Drive Axle Disassembly And Assembly
SPECIAL TOOLS
The following is a detailed list of all special service tools required to service a Model 60 Front or Rear axle. All tool numbers are Spicer numbers.
- 1 Installer - Rear Pinion Bearing Cup
- 2 *Scooter Gauge
- 3 *Arbor
- 4 *Pinion Height Block
- 5 *Arbor Discs
- 6 *Master Bearing Differential
- 7 *Master Pinion Block
- 8 Installer - Front Spindle Needle Bearing
- 9 Dial Indicator Set
- 10 Puller - Slide Hammer
- 11 Installer - Front Spindle Bushing
- 12 Installer - King Pin Bearing Cup (Heavy Duty)
- 13 Remover - Front Pinion Bearing Cup
- 14 Remover - Rear Pinion Bearing Cup
- 15 Installer - Pinion Oil Seal (National)
- 16 Installer - Pinion Oil Seal (Chicago Rawhide)
- 17 Spreader - Differential Carrier
- 18 Remover & Installer - Tapered King Pin Upper Ball Joint Pivot Stud
- 19 Installer - Steering Knuckle Lower Bearing Seal
- 20 Remover - Universal Joint Companion Flange or Yoke
- 21 Puller Press
- 22 Extension
- 23 Reducer Ring
- 24 Reducer Ring
- 25 Button
- 26 Adapter Set - Differential Bearing Cones
- 27 Adapter Set - Rear Pinion Bearing Cone
- 28 Installer - Rear Pinion Bearing Cone
- 29 Wrench - Universal Joint Flange or Yoke
- 30 Installer - Universal Joint Flange or Yoke
- 31 Installer - Differential Side Bearings
- 32 Torque Wrench - 50 Inch Pound
- 33 Torque Wrench - 100 Foot Pound
- 34 Torque Wrench - 300 Foot Pound
- 35 Torque Wrench - 1000 Foot Pound
- 36 Handle - Universal
- 37 Cup Remover - (Hub & Drum)
- 38 Wheel Bearing Wrench
- 39 Cup Remover
- 40 Installer - Cup (Outer - Hub & Rotor)
- 41 Installer - Cup (Inner - Hub & Rotor)
- 42 Seal Installer
- 2 *Scooter Gauge
*Pinion Setting Gauge and Master Differential Bearing Kit D-116-60.
| NOTICE |
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Torque wrenches D-193, C-524-A, C-4053, and DD-994 are optional and can be purchased separately. These torque wrenches are not included in the DW-60 Axle Tool Kit. |
Axle Identification
- 1. All axles are identified with a manufacturing date and the complete part number stamped in the right hand tube. Also, each axle contains a gear ratio tag, and if the axle is equipped with a limited slip differential, it will contain a tag specifying the use of limited slip lubricant.
- 2. In this figure, the axle is identified with 3.17 mm (1/8") high numbers stamped in the tube. For example: The manufacturing date or build date of the axle is interpreted as follows. The first number is the month, second number is the day of the month, the third number is the year, the letter is the shift, and the last number is the line that built the axle. The next number is the part (bill of material) number. The six digits reading from left to right is the basic number for identifying the particular axle assembly. The seventh digit following the dash will identify ratio, differential and end yoke options used in the assembly.
Show/hide tableNOTICE In the event there are two build dates, the latter will be the date in which the brake components were assembled. The number stamped next to the manufacturing date is the complete axle assembly part number.
It is recommended that when referring to the axle, obtain the complete part number and build date. To do this, it may be necessary to wipe or scrape off the dirt, etc., from the tube.
Show/hide tableNOTICE On front driving axles, the above numbers can be either on the long or short tube.
- 3. The gear ratio tag is located on the left side of the cover plate or at the bottom left hand side of the cover plate, and is held in place with one or two cover plate screws. This tag gives the tooth combination of the ring and pinion, and also the total gear ratio.
- 2. In this figure, the axle is identified with 3.17 mm (1/8") high numbers stamped in the tube. For example: The manufacturing date or build date of the axle is interpreted as follows. The first number is the month, second number is the day of the month, the third number is the year, the letter is the shift, and the last number is the line that built the axle. The next number is the part (bill of material) number. The six digits reading from left to right is the basic number for identifying the particular axle assembly. The seventh digit following the dash will identify ratio, differential and end yoke options used in the assembly.
Disassembly Of Wheel Ends - Hub And Rotor
| NOTICE |
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If it is necessary to replace brake components such as disc brake pads, backing plate, etc., refer to Vehicle Service Manual. |
1. Remove wheel from Hub and Rotor Assembly.
2. Remove wheel bearing lock nut, lock ring and the wheel bearing adjusting nut. Tool: Wheel Bearing Wrench.
3. Remove hub and rotor assembly, spring retainer and outer wheel bearing will slide out as rotor is removed.
4. Remove grease seal and inner bearing cone. Discard seal and replace with new one at time of assembly. Tool: Slide Hammer.
5. Remove inner and outer wheel bearing cups. Tools: Bearing Cup Remover (outer), Bearing Cup Remover (inner).
6. Assemble outer wheel bearing cup. Tool: Installer, Handle.
7. Assemble inner wheel bearing cup. Tools: Installer, Handle.
8. Distribute a sufficient amount of grease inside the hub between the bearing cups. Pack inner bearing cone full with the specified grease. Wipe the excess grease around the rollers. Assemble inner wheel bearing cone into cup.
9. Assemble new grease seal. Apply a small amount of grease around lip of seal. Tool: Seal Installer, Handle.
10. Assemble hub and rotor onto spindle. Pack outer wheel bearing with specified grease, wipe excess grease around the rollers. Assemble onto spindle.
11. To adjust wheel bearings, torque inner adjusting nut to 68 N m (50 lb. ft.) to seat bearings. Rotate hub, then back off inner adjusting nut one-fourth turn maximum. Assemble lock washer, turn nut to nearest hole in washer. Assemble outer locknut and torque to 68 N m (50 lb. ft.). Final, bearings adjustment to be 03.-.25 mm (001.-010) total end play. Tools: Wheel Bearing Wrench, Torque Wrench.
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For servicing spindle and knuckle, remove hub and drum as described in figures 5 through 7. |
12. Remove spindle. If necessary, tap lightly with a rawhide hammer to free it from the knuckle. Check bronze spacer located between axle shaft joint assembly and bearing. If wear is evident, replace with a new one.
13. Place spindle in vise. Do not locate on bearing diameters. Remove needle bearing. Tool: Slide Hammer.
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Be sure that vise jaws are equipped with brass protectors or similar type to protect the machined surfaces of any parts that are to be placed in the vise. |
14. Remove axle shaft joint assemble.
15. Remove cotter key and loosen tie rod nut. Tap on nut with rawhide hammer to break the stud loose from the steering arm. Remove nut and disconnect tie rod.
16. Remove four nuts on steering arm. Remove nuts alternately as compression spring will force steering arm up.
17. Remove steering arm, spacer, and gasket. Discard gasket, replace with new one at time of assembly.
18. Remove four cap screws on bearing cap. Remove bearing cap.
19. Remove king pin tapered bushing, spring retainer, and knuckle from yoke. Remove king pin seal.
20. Remove king pin as shown. Tool: King Pin Installer and Remover.
21. Remove king pin bearing cup, cone, grease retainer, and seal all at the same time. Assemble and use tools exactly as shown below. Discard seal and replace with new one at time of assembly. If grease retainer is damaged, replace with new one at time of assembly. Tools: Installer, Handle.
22. Assemble new grease retainer and king pin bearing cup. Tools: Installer, Handle.
23. Fill the area in grease retainer with specified grease, grease bearing cone and install. Install new king pin bearing oil seal. Tools: Installer, Handle.
24. Install king pin. Torque king pin to 678- 813 N m (500-600 lb. ft.). Tools: King Pin Installer and Remover, Torque Wrench.
25. Assemble felt seal to king pin, assemble knuckle assemble tapered bushing over king pin.
26. Assemble bearing cap with four cap screws. Tighten cap screws alternately and evenly. Torque cap screws to 95-122 N m (70-90 lb. ft.). Tool: Torque Wrench.
27. Assemble spring retainer and spacer on king pin bushing. Assemble steering arm, with new gasket, over four studs. Tighten nut alternately and evenly. Torque nuts 95-122 N m (70- 90 lb. ft.).
28. Assemble new needle bearing into spindle. Tools: Installer, Handle.
29. Assemble grease seal into spindle. The lip of the seal is to be directed away from the spindle.
30. Some front axles are equipped with a "V" seal, which is assembled to the axle shaft stone shield as shown. If seal is worn, remove and replace with a new one.
31. Assemble new seal as shown. Lip of the seal is to be directed towards the spindle.
32. Pack the area around the thrust face area of the shaft and seal full of grease. Also, fill the seal area of the spindle with grease.
33. Assemble axle shaft joint assemble into housing.
34. Assemble new bronze spacer and spindle.
Carrier Disassemble
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If it becomes necessary to disassemble any parts inside of the carrier, it is suggested that the entire axle be removed from the vehicle and held tight in a stand or rack. |
1. Remove drain plug and drain lubricant. If there is no drain plug in the carrier, the lube will drain out as the cover plate is removed.
2. Remove cover plate screws, cover plate, and cover plate gasket. Discard old gasket. Tip carrier to allow lube to drain completely. Also during this time clean the cover face of the carrier, making sure it is free from any nicks and any particles left by the old gasket. Do not use cleaning solvents of any type. Use of cleaning solvents may prevent the "RTV" sealer from adhering to the cover plate and carrier, resulting in leaks of axle lubricant.
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Before removing differential case and ring gear, make sure the axle shafts are pulled out far enough for clearance to remove differential. Refer to section of manual covering the type of axle assemble being serviced for procedures on removing the axle shafts. |
3. Remove bearing caps. Note: Mating letters stamped on caps and carrier. This is important at time of assembly as they are to be assembled exactly as removed. Letters or numbers are in vertical and horizontal position.
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After removing axle shafts from the rear axle, semi-float shaft riding bearing unit, assemble pinion mate shaft and lock pin (finger tight only) into the differential case. This procedure is necessary to prevent the cross shaft from dropping out, and the differential side gears and differential pinion mate gears from rotating in the case and dropping out when servicing the carrier section. |
4. Mount spreader to housing. Do not spread carrier over .38 mm (.015"). Use dial indicator as shown. Tools: Spreader, Indicator Set.
5. Pry differential case from carrier with two pry bars as shown. After differential case has been removed, remove spreader. Use caution to avoid damage to ring and pinion. Mark or tag bearing cups indicating from which side they were removed.
6. Remove differential bearings with a puller as shown. Wire shims, bearing cup and bearing cone together. Identify from which side they were removed. (Ring gear side or opposite side.) If shims are mutilated, replace with new ones at time of assembly. Shims are available in thicknesses of .08, .13, .25, and .76 mm (.003", .005", .010" and .030"). Reposition case in puller and remove other bearing cones as described above. Tools: Press, Adapter, Adapter Ring, Extension, Button.
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It is recommended that whenever bearings are removed, they are (regardless of mileage) to be replaced with new ones. |
7. Place a few shop towels over the vise to prevent the ring teeth from being nicked, after it is free from the case. Place case in vise. Remove ring gear screws. Tap ring gear with a rawhide hammer to free it from the case. Remove case and ring gear from vise.
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It is recommended that whenever the ring gear screws are removed they are to be replaced with new ones. |
8. Replace case in vise and drive out lock pin which secures the pinion mate shaft. Use a small drift as shown.
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The semi-float shaft riding bearing design has a lock pin that is removed with a wrench. The pinion mate shaft is of the slip fit design and can be removed by hand. |
9. Remove pinion mate shaft with drift as shown.
10. To remove side gears and pinion mate gears, rotate the side gears. This will allow the pinion mate gears to turn to the opening of the cae. Remove pinion mate gears and also the spherical washers behind the gears. Lift out side gears and thrust washers. Inspect all parts, including the machined surfaces of the case itself. If excessive wear is visible on all parts, it is suggested that the complete differential assembly be replaced. If any one of the gears are to be replaced, they are to be replaced as a set.
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Axle shafts which require end play adjustments have a spacer block in the differential case. The spacer block controls the end thrust of the axle shaft. If the ends of the spacer block are worn, it is to be replaced during assembly. Spacer block must not be used with ball or unitized wheel bearings. |
11. Turn nose of carrier in a horizontal position, remove pinion nut. Hold end yoke or flange with tool, as shown, and remove pinion nut and washer. Tool: Holding Wrench.
12. Remove end yoke of flange with tools as shown. If end yoke or flange shows wear in the area of the seal contact, it should be replaced. Tools: Holding Wrench, Yoke Remover.
13. Remove pinion by tapping with a rawhide hammer. Catch the pinion with your hand to prevent it from falling to the ground and being damaged.
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On the spline end of the pinion, there are bearing preload shims. These shims may stick to the pinion or bearing or even fall out. These shims are to be collected and kept together since they will be used later in assembly. Try not to mutilate shims. If shims are mutilated, replace with new ones. Shims are available in thicknesses of .08, .13, .25 and .76 mm (.003", .005", .010" and .030"). |
14. Pull out pinion seal with puller as shown. Discard seal. Replace with new one at time of assembly. Remove bearing cone and outer oil slinger. Tool: Slide Hammer.
15. Turn nose of carrier down. Remove outer pinion bearing cup. Locate driver on back edge of cup; drive cup out of carrier. Caution: Do not nick carrier bore. Tools: Cup Remover, Handle.
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The front and rear carrier section may vary in pinion bore depth due to the possibility of the need for either a baffle or slinger or both. |
16. The baffle serves the same purpose as a dam, to assure that the pinion bearings are maintained with lubricant. The slinger serves the purpose of assisting the lube to flow up through the oil channels to lubricate the pinion bearings. If used, they are part of the pinion setting adjustment. In the figure above, we show the four different options.
17. Remove the inner bearing cup with tools as shown. Tools: Handle, Cup Remover.
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Shims are located between the bearing cup and carrier bore and may also include an oil baffle. If shims and baffles are bent or nicked, they should be replaced at time of assembly. Wire and stack together and measure each. If stack has to be replaced, replace with same thickness. |
18. Remove pinion bearing with tools as shown. Tools: Press, Adapter Ring, Adapters.
| NOTICE |
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Both baffle and slinger are part of the pinion adjustment shims and are to be kept intact for assembly. |
Carrier Assembly
1. On all front driving axles there are axle shaft oil seals pressed into the tube ends of the carrier.
2. As shown above, this design consists of the integral seal (unit) whereby the seal and guide are combined. (One seal for each side.)
3. Assemble inner axle shaft seals and guides. To assembly seals use tools as shown. Tool: Installer.
4. When assembling the seals, make sure they are positioned straight and do not get cocked. Turn forcing screw until it stops; seals will then be positioned. Grease lips of seals.
5. Place differential case in vise as shown. Apply grease to new side gear thrust washers and to hubs and thrust face of the new side gears. Assemble both side gears. Apply grease to the new spherical washers, and the new pinion mate gears. Assemble new pinion mate gears and washers.
An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly.
Assemble both side gears and thrust washers, hold them in place with hand, then assemble the pinion mate gears and washers to hold the side gears in place.
Rotate the side gears until the holes of the washers and pinion gears line up with the holes of the case. If the gears cannot be rotated by hand, install one of the axle shafts into the side gear spline and use a pipe wrench to turn the shaft.
6. Use a drift to line up the holes with those of the differential case.
Assemble pinion mate shaft, drive on shaft to remove drift. Be sure lock pin hole of the shaft is lined up with the lock pin hole of the case.
7. Assemble lock pin. Peen metal of case over pin to lock in place.
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The semi-float shaft riding bearing design uses a lock pin that is assembled with the use of a wrench. Use lock pin and assemble finger tight only. This procedure is necessary to prevent differential side gears and differential pinion mate gears from rotating in the case and dropping out when servicing the carrier section. A new lock pin will be installed after assembling the axle shafts. |
8. Be sure flange face of the case is free of nicks or burrs. Assemble ring gear to case. Line up holes of the ring gear with those of the case. Use new ring gear screws. Draw up screws alternately and evenly. Torque ring gear screws to 136-163 N m (100-120 lb. ft.).
9. Install master differential bearings onto case. Remove all nicks, burrs, dirt, etc., from hubs to allow master bearings to rotate freely. Tool: Master Differential Bearings.
10. Assemble differential case into carrier (less pinion). Mount dial indicator with a magnetic base as shown. Locate tip of indicator on flat surface of one of the ring gear screw spot faces. Mark location with a piece of chalk. Force differential assembly as far as possible in the direction towards the indicator. With force still applied, set indicator at zero (0). Tool: Indicator Set.
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Dial indicator should have a minimum travel of 5.08 mm (.200"). |
11. Force the differential assembly as far as it will go in the opposite direction. Repeat these steps until you have obtained the same reading. Record the reading of the indicator. This will be the total amount of shims required (less preload) and will be calculated later during assembly. After making sure the readings are correct, remove indicator and differential assembly from housing. Do not remove master bearings from differential case at this time.
12. Ring gears and pinions are supplied in matched sets only. Matching numbers on both the pinion and ring gear are etched for verification. If a new gear set is being used, verify the numbers of each pinion and ring gear before proceeding with assembly.
The nominal distance from the centerline of the ring gear to the end of the pinion for the model 60 (front and rear) axle is 79.37 mm (3.125").
On the button end of each pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0) number which indicates the best running position for each particular gear set. This dimension is controlled by the shimming behind the inner bearing cup.
For example: If a pinion is etched a plus +3 (m+8), this pinion would require .08 mm (.003") less shims than a pinion etched "0". This means by removing shims, the mounting distance of the pinion is increased to 79.45 mm, (3.128"), which is just what a +3 (m+8) indicates. Or if a pinion is etched -3 (m-8), we would want to add .08 mm (.003") more shims than would be required if the pinion were etched "0". By adding .08 mm (.003") shims, the mounting distance of the pinion was decreased to 79.30 mm (3.122") which is just what a -3 (m-8) indicated.
If the old ring and pinion set is to be reused, measure the old shim pack and build a new shim pack to this same dimension. If a baffle is used in the axle assembly, it is considered as part of the shim pack.
To change the pinion adjustments, shims are available in thicknesses of .08, .13, and .25 mm (.003", .005", and .010").
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If baffle or slinger is bent or mutilated, it should be replaced. |
13. Measure each shim separately with a micrometer and add together to get total shim pack thickness from the original build up.
If a new gear set is being used, notice the (+) or (-) etching on both the old and new pinion and adjust the thickness of the new shim pack to compensate for the difference of these two figures.
For example: If the old pinion reads (+) 2 (m+5) and the new pinion is (-)2 (m-5), add .10 mm (.004") shims to the original shim pack.
The above procedures also apply to pinion adjustment on the front axle which includes the oil slinger between the inner bearing cone and pinion, and baffle between the inner bearing cup and carrier.
Pinion Setting Chart (English U.S. Standard).
Pinion Setting Chart Metric
14. If metric used pinion will be etched Exp. (m+5). Use these charts as a guideline to set pinion.
15. View of master pinion block, pinion height block, scooter gage, cross pin, and master bearing discs.
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Cross arbor, master bearing discs, and scooter gage can be used on both Model 60 and Model 70 axles. |
16. Make sure that all carrier bores are free from all nicks, dirt or any other contamination.
17. Place master pinion block into the pinion bore of the carrier as shown. Tool: Master Pinion Block.
18. Place arbor discs (small diameters) and arbor into cross bores of carrier as shown. Tools: Master Discs, Arbor.
19. Place pinion height block on top of master pinion block and against arbor as shown. Tool: Pinion Height Block.
20. Place scooter gage on small step of pinion height block. Apply pressure with fingers, making sure the gage is flat on the pinion block, while pressure is applied set indicator at zero "0". Tool: Scooter Gage.
21. Slide scooter gage over arbor. As gage slides over top of arbor, it will travel in a clockwise direction. When indicator is on center of arbor (on top) it will stop traveling in a clockwise direction. If indicator starts to travel in a counter-clockwise direction, this means you have passed the center (top) of the arbor. Record only the reading when the indicator is at the highest point.
This reading indicates the amount of shims necessary to obtain the shim pack, plus (+) or minus (-) the etching on the button end of the pinion.
If the etching is zero (0), the shim pack will remain unchanged.
For example: If the pinion is etched +3 (m+8), this pinion would require .08 mm (.003") less shims than a pinion etched zero (0).
If the pinion is etched -3 (m-8), this would require .08 mm (.003") more shims than a pinion etched zero (0).
22. Measure each shim separately with a micrometer and add together to get total shim pack thickness. If baffle is required it is to be included in the shim pack. If slinger is used between the inner bearing cone and thrust face of pinion, the slinger is also to be measured and included as part of the total shim pack.
23. Place the required amount of shims (and baffle if used) in the inner bearing bore; drive the inner bearing cup into the carrier. Make sure cup is seated. Tools: Cup Installer, Handle.
24. Assemble the outer pinion bearing cup into carrier as shown, make sure cup is seated. Tools: Cup Installer, Handle.
25. Assemble inner bearing cone (and slinger if used) on pinion. Drive bearing on shaft until it is completely seated. Tool: Bearing Installer.
26. Assemble pinion into carrier. Assemble outer pinion bearing cone (and slinger if used) and end yoke onto pinion spline.
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Do not assemble preload shims or pinion oil seal at this time. |
27. Use yoke installer as shown to assemble end yoke onto spline of pinion. Tools: Installer, Holder.
28. Assemble washer and pinion nut. Torque nut until it requires 1.13 N m (10 lb. in.) to rotate the pinion. Rotate pinion several times before checking pinion position. This is to seat the bearings and assure a more accurate reading pinion depth setting. Tool: In.-Lb. Torque Wrench.
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The reason for not assembling preload shims and new pinion seal, at this time, is due to the possibility of having to adjust pinion preload or pinion adjustment. It would be necessary to again remove the seal and, as mentioned, whenever seals are removed, they are to be replaced with new ones, due to possible damage. |
29. Place arbor and discs (small diameter discs for Model 60 axle and large diameter used on Model 70 axle) into cross bore of carrier. Place pinion height block on button end of pinion. Set dial indicator on small step of height block (high step of block is used for Model 70 axle.) Set dial indicator at zero "0". Slide scooter gage across or over arbor.
Indicator will read a plus (+) or minus (-) at its highest point, depending on the etching of the pinion.
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Later model pinion height blocks are designed for each individual model axle. Therefore, it is possible to have a height block that does not have a step as pictured and described. |
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Indicator reading within .05 mm (.002") of etching is considered acceptable. If pinion position is found to be within specifications continue with build up. If pinion position is not within specifications change shim pack thickness under inner bearing cup. |
30. Remove pinion nut, washer, end yoke, slinger, and bearing cone. Assemble preload shims (which were removed during disassembly) onto pinion. Assemble bearing cone, and slinger.
31. Apply a light coat of hypoid lubricant on the lip of pinion seal and assemble into carrier. Tools: (National) Seal Installer, (Chicago Rawhide) Seal Installer, Handle.
32. Assemble end yoke, washer, and new pinion nut. Torque nut to 325-406 N m (240-300 lb. ft.). Tools: Torque Wrench, Yoke Holder.
33. Using an in. lb. torque wrench as shown, rotate pinion. Torque to rotate pinion should read between 2.26-4.53 N m (20-40 lb. in.). To increase preload, remove shims; to decrease preload add shims.
34. The above illustration shows the arrow in the pinion pointing in two directions. The direction pointing towards the end yoke indicates that by removing pinion position shims, the distance from the centerline of the axle to pinion button is increased giving a plus reading. The preload shim pack does not effect the pinion depth setting. Arrows on the ring gear illustrate the method to increase or decrease backlash and differential bearing preload.
Assembly Of Differential
1. Place differential assembly (with pinion installed) into housing. Differential master bearings should still be assembled to case.
2. Set up dial indicator as shown. Be sure to locate dial indicator on same location as marked on page 17, Item 10.
3. Force the differential case (ring gear) away from the pinion gear to obtain an indicator reading. Repeat until the same reading is obtained each time. This reading will be the necessary amount of shims required between the differential case and differential bearings on the ring gear side. Remove indicator and differential case from the carrier. Remove master bearings from differential case.
4. Assemble the required amount of shim onto hub (ring gear side) as determined in Step 3. Place bearing cone on hub of case. Use bearing installer to seat bearing cone as shown. Tools: Installer, Handle, Button.
5. Assemble the remaining of the total shim pack which was determined on page , item 11 on the opposite side of the differential case. Add an additional .38 mm (.015") of shims on this side to compensate for differential bearing preload. Assemble differential bearing, using the same tools as shown above.
On page , item 11 (less pinion) a total of .107" indicator reading was recorded.
In item 3 (with pinion) a total of .055" indicator reading was recorded. This leaves a balance of .052" of shims for the opposite side and adds up to the .107" which was first recorded.
Add an additional .015" shims on the opposite side for bearing preload and backlash.
Ring Gear Side 1.40 mm (.055")
Opposite Side 1.32 mm (.052")
Opposite Side Preload .38 mm (.015")
6. Install spreader and indicator to carrier as shown. Do not spread carrier over .38 mm (.015"). Remove indicator.
7. Assemble differential bearing cups to differential bearing cones.
Install differential assembly into carrier.
Use a rawhide hammer to seat differential assembly into cross bore of carrier. Care should be taken to avoid nicking the teeth of the ring gear and pinion during assembly. Remove spreader.
8. Install bearing caps. Make sure the letters stamped on the caps correspond with those on the carriers. Torque bearing cap screws to 108-122 N m (80-90 lb. ft.). Tool: Torque Wrench.
9. Check ring gear and pinion backlash in three equally spaced points with dial indicator as shown.
Backlash tolerance is .10-23 mm (.004") to .009" and cannot vary more than .05 mm (.002") between points checked.
High backlash is corrected by moving the ring gear closer to the pinion.
Low backlash is corrected by moving ring gear away from the pinion.
These corrections are made by switching shims from one side of the differential case to the other.
10. Install new cover gasket and install cover plate. Torque screws to 41-54 N m (30-40 ft. lb.). Tool: Torque Wrench.
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There are two different design cover plates. One cover is of the flat mounting surface, and the other design is of the ribs between screw holes. |
11. This figure shows the flat mounting surface cover plate on Dana design axles. This cover plate requires the use of a silicone rubber sealer material rather than a gasket.
12. The cover face of the carrier and the flat surface of the cover plate must be free of any oil film or foreign material.
13. Sealant material must meet specifications of ASTM3, GE303, A19, B37, E16, E36, Z1, Z2 and Z3 sealant.
Apply sealer to cover plate surface. Ensure that the sealer bead is laid on the inside of the cover screw holes. The bead is not to pass through the holes or outside of the holes.
The bead is to be 3.18-6.35 mm (1/8" to 1/4") high and 3.18-6.35 mm (1/8" to 1/4") wide.
Assemble two cover screws into cover at 8 o'clock and 2 o'clock position. Use these two holes to guide cover plate into position on the carrier.
Install remaining screws. Tighten alternately and evenly. Torque screws to 41-54 N m (30-40 lbs. ft.).
Allow one hour cure time before filling carrier with the proper amount of specified lubricant and vehicle operation.
14. On cover plate of the rib design, a gasket must be used. Do not use silicone sealer. Torque screws to 41-54 N m (30-40 lbs. ft.).
Axle Lockscrew Installation
1. Axles built in model year 1980 and model year 1981 used lockscrew style A. Starting in model year 1982, axles were built using lockscrew style B.
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The lockscrews are not interchangeable. Care should be exercised to assure that the replacement lockscrew is identical to the one removed. To identify the case for proper screw selection, measure the distance from the centerline of the cross-shaft hole to the case surface where the lockscrew enters the case. If it measures approximately 1,000, it will require lockscrew style A. If it measures approximately 1.312, it will require lockscrew style B. |
2. Remove the differential pinion shaft lockscrew as shown.
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New lockscrews (style A) have locking type material on the threads that secures the pin when in place. New lockscrews (style B) have special threads that secures the pin when in place. Therefore, whenever the lockscrew is removed, it is to be discarded and replaced with a new one. Before installing lockscrew, make sure hole is free of dirt and oil. |
3. Install lockscrew, making sure hole in the differential cross-shaft is lined up with the screw hole in the differential case. Make sure threads in differential case and on the lockscrew are free of dirt and oil. Torque lockscrew to 20-34 N m (15-25 lbs. ft.) for style B and 11-16 N m (8-12 lbs. ft.) for style A. Tool: Torque Wrench.
Powr-Lok Disassembly
1. Remove differential bearing caps. Note letters stamped on both the bearing caps and the cover face of the carrier. Letters are to correspond in horizontal and vertical positions. This is very important at time of assembly.
2. Mount spreader to housing. Locate dial indicator with a magnetic base and extensions as shown. Allow sufficient travel on dial indicator. Locate dial tip of indicator on carrier as shown.
Set dial indicator at zero (0). Turn forcing screw of spreader until indicator records .38 mm (.015").
| NOTICE |
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Do not spread carrier in excess of .38 mm (.015"). |
Remove indicator. Tools: Spreader, Indicator Set.
3. Remove differential using two pry bars as shown. It will not be necessary to remove the differential bearings at this time, however, the bearing cups should be marked or tagged to indicate which side of the case they were removed.
4. All Spicer Powr-Loks are identified with a manufacturing date and a complete part number stamped on the button half of the case. If the axle is equipped with a Powr-Lok Limited Slip differential, it will contain a tag specifying the use of Limited Slip lubricant.
The Powr-Lok is identified with 3.18 mm (1.25") high numbers and letters stamped in the case. For example: The number 9-6-77A is the manufacturing date or build date of the Powr-Lok is interpreted as follows. The first number is the month; second number is the day of the month; third number is the year; the letter is the shift. For example: September 6, 1977 first shift. The other number stamped beside the manufacturing date is the complete Powr-Lok assembly part number.
| NOTICE |
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It is recommended that when referring to the Powr-Lok, obtain the complete part number and build date. To do this, it will be necessary to wipe the gear lubricant off the case. |
5. Place a few shop towels over and between the vise jaws. This will prevent possible damage to the bearing, etc.
6. Place one of the axle shafts into vise. Tighten shaft in vise with the spline end extending approximately 76.2 mm (3 inches) above the vise. This will be used as a holding device for disassembly and assembly of the Powr-Lok.
7. Place the case on the axle shaft as shown. The spline teeth of the side gear will engage those of the axle shaft, the shaft will now serve as a holding device. Use a piece of chalk or paint, scribe a line on one of the cross shaft and both halves of the case, and mark an "0" on the other cross shaft and both case halves as shown. This will permit reassembly (if used) of the shafts and case exactly as they were removed.
8. Remove case body screws. Remove case from axle shaft and place on bench.
9. Disassemble case. Keep the stack of plates and discs in exactly the same order in which they were removed. Inspect plates, discs, clutch rings, side gears, pinion mate gears, and pinion mate shafts for damage, scoring or wear. If any one of the plates or discs on either stack shows wear or scoring the complete stack is to be replaced on both sides. Clutch rings which show wear or scoring are also to be replaced in sets. The side gears and pinion mate gears that show damage or wear are also to be replaced in sets. If wear is indicated on the cams of the pinion mate shafts, these are also to be replaced in sets.
10. Above is a typical example of scoring and, as mentioned, all plates and discs of the Powr-Lok are to be replaced.
11. The pinion mate shafts are unlike the shaft of a conventional differential and, therefore, are not locked to the differential case.
12. Notice also that at the end of each shaft, they are formed into a "V", and each case half has "V" shaped surfaces. The "V" formation of the case is known as a ramp. If wear is evident on either case half, then both halves must be replaced.
13. Some semi-float axles require a spacer block to maintain proper end play and transmit thrust forces from one axle shaft to the opposite axle shaft and its wheel bearing. There is one type spacer block and it is known as the roll pin design. Axle shafts which do not require end play have no spacer block in the cross pins.
Powr-Lok Reassembly
1. Replace plates, discs, side gear and clutch ring in exactly the same position as they were removed, (unless rearrangement was required). Apply specified lubricant on each individual part. Refer to Vehicle Service Manual for the specified lubricant.
2. With the plates and discs now assembled to the side gear and clutch ring, line up the ears of the plate with the grooves in case so they will easily enter into the ring gear case half.
3. Install pinion mate shafts and pinion mate gears. Make sure the shafts correspond with the chalk as marked at time of disassembly. Refer to page 29, item 7. Install the other side gear, clutch ring, plates, and disc exactly as they were removed (unless rearrangement was required). Prelube each part. Line up ears of plates with grooves of the case.
4. Assemble button half of case, making sure chalk marks are lined up. Assemble case body screws finger tight.
5. Place case onto axle shaft as shown. Tighten body screw alternately and evenly. Torque screws to 88-95 N m (65-70 lbs. ft.).
6. Mount spreader onto housing. Locate dial indicator with a magnetic base and extensions as shown. Locate tip of indicator on housing as shown. Make sure the indicator has a minimum travel of .76 mm (.030") for this operation.
Set dial indicator at zero (0). Turn forcing screw until indicator records .38 mm (.015").
| NOTICE |
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Do not spread carrier in excess of .38 mm (.015"). |
Remove indicator. Tools: Spreader, Indicator Set.
7. Prelubricate differential bearing with specified gear lubricant. Assemble differential bearing cups to bearing cones. Assemble differential into carrier housing.
| NOTICE |
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Care should be taken when meshing the teeth of the ring gear with those of the pinion to prevent possible nicks, etc. |
8. Use a rawhide hammer to completely seat the case assembly into carrier crossbore.
Remove spreader.
9. Assemble bearing caps. Make sure the letters stamped on the bearing caps correspond with those stamped in the cover face of the carrier in both horizontal and vertical positions.
| NOTICE |
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Torque screws to 96-122 N m (70-90 lbs. ft.). |
| NOTICE |
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There are two different design cover plates. One cover is of the flat mounting surface, and the other design is of the rib between screw holes. |
10. The above illustration shows the flat mounting surface cover plate on Dana design axles. This cover requires the use of a silicone rubber sealer material rather than a gasket.
11. The cover face of the carrier and the flat surface of the cover plate must be free of any oil film or foreign material.
Sealant must meet specifications of ASTM3, GE303, A19, B37, E16, E36, Z1, Z2 & Z3 sealant.
Apply sealer to cover plate surface. Ensure that the sealer bead is laid on the inside of the cover screw holes. The bead is not to pass through or outside of the holes.
The bead is to be 3.18-6.35 mm (1/8" to 1/4") high, and 3.18-6.35 mm (1/8" to 1/4" wide.
Assemble two cover screws into cover at 8 o'clock and 2 o'clock position. Use these two holes to guide cover plate into position on the carrier.
Install remaining screws. Tighten alternately and evenly. Torque screws to 41-54 N m (30-40 lbs. ft.).
Allow one hour cure time before vehicle operation.
12. On cover plates of the rib design a gasket must be used. Do not use silicone sealer.
| NOTICE |
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Torque cover screws to 41-54 N m (30-40 lbs. ft.). |
| NOTICE |
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On all front axles the cover plate is of a different design and requires the use of a gasket. Do not use a silicone rubber sealer material. |
13. Assemble axle in vehicle. Fill axle with the specified lubricant. Refer to vehicle manufacturer's lubricant recommendations.
Assemble brake backing plate, etc., and axle shafts into housing. Refer to Vehicle Service Manual for the specified torques of wheel end components.
Assemble brake drums and wheels.
Powr-Lok Complete Assembly Replacement
1. If inspection reveals that replacement of the Powr-Lok as a unit is necessary, the following steps should be followed.
2. Place a few shop towels over and between the vise jaws to prevent the teeth of the ring gear from becoming nicked after it is free from the case.
3. Assemble differential case in vise. Remove both differential bearings, cones, and shim packs. Mark or tag each bearing cone and shim pack as they are removed and indicate from which side they were removed. Turn forcing screw to pull bearings off hubs. Tools: Press, Extension, Adapter, Button, Adapter Ring.
| NOTICE |
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It is recommended that whenever bearings are removed, they are (regardless of mileage) to be replaced with new one. |
4. Remove ring gear screws and ring gear.
5. Tap ring gear lightly with a rawhide hammer to free it from the case.
6. Remove Powr-Lok case and ring gear from vise.
| NOTICE |
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It is recommended that whenever ring gear screws are removed, they are to be replaced with new ones at time of assembly. |
7. Assemble ring gear to new Powr-Lok case. Make sure the pilot diameter and flange face of the Powr-Lok case are free of nicks or burrs. Line up the holes of the ring gear with those of the case. Assemble screws finger tight.
8. Reposition case in vise. Draw screws up alternately and evenly.
| NOTICE |
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Use new ring gear screws and torque to 135-162 N m (100-120 lbs. ft.). |
9. Inspect shim packs and bearings which were removed from the old case. If the shims or bearings show excessive wear or damage, they should be replaced. If used, make sure they are assembled on the same side of the Powr-Lok case from which they were removed. Assemble shims and differential bearing cones. Use hub button as shown to protect the cone from becoming damaged during assembly of the top bearing. Tools: Installer, Button.
10. Prelubricate differential bearing cones with the specified lubricant.
11. Assemble case into housing. Follow same procedure, as illustration on page 33, items 6-9.
12. Check backlash between ring gear and pinion in three equally spaced points with dial indicator and tip of indicator located as shown. Backlash tolerance is .102-229 mm (.004 to .009") and cannot vary more than .051 mm (.002") beyond points checked.
13. High backlash is corrected by moving the ring gear closer into the pinion.
14. Low backlash is corrected by moving the ring gear away from the pinion.
15. These corrections are made by switching shims from one side of the differential case to the other.
| NOTICE |
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For conversion from standard differential to Powr-Lok differential, items 2-12 should be followed. |