Dana® Spicer®

Single ReductionDS/RS340, 380(P), 400-PDS/RS341, 381(P), 401-PDS/RS402(P), 403(P), 451-P

Tandem Drive Axles

Service Manual AXSM-0041 July 1995

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Eaton Axle Service and Maintenance Instructions

Tandem Drive AxlesSingle Reduction Gearing

IntroductionEaton Corporation, Axle & Brake Division, presents this pub-lication to aid in maintenance and overhaul of Eaton tandemdrive axles.Instructions contained herein cover four basic axle models.Their design is common, with differences in load capacity.Capacity variations are achieved by combining basicdifferential carrier assemblies in different axle housings,axle shafts and wheel equipment.

Load Capacity Model No.

34,000 lbs. . . . . . . . . . . . . .. DS340, 34138,000 lbs. . . . . . . . . . . . . . . DS2380(P)38,000 lbs. . . . . . . . . . . . . .. DS381(P)*40,000 lbs. . . . . . . . . . . . . . . . DS400-P, DS401-P, DS402(P), DS403(P)45,000 lbs.. . . . . . . . . . . . . .. DS451-P

. , . . .

Some models (identified with letter “P”) are equipped with agear-driven pump, designed to provide additional lubricationto the inter-axle differential and related parts.Instructions contained herein are applicable to all axlemodels, unless specified otherwise.

Typical Eaton Single ReductionTandem Axle.

Design Variations:Two design variations of tandemaxles are included in this manual.The major difference is in the shaftspline design. Refer to page 6-7exploded view for details.

For brake information and axle mounting or suspensionsystems, refer to pertinent truck manufacturer’s literature. * NOTE: DS381 (P) axles manufactured

after April 1985 are rated at 40,000 lbs.

Contents

Description, Operation, Power Flow& Torque Lubrication

Cleaning Inspection, Replacement Adjustmentsl Wheel Bearings

l Adjust input Shaft End Play *l Adjust Pinion Bearing Preload

l Differential Bearing Preload andRing Gear Backlash Adjustment

l Ring Gear and Pinion Tooth Contact

Fastener Torque Specifications

Forward Axle DifferentialCarrier ReplacementPower Divider Replacement

Rear Axle DifferentialCarrier Replacement

Power Divider Overhaull Remove power Divider

from Differential Carrier l Disassemble Power Divider Cover

l Disassemble Inter-axle Differential

l Disassemble Output Shaft l Assemble Output Shaft

l Assemble Inter-axle Differential

l Assemble Power Divider Cover l install Power Divider

l Adjust input Shaft End Play*l Inter-Axle Differential Lockout Overhaul

Differential Carrier Overhaull Disassemble Differential Carrier

l Disassemble Drive Pinion l Disassemble Wheel Differential

l Assemble Wheel Differential

l Assemble Drive Pinion

l Assemble Differential Carrier

* Service Bulletin Supplement. Measure and Adjust Input Shaft End Play for Axle Models equippedwith an lnput Shaft Axial Spring and Thrust Button

*Drive Pinion Nut Fastening Chart

* Literature Listing

2 Price $3.50

Axle Specification Number

The complete axle is identified by the specificationnumber stamped on the side of the axle housing.This number identifies all component parts of theaxle as built by Eaton, including special OEMrequirements such as yoke or flange.

In addition, some axles may include a metalidentification tag (see illustration).

Metal Identification TagCOMPLETE AXLE SPECIFICATION NO

Ring Gear and Pinion Identification

Ring Gear and Drive Pinionare matched parts and must bereplaced in sets. Check the appro-priate Eaton Axle parts bookfor part numbers and orderinginstructions.

To aid in identifying gear sets,both parts are stamped with suchinformation as number of pinionand ring gear teeth, individual partnumber and matched set number(refer to adjacent drawing).

3

Eaton Single Reduction Tandem Drive Axles

Description and Operation

Eaton tandem drive axles des- Tandem Single Reductioncribed in this publication are single Gearing with Lube Pump.reduction units designed primarilyfor highway or turnpike. They arealso suitable for a variety of otherapplications.This type axle provides a vehiclewith superior load carrying androadability characteristics by divid-ing its work between two axles.The complete tandem assemblyconsists of two axle units coupledby a power divider.

Power DividerIn operation, the power divider accepts the torque from the vehicledriveline and distributes it equally to the two axles.This assembly is of the two-gear design consisting of an input shaft,inter-axle differential, output shaft and two constant-mesh helical gears.

The inter-axle differential compensates for axle speed variations in thesame way the wheel differential works between the two wheels of asingle drive axle. This unit also acts as a central point in distribution oftorque to the two axles.

The power divider also includes a driver-controlled, air-operated lockout.When lockout is engaged, it mechanically prevents inter-axle differentia-tion for better performance under poor traction conditions,

GearingThe gearing for each axle is of the spiral bevel design with drive pinionpositioned at centerline of the ring gear. The differential and drive pinionare mounted on tapered roller bearings. The wheel differential is a 4pinion and 2 side gear design.

Lube Pump System.

Lube PumpTandem Axles with suffix letter "P" in Model No. are equipped with alube pump to provide positive lubrication to the inter-axle differentialand other power divider parts. This pump is operated by a drive gearengaged with the input shaft splines. When vehicle is moving in aforward direction, pressurized lube is delivered to the vital powerdivider parts.The pump lube system incorporates a magnetic strainer screen. Tokeep the system clean, the magnet traps minute particles and thescreen blocks out large particles of foreign material.

4

Power Flow and Torque Distribution

Torque Distribution with Lockout Disengaged(Inter-axle Differential is Operating)

Torque (power flow) from thevehicle driveline is transmitted tothe input shaft and the inter-axledifferential spider. At this point,the differential distributes torqueequally to both axles.For the forward axle, torque istransmitted from the helical-sidegear to the pinion helical gear,drive pinion, ring gear, wheeldifferential and axle shafts.

For the rear axle, torque is trans-mitted from the output shaft sidegear, through the output shaft,inter-axle driveline, to the drivepinion, ring gear, wheel differentialand axle shafts.

Torque is transmitted to both axles through inter-axledifferential action.

Torque Distribution with Lockout Engaged(Inter-axle Differential is Not Operating)

A lockout mechanism is incorpor-ated in the power divider to enablethe vehicle driver to lock out theinter-axle differential and providemaximum traction under adverseroad conditions.

In operation, an air cylinder (con-trolled by a cab-mounted valve)shifts a sliding clutch. To lock outinter-axle differential action, theclutch engages the helical-sidegear and causes this gear, theinput shaft and differential to rotateas one assembly. This action pro-vides a positive drive to both axles.With Lockout engaged, torque isdistributed to both-axles withoutdifferential action. The forwardaxle pinion and ring gear aredriven by the helical-side gear.The rear axle gearing is drivenfrom the output shaft side gearand inter-axle driveline.

NOTE: Varied road surface condi-tions can result in unequal torquedistribution between the two axleassemblies.

5

Eaton Single Reduction Tandem Drive Axles

Differential Carrier AssemblyForward Axle

Other Design Variations

D340,380(P) , D341, 381(P),Axle Series 400-P 401-P, 402(P), 403(P), 451-P

Output Shaft SplinesSide Gear End 16 16

Output End 10 34

Input Shaft SplinesInput End 15 44Diff End 36 36

Helical Gears 7 pitch 5 pitch

Drive Pinion SplinesForward Axle 10 41Rear Axle 10 39

Axle ShaftSide Gear Splines D340 16 D341 39

D380(P) 16 D381(P), 402(P), 403(P) 41D400(P) 33 D401-P 451-P 33

6

Axle Series D340, 380(P), 400-PD341 , 381 (P), 401-P, 402(P), 403(P), 451-P

IMPORTANT: Seals,Yokes and Slingers.Before replacingthese parts, refer toRepair andReplacementInstructions forinterchangeabilityinformation.

Power Divider Cover with Lube Pump

*NOTE The dive shaft or early pump models IS equipped with a woodruff kev On latepump models, the key is eliminated. The drive shaft end has two machined flats and thedrlve gear mounting hole is shaped to accommodate these flats

7

Eaton® Single Reduction Tandem Drive Axles

Differential Carrier AssemblyRear Axle RS340, 341, 380, 400, 401, 402, 403, 451

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Lubrication

The ability of a drive axle to deliver quiet, trouble-freeoperation over a period of years is largely dependent uponthe use of good quality gear lubricant in correct quantity.The most satisfactory results can be obtained by followingthe directions contained in this manual.

The following lubrication instructions represent the mostcurrent recommendations from the Axle & Brake Division ofEaton Corporation.

Approved LubricantsGeneral—Gear lubrications acceptable under militaryspecification (MILSPEC) MIL-L-2105D (Lubricating Oils,Gear, Multipurpose) are approved for use in Eaton DriveAxles. The MIL-L-2105D specification defines performanceand viscosity requirements for multigrade oils. It super-sedes both MIL-L-2105B, MIL-L-2105C and cold weatherspecification MlL-L-l 0324A. This specification applies toboth petroleum-based and synthetic based gear lubricantsif they appear on the most current “Qualified Products List”(QPL-2105) for MIL-L-2105D.

Note: The use of separate oil additives and/or frictionmodifiers are not approved in Eaton Drive Axles.

Synthetic based — Synthetic-based gear lubricants exhibitsuperior thermal and oxidation stability, and generallydegrade at a lower rate when compared to petroleum-basedlubricants. The performance characteristics of these lubri-cants include extended change intervals, improved fueleconomy, better extreme temperature operation, reducedwear and cleaner component appearance. The family ofEaton RoadrangerTM gear lubricants represents a premiumquality synthetic lube which fully meets or exceeds therequirements of MIL-L-2105D. These products, available inboth 75W-90 and 80 W-140, have demonstrated superiorperformance in comparison to others qualified under theMILSPEC, as demonstrated by extensive laboratory and fieldtesting. For a complete list of Roadranger® approved syn-thetic lubricants contact your local Eaton representative. Seeback cover of this manual for appropriate phone number.

Makeup Lube — Maximum amount of non-syntheticmakeup lube is 100/o.

Viscosity/Ambient Temperature Recommendations -Thefollowing chart lists the varies SAE Grades covered byMIL-L-2105D and the associated ambient temperature rangefrom each. Those SAE grades shown with an asterisk (*). areavailable in the Roadranger family of synthetic gear lubricants.

The lowest ambient temperatures covered by this chart are-40°F and -40°C. Lubrication recommendations for thoseapplications which consistently operate below this tempera-ture range, must be obtained through the Eaton Corpora-tion by contacting your local Eaton representative.

Grade i Ambient Temperature Range.—75W -40°F to -1 50°F (-40°C to -26°C)

7 5 W - 8 0 -40°F to 80°F (-40°C to 21°C)—————75W-90* -40°F to 100°F (-40°C to 38°C)

75W-140 -40°F and above (-40°C and above)80W-90 -15°F to 100°F (-26°C to -38°C)

80W-140* -15°F and above (-26°C and above)

85W-140 10°F and above (-1 2°C and above)

Lube Change Intervals

This product combines the latest manufacturing and partwashing technology. When filled with an Eaton approvedsynthetic lubricant at the factory, the initial drain is notrequired.

Change the lubricant within the first 5,000 miles ofoperation when not using a Roadranger approvedsynthetic lubricant in either a new axle or after a carrierhead replacement. Base subsequent lubricant changes ona combination of the following chart and user assessmentof the application and operating environment.

Severe Service Lubrication Change Intervals-Severeservice applications are those where the vehicle consis-tently operates at or near its maximum GCW or GVWratings, dusty or wet environments, or consistent operationon grades greater than 8%. For these applications, theON/OFF HIGHWAY portion of the chart should be used.Typical applications are construction, logging, mining andrefuse removal.

Note: Remove metallic particles from the magnetic fillerplug and drain plugs. Clean or replace the breather at eachlubricant change.

9

Lubrication

Changing Lube

DrainingDrain when the lube is at normal operating temperature. It will run freelyand minimize the time necessary to fully drain the axle.

Unscrew the magnetic drain plug on the underside of the axle housingand allow the lube to drain into a suitable container. Inspect drain plugfor large quantities of metal particles. After initial oil change, theseare signs of damage or extreme wear in the axle, and inspection of theentire unit may be warranted. Clean the drain plug and replace it afterthe lube has drained completely.

Axles with Lube Pump: Remove the magnetic strainer from the powerdivider cover and inspect for wear material in the same manner as thedrain plug. Wash the magnetic strainer in solvent and blow dry withcompressed air to remove oil and metal particles.

CAUTION: EXERCISE CARE TO DIRECT COMPRESSED AIR INTOSAFE AREA. WEAR SAFETY GLASSES.

FillingRemove the filler hole plug fromthe center of the axle housingcover and fill the axle withapproved lubricant until levelwith the bottom of the hole.

Forward axles: Add two pints(0.94 liters) of lubricant throughfiller hole at the top of the differ-ential carrier near the powerdivider cover.

Oil Filler Hole at top of DifferentialCarrier.

NOTE: Lube fill capacities in theadjacent chart are good guidelinesbut will vary somewhat on thebasis of the angle the axle isinstalled in a particular chassis.

Always use the filler hole as thefinal reference. If lube is level withthe bottom of the hole, the axle isproperly filled.

Axle Installation Angles

Axles installed at angles exceeding10 degrees or operated regularlyin areas of continuous and lengthygrades may require standpipes toallow proper fill levels.

For specific recommendations,contact your local Eaton repre-sentation. See back cover of thismanual for phone numbers.

Magnetic Strainer for Axles withLube Pump.

Lube Capacities*DO NOT OVERFILL AXLES

Eaton Housings (Rectangular Arm)

Single Reduction Forward Rear

Tandem Series Axle AxlePints (liters) Pints (liters)

39 (18.5) 36 (17.0)

380(P), 381(P) . . . . . . . . . . . . . 400-P, 401-P402(P), 403(P), 451-P . . . . . . . . 39 (18.5) 36 (17.0)

Forward Axles: Add an additional 2 pints (0.94 liters) axle lubricantthrough filler hole at the top of the differential carrier near the powerdivider cover. (See photo above.)ÔCapacities Iisted are approximate. The amount of Iubricant wiII vary with angle ofaxle as installed in vehicle chassis. Figures do not apply to housings not designedor manufactured by Eaton

10

Wheel End Lubrication

IMPORTANT: Before operating the axle, the wheel hub cavities and bearings must be lubricated to prevent failure.

When wheel ends are serviced, follow Eaton’s wheel end lubrication procedure before operating the axle.

Eaton axles may be equipped with either of two wheel end designs:● Wheel ends with an oil fill hole.● Wheel ends without an oil fill hole.

Wheel Ends with an oil fill hole proceed as follows: (Fig. 1 )

1. Rotate the wheel end hub until the oil fill hole is up.2. Remove the oil fill plug.3. Pour 1/2 pint of axle sump lubricant into each hub through the wheel end fill hole.4. Install oil fill plug and tighten to specified torque.

Wheel Ends without an oil fill hole proceed as follows: (Fig. 2)

1. With axle level and wheel ends assembled, add lubricant through filler hole in axle housing cover untilfluid is level with the bottom of filler hole.

2. Raise the left side of the axle 6 inches or more. Hold axle in this position for one minute.3. Lower the left side.4. Raise the right side of the axle 6 inches or more. Hold axle in this position for one minute.5. Lower the right side.6. With axle on a level surface, add lubricant through housing cover oil filler hole until fluid is level with the

bottom of the hole.

Note: Axles without wheel end fill holes will require approximately 2.5 additional pints of lubricant to bring thelube level even with the bottom of fill hole.

I Wheel End with Oil Fill Hole

I WHEEL ENDOIL FILL HOLE

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PROPERLUBRICANT LEVEL

Wheel End without Oil Fill Hole

PROPERLUBRICANT LEVEL

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Fig. 1 Cutaway views of typical wheel end assemblies

WITH AXLE ON LEVEL SURFACE,FILL HOUSING WITH OIL TO

BOTTOM OF PLUG

TEMPERATURE SENSORMOUNTING HOLE

TILT HOUSING SIDE TO SIDE. 1 MINUTE PER SIDE.THEN RECHECK OIL LEVEL IN AXLE

Fig. 2 Wheel end lubrication procedure11

Cleaning, Inspection, Replacement

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As the drive axle is disassembled, set all parts aside for thoroughcleaning and inspection. Careful inspection will help determine whetherparts should be reused. In many cases, the causes of premature wear ordrive axle failure will also be revealed.

Cleaning

The differential carrier assembly may be steam-cleaned while mounted inthe housing as long as all openings are tightly plugged. Once removedfrom its housing, do not steam clean differential carrier or any compo-nents. Steam cleaning at this time could allow water to be trapped incored passages, leading to rust, lubricant contamination, and prematurecomponent wear. The only proper way to clean the assembly is to dis-assemble it completely. Other methods will not be effective except aspreparatory steps in the process. Wash steel parts with ground or polishedsurfaces in solvent. There are many suitable commercial solvents avail-able. Kerosene and diesel fuel are acceptable.

WARNING: GASOLINE IS NOT AN ACCEPTABLE SOLVENT BECAUSEOF ITS EXTREME COMBUSTIBILITY. IT IS UNSAFE IN THEWORKSHOP ENVIRONMENT.

Wash castings or other rough parts in solvent or clean in hot solutiontanks using mild alkali solutions. If a hot solution tank is used, makesure parts are heated thoroughly, before rinsing.Rinse thoroughly to remove all traces of the cleaning solution. Dry partsimmediately with clean rags.

Lightly oil parts if they are to be reused immediately. Otherwise, coatwith oil and wrap in corrosion-resistant paper. Store parts in a clean, dryplace.

Inspection

Inspect steel parts for notches, visible steps or grooves created by wear.Look for pitting or cracking along gear contact lines. Scuffing, deforma-tion or discoloration are signs of excessive heat in the axle, usuallyrelated to low lubricant levels or improper lubrication practices.

Before reusing a gear set, inspect teeth for signs of excessive wear.Check tooth contact pattern for evidence of incorrect adjustment (seeAdjustment Section for correct pattern).

Inspect machined surfaces of cast or malleable parts. They must be freeof cracks, scoring, and wear. Look for elongation of drilled holes, wearon surfaces machined for bearing fits and nicks or burrs in matingsurfaces.

Inspect fasteners for rounded heads, bends, cracks or damaged threads

The axle housing should be examined for cracks or leaks. Also look forloose studs or cross-threaded holes.

Inspect machined surfaces for nicks and burrs.

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Repair and Replacement

IMPORTANT: To achieve maximum value from an axle rebuild. replacelower-cost parts, such as thrust washers, seals, etc. These items protectthe axle from premature wear or loss of lubricants, Replacing theseparts will not increase rebuild cost significantly.

It is also important to replace other parts which display signs of heavywear even though not cracked or broken. A significant portion of such apartÕs useful life has been expended and the damage caused, should thepart fail, is far in excess of its cost,

Steel Parts Ñ Gear sets, input and output shafts, differential parts andbearings are not repairable, Worn or damaged parts should be discardedwithout hesitation. Also discard mating parts in some cases. Gear sets,for example, must be replaced in sets.

Miscellaneous Parts Ñ Seals and washers are routinely replac ed. Noneof these parts can be reused if damaged. Fasteners using self-lockingnylon "patchesÓ may be reused if not damaged, but should be securedby a few drops of Loctite #277 on the threaded surface of the hole duringinstallation and carefully torqued during installation.

Axle Housings Ñ Repairs are limited to removal of nicks or b urrs onmachined surfaces and the replacement of loose or broken studs.

CAUTION: ANY DAMAGE WHICH AFFECTS THE ALIGNMENT ORSTRUCTURAL INTEGRITY OF THE HOUSING REQUIRES HOUSINGREPLACEMENT. REPAIR BY WELDING OR STRAIGHTENINGSHOULD NOT BE ATTEMPTED. THIS PROCESS CAN AFFECT THEHOUSING HEAT TREATMENT AND CAUSE IT TO FAIL COMPLETELYWHEN UNDER LOAD.

Silicone Rubber Gasket Compound Ñ For more effective sealing , Eatonuses silicone rubber gasket compound to seal the majority of metal-to-metal mating surfaces.

Eaton includes gasket compound and application instructions in manyrepair parts kits.

It is recommended that this compound be used in place of conventionalgaskets. The compound will provide a more effective seal against lubesee page and is easier to remove from mating surfaces when replacingparts.

Seals, Yoke & Slinger Service InformationDuring the 4th Quarter of 1990, Eaton began using new seals and yoke & slingers on the models in thispublication. The new seals and slingers are noticeably different from the current seals and will affectinterchangeability.l The upgraded seals can be used on axles originally equipped with the old seals.

l Eaton recommends the replacement of old yoke & slinger assemblies when the new seals are installed. Theold yokes and slingers will work with the new seals, but new yoke and slinger assemblies provide maximumsealing protection and prevent premature seal wear due to poor yoke condition.l New yoke and slinger assemblies cannot be used with the old seal design on the tandem forward axles.l New yoke and slinger assemblies can be used with the old seal on the tandem rear pinions.

. Yoke Assembly & Oil Seal Kits contain oil seal, yoke & slinger and instructions.

l Most non-Eaton aftermarket seals will not be compatible with the new Eaton Yoke and Slinger assemblies.

l Eaton recommends the use of special installation tools conveniently packaged inÕs single kit (listed below).

l Refer to Eaton pads Book AXIP-0089 and Eaton Bulletin 90-06 for additional information,

Seal Driver Installation Kit 272139Includes:l 126917 Driver (Rear Axle

127786

Pinion)l

l

127787 Adapter (use with 126917 Driver for Forward Axle Input)

Driver (Forward Axle Output)

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AdjustmentsWheel Bearing Adjustment

Wheel bearings should be adjusted at regular intervalsusing the following procedure:

—WARNING: Never work un-

der a vehicle supported byonly a jack. Always supportvehicle with stands. Blockthe wheels and make surethe vehicle will not roll be-fore releasing the brakes

Wheel End Seal

Important: Wheel end seals can be easily damaged during handling. Leave the seal in its package until installation toprevent damage or contamination.

1. Remove:● The outer bearing and wheel.● The inner bearing.ž The oil seal or grease retainer and discard.● The old wear sleeve (2-piece design only) with a ball peen hammer and discard.

Caution: Do not cut through the old wear sleeve. Damage to the housing may result.

2. Inspect:● The spindle journal and hub bore for scratches or burns. Recondition with emery cloth as required.

Note: Deep gouges can be repaired by filling gouge with hardened gasket and smoothing with emery cloth.

3. Clean● The hub cavity and bearing bores before reassembly. Be sure to remove contaminants from all recesses and corners.• The bearings thoroughly with solvent and examine for damage. Replace damaged or worn bearings.

4. Before installation, lubricate with the same lubricant used in the axle sump.● The inner bearing.• The wheel seal following the directors provided by the seal supplier.

IMPORTANT: Always use the seal installation tool specified by the seal manufacturer. Using an improper toolcan distort or damage the seal and cause premature seal failure.

Wheel Bearing Adjustment

1. Identify the wheel nut system being installed. Three systems are available:● Three piece Dowel-type wheel nut system -Fig.1 -

● Three piece Tang-type wheel nut system - Fig.2● Four piece Tang/Dowel type wheel nut system - Fig.3

WARNING: Do not mix spindle nuts and lock washers from different systems. Mixing spindle nuts and lock washers can

than the lock washer for a three piece tang-

cause wheel separation.

NOTE: The lock washer for a four piece-dowel-type wheel system is thinnertype wheel nut system and is not designed to bear against the inner nut.

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2. Inspect the spindle and nut threads for corrosion and clean thoroughly or replace as required.

Note: Proper assembly and adjustment is not possible if the spindle or nut threads are corroded.

● Inspect the tang-type washer (if used). Replace the washer if the tangs are broken, cracked, or damaged.

3. Install the hub and drum on the spindle with care to prevent damage or distortion to the wheel seal.

* CAUTION: A wheel dolly is recommended during installation to make sure that the wheel seal is not damagedby the weight of the hub and drum. Never support the hub on the spindle with just the inner bearing and seal.This can damage the seal and cause premature failure.

● Completely fill the hub cavity between the inner and outer bearing races with the same lubricant used in the axle sump.

4. Before installation, lubricate the outer bearing with the same lubricant used in the axle sump.

Note: Lubricate only with clean axle lubricant of the same type used in the axle sump. Do not pack the bearing withgrease before installation. Grease will prevent the proper circulation of axle lubricant and may cause wheel seal failure.

5. ● Install the outer bearing on the spindle.● Install the inner nut on the spindle.● Tighten the inner nut to 200 lbs. ft. (271 N.M.) while rotating the wheel hub.

* CAUTION: Never use an impact Wrench to adjust wheel bearings. A torque wrench is required to assure thatthe nuts are property tightened.

6.

7.

8.

Back-off the inner nut one full turn. Rotate the wheel hub.

Re-tighten the inner nut to 50 lbs. ft. (68 N.M.) while rotating the wheel hub.

Back-off the inner nut exactly 1/4 turn.

Note: This adjustment procedure allows the wheel to rotate freely with 0.001"-0.005" (0.025mm to 0.1 27mm) end-play.

9. Install the correct lock washer for the wheel nut system being used.

THREE PIECE TANG-TYPE LOCK WASHER SYSTEM (see Fig. 2).

* Install the Tang-type lock washer on the spindle.

IMPORTANT: Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure.

* Install the outer nut on the spindle and tighten to 250 lbs. ft. (339 N.M.).

* Verify end-play (see End Play Verification Procedure)

* After verifying end play, secure wheel nuts by bending one of the lockingwasher tangs over the outer wheel nut and another tang over the inner wheelnut as shown in Figure 4. (below)

THREE PIECE DOWEL-TYPE LOCK WASHER SYSTEM (see Fig. 1)

* Install the Dowel-type lock washer on the spindle.

Note: If the dowel pin and washer are not aligned, remove washer, turn it overand reinstall. If required, loosen the inner nut just enough for alignment.

IMPORTANT: Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure.

* Install the outer nut on the spindle and tighten to 350 lbs. ft. (475 N.M.).

* Verify end-play (see End Play Verification Procedure)

15

FOUR PIECE TANG/DOWEL-TYPE LOCK WASHER SYSTEM (see Fig. 3)

*First, 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 in-ner nut just enough for alignment.

IMPORTANT: Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure.

*Install the Tang-type lock washer on the spindle.

*Install the outer nut on the spindle and tighten to 250 lbs. ft. (339 N. M.)

*Verify end-play (see End Play Verification Procedure)

*After verifying end play, secure the outer nut by bending two opposing (180° apart) tangs of the locking washerover the outer nut as shown in Figure 5 (below). I

10. Install*New gasket at axle shaft flange.*axle shaft.*Axle flange nuts and tighten to specified torque.

11. Lubricate axle wheel ends (see Wheel End Lubrication Procedure)

End Play Verification Procedure

Verify that end-play meets specification using a dial indicator. An indica-tor with 0.001” (0.03 mm) resolution is required. Wheel end play is thefree movement of the tire and wheel assembly along the spindle axis.

Figure 5

a. Attach a dial indicator with its magnetic base to the hub or brake drum as shown below:

End Play Adjustmentwith Tire & Wheel

AssemblyJ

—

Fig. 4 End Play

With indicator mounted at bottom,Push/Pull at sides of drum

Measurement

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End Play Adjustmentwith Wheel hub

— J

b. Adjust the dial indicator so that its plunger or pointer is against the end of the spindle with its line of action approxi-mately parallel to the axis of the spindle.

c. Grasp the wheel assembly at the 3 o’clock and 9 o’clock positions. Push the wheel assembly in and out whileoscillating it to seat the bearings. Read bearing end play as the total indicator movement.

* CAUTION: If end play is not within specification, readjustment is required.

End Play Re-adjustment Procedure

Excessive End Play - If end play is greater than .005” (.127 mm), remove the outer nut and pull the lock washer awayfrom the inner nut, but not off the spindle. Tighten the inner nut to the next alignment hole of the dowel-type washer (ifused). Reassemble the washer and torque the outer nut. Verify end play with a dial indicator.

Insufficient End Play - If end play is not present, remove the outer nut and pull the lock washer away from the innernut, but not off the spindle. Loosen the inner nut to the next adjustment hole of the dowel-type washer (if used). Reas-semble the washer and re-torque the outer nut. Verify end play with a dial indicator.

Fine Tuning the End Play - If, after performing the readjustment procedures, end play is still not within the .001”-.005”(.025 mm to .127 mm) range, disassemble and inspect the components. If parts are found to be defective, replace thedefective parts, reassemble and repeat wheel bearing adjustment procedure. Verify end play with a dial indicator.

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Differential Carrier

Adjustments help provide optimum axle life and performance by correctlypositioning bearings and gears under load.The tandem axles covered in this manual require the following adjustments:

Bearing Preload: This adjustment IS Ring Gear Tooth Contact: This adjust- Input Shaft End Play (Forward Axles):performed for both pinion and differ- ment positions ring gear and pinion This adjustment controls gear meshential bearings It maintains proper for best contact under load. Correct in the inter-axle differential. Propergear alignment by creating correct adjustment distributes torque evenly adjustment helps maximize life of allbearing cone and cup relationship for over gear teeth and helps maximize power divider parts.free rotation under load The pinion gear set Iife.pilot bearing does not require a pre-load adjustment,

Adjust Input Shaft End PlaySpecifications: Input shaft end play requirements will vary with operat-ing conditions, mileage and rebuild procedures. These variations areshown in the following chart.

Input Shaft End Play ChartNew or Rebuild with new parts NOTE: Because of manufacturing

0.003" to 0.007" variations in individual parts,correctly adjusted end play could

Rebuild with reused parts vary 0.010", after the unit is0.013" to 0.017" rotated.

Acceptable End Play Tolerances when measuring asa regular maintenance procedure with axle in truck.

Up to 0.060" with over 100,000 NOTE: If end play exceeds limits,miles or 1 year service off-road, disassemble power divider and

replace worn parts.Up to 0.040" with less than 100,000miles or 1 year service on- road.

Measure and Adjust End PlayIMPORTANT: In September 1988, Eaton added a Spring and a ThrustButton between the input and output shafts. End play tolerances are thesame for axles with or without this Spring and Button. However, end playmeasurement procedure is different than described below. Refer to ServiceBulletin Supplement at back of this manual for procedure variances.1. With power divider assembled to differential carrier, measure endplay with dial indicator positioned at yoke end of input shaft. Moveinput shaft axially and measure end play. If end play is not correct (seechart), adjust as follows.

2. Remove input shaft nut, flat washer and yoke. Remove bearing covercap screws and lockwashers. Remove cover and shim pack.

3. To increase end play, add shims:Desired end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003" to 0.007"Measured endplay (Step 1). . . . . . . . . . . . . . . . . . . . . . . 0.001" - 0.001"

Add shims to provide desired end play . . . . . . . . . . . . . 0.002" to 0.006"

4. To decrease end play, remove shims:Measured endplay (Step 1). . . . . . . . . . . . . . . . . . . . . 0.015" - 0.015"Desired end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003" to 0.007"

Remove shims to provide desired end play . . . . . . . . . 0.012" to 0.008"5. To reassemble input shaft, install the adjusted shim pack and bear-ing cover. Install cap screws and lockwashers. Torque screws to 75-85ft-lbs. (101-115 N.m).

NOTE: If difficulty is experienced in achieving correct torque on theinput yoke nut, torque the nut with truck on the ground and axle shaftsinstalled.

Measuring End Play with DialIndicator.

6. Install yoke, flat washer and nut.Tighten nut snugly. Tap end ofinput shaft lightly to seat bearings.7. Measure input shaft end playwith dial indicator. If end play isstill incorrect, repeat Steps 2through 6.8. With end play correct, seal shimpack to prevent lube leakage, thentorque input shaft nut and covercap screws (see chart).NOTE: When power divider hasbeen disassembled and reassem-bled, it may be desirable to adjustend play by measuring bearingcover clearance and calculatingshim pack size. For procedures,see page 39.

Torque Chart

I n p u tShaft Nut Ft-lbs. N.m1-5/8-18 780-960 1057-1301*M42 X 1.5 840-1020 1140-1383

Bearing CoverCap Screw1/2-13 75-85 101-115(Grade 5)

*Metric Nut used on Axles produced after 1-3-95

17

Adjustments

Pinion Bearing Preload

Most late model axles are provided with a “press-fit” outer bearing onthe drive pinion. Some of the early model axles use an outer bearingwhich slips over the drive pinion. Procedures for adjusting both typesof pinion bearing design are contained in this section.

Adjust Pinion Bearing Preload for Axles with"Press-fit” Outer Pinion Bearings

Trial Build-up1. Assemble pinion bearing cage,bearings and spacer (without drivepinion or oil seal). Center bearingspacer between two bearing cones.

NOTE: When new gear set orpinion bearings are used, selectnominal size spacer from the speci-fication chart below. If originalparts are used, use spacer removedduring disassembly.

2. With the bearings well lubri-cated, place the assembly in thepress. Position sleeve so that loadis applied directly to the back-faceof the outer bearing cone.

3. Apply press load (see chartbelow) to the assembly and checkrolling torque. Wrap soft wirearound the bearing cage, attachspring scale and pull. Preload iscorrect when torque required torotate the pinion bearing cage isfrom 10-20 inch-pounds. Thisspecification is translated intospring scale readings in the chartbelow.

4. If necessary, Adjust PinionBearing Preload by changing thepinion bearing spacer. A thickerspacer will decrease preload. Athinner spacer will increasepreload.

IMPORTANT: Once correct bear-ing preload has been established,note the spacer size used. Select aspacer 0.001” larger for use in thefinal pinion bearing cage assembly.The larger spacer compensatesfor slight “growth” in the bear-ings which occurs when they arepressed on the pinion shank. Thetrial build-up will result in properpinion bearing preload in threeof four cases.IMPORTANT: Do not assume thatall assemblies will retain properpreload once bearings are pressedon pinion shank. FINAL PRELOADTEST MUST BE MADE IN EVERYCASE.

Assemble these Parts forTrial Build-up.

9

Cage in Pressto Check BearingPreload.

Specifications for Pinion BearingTrial Build-up Preload Test

(“Press-fit” Outer Pinion Bearings)

Axle Models

Forward AxlesD340, 380(P),400-P

D341 ,381 (P),401-P,402 (P),403 (P), 451-P

Rear Axles(all models)

Nominal BearingSpacer Thickness

in. mm

O 638 1621

0496 1260

0638 16.21

Press Loads

Tons Metric Tons

13,5 -15,5 122 -140

17-19 154-17,2

14-15 127-136

SpringScale Reading

(withoutpinion seal)(for 10-20

in-lbs. torque)(1.1-2.3 N.m)

lbs. kgs.

3-7 1 4 - 3 . 2

3-7 1.4-32

4 - 8 1 8 - 3 6

18

Final Pinion Bearing Preload Test

1. Assemble the complete pinion bearing cage unit as recommendedin the assembly section of this manual.

NOTE: Forward axle pinion is equipped with helical gear. For easierdisassembly during bearing adjustment procedure, use a dummy yoke(if available) in place of helical gear.

2. Apply clamp load to the pinion bearing cage assembly. Either installthe yoke (or helical gear) and torque the pinion nut to specifications oruse a press to simulate nut torque (see chart below).

Vise Method - If the yoke and nut are used, mount the assembly in avise, clamping yoke firmly.Press Method - If a press is used, position a sleeve or spacer so thatload is applied directly to the back-face of the outer bearing cone.

3. Measure Pinion Bearing Preload - Use a spring scale to test theassembly rolling torque. To use the spring scale, wrap soft wire aroundthe bearing cage, attach the scale and pull. Preload is correct whentorque required to rotate the pinion bearing cage is from 15 to 35 inchpounds. This specification is translated into spring scale readings in thechart below.

4. Adjust Pinion Bearing Preload - If necessary, adjust pinion bearing

Measuring Bearing Preload withPinion in Vise.

preload. Disassemble the pinion bearing cage as recommended in this -

manual and change the pinion bearing spacer. A thicker spacer willdecrease preload. A thinner spacer will increase preload.

IMPORTANT: Use the correctly sized spacer. Do not use shim stock orgrind spacers. These practices can lead to loss of bearing preload andgear or bearing failure.

*Torque nut to 840 ft-lbs. (1139 N.m), then continue tightening nut to align nut slot to nearest hole in pinion shank.

ã

19

Adjustments

Adjust Pinion Bearing Preload for Axles with"Slip-fit" Outer Pinion Bearings

1. Lubricate bearings and assemble the drive pinion, bearings, andpinion bearing cage as recommended in the assembly section of thismanual. Use the pinion bearing spacer removed from the axle duringdisassembly. If the original spacer cannot be used, install the nominalspacer recommended in the adjacent chart.NOTE: Forward axle pinion is equipped with helical gear, For easierdisassembly during bearing adjustment procedure, use a dummy yoke(if available) in place of helical gear.

2. Apply clamp load to the pinion bearings. Install the yoke (or helicalgear) and torque the nut to specification or use a press to simulate nuttorque by applying pressure to the assembly (see chart below).

Vise Method - If the yoke and nut are used, mount the assemblyin a vise, clamping yoke firmly.

Press Method - If a press is used, position a sleeve or spacer so thatload is applied directly to the back-face of outer pinion bearing.3. Measure Pinion Bearing Preload - Use a spring scale to test theassembly rolling torque, To use the spring scale, wrap a soft wire aroundthe bearing cage, attach the scale and pull, Preload is correct whentorque required to rotate the pinion bearing cage is from 15 to 35 inchpounds. This specification is translated into spring scale readings in thechart below.

4. Adjust Pinion Bearing Preload - If necessary, adjust pinion bearingpreload. Disassemble the pinion bearing cage as recommended in thismanual and change the pinion bearing spacer. A thicker spacer willdecrease preload, A thinner spacer will increase preload.

IMPORTANT: Use the correctly sized spacer, Do not use shim stock orgrind spacers. These practices can lead to loss of bearing preload andgear or bearing failure.

Nominal PinionBearing Spacers

Spacer ThicknessAxle Model i n . m mForward AxlesD340, 380(P), 400-P, 0.638 16.205D341, 381(P), 401-P,402(P), 403(P), 451-P 0492 12497

Rear Axles(all models) 0638 16205

Measuring Bearing Preload withPinion in Vise.

Measuring Bearing Preload withPinion in Press.

*Torque nut to 840 ft-lbs. (1 139 N.m), then continue tightening nut to align nut slot to nearest hole in pinion shank.

20

Differential Bearing Preload and Ring GearBacklash Adjustment

Correct differential bearing preload insures proper location of thesebearings under load and helps position the ring gear for proper geartooth contact.

(Follow procedures in numerical sequence.)

Adjust Diff. Bearing Preload

1. Lubricate differential bearings. NOTE: Ring gear position for rear 3. Loosen the bearing adjusterIMPORTANT: When installing axle is illustrated. on the same side as the ring gearbearing caps and adjuster, exert teeth until its first thread iscare not to cross threads.

c

‘

visible.

2. Install adjusters and bearingcaps. Tighten bearing cap screwsfinger-tight. If this is difficult,use a hand wrench.

4. Tighten the bearing adjusteron the back-face side of the ringgear until there is no backlash. -

This can be tested by facing thering gear teeth and pushing thegear away from the body whilegently rocking the gear from sideto side. There should be no freemovement.Rotate the ring gear and checkfor any point where the gear maybind. If such a point exists,loosen and re tighten the backside adjuster. Make all furtheradjustments from the point oftightest mesh.

Adjust Ring Gear Backlash

To add backlash: Loosen theadjuster on the teeth side of the ringgear several notches. Loosen theopposite adjuster one notch.Return to adjuster on teeth side ofthe ring gear and tighten adjusteruntil it contacts the bearing cup.Continue tightening the same ad-juster 2 or 3 notches. Recheckbacklash.

5. At teeth side of ring gear,tighten adjuster until it contactsthe bearing cup. Continue tighten-ing adjuster two or three notchesand this will preload bearings andprovide backlash.

6. Measure backlash with a dial indicator.USED GEARING — Reset to backlash recorded before disassembly.NEW GEARING — Backlash should be between 0.006” and 0.016”.If backlash is incorrect, proceed as described below to readjust.

To remove backlash: Loosen theadjuster on the teeth side of the ring Igear several notches. Tighten theopposite adjuster one notch.Return to adjuster on teeth side ofring gear and tighten adjuster until itcontacts the bearing cup. Continuetightening the same adjuster 2 or 3 notches. Recheck backlash.

Moving adjuster one notch is themovement of the lead edge of oneadjuster lug to the lead edge of thenext lug past a preselected point.

21

Adjustments

NOTE: Rear axle gearing is shown in the following instructions. Correcttooth contact patterns and adjustments are the same for forward and -

rear axles.

Ring Gear and Pinion Tooth Contact

Check Tooth Contact Pattern (NEW GEAR)Paint twelve ring gear teeth with marking compoundand roll the gear to obtain a contact pattern. The correctpattern is well-centered on the ring gear tooth withlengthwise contact clear of the toe. The length of thepattern in an unloaded condition is approximately one-half to two-thirds of the ring gear tooth in most modelsand ratios.

Check Tooth Contact Pattern (USED GEAR)Used gearing will not usually display the square,even contact pattern found in new gear sets. Thegear will normally have a “pocket” at the toe-endof the gear tooth which tails into a contact linealong the root of tooth. The more use a gear hashad, the more the line becomes the dominantcharacteristic of the pattern.Adjust used gear sets to display the same contactpattern observed before disassembly. A correctpattern is clear of the toe and centers evenly alongthe face width between the top land and root.Otherwise, the length and shape of the pattern arehighly variable and is considered acceptable aslong as it does not run off the tooth at any point.

CORRECT PATTERN (NEW GEARING)

● Could vary in length.Pattern should cover1/2 tooth or more(face width).• pattern should

be evenly centeredbetween toothtop land androot.

● Pattern should be clear of tooth toe.

CORRECT PATTERN (USED GEARING)

● Pocket may beextended.

● Pattern along theface widthcould be longer.

—

22

Adjust Tooth Contact Pattern

If necessary, adjust the contact pattern by moving the ring gear anddrive pinion. Ring gear position controls the backlash. This adjustmentmoves the contact pattern along the face width of the gear tooth, Pinionposition is determined by the size of the pinion bearing cage shim pack. Itcontrols contact on the tooth depth of the gear tooth.

These adjustments are interrelated. As a result, they must be con-sidered together even though the pattern is altered by two distinctoperations. When making adjustments, first adjust the pinion, then thebacklash. Continue this sequence until the pattern is satisfactory.

Adjust Pinion PositionIf the gear pattern shows incorrect tooth depth contact, change drivepinion position by altering the shim pack. Used gears should achieveproper contact with the same shims removed from the axle at disassembly.

INCORRECT PATTERN

● Move piniontoward ring gear

● Pattern too close to tooth top land and off center.

INCORRECT PATTERN

• Move pinionaway fromring gear. /

● Pattern too close or off tooth root.

If the pattern is too close to the top land of thegear tooth, remove pinion shims.

If the pattern is too close to the root of the geartooth, add pinion shims.

NOTE: Check ring gear backlash after each shim change and adjust if necessary to maintain the 0.006” to0.016” specifications.

Adjust BacklashIf the gear pattern shows incorrect face width contact, change backlash.

INCORRECT PATTERN

● Move ring gearaway from pinionto increasebacklash

Ž Pattern too close to edge of tooth toe

INCORRECT PATTERN

to decreasebacklash

• Move ring geartoward pinion

● Pattern too far along tooth toward tooth heel,

With the pattern concentrated at the toe (too fardown the tooth), add backlash by loosening thebearing adjuster on the teeth side of ring gear sev-eral notches. Loosen the opposite adjuster one notch.

If the pattern is concentrated at the heel (toofar up-the tooth), remove backlash by loosening thebearing adjuster on the teeth side of ring gear sev-eral notches. Tighten the opposite adjuster one notch.

Return to adjuster on teeth side of ring gear and Return to adjuster on teeth side of ring gear andtighten adjuster until it contacts the bearing cup. tighten adjuster until it contacts the bearing cup.Continue tightening the same adjuster 2 or 3 Continue tightening the same adjuster 2 or 3notches. Recheck backlash. notches. Recheck backlash.

23

Fastener Tightening Specifications

Specifications are for all axle models unless specified otherwise.

24

Eaton Single Reduction Tandem Models:D340, 380(P), 400-PD341 , 381 (P), 401-P, 402(P), 403(P), 451-P

• Correct tightening torque values are extremely important to assurelong Eaton Axle life and dependable performance. Under-tighteningof attaching parts is just as harmful as over-tightening.

● Exact compliance with recommended torque values will assure thebest results.

Ž The data includes fastener size, grade and torque tightening values.Axle models are included to pinpoint identification of fasteners foryour particular axle.

• To determine bolt or cap screw grade, check for designation stampedon bolt head (see illustration).

NOTE 1: METRIC NUT USED ON AXLES PRODUCED AFTER 1/3/95. REF. CHART PG. 56

Bolt head markingsfor grade identification

Grade 5 Grade 8

25

Forward Axle Differential Carrier Replacement

I

Remove Differential Carrier Assembly from Axle HousingIMPORTANT: D341, 381 (P), 401-P, 402(P), 403(P), 451-P models do NOT use and output shaft Rear Bearing

Retaining Washer.WARNING: THE OUTPUT SHAFT REAR BEARING RETAINING WASHER IS FREQUENTLY LOSTWHEN THE DIFFERENTIAL CARRIER ASSEMBLY IS REMOVED. IT MAY ADHERE TO THE YOKE, TOTHE FACE OF THE OUTPUT SHAFT BEARING, FALL ON THE FLOOR OR INTO THE HOUSING. LOCATETHIS WASHER BEFORE CONTINUING! IF IT IS NOT REINSTALLED, THE END OF THE YOKE WILLWEAR THE OUTPUT SHAFT BEARING VERY QUICKLY. IF IT IS LEFT IN THE HOUSING, IT CAN BEPICKED UP BY THE RING GEAR MOTION AND CAUSE PREMATURE AXLE FAILURE.(Follow procedure in numerical sequence. )

8. Axle Housing Cover andOutput Shaft Bearing Parts.The bearing parts can be replacedwith cover removed or installed. Ifnecessary, remove axle housingcover. It is fastened with capscrews, nuts and lockwashers.

26

Install Differential Carrier AssemblyIMPORTANT:D341, 381 (P), 401-P, 402(P), 403(P), 451-P models do NOT use an output shaft Rear Bearing Retaining Washer.

WARNING: WHEN INSTALLING DIFFERENTIAL CARRIER ASSEMBLY, IT IS IMPORTANT TOFOLLOW CORRECT PROCEDURES TO ASSURE USEFUL LIFE. FAILURE TO CORRECTLY INSTALLREAR BEARING AND RETAINING WASHER COULD RESULT IN PREMATURE AXLE FAILURE.

IMPORTANT: Before installing carrier assembly, inspect and thoroughly clean interior of axle housing.

NOTE: Use silicone rubber SILICONE GASKET COMPOUND SILICONE GASKET COMPOUNDgasket compound on axle housing PATTERN DIFFERENTIAL CARRIER PATTERN. HOUSING COVER

mating surface as shown in theMATING SURFACE MATING SURFACE.

illustrations. Compound will set in20 minutes. Install carrier and axlehousing cover before compoundsets or reapply.

(Follow procedure in numerical sequence.)Location of hole inrear cover.

1. Apply silicone gasket compound. 2. Axle Housing Cover and Output Shaft Bearing Parts. If removed,Install differential carrier assembly install cover and fasten with nuts, cap screws and lockwashers. Tightenin axle housing. Install nuts and to correct torque. If removed, install bearing parts (see steps 3 throuqh 6).lockwashers. Tighten to correcttorque. (See Chart).

Torque Chart

Differential Carrier Stud/NutSize Ft-lbs. N.m

5/8-1 8 220-240 298-325(Grade 8 stud)

Axle Housing Cover Stud/NutSize Ft-lbs. N.m

7/1 6-20 78-86 94-116(Grade 8 stud)

Cap ScrewSize Ft-lbs. N.m

7/16-14 48-56 65-75(Grade 5 )

518-18 220-240 298-325(Grade 8)

NOTE: CHECK CARRIER DATE–

CODE. ON UNITS BUILT PRIORTO 1988, JULIAN CALENDARDATE CODE COULD BE FOUNDON THE METAL TAG ON THEDIFFERENTIAL.5. Install a new output shaft seal inthe axle housing cover.*Units built before March 13,1987(87072), seal should be flush withbottom of chamfer. Units builtafter March 13,1987 (87072), sealshould be installed until 3/32”deeper than bottom of chamfer.Lubricate the seal diameter toprevent damage during yokeinstallation.

3. Install output shaft rear bearing.Tap the outer race (with a sleeve ordrift) until it is seated firmly in themachined pocket of the cover.Secure with snap ring.

4. Lubricate and install the rear bear-ing sleeve on the output shaft. Makecertain it fits snugly against theshoulder at the forward edge of theshaft splines.

6. Slide the rear bearing retaining 9. Connect main and inter-axlewasher over the splines of the drivelines.outer shaft until it seats flush 10. Fill axle with correct lubricantagainst the output shaft bearing. (see Lubrication Section).IMPORTANT: *D341, 381(P), 11. Connect differential lockout401-P, 402(P), 403(P), 451-P air line.models do NOT use an outputshaft Rear Bearing RetainingWasher. IMPORTANT: When axle has been7. Install output yoke, flat washer disassembled or housing, gears,and self-locking nut. Tighten to axle shafts or wheel equipmentcorrect torque. Ref. chart pg. 24. replaced, check axle assembly for

proper differential action before8. Install axle shafts, and stud operating vehicle. Wheels mustnuts. (if used, also install lock- rotate freely and independently.washers and taper dowels).

*IMPORTANT: Refer to page 13 for service information on seals, yokes & slingers. 27NOTE 1: Washer not used on axles with metric threaded nuts. Ref. bulletin AXIB-9409.

Power Divider Replacement(with differential carrier assembled to axle housing)

Removing and Installing Power Divider.The power divider can be replaced with the axle assembly in or outof chassis and with differential carrier assembled to axle housing.

WARNING: DURING REMOVAL AND INSTALLATION, THEPOWER DIVIDER ASSEMBLY MUST BE SUPPORTED AS A SAFETYPRECAUTION. DURING REMOVAL OR INSTALLATION, THE lNTER-AXLE DIFFERENTIAL MAY FALL FROM CARRIER. EXERT CAUTIONTO PREVENT DAMAGE OR INJURY.

With axle out of chassis, use chain hoist. Fastenchain to input yoke to remove power divider.

NOTE: Lifting mechanism may create nicks andburrs on input yoke. Remove if present,

With axle installed in chassis, use a transmissionjack Ñ or a chain hoist and a sling. Wrap slingstrap around power divider and attach to chainhoist hook as shown in photos.

I , Removing Power Divider with Chain Hoist and Sling.

Remove Power Divider from Differential Carrier

1. Disconnect main driveline

2. Loosen, but do not removeinput yoke nut.

3. Disconnect lockout air line.4. Position drain pan under powerdivider cover.

5. To remove power dividerassembly, remove cover capscrews and lockwashers. Supportpower divider (see instructionsabove). Then, tap back-face ofinput yoke to dislodge cover fromdifferential carrier. If cover doesnot dislodge easily, strike thesides of the cover near the dowelpin locations (see illustration).Drain lube.

CAUTION: DURING REMOVAL of POWER DIVIDER, THE lNTER-AXLE DIFFERENTIAL MAY FALL FROM CARRIER. EXERT CAUTIONTO PREVENT DAMAGE OR INJURY.6. Pull power divider assembly forward until it is completely free of carrier,then remove the assembly.7. Inter-axle Differential. With power divider removed, the inter-axle differ-ential can be lifted off output shaft side gear (see photo on page 29).NOTE: Late Model Axles may be equipped with a compression spring andthrust button mounted between the input shaft and output shaft (seepage 54).8. Output Shaft. If necessary, remove output shaft as follows: Disconnectinter-axle driveline. Remove nut, flat washer and output shaft yoke. Pulloutput shaft assembly out of carrier (see photo on page 29).9. Axle Housing Cover and Output Shaft Bearing Parts. If necessary,remove these parts following instructions on page 26.

Power Divider CoverDowel Pin Locations

Pump model Illustrated

28

Install Power Divider on Differential Carrier(with carrier assembled to axle housing)

NOTE: Lubricate all parts before installation.

1. Axle Housing Cover and Output Shaft Bearing Parts. If removed,install these parts following instructions on page 27.

2. Output Shaft. If removed,lubricate "O" rings, then installshaft assembly in differential car-rier and housing cover. Lubricateseal lip. Make sure yoke is cleanand dry, then install yoke, flatwasher* and self-locking nut.Torque nut to correct specification.

NOTE: Late ModeI Axles may beequipped with a spring and thrustbutton mounted in end of outputshaft. (see page 54).

3. Inter-axle Differential. Installthis assembly on output shaft sidegear (with nuts facing away fromside gear).

CAUTION: DURING INSTALLATION OF POWER DIVIDER, THEINTER-AXLE DIFFERENTIAL MAY FALL FROM CARRIER. EXERTCAUTION TO PREVENT DAMAGE OR INJURY.5. Make certain dowel pins are installed in carrier (see drawing above),then install power divider assembly,

Use a transmission jack or a chain hoist and sling (see photo).

During installation, rotate input shaft to engage input shaft splines withinter-axle differential, After installation, again rotate input shaft to checkfor correct assembly. Output shaft should turn when input shaft isrotated.

6. Install power divider cover cap screws and lockwashers. On pumpmodels only, install socket-head cap screw in correct location (seedrawing on preceding page). Torque cap screw to 110-125 ft.-lbs.(149-170 N.m).

7. Check and Adjust Input Shaft End Play. With power divider assembledto differential carrier. check end play with dial indicator. If necessary,adjust end play (see page 17 or Service Bulletin Supplement page 54).After input shaft end play is within specifications, complete assemblyprocedure as follows:

8. Connect drivelines. Connect lockout air line.

9. Fill axle to proper lube level (see Lubrication Section).

IMPORTANT: When axle has been disassembled or housing, gears, axleshafts or wheel equipment replaced, check axle assembly for properdifferential action before operating vehicle. Wheels must rotate freelyand independently.

Silicone Gasket Compound

4. Power Divider Assembly. Usesilicone rubber gasket compoundon differential carrier mating sur-face as shown in the illustration.NOTE: Compound will set in 20minutes. Install power divider be-fore compound sets or reapply.

Installing Power Divider Assemblywith Chain Hoist and Sling.

Measuring Input Shaft End Playwith Dial Indicator.

*Washer not used on axles with metric threaded nuts.

29

Rear Axle Differential Carrier Replacement

Remove Differential Carrier Assembly from Axle Housing

(Follow procedure in numerical sequence.) 2. Disconnect inter-axle driveline.

NOTE: For easier disassembly, the drive pinionnut can be loosened after driveline isdisconnected.

3. Remove axle shaft, stud nuts, lockwashersand taper dowels (if used). If necessary, loosendowels by holding a brass drift in the center of Ithe shaft head and striking it a sharp blow with 4. WARNING: DO NOT LIE UNDER CARRIERa hammer. AFTER FASTENERS ARE REMOVED. USE

IMPORTANT: Do not strike the shaft head with TRANSMISSION JACK TO SUPPORT AND

a hammer. Do not use chisels or wedges to REMOVE DIFFERENTIAL CARRIER ASSEMBLY.

loosen shaft or dowels. Remove nuts and lockwashers fastening carrier toaxle housing.

Remove differential carrier assembly.

Install Differential Carrier Assembly

carrier assembly, inspect and (If used, also install lockwashersthoroughly clean interior of and taper dowels. )axle housing. 3. Connect inter-axle driveline.NOTE: Use silicone rubber gasket 4. Fill axle with correct lube (seecompound on axle housing mating Lubrication Section).

IMPORTANT: Before installing 2. Install axle shafts and stud nuts.

surface as shown in the illustration.Compound will set in 20 minutes.Install carrier before compound setsor reapply.1. Install differential carrier assem-bly in axle housing. Install stud nutsand lockwashers. Tighten to correcttorque (see chart).IMPORTANT: When axle has been dis

Torque Chart

Diff. Carrier Stud/Nut or Capscrew

Size Ft-lbs. N.m

5/8-18 220-240 298-325(Grade 8)

assembled or housing, gears,

Axle Housing Silicone GasketCompound Pattern.

axle shafts or wheel equipment replaced, check axle assembly forproper differential action before operating vehicle. Wheels must rotatefreely and independently.

30

Power Divider Overhaul

Remove Power Divider from Differential Carrier(with carrier removed from axle housing)

NOTE: It is assumed that the differential carrier and power divider assemblyhave been removed from axle housing (see page 24) prior to starting

the following procedures:

1. Mount differential carrier inrepair stand. Loosen input shaftNut..

.2. Remove power divider covercap screws and lockwashers.

CAUTION: DURING REMOVALOF POWER DIVIDER, THE lNTER-AXLE DIFFERENTIAL MAY FALLOFF INPUT SHAFT FROM DEF-ERENTIAL CARRIER. EXERTCAUTION TO PREVENTDAMAGE OR INJURY.

3. Attach chain hoist to input yokeand lift power divider off carrier, Ifpower divider does not separateeasily, strike the cover near thedowel pin locations with a malletsee illustration).

N0TE: Lifting mechanism maycreate nicks or burrs on input yoke.remove if present.

Power Divider CoverDowel Pin Location.

Pump model Illustrated

DOWELPIN

4. Inter-axle Differential. Lift dif-ferential assembly off output shaftside gear.

5. Output Shaft. Tilt carrier andremove the output shaft assembly.

6. Output Shaft Side Gear BearingCup. If replacement is necessary,use puller to remove bearing cupfrom carrier.

NOTE: Late Model Axles may be equipped with a spring and thrust button mounted between the input shaftand output shaft (see page 54).

NOTE: For instructions on removing axle housing cover and output shaft rear bearing parts, see page 26.

31

Power Divider Overhaul

Disassemble Power Divider Cover

Power Divider Cover and Input Shaft(without Lube Pump)

4. Remove cap screws lock-washers and input bearing coverand shim pack.

1. Remove snap ring frommachined groove at-rear of inputshaft.

WARNING: SNAP RING ISSPRING STEEL AND MAY POPOFF WEAR SAFETY GLASSESWHEN REMOVING. WITH SNAPRING REMOVED, THE HELICALSIDE GEAR MAY FALL OFFSHAFT. EXERT CARE TOPREVENT DAMAGE OR INJURY,

Slide helical-side gear off inputshaft, then remove bronze thrustwasher and "D" washer from shaft,

5. Slide input shaft assembly outof cover. Remove bearing spacerfrom shaft (used only on D340,380(P), 400-P).

BEARINGSPACER(Used only onD340, 380(P),400-P)

LOCKOUT FOR DESIGN VARIATIONS REFERTO LOCKOUT SERVICE INSTRUCTIONS

2. Axles with Lube Pump. At thispoint in disassembly, it is desirableto remove lube pump drive gearnut. Hold input shaft yoke tosecure drive gear, then loosenand remove drive gear nut.

3. Remove nut, flat washer andyoke from input shaft.

6. NOTE: Remove Lockout,Sliding Clutch and Shift Fork.Starting with axles built early in1991, the sliding clutch and helicalslide gear curvic teeth diameterwas increased to provide greatertooth engagements. For additionalparts and service information,refer to Eaton Bulletin 91-01.

32

Disassemble Power Divider Cover (Cont'd)

Step 6 (cont'd).To remove the "larger-diameter"sliding clutch, first remove thelockout (see pages 40-42).Then remove the sliding clutchand shift fork (with the two partsengaged). Grasp the assemblyby hand and maneuver theassembly past restrictions inthe power divider cover.

To remove the "smaller-diameter"sliding clutch, (used on earliermodel axles), the clutch can bedisengaged and removed withoutremoval of the lockout and shiftfork.

9. Axles with Lube Pump: Withdrive gear locknut previouslyremoved (step 2) and workingthrough power divider cover inputshaft bore, gently pry oil pumpdrive gear from its shaft. Seesteps 10 thru 12 for pumpdisassembly.

12. Unscrew and removemagnetic screen from powerdivider cover.

7. Remove oil seal from input 8. Remove input shaft bearingbearing cover. Remove bearing cone. Temporarily place lockoutcup from cover. sliding clutch over rear of input

shaft, teeth toward bearing cone.Place shaft in press and removebearing cone.

10. Remove oil pump cover cap 11. *NOTE: When used, removescrews and lockwashers. Remove woodruff key from gear shaft.pump cover and "O" ring. Remove pump gears from power

divider cover.

Power Divider Cover with Lube Pump

*NOTE: The drive shaft on early pump models is equipped with a woodruff key. On latepump models, the key IS eliminated The drive shaft end has two machined flats and thedrive gear mounting hole IS shaped to accommodate these flats

33

Power Divider Overhaul

Disassemble Inter-axle Differential

1. Punch mark differential casehalves for correct position duringreassembly.

2. Remove locknuts and bolts.Separate case halves and removethrust washers, side pinions, bush-ings, and spider.

NOTE: Side Pinion Bushings.Not used on tandems built afterNovember 1, 1991. Use whenoriginally equipped.

Current production Inter-AxleDifferential Assemblies are onlyserviced as a complete assembly.

"Non-Current Productionî Inter-Axle Differential

Disassemble Output Shaft

1. Mount shaft assembly in viseusing brass vise jaw protectors.Remove outer snap ring, side gearand bearing cone assembly. Ifreplacement is necessary, removeinner snap ring.

WARNING: SNAP RING ISSPRING STEEL AND MAY POPOFF, WEAR SAFETY GLASSESWHEN REMOVING

Output Shaft Assembly

.

I INOTE: Late Model Axles may be equippedwith a spring and thrust button mountedbetween the input shaft and output shaft(see page 54).

2. Remove output shaft "O" rings,If replacement is necessary,remove bushing mounted in endof output shaft, (NOTE 1)

3. Remove bearing cone from sidegear using press and split-typepuller.NOTE: For instructions coveringoutput shaft rear bearing parts,see page 26.

NOTE 1: Starting in June 1993, production axles were made withbushing less output shaft 128736. Do not attempt to install bushings in Removing Bearing Cone fromshafts with P/N's 128736 or 129194* stamped into them. Ref. bulletin Output Shaft Side Gear.AXIB-93-06 *(output shaft w/metric threads used in axles after 1-3-95)

34

Assemble Output Shaft

NOTE: Lubricate parts with gear lube durlng assembly

1. Press bearing cone on outputshaft side gear.

IMPORTANT: Provide protectionagainst possible gear teethdamage during press operation,2. Mount output shaft in vise,Lubricate and install "O" rings. Ifremoved, install bushing in end ofoutput shaft. (NOTE 1)3. If removed, install inner snapring on shaft, then install side gearand bearing cone assembly, andouter snap ring,

NOTE: Late Model Axles maybe equipped with a spring andthrust button mounted betweenthe input shaft and output shaft

WARNING: SNAP RING ISSPRING STEEL AND MAY POPOFF. WEAR SAFETY GLASSESWHEN INSTALLING.

(see page 54).

Assemble Inter-axle Differential

1. Install bushings, side pinionsand thrust washers on inter-axledifferential spider,2. Install spider assembly in onedifferential case half, align punchmarks and install other case half,Secure assembly with bolts andlocknuts, Tighten to correct torque(17-23 ft-lbs , 23-31 N.m),

NOTE: Side Pinion Bushings.Not used on tandems built afterNovember 1, 1991. Use whenoriginally equipped.

Assembling Non-Current Production Inter-Axle Differentials.

NOTE 1: Starting in June 1993, production axles were made withbushing less output shaft 128736. Do not attempt to install bushings inshafts with P/N's 128736 or 129194* stamped into them. Ref. bulletinAXIB-93-06* (output shaft w/metric threads used in axles after 1-3-95).

35

Power Divider Overhaul

Assemble Power Divider Cover

Power Divider(without Lube

Cover and Input ShaftPump)

\NOTE: Axles with Lube Pump. Assemble and install lube pump LOCKOUT FOR DESIGN VARIATIONS REFERand magnetic screen. See steps 1 to 4.

TO LOCKOUT SERVICE INSTRUCTIONS

1. *See note on exploded view.Install pump gears in power dividercover (position gear with long shaftin opening adjacent to input shaft).

2. Install "O" ring in pump cover,making sure "O" ring is seatedfirmly in cover. If removed, installdowel pins. Install pump cover onpower divider cover and securewith cap screws and lockwashers.Tighten to correct torque (85-105IN-LBS., 10-12 N.m).

Power Divider Cover with Lube Pump.

*NOTE: The drive shaft on early pump models IS equipped with a woodruff key On latepump models the key IS eliminated The drive shaft end has two machined flats and th edrive gear mounting hole IS shaped to accommodate these flats

3. Install Pump Drive Gear. Installdrive gear on pump shaft end.NOTE: Some pump drive shafts usea woodruff key. When key is used.place key in shaft slot. Position 4. Install magnetic screen in powergear on shaft engaging key. Then divider cover. Tighten to correctinstall gear with driver and hammer. torque (40-60 Ft-lbs., 54-81 N.m).

NOTE: Install and tighten drivegear nut after input shaft is assem-bled to power divider cover (seestep 10).

36

Assemble Power Divider

5. Press bearing cone on inputshaft.IMPORTANT: To prevent bearingdamage, be careful to use sleevethat only contacts the inner raceof bearing cone.

Input Bearing Cover Oil Sealand Bearing Cup Installation.

SEAL INSTALLATIONIMPORTANT: Before installingseal, refer to page 13 for serviceinformation on Seals, Yokes &Slingers.6. Press oil seal in cover using aseal driver or suitable sleeve.NOTE: CHECK CARRIER DATECODE (SEE PAGE 27, NOTEBEFORE 5). Units built beforeOctober 26, 1987 (87299), sealshould be flush with bottom ofchamfer. Units built after October26, 1987 (87299), seal should beinstalled until 3/32" deeper thanbottom of chamfer.

(ContÍd)

7. Install bronze bushings inhelical-side gear. (NOTE 1 )

NOTE 1: Helical Gears made after 1/3/95have a "step" at the end of Inner Bore.Bushings must reinstalled from the CurvicTooth side, inward towards this step. Pressflush against the shoulder of the step.

8. NOTE: Check expansion plug inpower divider cover (see photoabove) to make sure it is in placeand firmly seated. If loose, seat bytapping with a hammer. Replaceplug if necessary.Assemble lockout shift fork andsliding clutch with clutch teethfacing the helical-side gear, theninstall this assembly in powerdivider cover.NOTE: At this point in reassembly,assemble and install lockout (seepages 40-42).

Press bearing cup in inputbearing cover.

IMPORTANT: For correct cupinstallation, use appropriatesleeve. Take care to make surecup is not cocked and is firmlyseated all around.

9. Slide input shaft and bearingassembly into power divider coverfrom the front side. Engage shaftsplines in Iockout clutch.

Install bearing spacer on inputshaft (used only on D340, 380,380-P, 400-P). Temporarily installinput bearing cover assembly, capscrews and lockwashers.NOTE: Do not install any shimsunder bearing cover at this time.Correct shim pack will be deter-mined after the power divider isinstalled on differential carrier(Refer to "Adjust Input Shaft EndPlay" page 39).

IMPORTANT: For Axles withSpring and Thrust Button betweeninput shaft and output shaft: Forpreliminary adjustment of inputshaft end play, install a 0.045"(0.024 mm) shim pack underbearing cover (see ServiceBulletin Supplement, page 54).Tighten bearing cover cap screwsfinger-tight. Install input yoke, flatwasher and nut. Temporarilytighten nut snugly.

10. lMPORTANT Ñ Axles withLube Pump: Install and tightenlube pump drive gear locknut,holding input shaft to secure gear.Torque nut to 35-45 ft-lbs.(47-61 N.m).11. Slide "D" washer over inputshaft up to base of sliding clutchsplines.NOTE: Make sure flat part ofwasher inside diameter engagesshaft properly.

Install bronze washer. Installhelical gear. Secure with snap ring.

WARNING: SNAP RING IS SPRING STEEL AND MAY POP OFF. WEAR SAFETY GLASSES WHEN INSTALLING.

12. Install power divider coverassembly on differential carrier(see page 38).

37

Power Divider Overhaul

Install Power Divider on Differential Carrier(with carrier removed from axle housing)

NOTE: The following instructions pertain to installation of power divideron differential carrier with carrier removed from axle housing.

NOTE: Before installing power divider, install related parts as follows

1. Output Shaft Side Gear BearingCup. If removed, press bearing cupin carrier. Use a press and appro-priate sleeve or use a brass driftand a mallet. Tap bearing cup intoits' bore making certain cup isevenly and firmly seated.

NOTE: Late Model Axles maybe equipped with a spring andthrust button mounted betweenthe input shaft and output shaft(see page 54).

Silicone Gasket Compound

4. Apply silicone gasket com-pound on carrier mating surface(see illustration).

2. Output Shaft. Lubricate "O"rings, then install output shaftassembly in carrier.

5. Install Power Divider. Attachchain hoist to input yoke andinstall power divider assemblyDuring installation, rotate inputshaft to engage input shaft splineswith inter-axle differential. Afterinstallation, again rotate inputshaft. Output shaft should turnwhen input shaft is rotated ifassembly is correct.

NOTE: Lifting mechanism maycreate nicks and burrs on inputyoke. Remove if present.

3. Inter-axle Differential. Installdifferential assembly on outputshaft side gear (with nuts facingaway from output shaft side gear).

Power Divider CoverDowel Pin Location.

Pump model Illustrated

6. If removed, install dowel pinsin carrier. Install power dividercover cap screws and lock-washers. (On pump models only,place socket-head cap screw atlocation shown on drawing. Torquecap screws to 110-125 ft-lbs.(149-170 N.m).

7. Adjust Input Shaft End Play.Adjust end play with the powerdivider assembled to the differen-tial carrier. (See page 39.)

38

Adjust Input Shaft End PlayNOTE: After power divider overhaul and installation in power divider,check and adjust input shaft end play,

Correct end play when new parts are used in overhaul is 0.003" to0.007", with reused parts 0.013" to 0.017". Refer to page 15 for othervariations,

Measure and Adjust End PlayIMPORTANT: In September 1988, Eaton added a Spring and a ThrustButton between the input and output shafts. End play tolerances are thesame for axles with or without this Spring and Button. However, end playmeasurement procedure is different than described below. Refer to ServiceBulletin Supplement at back of this manual for procedure variances.

1. Remove input shaft nut, flat washer and yoke. Remove input bearingcover cap screws and lockwashers. Remove bearing cover (and shimpack if installed).

2. Reinstall bearing cover without shims. Hold in position with handpressure and measure clearance between power divider cover andbearing cover, using a feeler gauge.

3. The bearing cover clearance measured in Step 2 plus 0.005" willequal shim pack thickness required for desired end play (rebuild withnew parts). Add 0.015" to shim pack for rebuild with used parts.4. Install shim pack and bearing cover. Install cap screws and lock-washers, Torque screws to 75-85 ft-lbs. (101-115 N.m).

5. Install yoke, flat washer and nut. Tighten nut snugly. Tap end ofinput shaft lightly to seat bearings.

6. Check input shaft end play with dial indicator positioned at yokeend of input shaft. Move input shaft axially and measure end play. Ifend play is correct, seal shim pack to prevent lube leakage then torqueinput shaft nut and cover cap screws (see chart).

7. If end play is incorrect, change shim pack size, as follows:

Add shims to increase end play.Example: Desired end play (New Parts) . . . . . . . . . . . . . . 0.003" to 0.007"

Measured end play (Step 6) . . . . . . . . . . . . . . . 0.001" - 0.001"

Add shims to provide desired end play . . . . . 0.002" to 0.006"

Remove shims to decrease end play.Example: Measured end play (Step 6) . . . . . . . . . . . . . . . 0.015" - 0.015"

Desired end play (New Parts) . . . . . . . . . . . . . . 0.003" to 0.007"

Remove shims to provide desired end play . . 0.012" to 0.008"8. To add or remove shims, remove input shaft nut, flat washer and yoke.Remove cap screws, lockwashers and bearing cover. Add or removeshims as required.

9. Install bearing cover, cap screws and lockwashers. Install yoke, flatwasher and nut. Seal shim pack to prevent lube leakage then torqueinput shaft nut and cover cap screws (see chart).

Tightening Yoke Nut.

Torque Chart

Input Shaft Nut

Size Ft-lbs. N. m

1-5/8-18 780-960 1057-1301*M42 X 1.5 840-1020 1140-1383

Bearing Cover Cap Screw

1/2-13 75-85 101-115(Grade 5)

Measuring Bearing CoverClearance.

Installing Bearing Cover andShim Pack.

Measuring End Play with DialIndicator.

NOTE: If difin achieving

ficulty is experiencedcorrect torque on the

input yoke nut, torque the nut withtruck on the ground and axle shaftsinstalled.

*Metric Nut used in Production Axles after 1-3-95

33

Inter-Axle Differential Lockout Overhaul.Three differential model lockouts are used on Eaton Tandem Axles. Toidentify the lockout used on your axle, refer to the illustrations andrelated service instructions below.

“Reverse-Air” Lockout. The“Standard” Lockouts (Current and Non-Current Models). The “current” “Reverse-Air” lockout is spring-model is an improved version of and replaces the “non-current” lockout.Both are air-operated to engage the lockout and spring-released to

operated to engage the lockout and

disengage the lockout.air-operated to disengage thelockout. This model is similar to

Eaton Axles may be equipped with either of these lockouts. The the “non-current” “standard”“current” model is interchangeable with the “non-current” model as an lockout. It is not available in the newassembly. For service information, refer to the following page. “current” lockout.

“Standard” “Current” Model Lockout Overhaul

Disassemble and Remove Lockout.NOTE: With axle installed invehicle, place differential lockselector valve in the disengaged(or unlocked) position. Disconnectthe air line at the lockout pistonhousing.

“Standard” “Current” Model Lockout

1. Remove cap screws andlockwashers fastening mountingbracket to power divider cover.Remove bracket and pistonhousing.

2. Remove locknut, piston with NOTE: The shift fork and push rod“O” ring, compression spring and cannot be removed with powershoulder washer from push rod. divider cover installed (see Power

Divider instructions).

Assemble and Install Lockout1. With shift fork and sliding clutchinstalled, place the shoulderwasher (white plastic) over pushrod. The large diameter side of thewasher must face the powerdivider cover.

2. Install compression spring onpush rod.

3. Lubricate “O” ring with silicone-based lubricant and install “O” ringon piston.

4. Place piston assembly on pushrod. The large diameter end ofpiston must face power dividercover.

5. Install locknut on push rod andtighten to 13-17 lbs. -ft. (l8-23 N.m).

6. Install piston housing, makingsure the housing is correctly seatedand piloted in the shoulder washer.

7. Place mounting bracket overhousing and position on powerdivider cover. Install cap screwsand lockwashers and tighten to48-56 Ibs.-ft. (65-76 N.m).

NOTE: If axle is installed in vehicle,apply sealant to air line fitting andconnect air line. When tighteningair line, hold piston housing inmounting position using a wrenchapplied to the hexagon configura-tion at outer end of housing.

NOTE: A new style “Inter-Axle Differential Lockout” was beingreleased as this publication was being printed. If theInter-Axle Differential Lockout Assembly on your axle is notshown in this publication, call your local Eaton representative.

40

Retrofit “Non-Current” to “Current” Model Lockout

The “current” model (only as anassembly) is interchangeable withthe “non-current” lockout. Theoriginal shift fork and push rod canbe used for either model lockoutand need not be replaced.Retrofit Kits are available to convertthe “non-current” model to the“current” lockout. Parts (except the

shift fork), included in these kits are 2. Assemble and install “current”shown in the illustration on the lockout following instructions onpreceding page. For additional preceding page.information, refer to Eaton Parts NOTE: Do not use mounting screwsBooks (see back cover). from “non-current” model. TheyRetrofit as follows: are too long to use with the new

1. Disassemble and remove “current” model.

“non-current” lockout. Refer toinstructions below.

“Standard" “Non-Current” Model Lockout Overhaul

Service Parts Availability. The“non-current” lockout assembly,body, piston and body cover areno longer available. If any of theseitems are not serviceable, replacelockout with the new “current”model per instructions above. Forother parts, a Service Parts Kit(see illustration) is available toservice the “non-current” lockout.

“Standard” “Non-Current” Model Lockout

Disassemble and Remove Lockout1. Remove cap screws andlockwashers fastening cover to thebody. Remove cover and “O’’ ring.2. Remove nut, flat washer and“O’’ ring from push rod.

*Asterisk Identifies parts included in Service Kit 211201

NOTE: Axles with Lube Pumps: These axle models are equipped with apiston stop located at base of piston. It is important that this stop bereinstalled in reassembly.

3. Remove body cap screws and NOTE: The shift fork and push rodlockwashers, then remove body cannot be removed with powerand piston as an assembly. Remove divider cover installed (see Power“O’’ ring and felt oilers from the Divider instructions).piston.

Assemble and Install LockoutWith shift fork and sliding clutchinstalled in power divider cover,assemble and install lockout asfollows.

1. Apply silicone gasket compoundto mounting surface on powerdivider cover. See illustration.

2. Install lockout body. Secure withcap screws and lockwashers.Torque cap screws to 48-56 Ibs.-ft.(65-76 N.m).NOTE: Before installation, soakpiston felt oilers in SAE 30 engineoil and lubricate “O’’ rings with ahigh-viscosity silicone oil or bariumgrease “O’’ ring lubricant.

3. Install felt oilers and large“O” ring on piston.

Axles with Lube Pump. Beforeinstalling piston, place piston stopat base of lockout body.4. Install compression spring overshift fork push rod. Install piston inbody and secure with “O” ring, flatwasher and nut. Torque nut to20-26 Ibs.-ft. (27-35 N.m).

5. Install “O’’ ring in lockout bodycover. Install cover and secure withcap screws and lockwashers.Torque cap screws to 96-108LBS.-IN (10-12 N.m).

4 1

Infer-Axle Differential Lockout Overhaul.

"Reverse-Air" Lockout Overhaul

The "reverse-air" lockout unit is spring-operated to engage lockout andair-operated to disengage lockout. A clutch engages or disengages thehelical-side gear to lock or unlock the inter-axle differential.

Service Parts AvailabilityA new design of the original"Reverse-Air" Lockout has n o tbeen released at this writing.The piston, body and cover of theoriginal lockout are no longeravailable as individual parts. Ifthese parts are not serviceable,replace the complete unit. Forother parts, use a Service Parts Kit(see illustration for contents).

For additional information, refer toEaton Parts Books (see backcover).

Disassemble Lockout.1. Remove cap screws andlock washers fastening cover tobody. Remove cover, "O" ring andcompression spring.

I

I *Asterisk Identifies parts included in Service Kit 271202

2. Remove push rod nut and flat body "O" ring, and piston as anwasher. assembly. Remove seal ring from3. Remove body cap screws and threaded end of push rod.lockwashers. Then remove body,

Assemble and Install Lockout

With shift fork and sliding clutchinstalled in power divider cover,assemble and install lockout asfollows:

1. Install seal ring on shift forkpush rod (threaded end). Install"O" ring in body.

2. Apply silicone gasket compoundto lockout mounting surface (seeillustration).3. Install lockout body, cap screwsand lockwashers. Torque capscrews to 48-56 ft.-lbs. (65-76 N.m).NOTE: Before installation, soakpiston felt oilers in SAE 30 engineoil and lubricate "O" rings with ahigh-viscosity silicone oil or bariumgrease "O" ring lubricant.

4. Install felt oilers and "O" ring on 5. Place "O" ring on body cover.piston. Install piston assembly in Install compression spring, cover,body and secure to push rod with cap screws and lockwashers.flat washer and nut. Torque nut to Torque cap screws to 96-10820-26 ft.-lbs. (27-35 N.m). IN.-LBS. (10-12 N.m).

42

Differential Carrier Overhaul (Forward and Rear Axle)

Disassemble Dif ferent ial Carr ier (with power divider removed)

NOTE: If gear set IS to be reused, check tooth contact pattern and ringgear backlash before disassembling differential carrier Best results areobtained when established wear patterns are maintained in usinggearing Omit this step if the gear set is to be replaced.

1. Mount differential carrier inrepair stand.

NOTE: For easier disassembly.loosen but do not remove pinionself-locking nut. When forwardaxle pinion is equipped withslotted nut, remove roll pin with apin punch then loosen nut.

2. Punch mark differential bearingcaps. If reusing gear set, alsopunch mark bearing adjusters forreference during assembly.

4. Using a chain hoist, lift ringgear and differential assembly outof carrier.

5. Forward Axle: Remove pinionnut (see NOTE under Step 1).Remove helical drive gear, usingpuller if necessary.

NOTE: Remove outer pinionbearing cone if Òslip-fitÓ.

7. Rear Axle: Remove pinion bear-ing cage cap screws, then drivepinion, cage and yoke assemblyout of carrier.

IMPORTANT: Do not allow pinionto drop on hard surface. Removeshim pack.

3. Cut lockwire. Remove capscrews, flat washers and bearingcaps.

6. Forward Axle: Remove pinionbearing cage cap screws. Removedrive pinion and cage assemblyfrom carrier. Remove shim pack.

IMPORTANT: Forward and RearAxle: If gear set is to be reused,keep pinion bearing cage shimpack intact for use in reassembly.If the original shims cannot bereused, record the number andsize of shims in the pack.

43

Differential Carrier Overhaul (Forward and Rear Axles)

Dissassembly Drive Pinion

Rear Axle Pinion Illustrated.

NOTE: Eaton drive axles may be equipped with either ñslip-fitî or ñpress-fitî outer pinion bearings.Procedures are contained in-this section for disassembly of both types.

IMPORTANT: During the followingyoke removal procedure, the drivepinion may fall out of bearings andcage. Do not allow pinion to dropon hard surface.

1. Rear Axle Pinion Yoke:Remove yoke. If pinion nut wasnot loosened during earlier disas-sembly, clamp assembly in visejaws, use brass pads to preventdamage.

Loosen and remove pinion nutand flat washer.

Removing ñSlip-Fitî Outer BearingCone (Rear Axle illustrated).

2. Forward and Rear Axle PinionBearing Cage: For pinion withñpress-fitî bearing cone, supportcage and press pinion out of bear-ing cage and bearing cone.

For pinion with ñslip-fitî bearingcone, the cage, outer bearing andpinion can usually be disassem-bled easily without a press. Ifdifficulty is experienced, usea press.

3. Rear Axle Pinion Oil Seal andOuter Bearing Cone: Remove oilseal and bearing cone from cage.Discard oil seal. Remove bearingcups with suitable puller.

Removing Bearing Cage (RearAxle illustrated).

44

Disassemble Drive Pinion (Cont'd)

Forward Axle Pinion Illustrated.

ïD341, 381(P), 401-P, 402(P), 403(P), 451-P use self-locking or slotted nut and roll pm.Metric self-locking nuts used as of 1-3-95.

D340, 380(P), 400-P use self-locking nut only.

5. Remove pilot bearing and inner bearing cone from pinion, using asplit-type puller. Use two procedure steps to remove each bearing (seephotos above).

First, mount puller vertically to Second, mount puller horizontally4. Remove and retain split the bearing. to press pinion out of bearing.bearing spacer from pinion.

This action will force puller halves under bearing and start movingbearing off pinion.

The same procedure can be used to remove pilot bearing and pinioninner bearing cone.

45

Differential Carrier Overhaul (Forward and Rear Axles)

Disassemble Wheel Differential

Rear Axle Differential Illustrated.

DIFF BEARING THRUST SIDE SPIDER THRUST RINGBEARING CONE W A S H E R P I N I O N W A S H E R G E A RADJUSTER

I I I I I

I CASE PLAINBEARING CAP CASECUP SCREW HALF

3. Lift out side gear and thrustwasher.

6. Remove bearing cones fromcase halves using suitable puller(see photos).

7. Remove bearing cone fromplain case half in two steps: First,mount puller vertically to splitbearing (see photo). This actionwill start moving bearing off case.Second, mount puller vertically toremove cone.

8. Remove bearing cone fromflanged case half using suitablepuller.

v RINGSIDE GEARGEAR BOLT

1. Remove nuts and bolts fasten-ing ring gear to differential cases,allowing gear to fall free. If geardoes not fall, tap outer diameterwith soft mallet to loosen.

2. Punch mark differential casesfor correct location during assem-bly. Remove cap screws and lift offplain differential case half.

4. Lift out spider, side pinions andthrust washers.

F L A N G E D B E A R I N G D I F FCASE CONE BEARINGHALF I ADJUSTER

RING BEARINGGEARNUT

5. Remove side gear and thrustwasher.

Puller Mounted Verticallyto Split Bearing.

Removing Bearing Conefrom Flanged Case Half.

46

Assemble Wheel Differential

NOTE: Lubricate differential parts with gear lube during reassembly

1. Press bearing cones on differ-ential case halves (see photos).

IMPORTANT: To prevent bearingdamage, use suitable sleeve thatonly contacts the inner race of thecone.

Press Bearing Cone on FlangedDifferential Case.

Press Bearing Cone on PlainDifferential/ Case.

2. Place thrust washer and sidegear in flanged differential case.

3. Assemble side pinion and thrustwashers on spider. Place thisassembly in flanged differentialcase. Rotate gears and check forproper mesh.

4. Place side gear and thrustwasher on side pinions.

5. Align punch marks and installplain case half. Install cap screwsand tighten to correct torque.Check differential for free rotationby turning side gear hub. Differen-tial may require up to 50 ft-lbs.(68 N.m) torque to rotate.

6. Install ring gear. Secure withbolts and nuts. Torque nuts to 180-220 ft-lbs. (244-298 N.m).

47

Differential Carrier Overhaul (Forward and Rear Axles)

Assemble Drive Pinion (“Press-fit” outer pinion bearing)

Forward Axle Pinion Illustrated.

*D341, 381(P), 401-P, 402(P), 451-P use self-locklng or slotted nut and roll pinD340, 380(P), 400-P use self-locklng nut only

Rear Axle Pinion Illustrated.

.

1

NOTE: Eaton driveaxles may be equippedwith either “slip-fit” or‘(press-fit” outer pinionbearings. Proceduresare contained in thissection for assemblyof both types.NOTE: Lubricate partswith gear lube duringreassembly.

1. Using appropriate sleeve, pressbearing cups in cage (see adjacentdrawings).

NOTE: On rear axles, do not installoil seal in cage until bearingpreload is correctly adjusted.

IMPORTANT: After bearing cupsare installed, preselect pinionbearing spacer using the “trialbuild-up” procedure described inthe Adjustments Section of thismanual.

Rear Axle Pinion.Forward Axle Pinion.Press Bearing Cupsin Caqe.

Press Bearin Cage.

ing Cups

,

"A" — Cups must be firmly seated in cage.Check with feeler gauge (0.001")after installation

"A" Cups must abe firmly seated in cage.Check with feeler gauge (0.001")after installation.

NOTE: Install cups one at a time. NOTE: Install cups one at a time.

48

Assemble Drive Pinion ("Press-fit" outer pinion bearing) (Cont'd)

2. Press pilot bearing on pinion.IMPORTANT: To prevent bearingdamage, use suitable sleeve thatonly contacts inner bearing race.

5. Install preselected bearingspacer on pinion.

Rear Axle Pinion.Press Oil Sealin Cage(with pinion

installed

8. Rear Axle Only. With pinioninstalled and bearing preload ad-justment complete, Install oil sealwith a press, **

3. Stake pilot bearing using stakingtool, This is essential to retain thebearing.

NOTE: During pinion bearing i n -stallation, locate each part in sameposition that was used in "TrialBuild-up" Preload Test.

6. Install bearing cage on drivepinion,

9. Rear Axle Only. Prior to installa-tion of yoke, lubricate oil seal andmake sure yoke is clean and dry.Install yoke, flat washer* and nut.Torque nut to proper specification.(see page 24)

4. Press inner bearing cone onpinion.

IMPORTANT: To prevent bearingdamage, use suitable sleeve thatonly contacts inner race of bearingcone.

7. Press outer bearing cone onpinion.

IMPORTANT: To prevent bearingdamage, use suitable sleeve thatonly contacts inner race of bearingcone.

IMPORTANT: At this stage ofassembly, "final-check" pinion bear-ing preload. See Adjustment Sec-tion of this manual.

NOTE: After tightening pinionnut, recheck pinion bearing rollingtorque. See Adjustment Section for"Press-fit" outer pinion bearing.

10. Forward Axle Pinion HelicalGear and Nut: These parts areinstalled during pinion installation(see page 53).

** IMPORTANT: Refer to page 13 for service information on Seals, Yokes & Slingers.

* Nuts used on production axles after 1/3/95 are metric and do not use flat washer.49

Differential Carrier Overhaul (Forward and Rear Axles)

Assemble Drive Pinion ("Slip-fit" outer pinion bearing)

Forward Axle Pinion.Press Bearing Cupsin Cage.

I PRESS

1 Rear Axle Pinion.Press Bearing Cupsin Cage.

I PRESS

I I"A" - Caps must be firmly seated in cage

Check with feeler gauge (0.001")after installation.

NOTE: Install cups one at a time.

- Cups must be firmly seated in cageCheck with feeler gauge (1.0001")after installation

NOTE: Install cups one at a time.

1. Using appropriate sleeve, pressbearing cups in cage.

3. Stake pilot bearing using stakingtool and press. This is essential toretain the bearing.

6. Install bearing cage on drivepinion.

4. Press inner bearing cone onpinion.

lMPORTANT: To prevent bearingdamage, use suitable sleeve thatonly contacts inner race of bearingcone.

7. Install pinion outer bearing cone.NOTE: At this stage in assembly,check pinion bearing preload de-scribed in Adjustment Section ofthis manual for "slip-fit" outer pinionbearing. Rear Axle: Do not installoil seal until adjustment incomplete.

2. Press pilot bearing in pinion.

IMPORTANT: To prevent bearingdamage, use suitable sleeve thatonly contacts inner bearing race.

5. Install bearing spacer on pinion.NOTE: When new gear set or pinionbearings are used, select nominalsize spacer (see chart page 20). Iforiginal parts are used, use spacerremoved during disassembly.

8. Rear Axle Oil Seal and Yoke:Installation of these parts is thesame for "slip-fit" and "press-fit" bearings. See page 49 (step 8 and9) for instructions.

NOTE: For "slip-fit" bearings, pinionmay be temporarily removed tosimplify seal installation.9. Forward Axle Helical Gear andNut: See page 53 for instructions.

50

Assemble Differential Carrier

1. Forward Axle: Place shim packon carrier, making sure holes areproperly aligned.

Rear Axle: Place shim pack oncarrier making sure lube hole isclear (see photo above).NOTE: If gear set is to be reused,install same quantity and size ofshims removed during disassem-bly. When installing a new gearset, use nominal shim pack indi-cated below.

I Nominal Shim Pack II in. mm I

Forward axle . . . ..0.024 0.609Rear axle. . . . ...0.023 0.584

2. Forward Axle Drive Pinion:Install drive pinion assembly.Install bearing cage cap screwsand lockwashers. Torque capscrews to 155-175 ft-lbs.(210-237 N.m).

NOTE: Use a dummy yoke (ifavailable) in place of helical gear.This will result in easier disassem-bly and reassembly during carrieradjustments. (See page 52).

Install pinion nut and tighten tocorrect torque (see chart page 53)

NOTE: When slotted nut is used,do not install roll pin until carrieradjustments are completed.

Rear Axle Drive Pinion: Installpinion assembly. Install bearingcage cap screws and lockwashers.Torque cap screws to 110-125ft-lbs. (149170 N.m).

NOTE: Lubricate bearingsduring the following assemblyprocedures.

BEARINGCAPPEDESTAL

3. Place ring gear and differentialassembly in carrier. During installa-tion, tilt carrier to allow differentialcase pilot to mesh properly withedge of bearing cap pedestal (seephoto above).

Install bearing cups at both sidesof differential case.

4. Install bearing adjusters andcaps.

51

Differential Carrier Overhaul (Forward and Rear Axles)

Assemble Differential

5. Install and tighten bearing cap

Carrier (Cont'd)

screws finger tight. If this is difficult,use hand wrench. The assembly is now read-y for-adjustment of differ-ential bearing preload, ring gear backlash and gear tooth contact.6. At the teeth-side of ring gear, position bearing adjuster until its firstthread is visible.7. At the back-face side of ring gear, tighten adjuster until there is nobacklash.8. At the teeth-side of ring gear, tighten adjuster until it contacts thebearing cup. Continue tightening adjuster two or three notches. Thiswill preload bearings and provide backlash.9. Check Ring Gear Backlash. Measure backlash with a dial indicator.Specifications are listed below. Refer to page 21 for detailed instruc-tions on adjusting backlash.

Ring Gear Backlash SpecificationsUSED GEARING - Reset to backlash recorded before disassembly.NEW GEARING - Backlash should be between 0.006" and 0.016".

10. Check Ring Gear Tooth Contact. Paint ring gear teeth and checktooth contact pattern. Correct tooth patterns are illustrated below. Forchecking and adjusting procedures, see page 22.

CORRECT PATTERN (USED GEARING)

● Pocket may beextended.

● Pattern along the face widthcould be longer.

CORRECT PATTERN (NEW GEARING)

● Could vary in length.Pattern should cover1/2 tooth or more(face width).

● Pattern shouldbe evenly centeredbetween tooth top land androot. .

. Pattern should be clear of tooth toe.

11. With ring gear and pinion adjusted cor-rectly, align adjusters and locks, then tightendifferential bearing cap screws to correct torque(360-440 ft-lbs., 488-596 N.m). Install adjusterlocks and cotter pins. Lockwire differentialbearing cap screws.

Tightening Bearing Cap Screws.

Adjusting Bearing Adjuster.

Checking Ring Gear Backlash.

52

Assemble Differential Carrier (Cont'd)

12. Forward Axle Helical Gear.If dummy yoke was used, removenut and yoke. Install helical gearon pinion, positioned as shown inthe illustration. Install nut andtighten to correct torque (see chart)

Torque Chart

Forward Axle Pinion NutSelf-Locking Nut

Size Ft-lbs. N.m

(D340, 380(P), 400-P)1-1/2-18 560-700 759-949

(D341, 381(P), 401-P, 402(P), 451-P)1 -5/8-18 780-960 1057-1301

(D341 , 402(P), 403(P), 451(P)produced after 1/3/95M42 X 1.5 840-1020 1140-1383

Slotted Nut and Roll Pin

(D \341, 381 (P), 401-P, 402(P), 451-P only)1 -5/8-18 840Í 1139*

*IMPORTANT: Torque to 840 ft-lbs.(1139 N.m), then continue tighten-ing nut to align slot with the nearesthole in pinion shank. Install roll pin.

Pinion Helical GearMounting Position

NOTE: See Torque Chart forPinion Nut Variations

Installing Pinion Helical Gear.

53

Service Bulletin Supplement.

Input Shaft End Play for Axle Models equipped with an Input Shaft Axial Springand Thrust Button.

In September 1988, Eaton added an AxialSpring and Thrust Button between the inputand output shafts. The addition of these partsreduces shaft end play movement by loadingthe shafts axially in the direction of the yoke.

End play tolerances are the same for axleswith or without the new Spring and ThrustButton. However, end play measurementprocedure is different as described below.

Measure and Adjust Input Shaft EndPlayNOTE: The addition of the Spring andThrust Button between the input and outputshafts necessitates the fabrication of a “U”bracket to assist in measuring the shaft endplay. Proceed as follows:

1. Fabricate a “U” bracket from 1“ flat stock(minimum thickness 0.125”) as specified inthe illustration.

2. If axle is disassembled, build up a 0.045”(0.024 mm) thick shim pack and place shimpack and bearing cover on power dividercover. Then proceed with Step 3.

If axle is assembled, remove input shaft nut,flat washer and yoke. (NOTE: Axles built withmetric threaded nuts do NOT use flat washers)Then proceed with Step 3.

Location of Axial Spring and Thrust Button.

Input Shaft End Play Chart

New or Rebuild with new NOTE: Because of manufac-parts 0.003” to 0.007” turlng variations in individual

parts, correctly adjusted endRebuild with reused parts play could vary 0.010,” after0.013” to 0.017” the unit IS rotated

Acceptable End Play Tolerances when measuring as aregular maintenance procedure with axle in truck.

Up to 0.060” with over NOTE: If end play exceeds100,000 miles or 1 year limits, disassemble powerservice off-road divider and replace worn

parts.Up to 0.040” with less than100,000 miles or 1 yearservice on-road

“U” Bracket Specifications.

NOTE 1: Bushing removed from current production output shafts,See notes on page 35.

54

Measure and Adjust Input Shaft EndPlay Cont’d.

3. Install the “U” bracket on bearing cover,using two bearing cover cap screws (seeillustration). Install all other cover cap screwsand torque to 75-85 Ibs.-ft. (101-115 N.m).

4. Position a dial indicator on the end of theinput shaft (see illustration).

5. Insert a pry bar through the “U” bracketwith the end of the bar resting on the end ofthe input shaft. (see illustration).

6. Zero the dial indicator and lift up on thepry bar to move the input shaft axially until itbottoms out within the bearing cover.Measure the end play.

7. If end play is acceptable (see chart), remove“U” bracket and bearing cover. Seal shim packto prevent lube leakage. Reinstall bearingcover and cap screws. Torque cap screws to75-85 Ibs.-ft. (101-115 N.m). Continue axleassembly as necessary.

8. If end play is incorrect, change shim packsize as follows:

Add shims to increase end play.Desired end play 0.003” to 0.007”Measured end play (Step 6) 0.001 “ — 0.001“

Add shims to provide desired end play 0.002” to 0.006”

Remove shims to decrease end play.Measured end play (Step 6) 0.015” — 0.015”Desired end play 0.003” to 0.007”

Remove shims to provide desired end play 0.01 2“ to 0.008”

9. Recheck end play and adjust as necessaryuntil end play is within acceptable tolerance.

10. When end play is correct, remove “U”bracket and bearing cover. Seal shim pack toprevent lube leakage. Reinstall bearing coverand cap screws. Torque cap screws to 75-85Ibs.-ft. (101-115 N.m). Continue axle assemblyas necessary.

Note: Air lockout unit not shown.

“U” Bracket Installation

Dial indicator Mounting Position and CheckingInput Shaft End Play. -

55

Gear Pinion Nut Fastening Chart:

Style Models Size Ft-lbs. N.m

Self-Locking Pinion Nut D340 1-1/2-18 560-700 759-949380(P)400-P

D341,381 (P), 1 -5/8-18 780-960 1057-1301401-P, 402(P),403(P), 451-P

R-All Models 1-1/2-18 560-700 759-949

Slotted Nut & Roll Pin D341 , 381 (P) 1 -5/8-18 840’ 1139*401-P, 402(P),403-(P), 451 -P *IMPORTANT: Torque to 840 ft-lbs. (1139 N.m)

then continue tightening nut to align slot with thenearest hole in pinion shank.

Metric Self-Locking D341 , M42 X 1.5 840-1020 1140-1383Pinion Nut 402(P)

*used in production starting 403(P) **Metric nuts produced after 4/95 incorporate a1-3-95 451 -P pre-applied thread locking compound.

R-All Models M36 X 1.5 575-703 780-953

Nut Part No. Threads Nut Size Socket Size Location

95206 English 1-1/2-18 2.25” R-Pinion

118806 English 1 -5/8-18 2.50” D-Pinion

127589 Metric M36 X 1.5 55mm R-Pinion

126182 Metric M42 X 1.5 65mm D-Pinion

NOTE: Reference Bulletin AXIB-9409 and AXIB-9503 for more information.

CAUTION: Metric nuts have an integral flange washer built into them. Do not use separate washer in conjunction withthese nuts.

English (Inch) Style Nut Metric Style Nut

56

Parts BooksSingle Reduction Tandem Drive Axles■ 34,000 — 45,000 lbs. (340, 380, 400, 341, 381, 401, 402, 403, 451) . . . . . .AXIP-0089■ 34,000 — 45,000 lbs. (344, 404, 454) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXIP-0200■ 34,000 — 52,000 lbs. (With Controlled Traction Differentials) . . . . . . . . . . . .AXIP-0084Dual Range, Planetary Double Reduction Tandem Drive Axles■ 34,000 — 45,000 lbs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXIP-0087Single Reduction, Dual Range, Planetary Double Reduction (Tandem DriveAxles)■ 46,000 — 65,000 lbs. (Axle Series 461,521,581, 601, 651, 652) . . . . . . . .AXIP-0085

(Diff. Lock Models 461,521, 581) . . . . . . . . . . . . . . AXIP-0085AEaton® Axle Brakes■ All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. BRIP-0065Eaton® Steer Axles All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AXIP-0074

Service ManualsSingle Reduction Tandem Drive Axles■ 34,000 - - 45,000 lbs. (Axle Series 340 — 402, 451) . . . . . . . . . . . . . . . . . AXSM-0041■ 34,000 — 45,000 lbs. (Axle Series 344, 404, 454) . . . . . . . . . . . . . . . . . . .AXSM-0046■ 44,000 — 58,000 lbs. (Axle Series 440, 460 — 651) . . . . . . . . . . . . . . . . . AXSM-0042Dual Range and Planetary Double Reduction Tandem Drive Axles■ 34,000 — 45,000 lbs. (Axles Series 340 — 402, 451) . . . . . . . . . . . . . . .. AXSM-0045■ 44,000 — 65,000 lbs. (Axle Series 440, 460 — 651) . . . . . . . . . . . . . . . .. AXSM-0044Eaton® Axle Brakes■ EB& ES Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. AXSM-0033Eaton® Steer Axles■ E-1000I, E-1200I, E-1320I, E-1460I . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. AXSM-0038■ EFA12F3, 12F4, 13F3, 13F5, 20F4, 22 T2/T5, 24T2/T5 . . . . . . . . . . . . . . .AXSM-0037

These publications may all be ordered through the Eaton publications order system. An orderform may be obtained by calling Eaton(3 Roadranger@ Service Support. Phone numbers arelisted below.

Unique Eaton® Roadranger® Service Support.

Call: 1-800-TCM-HELP (U. S. A.)1-800-567-2145 (Canada)

57

Copyright Dana Corporation, 2001. DANA CORPORATION hereby grants its customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. THIS INFORMATION IS NOT INTENDED FOR SALE OR RE-SALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.

AXSM-004107/95 PODPrinted in U.S.A.

National Institute for

The Roadranger® System is an unbeatable combination of the best products from Eaton and Dana, partnering to provide you the most advanced, most trouble-free drivetrain in the industry. And it's backed by the Roadrangers -- the most experienced, most expert, most accessible drivetrain consultants in the business.

For spec'ing or service assistance,call 1-800-826-HELP (4357), 24 hours a day, 7 days a week, (Mexico: 8-332-1515) for more time on the road. Or visit our web site at http://roadranger.com.