9374902 dana 60 axle repair manual i

5/10/2018 9374902 Dana 60 Axle Repair Manual I

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AXLEMIAIINTENAN'CE

MAN lUI ,A IL ,

FR 'ON I'T ' ,A ND REARCAR, IRI I IE IR TYP'E

BPJCE'" AXLE10"''''ON I~AN'" " ' ' ' R ' 'D R ' '' ' 'I ' 'O ' 'Fc:!IR,T WAVINE. INDIANA,


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I N I D E X .

L 'UBA :IC A .T I10N ., .. " "',, ,.,. _ . " ,. " ". " . , " . " , " .. , ." : : I1 llllllE lN l'IF IlC A T lQ iN O l F S ERV IC I I! TO O LS, " _ . __ .._ "" " , , , .. " " , 4 ,AXLE ID IE N T IIIF IC A T IIO N " , _ , ., " . , . , , , , .. , ,,5,IFRONT AXLES""", WHIEEIL ENIOS

C ll il i lsedl KII l I 'wtkle Design {lJ-IlIJb& . D rum .} "' . . _ , , .. , . __ . ' ., ,.. , , .. , .8Spllf ' in,g] Lloadedl Kit1lQ P'iin D e s ~ g , 1 ' 1 I (~lUb a t R ob.'J1r} ",., ... _ . , , , . , n , , " " , " ' " " 14 ,REAR AXL~!i ~ W'IHEEl ENOS,. SEMI-FL,OAl' DIES~GN

UIl!1iltWlheell Bearilli'lg " " .. " " " .. "." " .. " . ", ... - .. " .,..- , , . " . , . , " " .. " 2.0(LlJ!!bwi'e3ted wiilhl HYl l lOid Ge,ar Lull'9)U!'ll~ "Whee!1 Bea rin g , , ,, ,., , .. , , , ., ,.,, ,, .. ,, .,, ., , .. , .. , .. ,.. ,, . , , , , 2:2(ll~ b r i' ~ ii lted ww,h ' G i l ll ' e ' ,a s e } l,Sha 'U R id lin g Bea ,l['in g "." " " .. , , ' , . , , . , _. , , , , '" , , . 2:1(l ll l .!briuG atedw ii1h H I,p o, i:d G ,ea r Lube)

f l lEAR AXLES, ""'"'WHI IEE IL ENO S ", FUL l-F LO I ,A T D E SI 'G N . _,.. , __ ,._; __ " . " , ...... , . , .. , . , ... 12C :A R ,IR IIIE R S,IE C T IO N , " , " " .. " .' " ,. , " . , . , " , .. '" . " .. , , . J. 4

I MPORTA lN T SAFIET't NOT I C EProper serv ice and repair is imponRn: t to 'the sa~e, :reliable' operation of a 1 ! l - ( 'Mo to r V l }h ic le s) Of' ~drivingH id es wE e ther they be; ffll:;m,'t, or I t" e!l 'r ). T h, '1 S s -e rv ic e p ro ee d ue es reeommeadad an d d i.esc ri .b ed ill tums servicern an na l a re ~ f1 !2 :c ti V!E :e th od s fu r perfurmins :3cerv:ieeoperatiOtlB, Som e of th ese se rv ie e o p.a rn ti on s roquir!'J tile

use ,af tl oo ls s pe ci Stl ]y d e :s ig ore d fo r the p1Hpos -e . Th il il !special 1001 :sholl i l d be used wl:1oo an d ;;'IS reCQmmeilde:ofI I .It is impossible t O o k~ow. evalluate. aad ~(hri;5ethe ~:rvic~ tradle ,fif ~1I a ; l' l lce i .v :B !Me ways In whlch sen.icemight he don~ OI r t J) :U ; !pl[)ssib]e h aaardous eonsequencea of' each way. -A ccord ing1y. 1m J"oue w ho uses a serv iee pl[ooei:lJure or tool which :i s not reClommended, must fil"S,t ~a.tisfyhimself t l lOl" lOUgbly that neither his sdety nor ehiele sd ty will] b e j lWpard iUld by the service methods heselects,

' N iO TE .T "n oo ug ho ut tb is .m :m ua L" t~ferernca is :mad.e to celi'EIIin tool nUfllbars whe!l l '.v~ s]pedal louts ar e l'e.'qrllli.tBdi,T t L sc [llllmb~Tgare numhers of Mi Jl er S pe ci aJ . Tools" 3 .2615, P,ark Lane, Garden Ci ty . Miehig';;l!n 4813.5,.. , _ . ! i i 'i .: F- ~ "'II '...... ~ I .. ...r _ . .. _ .,; _


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LUIIB RICATIION~t is not our intent to recommend ally p~rljc;1ilI]8!rbrand or make of lubdcant for the Spicer hypoid nxles.However, an S.A, . '90 or 80W~90 muliti-purpose gem" lubricant meeting .MIL, Spec.L-21o.5-C. and 5uitabl,efor A.P,L Senlc@ C]asl'MicaJioD GL-5. is suggested as a minimum requirement. Itmust prrcrvid,e necessery and5uibble :Ioad-c:ilr.tying charac~er:istics to p're1,ll~ntscod~ and wear, good stability in storage and ,l1;Ieitvioo,andgive go o d resistanee tocorrosion. Supplliers should assure tbesech;rqact4;;l1l"istiics and be responsible for theq.uaUty and $atisfaotory performance of tiheir product-

'WHEEL BEARmNIG LUIBRIIC,ATIO!NIWhee l be-a.ringB me lubrieasad by one of twodiffertmrt methods. One is to paek tllle whe~l Ibe~l'ri:ng withgrease; while the other meilio


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2.2.

J I l ' .

~J 49

. 1 3Sella '. ~G

S5.57

58

. . .48: 56 2:1 S : i l l 4 01120I~

S3

46. - 44

9I'

r o 38.142.

-- D 1'3'S

ITBM. 'fOOLNO, NO .1 D-111'" 2 J:HW'" ;3 D~115-3'" 1 0.-11&.1'" 5 D~116,2'" 6 D~Ili7' " 7 D-1'208 D-258

9' D-12810 D-i:U11 ))]4112 D-]42113 D~15314 D-155

15 D-158H I D-UH

ln struler - R ear P irilio nBearing CupS C Q Q l t e r GaugeArbor.Pin if]o. R e ight B iockArb en ]]~is,sMaster B~~rin~ Diffe:re:nti~lMastieT J'romFl : 1 3 1 1 0 ckTnstailer & Froot SpindleNeed i J' ll g Bear ingDial Indicaoo!r SetP u 1 1 m - ~ ,l ud e Hamme rIn 8 < t@ . n~ r Front Sj), ind1e HushingIn s:taJler - King Pin Beatin,g Cup~Kealf)' Duty}ntsn]].r . Fr:{mt Bndull H uhInner Belilnn g o .cup (Reg. ~Ins'~


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~TEMNO,82

**'86**'37*"'38"'*39**40:n41**'*42* * * 4 g

' [ ' IOOLNO.C~3281

34 C-4025A

1 ! )E8C] IUPT IONW r~m ;h.. U n i J \ ' e T s < ' I _ l o J orn:tBange or YokeIastaller ~Umversal )J()~ntFlange or Yokel ns ta ll er - D I f. ie :r er nt i;111i d ,eBearings[ ns tl ll l1 ec l: A x le S h~ ft O u t er

e m SealW,a5ilJ~n,Adapter Ring'Bolh;.Acl~pte:r R i l 1 J g -]nst.:a]le.rAcl~ptef Set. ~ RemQ'viI\g.F' I,al1,gePlateSc\'ewInstaller Fn:lI1J.t AxleDiffe.entkd I n l ' J ; @ : J ' O ~ ~ MalT()'fque Wrench -50 meh lPouiltdTorque Wrench -100 Foot } l lC)undTOrqll~ W rE ln Ch -

s o e FootPcn;md,T orrq ue W F e Jl .r ;; h ~I ( D O C ) .Foot PoundWrench . Wh~~l BeruingLock Nut Adjusting

< J ! ' 9 c-un50 C-4 ,203Sf D~232rl52 ])-24753 ID-.24B54 ~-~;l335 . ' 5 ID-'25556 D165A.')7 D~2:5758 D-25159 D-25660 D253

Hauid le - Universal['lIIS,~< !J 1e r - F'rontPhlionBC1.i!ring Ctilp]te:mover ,.BeatingIr!Lst~a~r . PreasI[lst~l~,er BaarilligInstaller - 0 il SealCup ID temove l 'fH1 ,lb &Drum~WbeelBe>ll ring WrenchCup Remo'l.'ermstaller Cup~Oute :r -Hub & Roto.d]rI!stalh~I' ~ Cup[Inner-Hub & RotorlSeal Installer

35 C-. les m .Wfl u'e ted . fl.S 'oUows" 'I"h,e first nusnberis the month, second humbet is the da.y of th em.ont'h. the th ira nurmhw: is t h . ( l > ye at, the letter isthe shift, an d th~ ~[I_stnwnber is the line tba:l: built

the axle. Th~ next number is file pan fbm ofmalW1"l ,al) number. The six. dig-jjt.$ n~adiI l!g from leftto right is the basie nu:mber fO"r identifymg 'thepart~cula[" a:d: assembly-The seventh digit f(jJlQ'w~I T; l, g th e dm5 !b .will. identify ratio, diUerentill1 an d ,e:m jyoke opt]orus used in the assemibly.

hl~be event thl'rt :aFe two b u i l d dates, t h : @ "laUGr will be thllil date i n w 1 1 : i C h . the brakecompom.mts were Msenil l led. ' l l"f le DlI.llllberstam.ped" nexrto th~ manufa.cturl~g daoo is theI "; .: omp l & :t e a , dJe a : :; se rnb ly :p.nt number,It 1'Srecommended that wh;$:11 rot~rrmg to theaxle. (~btar[n thJe oomp]ete p~rt number andbuild date. To do this, it may be neeessary towipe or: scrape of( the dirt atc., hOITl tibe tube.,

NOTEOnfmrnt cii 'l :vi l' l g ;;Ixkl's. the ab ovennm bers CMl.be l "; li J th i l3 , f n the lo n g o r short tube.


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, AX ILE ~DE,NTIFI'CATIO'N

The gill;}:!' ubo tag jg ~,(X:'aJteclIn the left $idg of thecover plate/or at the bottom kft. hand sid e ( 1 th eC!J!v,et plate, ;,ind is held .in place w~th one or twocov'el J "p I < l J te SCl"~W$.. 'fM iS tag gi\i"e~ thewothcombination of: t:ile ring: andpimon, and also thetotal g,~:arratio. '

IF RO 'N T ' A .X 'L EI)ISASS,~MBLV A .I N ID n I !A I SI !IMB ,:L Y 'O ' IFH 'U1BS, DR UM IS" WHE,Ell BEABIINGS" [ ETC .(CtOSEI) IKINIlJCKlE ILliESIIG'N}

- - ---- --F~gUlie LHl 5 10'1'"Hemov1e whe el bam drum assembly.

Fig,UUI13~mQve hub cap and sua]) riIlg-

If i'9ul~e 71 01!1O,Remoll,e nuts end washers t~Gm drive flallg~studs.

Remove dri'il'eflang~ and gasket, Discard. gasket.Replace with new (lHG at time ( ) I t a88erob~J'. '['{l frcetl,a.nge' from hub, tap lightly w]th a mwhidehammee,


7/30

F~g IVJre '9 1 Q l l ! 1 > g ,mi.emo'll 'e cuter ]ocknut .~oc] ; ; ; r iHg, ,and i.miL6il"Wne]bearing adjusting nnt,TQot: IC-4170 Wheel Wtefii::n,

F i ! g 1 1 ; 1 e 1 0 11i


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f RO I N I T ' AXLE

F 'igure 1~'ASo~


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FRONT AXLE

IFigunliHI' ~Qlf.1r!JAssemhle stl,ap ring' and hub cap. Tap lighdy w.ithhammer to seat hub crap.

D'ISASS.IEMIBlY AN'IJ 'REASSIEMBl,Y OfSH.AFTS, SIPIINDLE KNUCKLES ANID ETC.,(ClliOrSIECIKNIIJC.Kl~ DIESIGrIN)Remove wheel, hub and drum assembly as: shownin Fib'1\ll'ti'Je thru 10.

Flig u ra 20 li)19..20Remove backing p la :te S 'C r ew s rand remove back-ing p]tiJU:_

INOTEThe brake backing plate as'embly can. beretained V l . o i t h $Cl"I!'!WS o r nuts, r th,l'3 :l' luts are ofthe torque pre ail ing d!esiign, they are to btl'replaced liirith new (Jines.,

f'jQIWllf ,e :21llemov pindle,hammer to -breakknvckl .

1019-21Ta:p lightly with a rawhidetb e spindlg loose from th

A~~~ m~Place sf.lI.indl,ein vise, do not locate on bearingdiameters ..CAUTIIONBe su.re r l : i r l o : t , ~tH~ vise j~w8 8l..relequippr~dwitb

bl08,sS pli'I t "'tors, 01' ~imilM ' ~ Y l . f i ' e ' hi, pl!''Ot.ed themallch"o{!,d .!iurfa.Qll~ 'oS' 9.~y P,Rl'LEIth~t, ,il~'e MI be~Iaced W i the vis,Remove oronz: bushing wit.h slide hammerpuller.

l'(I{]~:NO 131 Slide Hammee,

Remove cotter key and loosen ti,e r-.odnut..ap onnut with rawhide h ..mmer to break the stud loosefrom the :sli~{.)ri:ngarm . Remove nut and d'lsconnecttie rod9


10/30

FRON'T AXLE. -

F i g U I \ " I S ! 24 U I < I 9 , . 2 i Iltemvve twelva eap screws. two retainer plates.felL seal, and oil seal. Discard retainer plat 5, feU;.sea]. and o~lsea]. RphlO~ with new ones at time of

assemMy. Cut felt seal in haU to disassemble.

Re:JUove fOI1l!" cap screws from the bottom bewingeap. Use < iI SCI wdriver tit) ~!)lJsenthe bearing capfrom the knuckle if neeessary.

INOl'l.!King pin. bearing" preload shims are locatedbet wefil'1Jahe bottom bearing cap and knuckle.\i' ire shims together as they will be I1Beddl;l.ring assembly. Shims m.ay sticlito, either theknuckle O r bearing ,cap. Be sure you have them.a n collected.Shims are available in thickl:1:esS~ of .003"..00,5", .1)10"', and .000" ~mm .08, .13, .25, and.76~. Remove ~Dd{! shaft joint assembly,

F1igullie 2 6Remove knuckle from baH yoke.

The O O W O D l l beot.m,g '''OlilL~ v.iiU fal ootli:S the~_1!illickleis biilling remove,d. flIil p:rIWmt dlllllLflgei:loth bearing, catch It with hand ..

Fiig u re 21 ' 10'1 ~ O ! ' ~ 'Place knuckle ]n vise as shown. Remove st "ring

arm. T3Jp' l ightly wit!! a :nrwhM.e h


11/30

IF i 91111! 28 , ~O~~l IRel.'[lo~!ekin,g ]?]fi hear: l lng cups from spiherl(;


12/30

' F RONT ' AXILE,

Locatio steeri:ng arm in vise ,as shQvm. Assembleconstant shim pack to the lknuc!lde ~if used).l \,ssem ble lm uck1e to M i!esteering are . A SE /em ble thefoul," nuts, tighten nuts altemate~)' 0 0 . ell'el'lly.TOH[lJ:enuts ~Q 70.-'9i0Lb. Ft. ~95~122 N'm),

f ' igllllr~eo : lSi 1' iJi i93SAs:;;.embl~ new bearing eone to king pin, greasb e ! l l J r a n g Wilh specified gIeas ,

liFi'9ure 3 '" 1m~.aGAS5;!:,mble axle ShilftL joint Ilss!!:mMy into housing.

If'igll!!lre 37 ' ill.l~31Assemble knuekle to ball Y{lke. Hold hot tom b " " f l ing (new) as shown to 'prev'~nt it froITtfaJIling out.

I ' , 1 !l1.9 -;j;8Asseroble bottomkin_g pin bearing cap, withpreload .slliims. and four cap SC:reVlo IS. Torque SCI l ' e 'W5to 10-90 T"b. Fe '(961122N'ml.

[figure 39 10t~49'Plaee a torque ww,'encb on If'termg arm nut asshown. orque to act;uare knuckle t c . o 9] 5 Lb. Ft.11220 -mr. V he-n checking torque rotation ofknuckle, make s~ro tie rQdand seals are notassemhled to knuckle.

1 2


13/30

FRONT A ,X lENlOliE

If preload is too tight. cOl=red by ,adding shims.H ' preload is 1 : . 0 0 loo-se" oorreC!: by ' removing'shim s. Preload shim :pack j~ ]ocalied on U'lebottom between ,t.hebeMhtg carpand Mlle'ide.Shims are available in thielmeases of .00(3",.005", .010", and.Oc30" (rom ,,08, , 1 3 , .25,and .76) ..

Assemble new -oil seal into knuclkle. Be sure splitof s~

Fiig'i.ll\e~1 10UI".! il-As~mble tie rod l i Q steering arm IO'r speci:fi,edUltque on hoe rod D 'u rt . r ef er to Vehide ServiceManmil. Assemble coLwrkey,

\

g?'o$ttion spindl~ in viae as shown an d assemb](lnew bushing, Oroease msid,e of bushing with~pedfj~d grease.Tools: UD141 lnstaUe;r, .41 '0-4171 Handle.A~:emNe spi!dle to knucide.

F II!g u re 4 3 l!1t9-4!3,A.8~mble blab backing p la te o t! J;s emb Iy . Refmw'VelUde Servilee Mmual fo.r specifid SI!!['eW '[email protected] lnspeetion p]ug fUl 'IT1 :kn:llIckl.ei:lndfiU

MC\lel to the plug ho~e with sp-ecified lubricant.As~mb~.e i t i ispectiIJD plug.

' N O TET oOset. toe-in r fer to V ~bic1e Sm "lliceM ~n1!l!1iII1.Adrj m ,tm e[lts CaJn be m ad e by looS>ening clOOl.p.son the tie rod. After proper !:idjius~me:ntsal'emad, :retighteitl tie rod clamps,

13


14/30

FR,ONT' A'XLI:,

D!~S.AS~E:MBlOFWHEEL ENDS"HUB: A IN ID ' R O T O R

If it 'is neeessa ry to replace brake cornponentssuch (;IS di;s( brake pads, becking plat n 'etc"-refer to Veh He! Serviee MtlllUaLRemove 1ll."heel f rom. Hub and ' Ro to r Assam bLy ,ollow the vehiele manufacturers recommen-

dasioas for the remov....~ 0 - the hub-lok assembly, iiu s e d . .

Figure 4.5 10HiIotfjR.emov. whael b a:ri l lg lock nut, lock ring and thwheel beal:1l'lgadjusting QULToo l; HD t -1 6i )A \i\FheeI Bearing Wl'enc:h.,

Fi ,g u re 46 1019-411Remove hub and rotor assembly. spr:illg retainerand outer wh~e~ be~.ring will slide out as rooo:a;isremoved.

IF j, g me!' 41 19",~7Jtemovegr;RSe seal end hmer bearing '!;I)ne.Di.soard sew' and rep]ace witb ~i2"W o: l1e at time ofassembly.1'001: II'D~131 Slide, Hammer,

Fi ;gUlr ia48 1~Ul-~Remove inner aadeuter wheeJI. bearing c.ups.Tools: #])-2.65 Bearing Cup Remover (Q'Ut~r)"#D-257 Bearin,g Cup Remo.ver I i n _ . n ~ f l .

14


15/30

FRONT A,Xl , IE

if'ig ure 49 1'Olg-04~Assem!:l]eouter wheel bearing cup.-l'ools~ #D-254 insLaUelf, IfC-41'H Handle.

F igure 5'1) ' 1 0 1 . 8 . 8 1 )Assembl.e inner wheel h ados' cup.Tools: ID-256 Installer, :#iC-4171 Handle,Drstdbut:e I f ! . silff~ci nt amount of grease :insidethe hub betw en the beadng cups, Pack innerbearing eons full with the spaciifi@d grease. Wipethe excess grease around th rolller::o. Assembleinner whelll] bearing eone into cup,

ssemble new grease SI':! ' !d, Apply a small ameune.o f grease around lip of seat ..ools: #D-253 Sea] Installer, H,c. .4171 Handle ..

As.semble hub and rotor on~((),pindle .. Pack outerwh el beanng ",;.t:h specified grease, wipe e l X e e s . e ;grease around the rollers. Assemble on"lospindle.

f i ' 9 1 1 1 I u ' \ e 53 1m118-i53To adjl lJst wheel beari~gs.,torqtJe i i rmElr adjusting

nut to 60 Lb. n. ~'Q8N' m), '~!l'seat beW'"IDgs. RO'tatehub, then back off inner adjusting nut one-fourthtum maximum. Assemble Lock washer, turn nut tonearest hnle in.Wa!l~ler.Assel'l'l.bLe outer loCKnut andi lorque to 50 Lb. t, {68 N' m~ . Final b Baring'S.jidjustment to be ,001.-.010 (.03~,'25 n 1 lI D j tlO t aJ e n dp:]ay.T bo Ls: CDa1 l6 5A Wheel B eariil '!g Wreneh, HC512ATorque \'lillfench.

NO l iEFor servlcing spindle and knuckle, I:emovehuband drum as described. i.n figu.res 4,5through47.


16/30

F'RO'NT ,AXLE

'Fi ,gl l l i l fl 'el 54 1Q1!fI.,~I te .r no v e s pi nd l e. if necessary, t8JP li,ght]y w i . t h . B.nwbide b m : n m .@ l " to fl'ee it .from th..e knuekle, Cbeckbrolflze spacer located bet! ...,e~IiI asle shaft jointassembly :and bea:ring_ [:f wsar is : Gl i1dwl l , replacewith ~ new one,

Ifig'lwe, 55!lI'l g,.5!SPti\(1 spin.d]e in vise, Do not [oc;;I,te on be.aringdi .ametel~~. R'emO'~-"el ] I i } OOie bearing,'Tool: #1)131 Siide Hammer.

GAIUTI 'O, INIBe sure fbat vi. J jPl1A'S l 'Ue ,eqmppell1ll\.-it,h bl'8.ss.PIl' 'Qte


17/30

IFiQI~lr,e 5 ' 9 ' i i 1 1 J i . < ~I,el'nov,e' king pj.]1 tOl])arndbrushing., spring re-~ail'ltl;r. and knuckle from. yoke" ft~lX!.ove king pin

~N1la.],

F i 'gll))!~e ,6 0 10'1~'"Remove king pin < ' . IS shown.

'fG(I~: ND, HI2 I{ng Pin Installerand Rem.over,

FI~gIJf'E;) 1 6 , ' 1,~119"61Remove king pir! ! oearil1lg cup, enne, greaseret


18/30

FR ,Q INT AXLE

'~igt!,l!re'64 101:9,64Install king pin. Torqu@. kingpin to 500-($00 Lb,:n , ,~6'i'S.81g Nm}.'l Lf ue il s: h D -J 9::J ; K i ng P in lI1rst~ler and Remove r ,

M D D 9 9 l t J , 'Iorque \"!.r]'~ncJI.

Fi:gure 65Assembie felt8 >~ a'1 to icin g pin , ~ $$ em b~ f2' knucldeasseunbl ta:pe:red bl].sh~fig~ve~rk.ing prin.

F i'gl~lre66 . 1 1 ] 1 l 1 - l 6 4 I ,Assemble bearing cap with fQu.I' cap screws.Tlghtfilln cap ~i!:;; l 'ew.'Sil l11.ema!Lelyand.~.! i.eI1l1y. Torquecap screws to 70- :90 Lb. F L , . (95-]22 Nm).1 ' :001 : HC-524~A TCIr'qUrf;!Wfi,lu;n.

Figll lJf iE:! ,6711U~'!lI :rAssemble sPl.ring :retai:ne~r and. eempresslen springon king pin bushing. AS$em hie st(:i!f;'llin_g arm. withnew g'asket., o",m fou.r studs, T~ghten nuLsaU .er .l "I .a le ly a nd evenly. ']'QJr~IJ!? JlliJ!ts ?( l ! 90Lb, 'Ft.(95.122 C o r ' m ) .

F i'g u, f, e 6 8Ass~~:r!IhleMW nee~ne buring' ~.nros:pi[iiJdle,Tools: ND-258 Installer, HC-4171 Handill.e,

fi,g!.! re 69 . .~O-H!-!&,iIAssemble g~;\ease ssal :into spindle. ' fh@o]]]} of th esea] is to be directed a w a r y from the spindle,Hi


19/30

FRONT AX l,E

'i,gu~e7 0 10:19,-70Some imnt axllesare 1 i ' < , ' Q . u i l P p e d ' W i t h . a '''vr' seal,

lh"hid'il ts !il!siSembledo the ,axl~ shaft ,stoillesbield asghown. If seal is worn; remeve ,and replace with II Inew one.

Figure, 71,er,g'71Ass@mble n!9'W seal as shown. Lip of the sei'll ]$ tobe directed towards the spindle,

Figll,U8' 7~ 111'19-1'2Pad: the area arounrl the thr-ust face area of the


20/30

BE,AR AX L!EI R EA IR AXLEUnit wheel b~ru'ing' design lubricated with hypoidlubricant,

N'O'T'ElIn ~twheel bearings that are dep endent onlubrication from thehypoid g~Oif lube in theaN ie h using, ~ il t. b~ ir t ha n greas " ru-enotequipp~d \;'oI'it,han :i.nner aIde l < ; ; h a f t ail seal asshown in f:igur~75.

;;

-1011.,.8 AI.IUlNlliTBEARING

r:~~ARING Fill;.l 'AI Nlel' l

F ig lJ I re ' 7 '5 1 0 U I . ..T 1 5 ,nlt whee] bearing LID without inner grease.seat

ID I ISASSE 'MB lY

Fllgll,JfiI!:! 76 tD1ii'..6After wheel is removed" rtlWOl,' brake drum.

A~~n ~~11.:TIt"),(i e backing plate. nuts ..hich hold the br< il!k ehacking plaJte to the rude h.ousing. Disc,arg nuts.

L ! " ' G C p l a o e with new one ~ at t i m e o f ,a Jl se .m b 1y . N u t il i o ftorque p evailing' design are not to be reused,

IF i g 1 1 l i i " e 78;01~'7e.R e mo v'!1 !th ea xle s ha ft: by p u.lL in g o n the axl .. Itm


21/30

REAR. AX L I E ,I

'F i guFe 7SlIt019!>79The b~aring cup illnormally stay in place witht.he housin.g. Tu r ' lC l ,aning, Inspectlng', and re1ubdcating wheelunit . b {Iring.Cl'ean bearing cup with , any of the standard metaldeaning' solvents. Insp ct cup for any p05S]Wewe~Ii[',!licks, et-c.The cone .a$sembly can be cleaned in plaee on the,axle shaft. Use anystal'idard metal cleanmg solventand a stiff bristle brush to remove any dLrt O f anyother oon'liElrrJ!J.nationh8iLmight be present, then usecompressed air" Air should be directed ",t th Qonei!I!$s.embiyso that it goes through tb, bearing fromone end uf the ronexs to the other. It 1::0m.po:rt.M'Itnot to "Spin Dry" the beMiing Wi{m compressed air.Spinning the dry bearing: may score the !raceways

and rollers due to l~clt O 'f lubricant.Use 3 ! sl8indfifd l 'IJ..etal cleaning solvent to deanoul, th,e be ru-ing bore in the housing. Wipe this areadean m~king sure it is free from dirt or any (lItil'fcontaninaUo that might be present.Aft~r the bearing: has - been. inspected andapproved f01l' continued service, it must be lubri-cated pri,orlo installation. The be.ar',19' must belu bricated b~ applying a sn lall aa'nO 'un t (If thespecified lube around the ]1oUers of th e hearingcone.

FiQllln,e' 80 '11119-S0ASSlemb[e bl'l~g plate bolts and backing phltea sembly.

Fi ' !J~.ue8110t!M11Assemble bearin;g ,cup into be'/King bore of thetu be , M01!k :esu re the cu p bacstace is agains; thebearin . seas of the tube.

Fiig I.ll'lel s a " 0 " 1 ~82Assemble 3Jx]e sbaft. into hOUSIng. (:8:1:'eshould betaken not to damage the bearing rollers.Line up the holes of the rdainer plate with thebol~, push a;df?$haft into the housing as far aspossfble.21


22/30

RE ..AR AXLEII

'F i lg u r e ' 83 . 1~1Ie8SStart n ut;s e n b < lC tli.n g p la te bolts by hii l !. .nd~ U $ ' 1 3 asp,eed wrench as showu and tiigh~en. to a.pprolKi-m ately 15]:;b- F t:. ~2iON -m ].The units should be t~gh:te;n~d.ina manner thatMS.l! l! [ '\@ S that the seal andcu]J rib l'lng' aJTl' ! drl: l!WTIoven ly aga:inst the cup intb~ hOU5~ng.

F i g . l . l l l r l S i , 8 4 1 U I 1 9 8 4U illi .l'II.gatorq U ! E ! wre' l1ch as ~h~lW'"n!{lrquE! In! iL11l t. Q25-85 Lb. n, ~4-4 '( N' ~mL As ssm ble brak>e d:mm:9 I

F!1tainer l]jiU~"S"whee~s, etc,Tuo! : N . 524~ATO i l 't i" ~ W t '~ n : h . .

U N lf W MIE IE L BE AIR WIN I'GIJI~'SU~NUJBiRIICAIIED 'W~TIHIGR. I~A8E :

N IO ' TEUnit wheel hearing that are dependent ong rease for lubr i c: at i! [J i n! ,[ 'a th e r than hiypoklgearlnhe f!lOrIl the ade bousing, a]'1~equipped. wit.h.am.jmn~r ~dw ~haft Qill seanas shown inngur@85 _

BItIAKE BA:CKIN,G PLATIE.

BEAIRIING ItIETAINEIRF igu rs 8:5,U I)Unit whMi bearirng UE) wm~grengSi seal,

If Fig 'u re ' a 6 , '~'Bl9"SGReroov~ li!1.I'1ICr ~le shaft sea] usitIg puUrasshown.Tool: #D-131 SUde Hammer,mscard sea land repkll:':$il with new oneas t!me ! O t ta$~embly.

'NOT~A\io: ideo rl 1. ta et in g s el 'l Jl sw i th cle~mg so l 'l 'e[ '! J ine l ,e .a ni ll g op eradon"

C LE AN IIM IG , ~N SP~C fl N G, Id l'4 1DR .E bUB IR I C A T II NG I I UiN I IT BEA .lR :IN I GS Clean bea'dn.g cup with a f [ 1 l . ) ' of the stmlldaJ'dmetalcleaning solvents. Inspect ell]? f,orr any po\S:;ible'weru, nkks,tl::"The COrne ass.embl;y ,can be deafi~d 1 ; 1 : 1 plate ,rlntheshaft,U8~ all!tandaro. :meta.i. cleaning sol .v .en: t 9 I .i .d . astiff briS'~le hrush to loosen the old geease. TQensure rurng'"a1 of the old. g:reflJse and anycemt1;l:mil'J.!iI~onh.nt m.ight be present, l 1 J J ! >E ! eompres-sed ai,', Air sh(lu~d be direatedat the eoaa assembly

$0Ul:at tt giles U':IrOrughtb.ebearingfmm (Dne el'lld 'ofthe rellers to the oth~r. lit L . " l (mpQrtant not to 'Spin22


23/30

D1')'" the beadng wiU~complN:!s~d air. Spinning t:b~dry bearing mCli;Y score the ~.~cewaY~!\ l ldJ ! )ol le :r$ due~othe liackeflu bricant;Use a :stCliili'ldam metal de~nlng s


24/30

'REA.R AXl,'E

Rimlio'v,etap and w"ip' excess grease on rollerbodies.

ASSEM'BLV

I F t g ' I . l I r e ' 9 2 , 1~19-92Asseml;d@new greas seal into housing.T (I .o l1O ;HC -4 0 26 A Sea l J.nsttl1l.'ler. N ' -4rn Handle,Aft'~seal has been assembled, greaseltp of ileal.

F T h g u r e ' 9 , 3 , 1 9 ~ 9 , . s aA.ssemb!l~ backing plate bolts and backing p,]at{l. ass _mbly.

F ig lu r e 94 1!;1fM4Assemble bearing cup : m t o bearlng bore O J thetube. . lake sure the cup backfaee is , ~gaifl(:o.i;thebea/d'IJ.gseat of the t l ) . l lbe.

F jig L 1 1 1 f i e 1 ' 9 : 5 , 10:1 9 < - 1 9 ' 5A~sembl


25/30

RE,AR AXLE

~i:g~re,97 '1U1tig7Ilse a t O J . C q j u e w~eIiich and to.rque n u t s to 25-35 Lb.

Ft. (34-47 NJ'mL

R IEMOV .A I L O F IU N :IIT B E A R :IN GFROM AXl.E SHIA , f lNOV IE

To disas:!lemt]e ,elXle;shaft from hmlS i lng , follow~he pl'ec:~dilite:s il.lI.lsb:8!te.d i r i l . f.igllll'eS 'Ui thru19, .

IFig ur'i ~9 8 11l1~Place axle:*afi. in a vlis!l!.Drm O J, 114" ~iU15ItItlJi)hole in the out!iicle of~.e retIDner ringt.o a d @J!lth[lJPP!l: 'oxlrn


26/30

I R ' EAR AXLE

nurtAL.LAT~I()IN OF NEW UNIT IBIEAIRINGNOlI::Th~ tetaitlel!' :r i.ng atea of the shaft is 1.'l72T'~45 . i Q J l m m) m .inim um in dlametsr, md. the'reil.ajn(l:r ~'i_!lg ]H$id~ diameter is 1.7675" (44.88rnm l m ax 1u m 1 i l l n . , and~he[l'efore" should reqlll].]f\esame 6000 lb. (266a8N~minimum ]n'l~88t;oseatthe ring ,agruni~he unit beating ..

IFigl~'f 'e!Ul1 10~~ctOlF lmJ ;1E! p la~ s.hould ! r l . : i l l be a~n~emble.d ~o thet:hil,[m~of Ul!tilI axle sihaft. .I!emove bolts from flfIJIligeplate, Assemble new:n:~tajne. pla~e and Gi l seal,Tho :ru bb er p nr til 'l ,tI i o f '~ne o~ l seal, which exteli.dsbeyond. the ca:;;ing'has numbers bonded in therubber. Thes~ nru;mbe;($ ,;lfre to (1EIiCeoow!iI:l 'd the

f b l i l i l : 1 J " T t l o f the ti,x]e sha f t . ,Assemble ne,.,,,,unit wheel bearingol1a:l!.h~ shaft,SHd~ ~ngl~]]ing rl[!g On arie shan/tEe surato locn~E!unit whee]beflrin:g on th'insid~ of the i~:!.stallitl!~ring. Slide fO'fclngpJ:a:~eon axle shaft and ~oe~j)eoniflStfJJIHngr4ng, InB~till holM: alld wal~be;r ~hnli!lghllt,~holes in the foI."Cicngpl ate and into na.ngce plate.TQob,~#SP~5543~AF1ang'\ep][I~e. U:8P5017Ada.p~ber R ing, H SP5.:140 A dapter 'Plate Ins~UGr. Q SlP~5 < 0 2 1 6 n301ts. n S P ~ 3 0 Q O Wasbers"

'f]g!:l~en. bolts ruLe.m9Jtaly an d evenly . .mtli lk.ing S!Jf'E!beatln,g ]s not. ~o(;:kedon ~de s h a r i l > . CO!'lIt]nl!.l!I UITti~lI!I.,neelbearing is sea:Led, To make sure bearing isseahed use a ,0015" LQ3,S1 mID)' fet;ll~T gag~be~w~(jn bearing $ea.t and. bear:irtg, If gage 'enters.Foree b ea]"ing furth~r on tJhe.u!l('lsnaft., until gag(ild oe s n o r!,;enWr.

F ig ll !! ll r,e 102Install 'ratainer !:'ing![lna::;::l~ shaft. 'Follow thesame prccedures lnfigu[le 101 to assemble the[e'~.;rineFring"Use a .00.1IYI (J)381 nllni' fee ler g,ilge oetwtlf:ln thebearing and retainer rin,g t@be sure U'J;t!ft~lile

retainer ring is seated. At least one point !1ihm~]dexist. ' V I - ' be:r~ t h i 2 gage l i N ' i U Hlot enter bel~w'eell theretainer ring and bea.ring. Ifg~se enters completelyar(mnd the d i an"J .~te .r . .f~~ a.]rlf!ltring m I1SEbefn:r:.cedonso the lJ.l'ilesnnlt.To assemble altl~ ~hai1t as~en1.bly into hOI.iJ.sing,f oUqJw s t, e'p s a s i lh.!~~t;r~ted in . figure 82t.m -ou,gh ,84 .

LIJIRI:CATIN'@ N!:W UN:lf1 8 iE .AR .1N i G I WliTH GRIEASE

F 1 ' 9 1 U I a ' 1 9 1 1 1 ' 0 1 3 , ~~1Q.100Posh seal and re'ta:in.er away frorn. b (S,;u:in.g toallow a cavity beh~ e!n ili(l s eal : 3 !l '1dhe aring.

26


27/30

REAR .AXlIE

Fin cavity with a good quality 1 i2 E.P. (ExtremePressure) lithlnm soap, whee l bea_t:inggr;~ase.

F i'g u m ' i e 1 U )S ~t1g.10SAfter ,c:ffirvity is fuU of grease ,wrap tapecernpletely areund rib rIng, and seal to enclose thecavity.

F~gur.eU)6, 1011HOOPush seal towards the baring unW it contacts therib ring- 'Iihi.s win f(tiJlcethe grease between ~herollers and eup,

N()TIEIf grease is not apparent on the sma]] ends ofthe rollers, repeat 'file s!.une steps until gNt'aseis evident between the smaU end of the I'QUe.rand cup, Remo'v,e t . . E ! . p ~ ,

REA IR AXLE SEIMI-IFlOAT SHA:FT RID~NGIl:nEAR ~N G D'ES IGNIlUEl,R~eA.lED W:ITH HYP'QIIOI lUlB'R~CANJ

Figun~1107 10~g.107WicLure of Sha.ft JUdi.ng Bearing Designt

After wheel is lema 'ed, remove brake drum.Remove drain plug and drain lubr.icant. If there is110 dmln p[ug in the carrier, the lube will drai.n outa s the 'COlver pJatce is ' remo ' l{ {; l d .


28/30

R,E ,AR AXLE

R'elHlo\"e ,cover plate SCTeW5, cover plate', andcover p]ate glltlilk'et.Discard old gasket. Tip carderto allow 1ube to drrun ,eomp]etelY. Also during 'thistime dean the cover fac of tb carrier, making SUI'@it is . Ire fll!)m ,anynicksand lllny particles left. by theold gasket, DO Nor USE CLEANING SOL,VEN. SOF ANY 'lYrE, Use o lf cleaning solvents mayprevent the ,. R 'TV " seal.,~1" frau.l adhering bO thecever plate and carrier. resuUing i l ' l leaks of axlelubricant.

FI 'g u re 1110 10191~0, lean CO 'V@1 plate, making sure it is free from anynicks and any paeticles leofi by the old gasketmaterial. Use a dean. rag or a bl~nt tool forremeving 'remaining ga~k,~tm~terial. DO NOT USECLEAN! G SOLVENTS OF ANY TYPE. Us ofelesning solv,'Ilts may pre\mEmt the , lOR-TV" sealerfrom adhering to the cover plate and ,e


29/30

IHt:.A!H A,XLI:on SEAL A IN ID WHEELB EA ,FU IN G FU5 1P lACEMENT

Figure 11.5 1019-115:r~,emO'!i'let.l1te axle shatta frulJ)] the heusing, heingcareful not to damage the oil seals" as shown inf'igur'~s 11.4 and 115.

Wbeu reDlQvi!lI!I,g the ad,e, &baits. b e : cardull nottllil :rohde the dtrfell'entjal side g , e O : l ' I l . Tm wi,neause ~'be :pllilion fiiIIa.te g{;la~,sWld U.ru~w,1 I6he1 's ~o t um tg,tlleopeniDg , I j ) , f the c as e lilJ n did l '@p out.

F I~gu r : e ! 1H j 1011M1j)Remo'l" thli;lbacking plate nuEs and bolts whichhold the hrake bacliiing plate to the axle twusj:~g, (3)places. Discard nuts, replace Witl l n w on s at time

of assembly, Nuts (If torque prevailing de,sih'll arenot to be reused. 1)0 not remOWi! 'br.uw ba,ekingpb.Le.IN IOT IE

The nil seal may be remo'll'ed and .m nstalledwithout removing the brake backing plate,nuts and bolts. Care should be taken so as notto damage the h ea:dng upon removing the.~~aL'1'.oo]s:NC=41n Handle HID-233 Seal In taller,S < I] Remover (s.crewdri er or other similarwoll,

!Figure'1 n " 11;111Mn'Remov,e ' the wheel bearing and oil seal as shown.Discard ohl seal and bearing"Tool : #ID'-2S2~1Bearing !Remi; l\l1El! l ' .Use a standaed metal cleaning S'ol,verrt to' cleanout the beming bore in the housing. Wipe this areaclean, making' sure it is free from dirt Or : : l i n y other,eont31minatilY1i that niight be present.

2 9


30/30

I N I O T I EThe bearing barre mu~~ be ftee from n~.ck:1landburrs. Wip0 the bar", lvittl emery clothw,assurea ~moofili s!I)!r;aoe. Cle an bere Qut with as ta '81c la :r d me ta l de

9374902 dana 60 axle repair manual i

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