Axsm 0046

Spicer
Tandem Drive Axles

Service Manual
Single Reduction & Single Reduction with
Wheel Differential Lock
AXSM0046
December 2008
DS/RS344
DS/RS404(P)
DS/RS405(P)
DS/RS454(P)
DD/RD404
DD/RD405
DD/RD454
DDT41(P)
DA/RA344
DA/RA404(P)
DA/RA405(P)
More time on the road
DSP/RSP40
DSP/RSP41
DSH/RSH40
DSH/RSH44
DDH/RDH40
DDH/RDH44
DST40(P)
DST41(P)
i
General Information
General Information
The description and specifications contained in this service
publication are current at the time of printing. Dana Corpora-
tion reserves the right to discontinue or to modify its models
and/or procedures and to change specifications at any time
without notice.
Any reference to brand names in this publication is made sim-
ply as an example of the types of tools and materials recom-
mended for use and should not be considered an
endorsement. Equivalents, if available, may be used.
This symbol is used throughout this
manual to call attention to procedures
where carelessness or failure to follow
specific instructions may result in personal
injury and/or component damage.
Departure from the instructions, choice of
tools, materials and recommended parts
mentioned in this publication may
jeopardize the personal safety of the
service technician or vehicle operator.
WARNING: Failure to follow indicated
procedures creates a high risk of personal
injury to the servicing technician.
CAUTION: Failure to follow indicated procedures
may cause component damage or malfunction.
IMPORTANT: Highly recommended procedures
for proper service of this unit.
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 Dana replacement parts.
Important Notice
ii
Table of Contents
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Table of Contents
General Information
General Information ..................................................... i
Introduction ................................................................ 1
Model Identification .................................................... 2
Ring Gear and Pinion .................................................. 3
Inspection
Failure Analysis ........................................................... 4
Prepare the Parts for Inspection ................................. 5
Inspection ................................................................... 6
Check Input Shaft End-play (Forward Axle) ................. 7
Remove Differential Carrier
Differential Carrier Assembly - Parts ........................... 8
Remove Differential Carrier (Forward and Rear) ......... 9
Install Differential Carrier
Install Differential Carrier (Forward and Rear) ........... 10
Differential Lockout
Inter-Axle Lockout Types .......................................... 11
Remove Lockout ....................................................... 14
Power Divider
Power Divider - Parts Exploded View ........................ 15
Remove Power Divider .............................................. 16
Disassemble, Assemble and Overhaul the
Power Divider .................................................... 17
Remove Lube Pump .................................................. 21
Install Power Divider to Carrier Assembly ................. 22
Disassemble, Assemble and Overhaul
Power Divider .................................................... 24
Remove Lube Pump-Assemblies Built Before June 15
2008 .................................................................. 27
Pump Removal: Assemblies
Built After June 15, 2008 ................................... 28
Lube Pump Installation:
Assemblies Built Before June 2008 .................... 29
Manifold Installation .................................................. 31
Hose/ Filter Assembly ............................................... 32
Install Power Divider to Carrier Assembly ................. 33
Disassemble, Assemble and Overhaul
Power Divider .................................................... 36
Lube Pump Removal: Assemblies
Built Before June 15, 2008 ................................. 39
Lube Pump Removal:
Assemblies Built After June 2008 ...................... 40
Lube Pump Installation:
Assemblies Built After June 2008 .......................41
Manifold Assembly ....................................................43
Hose/ Filter Assembly ................................................44
Install Power Divider to Carrier Assembly .................45
Measure and Adjust Input Shaft End-Play .................47
Carrier Assembly
Carrier Assembly - Parts Exploded View ....................49
Drive Pinion
Front Axle Pinion Assembly - Parts Exploded View ...53
Disassemble and Overhaul Drive Pinion ....................54
Replace Pinion Bearing Cage Cups ............................56
Adjust Pinion Bearing Preload ...................................57
Final Buildup ..............................................................58
Install Drive Pinion Assembly ....................................61
Wheel Differential Assembly
Wheel Differential - Parts Exploded View ...................63
Disassemble, Overhaul and Assemble Wheel
Differential (Forward and Rear Axles) .................64
Overhaul and Assemble Wheel Differential ................65
Measure and Adjust Carrier Assembly .......................67
Change Backlash Setting ...........................................68
Adjust Tooth Contact Pattern
Adjust Ring and Pinion Tooth contact Pattern ...........69
Adjust Pinion Position ...............................................70
Wheel Differential Lock - Parts Exploded View ..........71
Install and Adjust Wheel Differential Lock .................72
Housing and Output Shaft Assembly
Remove Output Shaft Assembly ................................74
Housing and Output Shaft Assembly -
Parts Exploded View ..........................................75
Overhaul and Assemble Output Shaft Assembly ........76
Measure and Adjust ...................................................78
Seals
Replace Seal ..............................................................79
Service Kit 217414 ....................................................80
IASS
Inter-Axle Speed Sensor - Parts Exploded View ........81
Disassemble Inter-Axle Speed Sensor .......................82
Install Inter-Axle Speed Sensor .................................83
iii
Table of Contents
Housing Breather
Install New Axle Housing Breather
(Metal and Plastic) ............................................. 84
Wheel End Seal
Wheel End Seal - Parts Exploded View ...................... 85
Remove and Overhaul Wheel End Seal ...................... 86
Wheel Adjustment Systems
Adjust Wheel Bearing ................................................ 87
Wheel End
Verify Wheel End-play Procedure .............................. 89
Lubricate Wheel End ................................................. 90
Wheel Ends Without Oil Fill Hole................................ 91
Lubrication
General Lubrication Information ............................... 92
Lube Change Intervals ............................................... 93
Change Lube ............................................................. 94
Standpipes ................................................................ 95
Towing
Proper Vehicle Towing .............................................. 97
Theory of Operation
Power Divider Operation
(Power Flow and Torque Distribution) ............... 98
Operate Wheel Differential Assembly ...................... 100
Wheel Differential Lock ........................................... 101
Parts Identification
Power Divider - Parts Exploded View ...................... 103
Front Drive Axle - Parts Exploded View ................... 104
Rear Drive Axle - Parts Exploded View .................... 105
Inter-Axle Speed Sensor - Parts Exploded View ...... 106
Housing and Output Shaft Assembly -
Parts Exploded View ........................................ 107
Torque Chart
Fastener Torque Specifications ............................... 108
1
General Information
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Introduction
Dana Spicer Corporation, Axle & Brake Division, presents this
publication to aid in maintenance and overhaul of Dana single
reduction drive axles.
Instructions contained cover the models listed below. 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.
The suffix letter P in the model number indicates a lube
pump is standard. Pump models are equipped with a gerotor
pump, designed to provide additional lubrication to the inter-
axle differential and related parts.
Model Listing
The following models are included in this publication.
Model Information
FORWARD AXLE REAR AXLE FORWARD AXLE REAR AXLE LOAD CAPACITY
DS344 RS344 34,000 lbs.
DA344 RA344
DS404(P) RS404 DSP41 RSP41 40,000 lbs.
DA404(P) RA404 DSH40 RSH40
DD404(P) RD404 DDH40 RDH40
DS405(P) RS405 DSH44 RSH44
DS405(P) RA405 DDH44 RDH44
DD405(P) RD405 DST40(P) RST40
DSP40 RSP40 DST41(P) RSDT41
DDT41(P)
DS454(P) RS454 DD454(P) RD454 45,000 lbs.
DA454(P) RA454(P)
Gear i ng
Capaci t y ( x 1000 l bs. )
Desi gn Level
Lube Pump
D - For war d Tandem Axl e
R - Rear Tandem Axl e
S - Si ngl e Reduct i on
T - Dual Range
P - Pl anet ar y Doubl e Reduct i on
D - Si ngl e Reduct i on wi t h Wheel Di f f er ent i al Lock
A - Si ngl e Reduct i on wi t h I n- Axl e Speed Sensor s ( I ASS)
Exampl e:
DS = For war d Tandem Axl e/ Si ngl e Reduct i on
or
RS = Rear Tandem Axl e/ Si ngl e Reduct i on
Exampl e: 40 = 40, 000 l bs.
P = St andar d
( P) = Opt i onal
D - Tandem For war d Axl e
wi t h I nt er - Axl e Di f f er ent i al
R - Tandem Rear Axl e
Gear i ng
S - Si ngl e Reduct i on
D - Dr i ver Cont r ol l ed Di f f er ent i al Lock
( P) = Opt i onal Lube Pump
H= Hi gh Per f or mance- 40
T= Tor si onal l y Tuned
P= Pr emi um

Capaci t y ( x 1000 l bs. )
Exampl e: 40 = 40, 000 l bs.
2
General Information
Model Identification
Drive Axle
Axle Housing
Axle Shaft
1 - Country or origin
2 - Axle model identification
3 - Specification number assigned to the axle built by Spicer.
Identifies all component parts of the axle including special
OEM requirements such as yokes or flanges.
4 - OEM part number assigned to the axle build
5 - Carrier assembly serial number assigned by the manufac-
turing plant
6 - Axle gear ratio
7 - Carrier assembly production or service part number
Data plate is located on
the axle centerline
Forward Axle (Side View) Rear Axle (Top View)
4
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1
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7
Spicer
MODEL PART NO. RATIO

MADE IN:
SPEC. SERIAL NO.
CUST. PART NO.
S p i c e r
M O D E L P A R T N O . R A T I O
M A D E I N :
S P E C . S E R I A L N O .
C U S T . P A R T N O . Spicer
MODEL PART NO. RATIO
MADE IN:
SPEC. SERIAL NO.
CUST. PART NO.
1 - ID Tag
1
PT. NO.
HSG. CAP. LBS.
HSG. I.D. NO.
HOUSING MADE IN
Spicer
2 - Axle shaft part number

2
3
General Information
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Ring Gear and Pinion
Note: Ring gear and drive pinion are matched parts and must be replaced in sets.
1Part number
2Number of ring gear teeth
3Manufacturing numbers
4Matching gear set number
5Number of pinion teeth
6Date code
7Indicates genuine Spicer parts
8Heat Code
41-8
SPICER
127381
OF
NL2
17
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7
8-41
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4
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6-39
JD77
85405
E A T O
N 8 6
5
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Inspection
Failure Analysis
Failure analysis is the process of determining the original
cause of a component failure in order to keep it from happen-
ing again. Too often, when a failed component is replaced
without determining its cause, there will be a recurring failure.
If a carrier housing is opened, revealing a ring gear with a bro-
ken tooth, it is not enough to settle on the broken tooth as the
cause of the carrier failure. Other parts of the carrier must be
examined. For a thorough understanding of the failure and
possible insight into related problems, the technician needs to
observe the overall condition of the vehicle.
No one benefits when a failed component goes on the junk
pile with the cause unknown. Nothing is more disturbing to a
customer than a repeat failure. Systematically analyzing a fail-
ure to prevent a repeat occurrence assures quality service by
avoiding unnecessary downtime and further expense to the
customer.
The true cause of a failure can be better determined by know-
ing what to look for, determining how a piece of the equip-
ment was running and learning about previous problems. In
the case of a rebuilt rear axle, mismatched gears may have
been installed.
The more successful shops prevent repeat equipment failures
by developing good failure analysis practices. Knowing how
to diagnose the cause of a premature failure is one of the pre-
requisites of a good heavy-equipment technician.
How to Diagnose a Failure
The following five steps are an effective approach to good fail-
ure diagnostics.
1. Document the problem.
2. Make a preliminary investigation.
3. Prepare the parts for inspection.
4. Find the cause of the failure
5. Correct the cause of the problem.
Document the Problem
Here are some guidelines for starting to learn about a failure,
including questions to ask:
Talk to the operator of the truck.
Look at the service records.
Find out when the truck was last serviced.
Ask: In what type of service is the truck being used?
Ask: Has this particular failure occurred before?
Ask: How was the truck working prior to the failure?
You need to be a good listener. Sometimes, insignificant or
unrelated symptoms can point to the cause of the failure.
Ask: Was the vehicle operating at normal tempera-
tures?
Ask: Were the gauges showing normal ranges of
operation?
Ask: Was there any unusual noise or vibration?
After listening, review the previous repair and maintenance
records. If there is more than one driver, talk to all of them
and compare their observations for consistency with the ser-
vice and maintenance records. Verify the chassis Vehicle
Identification Number (VIN) number from the vehicle identifi-
cation plate, as well as the mileage and hours on the vehicle.
Make a Preliminary Investigation
These steps consist of external inspections and observations
that will be valuable when combine with the results of the
parts examination.
Look for leaks, cracks or other damage that can
point to the cause of the failure.
Make note of obvious leaks around plugs and seals.
A missing fill or drain plug would be an obvious
cause for concern.
Look for cracks in the carrier housing (harder to see,
but sometimes visible).
Does the general mechanical condition of the vehicle
indicate proper maintenance or are there signs of
neglect?
Are the tires in good condition and do the sizes
match?
If equipped with a torque-limiting device, is it work-
ing properly?
During the preliminary investigation, write down anything out
of the ordinary for later reference. Items that appear insignifi-
cant now may take on more importance when the subassem-
blies are torn down.
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Inspection
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Prepare the Parts for Inspection
After the preliminary investigation, locate the failure and pre-
pare the part for examination. In carrier failure analysis, it may
be necessary to disassemble the unit.
When disassembling subassemblies and parts, do
not clean the parts immediately since cleaning may
destroy some of the evidence.
When tearing down the drive axle, do it in the recom-
mended manner. Minimize any further damage to the
unit.
Ask more questions when examining the interior of
the carrier. Does the lubricant meet the manufacturer
specifications regarding quality, quantity and viscos-
ity? As soon as you have located the failed part, take
time to analyze the data.
Find the Cause of the Failure
Here begins the real challenge to determine the exact cause of
the failure. Keep in mind that there is no benefit to replacing a
failed part without determining the cause of the failure. For
example, after examining a failed part and finding that the fail-
ure is caused by a lack of lubrication, you must determine if
there was an external leak. Obviously, if there is an external
leak, just replacing the failed gear is not going to correct the
situation.
Another important consideration here is to determine the spe-
cific type of failure which can be a valuable indicator for the
cause of failure. The following pages show different types of
failures and possible causes. Use this as a guide in determin-
ing types of failures and in correcting problems.
Correct the Cause of the Problem
Once the cause of the problem has been determine, refer to
the appropriate service manual to perform the repairs.
6
Inspection
Inspection
Clean
1. Wash steel parts with ground or polished surfaces in
solvent. There are many suitable commercial sol-
vents available. Kerosene and diesel fuel are accept-
able.
Gasoline is not an acceptable solvent because of its
extreme combustibility. It is unsafe in the workshop envi-
ronment.
2. Wash castings or other rough parts in solvent or
clean in hot solution tanks using mild alkali solu-
tions.
Note: If a hot solution tank is used, make sure parts are
heated thoroughly before rinsing.
3. Rinse thoroughly to remove all traces of the cleaning
solution.
4. Dry parts immediately with clean rags.
5. 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.
Inspect Axle Housing
Axle housing inspection and repairs are limited to the follow-
ing checks or repairs.
Visually inspect axle housing for cracks, nicks and
burrs on machined surfaces.
Check carrier bolt holes and studs for foreign mate-
rial.
Replace damaged fasteners. Look for loose studs or
cross threaded holes.
Any damage which affects the alignment or structural integ-
rity of the housing requires housing replacement. Do not
repair by bending or straightening. This process can affect
the material's properties and cause it to fail completely
under load.
Check all seals and gaskets.
Note: Replace conventional gaskets with silicone rubber gas-
ket compound (included in many repair kits). The com-
pound provides a more effective seal against lube
seepage and is easier to remove from mating surfaces
when replacing parts.
Inspect Components
Inspect all steel parts for:
Notches, visible steps or grooves created by wear
Pitting or cracking along gear contact lines
Scuffing, deformation or discolorations. These are
signs of excessive heat in the axle and are usually
related to low lubrication levels or improper lubrica-
tion practices.
In addition, inspect the following for damage:
Differential gearing
Bearings for loose fit on drive pinion, pilot bearing,
and differential bearings
All fasteners for rounded heads, bends, cracks or
damaged threads.
Inspect machined surfaces of cast or malleable
parts. They must be free of nicks, burrs, cracks,
scoring, and wear.
Look for elongation of drilled holes, wear on sur-
faces machined for bearing fits and nicks or burrs in
mating surfaces.
Inspect Primary Gearing
Before reusing a primary gear set, inspect teeth for signs of
excessive wear. Check tooth contact pattern for evidence of
incorrect adjustment.
WARNING
CAUTION
1 - Axle Housing
2 - Machined surface
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Inspection
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Check Input Shaft End-play (Forward Axle)
Note: Before disassembling the power divider, measure and
record input shaft end-play.
See illustration for steps 13.
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 mea-
sure/record end-play.
Adjustment
Correct end-play for a new assembly is .003" to .007". The
maximum end-play for a used assembly is no more than
.014". If end-play is incorrect, determine shim pack changes
as follows:
Add shims to increase end-play.
Remove shim to decreased end-play.
Check Output Shaft End-play
(Forward Axle)
1. Position dial indicator at yoke end of output shaft.
2. Push in on output shaft and zero the dial indicator.
3. Using a pry bar, move input shaft axially and mea-
Adjustment
.015". If end-play is incorrect, contact Dana.
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 shims to provide desired end-play 0.012 to 0.008
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(Forward and Rear)
Differential Carrier Assembly - Parts
1Carrier fasteners
2Carrier assembly
3Forward axle assembly
4Inter-axle differential lockout
5Rear axle assembly
1
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4
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9
(Forward and Rear)
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Remove Differential Carrier (Forward and Rear)
Note: The removal of the forward carrier does not require dis-
connecting of the inter-axle driveline and removal of the
output shaft yoke assembly as most other Dana tan-
dems require.
Standard Differentials
1. Block the vehicle.
2. Drain axle lubricant.
3. Rear Only: Disconnect inter-axle driveline.
4. Front Only: Disconnect main driveline.
5. Front Only: Disconnect differential lockout air line.
6. Disconnect lead wires to the selector switch and air
line at shift cylinder.
7. Remove axle shafts.
Diff-Lock Models
For removal of the locking wheel differential carrier assembly,
the differential lock must be engaged and held in the engaged
position. This can be accomplished by one of two methods;
either engage via air pressure or engage manually.
Engage via Air Pressure
a. Using an auxiliary air line, apply 80120 PSI air
pressure to shift cylinder air port to engage clutch.
Engage Manually
a. Install a .250 18 NPTF bolt over 1.5" long in the cyl-
inder air port to manually engage the clutches. GM
models require a M12 X 1.5 X 38mm bolt.
Note: Hand-tighten the bolt, over-torquing may cause damage
to the shift unit. To facilitate hand-tightening, coat bolt
threads with axle lube.
Note: With either method, the axle shaft may have to be
rotated to permit the clutch to become engaged.
Do not lie under carrier after fasteners are removed. Use
transmission jack to support differential carrier assembly
prior to loosening fasteners.
8. To remove axle shaft, remove axle stud nuts. (If
used, remove lock washers and taper dowels.)
9. Remove axle shafts.
Note: All models in this publication use axle shafts with
unequal lengths. Axle shafts may also be location spe-
cific with various wheel equipment. Do not misplace axle
shafts from their intended location. Identify left and right
shafts for reference during reassembly.
TIP: If necessary, loosen dowels by holding a brass drift in the
center of the shaft head and striking drift a sharp blow with a
hammer.
Do not strike the shaft head with a steel hammer. Do not
use chisels or wedges to loosen shaft or dowels.
10. Remove carrier capscrews, nuts and lock washers.
11. Remove differential carrier assembly.
1Connect 80-120 PSI air line to cylinder port
1
1Hand tighten with socket
2M12 x 1.5 x 38mm bolt GM only .250 18 NPTF all
models except GM
1
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WARNING
CAUTION
10
Install Differential Carrier
(Forward and Rear)
Install Differential Carrier (Forward and Rear)
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 hous-
ing mating surface as shown in the illustration. Com-
pletely remove all old gasket material prior to
applying new material. Compound will set in 20 min-
utes. Install carrier before compound sets or reapply.
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, capscrews
and nuts. Torque to proper specification. Torque to
230270 lbs. ft. (312366 Nm).
3. After 11/02/98, axle housing covers are welded in
place. If you have a bolt-on cover, install rear hous-
ing cover/output shaft assembly (see page 69).
Torque all fasteners to proper specifications. Torque
to 85103 lbs. ft. (115140 Nm). Install inter-axle
driveline making sure yokes are in phase.
4. Install axle shafts and axle stud nuts (if used, also
install lock washers and tapered dowels).
5. Add axle lubricant. Fill to bottom of filler hole.
6. Rear Only: Connect inter-axle driveline, making sure
all yokes are in phase. Lubricate U-joints.
7. Front Only: Connect main driveline, making sure all
yokes are in phase. Lubricate U-joints.
8. Front Only: Connect differential lockout air line.
IMPORTANT
1 Apply silicone gasket in this pattern
2 Common stud locations
1
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Inter-Axle Lockout Types
Since 1992, there have been 5 different power divider air lock-
out designs that are identified for service as either:
External - all models produced BEFORE 11/02/98
Integral - all models produced AFTER 11/02/98
Integral Shift Cylinder with Welded Push Rod Assembly
February 2, 2000 to Present
Redesigned shift system recessed into PDU cover.
Integral
All are air-operated to engage the lockout and spring-released
to disengage the lockout with the exception of the "Reverse-
Air" lockout. The "Reverse-Air" lockout is spring-released to
engage the lockout and air-operated to disengage the lockout.
Integral Shift Cylinder
November 2, 1998 to February 2, 2000
Redesigned shift system recessed into PDU cover.
Integral
1 - Compression spring
2 - Shift fork
3 - O-ring
4 - Piston
5 - O-ring
6 - Piston Cover
1
2
3
4
5
6
2 - Shift fork
3 - Snap ring
4 - Push rod
5 - O-ring
6 - Piston
7 - O-ring
8 - Piston Cover
1
2
4
3
5
6
7
8
12
Cast Iron Cover LockoutFebruary 1996 to November 1998
External type lockout.
Cast iron piston cover.
Cylindrical Design Lockout
November 1992 to February 1996
External type lockout
Stamped steel piston cover.
Interchangeable with the cast style cover only as a
complete assembly.
2 - Shift fork
3 - Push rod
4 - Piston
5 - O-ring
6 - Gasket
7 - Piston cover
8 - Hex head capscrew with flange
1
2
3
4
5
6
7
8
2 - Shift fork
3 - Push rod
4 - Shoulder washer
5 - Piston
6 - O-ring
7 - Shift cylinder
8 - Mounting bracket
9 - Mounting bracket capscrews
1
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3
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5
6
7
8
9
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Reverse-Air LockoutNavistar before November 1, 1996
External type lockout.
Cast iron piston cover.
1O-ring
2Pilot plate
3O-ring
4O-ring
5Snap ring
6Piston
7O-ring
8Snap ring
9Piston cover
10 Hex head capscrew with flange
11 O-ring
12 Push rod
13 Compression spring
14 Shift fork
15 Snap ring
10
9
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5
4
3
2
1
12
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15
14
13
14
Remove Lockout
External Type Lockout
1. With axle installed in vehicle, place differential lock
selector valve in the disengaged (or unlocked) posi-
tion.
2. Disconnect differential lockout air line.
3. Remove capscrews.
4. Remove shift cylinder body or cast iron cover, o-ring
and piston.
Do not remove push rod. Removal of push rod will result in
shift fork and compression spring falling into power divider
unit. If this occurs, disassembly of the power divider
assembly will be necessary.
5. Remove shoulder washer in cylindrical design lock-
outs. Cast iron cover lockout designs do not use a
shoulder washer.
Note: Cylindrical design lockout and cast iron cover lockout
are interchangeable only as complete assemblies.
Integral Type Lockout
1. With axle installed in vehicle, place differential lock
selector valve in the disengaged (or unlocked) posi-
tion.
2. Disconnect differential lockout air line.
3. Remove piston cover and o-ring.
4. Remove piston and o-ring assembly with pliers.
Note: To remove shift fork and push rod parts, the power
divider must be removed. See power divider section.
Install Lockout
External Type Lockout
1. Assemble o-rings onto piston. Apply silicone grease
to o-ring.
2. Install piston and o-ring assembly into cylinder body
or cast iron cover.
3. Attach shift cylinder body or cast iron cover to power
divider while aligning piston with push rod. Make
sure shoulder washer or gasket is in place.
4. For stamped steel style lockouts, attach mounting
bracket to cylinder body and secure capscrews.
5. Tighten capscrews to 2835 lbs. ft. (3847 Nm).
6. Connect differential lockout air line.
7. Cycle the lockout unit to insure there are no leaks
and system shifts freely.
Integral Type Lockout
1. Assemble o-rings onto piston and piston cover.
Apply silicone grease to o-rings.
2. Gently push piston and o-ring assembly into lockout
cylinder recess. Make sure piston is pushed all the
way in.
3. Install piston cover and o-ring assembly. Start by
hand tightening clockwise.
Do not to strip threads or use excessive force, damage to
part may occur.
4. Tighten piston cover to 25-35 lbs. ft. (35-47 Nm).
5. Connect differential lockout air line.
6. Cycle the lockout unit to make sure there are no
leaks and the system shifts freely.
IMPORTANT
CAUTION
15
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Power Divider - Parts Exploded View
1 Output shaft nut
2 Output yoke
3 Output seal
4 Output shaft bearing snap ring
5 Outer bearing cup
6 Outer bearing cone
7 Inner bearing cone
8 Inner bearing cup
9 Output shaft
10 Seal manifold assembly
11 Sump screen
12 Seal manifold feed tube
13 Output side gear bearing cup
14 Output side gear bearing cone
15 Pump locking Pin
16 Output side gear
17 Pump
17A ---Old style pump
17BOutput side gear bearing cup
18Snapping ring
19 Inter-axle differnential
20 Helical side gear
21 Sliding clutch
22 ---Push rod spring
23Shift fork assembly
24 Input shaft
25 Input shaft oil retainer
26 Input shaft bearing cone
27 Power divider cover (integral)
28 Lube trough
29 Capscrew
30 ---Shift fork
31 Power divider cover (Old style)
32 Push rod
33 Input bearing cup
34 Input cage shim
35 Input cage V-ring
36 Input cage
37 Capscrew
38 Oil seal
39 Input yoke
40 Input nut
1 8
1 9
1 0
1 4
1 3
1 2
1 1
1 5
3 0
3 3 3 5
3 1
3 2
3 4
3 6
2 9
1 6
7 9 1 3 5 2 4 6 8
1 7
2 2
2 3
2 4 2 1 2 6
2 7
2 8
2 5
2 0
l7A l78
37
38
39
40
16
Power Divider
Remove Power Divider
Assemblies built BEFORE 11/02/98
Power Divider Interchangeability
(D344/404/405/454 Models Only)
Note: Due to the 11/02/98 redesign of the power divider (inte-
gral air lockout and lube trough), the ability to inter-
change parts will vary by build.
Pre-11/02/98 carriers cannot be rebuilt with current
design power divider units parts that have the inte-
gral air lockout design and lube trough.
11/02/98-current models can be rebuilt using pre-
11/02/98 power divider parts.
For more information refer to Dana Bulletin ABIB-9901.
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 differ-
ential (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.
1. Disconnect the main driveline.
2. Disconnect the lockout air line.
3. If overhauling the power divider, loosen but do not
remove input nut.
4. Position a drain pan under the unit.
5. Remove PDU capscrews.
Method A
With Carrier Installed in Chassis
1. Use a transmission jack or a chain hoist and a sling.
2. Wrap sling strap around power divider and attach to
chain hoist hook.
3. Tap on the sides of the cover at the dowel pins with a
mallet to create a space large enough to finish free-
ing the cover from the dowel pins.
4. Pull the power divider forward until the input shaft
stub end is free of the output side gear, then remove
the assembly.
Method B
With Carrier Out of Chassis
1. Use a chain hoist.
2. Mount carrier assembly in carrier assembly stand.
4. Fasten chain or strap to input yoke to remove power
divider.
Note: Lifting mechanism may create nicks and burrs on input
yoke. Remove nicks and burrs if present.
5. Tap the sides of the cover at the dowel pin location
with a mallet to loosen cover.
CAUTION
1 - Carrier assembly stand
CAUTION
1
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Disassemble, Assemble and Overhaul the Power Divider
The power divider may be serviced with the carrier assembly
in or out of the axle housing.
Note: The following procedure assumes that the differential
carrier has been removed from the axle housing and that
the power divider has been removed from the carrier
assembly.
1. Remove output shaft side gear from differential car-
rier.
Note: On pump models it will be necessary to remove three
pump retaining screws and remove the pump and out-
put shaft side gear as an assembly.
2. If replacement of the output shaft side gear bearing
cup is necessary, use either of the following meth-
ods:
Weld: Place a weld bead around the inside of the
cup, when the weld cools the cup will fall out.
Hammer: Use slipper to get under the cup and with a
hammer and drift from the back side of carrier tap
out bearing cup.
3. Remove snap ring from machined groove at rear of
input shaft.
18
Power Divider
4. Slide helical side gear off input shaft.
5. Remove helical side gear thrust washer.
6. Remove input shaft nut.
7. Remove yoke from input shaft using a puller tool.
TIP: A yoke puller tool may be made from the center
section of most gear puller tools, or may be pur-
chased from your local tool distributor.
8. Remove capscrews, input bearing cover and shim
pack.
9. If input shaft bearing cup needs replacement, use
either of the following recommended practices:
Weld a bead around the cup, when the weld
cools the cup will fall out.
Drill a 1/4 size hole through the bearing cover to
the back side of the cup and use a punch to
remove the bearing cup.
10. Slide input shaft assembly out of cover.
11. Remove input shaft bearing cone and oil retainer.
Note: Shift fork cannot be removed until lockout cover is
removed and push rod is removed from shift fork. See
Differential Lockout Section.
12. Press new oil retainer on input shaft.
It is not recommended to reuse the oil retainer due to possi-
ble damage that may occur while removing the input shaft
bearing cone. While pressing on new oil retainer, make
sure not to over press, and/or press with the retainer at an
angle. If the retainer is bent or distorted it may rub on the
input cage or not seal properly to the v-ring.
1Helical side gear
2Thrust washer
3PDU Cover (after 11/02/98)
1
2
3
1Press
2Bearing
3Oil retainer
4Input shaft
1
2
3
4
CAUTION
19
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13. Press input bearing cone on input shaft.
14. Press bearing cup in input bearing cover.
15. Install oil v-ring on input bearing cage cover.
16. If bushing removal is needed, the bushings must exit
from the thrust washer side of the helical gear.
17. Install bronze bushing in helical side gear. Bushings
must be installed from thrust washer side of gear.
See illustration for dimensional tolerances.
18. Install shift fork, spring and push rod in cover
assembly, if removed.
19. Units with reverse air, install snap ring fork, spring
and push rod in cover assembly, if removed.
1Press
2Plate
3Drive sleeve
4Input shaft bearing cone
5Oil retainer
6Input shaft
1Bearing cup (press)
2V-ring
5
3
2
1
6
4
1
2
1Tap out bronze bushings
1Press
2Sleeve
31st bronze bushing (press to shoulder)
4Shoulder
5Sleeve
6Second bronze bushing (recess 1/32)
1
3
1
2
4
6
1
5
1/32"
20
Power Divider
20. Install lockout cylinder assembly if removed. Some
models may have a one piece cover. Refer to pages
14-17. Tighten capscrews to 2835 lbs. ft. (3847
Nm).
21. Place sliding clutch in power divider cover, engaging
clutch with shift fork. Position clutch teeth toward
helical side gear.
22. Slide input shaft into power divider cover. Engage
shaft splines in lockout sliding clutch.
23. Install input bearing cover and shims.
Note: Input shaft end-play must be adjusted after power
divider is assembled to differential carrier. For easier
adjustment, temporally install input bearing cage cover
and tighten capscrews finger tight.
24. Install helical thrust washer over input shaft.
25. Install helical side gear.
26. Install snap ring.
Snap ring is spring steel and may pop off. Wear safety
glasses when installing.
1Helical side gear
2Helical side gear thrust washer
3PDU cover (before 11/02/98)
1
2
3
WARNING
21
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Remove Lube Pump
1. Remove inter-axle differential (IAD) and pump collar.
TIP: The output shaft side gear and pump will be
removed as an assembly. The lube pump assembly
is located on the back side of the output shaft side
gear, between the output shaft side gear and bearing
cone.
Note: If the IAD assembly is to be reused, install in same
direction as removed.
2. Remove the three pump retaining screws and
remove the pump and output shaft side gear as an
assembly.
3. Inspect the lube pump if metal particles are found in
axle assembly.
4. Remove the magnetic strainer from the carrier and
inspect for wear material in the same manner as the
drain plug. Wash the magnetic strainer in solvent
and blow dry with compressed air to remove oil and
metal particles.
Note: The pump assembly must turn freely by hand. The
pump is non-serviceable and must be replaced as a
complete assembly.
Install Lube Pump
1. Install lube pump assembly onto output side gear.
Note: The lube pump assembly is a slip-fit on the output shaft
side gear, behind the press fit of the output shaft side
gear bearing. The output shaft side gear bearing cone
positions the pump assembly into the carrier.
2. Install bearing cone on output side gear.
3. Press bearing using proper tools until fully seated.
4. Reinstall output side gear pump and bearing assem-
bly into carrier.
5. Tighten lube pump retaining screws to 17-21 lbs. ft.
(23-38 Nm).
TIP: The lube pump assembly is orientated in such a
way that the three mounting/locating tabs will only
line up one way.
Note: The lube pump is driven off the IAD assembly through a
drive coupling. The drive coupling has drive tangs to
both the IAD assembly and the lube pump. The IAD has
notches that will accept the drive coupling on either
face.
6. Install pump drive coupling.
Note: If reusing the IAD assembly, install in same direction as
removed.
7. Reinstall IAD.
Exercise care to direct compressed air into a safe area.
Wear safety glasses.
1Magnetic strainer
1
CAUTION
22
Power Divider
Install Power Divider to Carrier Assembly
(In vehicle installations shown)
Note: Cleanliness in your work area is important as dirt is an
abrasive and will cause premature wear of the otherwise
serviceable parts.
Note: It is assumed that the differential carrier is secured in a
stand, or the power divider only is being serviced while
the axle is still attached to the housing.
During installation of power divider cover, the inter-axle dif-
ferential (IAD), input shaft assembly or IAD shift system
parts may fall from the carrier if not careful. Use caution to
prevent injury or damage.
1. Make sure dowel pins are installed in carrier.
2. Install 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 if removed.
5. Install the IAD assembly to the output side gear. If
reusing the IAD assembly, install in the same direc-
tion as removed.
Note: For lube pump models, see instructions on page 24.
If power divider was manufactured before 11/02/98, the
complete power divider assembly can be installed as one
unit. It can be lifted or lowered into place with the input
cage, input shaft, thrust washer, helical side gear and snap
ring assembled to the PDU cover.
TIP: The use of two guide pins in the carrier mating
surface will help align the PDU cover and aid in
installation. Guide pins may be made from M14 X 2
bolts approximately 4 inches long with the heads
removed.
6. Install power divider assembly to carrier assembly.
Use Dana approved RTV compound on the carrier
mating surface.
1O-rings
2Bearing cup
CAUTION
1
2
IMPORTANT
23
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7. During installation rotate input shaft to engage input
shaft splines with inter-axle differential. After instal-
lation, the output shaft should turn when the input
shaft is rotated and output shaft should turn inde-
pendently from the input shaft.
Note: Gasket compound will harden in 20 minutes. Install
power divider as quickly as possible to avoid future
leaks.
8. Install power divider capscrews. Torque to 114140
lbs. ft. (155190 Nm)
9. Reinstall input yoke if removed. All yokes have a slip
to interference fit on spline. Yokes should always be
installed with a press on tool to ensure they are fully
seated.
10. Even though you may have checked the input shaft
end-play before, you must check and adjust it again
now.

CAUTION
24
Power Divider
Disassemble, Assemble and Overhaul Power Divider
Assemblies built AFTER 11/02/98 (In Vehicle)
The power divider cover comes off as a unit followed by the
input shaft and then the helical side gear.
3. Remove input yoke.
4. Remove input seal.
5. Position a drain pan under the power divider unit.
7. Remove power divider cover.
8. Remove shift fork, compression spring and shift rod.
9. Remove input shaft drive assembly from the carrier.
10. Remove the IAD assembly from the output side gear.
CAUTION
25
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11. Remove helical side gear and snap ring.
12. Remove thrust washer.
13. Remove lockout sliding clutch from the input shaft.
14. Remove the output side gear.
Note: Remove lube pump if you have one. See page 30.
15. Inspect output side gear o-rings for nicks and cuts.
Replace if necessary.
16. Install new bearing cup.
17. Remove input shaft bearing cone and oil retainer, if
necessary.
1Press
2Bearing
3Oil retainer
4Input shaft
1
2
3
4
CAUTION
26
Power Divider
22. Install new oil v-ring on input bearing cage cover.
1 - Press
2 - Plate
3 - Drive Sleeve
4 - Input shaft bearing cone
5 - Oil retainer
6 - Input shaft
5
3
2
1
6
4
2V-ring
1Press
2Sleeve
4Shoulder
5Sleeve
1
2
1
3
1
2
4
6
1
5
1/32"
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Lube Pump Removal Install Lube Pump Assemblies
Assemblies Built Before June 2008 Assemblies Built Before June 2008
cone.
direction as removed.
assembly.
axle assembly.
metal particles.
complete assembly.
bly into carrier.
(23-38 Nm).
line up one way.
face.
removed.
7. Reinstall IAD.
1Magnetic strainer
1
CAUTION
28
Power Divider
Lube Pump Removal: Assemblies Built After June 15, 2008
For output side gear and/or pump replacement, follow the
procedure below.
1. Remove the output side gear bearing cone, if
required.
2. Remove pump locking dowel pin from the hole in the
output side gear hub.
3. Remove pump from the output side gear.
1 - Press
2 - Press Tool
1
2
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Lube Pump Installation: Assemblies Built After June 2008
Use these instructions with the carrier assembly in or out of
the vehicle.
If the unit does not have a pump, go to the Power Divider
Assembly section.
Note: Keep work area clean. Dirt is an abrasive and will cause
premature wear of the otherwise serviceable parts.
Note: For non-pump models, see output side gear seal mani-
fold installation.
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:
CAUTION: During installation of power divider cover, the inter-
axle differential (IAD), input shaft assembly or IAD shift sys-
tem parts may fall from the carrier if not careful. Use caution
to prevent injury or damage.
1. Install the pump into the output side gear so that the
pump shaft is facing toward the teeth end of the side
gear.
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.
CAUTION
1 2
1 - Machined Slot
2 - Pin
30
Power Divider
Lube Manifold Removal
1. Disconnect the hose from the lube manifold.
2. Remove the manifold assembly by prying it out
around the inner diameter.
IMPORTANT: Once removed, the seal manifold assembly can-
not be reused. This component should always be replaced
with new. Use the same removal procedure for the output side
gear seal removal on the non-pump models.
Note: Seals are not sold separately from the manifold.
IMPORTANT
1
1 - Barbed Nipple
31
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Manifold Installation
1. Install the manifold assembly into the output side
gear bore in the carrier. Make sure the barbed nipple
is lined up with the opening in the carrier casting.
2. Install the hose clamp on the hose, push the hose
onto the barbed fitting and slide the clamp over the
barbed nipple.
3. Route the suction end of the hose through the holes
in the carrier casting to the bottom of the carrier.
4. Fully press the manifold assembly into position.
Note: Use care when pressing the manifold assembly to avoid
damaging the seals and barbed nipple. Do not over-
press plastic.
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.
Assembly section.
If the unit contains a pump, go to the Pump Assembly section.
1
1 - Barbed Nipple
1 - Manifold Oil Inlet Hole
1
32
Power Divider
Hose/ Filter Assembly
1. Look to see that the hose guide collar is installed and
not damaged. If damaged or not present replace
with new
2. Now with the collar installed, push the hose through
the back side of the collar and install the filter to the
end of the hose.
3. Next, push the filter and hose down into the collar so
that the filter is fully seated. Because of the
increased diameter of the hose after the filter is
installed,the hose should fit snugly in the collar
4. Fully seated position. Know hose should be showing
and filter will contact the collar.
33
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Assemblies built AFTER 11/02/98 (In Vehicle)
Note: See page 34 for out of vehicle.
Note: Parts inspection and cleaning procedures are important
and should be adhered to. Cleanliness in your work area
is important as dirt is an abrasive and will cause prema-
ture wear of the otherwise serviceable parts.
During installation of power divider components, the inter-
axle differential, input shaft assembly or IAD shift system
2. Install 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.
4. Install the output side gear, if removed.
5. Install the IAD assembly to the output side gear. If
reusing the IAD assembly, install in the same direc-
tion as removed.
Note: For lube pump models, see page 30.
6. Out of the vehicleon a bench, install lockout slid-
ing clutch onto the input shaft.
1Lubricate o-rings
2Bearing cup
CAUTION
1
2
34
Power Divider
7. Install thrust washer.
8. Install helical side gear and snap ring.
9. Install input shaft drive assembly into the carrier.
10. Install shift fork, compression spring and shift rod.
During installation of power divider components, a part
may fall from the carrier. Use caution to prevent injury or
damage.
11. Install plastic trough in power divider cover.
12. Install power divider cover to carrier. Use Dana
approved RTV compound on the carrier mating sur-
face. Torque capscrews to 114140 lbs. ft. (155190
Nm).
power divider quickly as possible to avoid future leaks.
CAUTION
35
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13. Install input cage shim and input cage assembly.
14. Install input cage capscrews and tighten until snug.
15. Measure and adjust input shaft end-play, see page
40.
16. Torque input cage capscrews to 114140 lbs. ft.
(155190 Nm).
17. Install NEW input seal, see page 72.
18. Reinstall input yoke.
36
Power Divider
Disassemble, Assemble, and Overhaul Power Divider
Assemblies built AFTER 11/02/98 Out of Vehicle
The power divider cover comes off as a unit followed by the
input shaft and then the helical side gear.
3. Remove input yoke.
4. Remove input seal.
5. Position a drain pan under the power divider unit.
7. Remove power divider cover.
8. Remove shift fork, compression spring and shift rod.
9. Remove input shaft and helical thrust washer from
the carrier.
10. Remove helical side gear.
CAUTION
37
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11. Remove the IAD assembly from the output side gear.
12. Remove the output side gear.
Note: Remove lube pump if you have one.
13. Inspect output side gear o-rings for nicks and cuts.
Replace if necessary.
14. Install new bearing cup.
15. Remove input shaft bearing cone and oil retainer, if
necessary.
1Press
2Bearing
3Oil retainer
4Input shaft
1
2
3
4
CAUTION
38
Power Divider
20. Install new oil v-ring on input bearing cage cover.
1Press
2Plate
3Drive sleeve
4Input shaft bearing cone
5Oil retainer
6Input shaft
5
3
2
1
6
4
2V-ring
1Press
2Sleeve
4Shoulder
5Sleeve
1
2
1
3
1
2
4
6
1
5
1/32"
39
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Lube Pump Removal: Lube Pump Installation:
Assemblies Built Before June 15, 2008 Assemblies Built Before June 15, 2008
cone.
direction removed.
assembly.
axle assembly.
metal particles.
complete assembly.
bly into carrier.
(23-38 Nm).
line up one way.
face.
removed.
7. Reinstall IAD.
1Magnetic strainer
CAUTION
40
Power Divider
Lube Pump Removal: Assemblies Built After June 2008
For output side gear and/or pump replacement, follow the
procedure below.
1. Remove the output side gear bearing cone, if
required.
2. Remove pump locking dowel pin from the hole in the
output side gear hub.
3. Remove pump from the output side gear.
1 - Press
2 - Press Tool
1
2
41
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Power Divider
Lube Pump Installation: Assemblies Built After June 2008
Use these instructions with the carrier assembly in or out of
the vehicle.
Assembly section.
Note: Keep work area clean. Dirt is an abrasive and will cause
premature wear of the otherwise serviceable parts.
Note: For non-pump models, see page 17 for output side gear
seal manifold installation.
Note: Only service the power divider if the differential carrier
is secured in a stand or while the axle is still attached to
the housing.
1. Install the pump into the output side gear so that the
pump shaft is facing toward the teeth end of the side
gear.
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.
CAUTION
1 2
1 - Machined Slot
2 - Pin
42
Power Divider
Lube Manifold Removal
1. Disconnect the hose from the lube manifold.
2. Remove the manifold assembly by prying it out
around the inner diameter.
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.
IMPORTANT
1
1 - Barbed Nipple
43
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Power Divider
Manifold Installation
1. Install the manifold assembly into the output side
gear bore in the carrier. Make sure the barbed nipple
is lined up with the opening in the carrier casting.
2. Install the hose clamp on the hose, push the hose
onto the barbed fitting and slide the clamp over the
barbed nipple.
3. Route the suction end of the hose through the holes
in the carrier casting to the bottom of the carrier.
4. Fully press the manifold assembly into position.
Note: Use care when pressing the manifold assembly to avoid
damaging the seals and barbed nipple. Do not over-
press plastic.
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.
1
1 - Barbed Nipple
1 - Manifold Oil Inlet Hole
1
44
Power Divider
Hose/ Filter Assembly
1. Look to see that the hose guide collar is installed and
not damaged. If damaged or not present replace
with new
2. Now with the collar installed, push the hose through
the back side of the collar and install the filter to the
end of the hose.
3. Next, push the filter and hose down into the collar so
that the filter is fully seated. Because of the
increased diameter of the hose after the filter is
installed,the hose should fit snugly in the collar
4. Fully seated position. Know hose should be showing
and filter will contact the collar.
45
Power Divider
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Assemblies built AFTER 11/02/98 (Out of Vehicle)
Note: Parts inspection and cleaning procedures are important
and should be adhered to. Cleanliness in your work area
is important as dirt is an abrasive and will cause prema-
ture wear of the otherwise serviceable parts.
Note: It is assumed that the different carrier is secured in a
stand.
During installation of power divider components, parts may
fall from the carrier if not careful. Use caution to prevent
injury or damage.
2. Output side gear bearing cup. If removed, press
bearing cup in carrier. Use a press and an appropri-
ate sleeve. Make certain bearing cup is evenly and
firmly seated. If a press is not available, use a sleeve
or a bearing driver tool and a hammer to install the
cup.
4. Install the output side gear using one of the follow-
ing instructions (non-pump models or lube pump
models).
Non-pump Models
a. Install output side gear.
b. Install the IAD assembly to the output side gear. If
reusing the IAD assembly, install the same direction
as removed.
Lube Pump Models
a. Install output side gear/pump assembly into carrier.
The lube pump mounting holes are oriented in such
a way that it can be installed only in one position.
b. Lube pump couplingLine up the drive couplings
tangs with the pump and IAD notches. The spacing
of the tangs are the same, one side to the other. If
reusing the IAD assembly, install the same direction
as it was removed.
5. Install helical side gear.
CAUTION
46
Power Divider
6. Install thrust washer.
7. Install compression spring, shift fork, push rod and
lockout sliding clutch.
8. Install input shaft assembly.
Note: The input shaft snap ring is not used in this buildup.
9. Install plastic oil trough in power divider cover.
10. Install power divider cover to carrier. Use Dana
approved RTV compound on the carrier mating sur-
face. Torque capscrews to 114140 lbs. ft. (155190
Nm).
power divider as quickly as possible to avoid future
leaks.
11. Install input cage shim and input cage assembly.
12. Install input cage capscrews and tighten until snug.
13. Measure and adjust input shaft end-play, see page
39.
14. Torque input cage capscrews to 114140 lbs. ft.
(155190 Nm)
15. Install NEW input seal, see page 71.
16. Reinstall input yoke.
47
Power Divider
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Measure and Adjust Input Shaft End-Play
Note: After power divider overhaul and installation on carrier,
check and adjust input shaft end-play.
The correct end-play when new parts are used in overhaul is
.0.003 to 0.007, with reused parts the maximum is 0.014.
1. Remove input shaft nut. Remove input bearing cover
capscrews. Remove bearing cover (and shim pack if
installed).
2. Reinstall bearing cover without shims. Hold in posi-
tion with hand pressure and measure clearance
between power divider cover and bearing cover,
using a feeler gauge.
3. The bearing cover clearance measured in Step 2 plus
0.005 will equal shim pack thickness required for
desired end-play (rebuild with new parts). Add
0.015 to shim pack for rebuild with used parts.
4. Install shim pack and bearing cover. Install cap-
screws. Torque screws to 114140 lbs. ft. (155190
Nm). Make sure shims are flat with no kinks or
bends.
5. Install yoke using installation tool and nut. Tighten
nut snugly. Tap end of input shaft lightly to seat bear-
ings.
6. Check input shaft end-play with dial indicator posi-
tioned at yoke end of input shaft. Move input shaft
axially and measure end-play. If end-play is correct,
seal shim pack with Dana approved RTV compound
to prevent lube leakage. Then torque input shaft nut.
7. If end-play is incorrect, change shim pack size as fol-
lows:
Add shims to increase end-play.
Remove shim to decreased end-play.
1Push in and zero indicator, read and record
2Pry down
Add shims to provide desired end-play 0.002 to 0.006
Remove shims to provide desired end-
play
0.012 to 0.008
1
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48
Power Divider
8. To add or remove shims, remove input shaft nut and
yoke. Remove capscrews, lock washers and bearing
cover. Add or remove shims as required.
9. Install bearing cover and capscrews. Seal shim pack
with Dana approved RTV compound to prevent lube
leakage then torque input shaft capscrews 150165
lbs. ft. (204224 Nm).
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 8401020 lbs. ft. (11481383
Nm).
b. If a new nut with pre-applied thread adhesive
compound is unavailable, apply Loctite 277 or
271 (available in .5 ml tubeEaton 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 8401020 lbs. ft. (11481383 Nm).
Note: Use of a torque multiplier is recommended.
If difficulty is experienced in achieving correct torque, torque
the nut with the truck wheels on the ground and with the axle
shaft installed.
Follow the instructions specified by the thread adhesive
manufacture when applying thread adhesive compound.
2 Flats
(120 )
Midway thru
thickness of nut
IMPORTANT
49
Carrier Assembly
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Carrier Assembly - Parts Exploded View
Disassemble Carrier Assembly
(All Forward and Rear Axles)
Note: For models having the wheel differential lock option or a
carrier thrust bolt follow the steps below. These parts
must be removed first before further removal of the
wheel differential can take place.
Remove 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.
2. Remove shift cylinder mounting screws, then lift
shift cylinder, piston and o-ring assembly off carrier
and end of push rod.
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 pen-
cil-size tool through the cylinder air port.
4. Grasp push rod end and pull it out of the shift fork,
spring and carrier.
Note: When the push rod is disengaged from the shift fork,
the fork and sliding curvic clutch assembly can be
removed from carrier.
Note: Do not disassemble shift fork from the sliding curvic
clutch unless parts replacement is necessary. To disas-
semble, use pin punch to remove spring pin from long
leg of fork. The fork can now be disengaged from the
clutch.
1 Piston engagement bolt
2 Capscrew
3 Switch
4 Washer
5 O-ring
6 Piston
7 Setscrew
8 Piston driver
9 Pushrod
10 Clutch fork
11 Spring
12 Sliding clutch
13 Pin
14 Piston cover
12
10
11
9
13
8
7
6
5
3
1
2
4
14
1Shift cylinder
1
50
Carrier Assembly
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.
Models with Ring Gear Thrust Bolt
Note: If the carrier model has a ring gear thrust bolt installed,
it must be backed away from the ring gear before you
can 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 is flush with the inside of the carrier casting.
This will allow enough clearance between the ring
gear and the carrier pilot web.
1D-head carrier or front carrier
2Thrust bolt
3Thrust bolt jam nut
1
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2
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Carrier Assembly
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Remove Wheel Differential (All Standard Models)
Note: Omit this step if the gear set is to be replaced. If gear
set is to be reused, check tooth contact pattern and ring
gear backlash before disassembling differential carrier.
When checking backlash, a yoke or helical gear must be
installed and torqued to get an accurate reading. Best
results are obtained when established wear patterns are
maintained in used gearing.
1. Mount differential carrier in repair stand.
Note: For easier disassembly, loosen but do not remove pin-
ion (self-locking) nut. Forward axle pinion is equipped
with slotted nut, remove roll pin with a pin punch then
loosen nut.
2. If reusing gear set, also punch mark bearing adjust-
ers for reference during assembly.
3. Remove capscrews, flat washers and bearing caps.
Back off bearing adjusters and remove adjusters and
bearing cups.
4. Using a chain hoist, lift ring gear and differential
assembly out of carrier.
1Punch marks
1
52
Carrier Assembly
Remove Pinion Assembly
1. Remove pinion bearing cage capscrews. Remove
pinion and cage assembly from carrier. Remove
shim pack.
Note: For easier disassembly, loosen but do not remove pin-
ion (self-locking) nut. Forward axle pinion is equipped
with slotted nut, remove roll pin with a pin punch then
loosen nut.
2. Remove pinion bearing cage capscrews. Remove
pinion and cage assembly from carrier. Remove
shim pack.
Do not allow pinion to drop on hard surface.
If gear set is to be reused, keep pinion bearing cage shim
pack intact for use in reassembly. If the original shims can-
not be reused, record the number and size of shims in the
pack.
IMPORTANT
53
Drive Pinion
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Front Axle Pinion Assembly - Parts Exploded View
Rear Axle Pinion Assembly - Parts Exploded View
1Pinion pilot brg.
2Pinion
3Pinion brg. cone - inner
4Pinion brg. spacer*
5Pinion brg. cup - inner
6Shim
7Pinion brg. cage
8Capscrew
9Pinion brg. cup - outer
10Pinion brg. cone - outer
11Pinion helical gear
12Roll pin
13Slotted pinion nut
* Before 3/01/95 two spacers were used instead of the one shown.
14Pinion pilot brg.
15Pinion
16Pinion brg. cone - inner
17Pinion brg. spacer
18Pinion brg. cup - inner
19Shim
20Pinion brg. cage
21Capscrew
22Pinion brg. cup - outer
23Pinion brg. cone - outer
24Oil seal
25Yoke
26Pinion nut
1
2
3
4*
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
54
Drive Pinion
Disassemble and Overhaul Drive Pinion
The following procedures cover both forward and rear differ-
ential drive carrier disassembly.
1. Rear Axle Pinion Yoke: Remove yoke.
If pinion nut was not loosened during earlier disassembly,
clamp assembly in vise jaws, use brass pads to prevent
damage.
2. Loosen and remove pinion nut and flat washer.
Remove yoke from pinion using an appropriate tool.
3. Forward and Rear Axle Pinion Bearing Cage: Press
pinion out of bearing cage and bearing cone.
4. Rear Axle Pinion Oil Seal and Outer Bearing Cone:
Remove oil seal and bearing cone from cage. Dis-
card oil seal. Remove bearing cups with suitable
puller.
5. Remove bearing spacer from pinion.
6. Remove pilot bearing from pinion using a split-type
puller. Use two procedure steps to remove each
bearing.
a. Mount puller vertically to separate the bearing.
This action will force puller halves under bearing
and start moving bearing off pinion.
b. Mount puller horizontally to press pinion out of
bearing.
1 - Press ram
CAUTION
1
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Drive Pinion
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7. Remove inner bearing cone from pinion using a
split-type puller. Use two procedure steps to remove
each bearing.
a. Mount puller vertically to separate the bearing.
This action will force puller halves under bearing
and start moving bearing off pinion.
b. Mount puller horizontally to press pinion out of
bearing.
1 - Press
1
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Drive Pinion
Replace Pinion Bearing Cage Cups
1. Remove cups.
2. Clean and inspect bearing cages for damage, nicks
and burrs.
3. Install inner and outer pinion bearing cups. Use a
press and an appropriate drive sleeve. Make certain
bearing cup is evenly and firmly seated.
4. Seat cups securely to shoulder. Check clearance
between cup and bearing cage. Must be less than
.001.
1 - Cup(outer)
2 - Bearing cage
3 - Cup (inner)
1 - Press ram
2 - Sleeve must apply pressure to back face of outer bearing
cone
1
3
2
2
Front Rear
1
2
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Adjust Pinion Bearing Preload
Trial Buildup
1. Assemble pinion bearing cage, bearings, spacer and
spacer washer (without drive pinion or oil seal). Cen-
ter bearing spacer between two bearing cones.
Lubricate bearing cups and cones.
Note: When new gear set or pinion bearings are used, select
nominal size spacer from the specification chart. If origi-
nal parts are used, use spacer removed during disas-
sembly.
2. With the bearings well lubricated, place the assembly
in the press. Position sleeve so that load is applied
directly to the backface of the outer bearing cone.
3. Rotate pinion cage while applying press load (see
chart below) to the assembly and check rolling
torque. Wrap soft wire around the bearing cage,
attach spring scale and pull. Preload is correct when
torque required to rotate the pinion bearing cage is
from 513 lbs. (2.56.0 kgs.).
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 Nm)
Read only the torque value after the bearing cage starts to
rotate.
4. If necessary, adjust pinion bearing preload by chang-
ing the pinion bearing spacer. A thicker spacer will
decrease preload. A thinner spacer will increase pre-
load.
Once correct bearing preload has been established, note
the spacer size used. Select a spacer 0.001" larger for use
in the final pinion bearing cage assembly. The larger
spacer compensates for slight "growth" in the bearings
which occurs when they are pressed on the pinion shank.
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.
1 - Bearing
2 - Cup
3 - Spacer
4 - Cage
5 - Cup
6 - Bearing
1 - Press ram
2 - Sleeve must apply pressure to back face of outer bearing
cone
3 - Spring scale
1
2
3
4
5
6
3
1
2
Forward Axles Rear Axles
Spring Scale
Reading
5 - 13 lbs. ( 2.5 - 6.0 kgs.)
Press Loads 17-19 Tons
(15.4 - 17.2
Metric Tons)
14-15 Tons
(12.7-13.6
Metric Tons)
Nominal Bearing
Thickness Spacer
0.496 in.
(12.60 mm)
0.638 in.
(16.21 mm)
CAUTION
IMPORTANT
58
Drive Pinion
Final Buildup
Note: On rear axles, do not install oil seal in cage until bearing
preload is correctly adjusted.
After bearing cups are installed, preselect pinion bearing
spacer using the trial buildup procedure.
Note: During pinion bearing installation, locate each part in
same position that was used in trial buildup preload
test.
1. Press inner bearing cone on pinion.
To prevent bearing damage, use suitable sleeve that only
contacts inner race of bearing cone.
2. Install preselected bearing spacer.
3. Install bearing cage on drive pinion.
4. Press outer bearing cone on pinion.
To prevent bearing damage, spin cage while pressing outer
bearing on.
5. Apply clamp load to the pinion bearing cage assem-
bly. Either install the yoke (or helical gear) and
torque the pinion nut to specifications or use the
press to simulate nut torque (see chart on next
page).
IMPORTANT
IMPORTANT
IMPORTANT
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Drive Pinion
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Specifications for Pinion Bearing Final Buildup Preload Test
Torque to Rotate Bearing Cage (w/o pinion seal)
18 - 42 lbs. in. (2.0 - 4.7 Nm)
*Torque nut to 840 lbs. ft. (1,140 Nm), then continue tighten-
ing nut to align nut slot to nearest hole in pinion shank.
Vise Method
a. if the yoke and nut are used, mount the assem-
bly in a vise, clamping yoke firmly.
Press Method
a. If a press is used, position a sleeve or spacer so
that load is applied directly to the backface of
the outer bearing cone.
6. Measure Pinion Bearing Preload: Use a spring scale
to test the assembly rolling torque. To use the spring
scale, wrap flexible wire around the bearing cage,
attach the scale and pull. Preload is correct when
torque required to rotate the pinion bearing cage is
from 513 lbs. This specification is translated into
lbs. in. readings in the previous chart.
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 bear-
ing cage as recommended in this manual and
change the pinion bearing spacer. A thicker spacer
will decrease preload. A thinner spacer will increase
preload.
Use the correctly sized spacer. Do not use shim stock or
grind spacers. These practices can lead to loss of bearing
preload and gear or bearing failure.
8. Press pilot bearing on pinion.
contacts the inner race of bearing cone.
Forward Axles Rear Axles
Spring Scale
Reading
5 - 13 lbs. ( 2.5 - 6.0 kgs.)
Press Loads 1719 Tons
(15.417.2
Metric Tons)
1415 Tons
(12.713.6
Metric Tons)
Nut Torque 840 lbs. ft.*
(1,140 Nm*)
575703 lbs. ft.
(780953 Nm)
1 - Vise
1 - Press
1
1
CAUTION
IMPORTANT
IMPORTANT
60
Drive Pinion
9. Stake pilot bearing using staking tool. This is essen-
tial to retain the bearing.
10. Rear Axle Only: With pinion installed and bearing
preload adjustment complete, install oil seal. Use
properly sized installation tool as described on page
71 to prevent distortion.
11. Rear Axle Only: Prior to installation of yoke, make
sure yoke is clean and dry.
12. Install yoke.
13. Install yoke nut using one of the following options:
specified torque:
575703 lbs. ft. (780953 Nm) for rear pinion
nut.
8401020 lbs. ft. (11401383 Nm) for front
pinion nut.
compound is unavailable, apply Loctite 277 or
271 (available in .5 ml tube Dana P/N
the thickness.
manufacturer when applying thread adhesive compound.
TIP: If you can't get the correct torque on yoke nut, try torqu-
ing the nut with the truck wheels on the ground and with the
axle shafts installed.
Note: Forward axle pinion helical gear and bearing: These
parts are installed after pinion installation in carrier (see
page 54).
1 - Tool
2 - Seal
3 - Bearing cage
Stake Pattern
1
2
3
IMPORTANT
2 Flats
(120 )
Midway thru
thickness of nut
61
Drive Pinion
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Install Drive Pinion Assembly
1. Forward Axle Only: Place shim pack on carrier mak-
ing sure holes are properly aligned. Make sure shims
are flat with no kinks or bends.
2. Rear Axle Only: Place shim pack on carrier making
sure lube holes are clear.
Note: If gear set is to be reused, install same quantity and size
of shims removed during disassembly. When installing a
new gear set, use nominal shim pack indicated.
Nominal Shim Pack
3. Install drive pinion assembly. Install bearing cage
capscrews and lock washers. Torque capscrews to
114-140 lbs. ft. (155-190 Nm).
Note: Use a dummy yoke (if available) in place of helical gear.
This will result in easier disassembly and reassembly
during carrier adjustments.
Note: Do not install cotter pin until carrier adjustments are
completed.
4. Rear Axle Drive Pinion: Install pinion assembly.
Install bearing cage capscrews and lock washers.
Torque capscrews to 114-140 lbs. ft. (155-190
Nm).
5. Forward Axle Helical Gear Only: If dummy yoke
was used, remove nut and yoke. Install helical gear
on pinion. Install M42 X 1.5 nut and torque to
840-1,020 lbs. ft. (1,140-1,383 Nm).
1Lube slots
Axle in. mm
Forward 0.025 0.635
Rear 0.023 0.584
1
62
Drive Pinion
Torque to 840 lbs. ft. (1,140 Nm), then continue tightening
nut to align slot with the nearest hole in pinion shank.
Install roll pin.
1Roll pin
2Slotted nut
IMPORTANT
1
2
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Wheel Differential - Parts Exploded View
1 - Ring gear
2 - Capscrew
3 - Flat washer
4 - Diff. carrier bearing caps
5 - Cotter pin
6 - Diff. case - LH (flange half)
7 - Bearing cone - flange half
8 - Bearing cup - flange half
9 - Diff. brg. adjuster - flange half
10 - Bolt
11 - Nut
12 - Diff. brg. adjuster - plain half
13 - Bearing cup - plain half
14 - Bearing cone - plain half
15 - Diff. case - RH (plain half)
16 - Side gear thrust washer
17 - Side gear
18 - Diff. spider
19 - Side pinion
20 - Side pinion thrust
2
18
17
16
13
19
4
12
16
15
8
1
10
11
9
7 6
4
5
3
17
14
20
Flange Half (LH)
64
Disassemble, Overhaul, and Assemble Wheel Differential (Forward and Rear Axles)
Disassemble Wheel Differential
During following procedure, place differential assembly on
malleable surface to prevent damage when ring gear falls
off its mounting position.
1. Remove nuts and bolts fastening ring gear to differ-
ential cases, allowing gear to fall free. If gear does
not fall, tap outer diameter with soft mallet to loosen.
2. Punch mark differential cases for correct location
during reassembly. Remove capscrews and lift off
plain differential case half.
3. Lift out side gear and thrust washer.
4. Lift out spider, side pinions and thrust washers.
5. Remove remaining side gear and thrust washer.
6. Remove bearing cones from case halves using suit-
able puller.
7. Remove bearing cone from plain case half in two
steps:
a. Mount puller vertically to split bearing. This
action will start moving bearing off case.
b. Mount puller horizontally to remove cone.
8. Remove bearing cone from flanged case half using
suitable puller.
1 - Punch marks
IMPORTANT
1
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Overhaul and Assemble Wheel Differential
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 flange OD.
1. Press new flange half bearing cones on differential
case halves.
2. Press new plain half bearing cones on differential
case halves.
3. Place thrust washer and side gear in flanged differ-
ential case.
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.
6. Place side gear and thrust washer on side pinions.
7. Align punch marks and install plain case half. Install
capscrews and tighten to 114140 lbs. ft. (155190
Nm). Check differential for free rotation by turning
side gear hub.
IMPORTANT
1 - Punch marks
1
66
8. Install ring gear. Secure with bolts and nuts.
Note: Flange half differential cases were redesigned starting
with production axles built in January 1997. New style
ring gear bolts are also required with the new style
flange case, the torque specification for this bolt is dif-
ferent than the old 126219 bolt. (See chart).
Reference Dana Bulletin ABIB-9701 for more details.
9. Lower assembled differential assembly in to the car-
rier using a hoist and a strap. Be careful not to dam-
age the differential bearings lowering the assembly.
10. Install the bearing cup and bearing adjuster to the
flange half side first.
11. Install the bearing cup and bearing adjuster to the
plain half side. Use a long screwdriver or bar to lift
the differential up while installing the cup and bear-
ing adjuster.
Bolt No. Torque Specs.
129686 180-220 lbs. ft. (Nm 224-298)
126219 215-255 lbs. ft. (Nm 292-346)
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Measure and Adjust Carrier Assembly
Adjust Backlash and Preload
1. Turn the flange half bearing adjuster in until the ring
gear contacts the pinion (zero backlash) than back
the adjuster out two notches of the adjuster lugs.
2. Tighten the plain half adjuster until the bearing cup
just starts to turn, this is a zero bearing preload.
3. Tighten the plain half adjuster two lug notches. Start
with the notch at the top, count two notches coun-
terclockwise on the adjuster, turn the adjuster so
that the notch is facing straight up. You now have a
two notch preload.
4. Use a rubber mallet to make certain that both bear-
ing adjusters are fully seated.
5. Measure backlash. Make sure it is within specifica-
tion of .006".018".
TIP: To give yourself room to adjust contact pattern,
set it between .010".012".
1Flange half
2Plain half
1
2
1Flange half
2Plain half
1
2
68
Change Backlash Setting
If you have too much backlash the ring gear needs to move
closer to the pinion. Back off the plain half adjuster, count the
number of notches you back it off, each notch equals about
.003" of backlash.
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 350428 lbs. ft. (475580 Nm).
2. Recheck backlash: if the bearing adjusters were not
in straight or fully seated the backlash will change.
a. Used Gearing: Reset to backlash recorded
before disassembly.
b. New Gearing: Backlash should be between
0.006 and 0.018".
3. Check ring gear tooth contact pattern. Paint ring gear
teeth and check tooth contact pattern. Correct tooth
patterns. Checking and adjusting procedures are on
pages 61-62.
4. Install bearing adjuster cotter pins.
Measure Ring Gear Runout
Measure Ring Gear Total
1. Measure ring gear total radial run out. (Indicator
reading should not exceed .010").
2. Measure ring gear total back face run out (Indicator
reading should not exceed .010").
IMPORTANT
69
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Adjust Ring and Pinion Tooth Contact Pattern
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).
New Gearing - Correct Pattern
Paint six ring gear teeth 180 apart with marking compound
and roll the gear to obtain a contact pattern. The correct pat-
tern is slightly below center on the ring gear tooth with length-
wise contact up off the toe. The length of the pattern in an
unloaded condition is approximately one-half to two-thirds of
the ring gear tooth in most models and ratios.
The pattern could vary in length and should cover 1/2 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.
Used Gearing - Correct Pattern
Used gearing will not usually display the square, even contact
pattern found in new gear sets. The gear will normally have a
"pocket" at the heal end of the gear tooth. The more use a gear
has had, the more the line becomes the dominant characteris-
tic of the pattern.
Adjust used gear sets to display the same contact pattern
observed before disassembly. A correct pattern is up off the
toe and centers evenly along the face width between the top
land and root. Otherwise, the length and shape of the pattern
are highly variable and is considered acceptable as long as it
does not run off the tooth at any point.
Adjust Contact Pattern
If necessary, adjust the contact pattern by moving the ring
gear and drive pinion.
Ring gear position controls the backlash. This
adjustment moves the contact pattern along the face
width of the gear tooth.
Pinion position is determined by the size of the pin-
ion bearing cage shim pack. It controls contact on
the tooth depth of the gear tooth.
These adjustments are interrelated. As a result, they must be
considered together even though the pattern is altered by two
distinct operations. When making adjustments, first adjust the
pinion, then the backlash. Continue this sequence until the
pattern is satisfactory.
1 - Face width
2 - Tooth Depth
3 - Heel
4 - Top land
5 - Root
6 - Toe
1
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3
4
5
6
1 - Pattern along the face width could be longer
70
Adjust Pinion Position
If the gear pattern shows incorrect tooth depth contact,
change drive pinion position by altering the shim pack. Used
gears should achieve proper contact with the same shims
removed from the axle at disassembly.
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.
If the pattern is too close to the root of the gear tooth, add
pinion shims. Move pinion away from the ring gear.
Adjust Ring Gear Position (Backlash)
If the 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.
1. Loosen the bearing adjuster on the teeth side of the
ring gear several notches.
2. Loosen the opposite adjuster one notch.
3. Return to adjuster on teeth side of ring gear and
tighten adjuster until it contacts the bearing cup.
4. Continue tightening the same adjuster 2 or 3 notches
and recheck backlash.
If the pattern is concentrated at the heel (too far up the tooth),
move the ring gear toward the pinion to decrease backlash.
5. Loosen the bearing adjuster on the teeth side of the
ring gear several notches.
6. Tighten the opposite adjuster one notch.
7. Return to adjuster on teeth side of ring gear and
tighten adjuster until it contacts the bearing cup.
8. Continue tightening the same adjuster 2 or 3 notches
and recheck backlash.
71
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Wheel Differential Lock - Parts Exploded View
1Piston engagement bolt
2Capscrew
3 Switch
4Washer
5 O-ring
6 Piston
7Setscrew
8 Piston driver
9Pushrod
10Clutch fork
11Spring
12Sliding clutch
13Pin
14Piston cover
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72
Install and Adjust Wheel Differential Lock
Note: With differential carrier completely assembled and
adjusted, install differential lock as follows:
1. Install fixed curvic clutch on splined hub of flanged
differential case, then install snap ring.
2. If shift fork and sliding curvic clutch are disassem-
bled, engage fork with clutch hub and install spring
pin in the long leg of the fork. See illustration for fork
mounting position on clutch.
3. Position compression spring, shift fork and clutch
assembly in shift opening of the carrier. Align pilot
hole of shift fork with pilot hole of carrier. Install
pushrod, engaging shift fork head, and compression
spring in carrier.
4. Install new o-ring on piston.
5. Lubricate piston and o-ring with silicone grease and
install piston assembly in cylinder. Position piston
with small diameter hub toward closed end of cylin-
der.
6. Screw piston driver on push rod.
7. Tighten piston driver until shift fork clutch is approx-
imately .030 of an inch from the fixed clutch.
8. Push down by hand on the piston driver, both
clutches must be completely engaged.
9. Install set screw in piston driver, torque to 1215
lbs. ft. (1620 Nm).
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
capscrews.
11. Screw in manual engagement screw, by hand
approximately 1 inch or until snug fit (light resis-
tance pressure is felt) both clutches must be com-
pletely engaged.
12. Remove manual engagement screw, clutches must
completely disengaged. Repeat above procedure if
clutches not completely disengaged.
Note: Fork adjustment is correct when curvic clutch teeth are
fully engaged with the fork free when moved by hand.
When air pressure is released or the manual bolt is
removed, the shift assembly should disengage freely.
13. When adjustment is complete, torque fasteners to
2835 lbs. ft. (3847 Nm).
14. Install selector switch in cylinder cover. Torque
switch to 1012 lbs. ft. (1416 Nm).
.030"
CAUTION
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15. Check selector switch operation. Check switch elec-
trically with an ohmmeter or continuity tester. Switch
should close (show continuity) when clutches are
engaged and should open (no continuity) when
clutches are disengaged.
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 cor-
rect adjustment of .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. (203258 Nm).
3. Recheck to assure minimum clearance during full
rotation of ring gear.
1 - Piston engagement bolt
2 - Capscrew
3 - Switch
4 - Washer
5 - O-ring
6 - Piston
7 - Setscrew
8 - Piston driver
9 - Pushrod
10 - Clutch fork
11 - Spring
12 - Sliding clutch
13 - Pin
14 - Piston cover
12
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1 - D-head carrier or front carrier
2 - Thrust bolt
3 - Thrust bolt jam nut
1
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2
74
Housing and Output Shaft
Assembly
Remove Output Shaft Assembly
Note: For forward axle rear covers that are removable the out-
put shaft may be removed when the cover is in or out of
the axle assembly.
1. Disconnect the inter-axle driveline at the forward
axle rear cover position.
2. Remove yoke nut (shoulder nut).
3. Remove yoke from output shaft using appropriate
tool.
TIP: A yoke puller tool may be made from the center
section of most gear puller tools, or may be pur-
chased from your tool distributor.
4. Remove oil seal.
5. Remove snap ring.
6. Remove output shaft and outer bearing cup as an
assembly.
TIP: It may be helpful to loosely reinstall the yoke
and shoulder nut giving the technician more of an
area to grip when removing the output shaft.
7. Remove the inner bearing cup from rear cover
assembly. This may be removed from inside the axle
housing when the carrier is removed, or by removal
of the forward axle rear cover.
8. Remove both inner and outer bearing from output
shaft.
9. Remove output shaft inner bearing cup.
Note: On 11/02/98, a design change was made to the forward
axle housing in the 404 family axles. The rear axle hous-
ing cover is now a welded assembly. To replace the
inner output shaft bearing cup on axle housings that
have the welded-on D-Cover, follow the steps outlined
below.
Note: Components such as the inter-axle driveline, yoke, oil
seal and output shaft assembly should have been
removed according to normal service procedures.
Removing the differential assembly from the axle hous-
ing is not necessary, but would ease the removal pro-
cess of the inner bearing cup from the cover bore.
a. Using a bearing puller tool, remove the inner
bearing cup.
b. Visually inspect the inner-machined bore sur-
face of the welded-on cover for nicks and burrs.
Repair if necessary.
1 - Yoke puller tool
1 - Snap ring
2 - Outer bearing cup
3 - Output shaft assembly
4 - Inner bearing cup
5 - Rear cover assembly
1
2
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4
5
1 - Press
1
75
Assembly
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Housing and Output Shaft Assembly - Parts Exploded View
1 Output shaft nut
2 Output yoke
3 Output seal
4 Snap ring
5 Outer bearing cup
8 Inner bearing cup
9 Output shaft
10 Rear cover
11 Rear cover capscrew
12 Fill plug
13 Rear cover nut
14 Lock washer
15 Stud
16 Dowel
17 Jam nut
18 Locking ring
19 Spindle nut
20 Axle housing
21 Breather
22 Breather hose
23 Carriage capscrew
24 Lock washer
25 Nut
26 Lock washer
27 Stud
28 Drain plug
29 Axle shaft
20
21
22
24
23
27
26
25
28
29
29
17
18
19
Welded Rear Cover
Bolt on Rear Cover
17
18
19
12
10
4
5
6
7
8
9
1
2
3
11
13
14
15
16
76
Assembly
Overhaul and Assemble Output Shaft Assembly
Note: Lubricate the parts with gear lube during assembly.
1. The output shaft bearings are assembled with both
bearing cones back to back. Use a press and a sleeve
to install one bearing at a time.
To prevent bearing damage, use a suitable sleeve that only
contacts the bearing race.
2. Apply pressure until the inner bearing cone touches
the shoulder of the output shaft.
3. Apply pressure until the back of the outer bearing
cone touches the back of the inner bearing.
Note: Axle housings with welded-on covers procured through
service will include the inner bearing cup as part of the
"service" axle housing assembly. Go to Step 6 if the inner
cup has already been installed.
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 areato the bearing
rollers or outboard of the inner cup bore. Improper
application of the Loctite could lock the rollers or
cause excessive pre-load.
Add loctite adhesive to the inner bearing surface of the
housing and NOT to the bearing race itself. If added to the
race, excessive adhesive could get on the surface of the
outer bearing race journal during installation and cure the
outer cap in place with excessive pre-load.
5. Using a sleeve and driver (hammer), install the inner
bearing cup.
6. Put the output shaft and bearing assembly into the
axle housing assembly.
7. Using a sleeve and driver (hammer), install the outer
bearing cup into the housing assembly over the out-
put shaft bearing cone.
8. Using snap ring pliers, install the snap ring that fas-
tens the outer bearing cup into the welded-on cover
assembly.
9. Check the end-play of the output shaft. New assem-
blies should measure .001" to .015".
Note: Use the bearing cup driver to insure seating of snap
ring after installation with snap ring pliers.
CAUTION
CAUTION
1Press
2Plate
3Sleeve
4Press bearing on second
5Press bearing on first
6Output shaft
7Plate
1Snap ring
2Bearing cup
3 Output shaft assembly
4Inner bearing cup
5Rear cover assembly
3
2
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5
6
7
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5
77
Assembly
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10. Bolted rear cover only: If removed, install cover and
fasten with nuts, capscrews and lock washers.
Tighten to proper torque specifications.
Note: Use Dana approved RTV compound on axle housing
mating surface as shown in illustration. Completely
remove all old gasket material prior to applying new
material. Compound will set in 20 minutes. Install axle
housing cover and output shaft assembly before com-
pound sets or reapply.
11. Install output yoke.
12. Install yoke nut using one of the following options:
specified torque 680832 lbs. ft. (9201,130
Nm).
compound is unavailable, apply "Loctite 277" or
"271" (available in .5 ml tubeDana P/N
the thickness. Tighten the nut to the specified
torque 680832 lbs. ft. (5301,130 Nm).
manufacturer when applying thread adhesive compound.
If you can't get the correct torque on yoke nut, try torquing
the nut with the truck wheels on the ground and with the
axle shafts installed.
13. Install axle shafts and axle stud nuts (If used, also
install lock washers and taper dowels).
14. Connect inter-axle driveline. Make sure driveline is
properly phased. Lubricate U-joints.
15. Add axle lubricant. Fill to bottom of filler hole.
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.
16. Road test vehicle to bring axle lubricant up to tem-
perature. Recheck joints, drain and fill plugs for leak-
age. Retighten as necessary.
1Apply silicon gasket in this pattern
2Stud locations
1
2
Cover Side of Axle Housing
IMPORTANT
2 Flats
(120 )
Midway thru
thickness of nut
IMPORTANT
IMPORTANT
78
Assembly
Measure and Adjust
Note: Use bearing cup driver to insure seating of snap ring
after installation with snap ring pliers.
1. Assemble cover assembly to axle housing.
2. Position dial indicator at yoke end of output shaft.
3. Push in on output shaft and zero the dial indicator.
4. Using a pry bar, move output shaft axially and mea-
.015". If end-play is incorrect, contact Dana.
5. Install oil seal. Follow seal replacement procedures
on page 72 of this manual.
6. Install yoke.
7. Install yoke nut. One of the following options may be
utilized:
specified torque 680832 lbs. ft. (9201130
Nm).
compound is unavailable, apply "Loctite 277" or
"271" (available in .5 ml tubeDana P/N
the thickness (See illustration). Tighten the nut
to the specified torque 680832 lbs. ft. (920
1130 Nm).
2
1
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79
Seals
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Replace Seal
Dana strongly recommends using seal drivers when installing
new seals. Use the proper driver to make sure that the seal is
square and installed to the proper depth.
Oil seals can be easily damaged prior to installation. Use
care when handling the new seal to prevent damage or con-
tamination. Leave the seal in its package until installation.
On new yokes, leave the protector on the yoke until it is
installed on the shaft to prevent damage or contamination.
1. Inspect axle end-play at the yoke (see page 10). Ser-
vice if beyond specified limit.
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.
3. Remove seal. Use care when removing the old seal
to prevent damage to the housing seal bore.
4. Inspect the seal bore area for any damage (nicks,
gouges, corrosion). Carefully remove any slight
damage with a crocus cloth. Clean the bore area to
remove any loose debris.
Do not use any silicone or permatex-type bore sealant with
this seal.
5. Remove the new seal from its package and install
with the proper driver:
Service kit #217414
D-Input-Use driver #126917 only
D-Output-Use insert #128706 with driver #126917
R-Pinion-Use driver #126917 only
Due to the resiliency of the plastic driver, hammer rebound
may occur when the seal is seated. Keep clear of the ham-
mer rebound path!
6. 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.
7. Use a rubber mallet to drive the seal tool in until the
flange bottoms on the housing cover bore face. The
flange will locate the seal at the proper depth.
Guidelines for Reusing Yoke
Do not use the yoke if it has any damage on the seal surface
(nicks or scratches).
The surface of the yoke and the lips of the seal form a critical
interface which retains the axle's lubricant while sealing the
axle from outside contaminants. The condition of the yoke
hub's surface is a very important factor in determining seal
life.
Carefully inspect the seal surface area of the yoke hub for
signs of wear and damage. Do not reuse the yoke if there is
noticeable wear, such as heavy grooving, beyond normal pol-
ishing 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.
Do not use wear sleeves. Wear sleeves increase the yoke
hub surface diameter and cause premature seal wear and
repeat seal failure.
1 - Yoke puller tool
CAUTION
1
CAUTION
CAUTION
CAUTION
CAUTION
80
Seals
Service Kit 217414
New Welded D-Housing Cover
Lube Quantity Difference
0 (zero)
Standout of Output Shaft Yoke
Length increased by 6mm (.25), this should not have any
significant impact on inter-axle driveline length or drive line
angles.
Interchangeability of Parts
A cross reference chart of OLD axle housing to NEW axle
housings with welded on covers will be published in a sepa-
rate bulletin. The bolt on D-Housing covers will remain avail-
able for service.
126917
+
126917
128706
126917
Location
Tool
D-Input D-Output R-Pinion
81
IASS
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Inter-Axle Speed Sensor - Parts Exploded View
1Axle shaft
2Speed sensor
3Differential bearing adjuster
4Plated connector
5ABS Harness connector
1
3
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5
2
82
IASS
Disassemble Inter-Axle Speed Sensor
The design of the drive axle sensor allows replacement of sev-
eral individual components without disassembling the com-
plete sensor system. For example:
The differential bearing adjuster does not need to be
removed in order to replace any other component.
The sensor and rotor can be replaced without
removing or replacing the plated connector.
At every stage of drive axle service, try to isolate the problem
to specific components in order to avoid unnecessary disas-
sembly.
1. Disconnect two wires from sensor terminals.
2. Carefully inspect wires and connector. If connector
is intact and if there is no prior indication that con-
nectors and wires require replacement, do not
unscrew plated connector. The sensor may be
replaced without replacing connector and wire.
3. Remove four screws from face of sensor.
4. Remove sensor from differential bearing adjuster.
Overhaul Inter-Axle Speed Sensor
Note: If plated connector was damaged during axle disassem-
bly or if there is indication of a wiring fault, the connec-
tor assembly must be replaced.
There are two different connectors with two different lengths
of terminal wires. See Inter-Axle Speed Sensor Service Man-
ual AXSM-0034.
To install new connector:
1. Clean threaded hole in carrier and wire path to allow
proper seal for new connector. (Male threads on the
new connector have microencapsulated Loctite).
2. Insert connector and torque to 2028 lbs. ft. (2738
Nm).
3. Route wires to the sensor location.
If sensor assembly is to be replaced, install new sensor before
finishing installation of new connector. The final position of
the sensor terminals must be fixed before wires can be sealed
in place.
83
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Install Inter-Axle Speed Sensor
Except for routing the wires between the sensor and the
plated connector, procedures for installing both drive axle
speed sensors are identical. The instructions which follow
cover the long arm (plain half) side speed sensor and require
careful routing of the 6 inch long connector wires to prevent
pinching between the head and housing.
1. Lubricate interior rotor with axle lube or grease.
Check that the rotor turns freely by hand.
2. Mate the rotor and the sensor assembly.
3. Align the sensor/rotor assembly with the face of the
adjuster so that the terminals are nearest the carrier
mounting surface.
4. Orient the sensor to line up the holes in the sensor
with the threaded holes in the adjuster. Rotate the
sensor in either direction to get the fit that keeps the
terminals near the carrier mounting surface. This
final adjustment should only require a slight shift in
sensor position.
5. Apply Loctite to the four mounting screws. Install
the screws and tighten in a star pattern to maintain
sensor alignment. Torque to 2832 lbs. in. (3.23.6
Nm). (A preferred tightening approach is the turn
of bolt method: torque screws finger tight then
tighten additional 1/4 turn).
6. Attach the two round terminals to sensor. Either wire
can connect to either sensor blade. Make sure that
terminals are not bridged and that connectors are
not touching. Torque to 1015 lbs. in. (1.11.7
Nm).
7. Before sealing wires in place, check sensor continu-
ity by measuring the resistance between pins on the
outside of the connector. Resistance between con-
nector pins should be 1125 to 1375 ohms.
8. Check wire routing. Make sure wire is seated in the
cast-in channel and will not get pinched when the
head is reassembled to the housing. Seal wire in
place with RTV.
To replace sensor on the short arm (flanged half) side, repeat
previous steps. Since connector location is inside the mount-
ing surface, there is less concern for pinching of the shorter 4
inch connector wires. However, before final assembly, check
wire position and routing to make sure that it is not crimped
or pinched.
1Wires seated in channel
2Connector hole is on carrier mounting surface
36 inch long wires
4Sensor terminals positioned near carrier mounting
surface
1
2
3
4
1Installed position of axle shaft
2Sensor terminals positioned near connector hole
3Axle housing
44 inch long wires
5Connector hole is not on carrier mounting surface
6Axle carrier
2
1
3
4
5
6
84
Housing Breather
Install New Axle Housing Breather (Metal and Plastic)
Dana Truck Components has released a new axle housing
breather kit, part number 507162. This kit contains a fitting,
hose and clamp assembly, and instructions. This new
breather kit will replace the current breather (P/N 809560) and
snap cap (P/N 126980) on the models listed above for both
production and service. This newly designed breather has
improved resistance to water ingestion, clogging caused by
dirt, ice or snow buildup around the base of the breather. See
installation instructions below (all views from rear).
1. Install fitting in breather hole.
2. Tighten fitting finger tight.
3. Using a 3/4 wrench:
4. Metal only: rotate the fitting at least 1/2 turn until
nipple points to rear.
5. Plastic only: tighten until one thread is showing.
6. Insert hose onto fitting, long end down.
7. Push hose firmly against fitting. Rotate hose to point
down.
85
Wheel End Seal
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Wheel End Seal - Parts Exploded View
1Installation tool
2Seal
3Rear hub
1
2
3
86
Wheel End Seal
Remove and Overhaul Wheel End Seal
Never work under a vehicle supported by only a jack.
Always support vehicle with stands. Block the wheels and
make sure the vehicle will not roll before releasing the
brakes.
Wheel end seals can be easily damaged during handling.
Leave the seal in its package until installation to prevent
damage or contamination.
1. Remove outer bearing and wheel.
2. Remove oil seal.
3. Remove inner bearing.
4. Remove old wear sleeve (2-piece design only) with a
ball peen hammer and discard.
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 hard-
ening gasket cement and smoothing with emery cloth.
6. Clean hub cavity and bearing bores before reassem-
bly. 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.
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.
Install Wheel End Seal
1. Before installation, lubricate the following with the
same lubricant used in the axle sump.
Inner bearing
Wheel seal (follow the directions provided by
the seal supplier)
2. Place seal on installation tool.
3. Drive seal with installation tool onto hub.
WARNING
IMPORTANT
CAUTION
IMPORTANT
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Adjust Wheel Bearing
Do not mix spindle nuts and lock washers from different
systems. Mixing spindle nuts and lock washers can cause
wheel separation.
Note: The lock washer for a four-piece tang/dowel-type wheel
nut system is thinner than the lock washer for a three-
piece tang-type wheel nut system and is not designed to
bear against the inner nut.
1. Inspect the spindle and nut threads for corrosion
and clean thoroughly or replace as required.
Note: Proper assembly and adjustment is not possible if the
spindle or nut threads are corroded.
2. Inspect the tang-type washer (if used). Replace the
washer if the tangs are broken, cracked, or damaged.
3. Install the hub and drum on the spindle with care to
prevent damage or distortion to the wheel seal.
A wheel dolly is recommended during installation to make
sure that the wheel seal is not damaged by the weight of the
hub and drum. Never support the hub on the spindle with
just the inner bearing and seal. This can damage the seal
and cause premature failure.
4. Completely fill the hub cavity between the inner and
outer bearing races with the same lubricant used in
the axle sump.
5. Before installation, lubricate the outer bearing with
the same lubricant used in the axle sump.
Note: Lubricate only with clean axle lubricant of the same type
used in the axle sump. Do not pack the bearings with
grease before installation. Grease will prevent the proper
circulation of axle lubricant and may cause wheel seal
failure.
6. Install the outer bearing on the spindle.
7. Install the inner nut on the spindle. Tighten the inner
nut to 200 lbs. ft. (271 Nm) while rotating the wheel
hub.
Never use an impact wrench to adjust wheel bearings. A
torque wrench is required to assure that the nuts are prop-
erly tightened.
8. Back off the inner nut one full turn. Rotate the wheel
hub.
9. Retighten the inner nut to 50 lbs. ft. (68 Nm) while
rotating the wheel hub.
10. Back off the inner nut exactly 1/4 turn.
Note: This adjustment procedure allows the wheel to rotate
freely with 0.001"0.005" (0.025 mm0.127 mm) end-
play.
11. Install the correct lock washer for the wheel nut sys-
tem being used.
Three-piece Dowel-type Lock Washer System
a. Install the Dowel-type lock washer on the spindle.
Note: If the dowel pin and washer are not aligned, remove
washer, turn it over and reinstall. If required, loosen the
inner nut just enough for alignment.
Never tighten the inner nut for alignment. This can preload
the bearing and cause premature failure.
b. Install the outer nut on the spindle and tighten to 350
lbs. ft. (475 Nm).
c. Verify end-play, see page 81.
WARNING
CAUTION
CAUTION
1Inner nut (P/N 119882)
2Dowel pin
3Dowel-type lock washer (P/N 119883)
4Outer nut (P/N 119881)
1
2
3
4
IMPORTANT
88
Three-piece Tang-type Lock Washer System
a. Install the Tang-type lock washer on the spindle.
b. Install the outer nut on the spindle and tighten
to 250 lbs. ft. (339 Nm).
c. Verify end-play, see page 81.
d. After verifying end-play, secure wheel nuts by
bending one of the locking washer tangs over
the outer wheel nut and another tang over the
inner wheel nut.
e. Go to step 12.
Four-piece Tang/Dowel-type Lock Washer System
a. Install the Dowel-type lock washer on the spin-
dle.
Note: If the dowel pin and washer are not aligned, remove
washer, turn it over and reinstall. If required, loosen the
inner nut just enough for alignment.
b. Install the Tang-type lock washer on the spindle.
c. Install the outer nut on the spindle and tighten
to 250 lbs. ft. (339 Nm).
d. Verify end-play, see page 81.
e. After verifying end-play, secure the outer nut by
bending (180 apart) two opposing tangs of the
locking washer over the outer nut.
12. Install the following:
New gasket at axle shaft flange.
Axle shaft.
Axle flange nuts and tighten to specified torque.
13. Lubricate axle wheel ends.
2Tang-type lock washer (P/N 11245) .123 thick
1
2
3
IMPORTANT
2Dowel pin
3Dowel-type lock washer (P/N 119883)
4Tang-type lock washer (P/N 129132) .0478 thick
1
2
3
4
5
IMPORTANT
89
Wheel End
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Verify Wheel End-play Procedure
Verify that end-play meets specification using a dial indicator.
An indicator with 0.001" (0.03 mm) resolution is required.
Wheel end play is the free movement of the tire and wheel
assembly along the spindle axis.
Correct end-play is .001".005" (0.0250.125 mm).
1. Attach a dial indicator with its magnetic base to the
hub or brake drum as shown below:
2. Adjust the dial indicator so that its plunger or pointer
is against the end of the spindle with its line of action
approximately parallel to the axis of the spindle.
3. Grasp the wheel assembly at the 3 oclock and 9
oclock positions. Push the wheel assembly in and
out while oscillating it to seat the bearings. Read
bearing end-play as the total indicator movement.
If end-play is not within specification, readjustment is
required.
Adjust End-play with Tire and Wheel Assembly
Adjust End-play with Wheel Hub
Readjust Wheel End-play Procedure
Excessive End-playIf end-play is greater than .005"
(.127 mm), remove the outer nut and pull the lock washer
away from the inner nut, but not off the spindle. Tighten the
inner nut to the next alignment hole of the dowel-type washer
(if used). Reassemble the washer and re-torque the outer nut.
Verify end-play with a dial indicator.
Insufficient End-playIf end-play is not present, remove the
outer nut and pull the lock washer away from the inner nut,
but not off the spindle. Loosen the inner nut to the next
adjustment hole of the dowel-type washer (if used). Reassem-
ble the washer and re-torque the outer nut. Verify end-play
with a dial indicator.
Fine Tuning the End-playIf, after performing the readjust-
ment procedures, end-play is still not within the .001".005"
(.025.127 mm) range, disassemble and inspect the compo-
nents. If parts are found to be defective, replace the defective
parts, reassemble and repeat wheel bearing adjustment pro-
cedure. Verify end-play with a dial indicator.
CAUTION
With indicator mounted at bottom,
Push / Pull at sides of drum
90
Wheel End
Lubricate Wheel End
Before operating the axle, the wheel hub cavities and bear-
ings must be lubricated to prevent failure.
When wheel ends are serviced, follow Danas wheel end lubri-
cation 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.
Wheel Ends with an Oil Fill Hole
1. Rotate the wheel end hub until the oil fill hole is up.
2. Remove the oil fill plug.
3. Pour 1/2 pint of axle sump lubricant into each hub
through the wheel end fill hole.
4. Install oil fill plug and tighten to specified torque.
IMPORTANT
1Wheel end oil fill hole
2Proper lubricant level
3Lubricant flow from sump
3
1
2
Wheel End with Oil Fill Hole
Wheel End without Oil Fill Hole
91
Wheel End
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Wheel Ends Without Oil Fill Hole
1. With axle level and wheel ends assembled, add lubri-
cant through filler hole in axle housing cover until
fluid is level with the bottom of filler hole.
2. Raise the right side of the axle 6 inches or more.
Hold axle in this position for one minute.
3. Lower the right side.
4. Raise the left side of the axle 6 inches or more. Hold
axle in this position for one minute.
5. Lower the left side.
6. With axle on a level surface, add lubricant through
housing cover oil filler hole until fluid is level with the
bottom of the hole.
Note: Axles without wheel end fill holes will require approxi-
mately 2.5 additional pints of lubricant to bring the lube
level even with the bottom of fill hole.
1With axle on level surface, fill housing with oil to bottom of plug
2Temperature sensor mounting hole
3Oil will run into wheel end
4Oil will run into wheel end
5Tilt housing side to side (1 minute per side).
6Recheck oil level in axle.
1
3 4
2
92
Lubrication
General Lubrication Information
The ability of a drive axle to deliver quiet, trouble-free opera-
tion over a period of years is largely dependent upon the use
of good quality gear lubrication in the correct quantity. The
most satisfactory results can be obtained by following the
directions contained in this manual.
The following lubrication instructions represent the most cur-
rent recommendations from the Axle & Brake Division of Dana
Corporation.
Approved Lubricants
GeneralGear lubrications acceptable under military specifi-
cation (MILSPEC) MIL-L-2105D (Lubricating Oils, Gear, Mul-
tipurpose) are approved for use in Dana Drive Axles. The
MIL-L-2105D specification defines performance and viscosity
requirements for multigrade oils. It supersedes both
MIL-L-2105B, MIL-L-2105C and cold weather specification
MIL-L-10324A. This specification applies to both petroleum-
based and synthetic based gear lubricants if they appear on
the most current Qualified Products List (QPL-2105) for
MIL-L-2105D.
Note: The use of separate oil additives and/or friction modifi-
ers are not approved in Dana Drive Axles.
Synthetic basedSynthetic-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 lubri-
cants include extended change intervals, improved fuel econ-
omy, better extreme temperature operation, reduced wear and
cleaner component appearance. The family of Dana
Roadranger gear lubricants represents a premium quality
synthetic lube which fully meets or exceeds the requirements
of MIL-L-2105D. These products, available in both 75W-90
and 80/W-140, have demonstrated superior performance in
comparison to others qualified under the MILSPEC, as dem-
onstrated by extensive laboratory and field testing. For a com-
plete list of Roadranger approved synthetic lubricants
contact your local Dana representative. See back cover of this
manual for appropriate phone number.
Makeup LubeMaximum amount of non-synthetic makeup
lube is 10%.
Recommendations for Viscosity/Ambient
Temperature
The following chart lists the various SAE Grades covered by
MIL-L-2105D and the associated ambient temperature range
from each. Those SAE grades shown with an asterisk (*) are
available in the Roadranger family of synthetic gear lubri-
cants.
The lowest ambient temperatures covered by this chart are
-40F and -40C. Lubrication recommendations for those
applications which consistently operate below this tempera-
ture range, must be obtained through Dana Corporation by
contacting your local Dana representative.
* Available in the Roadranger family of synthetic gear lubri-
cants.
Grade Ambient Temperature Range
75W -40F to -15F (-40C to -26C)
75W-80 -40F to 80F (-40C to 21C)
75W-90* -40F to 100F (-40C to 38C)
75W-140 -40F and above (-40C and above)
80W-90 -15F to 100F (-26C to 38C)
80W-140* -15F and above (-26C and above)
85W-140 10F and above (-12C and above)
93
Lubrication
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Lube Change Intervals
This product combines the latest manufacturing and part
washing technology. When filled with an Dana approved
synthetic lubricant at the factory, the initial drain is not
required.
Change the lubricant within the first 5,000 miles of opera-
tion when not using a Roadranger approved synthetic lubri-
cant in either a new axle or after a carrier head
replacement. Base subsequent lubricant changes on a com-
bination of the following chart and user assessment of the
application and operating environment.
Severe Service Lubrication Change IntervalsSevere ser-
vice applications are those where the vehicle consistently
operates at or near its maximum GCW or GVW ratings, dusty
or wet environments, or consistent operation on grades
greater than 8%. For these applications, the ON/OFF HIGH-
WAY portion of the chart should be used. Typical applications
are construction, logging, mining and refuse removal.
Note: Clean metallic particles from the magnetic filler plug
and drain plugs. Clean or replace the breather yearly to
avoid lube contamination due to water ingestion.
* Axles using LMS wheel end system
** Axles using adjustable wheel bearing system
Synthetic or
Mineral
Lubricant SAE Change Interval for Line Haul Change Interval for Voca-
tional
Synthetic* SHAES-256 SAE 75W-90 500,000 miles [800,000 Km] or
5 years
120,000 miles (193,000 Km)
or 1year
Synthetic** SHAES-256 SAE 75W-90,
75W-140
250,000 miles (400,000 Km) or
3 years
60,000 miles [96,500 Km] or 1
year
Mineral
Base
MIL-L-2105E/J02360,
API GL-5 Gear Oil,
MIL-PRF-2105E
75W, 75W-90,
75W-140, 80W-
90, 85W-140
120,000 miles [193,000 Km] or
1 year
60,000 miles [96,500 Km] or
1 year
94
Lubrication
Change Lube
Drain
Drain when the lube is at normal operating temperature
(150200F). It will run freely and minimize the time neces-
sary to fully drain the axle, this insures the axle is flushed.
Unscrew the magnetic drain plug on the underside of the axle
housing and allow the lube to drain into a suitable container.
Note: Dispose of all used lubricants properly by following dis-
posal 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 completely. Inspect breather for clogging or cor-
rosion. Clean or replace as necessary.
Fill
Front Axle
a. With vehicle on level ground, remove the filler hole
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 pages 8183.
Always use the filler hole as the final reference. If lube is level
with the bottom of the hole, the axle is properly filled.
Note: Lube fill capacities (see chart) are basic guidelines and
will vary based on the angle the axle is installed in a
particular chassis. Torque fill plug to 4060 lbs. ft.
(5482 Nm).
TIP: The axle can be filled through the axle housing breather
hole. Fill until lube level is even with the bottom of filler hole in
axle housing rear cover.
Correct lube level at bottom of filler hole.
1 - With axle on level surface, fill housing with oil to bottom
of plug.
2 - Temperature sensor mounting hole.
95
Lubrication
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Standpipes
Drive axles are lubricated with oil drawn from a large sump
integral to the assembly. Most axle designs attempt to posi-
tion vital components such as pinion bearings in close prox-
imity to this sump, keeping them bathed in a generous supply
of oil at all times.
When drive axles are installed at severe angles in vehicle
chassis, the position of these components is changed relative
to the oil sump. The same effect is present when the vehicle
travels up a steep grade. Oil in the sump remains level while
the axle itself tilts up or down. This makes it possible for bear-
ings and gears located well forward in the assembly to
"starve" for lubrication even though the axle is filled to the
base of the fill plug hole as recommended by the manufac-
turer.
Axles should be modified with standpipes to raise lube levels
whenever chassis installation angles exceed 10 and when the
vehicle must negotiate continuous or lengthy grades on a rou-
tine basis.
The chart gives standpipe recommendations for vehicles
operating in consistently mountainous areas.
*Does not allow for standpipe.
Capacities do not include wheel equipment requirements. An
additional 12 pints is required in each wheel hub.
*Pinion pointing upward
*Pinion pointing upward
Axle Installation
Angle
Axle Location Quantity
(pints)
12 Rear 19*
10 Rear 21*
8 Rear 22.5*
6 Forward 24.5
6 Rear 25
4 Forward 27
4 Rear 25
2 Forward 29
2 Rear 26
0 Forward 31
0 Rear 28
Tandem Forward Axles
Installation
Angle*
5-10%
Grade
10-15%
Grade
15-20%
Grade
0
3 2.00"
5 1.00" 2.25"
7 1.25" 2.50"
10 1.50" 1.75" 2.75"
13 1.75" 2.00" 3.00"
15 2.50" 2.50" 3.25"
Tandem Rear Axles
Installation
Angle*
5-10%
Grade
10-15%
Grade
15-20%
Grade
0
3 1.00"
5 1.00" 1.75"
7 1.75" 2.00"
10 2.00" 2.25"
13 1.00" 2.25" 2.75"
15 2.00" 2.50" 3.25"
96
Lubrication
Horizontal Mounting
12 Installation
12 Installation with Standpipe
Note: Grades must be continuous or lengthy in nature. Moni-
tor oil temperatures before installing standpipes. Axles
should operate at approximately 100F (38C) over
ambient temperature and not exceed 240F (116C).
Final Check
Prior to putting vehicle back into service, run the vehicle to
bring axle lube up to temperature. Check filler and drain plugs
and axle joint for leakage. Re-tighten to specifications as nec-
essary.
1Oil filler hole
2Lost oil capacity
3Additional oil capacity
1
1
2
3
1
97
Towing
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Proper Vehicle Towing
Without Wheel Differential Lock
Lift the drive wheels completely off of the ground or damage
will occur.
Do not lift the front wheels (non-drive wheels). This alters
the oils 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 over-
heat resulting in axle damage or failure.
If this is impossible to lift the drive wheels, remove all axle
shafts to prevent gear rotation and cap the wheel hubs to pre-
vent loss of lubricant and a possible road hazard. See the fol-
lowing section Proper Vehicle Towing with Wheel Differential
Lock for removal procedure.
With Wheel Differential Lock
Follow this procedure to remove all axle shafts preventing
gear rotation with the drive wheels and possible lubrication
damage.
1. Engage the wheel differential lock, indicator light is
on (move vehicle to verify engagement).
2. Shift transmission into neutral.
3. With vehicle stationary, release the air pressure on
the wheel differential lock shift system and apply the
parking brake.
4. Disconnect the air supply and fitting at the shift cyl-
inder.
5. Install the shipping capscrew 128642 (.250 X 18 X
1.5") NPSM screw. GM models require part number
128274 (M12 X 1.5 X 38mm) screw. Tighten cap-
screw to manually engage the wheel differential lock
until the indicator light is on and the differential lock
is completely engaged.
6. Remove the axle shafts.
7. Install temporary cover on hub to prevent contami-
nation entering and also to prevent the loss of lubri-
cant.
WARNING
98
Theory of Operation
Power Divider Operation (Power Flow and Torque Distribution)
In operation, the power divider accepts torque from the vehi-
cle driveline and distributes it equally to the two axles.
This assembly is of the two-gear design consisting of an input
shaft, inter-axle differential, output shaft and two constant-
mesh helical gears.

With Lockout Engaged
(Inter-Axle Differential is Operating)
The inter-axle differential compensates for minor variations in
speed between the two axles, the same way the wheel differ-
ential works between the two wheels of a single drive axle.
This unit also acts as a central point in distribution of torque
to the two axles.
The power divider also includes a driver-controlled,
air-operated lockout. When lockout is engaged, it mechani-
cally prevents inter-axle differentiation for better performance
under poor traction conditions.
1 Input torque
2 Lockout disengaged
3 Forward axle torque is transmitted from the helical side
gear through the pinion helical gear, drive pinion, ring gear,
wheel differential and axle shafts.
4 Rear axle torque is transmitted from the output shaft side
gear through the output shaft, inter-axle driveline, drive pin-
ion, ring gear, wheel differential and axle shafts.
5 Input torque (power flow) from the vehicle driveline is
transmitted to the input shaft and the inter-axle differential
spider. The differential distributes torque equally to both axles.
1
2
3
5
4
99
Theory of Operation
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With Lockout Engaged
(Inter-Axle Differential is Not Operating)
Lockout should only be engaged when both axles are rotating
at the same speed. Operation should be limited to low-traction
situations and should be disengaged when normal traction
returns. Failure to do so will result in poor handling and dam-
age to the axle components.
Note: Varied road surface conditions can result in unequal
torque distribution between the two axle assemblies.
Prolonged operation with the lockout engaged can damage
axle and driveline components.
CAUTION
1 Input torque
2 Lockout engaged
3 Forward axle torque is transmitted from the helical side
gear through the pinion helical gear, drive pinion, ring gear,
wheel differential and axle shafts.
4 Rear axle torque is transmitted from the output shaft side
gear through the output shaft, inter-axle driveline, drive pin-
ion, ring gear, wheel differential and axle shafts.
5 Input torque (power flow) from the vehicle driveline is
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.
1
2
3
5
4
100
Theory of Operation
Operate Wheel Differential Assembly
The Dana wheel differential lock is driver-controlled and oper-
ated by a carrier mounted air-actuated shift unit. In operation,
it positively locks the wheel differential to provide improved
traction under adverse road conditions.
Control Systems for Differential Lock
Two systems may be used to control the differential lock oper-
ation.
Transmission Low-Range Interlock Control System
The wheel differential is locked manually with the transmis-
sion in Low-Range. It is unlocked by the driver or unlocked
when the transmission is shifted out of Low-Range.
Note: The interlock system is preferred for vehicles equipped
with an air-shifted, Low-Range transmission. It is
designed to ensure the differential lock is not left
engaged (and to prevent accidental engagement) when
transmission is in high range.
Direct Driver-controlled System
Direct Driver-controlled System
The driver manually locks and unlocks the wheel differential,
using a cab-mounted electric switch (or air valve). The follow-
ing description assumes the system includes a cab-mounted
electric switch and a solenoid valve as shown in the illustra-
tion. An air valve may be substituted for these components.
Operation is as follows:
1. With control switch in the unlock position, the
wheel differential functions normally.
2. When the control switch is placed in the lock posi-
tion, the air supply solenoid valve opens and air
pressure activates the shift cylinder. The shift fork is
moved to engage the curvic clutches, which, in turn,
lock the wheel differential.
3. When the control switch is placed in the unlock
position, air pressure supply to the shift cylinder is
shut off and air pressure is released from the cylin-
der. A compression spring moves the shift fork to
disengage the curvic clutch and unlock the wheel dif-
ferential.
1 Cab-mounted control valve (plunger invalve open)
2 Dry air supply tank 80120 PSI
3 Preferably equal in length
4 Power supply
5 Fuse or circuit breaker
6 Indicator light or audible signal
7 Wheel differential lock indicator switch (part of axle
assembly)
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)
10 Wheel differential lock indicator switch (part of axle
assembly)
11 Indicator light of audible signal
12 Fuse or circuit breaker
13 Power supply
14 66468 Quick release valve (optional) located on frame
rail and within 10 feet of tubing from control valve
2
1
14
9
10
11
6
12
5
13 4
8
7
3
101
Theory of Operation
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The Dana Wheel Differential Lock is an optional feature for
Dana Axles. In operation, it positively locks the wheel differen-
tial, to provide improved traction under adverse road condi-
tions.
The differential lock is driver-controlled through an electric
switch or air valve mounted in the cab. The locking mecha-
nism is air-operated to engage a mechanical clutch and lock
the wheel differential. It is spring-operated to disengage the
lock and permit the wheel differential to function normally.
The wheel differential lock consists of three major assemblies.
Shift Cylinder Assembly: Operates a shift fork and
push rod assembly.
Shift Fork and Push Rod Assembly: Engages and
disengages the differential lock curvic clutch assem-
bly.
Curvic Clutch Assembly: Consists of a sliding clutch
splined to a axle shaft and a fixed clutch which is
splined to the differential case hub.
The differential lock also includes a selector switch (electric)
which senses clutch engagement and sends an electrical sig-
nal to a cab mounted indicator light (or an audible signal
device).
1 Curvic clutch assembly
1aSliding clutch
1bFixed clutch
2 Shift fork and push rod assembly
2aShift fork
2bPushrod
3 Shift cylinder assembly
3aPiston driver
3bSelector switch
1
1b
1a
2
2a
2b
3
3a
3b
102
Theory of Operation
Differential Lock Engaged
Air pressure applied to the shift cylinder moves the piston,
push rod, shift fork and the sliding curvic clutch engages the
fixed curvic clutch.
The sliding clutch is splined to the axle shaft. The fixed clutch
is splined to the differential case hub. Engaging the two
clutches locks the wheel differential thus preventing wheel dif-
ferential action.
Differential Lock Disengaged
When air pressure at the shift cylinder is released, a compres-
sion spring (mounted on the push rod) moves the push rod,
shift fork and sliding clutch as an assembly. The sliding clutch
moves out of engagement with the fixed clutch. The wheel dif-
ferential is unlocked and operates normally.
Differential Lock Engagement Indicator
Differential lock engagement is detected by a switch (electric)
mounted on the differential carrier. An actuator, mounted in
the piston cover, operates the switch.
When the shift fork moves to engage the differential lock, the
push rod actuator moves away from the switch, allows the
switch to close and send an electrical signal to turn on a cab-
mounted indicator light (or an audible signal).
When the shift fork moves to disengage the differential lock,
the compression spring also moves the push rod actuator to
contact the switch. The switch is opened and turns off the
cab-mounted indicator light (or the audible signal).
Differential Lock Engaged
1 Spring is compressed
2 Shift fork
3 Push rod
4 Selector switch
5 Piston
6 Shift cylinder
7 Air pressure applied engages clutches
8 Fixed clutch splined to differential case
9 Sliding clutch splined to axle shaft
1
2 3
4
5
6
7
8
9
Differential Lock Disengaged
1 Spring is decompressed
2 Shift fork
3 Push rod
4 Selector switch
5 Piston
6 Shift cylinder
7 Air pressure applied disengages clutches
8 Fixed clutch splined to differential case
9 Sliding clutch splined to axle shaft
1
2
3
4
5
6
7
8 9
103
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Power Divider - Parts Exploded View
1 Output shaft nut
2 Output yoke
3 Output seal
4 Output shaft bearing snap ring
5 Outer bearing cup
8 Inner bearing cup
9 Output shaft
10 Seal manifold assembly
11 Sump screen
12 Seal manifold feed tube
13 Output side gear bearing cup
14 Output side gear bearing cone
15 Pump locking Pin
16 Output side gear
17 Pump
17A ---Old style pump
17BOutput side gear bearing cup
18Snapping ring
19 Inter-axle differnential
20 Helical side gear
21 Sliding clutch
22 ---Push rod spring
23Shift fork assembly
24 Input shaft
25 Input shaft oil retainer
26 Input shaft bearing cone
27 Power divider cover (integral)
28 Lube trough
29 Capscrew
30 ---Shift fork
31 Power divider cover (Old style)
32 Push rod
33 Input bearing cup
34 Input cage shim
35 Input cage V-ring
36 Input cage
37 Capscrew
38 Oil seal
39 Input yoke
40 Input nut
1 8
1 9
1 0
1 4
1 3
1 2
1 1
1 5
3 0
3 3 3 5
3 1
3 2
3 4
3 6
2 9
1 6
7 9 1 3 5 2 4 6 8
1 7
2 2
2 3
2 4 2 1 2 6
2 7
2 8
2 5
2 0
l7A l78
37
38
39
40
104
Front Drive Axle - Parts Exploded View
1 Flange half bearing adjuster
2 Flange half bearing cup
3 Flange half bearing cone
4 Flange half carrier cap
5 Flange half differential case
6 Nut
7 Ring gear
8 Side gear thrust washer
9 Side gear
10 Wheel differential spider
11 Side pinion
12 Side pinion thrust washer
13 Carrier cap bolt
14 Lock washer
15 Plain half carrier cap
16 Side gear
18 Plain half differential case
19 Plain half bearing cone
20 Plain half bearing cup
21 Plain half bearing adjuster
22 D-head carrier with pump
23 Core plugs
24 Pump filter
25 Core plugs
26 D-head carrier or front carrier
with a pump
27 1-inch core plug
28 Dowel
30 O-ring
31 Dowel
with thrust bolt
33 Thrust bolt jam nut
34 Thrust bolt
35 Pinion pilot bearing
36 Pinion
37 Inner pinion bearing cone
38 Pinion bearing spacer
39 Inner pinion bearing cup
40 Pinion cage shim
41 Pinion cage
42 Outer pinion bearing cup
43 Outer pinion bearing cone
44 Helical gear
45 Pinion roll pin
46 Pinion nut
1 2 3
7
8 9 10
11
32
12
5
4
13
14
15
24
23
25
26
22
27
28
16
17
18
19
20 21
29
30
31
33
34
35 36
37 38 39
40
41
42 43
44
45
46
6
105
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Rear Drive Axle - Parts Exploded View
1 Ring gear
2 Carrier cap bolt
3 Flange half carrier cap
4 Flange half differential case
5 Flange half bearing cone
6 Flange half bearing cup
7 Flange half bearing adjuster
8 Plain half bearing adjuster
9 Plain half bearing cup
10 Plain half bearing cone
11 Plain half differential case
13 Plain half carrier cap
14 Side gear
15 Side pinion
16 Side pinion thrust washer
17 Wheel differential spider
18 Side gear
20 R-head carrier or rear carrier
21 Thrust bolt
22 Thrust bolt jam nut
23 Pinion pilot bearing
24 Pinion
25 Inner pinion bearing cone
26 Pinion bearing spacer
27 Inner pinion bearing cup
28 Pinion cage shim
29 Pinion cage
30 Outer pinion bearing cup
31 Outer pinion bearing cone
32 Pinion seal
33 Pinion yoke
34 Pinion nut
35 R-head carrier with thrust bolt
2
18
21
22
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
13
19
4
12
16
8
1
10
11
9
7 6
4
5
3
17
14
15
20
106
Inter-Axle Speed Sensor - Parts Exploded View
Wheel Differential Lock Assembly -
Parts Exploded View
1 Sensor assembly
2 Fastener
3 Rotor assembly
4 Differential bearing adjuster
5 Sensor connector
4
5
3
2
1
1 Fixed curvic clutch gear
2 Snap ring
3 Curvic clutch gear
4 Spring pin
5 Shift fork
6 Compression spring
7 Push rod
8 Piston driver
9 Set screw
10 Piston
11 O-ring
12 Switch
13 Plastic washer
14 Piston cover
15 Capscrew-
flange head
16 Capscrew-
manual engagement
17 Gasket
15
16
13
12
11
10
9
8
7
6
5
4
3
2
1
14
17
107
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Housing and Output Shaft Assembly - Parts Exploded View
1 Output shaft nut
2 Output yoke
3 Output seal
4 Snap ring
5 Outer bearing cup
8 Inner bearing cup
9 Output shaft
10 Rear cover
11 Rear cover capscrew
12 Fill plug
13 Rear cover nut
14 Lock washer
15 Stud
16 Dowel
17 Jam nut
18 Locking ring
19 Spindle nut
20 Axle housing
21 Breather
22 Breather hose
23 Carriage capscrew
24 Lock washer
25 Nut
26 Lock washer
27 Stud
28 Drain plug
29 Axle shaft
20
21
22
24
23
27
26
25
28
29
29
17
18
19
Welded Rear Cover
Bolt on Rear Cover
17
18
19
12
10
4
5
6
7
8
9
1
2
3
11
13
14
15
16
108
Torque Chart
Fastener Torque Specifications
Power Divider Class Size Tool lbs. ft. Nm
Diff. lock cover to carrier 8.8 M10 X 1.5 13 mm 28-35 38-47
Diff. lock switch 8.8 M12 X 1.5 10-12 14-16
IAD lock cover capscrew 8.8 M10 X 1.5 13 mm 28-35 38-47
IAD lock cover capscrews 2pcs. M10 X 1.5 17 mm 28-35 38-47
Input brg. cage capscrew 10.9 M14 X 2 21 mm 114-140 155-190
Input shaft nut M42 X 1.5 55 mm 840-1020 1140-1383
Power divider cover capscrew 10.9 M14 X 2 21 mm 114-140 155-190
Power divider pipe plug NPTF .750-14 1/2 Drive 40-60 51-81
Diff and Gearing Class Size Tool lbs. ft. Nm
Front pinion helical nut Grade 8 M42 X 1.5 65 mm 840-1020* 1140-1383*
Output shaft nut M39 X 1.5 55 mm 680-832 920-1130
Rear pinion nut 8.8 M36 X 1.5 55 mm 575-703 780-953
Ring gear nut with bolt 126219** 12 M16 X 1.5 24 mm 215-255 292-346
Ring gear nut with bolt 129686** 11.9 M16 X 1.5 24 mm 180-220 244-298
Wheel diff. case capscrew 10.9 M14 X 2 16 mm 12 pt 114-140 155-190
Carrier Class Size Tool lbs. ft. Nm
ABS sensor assembly fasteners #1024 X 7/8 1/8 Allen Finger tight +1
turn
Carrier to housing capscrew 12.9 M16 X 2 24 mm 230-270 312-366
Carrier to housing nut 12 M16 X 1.5 24 mm 199-244 270-331
Diff. brg. capscrew 12.9 M20 X 2.5 30 mm 350-428 475-580
Filter assembly pump model NPTF .750-14 1 1/16 40-60 54-81
Lube pump attachment screw 8.8 M8 X 1.25 6 mm Allen 17-21 23-28
Thrust bolt jam nut 4 M24 X 2 36 mm 148-181 201-245
Housing Class Size Tool lbs. ft. Nm
Axle cover capscrew 12.9 M12 X 1.75 18 mm 85-103 115-140
.500-20 11/16 55-71 75-96
Axle shaft to wheel hub nuts .625-18 15/16 170-190 230-258
.750-16 1 1/8 285-345 386-468
Breather - old design NPSF .375-18 .750 Hex 20-26 27-35
Breather fitting - u-tube design .375-18 .750 Hex 20-26 27-35
Housing cover nut 12 M12 X 1.25 18 mm 85-103 115-140
Magnetic plug (fill)*** NPSF 1 X 11.5 13/16 40-60 54-81
109
Torque Chart
T
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C
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Note: Fasteners using self-locking thread patches may be reused if not damaged, but should be secured by a few drops of
Loctite #277 on threaded surface. Reused fasteners should be wiped clean of excess oil, but do not require special clean-
ing.
*** In June 1997, lube fill plug size was changed. See bulletin ABIB-9709.
** Ring gear bolt design changed 1/2/97. See bulletin ABIB-9701.
* Torque nut to 840 lbs. ft. (1140 Nm), then continue tightening to align nut slot with nearest hole in pinion shank.
Correct torque values are extremely important to assure long Eaton life and dependable performance. Under-tightening of parts
is just as harmful as over-tightening.
Exact compliance with recommended torque values will assure the best results.
The data includes class and torque tightening values.
Oil drain plug NPTF .750-14 1/2 Drive 40-60 54-81
Temperature sender/plug 40-60 54-81
Power Divider Class Size Tool lbs. ft. Nm
For specing or service assistance, call 1-800-826-HELP (4357) 24 hours a day, 7 days a week (Mexico:
001-800-826-4357), for more time on the road. Or visit our web site at www.roadranger.com.
Roadranger: Eaton, Dana and other trusted partners providing the best
products and services in the industry, ensuring more time on the road.
Dana Commercial Vehicle Products Group P.O. Box 4097 Kalamazoo, MI 49003 U.S.A. www.roadranger.com 2008 Dana Limited All rights reserved.
Printed in USA
Copyright Eaton Corporation and
Dana Limited, 2008. Eaton and Dana

hereby grant their customers, vendors, or
distributors permission to freely copy,
reproduce and/or distribute this document
in printed format. It may be copied only in its
entirety without any changes or modifications.
THIS INFORMATION IS NOT INTENDED
FOR SALE OR RESALE, AND THIS NOTICE
MUST REMAIN ON ALL COPIES.

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Tandem Drive Axles

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