Differential Case and Ring Gear

Differential Case and Ring Gear










Dana Model S110 Conventional Wheel Differential Assembly, Disassembled View










Dana Model S130 Conventional Wheel Differential Assembly, Disassembled View










Disassembly

All axles

1. Using the Transmission Holding Fixture, mount the carrier housing.





2. NOTICE: If reusing the differential ring gear and pinion, measure and record the backlash before disassembly. Assembling the differential ring gear and pinion to the recorded backlash will match the established wear patterns. Hand-rolled patterns will cover less area than the established patterns.

Using the Dial Indicator Gauge with Holding Fixture, measure and record the differential ring gear and pinion backlash.

- Check the backlash in 4 equally spaced positions around the differential ring gear.

- The tooth contact pattern can move only by adjusting backlash. The tooth contact pattern can move only in the direction of heel-to-toe and toe-to-heel. Depth of the tooth contact pattern is not adjustable. Contact Spicer Service at 1-800-826-4357 for assistance if unable to establish an acceptable tooth contact pattern within the limits of backlash.





3. Remove the bolt and the rear anti-lock brake sensor.





4. Remove the 2 adjusting ring cotter pins.





5. Loosen, but do not remove, the 6 bearing cap bolts.





6. Relieve the bearing preload.
- Loosen each differential bearing adjusting ring.





7. Remove the 6 differential bearing cap bolts, 2 bearing caps and 2 adjusting rings.





8. Carefully lift the differential subassembly out of the carrier.

9. Inspect the differential side bearing surfaces and differential side bearing cups for pitting, wear or overheating. Install new components as necessary.





10. Using the Bearing Puller, Front Wheel Hub Remover/Installer and Step Plate, remove the differential side bearings if worn or damaged.





11. Remove and discard the 12 ring gear bolts.





12. Place the differential assembly in a suitable press supported on the ring gear.

13. NOTICE: The differential case will fall after separation. Support the case so it will not result in damage to the component or equipment.

NOTE: It should not require more than 3 tons of press load to separate the ring gear from the differential case.

NOTE: It may be necessary to press in more than one position to free the ring gear from the case.

The press arbor will push on the differential ring gear bolt to separate the ring gear half of the differential from the cross shaft half of the assembly.





14. NOTE: Discard the anti-lock speed sensor ring if separating it from the ring gear side case half.

If necessary, remove the anti-lock speed sensor ring.





15. NOTICE: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum-based cleaning solvents.

NOTE: Use soft, clean, lintless towels to dry the components.

NOTE: After drying, lightly coat the parts with rust inhibitor or clean lubricant to prevent damage from corrosion. Wrap all parts that are going to be in storage for a prolonged period in wax paper.

NOTE: For Truetrac(R) differentials, submerge the entire differential assembly in a suitable solvent to wash away contaminants from within the housing.

Clean and dry the components.

16. The Truetrac(R) differential assembly is non-repairable. Discard the entire assembly if it is worn or damaged.





S110 axles

17. With a conventional differential, lift out the side gear.





18. Remove the differential pinion cross shaft lockpin.





19. NOTICE: Discard all gears in sets if one or more sustains wear or damage or damage to components may occur.

Remove the pinion cross shaft.





20. Remove the 2 pinion gears and pinion thrust washers.

21. Remove the inner side gear and thrust washer.





S130 axles

22. Remove the outer side gear.





23. Remove the differential shaft lockpins by turning the differential case opening facing down. Using a hammer, lightly tap the side of the case to free the lockpins.





24. Remove the lockpins.





25. Remove the halfshaft pinion shafts, pinions and washers.

1. Remove the halfshaft.

2. Remove the pinion and washer.





26. Remove the full shaft pinion shaft, pinions and washers.





27. Remove the inner side gear and thrust washer.





Assembly

All axles

1. If removed, install a new anti-lock speed sensor ring with a dead blow hammer.





S110 axles

2. Install the inner side gear thrust washer and inner side gear.





3. Align the pinion gear cross shaft with the pin hole vertical position.





4. NOTE: Lightly lubricate all of the mating surfaces with clean axle lubricant. This will aid in assembly and provide initial lubrication.

Install the first pinion gear thrust washer and pinion gear on the pinion cross shaft.





5. Install the second pinion gear and pinion gear thrust washer on the differential cross shaft.





6. Install the differential cross shaft lockpin.





7. NOTE: There is no thrust washer in this location.

Install the outer side gear.





8. Align the ring gear and the differential case bolt holes. Install the 12 new ring gear bolts in the holes finger-tight.





S130 axles

9. NOTE: Lubricate both sides of the thrust washer with axle lubricant.

Install the inner side gear thrust washer and inner side gear.





10. Position the full shaft pinion shaft in the shaft bores of the pinion case. Make sure it is the side that does not have lockpin holes.

1. Locate the lockpin holes.

2. Position the side pinion and thrust washer.

3. Start the full shaft into the differential case.





11. Install the opposite side pinion and washer.

1. Position the thrust washer and pinion.

2. Push the shaft through the pinion and washer.





12. Install a side pinion and thrust washer on the halfshaft side.

1. Position the side pinion and thrust washer.





13. Install the halfshaft so the pin is facing upward and push the shaft in until it stops.





14. Position the halfshaft in the case.

1. Align the halfshaft in the slot.

2. Align the lockpin hole with the halfshaft.





15. Install the lockpin.





16. Repeat Steps 6 and 7 to install the opposite halfshaft.

17. NOTE: There is no thrust washer in this location.

Install the outer side gear.





18. Remove the locating dowels from the ring gear.





19. Install the dowels over the lockpins.





20. Lower the ring gear on the case aligning the locking dowels.





21. Install the 12 new ring gear bolts finger-tight.





All axles

22. Using the Step Plate and a press, install the differential assembly half on the ring gear half.





23. Tighten the 12 new ring gear bolts.
- Tighten to 203 Nm (150 lb-ft).





24. Using the Wheel Speed Sensor Ring Installer and a suitable press, install the ring gear side carrier bearing.





25. Using the Wheel Speed Sensor Ring Installer and a suitable press, install the differential side carrier bearing.





26. Carefully position the differential assembly into the carrier housing.

27. NOTE: The bearing cups must seat on the differential side bearings.

NOTE: Align the match marks.

NOTE: The bolt threads must be clean.

Install the differential bearing caps.

1. Position the bearing cap onto the leg.

2. Apply threadlock to the bolt threads, and install the bolts.
- Tighten the bolts enough to eliminate visible space between the bearing cap and leg. Do not tighten the bolts at this time.





28. NOTICE: Align the differential assembly within the bearing bores before applying preload or damage to the bearings will result.

Install the differential bearing adjusting rings.

- Tighten both adjusting rings until there is zero end play and some backlash between the differential ring gear and pinion. Make sure the adjusting ring tooth aligns so that installation of the adjusting ring cotter pin is possible.





29. Using the Dial Indicator Gauge with Holding Fixture, set the backlash at zero.
- NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring cotter pin is possible.

Loosen the adjusting ring on the tooth side of the differential ring gear one tooth and tighten the opposite adjusting ring one tooth. Repeat this process until backlash is at zero.





30. Using the Dial Indicator Gauge with Holding Fixture, set the backlash and the bearing preload to specifications.
- With a new matched set installed, set the backlash to the specification.

- With the original matched set installed, set the backlash to the specification recorded prior to disassembly.

- NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring cotter pin is possible.

Tighten the adjusting ring on the tooth side of the differential ring gear until backlash is within specifications.





31. Using the Dial Indicator Gauge with Holding Fixture, check the differential ring gear and pinion backlash in 4 equally spaced positions around the differential ring gear.
- The acceptable backlash tolerance is ±0.0508 mm (0.002 in) from the backlash specification.

- If the backlash tolerance varies more than 0.080 mm (0.003 in) between the 4 positions, remove the differential and determine the cause.





32. Check the differential ring gear and pinion backlash, as described in the previous step, after tightening the differential bearing cap bolts.
- Tighten to 190 Nm (140 lb-ft).





33. Install the adjusting ring cotter pins.





34. Install the rear wheel speed sensor and bolt.
- Tighten to 20 Nm (177 lb-in).





35. Install the carrier. For additional information, refer to Differential Carrier Differential Carrier.