Spicer S400 Helical Gear Retrofit Kit Installation - Manual (Page 2)

Assembly Instructions:
1. Replace the output side gear bearing cup.
2. Press a new bearing cone onto the new output side gear.
3. Apply a thin coat of lube to the output side gear bearing rollers and install into carrier.
4. Lubricate the side pinions and thrust washers of the new IAD and install in carrier.
5. Lubricate the helical side gear needle bearing. If bearing is being replaced, carefully press bearing into helical
gear.
6. Install new helical side gear thrust washer and lubricate. (This will be a solid washer)
7. If necessary replace the input shaft bearing cup and cone.
8. Install the input shaft, sliding clutch and shift fork assembly. If necessary, refer to Dana Service manual
SHABD 195-1 for more detail.
9. Install input bearing retainer without shims.
10. Position dial indicator onto end of input shaft and measure input shaft endplay.
11. Proper endplay is .001” to .003” inch. Subtract .003” from the total endplay you have recorded and assemble
combination of shim that total proper thickness to establish correct endplay.
Example: Measurement with dial indicator = .080”
Preferred endplay - .003”
Required shim .077”
12. Remove input bearing retainer and install shims, reinstall retainer and capscrews, torque to 100 - 120 ft. lbs.
13. Recheck input shaft endplay should be .001” to .003”.
14. Install new input seal using the proper seal installation driver.
15. Install driveline yoke, apply Loctite 680 to threads of new nut. Torque to 900 -1200 ft. lbs.
16. Reinstalled PDU case to carrier housing and install capscrews. Torque to 100 - 120 ft.lbs.
17. Refill axle with lube.
18. Reconnect driveline and air shift airline.
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July 2003 All Rights Reserved. P.O. Box
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