Spicer Tandem Drive Axles Service Manual S400 - Manual (Page 23)

Using suitable pry bar and spacer, pry input shaft
out and record end play.
16. Proper end play for inter-axle is .001 to .003 inch
(.025 to .076 mm). Subtract .003 inch (.076 mm)
from recorded end play and assemble combination
of shims that total proper thickness to establish
correct end play.
EXAMPLE:
Measurement with dial indicator. .080in. (2.032 mm)
Preferred end play. .003in. (0.076 mm)
Required shims. .077in. (1.956 mm)
17. Remove input shaft bearing retainer and install shim
pack between bearing retainer and input shaft
bearing cup. Remove input shaft.
18. Install shift spring into the bottom of the shift well.
19. Check shift fork for excessive wear. Replace if
necessary.
20. Check clutch collar for wear or damage in groove,
on drive lugs, and splines. Replace if necessary.
21. Apply a thin coat of grease on the clutch collar
riding surface area of shift fork.
21
INTER-AXLE DIFFERENTIAL ASSEMBLY
1. Position inter-axle differential case on two 4" x 4"
blocks for reassembly
2. Install new rear differential bearing cup into case.
3. Press new bearing cone onto rear differential gear.
NOTE: Be certain that both cup and cone are seated
properly or false reading on end play of inter-axle may
occur.
4. Apply a light coating of gear lube to rear diff-gear
bearing, hub surface, and interior bore, then install.
.
5. Lubricate and place inter-axle differential assembly
inside of plastic lube retainer and install into case.
6. Align the bolt holes of the plastic lube retainer with
the case and install the two bolts and washers.
Tighten and torque lube retainer bolts to 20-25
Lb-Ft (27-34 N-m).
7. Press new needle bearing into I.D. of drive gear.
8. Lubricate needle bearing and carefully lower drive
gear into intermediate case until differential gear is
seated in inter-axle differential.
9. Press input shaft front bearing cone onto shaft until
seated completely against shoulder.
10. Lube the needle thrust bearing lightly and place on
front drive gear. Ensure that thin bearing race is
seated against drive gear and the thrust bearing is
seated between the two spacers.
NOTE: To establish proper end play, input shaft will be
installed into inter-axle differential prior to installing
shift collar, fork , and shift shaft.
11. Lube and install input shaft, turning slightly to
engage splines.
12. Install new input shaft front bearing cup into input
shaft bearing retainer without shims.
13. Install bearing retainer onto intermediate housing
and bolt into place.
14. Thread input flanged hex nut onto input shaft until
resistance is felt from locking compound.
FFFFFigur igur igur igur igure 2 e 2 e 2 e 2 e 21 1 1 1 1
Tap nut lightly with soft hammer.
15. Position dial indicator onto end of input shaft. See
Figure 21.