SPICER AXLE

SERVICE

MANUAL

MODEL

FRONT CARRIER TYPE

 INDEX
Page

LUBRICATION.................................................................. 3
SPECIAL SERVICE TOOLS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

AXLE IDENTIFICATION ......................................................... 5

SH AFT BEARINGS AND SEALS

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Assembly................................................................... 9

CARRIER SECTION
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

IMPORTANT SAFETY NOTICE

PROPER SERVICE AND REPAIR IS IMPORTANT TO THE SAFE, RELIABLE OPERATION OF ALL
MOTOR VEHICLES OR DRIVING AXLES WHETHER THEY BE FRONT OR REAR. THE SERVICE
PROCEDURES RECOMMENDED AND DESCRIBED IN THIS SERVICE MANUAL ARE EFFECTIVE
METHODS FOR PERFORMING SERVICE OPERATIONS. SOME OF THESE SERVICE OPERATIONS
REQUIRE THE USE OF TOOLS SPECIALLY DESIGNED FOR THE PURPOSE. THE SPECIAL TOOL
SHOULD BE USED WHEN AND AS RECOMMENDED.
IT IS IMPOSSIBLE TO KNOW, EVALUATE, AND ADVISE THE SERVICE TRADE OF ALL
CONCEIVABLE WAYS IN WHICH SERVICE MIGHT BE DONE OR OF THE POSSIBLE HAZARDOUS
CONSEQUENCES OF EACH WAY.
ACCORDINGLY, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED MUST FIRST SATISFY HIMSELF THOROUGHLY THAT NEITHER HIS SAFETY
NOR VEHICLE SAFETY WILL BE JEOPARDIZED BY THE SERVICE METHODS HE SELECTS.
SHOULD AN AXLE ASSEMBLY REQUIRE COMPONENT PARTS REPLACEMENT, IT IS
RECOMMENDED THAT "ORIGINAL EQUIPMENT" REPLACEMENT PARTS BE USED. THEY MAY
BE OBTAINED THROUGH YOUR LOCAL SERVICE DEALER OR OTHER ORIGINAL EQUIPMENT
MANUFACTURER PARTS SUPPLIER. THE USE OF NON-ORIGINAL EQUIPMENT REPLACEMENT
PARTS IS NOT RECOMMENDED AS THEIR USE MAY CAUSE UNIT FAILURE AND/OR EFFECT
VEHICLE SAFETY.

NOTE
Throughout this manual, reference is made to certain tool numbers whenever special tools are
required. These numbers are numbers of Miller Special Tools, 32615 Park Lane, Garden City,
Michigan 48135. They are used herein for customer convenience only. Dana makes no warranty or
representation to these tools.

?
 LUBRICATION

It is not our intent to recommend any particular brand or make of lubricant for the Spicer hypoid axles.
However, a S.A.E. 90 weight multipurpose gear lubricant meeting Mil. Spec. L-2105-B, or 80 W 90
multipurpose gear lubricant meeting Mil. Spec. L-2105-C, and suitable for A.P.I. Service Classification GL-
5 is suggested as a mimimum requirement.

SH AFT BEARING LUBRICATION

Shaft bearings are lubricated with the hypoid gear lube in the housing. To eliminate any risk of damage
prior to gear lube circulation reaching the shaft bearings, they must be packed with grease. For grease
packing it is recommended that a number 2 consistency, lithium base, 12 Hydroxy Stearate Grease
containing an E.P. additive be used.

COLD WEATH ER OPERATION

If the vehicle is operated below oo F (-18 C), it is advisable to use S.A.E. 80 Multi-Purpose Gear Lubricant
meeting Mil. Spec. L-2105-B, and suitable for A.P.I. Service Classification GL-5.

SUBMERSION OR DEEP WATER FORDING

In the event the gear carrier housing should become submerged in water, particularly if over the
breathers, it is recommended that the hypoid gear lubricant be drained daily and internal parts be
inspected for water damage and/or contamination.
Clean, examine, and if necessary, replace damaged parts, prior to assembling and refilling with the
specified hypoid lubricant.

NOTE
It is recommended that whenever bearings are removed they are to be replaced with new ones
regardless of mileage.

3
 SPECIAL SERVICE TOOLS

37,.
'-C' 26
32 2
34 .27
20 7 . .,
35 :

0 33 36 28

"'1' f:i
..

23 30 -kL
02 9

e
17
1
0
18 3 J
oco
i
25 6
11 8 11
-
19 21
24

'
- - -=- =- =---= -=-
40
--..,

41
39

Figure 2 1021-2

The following is a detailed list of all special tools required to service the Spicer Model 30 Axle Housing
and Shaft Assembly_

Item No. Tool No. Description Item No. Tool No. Description
1 D-113 Spreader *13 D-115-4 Arbor Disc
2 D-263-1 Adapter Blocks w/Hold- 14 D-147 Remover-Front Pinion
Down Screws Bearing Cup
3 DD-914-P Press 15 D-149 Remover-Rear Pinion
4 DD-914-9 Adapter Ring Bearing Cup
5 C-293-39 Adapter Set - Differential 16 C-452 Remover-Yoke
and Inner Pinion 17 D-144 Installer-Front Pinion
Bearing Cones Bearing Cup
6 SP-3289 Adapter Plug-Differential 18 D-146 Installer-Rear Pinion
Hub Bearing Cup
7 D-128 Indicator Set 19 W-262 Installer-Rear Pinion
*8 D-115 Scooter Gage Bearing
*9 D-115-1 Pinion Height Block 20 W-147-D Installer-Pinion Oil Seal
*10 D-138 Master Pinion Block 21 W-162 Installer-Yoke
*11 D-134 Master Bearing- 22 C-3281 Holder-Yoke
Differential 23 C-3716-A Installer-Differential
*12 D-115-3 Arbor Side Bearings

4
Item No. Tool No. Description Item No. Tool No. Description

24 D-131 Slide Hammer **30 D-270-1 Adapter Ring

25 C-4171 Handle-Universa! **31 L-4518-1 Receiver
**26 D-266 Installer-Shaft Bearing- **32 L-4454-8 Thrust Bearing
In Tube **33 L-4454-9 Main Body
**27 D-267 Installer-Shaft Seal- **34 L-4454-10 Screw
In tube **35 L-4454-11 Cup-Main Body
**28 D-268 Installer-Shaft Bearing- **36 L-4454-12 "0" Ring
In Housing **37 L-4454-13 Hex Nut (112-20)
**29 D-269 Installer-Shaft Seal- **38 L-4454-14 Washer
In Housing 39 C-4053 Torque W rench-
*Pinion Setting Gauge and Master Differential 300 Lbs.-Ft.
Bearing Kit No. D-115-30 40 C-3952A Torque Wrench-
**Axle Shaft Bearing and Seal Removal and 150 Lbs.-Ft.
Installation Kit No. D-30-AM 41 D-193 Torque Wrench-
50 Lbs.-Ft.
NOTE
Torque wrenches C-4053, C-3952A, and D-193 are optional and can be purchased separately. These
torque wrenches are not included in the axle tool kits.

AX LE IDENTIFICATION
All Dana axles are identified with a complete
part number and the manufacturing date stamped
on the axle tube in IJs'' high (3.17mm) characters. A
typical identification number would be 610078-8,
12 107A and is interpreted as follows: the seven
digit dash number is the Dana part number for the
complete axle. The next three numbers are the
build date (month, day, year), the next number is
the assembly line that built the axle, the first letter
is the work shift, second letter is the manufac
turing facility. For example: December 1, 1980,
Line 7, First Shift.
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 dirt, etc. from the axle tube.
There is also an axle gear ratio tag location on
the right side of the cover plate and held in place
with two of the cover plate screws. This tag gives
the tooth combination of the ring gear and pinion,
the total gear ratio, and also the customer part Figure 3 1021-3

number.

NOTE
All maintenance and service require
CAUTION
removal of the cover plate and axle shafts.
Where vehicle installation restricts cover Do not apply vehicle weight to wheels
plate removal,refer to vehicle manufacturer's without half-shafts in place and fasteners
properly torqued.
recommendations to remove the entire axle
housing and shaft assembly from the vehicle. Half-shaft to axle shaft flange bolt torque is
The procedures described here will consider 45 lbs.-ft. (6IN.m).
the axle housing and shaft assembly
removed.

5
 1-Axle Housing
2- Drive Gear Set

15 16 3-Oil Slinger (Inner)

4-Pinion Bearing (Inner)

I 5-Pinion Position Shims

6- Oil Baffel

1
7-Pinion Bearing Preload
Shims

JJ- 7
R- 18
8-Pinion Bearing (Outer)
9- Oil slinger (Outer)

32 3 11-
10-0il Seal
End Yoke Assembly

I 4 12-Washer
13-Nut

ffr1 'l 14- Cover Gasket

15-Carrier Cover

@I
34
16-Fill Plug

25
17-Identification Tag

0 .,
I 18- Cover Screw (10)

/!{!
r\ \:

19- Differential Case
(j) 19 20-Drive Gear Screw (10)
/

1
21- Differential Bearing
'< 2 Shims
-- 24 22-Differential Bearing
23- Differential Bearing Cap

\ijY\5
24- Differential Bearing

7 1

23 Cap Screw

L--
-
ro 25- Differential Cross Shaft

35/ I
Lock Pin
\

8 26-Cross Shaft
36 27- Differential Pinion

-"li.%''4.1' -Ju . Thrust Washer

I \12
9 28- Differential Pinion

13
29- Differential Side Gear
Thrust Washer
30- Differential Side Gear
31-Axle Shaft Snap Ring
32- Axle Shaft (L.H.)
33- Axle Shaft Seal (LH.)
34-Axle Shaft Bearing (LH.)
35-Axle Shaft Bearing (R.H.)
36-Axle Shaft Seal (R.H.)
37-Axle Shaft (R.H.)

Figure 4 1021-4
 SERVICE PROCEDURES

Loosen cover plate screws and allow lube to

drain out.

Figure 7 1021-7

Slide it from the grove expanding it far enough

so that by rotating the shaft 180 , the snap ring can
be pulled off with a pair of pliers or pryed out with a
large screw driver.
Figure 5 1021-5

Remove cover plate screws, cover plate, and

gasket (discard old gasket). Tip carrier to allow lube
CAUTION
to drain completely. Eye protection should be worn when
removing or installing the snap rings.
Place assembly on work bench and secure it by
clamping the axle tube in a vise.
At this time, clean the cover face of the carrier, Inspect the snap ring to be certain it is not broken.
making sure it is free from nicks and any particles Retrieve any broken pieces from the housing before
left by the old gasket. Remove RTV from two Vz'' proceeding.
diameter manufacturing holes.

Figure 6 1021-6

Remove axle shaft snap rings by rotating the

shaft so that the open side of the snap ring is Figure 8 1021-8
exposed, hold one side of the snap ring firmly with
a screw driver, while pushing on the other side, as
Remove the axle shafts.
shown.
7
 SERVICE PROCEDURES
SHAFT BEARINGS AND SEALS
DISASSEMBLY

Using the procedure and tools described for

FIGURE 9, install the puller on the L.H. shaft
bearing.

Figure 9 1o21-9

Insert the puller through the axle shaft seal and

bearing and position it to a depth that will allow the
flange on the ends of the main body to expand into
the relief behind the needle bearing. Expand the
puller by holding the nut and turn the screw until
the puller centers itself.
Tools-L-4454-9 Mainbody, L-4454-10 Screw,
L-4454-11 Cup, L-4454-12 "0" Ring, L-4454-13 Hex
Nut (1/2-20) and L-4454-14 Washer. -

Figure 1 2 1021-12

Place the receiver over the puller (adapter ring is

not required) and install the thrust bearing and
nut. Draw the bearing and seal from the housing.
Tools L-4518-1 Receiver, L-4454-8 Thrust
Bearing, L-4454-13 Nut.

Discard seal and bearing and replace with

new one at time of assembly.

Figure 1 0 1021-10

Place adapter ring and receiver over the puller as

shown, install the nut on the screw and draw the
bearing and seal into the receiver by holding the
screw and turning the nut.
Tools-D-270-1 Adapter Ring, L-4518-1 Receiver,
L-4454-13 Nut, L-4454-14 Washer,
Discard seal and bearing and replace with
new one at time of assembly.

NOTE
It is recommended that whenever bearings
are removed, they are (regardless of mileage)
Figure 1 1
replaced with new ones.
1021-11

8
 SERVICE PROCEDURES
ASSEMBLY - SH AFT BEARINGS AND SEALS

Figure 1 3 1o21-13 Figure 1 5 1021-15

Assemble new L.H. shaft bearing. (Seat bearing Assemble new R.H. shaft bearing. (Tool controls
against shoulder.) bearing installation depth.)
Tools-D-268 Installer, C-4171 Handle. Tools-D-266 Installer, C-4171 Handle.

Figure 1 4 1021-14 Figure 1 6 1021-16

Assemble new L.H. shaft seal. (Seat seal against Assemble new R.H. shaft seal. (Seat seal against
bearing.) shoulder.)
Tools-D-269 Installer, C-4171 Handle. Tools-D-267 Installer, C-4171 Handle.

CARRIER SECTION
DISASSEMBLY

With carrier positioned as shown and secured in

a vise, 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 should
correspond in both the horizontal and vertical
position.

NOTE
Axle shafts must be removed for service
procedures involving removal of the
differential.

Figure 1 7 1021-17

9
 SERVICE PROCEDURES

Figure 1 8 1021-18

Mount spreader with adapter blocks and

holddown screws to carrier as shown. Do not Figure 20 1021-2o

spread carrier over .020" (.50mm). Use dial Remove differential bearings with a puller as
indicator as shown. shown. Wire shims, bearing cup and bearing cone
After carrier has been spread, remove indicator. together. Identify from which side they were
Tools-D-113 Spreader, D-263-1 Adapter Blocks. removed (ring gear side or opposite side.) If shims
are mutilated replace with new shims at the time of
assembly. Shims are available in thicknesses of
.003", .005", .010", and .030" (mm .08, .13, .25 and
.76).
Tools-DD-914-P Press, DD-914-9 Adapter Ring,
SP-3289 Plug, C-293-39 Adapter Set.

NOTE
It is recommended that whenever bearings
are removed, they are (regardless of mileage)
. .. replaced with new ones.

Figure 1 9 1o21-19
Figure 21 1021-21

Pry differential case from carrier with two pry Place a few shop towels over the vise to prevent
bars as shown. After differential case has been the ring gear teeth from being nicked after it is free
removed, remove s preader. Use caution to from the case.
avoid damage to ring gear and pinion. Mark or tag Place case in vise. Remove ring gear screws. Tap
the bearing cups indicating from which side they ring gear with rawhide hammer to free it from the
were removed. case. Remove case and ring gear from vise.

10
 SERVICE PROCEDURES

NOTE
It is recommended that whenever the ring
gear screws are removed, they are replaced
with new ones.

. ;. -
-
L ?
1

Figure 24 1o21-24

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 case.
Remove pinion mate gears and also the spherical
washers behind the gears. Lift out gears and
thrust washers. Inspect all parts, including the
machined surfaces of the case itself. Where
necessary replace all worn parts. 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.
Figure 22 1021-22

Replace case in vise and drive out lock pin which

secures the pinion rnate shaft. Use a small drift as
shown.

Figure 25 1021-2s

Turn nose of carrier in a vertical position to

remove pinion nut. Hold end yoke with tool as
shown, and remove pinion nut and washer.

Figure 2 3 1o21-23

Remove pinion mate shaft with drift as shown. Tool-C-3281 Holding Wrench.

11
 SERVICE PROCEDURES

Figure 26 1021-26

Remove end yoke with tools as shown. If yoke

Figure 28 1021-2s
shows wear in the area of the seal contact, it should
be replaced. Pull out pmwn seal with puller as shown.
Tools-C-452 Remover - Yoke, C-3281 Holding Discard seal. Replace with new seal at time of
Wrench. assembly. Remove bearing cone and outer pinion
oil slinger.

I _J
Tools-D-131 Slide Hammer.

Figure 27 1021-27
Figure 29 1021-29
Remove pinion by tapping with a rawhide
hammer. Catch the pinion with your hand to Remove the inner bearing cup with tools as
prevent it from falling to the ground and being shown.
damaged. Tools-D-149 Remover, C-4171 Handle.

NOTE
NOTE An oil baffle and pinion position shims are
On the spline end of the pinion, there are located between the bearing cup and carrier
bearing preload shims. These shims may bore. The baffle will be damaged when
stick to the bearing or the pinion or even fall removing the bearing cup and must be
out. The shims are to be collected and kept replaced at time of assembly. If shims are
together since they will be used later in bent or nicked, they should be replaced at
assembly. Try not to mutilate shims. If shims time of assembly. Wire the shim stack
are mutilated, replace with new ones. Shims together (including the baffle) and measure
are available in thicknesses of .003", .005", each. If stack has to be replaced, replace with
.010", and .030" (mm.S, .13, .25 and .76). the same thickness.

12
 SERVICE PROCEDURES

NOTE
The oil slinger located between the bearing
cone and the pinion head affects pinion
position and must be kept intact for
assembly.

ASSEMBLY - CARRIER SECTION

Figure 30 1021-30

Turn nose of carrier down. Remove outer pinion

bearing cup as shown. Locate driver on back edge
of cup, drive cup out of carrier. CAUTION: Do not Figure 32 1021-32

nick carrier bore. Place differential case in vise as shown. Apply

Tools-D-147 Remover, C-4171 Handle. grease to new side gear thrust washers and hubs of
side gear. Assemble both side gears. Apply grease
to new pinion mate spherical washers and the
pinion mate gears. Assemble pinion mate gears.
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 gears 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.

Figure 31 1021-31

Remove mner pmwn bearing with tools as

shown.
Figure 33 1021-33

Tools-DD-914-P Press, DD-914-9 Adapter Ring,

Install pinion mate shaft. Assemble lock pm.
C-293-39 Adapter Set.
Peen metal of case over pin to lock in place.
13
 SERVICE PROCEDURES

Figure 36 1021-36

Figure 34 1021-34
Assemble differential case into carrier (less
Be sure flange face of the case is free of nicks or pinion). Mount dial indicator, with a magnetic
burrs. Assemble ring gear to case using new ring base as shown. Locate tip of indicator on flat
gear screws. Draw up screws alternately and surface of one of the gear screws. Mark screw with
evenly. a piece of chalk. Force the differential assembly as
Torque screws to 45-60 lbs. ft. (61.0-81.3 N.m). far as possible in the direction towards the
indicator. With force still applied, set indicator at
zero. (0).
Tool-Indicator D-128.

NOTE
Indicator should have a minimum of .200"
(5.08mm) travel.

Figure 37 1021-37

Force the differential assembly as far as it will

Figure 35 1o21-3s go in the opposite direction. Repeat these steps
Remove all nicks, burrs, dirt, etc. from differential until the same reading is obtained.
case bearing hubs to allow master bearings to Record the reading of the indicator.
rotate freely.
This will be the total amount of shims required
Install master differential bearing onto case.
(less preload) and will be calculated later during
Tools-Master Bearings D-134. assembly.
14
 SERVICE PROCEDURES
After making sure the readings are correct, On the button end of each pinion there is etched
remove indicator and differential assembly from a plus (+) number, a minus (-) number, or a zero (0),
housing. Do not remove master bearings from which indicates the best running position for each
differential case at this time. particular gear set. This dimension is controlled by
the shim pack which includes the baffle behind the
inner bearing cup, and the oil slinger between the
bearing cone and the pinion head.
For example: if a pinion is etched +3 (m + 8), this
pinion would require the .003" (.08mm) less shims
than a pinion etched "0". This means by removing
shims, the mounting distance of the pinion is
increased to 2.253" (57.2mm), which is just what a
+3 (m + 8) indicates. Or if a pinion is etched -3 (m-8),
we would want to add .003" (.08mm) more shims
than would be required if the pinion were etched
"0". By adding .003" (.08mm) shims the mounting
distance of the pinion was decreased to 2.24 7" (57
.lmm) which is just what a -3 (m - 8) etching
indicated.
If the old ring and pinion set is to be reused,
Figure 38 1021-38
measure the old shim pack and build a new shim
View of ring and pinion set. pack to this same dimension. The baffle is
Ring gears and pinions are supplied in matched considered as part of the shim pack.
sets only. Matching numbers on both the pinion To change the pinion adjustment, shims are
and ring gear are etched for verification. If a new available in thicknesses of .003", .005", and .010"
gear set is being used, verify the numbers of each (mm .08, .13 and .25).
pinion and ring before proceeding with assembly.
NOTE
If baffle or slinger is bent or mutilated, it
should be replaced.
Pinion in. mm.
Preload 1 .003 ( .08 l
j
Shims .005 ( .13 J Measure the baffle, the slinger and each shim
.o1o ( .251 separately with a micrometer and add together to
L .030 U6 l get total shim pack thickness from original build

{ in. mm. up.

Pinion Position .003 ( .08 J If a new gear set is being used, notice the (+) or (-)
Pinion Oil Baffle ,- Shims .005 (.13J etching on both the old and new pinion and adjust
--+---E .010 ( .251 the thickness of the new shim pack to compensate
Pinion Oil Slinger 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 .004" (.lOmm)
Front and Rear shims to the original shim pack.
Model 30
2.250 in. ( 57.15) mm.
Mtwi'IIIMMwti..
OI.:I'IRIIft
M11k11
-I -I -1 +1 +I +1 +
Centerline of
+ +0000 +0001 +0006 +01XO +000< +000! +0002 +0001

Ring Gear +I +0001 +0006 +01XO +000< +000! +0002 +0001 -0001

+1 +0006 +01XO +000< +000! +0002 +0001 -0001 -0002

+I +01XO +000< +000! +0002 +0001 0001 -0002 000!

+000< +0001 +0002 +0001 -0001 -0001 -000! 000<

-I +000! to002 +0001 -000\ -0001 -000! -000< 01XO

+0002 +0001 -000\ -0001 -OOOJ -000< -0001 -0006

+0001 -000! -000< -0001 -0006 -0001

-0001 -0000 -01XO 0006 -0008

Figure 39 1021-39
Figure 40 1021-40

The distance from the centerline of the ring gear

to the button end of the pinion for the Model 30 axle Use pinion setting chart shown as a guide to set
is 2.250 inches (63.5 mm). pinion position.

15
 SERVICE PROCEDURES

Figure 41 1021-41

View of cross arbor and arbor discs, height block, Figui'e 43 1021-43

scooter gage, and master pinion block. Place arbor discs and arbor into cross bores of
the carrier as shown.
Tools-Arbor D-115-3, Arbor Discs D-115-4.

NOTE
Cross arbor and master bearing discs can
be used on both the Model 30 and Model 44
axles. Use small diameter discs for Model 30
axles.

NOTE
Be sure that all carrier bores are free from
all nicks, dirt or any other contamination.

Figure 44 1021-44

Place pinion height block on top of master

pinion block, and against arbor as shown.
Tools-Pinion Height Block 115-1.

Figure 42 1o21-42

Place the master pinion block into the pinion

bore of the carrier as shown. Figure 45 1021-45

Tool-Master Pinion Block D-138. Place scooter gage on small step of pinion

16
 SERVICE PROCEDURES
height block. Apply pressure with fingers making Measure each shim separately with a
sure the gage is flat on the pinion height block, micrometer and add together to get total shim pack
while pressure is applied, set indicator at zero "0". thickness. The baffle and the slinger are to be
Tool-Scooter Gage D-115. measured and included as a part of the total shim
pack.

Figure 46 1o21-4s

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 travelling in a clockwise direction. If
indicator starts to travel in a counterclockwise
direction, this means that 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 correct shim pack, plus (+) or minus (-)
the etching on the button end of the pinion. If the Figure 48 1021-48

etching is zero (0) the shim pack will remain Place the baffle and the required amount of
unchanged. shims in the inner bearing bore, drive the inner
For example: If a pinion is etched +3 (m + 8), this bearing cup into carrier with tools as shown.
pinion would require .003" (.08mm) less shims Tools-D-146 Cup Installer, C-4171 Handle.
than a pinion etched zero "0".
If a pinion is etched-3 (m - 8), we would want to
add .003" (.08mm) more shims than would be
required if the pinion were etched zero "0".

Figure 49 1021-49

Assemble the outer pinion bearing cup into

carrier as shown.
Figure 47 1021-47 Tools-D-144 Cup Installer, C-4171 Handle.

17
 SERVICE PROCEDURES
Use yoke installer (as shown) to assemble end
yoke onto spline of pinion.
Tool-Installer W-162, Holder C-3281.

Figure 52 1021-52

Assemble washer and pmwn nut. Torque nut

until it requires 10 lbs.-in. (1.13 N.m) to rotate
pinion. Rotate pinion several t;,,s before checking
Figure 50 1021-50
pinion position. This is to seat the bearings and
Assemble slinger and inner bearing cone on assure a more accurate reading of pinion depth
pinion, place bearing installer over pinion stem as setting.
shown. Drive bearing on stem until it is completely
seated. NOTE
The reason for not assembling preload
Tool-W-262 Installer.
shims and new pinion oil 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 discarded, because of possible
damage.

Figure 51 1021-51

Install pinion into carrier.

Assemble outer pinion bearing cone, outer
pinion oil slinger, and end yoke onto pinion spline.

NOTE
Do not assemble preload shims or pinion oil
seal at this time.
Figure 53 1021-53

18
 SERVICE PROCEDURES
Place arbor and arbor discs (small diameter If pinion preload is within specifications, remove
discs for Model 30 axle) into cross bore of carrier. pinion nut, washer, end yoke and pinion. Assemble
Place pinion height block on button end of pinion. new pinion oil seal into housing as shown. Apply
Set dial indicator on zero "0". (Refer to FIGURE a light coat of oil to the lip of oil seal.
45).
Slide scooter gage across or over arbor. Tools-W-147D Seal Installer, C-4171 Handle.
Indicator will read a plus (+) or minus (-) at its
highest point, depending on the etching of the
p1mon.

NOTE
Indicator reading within .002 (.05mm) 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.

Insert pinion into carrier.

Assemble preload shims (which were removed
during disassembly) onto the pinion.
Assemble bearing cone, slinger, end yoke, washer
and pinion nut.
Torque pinion nut to 200-220 lbs. ft. (271-298
N.m).
Tool: Holder C-3281, Torque Wrench C-4053.
Using an inch pound torque wrench rotating
Figure 55 1021-55
torque of pinion should read between 20-40 lbs. inch
(2.3-4.5 N m) with new bearings. If original
Install pinion. Assemble end yoke, washer, and
bearings are used, torque reading should be 10-20
new pinion nut. Torque nut to 200-220 lbs. ft. (271-
lbs. in. (1.13-2.26 N.m). To increase preload, remove
298 Nm).
shims, to decrease preload, add shims.
Tools-C-3281 Yoke Holder.

Figure 56 1021-56

Using an inch lb. torque wrench as shown, rotate

pinion. Torque of pinion should read between 20-40
lbs. in. (2.3 - 4.5 N.m).
To increase preload, remove shims; to decrease
Figure 54 1021-54 preload, add shims.
19
 SERVICE PROCEDURES
Set up dial indicator as shown. Be sure to locate
dial indicator on same ring gear screw as shown in
FIGURE 36. Force ring gear to mesh with pinion
gear. Rock ring gear to allow the teeth of the gears
to mesh. With force still applied to the differential
case, set indicator at zero "0".
Tool-Indicator D-128.

Dlffll!!HTIAL lURING SIIIM PA()(S

Figure 57 1021-57

Figure 59 1021-59
The illustration shows the arrow in the pinion
pointing in two directions_ The direction of the Force the differential assembly (ring gear) away
arrow pointing towards the end yoke indicates from the pinion gear, to obtain an indicator
that by removing pinion locating shims, the reading. Repeat until the same reading is obtained
distance from the centerline of the axle to pinion each time. This reading will be the necessary
button, is increased giving a plus reading. The amount of shims between the differential case and
preload shim pack does not affect the pinion depth differential bearing on the ring gear side. Remove
setting. indicator and differential case from the carrier.
Arrows on the ring gear illustrate the method to Remove master bearings from differential case_
increase or decrease backlash, and differential
bearing load_

ASSEMBLY OF DIFFERE NTIAL

Place differential assembly (with pinion
assembled) into housing_ Differential master
bearings should still be installed to differential
case.

Figure 58 1021-58
Figure 60 1021-60

20
 SERVICE PROCEDURES
Assemble the required amount of shims onto
hub (ring gear side) as determined in FIGURE 59.
Place bearing cone on hub of case. Use bearing
installer to seat bearing cone as shown. Step plate
is used to prevent possible damage to hubs, while
assembling bearings.

Tools-Installer C3716-A, Handle C-4171.

Assemble the remaining of the total shim pack

which was determined in FIGURE 37 on the
opposite side of the differential case. Add an
additional .010" (.25mm) of shims on this side to
provide differential bearing preload. Assemble
differential bearing using the tools shown.

For example:
In FIGURE 37 (less pinion) a total of .085"
(2.03mm) indicator reading was recorded. Figure 62 1021-62

In FIGURE 59 (with pinion) a total of .055" A ssemble differential bearing cups to

(1.4mm) indicator reading was recorded. This differential bearing cones.
leaves a balance of .030" (.76mm) of shims for the Install differential assembly onto carrier.
opposite side and adds up to the .085" (2.16mm) Use a rawhide hammer to seat differential
which was first recorded. assembly into cross bore of carrier. Care should be
taken to avoid nicking the teeth of the ring gear
Add an additional .010" (.25mm) shims on the and pinion during assembly. Remove spreader.
opposite side for bearing preload and backlash.
Ring Gear Side .055" (1.4mm).
Opposite Side .030" (.76mm) balance plus
opposite side preload .010" (.25mm) for a total of
.040" (1.02mm).

Figure 63 1o21-6l

Install bearing caps. Make sure the letters

stamped on the caps correspond with those on the
carrier. Torque bearing cap screws to 35-50 lbs. ft.
(47.5 - 67.8 N.m).
Figure 61 1021-s1

Mount spreader with adapter blocks and hold-

down screws and indicator to carrier as shown.
Do not spread carrier ove r .020" (.50 mm).
After carrier has been spread, remove indicator.
Tools-D-113 Spreader, D-263-1 Adapter Blocks.

21
 SERVICE PROCEDURES

Figure 65 1o21-6s

Install axle shafts through side gear spline,

exposing the snap ring groove inside the
differential. Place the snap ring in the groove and
force it into place using a blunt screw driver or
other suitable tool.
Figure 64 1021-64

Check ring gear and pinion backlash in three CAUTION

equally spaced points with dial indicator shown. To avoid injury, wear eye protection. Ifthe
Backlash tolerance is .005" to .009" (.13 to tool slips, the snap ring may fly out.
.20mm) and cannot vary more than .003" (.75mm)
between points checked.
High backlash is corrected by moving the ring
gear closer to the pinion.
Low backlash is corrected by moving the ring
gear away from the pinion.
These corrections are made by switching shims
from one side of the differential case to the other.
Tool-D-128 Indicator.

TOTAL TORQUE TO ROTATE

Use an inch lb. torque wrench as illustrated in
FIGURE 56. The total torque to rotate both the
pinion and ring gear should read 40 lbs.-in. (4.5
N m) maximum.
Low torque reading is corrected by adding shims
to the side opposite the ring gear. Figure 66 1021-66

High torque reading is corrected by removing

shims from the side opposite the ring gear. Fill the two W' diameter manufacturing holes
If it becomes necessary to add or subtract shims with silicone-type sealant material meeting
for total turning torque, check backlash again to ASTM3 specification GE303, A19, B37, E16, Z1, Z2
make sure it is within specifications as spelled out and Z3. Install new cover gasket and cover plate.
in FIGURE 64. Torque screws to 30-40 lbs.-ft. (40.7-54.2 Nm).

22
 SPICER

RING GEAR & PINION TOOTH PATTERN INTERPRETATION

When setting the pinion position, many of the service manuals required a final pinion
position check by using gauges that verified the dimension from the center line of the
differential carrier (center line of ring gear) to the face of the pinion (button).
This surface (button) is not used on all new gears for verifying the pinion position. The
service tools will be used to establish the proper amount of shims required prior to in
stalling the pinion gear. The final pinion position will be verified by using the GEAR
CONTACT PATTERN METHOD, as described in this bulletin.

RING GEAR AND PINION TOOTH CONTACT PATTERN

LENGTHWISE
BEARING
ARC
HEEL

\o--..l.- _____ j __ _

Figure 1 - RING GEAR TOOTH

The TOE of the gear tooth is the portion of the tooth surface at the end towards the center.
The HEEL of the gear tooth is the portion of the tooth surface at the outer end. The TOP
LAND of a gear tooth is the surface of the top of the tooth. Every gear has a characteristic
pattern. The illustrations show typical patterns only, and explains how patterns shift as gear
location is changed. When making pinion position changes, shims should be changed in the
range of .002 inch (.05 mm) to .004 inch (.10 mm) until correct pattern has been obtained.
When a change in backlash is required, backlash shims should be changed in the range
of 1-112 times the amount of backlash required to bring the gears into specification. For
example, if the backlash needed to be changed by .004 inch (.10 mm), the shim pack
should be changed by .006 inch ( . 15 mm) as a starting point. The actual amount of backlash
change obtained will vary depending upon the ratio and gear size.
High backlash is corrected by moving the ring gear closer to the pinion. Low backlash
is corrected by moving the ring gear away from the pinion. These corrections are made by
switching shims from one side of the differential case to the other.

NOTE
When making changes, note that two variables are involved. Example: If you have the back
lash set correctly to specifications and you change the pinion position shim, you may have to
readjust the backlash to the correct specification before checking the pattern. Refer to pattern
interpretation.

WARNING: Gear teeth may have sharp edges.

When handling gears, use care to avoid personal
injury.
 STEPS
(I) Paint ring gear teeth with a marking compound to both the drive and coast side.
(2) Rotate ring gear one complete revolution in both directions while load is being
applied with a large screwdriver or similar tool between the carrier casting and
differential case flange.

PATTERN INTERPRETATION
(RING GEAR)
DRIVE SIDE COAST SIDE
HEEL TOE TOE HEEL Normal or desirable pattern. The drive pat

tern should be centered on the tooth. The
coast pattern should be centered on the tooth,
but may be slightly toward the toe. There
should be some clearance between the pattern
and the top of the tooth.

Backlash correct. Thinner pinion position

shim required.

Backlash correct. Thicker pinion position

shim required.

Pinion position shim correct. Decrease back

lash.

Pinion position shim correct. Increase back

lash.

PATTERN MOVEMENTS SUMMARIZED

(I) Decreasing backlash moves the ring gear closer to the pinion.
Drive pattern (convex side of gear) moves slightly lower and toward the toe.
Coast pattern (concave side of gear) moves lower and toward the toe.

(2) Increasing backlash moves the ring gear away from the pinion.
Drive pattern moves slightly higher and toward the heel.
Coast pattern moves higher and towards the heel.

(3) Thicker pinion position shim with the backlash constant moves the pinion closer to the
nng gear.
Drive pattern moves deeper on the tooth (flank contact) and slightly toward the toe.
Coast pattern moves deeper on the tooth and toward the heel.

(4) Thinner pinion position shim with the backlash constant moves the pinion further from
the ring gear.
Drive pattern moves toward the top of the tooth (face contact) and toward the heel.
Coast pattern moves toward the top of the tooth and slightly toward the toe.

Specifications, descriptions and illustrations contained in this manual are as accurate as known aJ
time this publication was approved for printing. Dana Corporation, Spicer Axle Division, reserves then<
to make changes from time to time without notice or obligation, in specifications, descriptions, ana
illustrations; to discontinue models or revise designs.

BULLETIN NO. 5325