Beruflich Dokumente
Kultur Dokumente
Service Manual
AXSM0057
January 2009
D170 Series
D190 Series
D590 Series
General Information
General Information
General Inspection
The description and specifications contained in this service publication are current at the time of printing.
Dana Corporation 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 simply as an example of the types of tools and materials recommended
for use and should not be considered an endorsement. Equivalents, if available, may be used.
Important Notice
General Information
Table of Contents
Drive
Pinion
page 25
Wheel
Differential
Assembly
page 35
Power
Divider
page 12
Carrier
Assembly
page 23
Seals
page 55
Inter-Axle
Lockout
page 11
Differential
Carrier
Assembly
page 8
Wheel
Differential
Lock
page 48
Wheel
End Seal
page 59
ii
Housing
Breather
page 58
Output Shaft
Assembly &
Rear Cover
page 49
Lubrication
page 66
Table of Contents
Introduction ........................................................1
Model Identification ............................................2
Parts Identification ...................................................... 2
Inspection ...........................................................6
Drive Pinion Overhaul and Assembly Forward and Rear Carrier Assembly ..................28
Wheel Differential - Parts Exploded View ..........35
Wheel Differential Disassembly .........................36
Wheel Differential Assembly .............................38
Wheel Differential Assembly ............................40
Adjust Tooth Contact Position ..........................45
Wheel Differential Lock Parts Exploded View .........................................47
Install and Adjust Wheel Differential Lock .........48
Housing and Output Shaft Assembly Parts Exploded View .........................................49
Drain.......................................................................... 68
Fill.............................................................................. 68
Standpipes ........................................................69
Final Check ................................................................ 70
Table of Contents
General Information
Introduction
Dana Corporation, Commercial Vehicle Systems Division, presents this publication to aid in maintenance and overhaul of
Dana tandem drive axles.
Instructions contained cover the models listed. Their design is
similar, with primarily 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 optional
lube pump. The pump is designed to provide additional lubrication to the inter-axle differential and related parts.
Model Information
The following models are included in this publication:
Heavy Tandems
D40-170
D46-590HP
D40-170(P)
D50-170
D40-170D(P)
D52-190P
D46-170
D52-190DP
D46-170(P)
D52-590P
D46-170D(P)
D60-190P
D46-170H
D60-590P
D46-170H(P)
D70-190P
D46-170DH(P)
Model Listing
D 46-1 7 0 D
D - Dual Drive Forward Axle
with Inter-Axle Differential
G - Single Rear Axle (Global)
R - Dual Drive Rear Axle
S - Single Rear Axle (N.A.)
GAW Rating
x 1000 lbs. (N. America) "-"
x 1 Tn. (Europe) "."
Gear Type
1 - Standard Single Reduction
2 - Dual Range
3 - Planetary Double Reduction
4 - Open
5 - Helical Reduction
Options
C - Controlled Traction
D - Differential Lock
E - High Entry Single
H - Heavy Wall
I - Integral Brake
L - Limited-Slip
P - Lube Pump
R - Retarder Ready
W - Wide-Track
Design Level
Head Assembly Series
General Information
General Information
Model Identification
Drive Axle
1 - Country or origin
2 - Axle model identification
3 - Specification number assigned to the axle built by Dana.
Identifies all component parts of the axle including special
OEM requirements such as yokes or flanges.
Parts Identification
Axle Housing
Axle Shaft
Spic
.
. NO
PT CAP. .
G. NO IN
HS I.D. DE
MA
G.
HS ING
US
HO
1 - ID Tag
erLBS.
General Information
38
127381
SPICER
OF
NL2
41-8
1
2
8
6
17
SPICER
H
70
12
8-41
428
127
3
1
L7038
6-39
85405
JD77
86
EA
TO
4
1 - Part number
2 - Number of ring gear teeth
3 - Manufacturing numbers
4 - Matching gear set number
5 - Number of pinion teeth
6 - Date code
7 - Indicates genuine Spicer parts
8 - Heat code
L70
4
6
17 G
Inspection
Failure Analysis
Failure analysis is the process of determining the original
cause of a component failure in order to keep it from
happening 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 broken 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.
Inspection
2.
3.
4.
5.
Inspection
When tearing down the drive axle, do it in the recommended manner. Minimize any further damage to the
unit.
Inspection
Inspection
Clean
1.
1
WARNING
1 - Axle housing
2 - Machined surface
Inspect Components
4.
5.
Oil parts.
Differential gearing.
Look for elongation of drilled holes, wear on surfaces machined for bearing fits and nicks or burrs in
mating surfaces.
CAUTION
Any damage which affects the alignment or structural integrity 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.
Inspection
Inspection
Endplay Procedure
Check Input Shaft Endplay (Forward Axle)
Note: Before disassembling the power divider, measure and
record input shaft endplay.
1.
2.
3.
Using a pry bar, move input shaft axially and measure/record endplay.
2.
3.
Using a pry bar, move output shaft axially and measure/record endplay.
Adjustment
Correct endplay for a new assembly is 0.001" to 0.045". The
maximum endplay for a used assembly is no more than
0.045". If endplay is incorrect, contact Dana.
Adjustment
Correct endplay for a new assembly is 0.001" to 0.005". See
the "Input Shaft Endplay" procedure in the "Power Divider
Assembly" section for proper endplay adjustment procedure.
1
2
3
1
Differential Carrier
Assembly
1 - Carrier fasteners
2 - Carrier assembly
3 - Forward axle assembly
4 - Rear axle assembly
2.
3.
4.
5.
6.
7.
WARNING
8.
9.
CAUTION
IMPORTANT
2.
3.
Install axle shafts and axle stud nuts. (If used, also
install lock washers and tapered dowels.)
4.
5.
6.
7.
Differential Carrier
Assembly
10
Inter-Axle Lockout
Disassembly
2
3
4
5
1.
2.
3.
4.
Note: In order to remove the shift fork and push rod parts,
first remove the power divider cover. See the Power
Divider section.
Assembly
1 - Compression spring
2 - Shift fork assembly
3 - Piston
4 - O-ring
5 - Piston cover
11
1.
2.
Gently push the piston o-ring assembly into the lockout cylinder bore. Make sure the piston assembly is
pushed in all the way.
3.
4.
5.
Power Divider
1
2
44
3
4
5
6
7
8
Power Divider
19
20
21
22
27
10
25
14
26
15 16
28
17
11
29
18
12
30
23
31
32
11
24
13
33
34
35
36
43
42
37
41
40
16 - Pin
17 - Output side gear
18 - Pump
19 - Inter-axle differential
20 - Helical side gear
21 - Thrust washer
22 - Lockout sliding clutch
23 - Shift fork spring
24 - Shift fork assembly
25 - V-ring
26 - Input shaft
27 - Input shaft
28 - Input shaft bearing cone
29 - Carrier housing
30 - Locking capscrew
38
39
31 - Input cover
32 - Input cover capscrew
33 - Bearing cup and cage
34 - Input seal
35 - Input yoke
36 - Input nut
37 - Piston
38 - O-ring
39 - Piston cover
40 - Pinion cover
41 - Input cover capscrew
42 - Input cover
43 - Carrier housing
12
Power Divider
2.
3.
4.
5.
CAUTION
CAUTION
8.
9.
2
3
6.
13
Power Divider
14. Input cage is threaded into the PDU cover, use the
proper tool to remove the cage from the cover.
Cover Pilot
Adjuster Pilot
14
Power Divider
Power Divider
Pump Disassembly
For output side gear and/or pump replacement, follow the
procedure below.
1.
3.
4.
1 - Press
2 - Press Tool
2.
15
Power Divider
2.
IMPORTANT
Power Divider
1 - Barbed Nipple
16
Power Divider
Manifold Assembly
1.
1 - Barbed Nipple
2.
3.
4.
Power Divider
Pump Assembly
Use these instructions with the carrier assembly in or out of
the vehicle.
2.
Power Divider
CAUTION
Install the pump into the output side gear so that the
pump shaft is facing toward the teeth end of the side
gear.
1 - Machined Slot
2 - Pin
18
Power Divider
5.
6.
1 - Press
2 - Press Tool
2.
Fully press the output side gear bearing cup into the
carrier seat.
IMPORTANT
4.
19
Power Divider
9.
b.
2
5
3
1.25 to 1.75 mm
1 - Press
2 - Sleeve
3 - 1st bushing (press to shoulder)
4 - Shoulder
5 - Sleeve
6 - 2nd bushing (recess 1.25 to 1.75 mm)
7.
8.
1 - Press
2 - Press Tool
3 - Bearing
4 - Input shaft
11. For High Entry Applications Only:
Install shaft/gear assembly. Proceed to step 13.
20
Power Divider
Power Divider
IMPORTANT
190 Cover
1 - One Notch
170 Cover
21
Power Divider
Stud
Jam Nut
CAUTION
WARNING
Failure to stake the pinion nut properly may result in the nut
coming loose during service. The pinion nut should never
be reused, always replace with new.
Note: A torque multiplier is recommended. If difficulty achieving correct torque, torque the nut with the truck wheels
on the ground and with the axle shaft installed.
22
Power Divider
22. Use a punch with a round tip to stake the pinion nuts
flange into the machined slot in the pinion shaft. See
diagram below.
Carrier Assembly
2.
3.
4.
5.
23
Carrier Assembly
6.
8.
2
1
9.
Carrier Assembly
24
Drive Pinion
Pinion Removal
1.
b. For S190 disassembly, use the pry slots provided at each end of the pilot web.
2.
1 - Slots
3.
Before the pinion nut can be loosened, you must destake the nut from the slot of the pinion.
4.
25
Drive Pinion
7.
1
Failure to de-stake the pinion nut will result in damage to
the drive pinion threads when removed. The pinion nut
should never be reused, always replace with new.
1
2
3
1 - Press
8.
5.
6.
2
1
IMPORTANT
1 - Carrier Assembly
2 - Press
3 - Pinion
4 - Wood Block
26
Drive Pinion
CAUTION
Drive Pinion
3
4
5
6
7
8
5
6
7
8
9
10
27
9 - Yoke
10 - Pinion nut
Drive Pinion
Drive Pinion Overhaul and Assembly - Forward and Rear Carrier Assembly
2.
Remove the inner pinion bearing cone from the pinion using a split-type puller. Use two procedure
steps to remove each bearing.
a. Mount the puller vertically to separate the
bearing from the pinion. This action will force
the puller halves behind the bearing race and
start moving the bearing from the pinion.
The following procedure covers both the forward and rear axle
carrier overhaul and assembly.
Note: See carrier disassembly for instructions on pinion and
yoke removal.
1.
1 - Press
28
Drive Pinion
Drive Pinion
IMPORTANT
EA
6-39
TO
N
3.
JD77
86
L7038
d. To install the outer bearing cup, place the carrier in a press with the top of the carrier facing
up.
4.
29
Drive Pinion
5.
7.
8.
Note: If you are using the same drive pinion, use the same
spacer that was originally installed in the assembly. If
the drive pinion is to be replaced, the original spacer will
be used as the starting point of adjustment.
1 - Large - Long Boss
6.
30
Drive Pinion
Drive Pinion
9.
11. Align a 6 x 6 x 6 wood block under the drive pinion, then lower the carrier and pinion assembly into
a press so that it is supported by the block.
10. Install a pinion nut finger tight. This will hold the pinion in place while it is positioned into the press.
12. Remove the pinion nut.
13. Place a press sleeve over the top of the outer bearing
cone. Use the press to apply 5 tons of force. It is
important to rotate the carrier slightly to make sure
that the rollers of the bearing are properly seated.
31
Drive Pinion
16. Run the nut down with an impact gun. The pinion
should still have the same slight drag that was
obtained in the press.
Drive Pinion
32
Drive Pinion
TIP: A torquing wedge can be made to hold the helical gear from turning while the nut is torqued.
18. Install the wedge between the carrier wall and the
teeth of the helical gear.
1 - Wedge
19. Torque the nut to 800-1000 lbs. ft.
(1084-1355 Nm).
Note: Always use a new nut and coat threads with Loctite 277
if not pre-coated.
TIP: If you are unable to torque the yoke nut correctly, try torquing the nut with the truck wheels on
the ground and with the axle shafts installed.
33
Drive Pinion
Drive Pinion
CAUTION
WARNING
1
Failure to stake the pinion nut properly may result in the nut
coming loose during service. The pinion nut should never
be reused, always replace with new.
22. For D170 assembly, install the pinion cover. Apply a
bead of Loctite 518 sealant to the outer flange of the
cover.
1 - Locating Sleeves
26. Install capscrews and torque to the proper specifications. See the Torque Chart.
23. Install the cover, making sure that the cover is parallel to the carrier opening.
34
Wheel Differential
1
2
3
4
7
8
6
9
11
12
10
35
6 - Side gear
7 - Side pinion
8 - Differential spider
9 - Differential case - plain half
Wheel Differential
4.
Place a block under the plain half, use a rubber mallet to remove the ring gear.
5.
IMPORTANT
Wheel Differential
2.
36
Wheel Differential
6.
37
b.
Wheel Differential
5.
6.
IMPORTANT
2.
3.
38
Wheel Differential
4.
Wheel Differential
39
7.
8.
9.
Wheel Differential
1.
Wheel Differential
Note: There are two ways to make sure that the threaded cups
are seated properly. If there is a misalignment, reinstall
the differential assembly at a slightly different angle.
3.
2
1
1 - No gap
40
Wheel Differential
4.
6.
1 - Parallel
5.
1 - Flange Half
2 - Plain Half
7.
1 - Two Notches
8.
41
Wheel Differential
9.
With a dial indicator, check the ring and pinion backlash. Set the backlash from 0.010" to 0.012". This
will give you room to adjust the contact pattern, if
necessary.
Note: If you have too much backlash, move the ring gear
closer to the pinion. Count the number of notches you
back off the plain half threaded cup. Each notch equals
about 0.003" (0.08 mm) of backlash.
IMPORTANT
15. Measure the ring gear total backface runout. Indicator reading should not exceed 0.010" (0.25 mm).
42
Wheel Differential
Wheel Differential
20. Use the correct socket and a breaker bar to rotate the
differential. The differential should be hard to turn.
Rotate the pinion until the ring gear rotates 3 or 4
times in both directions. See page 45 for descriptions of correct pattern position for new and used
gearing.
43
Wheel Differential
Wheel Differential
1 - Machined slot
2 - Bearing Adjustment Ring
3 - Round Head Punch
44
4
5
6
1 - Face width
2 - Tooth depth
3 - Heel
4 - Top land
5 - Root
6 - Toe
1 - Pattern along the face width could be longer
1.
2.
45
Pinion position is determined by the size of the pinion bearing cage shim pack. It controls contact on
the tooth depth of the gear tooth.
1.
2.
3.
4.
1.
2.
3.
4.
46
9
3
4
2
5
6
7
8
1 - Sliding clutch
2 - Spring
3 - Clutch fork
47
7 -Washer
8 - Switch
9 - Pin
2.
Position spring, shift fork and clutch in shift opening of the carrier. Align pilot hole of shift fork with
the pilot hole of carrier.
3.
4.
5.
6.
7.
8.
48
5
6
7
9
10
11
21
19
12
13
20
14
15
22
16
17
18
25
26
24
23
Welded Rear Cover
27
49
10 - Rear cover
11 - Rear cover capscrew
12 - Fill plug
13 - Rear cover nut
14 - Washer
15 - Stud
16 - Spindle nut - Outer
17 - Locking ring
18 - Spindle nut - Inner
19 - Axle housing
20 - Breather
21 - Breather hose
22 - Carrier capscrew
23 - Nut
24 - Washer
25 - Stud
26 - Drain plug
27 - Axle shaft
2.
3.
6
1
2
3
1.
6.
4
5
1 - Snap Ring
2 - Outer Bearing Cup
3 - Output Shaft Assembly
4 - Inner Bearing Cup
5 - Rear Cover Assembly
6 - Output Seal
5.
50
8.
1 - Press
51
9.
b.
CAUTION
8.
Using snap ring pliers, install the snap ring that fastens the outer bearing cup into the welded-on cover
assembly.
9.
Check the endplay of the output shaft. New assemblies should measure 0.001" to 0.045" (0.03 to 1.143
mm)
2.
3.
3
4
5
CAUTION
6.
1 - Press
2 - Plate
3 - Sleeve
4 - Press Bearing on Second
5 - Press Bearing on First
6 - Output Shaft
7 - Plate
52
7.
6
1
2
3
4
5
1 - Snap Ring
2 - Bearing Cup
3 - Output Shaft Assembly
4 - Inner Bearing Cup
5 - Rear Cover Assembly
6 - Output Seal
IMPORTANT
53
Measure
Correct endplay for a new assembly is 0.001" to 0.045" [0.03
to 1.143 mm]. The maximum endplay for a used assembly is
no more than 0.045" (1.143 mm). If endplay is incorrect, contact Dana.
Install oil seal.
2.
Install yoke.
3.
b.
1.
54
Seal - Replace
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.
CAUTION
5.
Inspect axle endplay at the yoke (see page 10). Service if beyond specified limit.
WARNING
55
3.
4.
6.
7.
Seal - Replace
CAUTION
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 polishing from the seal lips.
Note: Do not rework the yoke with abrasives such as emery
paper or crocus cloth. Clean the surface of the yoke as
necessary using chemical cleaners. Remove all trace of
the chemicals from the yoke after cleaning.
Seal - Replace
CAUTION
56
Seal - Replace
Service Kit
D-Input
D-Output
R-Pinion
Location
Tool
210749
210749
131471
131472
57
131472
Housing Breather
2.
Housing Breather
Housing Breather
4.
5.
3.
58
1 - Installation tool
2 - Seal
3 - Rear hub
59
1.
Inner bearing
2.
3.
IMPORTANT
2.
3.
4.
CAUTION
Note: Deep gouges can be repaired by filling gouge with hardening gasket cement and smoothing with emery cloth.
6.
Clean hub cavity and bearing bores before reassembly. Be sure to remove contaminants from all
recesses and corners.
7.
IMPORTANT
60
WARNING
3.
CAUTION
Back off the inner nut one full turn. Rotate the wheel
hub.
9.
CAUTION
5.
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.
61
6.
7.
3
4
1 - Inner Nut
2 - Dowel Pin
3 - Dowel-type Lock Washer
4 - Outer Nut
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).
2 1
1 - Inner Nut
2 - Dowel Pin
3 - Dowel-type Lock Washer
4 - Tang-type Lock Washer
5 - Outer Nut
1
2
1 - Inner Nut
2 - Tang-type Lock Washer
3 - Outer Nut
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.
CAUTION
Never tighten the inner nut for alignment. This can preload
the bearing and cause premature failure.
b. Install the Tang-type lock washer on the spindle.
CAUTION
Never tighten the inner nut for alignment. This can preload
the bearing and cause premature failure.
Axle shaft
62
2.
3.
CAUTION
63
Before operating the axle, the wheel hub cavities and bearings must be lubricated to prevent failure.
When wheel ends are serviced, follow Danas wheel end
lubrication procedure before operating the axle.
Dana axles may be equipped with either of two wheel end
designs:
Wheel ends with an oil fill hole.
Rotate the wheel end hub until the oil fill hole is up.
2.
3.
4.
1.
64
2.
With axle level and wheel ends assembled, add lubricant through filler hole in axle housing cover until
fluid is level with the bottom of filler hole.
Raise the right side of the axle 6 " or more. Hold axle
in this position for one minute.
3.
4.
Raise the left side of the axle 6 " or more. Hold axle in
this position for one minute.
1 - With axle on level surface, fill housing with oil to bottom of plug
2 - Temperature sensor mounting hole
3 - Oil will run into wheel end
4 - Oil will run into wheel end
5 - Tilt housing side to side (1 minute per side)
6 - Recheck oil level in axle
65
5.
6.
Note: Axles without wheel end fill holes will require approximately 2.5 additional pints of lubricant to bring the lube
level even with the bottom of fill hole.
Lubrication
Approved Lubricants
GeneralGear lubrications acceptable under military specification (MILSPEC) MIL-L-2105E (Lubricating Oils, Gear,
Multipurpose) are approved for use in Dana Drive Axles. The
MIL-L-2105E 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 petroleumbased and synthetic based gear lubricants if they appear on
the most current Qualified Products List (QPL-2105) for
MIL-L-2105E.
75W
Note: The use of separate oil additives and/or friction modifiers are not approved in Dana Drive Axles.
75W-90*
75W-80
75W-140
80W-90
80W-140*
85W-140
Lubrication
Grade
66
Lubrication
Severe Service Lubrication Change IntervalsSevere service 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 HIGHWAY 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.
Synthetic or Lubricant
Mineral
SAE
Synthetic*
SHAES-256
SAE 75W-90
Synthetic**
SHAES-256
SAE 75W-90,
75W-140
Mineral
Base
MIL-L-2105E/J02360,
API GL-5 Gear Oil,
MIL-PRF-2105E
75W, 75W-90,
75W-140, 80W90, 85W-140
67
Lubrication
Change Lube
Drain
Always use the filler hole as the final reference. If lube is level
with the bottom of the hole, the axle is properly filled.
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.
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 corrosion. Clean or replace as necessary.
Fill
Front Axle
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 section.
68
Lubrication
Lubrication
Standpipes
Drive axles are lubricated with oil drawn from a large sump
integral to the assembly. Most axle designs attempt to position vital components such as pinion bearings in close proximity 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 bearings 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 manufacturer.
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 routine basis.
The chart gives standpipe recommendations for vehicles
operating in consistently mountainous areas.
D190
Axle Installation
Angle
Axle Location
Quantity
(pints)
12
Rear
29*
10
Rear
30*
Rear
31
Forward
Rear
42.5
32
Forward
Rear
44.5
33.5
Forward
Rear
47
35
Forward
Rear
50
36
Axle Installation
Angle
Axle Location
Quantity
(pints)
12
Rear
29*
10
Rear
30*
Rear
31
Installation
Angle*
5-10%
Grade
10-15%
Grade
15-20%
Grade
Forward
Rear
39
32
2.00"
Forward
Rear
41
33.5
1.00"
2.25"
Forward
Rear
43
35
1.25"
2.50"
10
1.50"
1.75"
2.75"
Forward
Rear
45
36
13
1.75"
2.00"
3.00"
15
2.50"
2.50"
3.25"
69
Lubrication
12 Installation
5-10%
Grade
10-15%
Grade
15-20%
Grade
1.00"
1.00"
1.75"
1.75"
2.00"
10
2.00"
2.25"
13
1.00"
2.25"
2.75"
15
2.00"
2.50"
3.25"
2
1
Horizontal Mounting
Lubrication
2
1
2
1
Note: Grades must be continuous or lengthy in nature. Monitor 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 necessary.
70
Towing Guide
2.
3.
4.
5.
6.
Install temporary cover on hub to prevent contamination entering and also to prevent the loss of lubricant.
WARNING
71
Theory of Operation
5
3
1 - Input torque
4 - Rear axle torque is transmitted from the output shaft side
2 - Lockout disengaged
gear through the output shaft, inter-axle driveline, drive
3 - Forward axle torque is transmitted from the helical side
pinion, ring gear, wheel differential and axle shafts.
gear through the pinion helical gear, drive pinion, ring gear, 5 - Input torque (power flow) from the vehicle driveline is
wheel differential and axle shafts.
transmitted to the input shaft and the inter-axle differential
spider. The differential distributes torque equally to both
axles.
72
Theory of Operation
The power divider also includes a driver-controlled, air-operated lockout. When lockout is engaged, it mechanically prevents inter-axle differentiation for better performance under
poor traction conditions.
Theory of Operation
CAUTION
1
2
5
3
73
Theory of Operation
2.
When the control switch is placed in the lock position, 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.
74
Theory of Operation
1.
Theory of Operation
10
6
7
5
4
75
6
7
8
Theory of Operation
9
3
4
2
5
6
7
8
1 - Sliding clutch
2 - Spring
3 - Clutch fork
4 - Piston and rod
5 - O-ring
6 - Piston cover
7 - Washer
8- Switch
10
9 - Pin
10 - Carrier
76
Theory of Operation
Theory of Operation
When air pressure at the shift cylinder is released, a compression 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 differential is unlocked and operates normally.
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 differential action.
5
4
5
4
1
6
6
77
Parts Identification
1
2
44
3
4
5
6
7
8
19
20
21
22
27
10
25
14
26
15 16
28
17
11
29
18
12
30
23
31
32
Parts Identification
11
24
13
33
34
35
36
43
42
37
41
40
38
39
29 - Carrier housing
30 - Locking capscrew
31 - Input cover
32 - Input cover capscrew
33 - Bearing cup and cage
34 - Input seal
35 - Input yoke
36 - Input nut
37 - Piston
38 - O-ring
39 - Piston cover
40 - Pinion cover
41 - Input cover capscrew
42 - Input cover
43 - Carrier housing
78
Parts Identification
2
1
3
4
5
6
7
8
79
Parts Identification
2
3
4
1
5
6
7
8
9
10
9 - Yoke
10 - Pinion nut
Parts Identification
80
Parts Identification
9
3
4
2
5
6
7
8
1 - Sliding clutch
2 - Spring
3 - Clutch fork
81
7 - Washer
8 - Switch
9 - Pin
Parts Identification
1
2
3
5
6
7
9
10
11
21
19
12
13
20
14
Parts Identification
15
22
16
17
18
25
26
24
23
Welded Rear Cover
27
10 - Rear cover
11 - Rear cover capscrew
12 - Fill plug
13 - Rear cover nut
14 - Washer
15 - Stud
16 - Spindle nut - Outer
17 - Locking ring
18 - Spindle nut - Inner
19 - Axle housing
20 - Breather
21 - Breather hose
22 - Carrier capscrew
23 - Nut
24 - Washer
25 - Stud
26 - Drain plug
27 - Axle shaft
82
Size
Lbs. Ft.
Nm
M8 x 1.0 x 30
13 + 17
17 + 23
M12 x 1.75
15 + 20
20 +27
M12 x 1.75
60 +65
81 + 88
2.375 - 16 UN-2A
65 + 10
85 + 15
M14 x 1.5 x 45
175 + 10
235 + 10
M48 x 1.5
900 + 100
1220 + 135
M48 x 1.5
900 + 100
1220 + 135
M42 x 1.5
900 + 100
1220 + 135
M48 x 1.5
900 + 100
1220 + 135
M20 x 1.5 x 55
500 + 25
675 + 30
M18 x 1.5 x 85
265 + 15
360 + 20
M16 x 1.5 x 85
250 + 15
335 + 20
M16 x 1.5 x 55
250 + 15
335 + 20
M16 x 1.5
250 + 15
335 + 20
M16 x 1.5 x 70
210 + 10
285 + 15
M14 x 1.5
10 + 1
15 + 3
2.375 - 16 UN-2A
65 + 10
85 + 15
M16 x 1.5 x 70
250 + 15
335 + 20
M16 x 1.5 x 55
250 + 15
335 + 20
M16 x 1.5
250 + 15
335 + 20
1 x 11.5 NPTF
50 + 5
72 + 5
Drain Plug
0.750 - 14 NPTF
50 + 5
72 + 5
Housing Breather
0.375 - 18 NPTF
20 - 26
27 - 35
0.500 - 20 NPTF
50 + 5
72 + 5
0.625 - 18
180 + 10
245 + 15
0.750 - 16
315 + 30
425 + 40
2.37-16UN 2A
65 + 10
85 + 15
POWER DIVIDER
CARRIER
HOUSING
Rear Cover Capscrews
83
For specing or service assistance, call 1-800-826-HELP (4357) or visit our web site at
www.roadranger.com. In Mexico, call 001-800-826-4357.
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Dana Commercial Vehicle Products Group P.O. Box 4097 Kalamazoo, MI 49003 U.S.A. www.roadranger.com