearing cup is complete power divider assembly can be installed as one
evenly and firmly seated. If a press is not available, unit. It can be lifted or lowered into place with the input
use a sleeve or a bearing driver tool and a hammer to cage, input shaft, thrust washer, helical side gear and snap
install the cup. ring assembled to the PDU cover.
3. Lubricate o-rings. TIP: The use of two guide pins in the carrier mating
surface will help align the PDU cover and aid in
installation. Guide pins may be made from M14 X 2
1 bolts approximately 4 inches long with the heads
removed.
2 6. Install power divider assembly to carrier assembly.
Use Spicer approved RTV compound on the carrier
mating surface.
1—O-rings
2—Bearing cup
4. Install the output side gear if removed.
22
Power Divider
CAUTION
During installation of power divider cover, the inter-axle dif-

ferential (IAD), input shaft assembly or IAD shift system
prevent injury or damage.
7. During installation rotate input shaft to engage input
shaft splines with inter-axle differential. After instal-
lation, the output shaft should turn when the input
shaft is rotated and output shaft should turn inde-
pendently from the input shaft.
Power Divider
Note: Gasket compound will harden in 20 minutes. Install
power divider as quickly as possible to avoid future
leaks.
8. Install power divider capscrews. Torque to 114–140
lbs. ft. (155–190 N•m)
9. Reinstall input yoke if removed. All yokes have a slip
to interference fit on spline. Yokes should always be
installed with a press on tool to ensure they are fully
seated.
10. Even though you may have checked the input shaft
end-play before, you must check and adjust it again
now.
23
Power Divider
Disassemble, Assemble and Overhaul Power Divider

Assemblies built AFTER 11/02/98 (In Vehicle) 8. Remove shift fork, compression spring and shift rod.
The power divider cover comes off as a unit followed by the
input shaft and then the helical side gear.
The power divider can be replaced with the axle assembly

assembled to the axle housing.
CAUTION
During removal of power divider cover, the inter-axle differ-

ential (IAD), input shaft assembly or IAD shift system parts
1. Disconnect the main driveline.
9. Remove input shaft drive assembly from the carrier.
3. Remove input yoke.
4. Remove input seal.
5. Position a drain pan under the power divider unit.
7. Remove power divider cover.
10. Remove the IAD assembly from the output side gear.
24
Power Divider
11. Remove helical side gear and snap ring. Note: Remove lube pump if you have one. See page 30.
Power Divider
15. Inspect output side gear o-rings for nicks and cuts.
12. Remove thrust washer. Replace if necessary.
13. Remove lockout sliding clutch from the input shaft.
1—Press
2—Bearing
3—Oil retainer
4—Input shaft
16. Install new bearing cup.

17. Remove input shaft bearing cone and oil retainer, if
necessary.
14. Remove the output side gear.
CAUTION

ble damage that may occur while removing the input shaft
25
Power Divider
19. Press input bearing cone on input shaft. 21. Press bearing cup in input bearing cover.
22. Install new oil v-ring on input bearing cage cover.
1
2
1
4
1—Bearing cup (press)
2—V-ring
5
23. If bushing removal is needed, the bushings must exit
from the thrust washer side of the helical gear.
6 1
1 - Press 4 - Input shaft bearing cone

2 - Plate 5 - Oil retainer
3 - Drive Sleeve 6 - Input shaft 1—Tap out bronze bushings
20. If input shaft bearing cup needs replacement, use 24. Install bronze bushing in helical side gear. Bushings
either of the following recommended practices: must be installed from thrust washer side of gear.
See illustration for dimensional tolerances.
• Weld a bead around the cup, when the weld
cools the cup will fall out. 1 1
• Drill a 1/4 size hole through the bearing cover to 2
the back side of the cup and use a punch to 5
3 6 1/32"
1—Press
2—Sleeve
3—1st bronze bushing (press to shoulder)
4—Shoulder
5—Sleeve
6—Second bronze bushing (recess 1/32”)
26
Power Divider
Lube Pump Removal Install Lube Pump Assemblies

Assemblies Built Before June 2008 Assemblies Built Before June 2008
1. Remove inter-axle differential (IAD) and pump collar. 1. Install lube pump assembly onto output side gear.
TIP: The output shaft side gear and pump will be Note: The lube pump assembly is a slip-fit on the output shaft
removed as an assembly. The lube pump assembly side gear, behind the press fit of the output shaft side
is located on the back side of the output shaft side gear bearing. The output shaft side gear bearing cone
gear, between the output shaft side gear and bearing positions the pump assembly into the carrier.
cone.
2. Install bearing cone on output side gear.
Note: If the IAD assembly is to be reused, install in same
direction as removed. 3. Press bearing using proper tools until fully seated.
Power Divider
4. Reinstall output side gear pump and bearing assem-
bly into carrier.
5. Tighten lube pump retaining screws to 17-21 lbs. ft.
2. Remove the three pump retaining screws and
(23-38 N•m).
remove the pump and output shaft side gear as an
assembly. TIP: The lube pump assembly is orientated in such a
1 line up one way.
Note: The lube pump is driven off the IAD assembly through a
drive coupling. The drive coupling has drive tangs to
both the IAD assembly and the lube pump. The IAD has
1—Magnetic strainer notches that will accept the drive coupling on either
face.
axle assembly. 6. Install pump drive coupling.
4. Remove the magnetic strainer from the carrier and Note: If reusing the IAD assembly, install in same direction as
inspect for wear material in the same manner as the removed.
drain plug. Wash the magnetic strainer in solvent
and blow dry with compressed air to remove oil and 7. Reinstall IAD.
metal particles. CAUTION
Note: The pump assembly must turn freely by hand. The
Exercise care to direct compressed air into a safe area.
pump is non-serviceable and must be replaced as a
complete assembly. Wear safety glasses.
27
Power Divider
Lube Pump Removal: Assemblies Built After June 15, 2008

For output side gear and/or pump replacement, follow the 3. Remove pump from the output side gear.
procedure below.
1. Remove the output side gear bearing cone, if
required.
1 - Press
2 - Press Tool
2. Remove pump locking dowel pin from the hole in the

output side gear hub.
28
Power Divider
Lube Pump Installation: Assemblies Built After June 2008

Use these instructions with the carrier assembly in or out of 2. Install the pump locking dowel pin into the hole in
the vehicle. the output side gear hub. Make sure the pin is lined
up with the machined slot in the pump body.
If the unit does not have a pump, go to the Power Divider
Assembly section.
Note: Keep work area clean. Dirt is an abrasive and will cause
premature wear of the otherwise serviceable parts.
Note: For non-pump models, see output side gear seal mani-
fold installation.
Power Divider
Note: Only service the power divider if the differential carrier
is secured in a stand or while the axle is still attached to
the housing.
CAUTION:
1 2
CAUTION
CAUTION: During installation of power divider cover, the inter-

axle differential (IAD), input shaft assembly or IAD shift sys-
tem parts may fall from the carrier if not careful. Use caution
to prevent injury or damage.
1. Install the pump into the output side gear so that the
pump shaft is facing toward the teeth end of the side
gear. 1 - Machined Slot
2 - Pin
29
Power Divider
Lube Manifold Removal

1. Disconnect the hose from the lube manifold.
2. Remove the manifold assembly by prying it out
around the inner diameter.
IMPORTANT
IMPORTANT: Once removed, the seal manifold assembly can-

not be reused. This component should always be replaced
with new. Use the same removal procedure for the output side
gear seal removal on the non-pump models.
Note: Seals are not sold separately from the manifold.
1 - Barbed Nipple
30
Power Divider
Manifold Installation
1. Install the manifold assembly into the output side Note: For non-pump manifold installation, it is important to
gear bore in the carrier. Make sure the barbed nipple line up the oil inlet path hole in the manifold with the oil
is lined up with the opening in the carrier casting. path opening in the carrier manifold casting.
Power Divider
1 - Manifold Oil Inlet Hole

Assembly section.
If the unit contains a pump, go to the Pump Assembly section.

1
1 - Barbed Nipple
2. Install the hose clamp on the hose, push the hose

onto the barbed fitting and slide the clamp over the
barbed nipple.
3. Route the suction end of the hose through the holes
in the carrier casting to the bottom of the carrier.
4. Fully press the manifold assembly into position.

Note: Use care when pressing the manifold assembly to avoid
damaging the seals and barbed nipple. Do not over-
press plastic.
31
Power Divider
Hose/ Filter Assembly

1. Look to see that the hose guide collar is installed and 3. Next, push the filter and hose down into the collar so
not damaged. If damaged or not present replace that the filter is fully seated. Because of the
with new increased diameter of the hose after the filter is
installed,the hose should fit snugly in the collar
2. Now with the collar installed, push the hose through

the back side of the collar and install the filter to the 4. Fully seated position. Know hose should be showing
end of the hose. and filter will contact the collar.
32
Power Divider

Assemblies built AFTER 11/02/98 (In Vehicle) 4. Install the output side gear, if removed.
Note: See page 34 for out of vehicle.
Note: Parts inspection and cleaning procedures are important
and should be adhered to. Cleanliness in your work area
is important as dirt is an abrasive and will cause prema-
ture wear of the otherwise serviceable parts.
CAUTION
During installation of power divider components, the inter-
Power Divider
axle differential, input shaft assembly or IAD shift system
1. Make sure dowel pins are installed in carrier.
5. Install the IAD assembly to the output side gear. If
2. Install output side gear bearing cup, if removed. reusing the IAD assembly, install in the same direc-
Press bearing cup in carrier. Use a press and an tion as removed.
appropriate sleeve. Make certain bearing cup is
evenly and firmly seated. If a press is not available,
use a sleeve or a bearing driver tool and a hammer to
install the cup.
Note: For lube pump models, see page 30.

1—Lubricate o-rings
6. Out of the vehicle—on a bench, install lockout slid-
2—Bearing cup
ing clutch onto the input shaft.
3. Lubricate o-rings.
33
Power Divider
7. Install thrust washer. 10. Install shift fork, compression spring and shift rod.
8. Install helical side gear and snap ring.

CAUTION
During installation of power divider components, a part

may fall from the carrier. Use caution to prevent injury
or damage.
11. Install plastic trough in power divider cover.

12. Install power divider cover to carrier. Use Spicer
Loctite 518 anaerobic sealant on the carrier mating
surface. Torque capscrews to 114–140 lbs. ft.
(155–190 N•m).
9. Install input shaft drive assembly into the carrier.
NOTE: Gasket compound will harden in 20 minutes. Install

power divider quickly as possible to avoid future
leaks.
34
Power Divider
13. Install input cage shim and input cage assembly. 14. Install input cage capscrews and tighten until snug.
15. Measure and adjust input shaft end-play, see page
40.
16. Torque input cage capscrews to 114–140 lbs. ft.
(155–190 N•m).
17. Install NEW input seal, see page 72.
18. Reinstall input yoke.
Power Divider
35
Power Divider
Disassemble, Assemble, and Overhaul Power Divider

Assemblies built AFTER 11/02/98 – Out of Vehicle 8. Remove shift fork, compression spring and shift rod.
The power divider cover comes off as a unit followed by the
input shaft and then the helical side gear.
The power divider can be replaced with the axle assembly

assembled to the axle housing.
CAUTION
During removal of power divider cover, the inter-axle differ-

ential (IAD), input shaft assembly or IAD shift system parts
9. Remove input shaft and helical thrust washer from
1. Disconnect the main driveline.
the carrier.
3. Remove input yoke.
4. Remove input seal.
5. Position a drain pan under the power divider unit.
7. Remove power divider cover.
10. Remove helical side gear.
36
Power Divider
11. Remove the IAD assembly from the output side gear. 15. Remove input shaft bearing cone and oil retainer, if
necessary.
Power Divider
12. Remove the output side gear.
4
Note: Remove lube pump if you have one.
1—Press
2—Bearing
3—Oil retainer
4—Input shaft
CAUTION
13. Inspect output side gear o-rings for nicks and cuts.
Replace if necessary.
14. Install new bearing cup. ble damage that may occur while removing the input shaft
37
Power Divider
17. Press input bearing cone on input shaft. 19. Press bearing cup in input bearing cover.
20. Install new oil v-ring on input bearing cage cover.
2
1
1 - Bearing cup (press)

2 - V-ring
21. If bushing removal is needed the bushings must exit

from the thrust washer side of the helical gear. Press
out bronze bushings.
1 - Press 4 - Input shaft bearing cone

2 - Plate 5 - Oil retainer 22. Install bronze bushing in helical side gear. Bushings
3 - Drive sleeve 6 - Input shaft must be installed from thrust washer side of gear.
18. If input shaft bearing cup needs replacement, use

either of the following recommended practices:
• Weld a bead around the cup, when the weld
cools the cup will fall out.
• Drill a 1/4 size hole through the bearing cover to
the back side of the cup and use a punch to
23. The bushing installation depth is 1/8” below the thrust

washer surface. The top of the outer bushing should be
just below the machined staking groove.
38
Power Divider
24. With the bushings installed to the proper depth, clamp

the assembly in a vice for the staking process. Place a
rag between the gear and vice to protect against
damage to the gear.
Power Divider
25. With a round, flat-tipped drift, stake the bushing flush
to the machined groove.
NOTE: It is important that the angle of the staking tool is at
the same angle as the machined groove.
26. The depth of the stake is correct when the bushing

material is fully seated in the machined groove.
27. The bushing must be staked in four positions 90°

apart, as shown in the illustration below.
39
Power Divider
Lube Pump Removal: Lube Pump Installation:

Assemblies Built Before June 15, 2008 Assemblies Built Before June 15, 2008
1. Remove inter-axle differential (IAD) and pump collar. 1. Install lube pump assembly onto output side gear.
TIP: The output shaft side gear and pump will be
removed as an assembly. The lube pump assembly NOTE: The lube pump assembly is a slip-fit on the output
is located on the back side of the output shaft side shaft side gear, behind the press fit of the output
gear, between the output shaft side gear and bearing shaft side gear bearing. The output shaft side gear
cone. bearing cone positions the pump assembly into the
carrier.
NOTE: If the IAD assembly is to be reused, install in same
direction removed. 2. Install bearing cone on output side gear.
3. Press bearing using proper tools until fully seated.
2. Remove the three pump retaining screws and 4. Reinstall output side gear pump and bearing assembly
remove the pump and output shaft side gear as an into carrier.
assembly. 5. Tighten lube pump retaining screws to 17-21 lbs. ft.
(23-38 N•m).
TIP: The lube pump assembly is orientated in such a
line up one way.
1 - Magnetic strainer

axle assembly. NOTE: The lube pump is driven off the IAD assembly through
a drive coupling. The drive coupling has drive tangs to
4. Remove the magnetic strainer from the carrier and both the IAD assembly and the lube pump. The IAD
inspect for wear material in the same manner as the has notches that will accept the drive coupling on
drain plug. Wash the magnetic strainer in solvent either face.
and blow dry with compressed air to remove oil and
metal particles. 6. Install pump drive coupling.
NOTE: If reusing the IAD assembly, install in same direction
NOTE: The pump assembly must turn freely by hand. The as removed.
pump is non-serviceable and must be replaced as a
complete assembly. 7. Reinstall IAD.
CAUTION
Exercise care to direct compressed air into a safe area.
Wear safety glasses.
40
Power Divider
Lube Pump Removal: Assemblies Built After June 2008

For output side gear and/or pump replacement, follow the 3. Remove pump from the output side gear.
procedure below.
1. Remove the output side gear bearing cone, if
required.
Power Divider
1 - Press
2 - Press Tool
2. Remove pump locking dowel pin from the hole in the

output side gear hub.
41
Power Divider
Lube Pump Installation: Assemblies Built After June 2008

Use these instructions with the carrier assembly in or out of 2. Install the pump locking dowel pin into the hole in
the vehicle. the output side gear hub. Make sure the pin is lined
up with the machined slot in the pump body.
Assembly section.
NOTE: Keep work area clean. Dirt is an abrasive and will

cause premature wear of the otherwise serviceable parts.
NOTE: For non-pump models, see page 17 for output side

gear seal manifold installation.
NOTE: Only service the power divider if the differential

carrier is secured in a stand or while the axle is still at-
tached to the housing.
CAUTION
During installation of power divider cover, the inter-axle
differential (IAD), input shaft assembly or IAD shift system
1. Install the pump into the output side gear so that

the pump shaft is facing toward the teeth end of the
side gear.
1 - Machined Slot
2 - Pin
42
Power Divider
Lube Manifold Removal

1. Disconnect the hose from the lube manifold.
2. Remove the manifold assembly by prying it out
around the inner diameter.
IMPORTANT
Once removed, the seal manifold assembly cannot be
reused. This component should always be replaced with 1 - Barbed Nipple
new. Use the same removal procedure for the output side
gear seal removal on the non-pump models. 2. Install the hose clamp on the hose, push the hose
onto the barbed fitting and slide the clamp over the
barbed nipple.
Power Divider
3. Route the suction end of the hose through the holes
in the carrier casting to the bottom of the carrier.
NOTE: Seals are not sold separately from the manifold.
4. Fully press the manifold assembly into position.

1 - Barbed Nipple
NOTE: Use care when pressing the manifold assembly to
avoid damaging the seals and barbed nipple. Do not
Manifold Installation over press plastic.
1. Install the manifold assembly into the output side
gear bore in the carrier. Make sure the barbed
NOTE: For non-pump manifold installation, it is important to
nipple is lined up with the opening in the carrier
line up the oil inlet path hole in the manifold with the
casting.
oil path opening in the carrier manifold casting.
1 - Manifold Oil Inlet Hole
43
Power Divider
Hose/ Filter Assembly

1. Look to see that the hose guide collar is installed and 3. Next, push the filter and hose down into the collar so
not damaged. If damaged or not present replace that the filter is fully seated. Because of the
with new increased diameter of the hose after the filter is
installed,the hose should fit snugly in the collar
2. Now with the collar installed, push the hose through

4. Fully seated position. Know hose should be showing
the back side of the collar and install the filter to the
and filter will contact the collar.
end of the hose.
44
Power Divider

Assemblies built AFTER 11/02/98 (Out of Vehicle) Non-pump Models
Note: Parts inspection and cleaning procedures are important a. Install output side gear.
and should be adhered to. Cleanliness in your work area
b. Install the IAD assembly to the output side gear. If
is important as dirt is an abrasive and will cause prema-
reusing the IAD assembly, install the same direction
ture wear of the otherwise serviceable parts.
as removed.
Note: It is assumed that the different carrier is secured in a
stand.
CAUTION
Power Divider
During installation of power divider components, parts may
fall from the carrier if not careful. Use caution to prevent
injury or damage.
1. Make sure dowel pins are installed in carrier.
2. Output side gear bearing cup. If removed, press
bearing cup in carrier. Use a press and an appropri-
ate sleeve. Make certain bearing cup is evenly and
firmly seated. If a press is not available, use a sleeve
or a bearing driver tool and a hammer to install the
cup. Lube Pump Models
3. Lubricate o-rings. a. Install output side gear/pump assembly into carrier.
4. Install the output side gear using one of the follow- The lube pump mounting holes are oriented in such
ing instructions (non-pump models or lube pump a way that it can be installed only in one position.
models). b. Lube pump coupling—Line up the drive couplings
tangs with the pump and IAD notches. The spacing
of the tangs are the same, one side to the other. If
reusing the IAD assembly, install the same direction
as it was removed.
5. Install helical side gear.
45
Power Divider
6. Install thrust washer. 10. Install power divider cover to carrier. Use Spicer
approved RTV compound on the carrier mating sur-
face. Torque capscrews to 114–140 lbs. ft. (155–190
N•m).
Note: Gasket compound will harden in 20 minutes. Install
power divider as quickly as possible to avoid future
leaks.
7. Install compression spring, shift fork, push rod and

lockout sliding clutch.
11. Install input cage shim and input cage assembly.
8. Install input shaft assembly. 12. Install input cage capscrews and tighten until snug.
Note: The input shaft snap ring is not used in this buildup.
13. Measure and adjust input shaft end-play, see page

39.
14. Torque input cage capscrews to 114–140 lbs. ft.
9. Install plastic oil trough in power divider cover. (155–190 N•m)
15. Install NEW input seal, see page 71.
16. Reinstall input yoke.
46
Power Divider
Measure and Adjust Input Shaft End-Play

4. Install shim pack and bearing cover. Install cap-
screws. Torque screws to 114–140 lbs. ft. (155–190
NOTE: After power divider overhaul and installation on N•m). Make sure shims are flat with no kinks or
carrier, check and adjust input shaft end-play. bends.
1
The correct end-play when new parts are used in overhaul
is 0.003” to 0.007”, with reused parts the maximum is
0.014”.
1. Remove input shaft nut. Remove input bearing cover

capscrews. Remove bearing cover (and shim pack if
installed).
Power Divider
2. Reinstall bearing cover without shims. Hold in posi- 2
tion with hand pressure and measure clearance
between power divider cover and bearing cover,
using a feeler gauge.
1 - Push in and zero indicator, read and record

2 - Pry down
5. Install yoke using installation tool and nut. Tighten

nut snugly. Tap end of input shaft lightly to seat bear-
ings.
6. Check input shaft end-play with dial indicator posi-

tioned at yoke end of input shaft. Move input shaft
axially and measure end-play. If end-play is correct,
seal shim pack with Loctite 518 anaerobic sealant
to prevent lube leakage. Then torque input shaft nut.
7. If end-play is incorrect, change shim pack size as

follows:
3. The bearing cover clearance measured in Step 2 plus
0.005” will equal shim pack thickness required for Add shims to increase end-play
desired end-play (rebuild with new parts). Add Desired end-play (New Parts) 0.003” to 0.007”
0.015” to shim pack for rebuild with used parts. Measured end-play (Step 6) 0.001” – 0.001”
Add shims to provide desired end-play 0.002” to 0.006”
Remove shim to decreased end-play

Remove shims to provide desired end- 0.012” to 0.008”
play
47
Power Divider
8. To add or remove shims, remove input shaft nut and “271” (available in .5 ml tube– P/N 129293)
yoke. Remove capscrews, lock washers and bearing to the nut along two threads, for at least two
cover. Add or remove shims as required. flats (120°) of the nut midway through the
thickness. Tighten the nut to the specified
9. Install bearing cover and capscrews. Seal shim pack
with Spicer approved RTV compound to prevent lube torque 840–1020 lbs. ft. (1148–1383 N•m).
leakage then torque input shaft capscrews 150–165
lbs. ft. (204–224 N•m).
10. Install yoke.
11. Install yoke nut. One of the following options may be
used.
a. Install a new nut with the pre-applied thread 2 Flats
adhesive compound. Tighten the nut to the (120 ˚)
Midway thru
specified torque 840–1020 lbs. ft. (1148–1383 thickness of nut
N•m).
Note: Use of a torque multiplier is recommended.
If difficulty is experienced in achieving correct torque, torque

the nut with the truck wheels on the ground and with the axle
shaft installed.
IMPORTANT
Follow the instructions specified by the thread adhesive

manufacture when applying thread adhesive compound.
b. If a new nut with pre-applied thread adhesive

compound is unavailable, apply “Loctite 277” or
48
Carrier Assembly
Carrier Assembly - Parts Exploded View
Disassemble Carrier Assembly

(All Forward and Rear Axles)
1
2 Note: For models having the wheel differential lock option or a
carrier thrust bolt follow the steps below. These parts
must be removed first before further removal of the
3
wheel differential can take place.
14 4 Remove Wheel Differential – Models with Wheel
5
Differential Lock
1. For ease of servicing, mount differential carrier in
6
stand with differential lock facing up.
7
Note: To overhaul and reassemble the wheel differential, the
8 shift fork and clutch assembly must be removed from
carrier. See instructions below.
13 2. Remove shift cylinder mounting screws, then lift
9 shift cylinder, piston and o-ring assembly off carrier
and end of push rod.
10
12
Carrier Assembly
11
1
1 — Piston engagement bolt
2 — Capscrew
3 — Switch
4 — Washer
5 — O-ring
6 — Piston
7 — Setscrew
8 — Piston driver
9 — Pushrod 1—Shift cylinder
10 — Clutch fork
3. To disassemble shift cylinder for inspection, first
11 — Spring
remove or back off actuator switch. The piston and
12 — Sliding clutch
o-ring assembly can be removed by inserting a pen-
13 — Pin
cil-size tool through the cylinder air port.
14 — Piston cover
4. Grasp push rod end and pull it out of the shift fork,
spring and carrier.
Note: When the push rod is disengaged from the shift fork,
the fork and sliding curvic clutch assembly can be
removed from carrier.
Note: Do not disassemble shift fork from the sliding curvic
clutch unless parts replacement is necessary. To disas-
semble, use pin punch to remove spring pin from long
leg of fork. The fork can now be disengaged from the
clutch.
49
Carrier Assembly
5. Remove the snap ring, then lift fixed curvic clutch off 2. Back out thrust bolt from the carrier until the end of
differential case hub spline. Further disassembly of the bolt is flush with the inside of the carrier casting.
carrier is the same for axles without differential lock. This will allow enough clearance between the ring
gear and the carrier pilot web.
Models with Ring Gear Thrust Bolt
2
3
Note: If the carrier model has a ring gear thrust bolt installed,
it must be backed away from the ring gear before you 1—D-head carrier or front carrier
can remove the wheel differential. 2—Thrust bolt
3—Thrust bolt jam nut
1. Back off thrust bolt jam nut.
50
Carrier Assembly
Remove Wheel Differential (All Standard Models) 3. Remove capscrews, flat washers and bearing caps.
Back off bearing adjusters and remove adjusters and
Note: Omit this step if the gear set is to be replaced. If gear
bearing cups.
set is to be reused, check tooth contact pattern and ring
gear backlash before disassembling differential carrier.
When checking backlash, a yoke or helical gear must be
installed and torqued to get an accurate reading. Best
results are obtained when established wear patterns are
maintained in used gearing.
1. Mount differential carrier in repair stand.
4. Using a chain hoist, lift ring gear and differential

assembly out of carrier.
Note: For easier disassembly, loosen but do not remove pin-
Carrier Assembly
ion (self-locking) nut. Forward axle pinion is equipped
with slotted nut, remove roll pin with a pin punch then
loosen nut.
2. If reusing gear set, also punch mark bearing adjust-
ers for reference during assembly.
1—Punch marks
51
Carrier Assembly
Remove Pinion Assembly 2. Remove pinion bearing cage capscrews. Remove

pinion and cage assembly from carrier. Remove
1. Remove pinion bearing cage capscrews. Remove
shim pack.
pinion and cage assembly from carrier. Remove
shim pack.
Note: For easier disassembly, loosen but do not remove pin-

ion (self-locking) nut. Forward axle pinion is equipped
with slotted nut, remove roll pin with a pin punch then IMPORTANT
loosen nut.
Do not allow pinion to drop on hard surface.
If gear set is to be reused, keep pinion bearing cage shim

pack intact for use in reassembly. If the original shims can-
not be reused, record the number and size of shims in the
pack.
52
Drive Pinion
Front Axle Pinion Assembly - Parts Exploded View
Drive Pinion
1
2
3
4*
5
6
7 8
9
10
11
12
13
1—Pinion pilot brg. 8—Capscrew

2—Pinion 9—Pinion brg. cup - outer
3—Pinion brg. cone - inner 10—Pinion brg. cone - outer
4—Pinion brg. spacer* 11—Pinion helical gear
5—Pinion brg. cup - inner 12—Roll pin
6—Shim 13—Slotted pinion nut
7—Pinion brg. cage
* Before 3/01/95 two spacers were used instead of the one shown.
Rear Axle Pinion Assembly - Parts Exploded View

14
15
16
17
18
19
20
22
23
24
25
21
26
14—Pinion pilot brg. 21—Capscrew

15—Pinion 22—Pinion brg. cup - outer
16—Pinion brg. cone - inner 23—Pinion brg. cone - outer
17—Pinion brg. spacer 24—Oil seal
18—Pinion brg. cup - inner 25—Yoke
19—Shim 26—Pinion nut
20—Pinion brg. cage
53
Drive Pinion
Disassemble and Overhaul Drive Pinion

The following procedures cover both forward and rear differ- 6. Remove pilot bearing from pinion using a split-type
ential drive carrier disassembly. puller. Use two procedure steps to remove each
bearing.
1. Rear Axle Pinion Yoke: Remove yoke.
a. Mount puller vertically to separate the bearing.
CAUTION This action will force puller halves under bearing
and start moving bearing off pinion.
If pinion nut was not loosened during earlier disassembly,
clamp assembly in vise jaws, use brass pads to prevent
damage.
2. Loosen and remove pinion nut and flat washer.
Remove yoke from pinion using an appropriate tool.
3. Forward and Rear Axle Pinion Bearing Cage: Press
pinion out of bearing cage and bearing cone.
b. Mount puller horizontally to press pinion out of

bearing.
1 - Press ram
4. Rear Axle Pinion Oil Seal and Outer Bearing Cone:

Remove oil seal and bearing cone from cage. Dis-
card oil seal. Remove bearing cups with suitable
puller.
5. Remove bearing spacer from pinion.
54
Drive Pinion
7. Remove inner bearing cone from pinion using a

split-type puller. Use two procedure steps to remove
Drive Pinion
each bearing.
a. Mount puller vertically to separate the bearing.
This action will force puller halves under bearing
and start moving bearing off pinion.
b. Mount puller horizontally to press pinion out of

bearing.
1 - Press
55
Drive Pinion
Replace Pinion Bearing Cage Cups

4. Seat cups securely to shoulder. Check clearance
between cup and bearing cage. Must be less than
.001”.
1
Front Rear
2 2
1 - Cup(outer)
2 - Bearing cage
3 - Cup (inner)
1. Remove cups.
2. Clean and inspect bearing cages for damage, nicks
and burrs.
1
2
1 - Press ram
2 - Sleeve must apply pressure to back face of outer bearing
cone
3. Install inner and outer pinion bearing cups. Use a

press and an appropriate drive sleeve. Make certain
bearing cup is evenly and firmly seated.
56
Drive Pinion
Adjust Pinion Bearing Preload
Drive Pinion
Trial Buildup 3. Rotate pinion cage while applying press load (see
chart below) to the assembly and check rolling
1. Assemble pinion bearing cage, bearings, spacer and
torque. Wrap soft wire around the bearing cage,
spacer washer (without drive pinion or oil seal). Cen-
attach spring scale and pull. Preload is correct when
ter bearing spacer between two bearing cones.
torque required to rotate the pinion bearing cage is
Lubricate bearing cups and cones.
from 5–13 lbs. (2.5–6.0 kgs.).
1 Specifications for Pinion Bearing Trial Buildup Preload Test
2 Torque to Rotate Bearing Cage (w/o pinion seal)
18 - 42 in. lbs (2.0 - 4.7 N•m)
3
Forward Axles Rear Axles
4
Spring Scale 5 - 13 lbs. ( 2.5 - 6.0 kgs.)
5 Reading
6 Press Loads 17-19 Tons 14-15 Tons

(15.4 - 17.2 (12.7-13.6
Metric Tons) Metric Tons)
Nominal Bearing 0.496 in. 0.638 in.
Thickness Spacer (12.60 mm) (16.21 mm)
1 - Bearing
2 - Cup
3 - Spacer CAUTION
4 - Cage
5 - Cup Read only the torque value after the bearing cage starts to
6 - Bearing rotate.
Note: When new gear set or pinion bearings are used, select 4. If necessary, adjust pinion bearing preload by chang-
nominal size spacer from the specification chart. If origi- ing the pinion bearing spacer. A thicker spacer will
nal parts are used, use spacer removed during disas- decrease preload. A thinner spacer will increase pre-
sembly. load.
2. With the bearings well lubricated, place the assembly IMPORTANT

in the press. Position sleeve so that load is applied
directly to the backface of the outer bearing cone.
Once correct bearing preload has been established, note
the spacer size used. Select a spacer 0.001" larger for use
1
in the final pinion bearing cage assembly. The larger
2 spacer compensates for slight "growth" in the bearings
which occurs when they are pressed on the pinion shank.
Do not assume that all assemblies will retain proper pre-

load once bearings are pressed on pinion shank. FINAL
PRELOAD TEST MUST BE MADE IN EVERY CASE.
3
1 - Press ram
2 - Sleeve must apply pressure to back face of outer bearing
cone
3 - Spring scale
57
Drive Pinion
Final Buildup
Note: On rear axles, do not install oil seal in cage until bearing 3. Install bearing cage on drive pinion.
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.
4. Press outer bearing cone on pinion.
IMPORTANT
To prevent bearing damage, spin cage while pressing outer

bearing on.
IMPORTANT
To prevent bearing damage, use suitable sleeve that only

contacts inner race of bearing cone.
2. Install preselected bearing spacer.
5. Apply clamp load to the pinion bearing cage assem-

bly. Either install the yoke (or helical gear) and
torque the pinion nut to specifications or use the
press to simulate nut torque (see chart on next
page).
58
Drive Pinion
Specifications for Pinion Bearing Final Buildup Preload Test 6. Measure Pinion Bearing Preload: Use a spring scale
to test the assembly rolling torque. To use the spring
Drive Pinion
Torque to Rotate Bearing Cage (w/o pinion seal)
scale, wrap flexible wire around the bearing cage,
18 - 42 lbs. in. (2.0 - 4.7 N•m)
attach the scale and pull. Preload is correct when
Forward Axles Rear Axles torque required to rotate the pinion bearing cage is
from 5–13 lbs. This specification is translated into
Spring Scale 5 - 13 lbs. ( 2.5 - 6.0 kgs.) lbs. in. readings in the previous chart.
Reading
CAUTION
Press Loads 17–19 Tons 14–15 Tons
(15.4–17.2 (12.7–13.6
Metric Tons) Metric Tons) Read only the torque value after the bearing cage starts to
rotate.
Nut Torque 840 lbs. ft.* 575–703 lbs. ft.
(1,140 N•m*) (780–953 N•m) 7. Adjust Pinion Bearing Preload: If necessary, adjust
pinion bearing preload. Disassemble the pinion bear-
ing cage as recommended in this manual and
*Torque nut to 840 lbs. ft. (1,140 N•m), then continue tighten-
change the pinion bearing spacer. A thicker spacer
ing nut to align nut slot to nearest hole in pinion shank.
will decrease preload. A thinner spacer will increase
Vise Method preload.
a. if the yoke and nut are used, mount the assem- IMPORTANT
bly in a vise, clamping yoke firmly.
Use the correctly sized spacer. Do not use shim stock or

grind spacers. These practices can lead to loss of bearing
preload and gear or bearing failure.
8. Press pilot bearing on pinion.
IMPORTANT
1
To prevent bearing damage, use suitable sleeve that only
contacts the inner race of bearing cone.
1 - Vise
Press Method
a. If a press is used, position a sleeve or spacer so
that load is applied directly to the backface of
the outer bearing cone.
1 - Press
59
Drive Pinion
9. Stake pilot bearing using staking tool. This is essen- 11. Rear Axle Only: Prior to installation of yoke, make
tial to retain the bearing. sure yoke is clean and dry.
Stake Pattern
12. Install yoke.

13. Install yoke nut using one of the following options:
10. Rear Axle Only: With pinion installed and bearing a. Install a new nut with the pre-applied thread
preload adjustment complete, install oil seal. Use adhesive compound. Tighten the nut to the
properly sized installation tool as described on page specified torque:
71 to prevent distortion. • 575–703 lbs. ft. (780–953 N•m) for rear pinion
nut.
• 840–1020 lbs. ft. (1140–1383 N•m) for front
1
pinion nut.
compound is unavailable, apply “Loctite 277” or
2 “271” (available in .5 ml tube – P/N 129293)
to the nut along two threads, for at least two
flats (120°) of the nut midway through the
thickness.
IMPORTANT
3 Follow the instructions specified by the thread adhesive

manufacturer when applying thread adhesive compound.
1 - Tool
2 Flats
2 - Seal
(120 ˚)
3 - Bearing cage Midway thru
thickness of nut
TIP: If you can't get the correct torque on yoke nut, try torqu-
ing the nut with the truck wheels on the ground and with the
axle shafts installed.
Note: Forward axle pinion helical gear and bearing: These
parts are installed after pinion installation in carrier (see
page 54).
60
Drive Pinion
Install Drive Pinion Assembly
Drive Pinion
1. Forward Axle Only: Place shim pack on carrier mak- 3. Install drive pinion assembly. Install bearing cage
ing sure holes are properly aligned. Make sure shims capscrews and lock washers. Torque capscrews to
are flat with no kinks or bends. 114-140 lbs. ft. (155-190 N•m).
Note: Use a dummy yoke (if available) in place of helical gear.
This will result in easier disassembly and reassembly
during carrier adjustments.
2. Rear Axle Only: Place shim pack on carrier making

sure lube holes are clear. 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 114-140 lbs. ft. (155-190
N•m).
5. Forward Axle Helical Gear Only: If dummy yoke
was used, remove nut and yoke. Install helical gear
1 on pinion. Install M42 X 1.5 nut and torque to
840-1,020 lbs. ft. (1,140-1,383 N•m).
1—Lube slots
Note: If gear set is to be reused, install same quantity and size

of shims removed during disassembly. When installing a
new gear set, use nominal shim pack indicated.
Nominal Shim Pack
Axle in. mm
Forward 0.025 0.635
Rear 0.023 0.584
61
Drive Pinion
IMPORTANT
Torque to 840 lbs. ft. (1,140 N•m), then continue tightening

nut to align slot with the nearest hole in pinion shank.
Install roll pin.
1 2
1—Roll pin
2—Slotted nut
62
Wheel Differential - Parts Exploded View
3
4 9
2 8
5
6 7
Wheel Differential
1
11
Assembly
20
Flange Half (LH)
19
18
4
10
17 16
16
17
14
13
15
12
1 - Ring gear 11 - Nut

2 - Capscrew 12 - Diff. brg. adjuster - plain half
3 - Flat washer 13 - Bearing cup - plain half
4 - Diff. carrier bearing caps 14 - Bearing cone - plain half
5 - Cotter pin 15 - Diff. case - RH (plain half)
6 - Diff. case - LH (flange half) 16 - Side gear thrust washer
7 - Bearing cone - flange half 17 - Side gear
8 - Bearing cup - flange half 18 - Diff. spider
9 - Diff. brg. adjuster - flange half 19 - Side pinion
10 - Bolt 20 - Side pinion thrust
63
Disassemble, Overhaul, and Assemble Wheel Differential (Forward and Rear Axles)
Disassemble Wheel Differential 4. Lift out spider, side pinions and thrust washers.
IMPORTANT
During following procedure, place differential assembly on

malleable surface to prevent damage when ring gear falls
off its mounting position.
1. Remove nuts and bolts fastening ring gear to differ-
ential cases, allowing gear to fall free. If gear does
not fall, tap outer diameter with soft mallet to loosen.
5. Remove remaining side gear and thrust washer.
6. Remove bearing cones from case halves using suit-
able puller.
7. Remove bearing cone from plain case half in two
steps:
a. Mount puller vertically to split bearing. This
action will start moving bearing off case.
2. Punch mark differential cases for correct location

during reassembly. Remove capscrews and lift off
plain differential case half.
b. Mount puller horizontally to remove cone.
1 - Punch marks
3. Lift out side gear and thrust washer.
8. Remove bearing cone from flanged case half using

suitable puller.
64
Overhaul and Assemble Wheel Differential

IMPORTANT
To prevent bearing damage, use suitable sleeve that only 4. Lubricate all differential parts.
contacts the inner race of the cone. A used bearing race
5. Assemble side pinion and thrust washers on spider.
would be a suitable tool. This tool should have a slit cut if
Place this assembly in flanged differential case.
the ID is the same as the flange OD.
Rotate gears and check for proper mesh.
1. Press new flange half bearing cones on differential
case halves.
Wheel Differential
Assembly
6. Place side gear and thrust washer on side pinions.
2. Press new plain half bearing cones on differential

case halves.
7. Align punch marks and install plain case half. Install

capscrews and tighten to 114–140 lbs. ft. (155–190
N•m). Check differential for free rotation by turning
side gear hub.
3. Place thrust washer and side gear in flanged differ-

ential case. 1
1 - Punch marks
65
8. Install ring gear. Secure with bolts and nuts. Reference Spicer Bulletin ABIB-9701 for more details.
Note: Flange half differential cases were redesigned starting 9. Lower assembled differential assembly in to the carrier
with production axles built in January 1997. New style using a hoist and a strap. Be careful not to damage
ring gear bolts are also required with the new style the differential bearings lowering the assembly.
flange case, the torque specification for this bolt is different 10. Install the bearing cup and bearing adjuster to the
than the old 126219 bolt. (See chart). flange half side first.
Bolt No . Torque Specs .

129686 260-280 lbs. ft. (N•m 352-380)
126219 215-255 lbs. ft. (N•m 292-346)
11. Install the bearing cup and bearing adjuster to the
plain half side. Use a long screwdriver or bar to lift
the differential up while installing the cup and bearing
adjuster.
Ring Gear Bolt Torque Turn Specification
Bolt No . Torque Turn Angle
129686 125 Nm (92 ft. lbs) 65°
A. With a calibrated torque wrench, torque each ring gear

bolts to 125 Nm in a crisscross pattern.
B. With a torque wrench that reads torque turn angle,
tighten each fastener clockwise, 65 degrees.
IMPORTANT NOTE: If the torque exceeds 447 Nm

(330 ft. lbs.) when the 650 turn angle is achieved,
the bolt and nut need to be replaced.
66
Measure and Adjust Carrier Assembly

Adjust Backlash and Preload 3. Tighten the plain half adjuster two lug notches. Start
with the notch at the top, count two notches coun-
1. Turn the flange half bearing adjuster in until the ring
terclockwise on the adjuster, turn the adjuster so
gear contacts the pinion (zero backlash) than back
that the notch is facing straight up. You now have a
the adjuster out two notches of the adjuster lugs.
two notch preload.
2
1
Wheel Differential
1
Assembly
1—Flange half
2—Plain half
4. Use a rubber mallet to make certain that both bear-

1—Flange half
ing adjusters are fully seated.
2—Plain half
5. Measure backlash. Make sure it is within specifica-
2. Tighten the plain half adjuster until the bearing cup tion of .006"–.018".
just starts to turn, this is a zero bearing preload.
TIP: To give yourself room to adjust contact pattern,
set it between .010"–.012".
67
Change Backlash Setting

If you have too much backlash the ring gear needs to move Measure Ring Gear Runout
closer to the pinion. Back off the plain half adjuster, count the
number of notches you back it off, each notch equals about Measure Ring Gear Total
.003" of backlash.
1. Measure ring gear total radial run out. (Indicator
IMPORTANT reading should not exceed .010").
In order to maintain the differential bearing preload you will

need to turn the flange half bearing adjuster the same
amount in the same direction. If you need more backlash
reverse this procedure.
1. Install carrier bearings caps and torque carrier cap
bolts to 350–428 lbs. ft. (475–580 N•m).
2. Recheck backlash: if the bearing adjusters were not
in straight or fully seated the backlash will change.
a. Used Gearing: Reset to backlash recorded
before disassembly.
b. New Gearing: Backlash should be between 2. Measure ring gear total back face run out (Indicator
0.006 and 0.018". reading should not exceed .010").
3. Check ring gear tooth contact pattern. Paint ring gear

teeth and check tooth contact pattern. Correct tooth
patterns. Checking and adjusting procedures are on
pages 61-62.
4. Install bearing adjuster cotter pins.
68
Adjust Ring and Pinion 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
2 "pocket" at the heal end of the gear tooth. The more use a gear
has had, the more the line becomes the dominant characteris-
tic of the pattern.
1 Adjust used gear sets to display the same contact pattern

3
observed before disassembly. A correct pattern is up off the
4 toe and centers evenly along the face width between the top
5 land and root. Otherwise, the length and shape of the pattern
6 are highly variable and is considered acceptable as long as it
does not run off the tooth at any point.
1 - Face width
2 - Tooth Depth
3 - Heel
4 - Top land
5 - Root
6 - Toe
Note: Rear axle gearing is shown in the following instructions.

Correct tooth contact patterns and adjustments are the
same for forward and rear axles.
Adjust Tooth Contact

1. Identify if new or used gearing.
2. Check tooth contact pattern (new or used gearing).
Pattern
New Gearing - Correct Pattern 1 - Pattern along the face width could be longer
Paint six ring gear teeth 180° apart with marking compound
and roll the gear to obtain a contact pattern. The correct pat- Adjust Contact Pattern
tern is slightly below center on the ring gear tooth with length- If necessary, adjust the contact pattern by moving the ring
wise contact up off the toe. The length of the pattern in an gear and drive pinion.
unloaded condition is approximately one-half to two-thirds of • Ring gear position controls the backlash. This
the ring gear tooth in most models and ratios. adjustment moves the contact pattern along the face
width of the gear tooth.
The pattern could vary in length and should cover 1/2 tooth or
more (face width). The pattern should be evenly centered • Pinion position is determined by the size of the pin-
between tooth top land and root and should be up off the ion bearing cage shim pack. It controls contact on
tooth toe. 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, first adjust the
pinion, then the backlash. Continue this sequence until the
pattern is satisfactory.
69
Adjust Pinion Position

If the gear pattern shows incorrect tooth depth contact, Adjust Ring Gear Position (Backlash)
change drive pinion position by altering the shim pack. Used
gears should achieve proper contact with the same shims
If the gear pattern shows incorrect face width contact, change
removed from the axle at disassembly.
backlash by adjusting the ring gear.
Note: Check ring gear backlash after each shim change and
adjust if necessary to maintain the 0.006" to 0.018" If the pattern is too close to the edge of the tooth toe, move
specifications. the ring gear away from the pinion to increase backlash.
If the pattern is too close to the top land of the gear tooth,
remove pinion shims. Move pinion toward the ring gear.
1. Loosen the bearing adjuster on the teeth side of the

ring gear several notches.
If the pattern is too close to the root of the gear tooth, add 2. Loosen the opposite adjuster one notch.
pinion shims. Move pinion away from the ring gear.
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.
If the pattern is concentrated at the heel (too far up the tooth),

move the ring gear toward the pinion to decrease backlash.
5. Loosen the bearing adjuster on the teeth side of the

ring gear several notches.
6. Tighten the opposite adjuster one notch.
7. Return to adjuster on teeth side of ring gear and
tighten adjuster until it contacts the bearing cup.
8. Continue tightening the same adjuster 2 or 3 notches
and recheck backlash.
70
Wheel Differential Lock - Parts Exploded View
1
2
3
4
14
5
7
8
13
9
10
12
11

1—Piston engagement bolt 8 —Piston driver
2—Capscrew 9—Pushrod
3 —Switch 10—Clutch fork
4—Washer 11—Spring
5 —O-ring 12—Sliding clutch
6 —Piston 13—Pin
7—Setscrew 14—Piston cover
71
Install and Adjust Wheel Differential Lock

Note: With differential carrier completely assembled and 8. Push down by hand on the piston driver, both
adjusted, install differential lock as follows: clutches must be completely engaged.
1. Install fixed curvic clutch on splined hub of flanged 9. Install set screw in piston driver, torque to 12–15
differential case, then install snap ring. lbs. ft. (16–20 N•m).
2. If shift fork and sliding curvic clutch are disassem- CAUTION
bled, engage fork with clutch hub and install spring
pin in the long leg of the fork. See illustration for fork
On 3.90 ratio models only, a washer (P/N 210288) must be
mounting position on clutch.
used between the piston driver and piston. Failure to install
3. Position compression spring, shift fork and clutch the washer will cause engagement and disengagement
assembly in shift opening of the carrier. Align pilot problems in the differential lock.
hole of shift fork with pilot hole of carrier. Install
10. Trial fit, install piston cover assembly. Hand tighten
pushrod, engaging shift fork head, and compression
capscrews.
spring in carrier.
11. Screw in manual engagement screw, by hand
4. Install new o-ring on piston.
approximately 1 inch or until snug fit (light resis-
5. Lubricate piston and o-ring with silicone grease and tance pressure is felt) both clutches must be com-
install piston assembly in cylinder. Position piston pletely engaged.
with small diameter hub toward closed end of cylin-
12. Remove manual engagement screw, clutches must
der.
completely disengaged. Repeat above procedure if
6. Screw piston driver on push rod. clutches not completely disengaged.
7. Tighten piston driver until shift fork clutch is approx- Note: Fork adjustment is correct when curvic clutch teeth are
imately .030 of an inch from the fixed clutch. fully engaged with the fork free when moved by hand.
When air pressure is released or the manual bolt is
removed, the shift assembly should disengage freely.
13. When adjustment is complete, torque fasteners to
28–35 lbs. ft. (38–47 N•m).
.030"
14. Install selector switch in cylinder cover. Torque
switch to 10–12 lbs. ft. (14–16 N•m).
72

15. Check selector switch operation. Check switch elec- Install and Adjust Ring Gear Thrust Bolt
trically with an ohmmeter or continuity tester. Switch
should close (show continuity) when clutches are 1. Thread thrust screw into the carrier until firm contact
engaged and should open (no continuity) when with the back face of the ring gear is made.
clutches are disengaged. 2. Loosen the thrust screw 1/4 turn to obtain the cor-
rect adjustment of .020" (.50mm) clearance between
1 gear face and screw. Tighten jam nut, holding thrust
2 screw stationary with a wrench, torque jam nut 150–
190 lbs. ft. (203–258 N•m).
3. Recheck to assure minimum clearance during full
3 rotation of ring gear.
4
14
5
1
6
7
8
13
9
10
12
11 2
3
1 - D-head carrier or front carrier
2 - Thrust bolt
3 - Thrust bolt jam nut
1 - Piston engagement bolt

2 - Capscrew
3 - Switch
4 - Washer
5 - O-ring
6 - Piston
7 - Setscrew
8 - Piston driver
9 - Pushrod
10 - Clutch fork
11 - Spring
12 - Sliding clutch
13 - Pin
14 - Piston cover
73
Housing and Output Shaft
Assembly
Remove Output Shaft Assembly

Note: For forward axle rear covers that are removable the out- TIP: It may be helpful to loosely reinstall the yoke
put shaft may be removed when the cover is in or out of and shoulder nut giving the technician more of an
the axle assembly. area to grip when removing the output shaft.
1. Disconnect the inter-axle driveline at the forward 7. Remove the inner bearing cup from rear cover
axle rear cover position. assembly. This may be removed from inside the axle
housing when the carrier is removed, or by removal
2. Remove yoke nut (shoulder nut).
of the forward axle rear cover.
3. Remove yoke from output shaft using appropriate
8. Remove both inner and outer bearing from output
tool.
shaft.
1 - Yoke puller tool
TIP: A yoke puller tool may be made from the center 1 - Press
section of most gear puller tools, or may be pur-
chased from your tool distributor. 9. Remove output shaft inner bearing cup.
4. Remove oil seal. Note: On 11/02/98, a design change was made to the forward
5. Remove snap ring. axle housing in the 404 family axles. The rear axle hous-
ing cover is now a welded assembly. To replace the
6. Remove output shaft and outer bearing cup as an inner output shaft bearing cup on axle housings that
assembly. have the welded-on D-Cover, follow the steps outlined
below.
1
2
Note: Components such as the inter-axle driveline, yoke, oil
seal and output shaft assembly should have been
removed according to normal service procedures.
3
Removing the differential assembly from the axle hous-
ing is not necessary, but would ease the removal pro-
cess of the inner bearing cup from the cover bore.
4
a. Using a bearing puller tool, remove the inner
5 bearing cup.
b. Visually inspect the inner-machined bore sur-
face of the welded-on cover for nicks and burrs.
Repair if necessary.
1 - Snap ring 4 - Inner bearing cup

2 - Outer bearing cup 5 - Rear cover assembly
3 - Output shaft assembly
74
Assembly
Housing and Output Shaft Assembly - Parts Exploded View

Welded Rear Cover
18 19
17

1 29
2
3
4
Assembly
5
6
7
8
10 9
11 16
12
Bolt on Rear Cover 22

13 20 21
14
15
24
23
18 19 27
17 26 25
28
29
1— Output shaft nut 11— Rear cover capscrew 21— Breather

2— Output yoke 12— Fill plug 22— Breather hose
3— Output seal 13— Rear cover nut 23— Carriage capscrew
4— Snap ring 14— Lock washer 24— Lock washer
5— Outer bearing cup 15— Stud 25— Nut
6— Outer bearing cone 16— Dowel 26— Lock washer
7— Inner bearing cone 17— Jam nut 27— Stud
8— Inner bearing cup 18— Locking ring 28— Drain plug
9— Output shaft 19— Spindle nut 29— Axle shaft
10— Rear cover 20— Axle housing
75
Assembly
Overhaul and Assemble Output Shaft Assembly

Note: Lubricate the parts with gear lube during assembly. Note: Use the bearing cup driver to insure seating of snap
ring after installation with snap ring pliers.
1. The output shaft bearings are assembled with both
bearing cones back to back. Use a press and a sleeve
1
to install one bearing at a time.
CAUTION 2
To prevent bearing damage, use a suitable sleeve that only

contacts the bearing race. 3
2. Apply pressure until the inner bearing cone touches

the shoulder of the output shaft. 4
3. Apply pressure until the back of the outer bearing
5
cone touches the back of the inner bearing.
Note: Axle housings with welded-on covers procured through
service will include the inner bearing cup as part of the
"service" axle housing assembly. Go to Step 6 if the inner
cup has already been installed.
6
4. Lightly coat the output bore of the axle housing
cover with a 9.5 (.38) wide application of Loctite 680
where the bore contacts the inner bearing cup. Do
not apply Loctite outside of this area—to the bearing 7
rollers or outboard of the inner cup bore. Improper
application of the Loctite could lock the rollers or
cause excessive pre-load. 1—Press 5—Press bearing on first
2—Plate 6—Output shaft
CAUTION 3—Sleeve 7—Plate
4—Press bearing on second
Add loctite adhesive to the inner bearing surface of the
housing and NOT to the bearing race itself. If added to the 1
race, excessive adhesive could get on the surface of the 2
outer bearing race journal during installation and cure the
outer cap in place with excessive pre-load. 3
5. Using a sleeve and driver (hammer), install the inner

bearing cup.
4
6. Put the output shaft and bearing assembly into the
axle housing assembly. 5
7. Using a sleeve and driver (hammer), install the outer

bearing cup into the housing assembly over the out-
put shaft bearing cone.
8. Using snap ring pliers, install the snap ring that fas-
tens the outer bearing cup into the welded-on cover
assembly.
1—Snap ring
9. Check the end-play of the output shaft. New assem- 2—Bearing cup
blies should measure .001" to .015". 3 —Output shaft assembly
4—Inner bearing cup
5—Rear cover assembly
76
Assembly
10. Bolted rear cover only: If removed, install cover and IMPORTANT
fasten with nuts, capscrews and lock washers.
Tighten to proper torque specifications.
Follow the instructions specified by the thread adhesive
Note: Use Spicer approved RTV compound on axle housing manufacturer when applying thread adhesive compound.
mating surface as shown in illustration. Completely
remove all old gasket material prior to applying new
material. Compound will set in 20 minutes. Install axle
housing cover and output shaft assembly before com-
pound sets or reapply.
2 Flats

Cover Side of Axle Housing (120 ˚)
Midway thru
thickness of nut
Assembly
IMPORTANT
If you can't get the correct torque on yoke nut, try torquing
the nut with the truck wheels on the ground and with the
axle shafts installed.
13. Install axle shafts and axle stud nuts (If used, also
install lock washers and taper dowels).
14. Connect inter-axle driveline. Make sure driveline is
2 properly phased. Lubricate U-joints.
1 15. Add axle lubricant. Fill to bottom of filler hole.
1—Apply silicon gasket in this pattern IMPORTANT
2—Stud locations
11. Install output yoke. When axle has been disassembled or housing, axle shafts
or wheel equipment replaced, check axle assembly for
12. Install yoke nut using one of the following options: proper differential actions before operating vehicle. Wheels
a. Install a new nut with the pre-applied thread must rotate freely and independently.
adhesive compound. Tighten the nut to the 16. Road test vehicle to bring axle lubricant up to tem-
specified torque 680–832 lbs. ft. (920–1,130 perature. Recheck joints, drain and fill plugs for leak-
N•m). age. Retighten as necessary.
compound is unavailable, apply "Loctite 277" or
"271" (available in .5 ml tube—P/N 129293)
thickness. Tighten the nut to the specified
torque 680–832 lbs. ft. (530–1,130 N•m).
77
Assembly
Measure and Adjust

Note: Use bearing cup driver to insure seating of snap ring Correct end-play for a new assembly is .001" to .015". The
after installation with snap ring pliers. maximum end-play for a used assembly is no more than
.015". If end-play is incorrect, contact Dana.
5. Install oil seal. Follow seal replacement procedures
1. Assemble cover assembly to axle housing. on page 72 of this manual.
2. Position dial indicator at yoke end of output shaft. 6. Install yoke.
3. Push in on output shaft and zero the dial indicator. 7. Install yoke nut. One of the following options may be
utilized:
4. Using a pry bar, move output shaft axially and mea-
sure/record end-play. a. Install a new nut with the pre-applied thread
4 adhesive compound. Tighten the nut to the
specified torque 680–832 lbs. ft. (920–1130
N•m).
compound is unavailable, apply "Loctite 277" or
"271" (available in .5 ml tube—P/N 129293)
3 thickness (See illustration). Tighten the nut
to the specified torque 680–832 lbs. ft. (920–
1130 N•m).
2
1
78
Seals
Replace Seal
Dana strongly recommends using seal drivers when installing
new seals. Use the proper driver to make sure that the seal is
CAUTION
square and installed to the proper depth.
CAUTION Due to the resiliency of the plastic driver, hammer rebound

may occur when the seal is seated. Keep clear of the ham-
Oil seals can be easily damaged prior to installation. Use mer rebound path!
care when handling the new seal to prevent damage or con- 6. Handle the seal by its outside diameter avoiding any
tamination. Leave the seal in its package until installation. contact with the seal lips. During installation, use the
On new yokes, leave the protector on the yoke until it is proper driver to make sure that the seal is mounted
installed on the shaft to prevent damage or contamination. properly.
1. Inspect axle end-play at the yoke (see page 10). Ser- 7. Use a rubber mallet to drive the seal tool in until the
vice if beyond specified limit. flange bottoms on the housing cover bore face. The
2. Remove the old yoke using appropriate tool. A yoke flange will locate the seal at the proper depth.
puller tool may be made from the center section of
most gear puller tools, or may be purchased from
your local tool distributor.
Seals
Guidelines for Reusing Yoke
CAUTION
1
Do not use the yoke if it has any damage on the seal surface
1 - Yoke puller tool (nicks or scratches).
3. Remove seal. Use care when removing the old seal The surface of the yoke and the lips of the seal form a critical
to prevent damage to the housing seal bore. interface which retains the axle's lubricant while sealing the
4. Inspect the seal bore area for any damage (nicks, axle from outside contaminants. The condition of the yoke
gouges, corrosion). Carefully remove any slight hub's surface is a very important factor in determining seal
damage with a crocus cloth. Clean the bore area to life.
remove any loose debris.
Carefully inspect the seal surface area of the yoke hub for
CAUTION
signs of wear and damage. Do not reuse the yoke if there is
noticeable wear, such as heavy grooving, beyond normal pol-
Do not use any silicone or permatex-type bore sealant with
ishing from the seal lips.
this seal.
Note: Do not rework the yoke with abrasives such as emery
5. Remove the new seal from its package and install
paper or crocus cloth. Clean the surface of the yoke as
with the proper driver:
necessary using chemical cleaners. Remove all trace of
Service kit #217414 the chemicals from the yoke after cleaning.
D-Input-Use driver #126917 only CAUTION
D-Output-Use insert #128706 with driver #126917
R-Pinion-Use driver #126917 only Do not use wear sleeves. Wear sleeves increase the yoke
hub surface diameter and cause premature seal wear and
repeat seal failure.
79
Seals
Service Kit 217414
D-Input D-Output R-Pinion
Location
126917
Tool
+
126917 126917
128706
New Welded D-Housing Cover Interchangeability of Parts

A cross reference chart of “OLD” axle housing to “NEW” axle
Lube Quantity Difference
housings with welded on covers will be published in a sepa-
0 (zero) rate bulletin. The bolt on D-Housing covers will remain avail-
able for service.
Standout of Output Shaft Yoke
Length increased by 6mm (.25”), this should not have any
significant impact on inter-axle driveline length or drive line
angles.
80
IASS
Inter-Axle Speed Sensor - Parts Exploded View
IASS
3
5
1—Axle shaft
2—Speed sensor
3—Differential bearing adjuster
4—Plated connector
5—ABS Harness connector
81
IASS
Disassemble Inter-Axle Speed Sensor

The design of the drive axle sensor allows replacement of sev- Overhaul Inter-Axle Speed Sensor
eral individual components without disassembling the com-
plete sensor system. For example: Note: If plated connector was damaged during axle disassem-
bly or if there is indication of a wiring fault, the connec-
• The differential bearing adjuster does not need to be
tor assembly must be replaced.
removed in order to replace any other component.
• The sensor and rotor can be replaced without There are two different connectors with two different lengths
removing or replacing the plated connector. of terminal wires. See Inter-Axle Speed Sensor Service Man-
ual AXSM-0034.
At every stage of drive axle service, try to isolate the problem
to specific components in order to avoid unnecessary disas- To install new connector:
sembly.
1. Clean threaded hole in carrier and wire path to allow
1. Disconnect two wires from sensor terminals. proper seal for new connector. (Male threads on the
new connector have microencapsulated Loctite).
2. Carefully inspect wires and connector. If connector
is intact and if there is no prior indication that con- 2. Insert connector and torque to 20–28 lbs. ft. (27–38
nectors and wires require replacement, do not N•m).
unscrew plated connector. The sensor may be
3. Route wires to the sensor location.
replaced without replacing connector and wire.
3. Remove four screws from face of sensor. If sensor assembly is to be replaced, install new sensor before
finishing installation of new connector. The final position of
4. Remove sensor from differential bearing adjuster.
the sensor terminals must be fixed before wires can be sealed
in place.
82
IASS
Install Inter-Axle Speed Sensor

Except for routing the wires between the sensor and the 7. Before sealing wires in place, check sensor continu-
IASS
plated connector, procedures for installing both drive axle ity by measuring the resistance between pins on the
speed sensors are identical. The instructions which follow outside of the connector. Resistance between con-
cover the long arm (plain half) side speed sensor and require nector pins should be 1125 to 1375 ohms.
careful routing of the 6 inch long connector wires to prevent
8. Check wire routing. Make sure wire is seated in the
pinching between the head and housing.
cast-in channel and will not get pinched when the
head is reassembled to the housing. Seal wire in
place with RTV.
To replace sensor on the short arm (flanged half) side, repeat

1 previous steps. Since connector location is inside the mount-
4 ing surface, there is less concern for pinching of the shorter 4
inch connector wires. However, before final assembly, check
wire position and routing to make sure that it is not crimped
or pinched.
2
3
1
1—Wires seated in channel

2—Connector hole is on carrier mounting surface
3—6 inch long wires
2
4—Sensor terminals positioned near carrier mounting
surface
3
1. Lubricate interior rotor with axle lube or grease. 4
Check that the rotor turns freely by hand.
6 5
2. Mate the rotor and the sensor assembly.
3. Align the sensor/rotor assembly with the face of the 1—Installed position of axle shaft
adjuster so that the terminals are nearest the carrier 2—Sensor terminals positioned near connector hole
mounting surface. 3—Axle housing
4. Orient the sensor to line up the holes in the sensor 4—4 inch long wires
with the threaded holes in the adjuster. Rotate the 5—Connector hole is not on carrier mounting surface
sensor in either direction to get the fit that keeps the 6—Axle carrier
terminals near the carrier mounting surface. This
final adjustment should only require a slight shift in
sensor position.
5. Apply Loctite to the four mounting screws. Install
the screws and tighten in a “star” pattern to maintain
sensor alignment. Torque to 28–32 lbs. in. (3.2–3.6
N•m). (A preferred tightening approach is the “turn
of bolt” method: torque screws finger tight then
tighten additional 1/4 turn).
6. Attach the two round terminals to sensor. Either wire
can connect to either sensor blade. Make sure that
terminals are not bridged and that connectors are
not touching. Torque to 10–15 lbs. in. (1.1–1.7
N•m).
83
Housing Breather
Install New Axle Housing Breather (Metal and Plastic)

Spicer Truck Components has released a new axle housing 5. Plastic only: tighten until one thread is showing.
breather kit, part number 507162. This kit contains a fitting,
hose and clamp assembly, and instructions. This new
breather kit will replace the current breather (P/N 809560) and
snap cap (P/N 126980) on the models listed above for both
production and service. This newly designed breather has
improved resistance to water ingestion, clogging caused by
dirt, ice or snow buildup around the base of the breather. See
installation instructions below (all views from rear).
1. Install fitting in breather hole. 6. Insert hose onto fitting, long end down.
2. Tighten fitting finger tight.
7. Push hose firmly against fitting. Rotate hose to point

down.
3. Using a 3/4” wrench:

4. Metal only: rotate the fitting at least 1/2 turn until
nipple points to rear.
84
Wheel End Seal
Wheel End Seal - Parts Exploded View
Wheel End Seal

3
1—Installation tool
2—Seal
3—Rear hub
85
Wheel End Seal
Remove and Overhaul Wheel End Seal

WARNING
Never work under a vehicle supported by only a jack. Note: Deep gouges can be repaired by filling gouge with hard-
Always support vehicle with stands. Block the wheels and ening gasket cement and smoothing with emery cloth.
make sure the vehicle will not roll before releasing the
6. Clean hub cavity and bearing bores before reassem-
brakes.
bly. Be sure to remove contaminants from all
IMPORTANT recesses and corners.
7. Clean bearings thoroughly with solvent and examine
Wheel end seals can be easily damaged during handling. for damage. Replace damaged or worn bearings.
Leave the seal in its package until installation to prevent
IMPORTANT
damage or contamination.
1. Remove outer bearing and wheel.
Always use the seal installation tool specified by the seal
2. Remove oil seal. manufacturer. Using an improper tool can distort or damage
3. Remove inner bearing. the seal and cause premature seal failure.
4. Remove old wear sleeve (2-piece design only) with a

ball peen hammer and discard. Install Wheel End Seal
CAUTION 1. Before installation, lubricate the following with the
same lubricant used in the axle sump.
Do not cut through the old wear sleeve. Damage to the • Inner bearing
housing may result. • Wheel seal (follow the directions provided by
5. Inspect spindle journal and hub bore for scratches or the seal supplier)
burrs. Recondition with an emery cloth as required. 2. Place seal on installation tool.
3. Drive seal with installation tool onto hub.
86
Adjust Wheel Bearing
Wheel Adjustment
WARNING
Systems
Do not mix spindle nuts and lock washers from different 8. Back off the inner nut one full turn. Rotate the wheel
systems. Mixing spindle nuts and lock washers can cause hub.
wheel separation.
9. Retighten the inner nut to 50 lbs. ft. (68 N•m) while
Note: The lock washer for a four-piece tang/dowel-type wheel rotating the wheel hub.
nut system is thinner than the lock washer for a three-
10. Back off the inner nut exactly 1/4 turn.
piece tang-type wheel nut system and is not designed to
bear against the inner nut. Note: This adjustment procedure allows the wheel to rotate
freely with 0.001"–0.005" (0.025 mm–0.127 mm) end-
1. Inspect the spindle and nut threads for corrosion
play.
and clean thoroughly or replace as required.
11. Install the correct lock washer for the wheel nut sys-
Note: Proper assembly and adjustment is not possible if the
tem being used.
spindle or nut threads are corroded.
Three-piece Dowel-type Lock Washer System
2. Inspect 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.
CAUTION
A wheel dolly is recommended during installation to make

sure that the wheel seal is not damaged by the weight of the 1
hub and drum. Never support the hub on the spindle with 2
just the inner bearing and seal. This can damage the seal 3
and cause premature failure. 4
4. Completely fill the hub cavity between the inner and 1—Inner nut (P/N 119882)
outer bearing races with the same lubricant used in 2—Dowel pin
the axle sump. 3—Dowel-type lock washer (P/N 119883)
4—Outer nut (P/N 119881)
5. Before installation, lubricate the outer bearing with
the same lubricant used in the axle sump.
a. Install the Dowel-type lock washer on the spindle.
Note: Lubricate only with clean axle lubricant of the same type
Note: If the dowel pin and washer are not aligned, remove
used in the axle sump. Do not pack the bearings with
washer, turn it over and reinstall. If required, loosen the
grease before installation. Grease will prevent the proper
inner nut just enough for alignment.
circulation of axle lubricant and may cause wheel seal
failure. IMPORTANT
6. Install the outer bearing on the spindle.
Never tighten the inner nut for alignment. This can preload
7. Install the inner nut on the spindle. Tighten the inner
the bearing and cause premature failure.
nut to 200 lbs. ft. (271 N•m) while rotating the wheel
hub. b. Install the outer nut on the spindle and tighten to 350
lbs. ft. (475 N•m).
CAUTION
c. Verify end-play, see page 81.
Never use an impact wrench to adjust wheel bearings. A

torque wrench is required to assure that the nuts are prop-
erly tightened.
87
Three-piece Tang-type Lock Washer System Four-piece Tang/Dowel-type Lock Washer System
3
4
5
1
2 1
2
3
1—Inner nut (P/N 11249) 1—Inner nut (P/N 119882)

2—Tang-type lock washer (P/N 11245) .123” thick 2—Dowel pin
3—Outer nut (P/N 11249) 3—Dowel-type lock washer (P/N 119883)
4—Tang-type lock washer (P/N 129132) .0478” thick
a. Install the Tang-type lock washer on the spindle. 5—Outer nut (P/N 119881)
IMPORTANT a. Install the Dowel-type lock washer on the spin-
dle.
Never tighten the inner nut for alignment. This can preload
Note: If the dowel pin and washer are not aligned, remove
the bearing and cause premature failure.
washer, turn it over and reinstall. If required, loosen the
b. Install the outer nut on the spindle and tighten inner nut just enough for alignment.
to 250 lbs. ft. (339 N•m).
IMPORTANT
c. Verify end-play, see page 81.
d. After verifying end-play, secure wheel nuts by Never tighten the inner nut for alignment. This can preload
bending one of the locking washer tangs over the bearing and cause premature failure.
the outer wheel nut and another tang over the
b. Install the Tang-type lock washer on the spindle.
inner wheel nut.
e. Go to step 12. c. Install the outer nut on the spindle and tighten
to 250 lbs. ft. (339 N•m).
d. Verify end-play, see page 81.
e. After verifying end-play, secure the outer nut by
bending (180° apart) two opposing tangs of the
locking washer over the outer nut.
12. Install the following:
• New gasket at axle shaft flange.
• Axle shaft.
• Axle flange nuts and tighten to specified torque.
13. Lubricate axle wheel ends.
88
Wheel End
Verify Wheel End-play Procedure

Verify that end-play meets specification using a dial indicator. Adjust End-play with Wheel Hub
An indicator with 0.001" (0.03 mm) resolution is required.
Wheel end play is the free movement of the tire and wheel
assembly along the spindle axis.
Correct end-play is .001"–.005" (0.025–0.125 mm).

1. Attach a dial indicator with its magnetic base to the
hub or brake drum as shown below:
2. 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.
Wheel End
3. 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 With indicator mounted at bottom,
bearing end-play as the total indicator movement. Push / Pull at sides of drum
CAUTION
If end-play is not within specification, readjustment is

Readjust Wheel End-play Procedure
required.
Excessive End-play—If end-play is greater than .005"
Adjust End-play with Tire and Wheel Assembly (.127 mm), remove the outer nut and pull the lock washer
away from the inner nut, but not off the spindle. Tighten the
inner nut to the next alignment hole of the dowel-type washer
(if used). Reassemble the washer and re-torque the outer nut.
Verify end-play with a dial indicator.
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). Reassem-
ble the washer and re-torque the outer nut. Verify end-play
with a dial indicator.
Fine Tuning the End-play—If, after performing the readjust-

ment procedures, end-play is still not within the .001"–.005"
(.025–.127 mm) range, disassemble and inspect the compo-
nents. If parts are found to be defective, replace the defective
parts, reassemble and repeat wheel bearing adjustment pro-
cedure. Verify end-play with a dial indicator.
89
Wheel End
Lubricate Wheel End

IMPORTANT
Before operating the axle, the wheel hub cavities and bear-
ings must be lubricated to prevent failure.
Wheel End with Oil Fill Hole
When wheel ends are serviced, follow Spicer’s wheel end lubri-
cation procedure before operating the axle. 1
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
1. Rotate the wheel end hub until the oil fill hole is up.
2. Remove the oil fill plug.
2
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.
Wheel End without Oil Fill Hole
1—Wheel end oil fill hole

2—Proper lubricant level
3—Lubricant flow from sump
90
Wheel End
Wheel Ends Without Oil Fill Hole

1. With axle level and wheel ends assembled, add lubri- 5. Lower the left side.
cant through filler hole in axle housing cover until
6. With axle on a level surface, add lubricant through
fluid is level with the bottom of filler hole.
housing cover oil filler hole until fluid is level with the
2. Raise the right side of the axle 6 inches or more. bottom of the hole.
Hold axle in this position for one minute.
Note: Axles without wheel end fill holes will require approxi-
3. Lower the right side. mately 2.5 additional pints of lubricant to bring the lube
4. Raise the left side of the axle 6 inches or more. Hold level even with the bottom of fill hole.
axle in this position for one minute.
Wheel End
3 4
1
1—With axle on level surface, fill housing with oil to bottom of plug
2—Temperature sensor mounting hole
3—Oil will run into wheel end
4—Oil will run into wheel end
5—Tilt housing side to side (1 minute per side).
6—Recheck oil level in axle.
91
Lubrication
General Lubrication Information

The ability of a drive axle to deliver quiet, trouble-free opera- Recommendations for Viscosity/Ambient
tion over a period of years is largely dependent upon the use
of good quality gear lubrication in the correct quantity. The Temperature
most satisfactory results can be obtained by following the
directions contained in this manual. The following chart lists the various SAE Grades covered by
MIL-L-2105D and the associated ambient temperature range
The following lubrication instructions represent the most cur- from each. Those SAE grades shown with an asterisk (*) are
rent recommendations from Dana. available in the Spicer family of synthetic gear lubricants.
The lowest ambient temperatures covered by this chart are

Approved Lubricants -40°F and -40°C. Lubrication recommendations for those
applications which consistently operate below this tempera-
General— Gear lubrications acceptable under military specifi- ture range, must be obtained through Dana by contacting
cation (MILSPEC) MIL-L-2105D (Lubricating Oils, Gear, Mul- your local Dana Spicer representative.
tipurpose) are approved for use in Spicer Drive Axles. The
Grade Ambient Temperature Range
MIL-L-2105D specification defines performance and viscosity
requirements for multigrade oils. It supersedes both 75W -40°F to -15°F (-40°C to -26°C)
MIL-L-2105B, MIL-L-2105C and cold weather specification
75W-80 -40°F to 80°F (-40°C to 21°C)
MIL-L-10324A. This specification applies to both petroleum-
based and synthetic based gear lubricants if they appear on 75W-90* -40°F to 100°F (-40°C to 38°C)
the most current “Qualified Products List” (QPL-2105) for
75W-140 -40°F and above (-40°C and above)
MIL-L-2105D.
80W-90 -15°F to 100°F (-26°C to 38°C)
Note: The use of separate oil additives and/or friction modifi-
ers are not approved in Spicer Drive Axles. 80W-140* -15°F and above (-26°C and above)
85W-140 10°F and above (-12°C and above)
Synthetic based— Synthetic-based gear lubricants exhibit
superior thermal and oxidation stability, and generally
degrade at a lower rate when compared to petroleum-based * Available in the Spicer family of synthetic gear lubricants
lubricants. The performance characteristics of these lubri-
cants include extended change intervals, improved fuel econ-
omy, better extreme temperature operation, reduced wear and
cleaner component appearance. The family of Spicer gear
lubricants represents a premium quality synthetic lube which
fully meets or exceeds the requirements of MIL-L-2105D.
These products, available in both 75W-90 and 80/W-140,
have demonstrated superior performance in comparison
to others qualified under the MILSPEC, as demonstrated by
extensive laboratory and field testing. For a complete list of
Spicer approved synthetic lubricants contact your local
Dana representative. See back cover of this manual for
appropriate phone number.
Makeup Lube— Maximum amount of non-synthetic makeup

lube is 10%.
92
Lubrication
Lube Change Intervals

This product combines the latest manufacturing and part Severe Service Lubrication Change Intervals—Severe ser-
washing technology. When filled with a Spicer approved vice applications are those where the vehicle consistently
synthetic lubricant at the factory, the initial drain is operates at or near its maximum GCW or GVW ratings, dusty
not required. or wet environments, or consistent operation on grades
greater than 8%. For these applications, the ON/OFF HIGH-
Change the lubricant within the first 5,000 miles of opera- WAY portion of the chart should be used. Typical applications
tion when not using a Spicer approved synthetic lubricant are construction, logging, mining and refuse removal.
in either a new axle or after a carrier head replacement.
Note: Clean metallic particles from the magnetic filler plug
Base subsequent lubricant changes on a combination of
and drain plugs. Clean or replace the breather yearly to
the following chart and user assessment of the application
avoid lube contamination due to water ingestion.
and operating environment.
Synthetic or Lubricant SAE Change Interval for Line Haul Change Interval for Voca-
Mineral tional
Synthetic* SHAES-256 SAE 75W-90 500,000 miles [800,000 Km] or 120,000 miles (193,000 Km)
5 years or 1year
Synthetic** SHAES-256 SAE 75W-90, 250,000 miles (400,000 Km) or 60,000 miles [96,500 Km] or 1
75W-140 3 years year
Mineral MIL-L-2105E/J02360, 75W, 75W-90, 120,000 miles [193,000 Km] or 60,000 miles [96,500 Km] or
Base API GL-5 Gear Oil, 75W-140, 80W- 1 year 1 year
MIL-PRF-2105E 90, 85W-140
Lubrication
* Axles using LMS wheel end system
** Axles using adjustable wheel bearing system
93
Lubrication
Change Lube
Drain Always use the filler hole as the final reference. If lube is level
with the bottom of the hole, the axle is properly filled.
Drain when the lube is at normal operating temperature Note: Lube fill capacities (see chart) are basic guidelines and
(150°–200°F). It will run freely and minimize the time neces- will vary based on the angle the axle is installed in a
sary to fully drain the axle, this insures the axle is flushed. particular chassis. Torque fill plug to 40–60 lbs. ft.
(54–82 N•m).
Unscrew the magnetic drain plug on the underside of the axle
housing and allow the lube to drain into a suitable container. TIP: The axle can be filled through the axle housing breather
Note: Dispose of all used lubricants properly by following dis- hole. Fill until lube level is even with the bottom of filler hole in
posal methods approved for mineral or synthetic based axle housing rear cover.
oils.
After initial oil change, inspect drain plug for large quantities
of metal particles. These are signs of damage or extreme wear
in the axle. Clean the drain plug and replace it after the lube
has drained completely. Inspect breather for clogging or cor-
rosion. Clean or replace as necessary.
Fill
Front Axle
a. With vehicle on level ground, remove the filler hole
1 - With axle on level surface, fill housing with oil to bottom
plug from the axle housing cover and fill the axle
of plug.
with approved lubricant until level with the bottom of
2 - Temperature sensor mounting hole.
the hole.
Rear Axle
a. Remove the filler hole plug from the axle housing
cover and fill the axle with the approved lubricant
until level with the bottom of the hole.
b. If wheel ends were removed, follow instructions in
wheel end servicing pages 81–83.
Correct lube level at bottom of filler hole.
94
Lubrication
Standpipes
Drive axles are lubricated with oil drawn from a large sump
integral to the assembly. Most axle designs attempt to posi-
tion vital components such as pinion bearings in close prox- Tandem Forward Axles
imity to this sump, keeping them bathed in a generous supply Installation 5-10% 10-15% 15-20%
of oil at all times. Angle* Grade Grade Grade
When drive axles are installed at severe angles in vehicle 0° – – –

chassis, the position of these components is changed relative 3° – – 2.00"
to the oil sump. The same effect is present when the vehicle
travels up a steep grade. Oil in the sump remains level while 5° – 1.00" 2.25"
the axle itself tilts up or down. This makes it possible for bear- 7° – 1.25" 2.50"
ings and gears located well forward in the assembly to
"starve" for lubrication even though the axle is filled to the 10° 1.50" 1.75" 2.75"
base of the fill plug hole as recommended by the manufac- 13° 1.75" 2.00" 3.00"
turer.
15° 2.50" 2.50" 3.25"
Axles should be modified with standpipes to raise lube levels
whenever chassis installation angles exceed 10° and when the *Pinion pointing upward
vehicle must negotiate continuous or lengthy grades on a rou-
tine basis.
Tandem Rear Axles
The chart gives standpipe recommendations for vehicles Installation 5-10% 10-15% 15-20%
operating in consistently mountainous areas. Angle* Grade Grade Grade
Lubrication
Axle Installation Axle Location Quantity 0° – – –
Angle (pints)
3° – – 1.00"
12° Rear 19*
5° – 1.00" 1.75"
10° Rear 21*
7° – 1.75" 2.00"
8° Rear 22.5*
10° – 2.00" 2.25"
6° Forward 24.5
13° 1.00" 2.25" 2.75"
6° Rear 25
15° 2.00" 2.50" 3.25"
4° Forward 27
4° Rear 25 *Pinion pointing upward
2° Forward 29
2° Rear 26
0° Forward 31
0° Rear 28
*Does not allow for standpipe.
Capacities do not include wheel equipment requirements. An

additional 1–2 pints is required in each wheel hub.
95
Lubrication
Horizontal Mounting Final Check

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 nec-
essary.
12° Installation
2
1
12° Installation with Standpipe
3
1
1—Oil filler hole

2—Lost oil capacity
3—Additional oil capacity
Note: Grades must be continuous or lengthy in nature. Moni-

tor oil temperatures before installing standpipes. Axles
should operate at approximately 100°F (38°C) over
ambient temperature and not exceed 240°F (116°C).
96
Towing
Proper Vehicle Towing
Towing
Without Wheel Differential Lock With Wheel Differential Lock
Lift the drive wheels completely off of the ground or damage Follow this procedure to remove all axle shafts preventing
will occur. gear rotation with the drive wheels and possible lubrication
damage.
WARNING
1. Engage the wheel differential lock, indicator light is
on (move vehicle to verify engagement).
Do not lift the front wheels (non-drive wheels). This alters
the oil’s position in the drive axle, draining it away from the 2. Shift transmission into neutral.
drive pinion and its bearings. If the pinion is rotated under 3. With vehicle stationary, release the air pressure on
these conditions for any period of time, bearings will over- the wheel differential lock shift system and apply the
heat resulting in axle damage or failure. parking brake.
If this is impossible to lift the drive wheels, remove all axle 4. Disconnect the air supply and fitting at the shift cyl-
shafts to prevent gear rotation and cap the wheel hubs to pre- inder.
vent loss of lubricant and a possible road hazard. See the fol- 5. Install the shipping capscrew 128642 (.250 X 18 X
lowing section Proper Vehicle Towing with Wheel Differential 1.5") NPSM screw. GM models require part number
Lock for removal procedure. 128274 (M12 X 1.5 X 38mm) screw. Tighten cap-
screw to manually engage the wheel differential lock
until the indicator light is on and the differential lock
is completely engaged.
6. Remove the axle shafts.
7. Install temporary cover on hub to prevent contami-
nation entering and also to prevent the loss of lubri-
cant.
97
Theory of Operation
Power Divider Operation (Power Flow and Torque Distribution)

In operation, the power divider accepts torque from the vehi- The inter-axle differential compensates for minor variations in
cle driveline and distributes it equally to the two axles. speed between the two axles, the same way the wheel differ-
ential works between the two wheels of a single drive axle.
This assembly is of the two-gear design consisting of an input This unit also acts as a central point in distribution of torque
shaft, inter-axle differential, output shaft and two constant- to the two axles.
mesh helical gears.
The power divider also includes a driver-controlled,
air-operated lockout. When lockout is engaged, it mechani-
cally prevents inter-axle differentiation for better performance
under poor traction conditions.
With Lockout Engaged
(Inter-Axle Differential is Operating)
1
2
5
3
1— Input torque 4— Rear axle torque is transmitted from the output shaft side
2— Lockout disengaged gear through the output shaft, inter-axle driveline, drive pin-
3— Forward axle torque is transmitted from the helical side ion, ring gear, wheel differential and axle shafts.
gear through the pinion helical gear, drive pinion, ring gear, 5— Input torque (power flow) from the vehicle driveline is
wheel differential and axle shafts. transmitted to the input shaft and the inter-axle differential
spider. The differential distributes torque equally to both axles.
98
Theory of Operation
With Lockout Engaged Note: Varied road surface conditions can result in unequal
(Inter-Axle Differential is Not Operating) torque distribution between the two axle assemblies.
Lockout should only be engaged when both axles are rotating
at the same speed. Operation should be limited to low-traction CAUTION
situations and should be disengaged when normal traction
returns. Failure to do so will result in poor handling and dam- Prolonged operation with the lockout engaged can damage
age to the axle components. axle and driveline components.
1
2
Theory of Operation
5
3
1— Input torque 4— Rear axle torque is transmitted from the output shaft side
2— Lockout engaged gear through the output shaft, inter-axle driveline, drive pin-
3— Forward axle torque is transmitted from the helical side ion, ring gear, wheel differential and axle shafts.
gear through the pinion helical gear, drive pinion, ring gear, 5— Input torque (power flow) from the vehicle driveline is
wheel differential and axle shafts. transmitted directly to the helical side gear and the output
shaft. A positive drive is provided to both axles for maximum
traction under adverse road conditions.
99
Theory of Operation
Operate Wheel Differential Assembly

The Spicer wheel differential lock is driver-controlled and oper- Direct Driver-controlled System
ated by a carrier mounted air-actuated shift unit. In operation, The driver manually locks and unlocks the wheel differential,
it positively locks the wheel differential to provide improved using a cab-mounted electric switch (or air valve). The follow-
traction under adverse road conditions. ing description assumes the system includes a cab-mounted
electric switch and a solenoid valve as shown in the illustra-
tion. An air valve may be substituted for these components.
Control Systems for Differential Lock Operation is as follows:
Two systems may be used to control the differential lock oper-
ation. 1. With control switch in the “unlock” position, the
wheel differential functions normally.
Transmission Low-Range Interlock Control System
The wheel differential is locked manually with the transmis- 2. When the control switch is placed in the “lock” posi-
sion in Low-Range. It is unlocked by the driver or unlocked tion, the air supply solenoid valve opens and air
when the transmission is shifted out of Low-Range. pressure activates the shift cylinder. The shift fork is
moved to engage the curvic clutches, which, in turn,
Note: The interlock system is preferred for vehicles equipped lock the wheel differential.
with an air-shifted, Low-Range transmission. It is
designed to ensure the differential lock is not left 3. When the control switch is placed in the “unlock”
engaged (and to prevent accidental engagement) when position, air pressure supply to the shift cylinder is
transmission is in high range. shut off and air pressure is released from the cylin-
der. A compression spring moves the shift fork to
Direct Driver-controlled System disengage the curvic clutch and unlock the wheel dif-
ferential.
14
11 12 5 6
3
10 13 4
7
9 8
1— Cab-mounted control valve (plunger in—valve open) 9— Forward rear axle wheel differential lock air shift cylinder
2— Dry air supply tank 80–120 PSI (part of axle assembly)
3— Preferably equal in length 10— Wheel differential lock indicator switch (part of axle
4— Power supply assembly)
5— Fuse or circuit breaker 11— Indicator light of audible signal
6— Indicator light or audible signal 12— Fuse or circuit breaker
7— Wheel differential lock indicator switch (part of axle 13— Power supply
assembly) 14— 66468 Quick release valve (optional) located on frame
8— Rear axle wheel differential lock air shift cylinder (part rail and within 10 feet of tubing from control valve
of axle assembly)
100
Theory of Operation

The Spicer Wheel Differential Lock is an optional feature for • Shift Cylinder Assembly: Operates a shift fork and
Spicer Axles. In operation, it positively locks the wheel differen- push rod assembly.
tial, to provide improved traction under adverse road condi-
• Shift Fork and Push Rod Assembly: Engages and
tions.
disengages the differential lock curvic clutch assem-
bly.
The differential lock is driver-controlled through an electric
switch or air valve mounted in the cab. The locking mecha- • Curvic Clutch Assembly: Consists of a sliding clutch
nism is air-operated to engage a mechanical clutch and lock splined to a axle shaft and a fixed clutch which is
the wheel differential. It is spring-operated to disengage the splined to the differential case hub.
lock and permit the wheel differential to function normally.
Theory of Operation
The differential lock also includes a selector switch (electric)
The wheel differential lock consists of three major assemblies. which senses clutch engagement and sends an electrical sig-
nal to a cab mounted indicator light (or an audible signal
device).
1
1b
1a
2a
2b
3a
2
3b
1— Curvic clutch assembly

1a—Sliding clutch
1b—Fixed clutch
2— Shift fork and push rod assembly
2a—Shift fork
2b—Pushrod
3— Shift cylinder assembly
3a—Piston driver
3b—Selector switch
101
Theory of Operation
Differential Lock Engaged Differential Lock Engagement Indicator

Air pressure applied to the shift cylinder moves the piston, Differential lock engagement is detected by a switch (electric)
push rod, shift fork and the sliding curvic clutch engages the mounted on the differential carrier. An actuator, mounted in
fixed curvic clutch. the piston cover, operates the switch.
The sliding clutch is splined to the axle shaft. The fixed clutch When the shift fork moves to engage the differential lock, the
is splined to the differential case hub. Engaging the two push rod actuator moves away from the switch, allows the
clutches locks the wheel differential thus preventing wheel dif- switch to close and send an electrical signal to turn on a cab-
ferential action. mounted indicator light (or an audible signal).
Differential Lock Disengaged
When the shift fork moves to disengage the differential lock,
When air pressure at the shift cylinder is released, a compres-
the compression spring also moves the push rod actuator to
sion spring (mounted on the push rod) moves the push rod,
contact the switch. The switch is opened and turns off the
shift fork and sliding clutch as an assembly. The sliding clutch
cab-mounted indicator light (or the audible signal).
moves out of engagement with the fixed clutch. The wheel dif-
ferential is unlocked and operates normally.
2
4
2 3 3
1 5
4
1 6
5
6 7
8 9
8 9 Differential Lock Disengaged

1— Spring is decompressed
Differential Lock Engaged 2— Shift fork
1— Spring is compressed 3— Push rod
2— Shift fork 4— Selector switch
3— Push rod 5— Piston
4— Selector switch 6— Shift cylinder
5— Piston 7— Air pressure applied disengages clutches
6— Shift cylinder 8— Fixed clutch splined to differential case
7— Air pressure applied engages clutches 9— Sliding clutch splined to axle shaft
8— Fixed clutch splined to differential case
9— Sliding clutch splined to axle shaft
102
Parts Identification
Power Divider - Parts Exploded View
1 2 3 4 5 6 7 8 9
14 16 19 20
13 ! " 15
17
10 18
12
28
11
21 24 25 26 27 31
29
30
22
32
23
33 34 35 36

1 —Output shaft nut 13 —Output side gear bearing cup 26 —Input shaft bearing cone
2 —Output yoke 14 —Output side gear bearing cone 27 —Power divider cover (integral)
3 —Output seal 15 —Pump locking Pin 28 —Lube trough
4 —Output shaft bearing snap ring 16 —Output side gear 29 —Capscrew
5 —Outer bearing cup 17 —Pump 30 ---Shift fork
6 —Outer bearing cone 17A ---Old style pump 31 —Power divider cover (Old style)
7 —Inner bearing cone 17B—Output side gear bearing cup 32 —Push rod
8 —Inner bearing cup 18—Snapping ring 33 —Input bearing cup
9 —Output shaft 19 —Inter-axle differnential 34 —Input cage shim
10 —Seal manifold assembly 20 —Helical side gear 35 —Input cage V-ring
11 —Sump screen 21 —Sliding clutch 36 —Input cage
12 —Seal manifold feed tube 22 ---Push rod spring 37 —Capscrew
23—Shift fork assembly 38 —Oil seal
24 —Input shaft 39 —Input yoke
25 —Input shaft oil retainer 40 —Input nut
103
Front Drive Axle - Parts Exploded View

4
7 12
11
5
1 2 3 8 9 10
6
25 26
24
13 23
14 27
15
32
22 28
16 17 19 20 21 30
29
18
34
33
31
41 45
37 38 39 40 44
35 36 42 43
46
1— Flange half bearing adjuster 17— Side gear thrust washer 32— D-head carrier or front carrier
2— Flange half bearing cup 18— Plain half differential case with thrust bolt
3— Flange half bearing cone 19— Plain half bearing cone 33— Thrust bolt jam nut
4— Flange half carrier cap 20— Plain half bearing cup 34— Thrust bolt
5— Flange half differential case 21— Plain half bearing adjuster 35— Pinion pilot bearing
6— Nut 22— D-head carrier with pump 36— Pinion
7— Ring gear 23— Core plugs 37— Inner pinion bearing cone
8— Side gear thrust washer 24— Pump filter 38— Pinion bearing spacer
9— Side gear 25— Core plugs 39— Inner pinion bearing cup
10— Wheel differential spider 26— D-head carrier or front carrier 40— Pinion cage shim
11— Side pinion with a pump 41— Pinion cage
12— Side pinion thrust washer 27— 1-inch core plug 42— Outer pinion bearing cup
13— Carrier cap bolt 28— Dowel 43— Outer pinion bearing cone
14— Lock washer 29— D-head carrier or front carrier 44— Helical gear
15— Plain half carrier cap 30— O-ring 45— Pinion roll pin
16— Side gear 31— Dowel 46— Pinion nut
104
Rear Drive Axle - Parts Exploded View
3 9
4 8
2
5 6 7
1
11
20
19
18
4
10
17 22
16
21
14
13
15
12
22
21 28
20 29
30
31
32
33
34
23
24
25
26
27
1— Ring gear 13— Plain half carrier cap 25— Inner pinion bearing cone
2— Carrier cap bolt 14— Side gear 26— Pinion bearing spacer
3— Flange half carrier cap 15— Side pinion 27— Inner pinion bearing cup
4— Flange half differential case 16— Side pinion thrust washer 28— Pinion cage shim
5— Flange half bearing cone 17— Wheel differential spider 29— Pinion cage
6— Flange half bearing cup 18— Side gear 30— Outer pinion bearing cup
7— Flange half bearing adjuster 19— Side gear thrust washer 31— Outer pinion bearing cone
8— Plain half bearing adjuster 20— R-head carrier or rear carrier 32— Pinion seal
9— Plain half bearing cup 21— Thrust bolt 33— Pinion yoke
10— Plain half bearing cone 22— Thrust bolt jam nut 34— Pinion nut
11— Plain half differential case 23— Pinion pilot bearing 35— R-head carrier with thrust bolt
12— Side gear thrust washer 24— Pinion
105
Inter-Axle Speed Sensor - Parts Exploded View
Wheel Differential Lock Assembly -

Parts Exploded View
2
3
6
5
1 7
17
8
9
5 10
11
4 16
3 14 13 12
2 15
1— Sensor assembly
2— Fastener
3— Rotor assembly
1— Fixed curvic clutch gear 10— Piston
4— Differential bearing adjuster
2— Snap ring 11— O-ring
5— Sensor connector
3— Curvic clutch gear 12— Switch
4— Spring pin 13— Plastic washer
5— Shift fork 14— Piston cover
6— Compression spring 15— Capscrew-
7— Push rod flange head
8— Piston driver 16— Capscrew-
9— Set screw manual engagement
17— Gasket
106
Housing and Output Shaft Assembly - Parts Exploded View
Welded Rear Cover
18 19
17
1 29
2
3
4
5
6
7
8
10 9
11 16
12
Bolt on Rear Cover 22
13 20 21
14
15
24
23
18 19 27
17 26 25
28
29
1— Output shaft nut 11— Rear cover capscrew 21— Breather

2— Output yoke 12— Fill plug 22— Breather hose
3— Output seal 13— Rear cover nut 23— Carriage capscrew
4— Snap ring 14— Lock washer 24— Lock washer
5— Outer bearing cup 15— Stud 25— Nut
6— Outer bearing cone 16— Dowel 26— Lock washer
7— Inner bearing cone 17— Jam nut 27— Stud
8— Inner bearing cup 18— Locking ring 28— Drain plug
9— Output shaft 19— Spindle nut 29— Axle shaft
10— Rear cover 20— Axle housing
107
Torque Chart
Fastener Torque Specifications
Class Size Tool Size Lbs. Ft. N•m
Power Divider
Diff. lock cover to carrier 8.8 M10 X 1.5 13 mm 28-35 38-47
Diff. lock switch 8.8 M12 X 1.5 10-12 14-16
IAD lock cover capscrew 8.8 M10 X 1.5 13 mm 28-35 38-47
IAD lock cover capscrews 2pcs. M10 X 1.5 17 mm 28-35 38-47
Input brg. cage capscrew 10.9 M14 X 2 21 mm 114-140 155-190
Input shaft nut M42 X 1.5 55 mm 840-1020 1140-1383
Power divider cover capscrew 10.9 M14 X 2 21 mm 114-140 155-190
Power divider pipe plug NPTF .750-14 1/2 Drive 40-60 51-81
Diff and Gearing Class Size Tool lbs. ft. N•m
Front pinion helical nut Grade 8 M42 X 1.5 65 mm 840-1020* 1140-1383*
Output shaft nut M39 X 1.5 55 mm 680-832 920-1130
Rear pinion nut 8.8 M36 X 1.5 55 mm 575-703 780-953
Ring gear nut with bolt 126219** 12 M16 X 1.5 24 mm 180-220 244-298
Ring gear nut with bolt 129686** 11.9 M16 X 1.5 24 mm 260-280 352-380
Bolt 129686 (Torque Turn Angle) Initial Torque 125 Nm (92 ft. lbs.) Plus 65° Turn Angle
Wheel diff. case capscrew 10.9 M14 X 2 16 mm 12 pt 114-140 155-190
Carrier
ABS sensor assembly fasteners #1024 X 7/8 1/8 Allen Finger tight
+1 turn
Carrier to housing capscrew 12.9 M16 X 2 24 mm 230-270 312-366
Carrier to housing nut 12 M16 X 1.5 24 mm 199-244 270-331
Diff. brg. capscrew 12.9 M20 X 2.5 30 mm 350-428 475-580
Filter assembly pump model NPTF .750-14 1 1/16 40-60 54-81
Lube pump attachment screw 8.8 M8 X 1.25 6 mm Allen 17-21 23-28
Thrust bolt jam nut 4 M24 X 2 36 mm 148-181 201-245
108
Torque Chart
Torque Chart
Class Size Tool Size Lbs. Ft. N•m
Housing
Axle cover capscrew 12.9 M12 X 1.75 18 mm 85-103 115-140
.500-20 11/16 55-71 75-96
Axle shaft to wheel hub nuts .625-18 15/16 170-190 230-258
.750-16 1 1/8 285-345 386-468
Breather - old design NPSF .375-18 .750 Hex 20-26 27-35
Breather fitting - u-tube design .375-18 .750 Hex 20-26 27-35
Housing cover nut 12 M12 X 1.25 18 mm 85-103 115-140
Magnetic plug (fill)*** NPSF 1 X 11.5 13/16 40-60 54-81
Temperature sender/plug 40-60 54-81
NOTE: Fasteners using self-locking thread “patches” may be reused if not damaged, but should be secured by a few drops of
Loctite #277 on threaded surface. Reused fasteners should be wiped clean of excess oil, but do not require special cleaning
*** In June 1997, lube fill plug size was changed. See bulletin ABIB-9709.
** Ring gear bolt design changed 1/2/97. See bulletin ABIB-9701.
* Torque nut to 840 lbs. ft. (1140 N•m), then continue tightening to align nut slot with nearest hole in pinion shank.
Correct torque values are extremely important to assure long Spicer life and dependable performance. Under-tightening of parts
is just as harmful as over-tightening.
Exact compliance with recommended torque values will assure the best results.
The data includes class and torque tightening values.
109
For spec’ing or service assistance, call 1-877-777-5360 or visit our website at www.dana.com/cv
Dana Commercial Vehicle Products Group

3939 Technology Drive
Maumee, Ohio, USA 43537
www.dana.com/cv
Application Policy
Capacity ratings, features, and specifications vary depending upon the model and type of service. Application approvals must be obtained from Dana; contact your
representative for application approval. We reserve the right to change or modify our product specifications, configurations, or dimensions at any time without notice. Printed in USA AXSM-0046 07/16

Service Manual: Spicer Tandem Drive Axles

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Service Manual: Spicer Tandem Drive Axles

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Spicer Tandem Drive Axles

TIP: Helpful removal and installation proce-

Always use genuine Spicer replacement parts.

General Information Install Power Divider to Carrier Assembly

Housing and Output Shaft Assembly Theory of Operation

Seals Parts Identification

Wheel End Seal

Wheel Adjustment Systems

DS344 R S3 44 34,000 lbs.

DS404(P) RS404 DSP41 RSP41 40,000 lbs.

DA404(P) RA404 DSH40 RSH40

DD404(P) RD404 DDH40 RDH40

DS405(P) RS405 DSH44 RSH44

DS405(P) RA405 DDH44 RDH44

DD405(P) RD405 DST40(P) RST40

DSP40 RSP40 DST41(P) RSDT41

DS454(P) RS454 DD454(P) RD454 45,000 lbs.

Gearing Lube Pump (P) = Optional Lube Pump

.CEPS Data plate is located on CUST. PART NO.

the axle centerline

:NI EDAM MADE IN:

Forward Axle (Side View) Rear Axle (Top View)

1 - Country or origin 4 - OEM part number assigned to the axle build

Parts Identification Axle Shaft

2 - Axle shaft part number

Ring Gear and Pinion

Prepare the Parts for Inspection

Check Input Shaft End-play (Forward Axle)

Desired end-play (New Parts) 0.003” to 0.007”

Remove shim to decreased end-play.

Measured end-play (Step 3) 0.015” – 0.015”

Differential Carrier Assembly - Parts

Remove Differential Carrier (Forward and Rear)

1. Block the vehicle.

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

Install Differential Carrier (Forward and Rear)

1— Apply silicone gasket in this pattern

Inter-Axle Lockout Types

Integral Shift Cylinder with Welded Push Rod Assembly—

1 - Compression spring 4 - Piston

Integral Shift Cylinder—

1 - Compression spring 5 - O-ring

Cast Iron Cover Lockout—February 1996 to November 1998

1 - Compression spring 5 - O-ring

Cylindrical Design Lockout—

1 - Compression spring 5 - Piston

1—O-ring 9—Piston cover

3. Remove piston cover and o-ring. CAUTION

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

Power Divider - Parts Exploded View

Remove Power Divider

1 - Carrier assembly stand

Disassemble, Assemble and Overhaul the Power Divider

3. Remove snap ring from machined groove at rear of

11. Remove input shaft bearing cone and oil retainer.

1—Helical side gear 1

6. Remove input shaft nut.

It is not recommended to reuse the oil retainer due to possi-

17. Install bronze bushing in helical side gear. Bushings