Dana Spicer Axles & Brakes ABIB-0202R1 Information Bulletin Bulletin Type: Service/Parts Topic: Carrier to Housing Leak Repair Procedure Affected Models: D & R 404 Family of Tandem Drive Axles This document will explain the recommended repair procedure for a leaking carrier-to-housing joint. This procedure must be used with Dana Carrier Installation Kit (P/N 511897) specific contents of this kit are listed below. Refer to Dana Information Bulletin ABIB-0203 for the proper diagnoses and recommended repair procedure. It is important that you observe all of the normal safety procedures, including wearing proper protection for every step in this procedure. Axle Housing Hardware Kit P/N: 511600 Carrier Installation Adapter Kit P/N: 511897 Contents: 1- Forward Carrier Adapter Plate - P/N 130840 1- Rear-Rear Carrier Adapter Plate - P/N 130841 4- Guide Pins - P/N 130843 4- Rear-Rear Adapter Plate Capscrew - P/N 130842 1- Instruction Sheet - P/N SHAIS135 Required Tool List: Clean Oil Pan Wire Wheel or Abrasive Pad Transmission Jack Large screwdriver / Pry-Bar Jack Stands Hammer / Mallet ½ Impact Gun 14 mm 12 pt. Impact Socket 21 mm Impact Socket 24 mm Impact Socket 9/16 Combination Wrench Installation: 1. Block vehicle tires. 2. Disconnect driveline. 3. Drain axle lube into a clean pan. Lube will be reused at the end of this procedure. 4. Remove axle shaft nuts, washers and shaft. 5. Remove all but one carrier fastener. The remaining capscrew will hold the carrier in place until the transmission jack and adapter plate are moved in place and secured
Carrier Removal : Forward - Rear Axle a. Disconnect the IAD shift cylinder air line. b. Install carrier guide pins at 4:00 and 9:30 positions of housing mounting holes. 9:30 4:00 Install Carrier Guide Pins 4:00 and 9:30 positions c. Remove power divider cap screws at 5:30 and 7:30 positions. d. Position adapter plate. Adjust transmission jack table to align with power divider cover holes. Note: There are some vehicles that may sit lower than others, if the adapter plate will not line up you may need to jack the truck up and put it on jack stands. D-Carrier Adapter Plate Adapter Plate Position On Forward Carrier e. Reinstall capscrews and snug with impact gun. Warning: It is important that the adapter plate is properly secured and positioned on the transmission jack before the carrier is removed. f. Remove remaining carrier capscrew and carefully remove the carrier assembly. Use a large screw driver or pry bar to back the carrier off the housing studs.
Carrier Removal: Rear-Rear Axle a. Install carrier guide pins at 3:30 and 9:30 positions. b. Remove pinion cage cap screws at 5:30 and 7:30 positions. R-Carrier Adapter Plate Remove Bottom Two Pinion Cage Bolts c. Position adapter plate. Adjust transmission jack table to align bolt holes. d. Install M14 x 2.0 x 60mm capscrews and snug with impact gun. Position Adapter Plate Install Longer Capscrews Warning: It is important that the adapter plate is properly secured and positioned on the transmission jack before the carrier is removed. e. Remove remaining capscrew and carefully remove the carrier assembly.
Carrier Flange and Housing Ring Cleaning Note: Before installing new fastener hardware or the carrier assembly, inspect the axle housing visually for cracks, nicks or burrs on all machined surfaces. It is important that all surfaces are cleaned properly. 1. Stud should only to be replaced if the stud came out with the nut at the time of disassembly. 2. Use a wire wheel to remove any paint, old sealant or oil from the housing and carrier mounting surfaces. Wipe surfaces down with cleaning solvent to remove any residual oil or dirt. Wire Wheel Surfaces Clean Capscrew Holes 3. Apply a 1/8 bead of Loctite 5699 Ultra Grey or Dow Corning 3-0100 Automotive Sealant to the housing surface, it s important to apply the sealant around (make a loop) all of the threaded bolt holes. Important Note : Do not spread or smooth-out RTV once applied. RTV will set in 20 Minutes. Install carrier before RTV sets or reapply. 1/8 Bead of Approved RTV Make Loop Around All Bolt Holes
Carrier Installation 1. Adjust the Transmission jack to start the carrier on the guide pins. Note : The carrier may have moved forward when it was removed from the housing, the transmission jack table should be readjusted to compensate for this movement. 2. Adjust the carrier so that it is just contacting all four of the housing studs. Align Guide Pins Adjust Carrier to Studs 3. It is important that the carrier is at the same angle as the housing. Make sure that the carrier flange is just touching each of the studs. Again the gap between the carrier flange and the housing ring should be the same all the way around. Same Gap Top-to-Bottom and Right-to-Left Use the Studs to Check Carrier Alignment. 4. Rotate the input yoke to align the output side gear splines to the output shaft. Raise or lower the assembly until it slides into place. If it does not slide in easy, check the carrier to housing alignment. Right-to-left, top-tobottom. 5. Disconnect carrier adapter plate: For the forward and rear carriers remove the capscrews holding the adapter plate. Apply Loctite 277 to the threads of the original capscrews, reinstall and torque to 114 140 ft. lbs. 6. Install one of the new carrier fasteners to hold the carrier in place so you can remove the alignment studs. 7. Remove the alignment studs.
8. Install new fasteners supplied in kit and run them down with an impact gun in a crisscross pattern. Torque Specification Chart - (Carrier - to - Housing) Model Series Dana Part-No. Fastener Location Class Size lbs-ft N.m D/R344, 404 127567 Carrier - to - Housing Nut 12 M16x1.5 250-300 312-366 130158 Carrier - to - Housing Capscrew 12.9 M16x2 250-300 312-366 9. Most ½ drive impact guns will put out a maximum torque of 250-300 ft. lbs. Check at least one capscrew to verify that your impact gun is putting out a minimum of 250 ft. lbs. Note: Remember, if you use a socket with a swivel or extension you will get less torque to the fastener. For example if you verify your impact gun with a straight socket at 250 ft. lbs. The same impact gun with a swivel or extension will only put out 210-230 ft. lbs.. If a swivel or extension are used you must verify those torque s with a torque wrench. 10. Clean axle shaft flanges and wheel hub surfaces and install new axle shaft gasket. 11. Reinstall the axle shaft, washers and nuts, torque to spec. 12. Reconnect IAD shift cylinder airline. 13. Reinstall the driveline. 14. Remove fill plug from housing cover and refill the housing using the same lubricant that was removed. If needed, add lube and fill until level with the bottom of the fill hole. For spec ing or service assistance, call 1-800-826-HELP (4357) 24 hours a day, 7 days a week, (Mexico: 8-332-1515). Or visit our web site at: http://www.roadranger.com Copyrights 2002, Dana Corporation Commercial Vehicle Axle Division Dana Corporation January 2002 All Rights Reserved. P.O. Box 4097 Printed in U.S.A. www.dana.com/heavytruck Kalamazoo, MI 49003