Service Manual: Spicer Tandem Drive Axles

Spicer Tandem Drive Axles
Service Manual
Single Reduction with Wheel Differential Lock
AXSM-0074
February 2018
D40-157D
D40-157S
D40-157X
General Information
General Information
The description and specifications contained in this service Any reference to brand names in this publication is made simply as
publication are current at the time of printing. Dana reserves the an example of the types of tools and materials recommended for
right to discontinue or to modify its models and/or procedures and use and should not be considered an endorsement. Equivalents, if
to change specifications at any time without notice. available, may be used.
Important Notice
! WARNING: Failure to follow indicated procedures

creates a high risk of personal injury to
the servicing technician.
This symbol is used throughout this manual to call
attention to procedures where carelessness or ! CAUTION: Failure to follow indicated procedures
failure to follow specific instructions may result in may cause component damage or
personal injury and/or component damage. malfunction.
Departure from the instructions, choice of tools,
! IMPORTANT: Highly recommended procedures for
materials and recommended parts mentioned in this
publication may jeopardize the personal safety of the proper service of this unit.
service technician or vehicle operator. Note: Additional service information not covered in
the service procedures.
TIP: Helpful removal and installation procedures to

aid in the service of this unit.
Always use genuine Spicer replacement parts.
Note: Interactive PDF functions may not work correctly unless viewed using the free Adobe Acrobat Reader.
i
Table of Contents
Introduction Adjust Ring and Pinion Tooth Contact Pattern .......................................47

Model Listing...........................................................................................1 Adjust Pinion Position ...........................................................................48
Drive Axle ................................................................................................2 Adjust Ring Gear Position (Backlash) ....................................................48
Part Identification ....................................................................................2 Wheel Differential Lock - Forward .........................................................49
Install and Adjust Wheel Differential Lock .............................................50
Inspection
Install and Adjust Ring Gear Thrust Bolt................................................51
Failure Analysis .......................................................................................4
Housing and Output Shaft Assembly - Forward.....................................52
How to Diagnose a Failure .......................................................................4
Disassemble Output Shaft Assembly .....................................................53
Prepare the Parts for Inspection .............................................................5
Overhaul and Assemble Output Shaft Assembly ....................................54
Find the Cause of the Failure ...................................................................5
Measure and Adjust ...............................................................................56
Correct the Cause of the Problem ............................................................5
Replace Seal ..........................................................................................56
Inspect Axle Housing ...............................................................................6
Guidelines for Reusing Yoke ..................................................................57
Inspect Components ...............................................................................6
Inspect Primary Gearing ..........................................................................7 Rear Assembly
Check Input Shaft End-play (Forward Axle) ............................................7 Differential Carrier Assembly - Rear - Rear............................................58
Check Output Shaft End-play (Forward Axle)...........................................7 Differential Carrier - Rear.......................................................................59
Install Differential Carrier - Rear ............................................................60
Tandem Axle
Drive Pinion ...........................................................................................61
Tandem Axle Assemblies .........................................................................8
Pinion Disassembly ...............................................................................62
Forward Assembly Pinion Installation ..................................................................................63
Differential Carrier Assembly - Forward...................................................9
Install Differential Carrier - Forward ......................................................10
Wheel Differential
Wheel Differential Assembly ..................................................................65
Inter-Axle Lockout Types - Forward .......................................................11
Disassemble, Overhaul, and Assemble Wheel Differential ....................66
Disassemble Lockout ............................................................................12
Assemble Wheel Differential ..................................................................68
Install Lockout .......................................................................................12
Power Divider - Forward........................................................................13 Forward Carrier
Disassemble, Assemble and Overhaul Power Divider - In Vehicle .........14 Forward Carrier – Assembly ..................................................................71
Install Power Divider to Carrier Assembly - In Vehicle...........................17 Measure Ring Gear Runout ...................................................................75
Disassemble, Assemble and Overhaul Power Divider - Out of Vehicle...19 Wheel Differential
Install Power Divider to Carrier Assembly - Out of Vehicle ....................22 Adjust Ring and Pinion Tooth Contact Pattern .......................................76
Lube Pump Disassembly .......................................................................24
Seals
Lube Pump Installation..........................................................................24
Service Kit 217414 ................................................................................78
Lube Manifold Disassembly ..................................................................25
Lube Manifold Installation .....................................................................25
Lubrication
General Lubrication Information ............................................................79
Measure and Adjust Input Shaft End-Play .............................................27
Lube Change Intervals ...........................................................................80
Carrier Assembly - Forward ...................................................................29
Change Lube .........................................................................................81
Disassemble Carrier Assembly ..............................................................30
Disassemble Wheel Differential (All Standard Models) ..........................31 Wheel End Seal
Disassemble Pinion Assembly ...............................................................32 Wheel End Seal - Parts Exploded View ..................................................82
Front Axle Pinion Assembly - Forward...................................................33 Disassemble and Overhaul Wheel End Seal ..........................................83
Disassemble and Overhaul Drive Pinion ................................................34 Verify Wheel End-play Procedure ..........................................................84
Replace Pinion Bearing Cage Cups ........................................................35 Lubricate Wheel End .............................................................................85
Adjust Pinion Bearing Preload ...............................................................36 Vehicle Towing
Final Buildup ..........................................................................................37 Proper Vehicle Towing ...........................................................................86
Install Drive Pinion Assembly ................................................................40
Theory of Operation
Wheel Differential - Forward ..................................................................41
Power Divider Operation (Power Flow and Torque Distribution)............87
Disassemble, Overhaul, and Assemble Wheel Differential - Forward .....42
Operate Wheel Differential Assembly.....................................................89
Overhaul and Assemble Wheel Dierential ..............................................43
Wheel Differential Lock..........................................................................90
Measure and Adjust Carrier Assembly ...................................................45
Differential Lock Engaged ......................................................................91
Change Backlash Setting .......................................................................46
Differential Lock Disengaged .................................................................91
Measure Ring Gear Runout ...................................................................46
ii
Table of Contents (Continued)
Parts Identification
Power Divider - Forward........................................................................92
Front Drive Axle .....................................................................................93
Wheel Differential Lock Assembly .........................................................94
Parts Exploded View ..............................................................................95
Housing and Output Shaft Assembly .....................................................96
Torque Specifications
Fastener Torque Specifications ..............................................................97
iii
Introduction Return to Table of Contents
Introduction
Dana Spicer Corporation, Commercial Vehicle Division, presents
this publication to aid in maintenance and overhaul of Dana Spicer
single drive axles. Instructions contained cover the models listed.
Their design is common, with differences in load capacity. Capacity
variations are achieved by combining basic differential carrier
assemblies with different axle housings, axle shafts and
wheel equipment.
Model Listing
Tandem Axles Load Capacity
D40-157 40,000 Lbs [18,144 kg]
D 40 - 1 5 7 S
O p t io ns
D - D u a l D r i ve F o r wa r d A x le D - W he el D i ff er en t ia l L o ck
w i t h I n t er- A x le D i ff er en t ia l ( f o r w a r d uni t o nl y )
R - D ua l D r i ve R e a r A x le H - H e av y Wa ll H o u sing
P - L ub e P ump
G AW R a t ing x 10 0 0 lb s . S - S ele c tTr ack
X - W i t h o u t I n t er- A x le
G e a r Ty p e
1 - S t a n da r d S ingle R e du c t io n
D e sign L evel
H e ad A s s embl y S er ie s
1
Drive Axle
4
5
3
CUST. PART NO. Spicer®
SPEC. SERIAL NO.
MODEL PART NO. RATIO
MADE IN:
2 6
Spicer®
CUST. PART NO.
SERIAL NO.
SPEC.
RATIO
MODEL PART NO.
1
MADE IN:
Rear Carrier Forward Carrier
1 — Country of origin 4 — OEM part number assigned to the

2 — Axle model identification axle build
3 — Specification number assigned to the 5 — Carrier assembly serial number assigned
axle built by Dana Spicer. Identifies all by the manufacturing plant
component parts of the axle including 6 — Axle gear ratio
special OEM requirements such as yokes 7 — Carrier assembly production or service
or flanges part number
Part Identification
®
er
SpicLB S.
.
NO
PT. CAP. .
HSG. I.D . NO DE IN
HSG. ING MA
US
1
HO
1 — ID Tag
2 — Axle shaft part number
2
Ring Gear and Pinion

Note: Ring gear and drive pinion are matched parts and must be
replaced in sets.
Forward Axle Rear Axle

8
3 8
3
38
L70
38
L70 G
17 G
127381 17
127381 OF SPICER OF
SPICER 41-8 NL2 41-8 NL2
4 4
1 6 1 7 6
7
5
8
7 8-41
12 6
12
7
0H
SPICER
7
17
428
G
127
3
1
6-39
JD77
85405
86
1 — Part number 5 — Number of pinion teeth

2 — Number of ring gear teeth 6 — Date code
3 — Manufacturing numbers 7 — Indicates genuine Dana Spicer parts
4 — Matching gear set number 8 — Heat Code
3
Inspection Return to Table of Contents
Inspection 4. Ask: In what type of service is the truck being used?
Failure Analysis 5. Ask: Has this particular failure occurred before?
Failure analysis is the process of determining the original cause of 6. Ask: How was the truck working prior to the failure?You need
a component failure in order to keep it from happening again. Too to be a good listener. Sometimes, insignificant or unrelated
often, when a failed component is replaced without determining symptoms can point to the cause of the failure:
its cause, there will be a recurring failure. If a carrier housing is
opened, revealing a ring gear with a broken tooth, it is not enough 7. Ask: Was the vehicle operating at normal temperatures?
to settle on the broken tooth as the cause of the carrier failure.
8. Ask: Were the gauges showing normal ranges of operation?
Other parts of the carrier must be examined. For a thorough
understanding of the failure and possible insight into related 9. Ask: Was there any unusual noise or vibration?
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 and
No one benefits when a failed component goes on the junkpile compare their observations for consistency with the service and
with the cause unknown. Nothing is more disturbing to acustomer maintenance records. Verify the chassis Vehicle Identification
than a repeat failure. Systematically analyzing a failure to prevent a Number (VIN) number from the vehicle identification plate, as well
repeat occurrence assures quality service byavoiding unnecessary as the mileage and hours on the vehicle.
downtime and further expense to thecustomer.
The true cause of a failure can be better determined by knowing Make a Preliminary Investigation
what to look for, determining how a piece of the equipment
These steps consist of external inspections and observations that
was running and learning about previous problems. In the
will be valuable when combined with the results of the
case of a rebuilt rear axle, mismatched gears may have been
parts examination.
installed. The more successful shops prevent repeat equipment
failures by developing good failure analysis practices. Knowing 1. Look for leaks, cracks or other damage that can point to the
how to diagnose the cause of a premature failure is one of the cause of the failure.
prerequisites of a good heavy-equipment technician.
2. Make note of obvious leaks around plugs and seals. A missing
How to Diagnose a Failure fill or drain plug would be an obvious cause for concern.
The following five steps are an effective approach to good 3. Look for cracks in the carrier housing (harder to see, but
failurediagnostics. sometimes visible).
1. Document the problem. 4. Does the general mechanical condition of the vehicle indicate
proper maintenance or are there signs of neglect?
2. Make a preliminary investigation.
5. Are the tires in good condition and do the sizes match?
3. Prepare the parts for inspection.
6. If equipped with a torque-limiting device, is it working properly?
4. Find the cause of the failure.
During the preliminary investigation, write down anything out of
5. Correct the cause of the problem. the ordinary for later reference. Items that appear insignificant
now may take on more importance when the subassemblies are
Document the Problem torn down.
Here are some guidelines for starting to learn about a
failure,including questions to ask:
1. Talk to the operator of the truck.
2. Look at the service records.
3. Find out when the truck was last serviced.
4
Prepare the Parts for Inspection Find the Cause of the Failure
After the preliminary investigation, locate the failure and prepare Here begins the real challenge to determine the exact cause of the
the part for examination. In carrier failure analysis, it may be failure. Keep in mind that there is no benefit to replacing a failed
necessary to disassemble the unit. part without determining the cause of the failure. For example,
after examining a failed part and finding that the failure is caused
7. When disassembling subassemblies and parts, do not clean the by a lack of lubrication, you must determine if there was an
parts immediately since cleaning may destroy some of external leak. Obviously, if there is an external leak, just replacing
the evidence. the failed gear is not going to correct the situation.
8. When tearing down the drive axle, do it in the recommended Another important consideration is to determine the specific type
manner. Minimize any further damage to the unit. of failure which can be a valuable indicator for the cause of failure.
The following pages show different types of failures and possible
9. Ask more questions when examining the interior of the carrier. causes. Use this as a guide in determining types of failures and in
Does the lubricant meet the manufacturer specifications correcting problems.
regarding quality, quantity and viscosity? As soon as you have
located the failed part, take time to analyze the data. Correct the Cause of the Problem
Once the cause of the problem has been determined, refer to the
appropriate service manual to perform the repairs.
Clean
10. Wash steel parts with ground or polished surfaces in solvent.
There are many suitable commercial solvents available.
Kerosene and diesel fuel are acceptable.
! WARNING: Gasoline is not an acceptable solvent because of its
extreme combustibility. It is unsafe in the workshop
environment.
11. Wash castings or other rough parts in solvent or clean in hot

solution tanks using mild alkali solutions.
Note: If a hot solution tank is used, make sure parts are heated
thoroughly before rinsing.
12. Rinse thoroughly to remove all traces of the cleaning solution.
13. Dry parts immediately with clean rags.
14. Oil parts.
• If parts are to be reused immediately: Lightly oil.

• If parts are to be stored: Coat with oil, wrap in corrosion
resistant paper and store in a clean, dry place.
5
Inspect Axle Housing Inspect Components

Axle housing inspection and repairs are limited to the following Inspect all steel parts for:
checks or repairs:
• Notches, visible steps or grooves created by wear
• Visually inspect axle housing for cracks, nicks and burrs on
• Pitting or cracking along gear contact lines
machined surfaces.
• Scuffing, deformation or discolorations. These are signs
• Check carrier bolt holes and studs for foreign material.
of excessive heat in the axle and are usually related to low
• Replace damaged fasteners. Look for loose studs or cross lubrication levels or improper lubrication practices.
threaded holes. In addition, inspect the following for damage:
! CAUTION: Any damage which affects the alignment or structural
• Differential gearing
integrity of the housing requires housing replacement.
Do not repair by bending or straightening. This process • Bearings for loose fit on drive pinion, pilot bearing, and
can affect the material’s properties and cause it to fail differential bearings
completely under load. • All fasteners for rounded heads, bends, cracks or
damaged threads.
• Check all seals and gaskets.
• Inspect machined surfaces of cast or malleable parts. They
Note: Replace conventional gaskets with silicone rubber gasket
must be free of nicks, burrs, cracks, scoring, and wear.
compound (included in many repair kits). The compound
provides a more effective seal against lube seepage and is • Look for elongation of drilled holes, wear on surfaces
easier to remove from mating surfaces when machined for bearing fits and nicks or burrs in
replacing parts. mating surfaces.
1
1 — Axle housing
2 — Machined surface
6
Inspect Primary Gearing Check Output Shaft End-play (Forward Axle)

Before reusing a primary gear set, inspect teeth for signs of See illustration for steps 1-3.
excessive wear. Check tooth contact pattern for evidence of
1. Position dial indicator at yoke end of output shaft.
incorrect adjustment.
Check Input Shaft End-play (Forward Axle) 2. Push in on output shaft and zero the dial indicator.
Note: Before disassembling the power divider, measure and record 3. Using a pry bar, move input shaft axially and measure/record
input shaft end-play. end-play.
See illustration for steps 1-3. 3
1. Position dial indicator at yoke end of input shaft.
2. Push in on input shaft and zero the dial indicator.
3. Using a pry bar, move input shaft axially and measure/record

end-play.
3 2
Adjustment
Correct end-play for a new assembly is 0.001” to 0.005”. The
maximum end-play for a used assembly is no more than 0.005”. If
2
end-play is incorrect, contact Dana.
Adjustment
maximum end-play for a used assembly is no more than 0.014”. If
end-play is incorrect, determine shim pack changes as follows:
Add shims to increase end-play

Desired end-play (New Parts) 0.003” to 0.007”
Measured end-play (Step 3) 0.001” – 0.001”
Add shims to provide desired end-play 0.002” to 0.006”
Remove shim to decrease end-play

Remove shims to provide desired end-play 0.012” to 0.008”
7
Tandem Axle Return to Table of Contents
Tandem Axle
Tandem Axle Assemblies
5
1
2
3
1 — Carrier fasteners 4 — Rear axle assembly

2 — Carrier assembly 5 — Inter-axle differential lockout
3 — Front axle assembly
8
Forward Assembly Return to Table of Contents
Forward Assembly Note: Hand-tighten the bolt, over-torquing may cause damage to
the shift unit. To facilitate hand-tightening, coat bolt threads
Differential Carrier Assembly - Forward with axle lube.
Disassemble Carrier - Forward 1
Note: The removal of the forward carrier does not require

2
disconnecting of the inter-axle driveline and removal of the
output shaft yoke assembly as most other Dana
tandems require.
Standard Differentials
1. Block the vehicle.
2. Drain axle lubricant.
3. Disconnect main driveline.
4. Disconnect differential lockout air line. 1 — Hand tighten with socket

2 — M12 x 1.5 x 38mm bolt – GM only 0.250 – 18 NPTF – all
5. Disconnect lead wires to the selector switch and air line at
models except GM
shift cylinder.
Note: With either method, the axle shaft may have to be rotated to
6. Remove axle shafts. permit the clutch to become engaged.
Diff-Lock Models ! WARNING: Do not lie under carrier after fasteners are removed.
For removal of the locking wheel differential carrier assembly, Use transmission jack to support differential carrier
the differential lock must be engaged and held in the engaged assembly prior to loosening fasteners.
position. This can be accomplished by one of two methods; 7. To remove axle shaft, remove axle stud nuts (If used, remove
either engage via air pressure or engage manually. lock washers and taper dowels).
Engage via Air Pressure 8. Remove axle shafts.
a. Using an auxiliary air line, apply 80–120 PSI air pressure to
shift cylinder air port to engage clutch. Note: All models in this publication use axle shafts with unequal
lengths. Axle shafts may also be location specific with
various wheel equipment. Do not misplace axle shafts from
1 their intended location. Identify left and right shafts for
reference during reassembly.
TIP: If necessary, loosen dowels by holding a brass drift in the

center of the shaft head and striking drift a sharp blow with
a hammer.
! CAUTION: Do not strike the shaft head with a steel hammer. Do
not use chisels or wedges to loosen shaft or dowels.
9. Remove carrier cap screws, nuts and lock washers.
10. Remove differential carrier assembly.

1 — Connect 80-120 PSI air line to cylinder port
Engage Manually
a. Install a 0.250 – 18 NPTF bolt over 1.5” long in the cylinder
air port to manually engage the clutches. GM models require a
M12 X 1.5 X 38mm bolt.
9
Install Differential Carrier - Forward

Note: Before installing carrier assembly, inspect and thoroughly
clean interior of axle housing using an appropriate solvent
and clean rag.
1. Apply Dana approved RTV compound on axle housing mating

surface as shown in the illustration. Completely remove all old
gasket material prior to applying new material. Compound will
set in 20 minutes. Install carrier before compound sets
or reapply.
1 — Apply silicone gasket in this pattern

2 — Common stud locations
TIP: To assist in installing complete differential carrier use two

pieces of threaded rod (M16 X 1.5) threaded into carrier cap
screw holes. Rod should be approximately 6” long. Use these
to pilot the carrier into the housing.
2. Install carrier to housing, lock washers, cap screws and nuts.

Torque to proper specification. Torque to
230–270 lb-ft. (312–366 N•m).
3. After 11/02/98, axle housing covers are welded in place. If

you have a bolt-on cover, install rear housing cover/output
shaft assembly (see page 52). Torque all fasteners to proper
specifications. Torque to 85–103 lb-ft. (115–140 N•m). Install
inter-axle driveline making sure yokes are in phase.
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. Connect main driveline, making sure all yokes are in phase.

Lubricate U-joints.
7. Connect differential lockout air line.
10
Inter-Axle Lockout Types - Forward

Parts Exploded View
1 2
3
4
5
6
1 — Compression spring 4 — Piston

2 — Shift fork 5 — O-ring
3 — O-ring 6 — Piston Cover
Air-operated to engage the lockout and spring-released to

disengage the lockout.
11
Disassemble Lockout Install Lockout

External Type Lockout External Type Lockout
8. With axle installed in vehicle, place differential lock selector 1. Assemble o-rings onto piston. Apply silicone grease to o-ring.
valve in the disengaged (or unlocked) position.
2. Install piston and o-ring assembly into cylinder body or cast
9. Disconnect differential lockout air line. iron cover.
10. Remove cap screws. 3. Attach shift cylinder body or cast iron cover to power divider
while aligning piston with push rod. Make sure shoulder washer
11. Remove shift cylinder body or cast iron cover, o-ring or gasket is in place.
and piston.
4. For stamped steel style lockouts, attach mounting bracket to
! IMPORTANT: Do not remove push rod. Removal of push rod will
cylinder body and secure cap screws.
result in shift fork and compression spring falling
into power divider unit. If this occurs, disassembly 5. Tighten cap screws to 28–35 lb-ft. (38–47 N•m).
of the power divider assembly will be necessary.
6. Connect differential lockout air line.
12. Remove shoulder washer in cylindrical design lock-outs. Cast
iron cover lockout designs do not use a shoulder washer. 7. Cycle the lockout unit to ensure there are no leaks and system
shifts freely.
Note: Cylindrical design lockout and cast iron cover lockout are
interchangeable only as complete assemblies. Integral Type Lockout
1. Assemble o-rings onto piston and piston cover. Apply silicone
Integral Type Lockout
grease to o-rings.
1. With axle installed in vehicle, place differential lock selector
valve in the disengaged (or unlocked) position. 2. Gently push piston and o-ring assembly into lockout cylinder
recess. Make sure piston is pushed all the way in.
2. Disconnect differential lockout air line.
3. Install piston cover and o-ring assembly. Start by hand
3. Remove piston cover and o-ring. tightening clockwise. Do not to strip threads or use excessive
force, damage to part may occur.
4. Remove piston and o-ring assembly with pliers.
4. Tighten piston cover to 25-35 lb-ft. (35-47 N•m).
Note: To remove shift fork and push rod parts, the power divider
must be removed. See power divider section. 5. Connect differential lockout air line.
6. Cycle the lockout unit to make sure there are no leaks and the
system shifts freely.
12
Power Divider - Forward

Parts Exploded View
1 2 3 4 5 6 7 8 9
10 13 14 15 16 17 18 19 20 21 24 25 26
12
11
28 23 22
27
29 30 31 32 33 34 35 36 37
1 — Output shaft nut 14 — Output side gear bearing cone 27 — Power divider cover
2 — Output yoke 15 — Pump locking pin 28 — Lube trough
3 — Output seal 16 — Output side gear 29 — Cap screw
4 — Output shaft bearing snap ring 17 — Pump 30 — Input bearing cup
5 — Outer bearing cup 18 — Snapping ring 31 — Input cage shim
6 — Outer bearing cone 19 — Inter-axle differential 32 — Input cage V-ring
7 — Inner bearing cone 20 — Helical side gear 33 — Input cage
8 — Inner bearing cup 21 — Sliding clutch 34 — Cap screw
9 — Output shaft 22 — Shift fork assembly 35 — Oil Seal
10 — Seal manifold assembly 23 — Spring 36 — Input yoke
11 — Sump screen 24 — Input shaft 37 — Input nut
12 — Seal manifold feed tube 25 — Input shaft oil retainer
13 — Output side gear bearing cup 26 — Input shaft bearing cone
13
Disassemble, Assemble and Overhaul Power Divider - In Vehicle

The power divider cover comes off as a unit followed by the input 14. Remove shift fork, compression spring and shift rod.
shaft and then the helical side gear.
The power divider can be replaced with the axle assembly both in
or out of the chassis and with the differential carrier assembled to
the axle housing.
During removal of power divider cover, the inter-axle differential
(IAD), input shaft assembly or IAD shift system parts may fall
from the carrier if not careful. Use caution to pre-vent injury
or damage.
7. Disconnect the main driveline.
8. Disconnect the lockout air line.
9. Remove input yoke. 15. Remove input shaft drive assembly from the carrier.
10. Remove input seal.
11. Position a drain pan under the power divider unit.
12. Remove PDU cap screws.
13. Remove power divider cover.
16. Remove the IAD assembly from the output side gear.
14
17. Remove helical side gear and snap ring. Note: Remove lube pump if you have one. See page 29.
21. Inspect output side gear o-rings for nicks and cuts. Replace
18. Remove thrust washer. if necessary.
19. Remove lockout sliding clutch from the input shaft.
1 — Press
2 — Bearing
3 — Oil retainer
4 — Input shaft
22. Install new bearing cup.
23. Remove input shaft bearing cone and oil retainer, if necessary.
24. Press new oil retainer on input shaft.

20. Remove the output side gear. ! CAUTION: It is not recommended to reuse the oil retainer due to
possible damage that may occur while removing the
input shaft bearing cone. While pressing on new oil
retainer, make sure not to over press, and/or press
with the retainer at an angle. If the retainer is bent
or distorted it may rub on the input cage or not seal
properly to the v-ring.
15
25. Press input bearing cone on input shaft. 27. Press bearing cup in input bearing cover.
1 28. Install new oil v-ring on input bearing cage cover.
2
1
1 — Bearing cup (press)

2 — V-ring
5
29. 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
26. If input shaft bearing cup needs replacement, use either of the
30. Install bronze bushing in helical side gear. Bushings must be
following recommended practices:
installed from thrust washer side of gear. See illustration for
• Weld a bead around the cup, when the weld cools the cup will dimensional tolerances.
fall out. 1 1
• Drill a 1/4 size hole through the bearing cover to the back side
2
of the cup and use a punch to remove the bearing cup. 5
3 6 1/32"
1 — Press 4 — Shoulder
2 — Sleeve 5 — Sleeve
3 — 1st bronze bushing 6 — Second bronze bushing
(press to shoulder) (recess 1/32”)
16
Install Power Divider to Carrier Assembly - In Vehicle 5. Install the IAD assembly to the output side gear. If reusing the
IAD assembly, install in the same direction as removed.
Note: See page 19 for out of vehicle.
Note: Parts inspection and cleaning procedures are important

and should be adhered to. Cleanliness in your work area is
important as dirt is an abrasive and will cause premature
wear of the otherwise serviceable parts.
! CAUTION: During installation of power divider components, the
inter-axle differential, input shaft assembly or IAD shift
system parts may fall from the carrier if not careful. Use
caution to prevent injury or damage.
1. Make sure dowel pins are installed in carrier.
2. Install output side gear bearing cup, if removed. Press bearing

Note: For lube pump models, see page 22.
cup in carrier. Use a press and an appropriate sleeve. Make
certain bearing cup is evenly and firmly seated. If a press is not 6. Out of the vehicle—on a bench, install lockout sliding clutch
available, use a sleeve or a bearing driver tool and a hammer to onto the input shaft.
install the cup.
1 — Lubricate o-rings
2 — Bearing cup
7. Install thrust washer.
3. Lubricate o-rings.
4. Install the output side gear, if removed.
17
8. Install helical side gear and snap ring. 11. Install plastic trough in power divider cover.
12. Install power divider cover to carrier. Use Dana approved RTV
compound on the carrier mating surface. Torque cap screws
to 114–140 lb-ft. (155–190 N•m).
Note: Gasket compound will harden in 20 minutes. Install power

divider quickly as possible to avoid future leaks.
13. Install input cage shim and input cage assembly.

9. Install input shaft drive assembly into the carrier.
10. Install shift fork, compression spring and shift rod.
14. Install input cage cap screws and tighten until snug.
15. Measure and adjust input shaft end-play, see page 27.
16. Torque input cage cap screws to

! CAUTION: During installation of power divider components, a part 114–140 lb-ft. (155–190 N•m).
may fall from the carrier. Use caution to prevent injury
or damage. 17. Install NEW input seal.
18. Reinstall input yoke.
18
Disassemble, Assemble and Overhaul Power Divider - Out of Vehicle

The power divider cover comes off as a unit followed by the input 8. Remove shift fork, compression spring and shift rod.
shaft and then the helical side gear.
The power divider can be replaced with the axle assembly both in
or out of the chassis and with the differential carrier assembled to
the axle housing.
! CAUTION: During removal of power divider cover, the inter-axle
differential (IAD), input shaft assembly or IAD shift
1. Disconnect the main driveline.
2. Disconnect the lockout air line.

9. Remove input shaft and helical thrust washer from the carrier.
3. Remove input yoke.
4. Remove input seal.
5. Position a drain pan under the power divider unit.
6. Remove PDU cap screws.
7. Remove power divider cover.
10. Remove helical side gear.
19
11. Remove the IAD assembly from the output side gear. 16. Press new oil retainer on input shaft.
! CAUTION: It is not recommended to reuse the oil retainer due to
possible damage that may occur while removing the
input shaft bearing cone. While pressing on new oil
retainer, make sure not to over press, and/or press
with the retainer at an angle. If the retainer is bent
or distorted it may rub on the input cage or not seal
properly to the v-ring.
17. Press input bearing cone on input shaft.

12. Remove the output side gear.
1
Note: Remove lube pump if you have one.
13. Inspect output side gear o-rings for nicks and cuts. Replace
4
if necessary.
14. Install new bearing cup.

5
15. Remove input shaft bearing cone and oil retainer, if necessary.
2 6
1 — Press 4 — Input shaft bearing cone

2 — Plate 5 — Oil retainer
4
3 — Drive sleeve 6 — Input shaft
1 — Press 3 — Oil retainer

2 — Bearing 4 — Input shaft
20
18. If input shaft bearing cup needs replacement, use either of the 21. If bushing removal is needed, the bushings must exit from the
following recommended practices: thrust washer side of the helical gear.
• Weld a bead around the cup, when the weld cools the cup will
1
fall out.
• Drill a 1/4 size hole through the bearing cover to the back side
of the cup and use a punch to remove the bearing cup.
1 — Tap out bronze bushings
22. Install bronze bushing in helical side gear. Bushings must be

installed from thrust washer side of gear. See illustration for
dimensional tolerances.
1 1
2
5
19. Press bearing cup in input bearing cover.

3 6 1/32"
20. Install new oil v-ring on input bearing cage cover.
4
2
1
1 — Press 4 — Shoulder
2 — Sleeve 5 — Sleeve
3 — 1st bronze bushing 6 — Second bronze bushing
(press to shoulder) (recess 1/32”)
1 — Bearing cup (press)

2 — V-ring
21
Install Power Divider to Carrier Assembly - Out of Vehicle

Note: Parts inspection and cleaning procedures are important Lube Pump Models
and should be adhered to. Cleanliness in your work area is
a. Install output side gear/pump assembly into carrier. The lube
important as dirt is an abrasive and will cause premature
pump mounting holes are oriented in such a way that it can be
wear of the otherwise serviceable parts.
installed only in one position.
Note: It is assumed that the different carrier is secured in a stand.
b. Lube pump coupling—Line up the drive couplings tangs with
! CAUTION: During installation of power divider components, parts the pump and IAD notches. The spacing of the tangs are the
may fall from the carrier if not careful. Use caution to same, one side to the other. If reusing the IAD assembly, install
prevent injury or damage. the same direction as it was removed.
1. Make sure dowel pins are installed in carrier. 5. Install helical side gear.
2. Output side gear bearing cup. If removed, press bearing cup

in carrier. Use a press and an appropriate sleeve. Make certain
bearing cup is evenly and firmly seated. If a press is not
available, use a sleeve or a bearing driver tool and a hammer to
install the cup.
3. Lubricate o-rings.
4. Install the output side gear using one of the following 6. Install thrust washer.
instructions (non-pump models or lube pump models).
Non-pump Models
7. Install compression spring, shift fork, push rod and lockout
a. Install output side gear. sliding clutch.
b. Install the IAD assembly to the output side gear. If reusing the
IAD assembly, install the same direction as removed.
8. Install input shaft assembly.
22
Note: The input shaft snap ring is not used in this buildup. 12. Install input cage cap screws and tighten until snug.
13. Measure and adjust input shaft end-play, see page 27.
9. Install plastic oil trough in power divider cover.
14. Torque input cage cap screws to
10. Install power divider cover to carrier. Use Dana approved RTV 114–140 lb-ft. (155–190 N•m)
compound on the carrier mating surface. Torque cap screws
to 114–140 lb-ft. (155–190 N•m). 15. Install NEW input seal.
Note: Gasket compound will harden in 20 minutes. Install power 16. Reinstall input yoke.
divider as quickly as possible to avoid future leaks.
11. Install input cage shim and input cage assembly.
23
Lube Pump Disassembly Lube Pump Installation

For output side gear and/or pump replacement, follow the Use these instructions with the carrier assembly in or out of the
procedure below. vehicle. If the unit does not have a pump, go to the Power Divider
Assembly section.
1. Remove the output side gear bearing cone, if required.
Note: Keep work area clean. Dirt is an abrasive and will cause
1 premature wear of the otherwise serviceable parts.
Note: For non-pump models, see page 16 for output side gear seal
manifold installation.
2
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: During installation of power divider cover, the inter-axle
differential (IAD), input shaft assembly or IAD shift
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 — Press
2 — Press tool
2. Remove pump locking dowel pin from the hole in the output
side gear hub.
2. Install the pump locking dowel pin into the hole in the output
side gear hub. Make sure the pin is lined up with the machined
slot in the pump body.
3. Remove pump from the output side gear.
1
2
1 — Machined slot
2 — Pin
24
Lube Manifold Disassembly Lube Manifold Installation

1. Disconnect the hose from the lube manifold. 1. Install the manifold assembly into the output side gear bore
in the carrier. Make sure the barbed nipple is lined up with the
2. Remove the manifold assembly by prying it out around the opening in the carrier casting.
inner diameter.
! IMPORTANT: Once removed, the seal manifold assembly cannot
be reused. This component should always be
replaced with new. Use the same removal procedure
for the output side gear seal removal on the non-
pump models.
Note: Seals are not sold separately from the manifold.
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.
1
3. Route the suction end of the hose through the holes in the
carrier casting to the bottom of the carrier.
1 — Barbed nipple
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.
25
Note: For non-pump manifold installation, it is important to line

up the oil inlet path hole in the manifold with the oil path
opening in the carrier manifold casting.
26
Measure and Adjust Input Shaft End-Play 4. Install shim pack and bearing cover. Install cap screws. Torque
screws to 114–140 lb-ft. (155–190 N•m). Make sure shims are
Note: After power divider overhaul and installation on carrier, flat with no kinks or bends.
check and adjust input shaft end-play.The correct end-play
when new parts are used in overhaul is 0.003” to 0.007”, 1
with reused parts the maximum is 0.014”.
1. Remove input shaft nut. Remove input bearing cover cap

screws. Remove bearing cover (and shim pack if installed).
2. Reinstall bearing cover without shims. Hold in position with

hand pressure and measure clearance between power divider
cover and bearing cover, using a feeler gauge.
2
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 bearings.
6. Check input shaft end-play with dial indicator positioned at yoke

end of input shaft. Move input shaft axially and measure end-
play. If end-play is correct, seal shim pack with Dana approved
RTV compound to prevent lube leakage. Then torque input
shaft nut.
3. The bearing cover clearance measured in Step 2 plus 0.005”
will equal shim pack thickness required for desired end-play 7. If end-play is incorrect, change shim pack size as follows:
(rebuild with new parts). Add 0.015” to shim pack for rebuild Add shims to increase end-play
with used parts.
Add shims to provide desired end-play 0.002” to 0.006”
Remove shim to decrease end-play

Remove shims to provide desired end-play 0.012” to 0.008”
27
8. To add or remove shims, remove input shaft nut and yoke. If difficulty is experienced in achieving correct torque, torque
Remove cap screws, lock washers and bearing cover. Add or the nut with the truck wheels on the ground and with the axle
remove shims as required. shaft installed.
9. Install bearing cover and cap screws. Seal shim pack with ! IMPORTANT: Follow the instructions specified by the thread
Dana approved RTV compound to prevent lube leakage then adhesive manufacture when applying thread
torque input shaft cap screws 150–165 lb-ft. (204–224 N•m). adhesive compound.
10. Install yoke.
11. Install yoke nut. One of the following options may be used.
a. Install a new nut with the pre-applied thread adhesive

compound. Tighten the nut to the specified torque
840–1020 lb-ft. (1148–1383 N•m).
b. If a new nut with pre-applied thread adhesive compound is

unavailable, apply “Loctite 277” or “271” (available in 0.5 ml
tube – Dana P/N 129293) to the nut along two threads, for at
least two flats (120°) of the nut midway through the thickness.
Tighten the nut to the specified torque
840–1020 lb-ft. (1148–1383 N•m).
2 Flats
(120˚)
Midway thru
thickness of nut
Note: Use of a torque multiplier is recommended.
28
Carrier Assembly - Forward

Parts Exploded View
1
2
3
14 4
7
8
13
9
10
12
11
1 — Piston engagement bolt 8 — Piston driver

2 — Cap screw 9 — Push rod
3 — Switch 10 — Clutch fork
4 — Washer 11 — Spring
5 — O-ring 12 — Sliding clutch
6 — Piston 13 — Pin
7 — Setscrew 14 — Piston cover
29
Disassemble Carrier Assembly Models with Ring Gear Thrust Bolt

For models having the wheel differential lock option or a carrier
thrust bolt follow the steps below. These parts must be removed
first before further removal of the wheel differential can take place.
Disassemble Wheel Differential – Models with Wheel

Differential Lock
1. For ease of servicing, mount differential carrier in stand with
differential lock facing up.
Note: To overhaul and reassemble the wheel differential, the shift

fork and clutch assembly must be removed from carrier. See
instructions below.
Note: If the carrier model has a ring gear thrust bolt installed, it
2. Remove shift cylinder mounting screws, then lift shift cylinder, must be backed away from the ring gear before you can
piston and o-ring assembly off carrier and end of push rod. remove the wheel differential.
1. Back off thrust bolt jam nut.
2. Back out thrust bolt from the carrier until the end of the bolt
1
is flush with the inside of the carrier casting. This will allow
enough clearance between the ring gear and the carrier
pilot web.
1 — Shift cylinder
3. To disassemble shift cylinder for inspection, first remove or

back off actuator switch. The piston and o-ring assembly can
be removed by inserting a pencil-size tool through the cylinder
air port.
4. Grasp push rod end and pull it out of the shift fork, spring
and carrier.
2
Note: When the push rod is disengaged from the shift fork, the
3
fork and sliding curvic clutch assembly can be removed
from carrier. 1 — D-head carrier or front carrier
2 — Thrust bolt
Note: Do not disassemble shift fork from the sliding curvic clutch
3 — Thrust bolt jam nut
unless parts replacement is necessary. To disassemble, use
pin punch to remove spring pin from long leg of fork. The
fork can now be disengaged from the clutch.
5. Remove the snap ring, then lift fixed curvic clutch off
differential case hub spline. Further disassembly of carrier is
the same for axles without differential lock.
30
Disassemble Wheel Differential (All Standard Models)

Note: Omit this step if the gear set is to be replaced. If gear set 3. Remove cap screws, flat washers and bearing caps. Back off
is to be reused, check tooth contact pattern and ring gear bearing adjusters and remove adjusters and bearing cups.
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 pinion

(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 adjusters for

reference during assembly.
1
1 — Punch marks
31
Disassemble Pinion Assembly

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

(self-locking) nut. Forward axle pinion is equipped with
slotted nut, remove roll pin with a pin punch then
loosen nut.
2. Remove pinion bearing cage cap screws. Remove pinion and

cage assembly from carrier. Remove shim pack.
! IMPORTANT: Do not allow pinion to drop on hard surface.If gear

set is to be reused, keep pinion bearing cage shim
pack intact for use in reassembly. If the original
shims cannot be reused, record the number and size
of shims in the pack.
32
Front Axle Pinion Assembly - Forward

Parts Exploded View
1
2
3
4*
5
6
7 8
9
10
11
12
13
1 — Pinion pilot bearing 8 — Cap screw

2 — Pinion 9 — Pinion bearing cup - outer
3 — Pinion bearing cone - inner 10 — Pinion bearing cone - outer
4 — Pinion bearing spacer* 11 — Pinion helical gear
5 — Pinion bearing cup - inner 12 — Roll pin
6 — Shim 13 — Slotted pinion nut*
7 — Pinion bearing cage
* Before 3/01/95 two spacers were used instead of the one shown.
33
Disassemble and Overhaul Drive Pinion 9. Remove pilot bearing from pinion using a split-type puller. Use
two procedure steps to remove each bearing.
The following procedures cover both forward and rear differential
drive carrier disassembly. a. Mount puller vertically to separate the bearing. This action will
3. Remove the pinion nut roll pin. force puller halves under bearing and start moving bearing
off pinion.
4. Loosen and remove the pinion nut.
5. Remove the helical gear with the proper puller tool.
6. Press pinion out of bearing cage and bearing cone.
b. Mount puller horizontally to press pinion out of bearing.
1 — Press ram
7. Remove bearing cups with proper puller tool.
8. Remove bearing spacer from pinion.
34
10. Remove inner bearing cone from pinion using a split-type Replace Pinion Bearing Cage Cups
puller. Use two procedure steps to remove each bearing.
a. Mount puller vertically to separate the bearing. This action will 1

force puller halves under bearing and start moving bearing
off pinion.
Front Rear
2 2
1 — Cup (outer)
2 — Bearing cage
3 — Cup (inner)
1. Remove cups.
1
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
1 — Press appropriate drive sleeve. Make certain bearing cup is evenly and
firmly seated.
35
4. Seat cups securely to shoulder. Check clearance between cup Adjust Pinion Bearing Preload
and bearing cage. Must be less than 0.001”.
Trial Buildup
1. Assemble pinion bearing cage, bearings, spacer and spacer
washer (without drive pinion or oil seal). Center bearing spacer
between two bearing cones. Lubricate bearing cups and cones.
1
5
6
1 — Bearing 4 — Cage
2 — Cup 5 — Cup
3 — Spacer 6 — Bearing
Note: When new gear set or pinion bearings are used, select
nominal size spacer from the specification chart. If original
parts are used, use spacer removed during disassembly.
2. With the bearings well lubricated, place the assembly in the

press. Position sleeve so that load is applied directly to the back
face of the outer bearing cone.
1
2
1 — Press ram
2 — Sleeve must apply pressure to back face of outer
bearing cone
3 — Spring scale
36
3. Rotate pinion cage while applying press load (see chart below) Final Buildup
to the assembly and check rolling torque. Wrap soft wire
around the bearing cage, attach spring scale and pull. Preload Note: During pinion bearing installation, locate each part in same
is correct when torque required to rotate the pinion bearing position that was used in “trial buildup” preload test.
cage is from 5–13 lbs. (2.5–6.0 kg.).
1. Press inner bearing cone on pinion.
Specifications for Pinion Bearing Trial Buildup Preload Test
• Torque to Rotate Bearing Cage (w/o pinion seal)
18 - 42 in. lbs (2.0 - 4.7 N•m)
Forward Axles Rear Axles
Spring Scale
5 - 13 lbs. (2.5 - 6.0 kg)
Reading
17-19 Tons (15.4 - 14-15 Tons (12.7-
Press Loads
17.2 Metric Tons) 13.6 Metric Tons)
Nominal Bearing
0.638 in.
Thickness 0.496 in. (12.60 mm)
(16.21 mm)
Spacer
Read only the torque value after the bearing cage starts to rotate.
4. If necessary, adjust pinion bearing preload by changing the

pinion bearing spacer. A thicker spacer will decrease preload.
A thinner spacer will increase preload.
! IMPORTANT: To prevent bearing damage, use suitable sleeve that
! CAUTION: Once correct bearing preload has been established,
only contacts inner race of bearing cone.
note the spacer size used. Select a spacer 0.001”
larger for use in the final pinion bearing cage 2. Install preselected bearing spacer.
assembly. The larger spacer compensates for slight
“growth” in the bearings which occurs when they are
pressed on the pinion shank.
! IMPORTANT: 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.
37
3. Install bearing cage on drive pinion. Specifications for Pinion Bearing Trial Buildup Preload Test
• Torque to Rotate Bearing Cage (w/o pinion seal)
18 - 42 in. lbs (2.0 - 4.7 N•m)
Forward Axles Rear Axles
Spring Scale
5 - 13 lbs. (2.5 - 6.0 kg)
Reading
17-19 Tons (15.4 - 14-15 Tons (12.7-
Press Loads
17.2 Metric Tons) 13.6 Metric Tons)
840 lbs. ft.* 575–703 lbs. ft.
Nut Torque
(1,140 N•m*) (780–953 N•m)
*Torque nut to 840 lbs. ft. (1,140 N•m), then continue tightening
nut to align nut slot to nearest hole in pinion shank.
Vise Method
4. Press outer bearing cone on pinion. a. if the yoke and nut are used, mount the assembly in a vise,
clamping yoke firmly.
! IMPORTANT: To prevent bearing damage, spin cage while pressing
outer bearing on.
1 — Vise
5. Apply clamp load to the pinion bearing cage assembly. Either

install the yoke (or helical gear) and torque the pinion nut to
specifications or use the press to simulate nut torque (see chart
at right).
38
Press Method
a. If a press is used, position a sleeve or spacer so that load is
applied directly to the back face of the outer bearing cone.
1 — Press
6. Measure Pinion Bearing Preload: Use a spring scale to test the 9. Stake pilot bearing using staking tool. This is essential to retain
assembly rolling torque. To use the spring scale, wrap flexible the bearing.
wire around the bearing cage, attach the scale and pull. Preload
is correct when torque required to rotate the pinion bearing Stake Pattern
cage is from 5–13 lbs. This specification is translated into lbs.
in. readings in the previous chart.
! CAUTION: Read only the torque value after the bearing cage starts
to rotate.
7. Adjust Pinion Bearing Preload: If necessary, adjust pinion

bearing preload. Disassemble the pinion bearing cage as
recommended in this manual and change the pinion bearing
spacer. A thicker spacer will decrease preload. A thinner spacer
will increase preload.
! IMPORTANT: 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.

only contacts the inner race of bearing cone.
39
Install Drive Pinion Assembly 3. If dummy yoke was used, remove nut and yoke. Install helical
gear on pinion. Install M42 X 1.5 nut and torque to
1. Place shim pack on carrier making sure holes are properly 840-1,020 lb-ft. (1,140-1,383 N•m).
aligned. Make sure shims are flat with no kinks or bends.
Note: If gear set is to be reused, install same quantity and size

of shims removed during disassembly. When installing a
new gear set, use nominal shim pack indicated. ! IMPORTANT: Torque to 840 lbs. ft. (1,140 N•m), then continue
tightening nut to align slot with the nearest hole in
Nominal Shim Pack
pinion shank. Install roll pin.
Axle in. mm
Rear 0.023 0.584
1 2
2. Install drive pinion assembly. Install bearing cage cap screws
and lock washers. Torque cap screws to
114-140 lb-ft. (155-190 N•m).
Note: Use a dummy yoke (if available) in place of helical gear.

This will result in easier disassembly and reassembly during
carrier adjustments.
1 — Roll nut
2 — Slotted nut
Note: Do not install cotter roll until carrier adjustments

are completed.
40
Wheel Differential - Forward

Parts Exploded View
3
4 9
2 8
5
6 7
1
11
20
Flange Half (LH)
19
18
4
10
17 16
16
17
14
13
15
12
1 — Ring gear 11 — Nut

2 — Cap screw 12 — Diff. bearing 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. bearing adjuster - flange half 19 — Side pinion
10 — Bolt 20 — Side
41
Disassemble, Overhaul, and Assemble Wheel Differential - Forward

Disassemble Wheel Differential 4. Lift out spider, side pinions and thrust washers.
! IMPORTANT: During following procedure, place differential
assembly on malleable surface to prevent damage
when ring gear falls off its mounting position.
1. Remove nuts and bolts fastening ring gear to differential

cases, allowing gear to fall free. If gear does not fall, tap outer
diameter with soft mallet to loosen.
5. Remove remaining side gear and thrust washer.
6. Remove bearing cones from case halves using suitable puller.
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 cap screws 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.
42
Overhaul and Assemble Wheel Dierential 3. Place thrust washer and side gear in flanged differential case.
only contacts the inner race of the cone. A used
bearing race would be a suitable tool. This tool
should have a slit cut if the ID is the same as the
fange OD.
1. Press new ange half bearing cones on differential case halves.
4. Lubricate all differential parts.
5. Assemble side pinion and thrust washers on spider. Place this

assembly in flanged differential case. Rotate gears and check
for proper mesh.
2. Press new plain half bearing cones on differential case halves.
6. Place side gear and thrust washer on side pinions.
43
7. Align punch marks and install plain case half. Install cap screws 10. Install the bearing cup and bearing adjuster to the flange half
and tighten to 114–140 lb-ft. (155–190 N•m). Check differential side first.
for free rotation by turning side gear hub.
11. Install the bearing cup and bearing adjuster to the plain half
1 — Punch marks side. Use a long screwdriver or bar to lift the differential up
8. Install ring gear. Secure with bolts and nuts. while installing the cup and bearing adjuster.
Bolt No. Torque Specs.

126219 215-255 lb-ft. (N•m 292-346)
9. Lower assembled differential assembly in to the carrier using

a hoist and a strap. Be careful not to damage the differential
bearings lowering the assembly.
44
Measure and Adjust Carrier Assembly 3. Tighten the plain half adjuster two lug notches. Start with the
notch at the top, count two notches counterclockwise on the
Adjust Backlash and Preload adjuster, turn the adjuster so that the notch is facing straight
1. Turn the flange half bearing adjuster in until the ring gear up. You now have a two notch preload.
contacts the pinion (zero backlash) than back the adjuster out 2
two notches of the adjuster lugs.
2
1
1 — Flange half
2 — Plain half
4. Use a rubber mallet to make certain that both bearing adjusters

are fully seated.
5. Measure backlash. Make sure it is within specification of

1 — Flange half 0.006”– 0.018”.
2 — Plain half
TIP: To give yourself room to adjust contact pattern, set it between
2. Tighten the plain half adjuster until the bearing cup just starts to 0.010”–0.012”.
turn, this is a zero bearing preload.
45
Change Backlash Setting Measure Ring Gear Runout

If you have too much backlash the ring gear needs to move closer Measure Ring Gear Total
to the pinion. Back off the plain half adjuster, count the number of
notches you back it off, each notch equals about 0.003” 1. Measure ring gear total radial run out. (Indicator reading should
of backlash. not exceed 0.010”).
! IMPORTANT: In order to maintain the differential bearing preload

you will need to turn the flange half bearing adjuster
the same amount in the same direction. If you need
more backlash reverse this procedure.
1. Install carrier bearings caps and torque carrier cap bolts to

350–428 lbs. ft. (475–580 N•m).
2. Recheck backlash: if the bearing adjusters were not in straight

or fully seated the backlash will change.
c. Used Gearing: Reset to backlash recorded before disassembly.

2. Measure ring gear total back face run out (Indicator reading
d. New Gearing: Backlash should be between 0.006 and 0.018”.
should not exceed 0.010”).
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 47-48.
4. Install bearing adjuster cotter pins.
46
Adjust Ring and Pinion Tooth Contact Pattern Used Gearing - Correct Pattern
Used gearing will not usually display the square, even contact
2
pattern found in new gear sets. The gear will normally have a
“pocket” at the heal end of the gear tooth. The more use a gear
has had, the more the line becomes the dominant characteristic of
the pattern.
1
3 Adjust used gear sets to display the same contact pattern
4 observed before disassembly. A correct pattern is up off the toe
5 and centers evenly along the face width between the top land and
6 root. Otherwise, the length and shape of the pattern are highly
variable and is considered acceptable as long as it does not run off
1 — Face width 4 — Top land the tooth at any point.
2 — Tooth depth 5 — Root
3 — Heel 6 — Toe
Note: Rear axle gearing is shown in the following instructions.

Correct tooth contact patterns and adjustments are the same
for forward and rear axles.
1. Identify if new or used gearing.
2. Check tooth contact pattern (new or used gearing). 1 — Pattern along the face width could be longer
New Gearing - Correct Pattern Adjust Contact Pattern

Paint six ring gear teeth 180° apart with marking compound If necessary, adjust the contact pattern by moving the ring gear
and roll the gear to obtain a contact pattern. The correct pattern and drive pinion.
is slightly below center on the ring gear tooth with length-wise • Ring gear position controls the backlash. This adjustment
contact up off the toe. The length of the pattern in an unloaded moves the contact pattern along the face width of the
condition is approximately one-half to two-thirds of the ring gear gear tooth.
tooth in most models and ratios.
• Pinion position is determined by the size of the pinion bearing
The pattern could vary in length and should cover 1/2 tooth or cage shim pack. It controls contact on the tooth depth of the
more (face width). The pattern should be evenly centered between gear tooth.
tooth top land and root and should be up off the tooth toe.
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.
47
Adjust Pinion Position Adjust Ring Gear Position (Backlash)

If the gear pattern shows incorrect tooth depth contact, change If the gear pattern shows incorrect face width contact, change
drive pinion position by altering the shim pack. Used gears should backlash by adjusting the ring gear.
achieve proper contact with the same shims removed from the If the pattern is too close to the edge of the tooth toe, move the
axle at disassembly. ring gear away from the pinion to increase backlash.
Note: Check ring gear backlash after each shim change and adjust
if necessary to maintain the 0.006” to 0.018” specifications.
If the pattern is too close to the top land of the gear tooth, remove
pinion shims. Move pinion toward the ring gear.
3. Loosen the bearing adjuster on the teeth side of the ring gear
several notches.
4. Loosen the opposite adjuster one notch.
If the pattern is too close to the root of the gear tooth, add pinion 5. Return to adjuster on teeth side of ring gear and tighten
shims. Move pinion away from the ring gear. adjuster until it contacts the bearing cup.
6. 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.
several notches.
8. Tighten the opposite adjuster one notch.
9. Return to adjuster on teeth side of ring gear and tighten

adjuster until it contacts the bearing cup.
10. Continue tightening the same adjuster 2 or 3 notches and

recheck backlash.
48
Wheel Differential Lock - Forward

Parts Exploded View
1
2
3
4
14
5
7
8
13
9
10
12
11
1 — Piston engagement bolt 8 — Piston driver

2 — Cap screw 9 — Push rod
3 — Switch 10 — Clutch fork
4 — Washer 11 — Spring
5 — O-ring 12 — Sliding clutch
6 — Piston 13 — Pin
7 — Setscrew 14 — Piston cover
49
Install and Adjust Wheel Differential Lock 11. Screw in manual engagement screw, by hand approximately
1 inch or until snug fit (light resistance pressure is felt) both
Note: With differential carrier completely assembled and adjusted, clutches must be completely engaged.
install differential lock as follows:
12. Remove manual engagement screw, clutches must completely
1. Install fixed curvic clutch on splined hub of flanged differential disengaged. Repeat above procedure if clutches not
case, then install snap ring. completely disengaged.
2. If shift fork and sliding curvic clutch are disassembled, engage Note: Fork adjustment is correct when curvic clutch teeth are fully
fork with clutch hub and install spring pin in the long leg of the engaged with the fork free when moved by hand. When air
fork. See illustration for fork mounting position on clutch. pressure is released or the manual bolt is removed, the shift
assembly should disengage freely.
3. Position compression spring, shift fork and clutch assembly
in shift opening of the carrier. Align pilot hole of shift fork with 13. When adjustment is complete, torque fasteners to
pilot hole of carrier. Install pushrod, engaging shift fork head, 28–35 lb-ft. (38–47 N•m).
and compression spring in carrier.
14. Install selector switch in cylinder cover. Torque switch to
4. Install new o-ring on piston. 10–12 lb-ft. (14–16 N•m).
5. Lubricate piston and o-ring with silicone grease and install 15. Check selector switch operation. Check switch electrically with
piston assembly in cylinder. Position piston with small diameter an ohmmeter or continuity tester. Switch should close (show
hub toward closed end of cylinder. continuity) when clutches are engaged and should open (no
continuity) when clutches are disengaged.
6. Screw piston driver on push rod.
7. Tighten piston driver until shift fork clutch is approximately

0.030 of an inch from the fixed clutch.
.030"
8. Push down by hand on the piston driver, both clutches must be

completely engaged.
9. Install set screw in piston driver, torque to

12–15 lb-ft. (16–20 N•m).
! CAUTION: On 3.90 ratio models only, a washer (P/N 210288)
must be used between the piston driver and piston.
Failure to install the washer will cause engagement and
disengagement problems in the differential lock.
10. Trial fit, install piston cover assembly. Hand tighten

cap screws.
50
Install and Adjust Ring Gear Thrust Bolt

1. Thread thrust screw into the carrier until firm contact with the
back face of the ring gear is made.
2. Loosen the thrust screw 1/4 turn to obtain the correct

adjustment of 0.020” (.50mm) clearance between gear face and
screw. Tighten jam nut, holding thrust screw stationary with a
wrench, torque jam nut 150–190 lbs. ft. (203–258 N•m).
3. Recheck to assure minimum clearance during full rotation of

ring gear.
2
3
1 — D-head carrier or front carrier

2 — Thrust bolt
3 — Thrust bolt jam nut
51
Housing and Output Shaft Assembly - Forward

Parts Exploded View
1
2
3
4
5
6
7
8
9 14 16 15
10
18
17
12 13
11
22 21 20 19
23
1 — Output shaft nut 9 — Output shaft 17 — Carriage cap screw

2 — Output yoke 10 — Fill plug 18 — Lock washer
3 — Output seal 11 — Jam nut 19 — Nut
4 — Snap ring 12 — Locking ring 20 — Lock washer
5 — Outer bearing cup 13 — Spindle nut 21 — Stud
6 — Outer bearing cone 14 — Axle housing 22 — Drain plug
7 — Inner bearing cone 15 — Breather 23 — Axle shaft
8 — Inner bearing cup 16 — Breather hose
52
Disassemble Output Shaft Assembly TIP: It may be helpful to loosely reinstall the yoke and shoulder
nut giving the technician more of an area to grip when
Note: For forward axle rear covers that are removable the output removing the output shaft.
shaft may be removed when the cover is in or out of the
axle assembly. 7. Remove the inner bearing cup from rear cover assembly. This
may be removed from inside the axle housing when the carrier
1. Disconnect the inter-axle driveline at the forward axle rear is removed, or by removal of the forward axle rear cover.
cover position.
8. Remove both inner and outer bearing from output shaft.
2. Remove yoke nut (shoulder nut).
1
3. Remove yoke from output shaft using appropriate tool.
1
1 — Press
9. Remove output shaft inner bearing cup.

1 — Yoke puller tool
Note: Components such as the inter-axle driveline, yoke, oil seal
TIP: A yoke puller tool may be made from the center section of and output shaft assembly should have been removed
most gear puller tools, or may be purchased from your according to normal service procedures. Removing the
tool distributor. differential assembly from the axle housing is not necessary,
but would ease the removal process of the inner bearing cup
4. Remove oil seal.
from the cover bore.
5. Remove snap ring.
e. Using a bearing puller tool, remove the inner bearing cup.
6. Remove output shaft and outer bearing cup as an assembly.
f. Visually inspect the inner-machined bore surface of the welded-
1 on cover for nicks and burrs. Repair if necessary.
2
1 — Snap ring 4 — Inner bearing cup

2 — Outer bearing cup 5 — Rear cover assembly
3 — Output shaft assembly
53
Overhaul and Assemble Output Shaft Assembly Note: Use the bearing cup driver to insure seating of snap ring
after installation with snap ring pliers.
Note: Lubricate the parts with gear lube during assembly.
1. The output shaft bearings are assembled with both bearing 1

cones back to back. Use a press and a sleeve to install one
bearing at a time. 2
! CAUTION: 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 cone touches
5
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
7
area—to the bearing rollers or outboard of the inner cup bore.
Improper application of the Loctite could lock the rollers or
cause excessive pre-load. 1 — Press 5 — Press bearing on first
2 — Plate 6 — Output shaft
! CAUTION: Add loctite adhesive to the inner bearing surface of the 3 — Sleeve 7 — Plate
housing and NOT to the bearing race itself. If added to 4 — Press bearing on second
the race, excessive adhesive could get on the surface
of the outer bearing race journal during installation and
1
cure the outer cap in place with excessive pre-load.
2
5. Using a sleeve and driver (hammer), install the inner
bearing cup. 3
6. Put the output shaft and bearing assembly into the axle
housing assembly. 4
7. Using a sleeve and driver (hammer), install the outer bearing 5

cup into the housing assembly over the output shaft
bearing cone.
8. Using snap ring pliers, install the snap ring that fastens the
outer bearing cup into the welded-on cover assembly.
9. Check the end-play of the output shaft. New assemblies should

measure 0.001” to 0.015”.
1 — Snap ring 4 — Inner bearing cup
2 — Bearing cup 5 — Rear cover
3 — Output shaft assembly
10. Install output yoke.
54
11. Install yoke nut using one of the following options:
g. Install a new nut with the pre-applied thread adhesive

680–832 lbs. ft. (920–1,130 N•m).
h. If a new nut with pre-applied thread adhesive compound is

unavailable, apply “Loctite 277” or “271” (available in 0.5 ml
tube—Dana P/N 129293) to the nut along two threads, for at
least two flats (120°) of the nut midway through the thickness.
Tighten the nut to the specified torque
680–832 lb-ft. (530–1,130 N•m).
! IMPORTANT: Follow the instructions specified by the thread
adhesive manufacturer when applying thread
adhesive compound.
Note: Use of a torque multiplier is recommended. 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.
12. Install axle shafts and axle stud nuts (If used, also install lock
washers and taper dowels).
13. Connect inter-axle driveline. Make sure driveline is properly

phased. Lubricate U-joints.
14. Add axle lubricant. Fill to bottom of filler hole.

! IMPORTANT: When axle has been disassembled or housing,
axle shafts or wheel equipment replaced, check
axle assembly for proper differential actions before
operating vehicle. Wheels must rotate freely
and independently.
15. Road test vehicle to bring axle lubricant up to temperature.

Recheck joints, drain and fill plugs for leakage. Retighten
as necessary.
55
Measure and Adjust Replace Seal

Note: Use bearing cup driver to insure seating of snap ring after Dana strongly recommends using seal drivers when installing new
installation with snap ring pliers. See illustration for steps seals. Use the proper driver to make sure that the seal is square
1–4. and installed to the proper depth.
! CAUTION: Oil seals can be easily damaged prior to installation.
1. Assemble cover assembly to axle housing.
Use care when handling the new seal to prevent
2. Position dial indicator at yoke end of output shaft. damage or contamination. Leave the seal in its package
until installation. On new yokes, leave the protector
3. Push in on output shaft and zero the dial indicator. on the yoke until it is installed on the shaft to prevent
damage or contamination.
4. Using a pry bar, move output shaft axially and measure/record
end-play. 1. Inspect axle end-play at the yoke (see page 9). Service if
beyond specified limit.
4
2. Remove the old yoke using appropriate tool. A yoke puller tool
may be made from the center section of most gear puller tools,
or may be purchased from your local tool distributor.

maximum end-play for a used assembly is no more than 0.015”. If 1
end-play is incorrect, contact Dana.
1 — Yoke puller tool
5. Install oil seal. Follow seal replacement procedures on page 83
of this manual.
3. Remove seal. Use care when removing the old seal to prevent
6. Install yoke. damage to the housing seal bore.
7. Install yoke nut. One of the following options may be utilized: 4. Inspect the seal bore area for any damage (nicks, gouges,
corrosion). Carefully remove any slight damage with a crocus
i. Install a new nut with the pre-applied thread adhesive
cloth. Clean the bore area to remove any loose debris.
680–832 lbs. ft. (920–1130 N•m). Do not use any silicone or permatex-type bore sealant with
this seal.
j. If a new nut with pre-applied thread adhesive compound is
unavailable, apply “Loctite 277” or “271” (available in 0.5 ml 5. Remove the new seal from its package and install with the
tube—Dana P/N 129293) to the nut along two threads, for at proper driver:
least two flats (120°) of the nut midway through the thickness
• Service kit #217414
(See illustration). Tighten the nut to the specified torque
680–832 lbs. ft. (920–1130 N•m). • D-Input-Use driver #126917 only
• D-Output-Use insert #128706 with driver #126917
• R-Pinion-Use driver #126917 only
56
! CAUTION: Due to the resiliency of the plastic driver, hammer Guidelines for Reusing Yoke
rebound may occur when the seal is seated. Keep
! CAUTION: Do not use the yoke if it has any damage on the seal
clear of the hammer rebound path!
surface (nicks or scratches).
6. Handle the seal by its outside diameter avoiding any contact
The surface of the yoke and the lips of the seal form a critical
with the seal lips. During installation, use the proper driver to
interface which retains the axle’s lubricant while sealing the axle
make sure that the seal is mounted properly.
from outside contaminants. The condition of the yoke hub’s
7. Use a rubber mallet to drive the seal tool in until the flange surface is a very important factor in determining seal life.
bottoms on the housing cover bore face. The flange will locate Carefully inspect the seal surface area of the yoke hub for signs
the seal at the proper depth. of wear and damage. Do not reuse the yoke if there is noticeable
wear, such as heavy grooving, beyond normal polishing from the
seal lips.
Note: Do not rework the yoke with abrasives such as emery paper
or crocus cloth. Clean the surface of the yoke as necessary
using chemical cleaners. Remove all trace of the chemicals
from the yoke after cleaning.
! CAUTION: Do not use wear sleeves. Wear sleeves increase the
yoke hub surface diameter and cause premature seal
wear and repeat seal failure.
57
Rear Assembly Return to Table of Contents
Rear Assembly
Differential Carrier Assembly - Rear - Rear
2
1
1 — Carrier fastener
2 — Carrier assembly rear assembly
58
Differential Carrier - Rear

Parts Exploded
22
23
26 24
25
20B
19 20A 15 16
14
13
11
12
32
27
29 28 21 9
30 10
31 18
8
17
7
6
5
4
3
1 — Pinion nut 12 — Ring gear 23 — Flat washer

2 — End yoke and slinger 13 — Ring gear bolts 24 — Flange half cap
3 — Oil seal 14 — Flange half bearing cone 25 — Plain half cap
4 — Outer pinion bearing cone 15 — Flange half bearing cup 26 — Cotter pin
5 — Outer pinion bearing cup 16 — Flange half bearing adjuster 27 — Side gear thrust washer
6 — Pinion spacer 17 — Side pinion thrust washer 28 — Plain half diff case
7 — Inner pinion bearing cup 18 — Side pinion 29 — Plain half bearing cone
8 — Inner pinion bearing cone 19 — Side gear 30 — Plain half bearing cup
9 — Drive pinion 20 — A/B - Differential shaft 31 — Plain half bearing adjuster
10 — Carrier housing 21 — Pin 32 — Pipe plug
11 — Diff case dowels 22 — Cap screw
59
Install Differential Carrier - Rear

! IMPORTANT: Before installing carrier assembly, inspect and
thoroughly clean interior of axle housing using an
appropriate solvent and clean rag.
1. Apply Dana Spicer approved RTV compound on axle housing

mating surface as shown in the illustration. Completely
remove all old gasket material prior to applying new material.
Compound will set in 20 minutes. Install carrier before
compound sets or reapply.
1 — Apply RTV gasket in this pattern

Note: To assist in installing complete differential carrier use two
pieces of threaded rod (M14X2) threaded into carrier cap
screw holes. Rod should be approximately 4” (102 mm)
long. Use these to pilot the carrier into the housing.
2. Install carrier to housing, lock washers and cap screws. Torque

to proper specification. Torque to
142–158lb-ft. (193–214 N•m).
3. Install axle shafts and axle stud nuts.
4. Add axle lubricant. Fill to bottom of filler hole in carrier.
5. Connect main driveline and lubricate joints.
60
Drive Pinion
Rear Axle Pinion Assembly Parts
11
10
7
6
5
4
1 — Pinion nut 7 — Pinion spacer

2 — End yoke 8 — Inner pinion bearing cup
3 — Slinger 9 — Inner pinion bearing
4 — Oil seal 10 — Drive pinion
5 — Outer pinion bearing cone 11 — Carrier
6 — Outer pinion bearing cup
61
Pinion Disassembly 7. Remove bearing preload spacer and save for use in reassembly.
1. Remove yoke nut. 8. Remove inner bearing cone from pinion using a split-type
puller. Use two procedure steps to remove each bearing.
2. Remove yoke using a yoke puller service tool.
a. Mount puller vertically to separate the bearing. This action will
force puller halves under bearing and start moving bearing
off pinion.
1 — Yoke puller
3. Remove oil seal.
4. Place carrier in a press with threaded end of pinion face up.

5. Place a wood block under pinion to avoid damage to gear teeth.
1
1
3 2
4
1 — Press 4 — Wood block
2 — Outer bearing 5 — Drive pinion
3 — Inner bearing 6 — Bearing preload spacer 1 — Press
9. If bearings are to be replaced, remove bearing cups from carrier

casting at this time. Pinion removal complete.
6. Press pinion through outer bearing and out of carrier casting.
62
Pinion Installation 3. Press inner and outer bearing cups into the carrier until seated.
Use a feeler gage (0.0015” [0.038 mm] approximately) to make
Final Buildup sure that bearing cups are fully seated in bearing bores. Apply
Note: Do not install oil seal in carrier until bearing preload is lubricant to both cup and cone.
correctly adjusted.
4. Place carrier housing in press with the pinion supported by
1. Press inner bearing cone on pinion. wood block (6”x6”x6” [152 x 152 x 152 mm]), so the inner
pinion bearing is mated to the cone.
4
3
1 — Press 4 — Drive pinion

2 — Outer pinion bearing 5 — Bearing preload spacer
! IMPORTANT: To prevent bearing damage, use suitable sleeve that 3 — Wood block
only contacts inner race of bearing cone.
5. Press outer bearing onto pinion until completely seated. Rotate
2. Install preselected bearing spacer. carrier during seating process.
6. Use torque multiplier and torque pinion nut to

710-1040 lbs. ft. (848-1410 N•m).
63
7. Measure torque to rotate the pinion with an inch-pound torque 11. Use a rubber mallet to drive the seal tool in until the flange
wrench. Torque measurements should be taken every fourth bottoms on the housing cover bore face. The flange will locate
(4th) revolution and should read between 34-42 in.lbs. of the seal at the proper depth.
bearing preload.
1
Note: If bearing preload does not fall within allowed limits, preload
can be increased by using a thinner spacer and decreased
by using a thicker spacer.
1 — Seal Driver
Always measure each spacer before assembly to ensure 2 — Oil Seal
correct thickness. 3 — Pinion Cage
8. Repeat process until torque to rotate is between 34-42 in. lbs. 12. Install end yoke.
After proper preload is achieved, remove yoke and install new Note: Dana Spicer recommends that new torque prevailing nuts
seal with proper service tool. be used.
! CAUTION: Do not use any silicone or permatex-type bore sealant
13. Use torque multiplier and torque pinion nut to
with this seal. 710-1040lbs. ft. (848-1410N•m).
9. Remove the new seal from its package and install with the
proper driver: R-Pinion-Use drive #126917 only
! WARNING: Due to the resiliency of the plastic driver, hammer
rebound may occur when the seal is seated. Keep
clear of the hammer rebound path!
10. Handle the seal by its outside diameter avoiding any contact
with the seal lips. During installation, use the proper driver to
make sure that the seal is mounted properly.
64
Wheel Differential Return to Table of Contents
Wheel Differential
Wheel Differential Assembly
Parts Exploded View
9
8
9
10
7 6
6
10
9
9 14 15
13
12
16
11
3 4
2
1
1 — Diff. case bearing adjuster 9 — Side pinion thrust washer

2 — Diff. bearing cup 10 — Pin
3 — Diff. case bearing cone 11 — Ring gear
4 — Differential case 12 — Ring gear bolt
5 — Side gear thrust washer 13 — Ring gear bearing cone
6 — Side gear 14 — Ring gear bearing cup
7 — Differential shaft 15 — Ring gear bearing adjuster
8 — Side pinion 16 — Locating dowels
65
Disassemble, Overhaul, and Assemble Wheel Differential

Disassemble Wheel Differential ! CAUTION: The differential case and gears will fall after separation.
! IMPORTANT: Do not press on the wheel differential shaft to Support the case so that it will not cause damage to the
differential or bodily injury.
free the ring gear from the case. Pressing on the
wheel differential shaft may cause it to bend 3. Remove the outer side gear.
and/or fatigue.
1. Remove cap screws fastening ring gear to differential case.
4. Remove the differential shaft locking pins by turning the

differential case opening facing down. Use a hammer to lightly
2. The ring gear to differential case interface is a press fit. Place
tap on the side of the case to free the locking pins.
the assembly in a press with the case facing downward.
Support the assembly on either side of the ring gear. Thread a
cap screw back into one of the case holes by hand. Press down
on the head of the cap screw, you may need to press in more
than one position to free the ring gear from the case.
66
5. The locking pins are slip fit and should fall from the case easily. 9. Remove bearing cones from ring gear and differential case in
two steps:
a. Mount puller vertically to split bearing. This action will start

moving the bearing off case and gear.
6. Remove the half shafts first and then remove their side pinions
and thrust washers.
b. Mount puller horizontally to remove cone.
Half
Differential
Shaft
7. Remove the full shaft, side pinions and thrust washers.
8. Remove inner side gear and thrust washer.
67
Assemble Wheel Differential 13. Start the full differential shaft into the shaft bores in the case
that does not have a locking pin hole.
10. Press new bearing cone on the differential case.
Side Pinion
and Thrust
Washer
Full
Differential
Shaft
Locking
Pin Holes
14. Install a side pinion and thrust washer and push the shaft
through the side pinion.
Side Pinion
and Thrust
Washer
11. Place thrust washer on the side gear. Lubricate both sides of
the thrust washer before installing.
15. Install the side pinion and thrust washer to the other side of
the full shaft.
12. Install the side gear and thrust washer in the differential case.
68
16. Install a side pinion and thrust washer on the half shaft side. 19. Install the locking pins to both sides of the differential case.
Side Pinion
and Thrust
Washer Locking
Pin
17. Install the half shaft so that the pin is facing upward and push
it in until it stops.
Half 20. Install outer side gear.

Differential Pin Hole
Shaft Facing
Upward Note: No thrust washer is used at this location.
18. The end of the half shaft should fit into the slot of the full shaft
at the same time as the hole in the case lines up with the hole
in the half shaft.
21. Lower the ring gear onto the case assembly aligning the
locking dowels.
69
22. Install and hand-tighten all new ring gear cap screws 24. Press new ring gear bearing cone.
23. The interface of the ring gear to differential case is a press fit.
Put the assembly in a press with the ring gear facing upward.
Make certain that the ring gear is flush and square to the
differential case before pressing. Press until ring gear
bottoms out on the case. ! IMPORTANT: When pressing differential case bearing cones, note
that the bearing is beyond flush with the top of the
! IMPORTANT: DO NOT use the cap screws to draw the ring gear
case. The cone must be fully seated. To prevent
into place. Only use a press. bearing damage, use suitable sleeve that only
contacts the inner race of the cone. A used bearing
race would be a suitable tool. This tool should have a
slit cut if the ID is the same as the bearing boss OD.
25. Tighten and torque ring gear cap screws in an alternating

pattern. Torque to 435-465 lbs. ft. (589-630 N•m).
70
Forward Carrier Return to Table of Contents
Forward Carrier 3. Starting on the flange half side, install the bearing cup by using
a long screw driver to lift the case assembly to make
Forward Carrier – Assembly alignment easier.
1. Using a chain hoist and the proper lift tool, lift the ring gear and
wheel differential assembly from the carrier.
4. Now install the bearing adjuster. It’s important to make sure the
adjuster is installed squarely to the bearing cup.
2. Apply a thin coat of oil to both wheel differential bearings.
5. Back the bearing adjuster off one full turn to allow movement
when installing the plain half bearing cup and adjuster.
71
6. Again with a screw driver, lift the differential case so plain half 8. We can now set a “rough” backlash. With the plain half adjuster
bearing cup can be installed. loose, turn the flange half adjust so that the ring gear is moving
in the direction of the pinion gear. Keep adjusting the flange half
bearing adjuster until the ring gear contacts the pinion gear.
9. Now back the flange half adjuster off three notches of the
bearing adjuster.
7. Now install the plain half bearing adjuster. Make sure the
adjuster is square to the bearing cup.
72
10. Now turn the plain half adjuster inward until you feel 12. With a dead blow hammer seat each of the bearing adjusters.
resistance on the adjuster. Continue to rotate the adjuster until
the bearing cup just starts to rotate, stop. This is your “zero”
bearing preload setting.
13. Mount the base of a dial indicator to the flange of the carrier.
11. Tighten the bearing adjust two additional notches to create the
proper bearing preload.
73
14. Place the tip of the indicator to the drive side heel of a ring 17. Start by backing off the bearing adjuster on the side that the
gear tooth. gear set needs to move. Example: To increase the backlash,
back off the flange half adjuster first. To decrease the amount
15. Record the actual backlash. Remember this is a rough lash. of backlash, back off the plain half bearing adjuster first.
16. Now we can make our final backlash adjustments. The

backlash specification for this axle model is
0.008” – 0.018”. We want to set the backlash at
0.012” – 0.013” for new gearing. If the backlash has to ! IMPORTANT: Remember we just set our bearing preload at two
increase in size the ring gearing must move away from notches. When you back off one of the adjusters you
the pinion. Each notch in the adjuster equals must tighten the opposite adjuster the same number
0.003” – 0.004” of backlash. of notches.
74
18. With the backlash set at 0.012” – 0.013”, install the flange Measure Ring Gear Runout
half and plain half bearing cups.
Measure Ring Gear Total
1. Measure ring gear total radial runout. (Indicator reading should
not exceed 0.010” [.25 mm]).
19. Snug the bolts down with an impact gun.
2. Measure ring gear total backface runout. (Indicator reading

should not exceed 0.010” [.25 mm]).
20. The backlash must be remeasured at this time. If the backlash

did not remain at 0.012” – 0.013” the cups should be
removed and the backlash must be readjusted. This process
must be repeated until the specified backlash is achieved with
the bearing cups installed and torqued to Dana specifications.
75
Wheel Differential Used Gearing - Correct Pattern

• Used gearing will not usually display the square, even contact
Adjust Ring and Pinion Tooth Contact Pattern 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 characteristic
of the pattern.
• Adjust used gear sets to display the same contact pattern
1 observed before disassembly. A correct pattern is up off the toe
3
and centers evenly along the face width between the top land
4
and root. Otherwise, the length and shape of the pattern are
5
highly variable and is considered acceptable as long as it does
6 not run off the tooth at any point.
1 — Face width 4 — Top land
2 — Tooth depth 5 — Root
3 — Heel 6 — Toe
1. Identify if new or used gearing.
2. Check tooth contact pattern (new or used gearing).
New Gearing - Correct Pattern

• Paint six ring gear teeth 180° apart and roll the gear to obtain a 1 — Pattern along the face width could be longer
contact pattern. The correct pattern is slightly below center on
the ring gear tooth with lengthwise contact up off the toe. The
length of the pattern in an unloaded condition is approximately
one-half (1/2) to two-thirds (2/3) of the ring gear tooth in most
models and ratios.
• The pattern could vary in length and should cover half (1/2) of
the tooth or more (face width). The pattern should be evenly
centered between tooth top land and root and should be up off
the tooth toe.
Adjust Ring Gear Position (Backlash)

If the ring gear pattern shows incorrect face width contact, change
backlash by adjusting the ring gear.
If the pattern is too close to the edge of the tooth toe, move the
ring gear away from the pinion to increase backlash.
76
ring gear away from the pinion to increase backlash.
several notches.
2. Loosen the opposite adjuster one notch.
3. Return to adjuster on teeth side of the ring gear and tighten

4. Continue tightening the same adjuster two (2) or three (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.
several notches.
6. Tighten the opposite adjuster one notch.
7. Return to adjuster on teeth side of ring gear and tighten

8. Continue tightening the same adjuster two (2) or three (3)

notches and recheck backlash.
77
Seals Return to Table of Contents
Seals
Service Kit 217414
D-Input D-Output R-Pinion
Location
126917
Tool
+
126917 126917
128706
78
Lubrication Return to Table of Contents
Lubrication Recommendations for Viscosity/Ambient Temperature

The following chart lists the various SAE grades covered by MIL-
General Lubrication Information L-2105D and the associated ambient temperature range from
The ability of a drive axle to deliver quiet, trouble-free operation each. Those SAE grades shown with an asterisk (*) are available in
over a period of years is largely dependent upon the use of the Spicer family of synthetic gear lubricants.
good quality gear lubrication in the correct quantity. The most The lowest ambient temperatures covered by this chart are -40°F
satisfactory results can be obtained by following the directions and -40°C. Lubrication recommendations for those applications
contained in this manual. which consistently operate below this temperature range, must be
The following lubrication instructions represent the most current obtained through Dana by contacting your local
recommendations from Dana. Dana representative.
Approved Lubricants Grade Ambient Temperature Range

General—Gear lubrications acceptable under military specification 75W -40°F to -15°F (-40°C to -26°C)
(MILSPEC) MIL-L-2105D (Lubricating Oils, Gear, Multipurpose) 75W-80 -40°F to 80°F (-40°C to 21°C)
are approved for use in Spicer Drive Axles. The MIL-L-2105D 75W-90* -40°F to 100°F (-40°C to 38°C)
specification defines performance and viscosity requirements for
75W-140 -40°F and above (-40°C and above)
multigrade oils. It supersedes both MIL-L-2105B, MIL-L-2105C
and cold weather specification MIL-L-10324A. This specification 80W-90 -15°F to 100°F (-26°C to 38°C)
applies to both petroleum-based and synthetic based gear 80W-140* -15°F and above (-26°C and above)
lubricants if they appear on the most current “Qualified Products 85W-140 10°F and above (-12°C and above)
List” (QPL-2105) forMIL-L-2105D.
* Available in the Spicer family of synthetic gear lubricants
Note: The use of separate oil additives and/or friction modifiers
are not approved in Spicer Drive Axles.
Synthetic based—Synthetic-based gear lubricants exhibit
superior thermal and oxidation stability, and generally degrade
at a lower rate when compared to petroleum-based lubricants.
The performance characteristics of these lubricants include
extended change intervals, improved fuel economy,better extreme
temperature operation, reduced wear and cleaner component
appearance. The family of Spicer gear lubricants represents a
premium quality synthetic lube which fully meets or exceeds the
requirements ofMIL-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 makeuplube
is 10%.
79
Lube Change Intervals Severe Service Lubrication Change Intervals

This product combines the latest manufacturing and part washing Severe service applications are those where the vehicle
technology. When filled with a Spicer approved synthetic lubricant consistently operates at or near its maximum GCW or GVW
at the factory, the initial drain is not required. ratings, dusty or wet environments, or consistent operation
on grades greater than 8%. For these applications, the ON/OFF
Change the lubricant within the first 5,000 miles of operation
HIGHWAY portion of the chart should be used. Typical applications
when not using a Spicer approved synthetic lubricant in either a
are construction, logging, mining and refuse removal.
new axle or after a carrier head replacement.
Base subsequent lubricant changes on a combination of the Note: Clean metallic particles from the magnetic filler plug and
following chart and user assessment of the application and drain plugs. Clean or replace the breather yearly to avoid
operating environment. lube contamination due to water ingestion.
Synthetic or Mineral Lubricant SAE Change Interval for Line Haul Change Interval for Vocational
500,000 miles (800,000 Km) 120,000 miles (193,000 Km)
Synthetic* SHAES-256 SAE 75W-90
or 5 years or 1 year
SAE 75W-90, 250,000 miles (400,000 Km) 60,000 miles (96,500 Km)
Synthetic** SHAES-256
75W-140 or 3 years or 1 year
75W, 75W-90,
MIL-L-2105E/J02360,
75W-140, 120,000 miles (193,000 Km) 60,000 miles (96,500 Km)
Mineral Base API GL-5 Gear Oil,
80W-90, or 1 year or 1 year
MIL-PRF-2105E
85W-140
* Axles using LMS wheel end system
** Axles using adjustable wheel bearing system
80
Change Lube Note: Lube fill capacities (see chart) are basic guidelines and will
vary based on the angle the axle is installed in a particular
Drain chassis. Torque fill plug to 40–60 lbs. ft. (54–82 N•m).
Drain when the lube is at normal operating temperature
(150°–200°F). It will run freely and minimize the time necessary to TIP: The axle can be filled through the axle housing breather hole.
fully drain the axle, this ensures the axle is flushed. Fill until lube level is even with the bottom of filler hole in axle
housing rear cover.
Unscrew the magnetic drain plug on the underside of the axle
housing and allow the lube to drain into a suitable container.
Note: Dispose of all used lubricants properly by following

disposal methods approved for mineral or synthetic
based oils.
After initial oil change, inspect drain plug for large quantities of
metal particles. These are signs of damage or extreme wear in the
axle. Clean the drain plug and replace it after the lube has drained 1 — With axle on level surface, fill housing with oil to
completely. Inspect breather for clogging or corrosion. Clean or bottom of plug
replace as necessary. 2 — Temperature sensor mounting hole
Fill
Front Axle
a. With vehicle on level ground, remove the filler hole plug from
the axle housing cover and fill the axle with approved lubricant
until level with the bottom of the hole.
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 page 83.
Correct lube level at bottom of filler hole.
Always use the filler hole as the final reference. If lube is level with
the bottom of the hole, the axle is properly filled.
81
Wheel End Seal Return to Table of Contents
Wheel End Seal

Wheel End Seal - Parts Exploded View
1 — Installation tool
2 — Seal
3 — Rear hub
82
Disassemble and Overhaul Wheel End Seal Install Wheel End Seal
! WARNING: Never work under a vehicle supported by only a jack. 1. Before installation, lubricate the following with the same
Always support vehicle with stands. Block the wheels lubricant used in the axle sump.
and make sure the vehicle will not roll before releasing
• Inner bearing
the brakes.
• Wheel seal (follow the directions provided by the seal supplier)
! IMPORTANT: Wheel end seals can be easily damaged during
handling. Leave the seal in its package until 2. Place seal on installation tool.
installation to prevent damage or contamination.
3. Drive seal with installation tool onto hub.
1. Remove outer bearing and wheel.
2. Remove oil seal.
3. Remove inner bearing.
4. Remove old wear sleeve (2-piece design only) with a ball peen
hammer and discard.
! IMPORTANT: Do not cut through the old wear sleeve. Damage to
the housing may result.
5. Inspect spindle journal and hub bore for scratches or burrs.

Recondition with an emery cloth as required.
Note: Deep gouges can be repaired by filling gouge with hardening

gasket cement and smoothing with emery cloth.
6. Clean hub cavity and bearing bores before reassembly. Be sure

to remove contaminants from all recesses and corners.
7. Clean bearings thoroughly with solvent and examine for

damage. Replace damaged or worn bearings.
! IMPORTANT: Always use the seal installation tool specified by
the seal manufacturer. Using an improper tool can
distort or damage the seal and cause premature
seal failure.
83
Verify Wheel End-play Procedure Adjust End-play with Wheel Hub

Verify that end-play meets specification using a dial indicator. An
indicator with 0.001” (0.03 mm) resolution is required. Wheel end
play is the free movement of the tire and wheel assembly along the
spindle axis. Correct end-play is
0.001”– 0.005” (0.025–0.125 mm).
4. Attach a dial indicator with its magnetic base to the hub or

brake drum as shown below:
5. Adjust the dial indicator so that its plunger or pointer is against

the end of the spindle with its line of action approximately
parallel to the axis of the spindle.
6. Grasp the wheel assembly at the 3 o’clock and 9 o’clock

positions. Push the wheel assembly in and out while oscillating With indicator mounted at bottom,
it to seat the bearings. Read bearing end-play as the total Push / Pull at sides of drum
indicator movement.
! CAUTION: If end-play is not within specification, readjustment
Readjust Wheel End-play Procedure
is required.
Excessive End-play—If end-play is greater than
Adjust End-play with Tire and Wheel Assembly 0.005” (.127 mm), remove the outer nut and pull the lock washer
away from the inner nut, but not off the spindle. Tighten the inner
nut to the next alignment hole of the dowel-type washer (if used).
Reassemble the washer and re-torque the outer nut. Verify end-
play with a dial indicator.
Insufficient End-play—If end-play is not present, remove the
outer nut and pull the lock washer away from the inner nut, but
not off the spindle. Loosen the inner nut to the next adjustment
hole of the dowel-type washer (if used). Reassemble the washer
and re-torque the outer nut. Verify end-play with a dial indicator.
Fine Tuning the End-play—If, after performing the readjustment
procedures, end-play is still not within the
0.001” – 0.005” (0.025 – 0.127 mm) range, disassemble and
inspect the components. If parts are found to be defective,
replace the defective parts, reassemble and repeat wheel bearing
adjustment procedure. Verify end-play with a dial indicator.
84
Lubricate Wheel End Wheel End with Oil Fill Hole

! IMPORTANT: Before operating the axle, the wheel hub cavities and 1
bearings must be lubricated to prevent failure.
When wheel ends are serviced, follow Dana’s wheel end
lubrication procedure before operating the axle.
Dana axles may be equipped with either of two wheel end designs:
• Wheel ends with an oil fill hole.

• Wheel ends without an oil fill hole. 2
Wheel Ends with an Oil Fill Hole

7. Rotate the wheel end hub until the oil fill hole is up.
8. Remove the oil fill plug. Wheel End without Oil Fill Hole
9. Pour 1/2 pint of axle sump lubricant into each hub through the
wheel end fill hole.
10. Install oil fill plug and tighten to specified torque.
1 — Wheel end oil fill hole

2 — Proper lubricant level
3 — Lubricant flow from sump
85
Proper Vehicle Towing Return to Table of Contents
Vehicle Towing
Proper Vehicle Towing
Without Wheel Differential Lock
Lift the drive wheels completely off of the ground or damage
will occur.
! WARNING: Do not lift the front wheels (non-drive wheels). This
alters the oil’s position in the drive axle, draining it
away from the drive pinion and its bearings. If the
pinion is rotated under these conditions for any
period of time, bearings will overheat resulting in axle
damage or failure.
If it is impossible to lift the drive wheels, remove all axle shafts
to prevent gear rotation and cap the wheel hubs to prevent loss
of lubricant and a possible road hazard. See the following section
Proper Vehicle Towing with Wheel Differential Lock for
removal procedure.
86
Theory of Operation Return to Table of Contents
Theory of Operation
Power Divider Operation (Power Flow and Torque Distribution)
In operation, the power divider accepts torque from the vehicle The inter-axle differential compensates for minor variations in
driveline and distributes it equally to the two axles. speed between the two axles, the same way the wheel differential
This assembly is of the two-gear design consisting of an input works between the two wheels of a single drive axle. This unit also
shaft, inter-axle differential, output shaft and two constant-mesh acts as a central point in distribution of torque to the two axles.
helical gears. The power divider also includes a driver-controlled, air-operated
lockout. When lockout is engaged, it mechanically prevents inter-
axle differentiation for better performance under poor
traction conditions.
With Lockout Engaged (Inter-Axle Differential is Operating)

2
5
3
1 — Input torque 4 — Rear axle torque is transmitted from the output shaft side gear
2 — Lockout disengaged through the output shaft, inter-axle driveline, drive pinion, ring
3 — Forward axle torque is transmitted from the helical side gear gear, wheel differential and axle shafts.
through the pinion helical gear, drive pinion, ring gear, wheel 5 — Input torque (power flow) from the vehicle driveline is
differential and axle shafts. transmitted to the input shaft and the inter-axle differential
spider. The differential distributes torque equally to both axles.
87
With Lockout Engaged Note: Varied road surface conditions can result in unequal torque
(Inter-Axle Differential is Not Operating) distribution between the two axle assemblies.
Lockout should only be engaged when both axles are rotating ! CAUTION: Prolonged operation with the lockout engaged can
at the same speed. Operation should be limited to low-traction
damage axle and driveline components.
situations and should be disengaged when normal traction
returns. Failure to do so will result in poor handling and
damage to the axle components.
1
2
5
3
1 — Input torque 4 — Rear axle torque is transmitted from the output shaft side gear
2 — Lockout engaged through the output shaft, inter-axle driveline, drive pinion, ring
3 — Forward axle torque is transmitted from the helical side gear gear, wheel differential and axle shafts.
through the pinion helical gear, drive pinion, ring gear, wheel 5 — Input torque (power flow) from the vehicle driveline is
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.
88
Operate Wheel Differential Assembly Direct Driver-controlled System

The Dana wheel differential lock is driver-controlled and The driver manually locks and unlocks the wheel differential,
operated by a carrier mounted air-actuated shift unit. In operation, using a cab-mounted electric switch (or air valve). The following
it positively locks the wheel differential to provide improved description assumes the system includes a cab-mounted electric
traction under adverse road conditions. switch and a solenoid valve as shown in the illustration. An air
valve may be substituted for these components. Operation is
Control Systems for Differential Lock as follows:
Two systems may be used to control the differential
1. With control switch in the “unlock” position, the wheel
lock operation.
differential functions normally.
Transmission Low-Range Interlock Control System
2. When the control switch is placed in the “lock”position, the air
The wheel differential is locked manually with the transmission supply solenoid valve opens and air pressure activates the shift
in Low-Range. It is unlocked by the driver or unlocked when the cylinder. The shift fork is moved to engage the curvic clutches,
transmission is shifted out of Low-Range. which, in turn, lock the wheel differential.
Note: The interlock system is preferred for vehicles equipped 3. When the control switch is placed in the “unlock” position, air
with an air-shifted, Low-Range transmission. It is designed pressure supply to the shift cylinder is shut off and air pressure
to ensure the differential lock is not left engaged (and to is released from the cylinder. A compression spring moves the
prevent accidental engagement) when transmission is in shift fork to disengage the curvic clutch and unlock the
high range. wheel differential.
Direct Driver-controlled System
14
11 12 5 6
3
10 13 4
7
9 8
1 — Cab-mounted control valve (plunger in—valve open) 10 — Wheel differential lock indicator switch (part of axle
2 — Dry air supply tank 80–120 PSI assembly)
3 — Preferably equal in length 11 — Indicator light of audible signal
4 — Power supply 12 — Fuse or circuit breaker
5 — Fuse or circuit breaker 13 — Power supply
6 — Indicator light or audible signal 14 — 66468 Quick release valve (optional) located on frame rail
7 — Wheel differential lock indicator switch (part of axle assembly) and within 10 feet of tubing from control valve
8 — Rear axle wheel differential lock air shift cylinder
(part of axle assembly)
9 — Forward rear axle wheel differential lock air shift cylinder (part
of axle assembly)
89
Wheel Differential Lock • Shift Cylinder Assembly: Operates a shift fork and push
rod assembly.
The Dana Wheel Differential Lock is an optional feature for Dana
Axles. In operation, it positively locks the wheel differential to • Shift Fork and Push Rod Assembly: Engages and disengages
provide improved traction under adverse road conditions. the differential lock curvic clutch assembly
The differential lock is driver-controlled through an electric • Curvic Clutch Assembly: Consists of a sliding clutch splined
switch or air valve mounted in the cab. The locking mechanism to a axle shaft and a fixed clutch which is splined to the
is air-operated to engage a mechanical clutch and lock the wheel differential case hub.
differential. It is spring-operated to disengage the lock and permit The differential lock also includes a selector switch (electric) which
the wheel differential to function normally. senses clutch engagement and sends an electrical signal to a cab
The wheel differential lock consists of three major assemblies. 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
90
Differential Lock Engaged Differential Lock Engagement Indicator

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

1 — Spring is compressed 1 — Spring is decompressed
2 — Shift fork 2 — Shift fork
3 — Push rod 3 — Push rod
4 — Selector switch 4 — Selector switch
5 — Piston 5 — Piston
6 — Shift cylinder 6 — Shift cylinder
7 — Air pressure applied engages clutches 7 — Air pressure applied disengages clutches
8 — Fixed clutch splined to differential case 8 — Fixed clutch splined to differential case
9 — Sliding clutch splined to axle shaft 9 — Sliding clutch splined to axle shaft
91
Parts Identification Return to Table of Contents
Parts Identification
Power Divider - Forward
Parts Exploded View
1 2 3 4 5 6 7 8 9
10 13 14 15 16 17 18 19 20 21 24 25 26
12
11
28 23 22
27
29 30 31 32 33 34 35 36 37
1 — Output shaft nut 14 — Output side gear bearing cone 27 — Power divider cover
2 — Output yoke 15 — Pump locking pin 28 — Lube trough
3 — Output seal 16 — Output side gear 29 — Cap screw
4 — Output shaft bearing snap ring 17 — Pump 30 — Input bearing cup
5 — Outer bearing cup 18 — Snapping ring 31 — Input cage shim
6 — Outer bearing cone 19 — Inter-axle differential 32 — Input cage V-ring
7 — Inner bearing cone 20 — Helical side gear 33 — Input cage
8 — Inner bearing cup 21 — Sliding clutch 34 — Cap screw
9 — Output shaft 22 — Shift fork assembly 35 — Oil Seal
10 — Seal manifold assembly 23 — Spring 36 — Input yoke
11 — Sump screen 24 — Input shaft 37 — Input nut
12 — Seal manifold feed tube 25 — Input shaft oil retainer
13 — Output side gear bearing cup 26 — Input shaft bearing cone
92
Front Drive Axle

Parts Exploded View
4
11 12
5 7
1 2 3 8 9 10
13
14
15
22
16 17 19 20 21
18 23
24 25 26 27 28 29 30 31 32 33 34 35
1 — Flange half bearing adjuster 13 — Carrier cap bolt 25 — Pinion

2 — Flange half bearing cup 14 — Lock washer 26 — Inner pinion bearing cone
3 — Flange half bearing cone 15 — Plain half carrier cap 27 — Pinion bearing spacer
4 — Flange half carrier cap 16 — Side gear 28 — Inner pinion bearing cup
5 — Flange half differential case 17 — Side gear thrust washer 29 — Pinion cage shim
6 — Nut 18 — Plain half differential case 30 — Pinion cage
7 — Ring gear 19 — Plain half bearing cone 31 — Outer pinion bearing cup
8 — Side gear thrust washer 20 — Plain half bearing cup 32 — Outer pinion bearing cone
9 — Side gear 21 — Plain half bearing adjuster 33 — Helical gear
10 — Wheel differential spider 22 — D-head carrier or front carrier 34 — Pinion roll pin
11 — Side pinion 23 — Dowel 35 — Pinion nut
12 — Side pinion thrust washer 24 — Pinion pilot bearing
93
Wheel Differential Lock Assembly

Parts Exploded View
1
2
3
4
6
5
17
8 7
9
16 10
11
12
13
14
15
1 — Fixed curvic clutch gear 7 — Push rod 13 — Plastic washer

2 — Snap ring 8 — Piston driver 14 — Piston cove
3 — Curvic clutch gear 9 — Set screw 15 — Cap screw- flange head
4 — Spring pin 10 — Piston 16 — Cap screw- manual engagement
5 — Shift fork 11 — O-ring 17 — Gasket
6 — Compression spring 12 — Switch
94
Parts Exploded View
22
23
26 24
25
20B
19 20A 15 16
14
13
11
12
32
27
29 28 21 9
30 10
31 18
8
17
7
6
5
4
3
1 — Pinion nut 13 — Ring gear bolts 25 — Plain half cap

2 — End yoke and slinger 14 — Flange half bearing cone 26 — Cotter pin
3 — Oil seal 15 — Flange half bearing cup 27 — Side gear thrust washer
4 — Outer pinion bearing cone 16 — Flange half bearing adjuster 28 — Plain half diff case
5 — Outer pinion bearing cup 17 — Side pinion thrust washer 29 — Plain half bearing cone
6 — Pinion spacer 18 — Side pinion 30 — Plain half bearing cup
7 — Inner pinion bearing cup 19 — Side gear 31 — Plain half bearing adjuster
8 — Inner pinion bearing cone 20 — A, B - Differential shaft 32 — Pipe plug parts
9 — Drive pinion 21 — Pin
10 — Carrier housing 22 — Capscrew
11 — Diff case dowels 23 — Flat washer
12 — Ring gear 24 — Flange half cap
95
Housing and Output Shaft Assembly

Parts Exploded View
1
2
3
4
5
6
7
8
9
11
12
10
23
13
14
19
21 20
22
16 15
17
18
1 — Output shaft nut 9 — Output shaft 17 — Stud

2 — Output yoke 10 — Axle housing 18 — Drain plug
3 — Output seal 11 — Breather hose 19 — Spindle nut
4 — Snap ring 12 — Breather 20 — Locking ring
5 — Outer bearing cup 13 — Lock washer 21 — Jam nut
6 — Outer bearing cone 14 — Carriage cap screw 22 — Axle shaft
7 — Inner bearing cone 15 — Nut 23 — Fill
8 — Inner bearing cup 16 — Lock washer
96
Torque Specifications Return to Table of Contents
Torque Specifications
Fastener Torque Specifications
Forward Carrier
Location Size Lbs. Ft. N•m
Power Divider
Input shaft nut M42 x 1.5 925 ± 30 1254 ± 41
Input cage bolts M14 x 2 125 ± 20 169 ± 27
Power diver cover M14 x 2 125 ± 20 169 ± 27
IAD shift cylinder cap M10 x 1.5 32 ± 5 43 ± 7
Output shaft nut M39 x 1.5 756 ± 30 1025 ± 41
Forward Axle - Carrier and Differential
Carrier cap bolt M20 x 2.5 390 ± 20 530 ± 27
Pinion nut* M42 x 1.5 925 ± 30* 1254 ± 41*
Ring gear bolt nut M16 x 1.5 270 ± 10 380 ± 13
Wheel diff case M14 x 2 125 ± 20 169 ± 27
Thrust bolt jam nut M24 x 2 170 ± 20 230 ± 27
Rear Axle - Carrier and Differential
Carrier cap bolt M24 x 3 675 ± 30 915 ± 41
Pinion nut M42 x 1.5 925 ± 30 1254 ± 41
Ring gear bolt M20 x 1.5 635 ± 10 860 ± 13
Carrier to Housing
Bolt - carrier to housing M16 x 1.5 310 ± 10 420 ± 13
Nut - carrier to housing M16 x 1.5 280 ± 10 380 ± 13
Wheel diff lock cap M10 x 1.5 32 ± 5 43 ± 7
Wheel diff lock switch M12 x 1.5 25 ± 5 34 ± 7
Housing
Forward axle - fill plug 1 x 11.5 50 ± 5 67 ± 7
Rear-rear axle - fill plug 1 x 11.5 50 ± 5 67 ± 7
Forward drain plug 1 x 11.5 50 ± 5 67 ± 7
Breather .375 - 18 25 ± 5 34 ± 7
Temperature sending plug .5 - 20 50 ± 5 67 ± 7
Note: Fasteners using self-locking thread “patches” may be reused if not damaged, but should be secured by a few drops of Loctite #277
on threaded surface. Reused fasteners should be wiped clean of excess oil, special cleaning not required.
* Torque nut to 840 lb-ft. (1140 N•m), then continue tightening to align nut slot with nearest hole in pinion shank.
Correct torque values are extremely important to assure long Dana life and dependable performance. Under-tightening of parts is just as
harmful as over-tightening.
Exact compliance with recommended torque values will assure the best results.
97
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
respresentative 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-0074 02/18

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! WARNING: Failure to follow indicated procedures

TIP: Helpful removal and installation procedures to

Always use genuine Spicer replacement parts.

Introduction Adjust Ring and Pinion Tooth Contact Pattern .......................................47

MODEL PART NO. RATIO

Rear Carrier Forward Carrier

1 — Country of origin 4 — OEM part number assigned to the

Ring Gear and Pinion

Forward Axle Rear Axle

1 — Part number 5 — Number of pinion teeth

Inspection 4. Ask: In what type of service is the truck being used?

Failure Analysis 5. Ask: Has this particular failure occurred before?

1. Talk to the operator of the truck.

2. Look at the service records.

3. Find out when the truck was last serviced.

11. Wash castings or other rough parts in solvent or clean in hot

12. Rinse thoroughly to remove all traces of the cleaning solution.

13. Dry parts immediately with clean rags.

14. Oil parts.

• If parts are to be reused immediately: Lightly oil.

Inspect Axle Housing Inspect Components

Inspect Primary Gearing Check Output Shaft End-play (Forward Axle)

See illustration for steps 1-3. 3

1. Position dial indicator at yoke end of input shaft.

2. Push in on input shaft and zero the dial indicator.

3. Using a pry bar, move input shaft axially and measure/record

Add shims to increase end-play

Remove shim to decrease end-play

1 — Carrier fasteners 4 — Rear axle assembly

Disassemble Carrier - Forward 1

Note: The removal of the forward carrier does not require

2. Drain axle lubricant.

3. Disconnect main driveline.

4. Disconnect differential lockout air line. 1 — Hand tighten with socket

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

9. Remove carrier cap screws, nuts and lock washers.

10. Remove differential carrier assembly.

Install Differential Carrier - Forward

1. Apply Dana approved RTV compound on axle housing mating

1 — Apply silicone gasket in this pattern

TIP: To assist in installing complete differential carrier use two

2. Install carrier to housing, lock washers, cap screws and nuts.

3. After 11/02/98, axle housing covers are welded in place. If

5. Add axle lubricant. Fill to bottom of filler hole.

6. Connect main driveline, making sure all yokes are in phase.

7. Connect differential lockout air line.

Inter-Axle Lockout Types - Forward

1 — Compression spring 4 — Piston

Air-operated to engage the lockout and spring-released to

Disassemble Lockout Install Lockout

Power Divider - Forward

Disassemble, Assemble and Overhaul Power Divider - In Vehicle

7. Disconnect the main driveline.

8. Disconnect the lockout air line.

11. Position a drain pan under the power divider unit.

12. Remove PDU cap screws.

13. Remove power divider cover.

19. Remove lockout sliding clutch from the input shaft.