Spicer DS462 - Manual

Spicer ®
Axles & Brakes
ABIB-0207
Information Bulletin
Bulletin Type: Parts/Service Information
Topic: DS404 and DS462 Housing Cover Weld Repair Instructions
WARNING: It is important that you observe all of the normal safety procedures,
including wearing proper protection for every step in this procedure.
This document explains the recommended procedure for repairing a cracked rear cover weld. This is the
only approved method for this repair. Any other method of repair may result in damage to the axle, axle
housing or other vehicle components and could affect performance and safety. Failure to follow all steps of
this procedure will result in a poor repair and the crack could occur again. Welding at any other locations
on the axle housing will void the warranty and can result in an early failure and unsafe operation of the
axle. DO NOT ATTEMPT ANY OTHER TYPE OF WELD REPAIR ON DANA DRIVE AXLES.
When performing this repair on certain types of vehicles, including tank trucks hauling flammable liquids,
it will be necessary to remove the axle from the vehicle before welding.
Welding Equipment and Specifications:
Mig (wire) Welding
Welding Gas – recommended – 80% Argon, 20% C-O2 Gas Flow Setting – 50-60 cfh.
Wire Size – ER70S-3 or ER70S-6 .035”
First and second passes cover weld, approximate settings – 30 volts, 180 amps.
Third filler pass, cover weld, approximate settings – 26 volts, 140 amps.
Apply three weld passes to the cover. The first pass should be centered over the fit-up line and penetrate the failure
area. The second pass should be placed slightly above the first. Blend the weld smoothly
(without significant cross section enlargement) with the housing and first pass. The third pass should penetrate the
lower half of the second pass to the edge of the housing cover. Avoid any significant overlap of weld or undercut.
When making the second and third passes the weld direction should be reversed. Always start the weld at one end,
never in the middle the intended weld area. See illustrations below for more information.
Arc (stick) Welding
Miller DC type stick welder set at 140 -150 amp setting.
Use E7018 1/8 inch Electrode for all three passes. Note** Remove slag between passes. E7018 rod must be stored
in heated rod oven. Apply three weld passes to the cover. The first pass should be centered over the fit-up line and
penetrate the failure area. The second pass should be placed slightly above the first. Blend the weld smoothly
(without significant cross section enlargement) with the housing and first pass. The third pass should penetrate the
lower half of the second pass to the edge of the housing cover. Avoid any significant overlap of weld or undercut.
This bulletin contains product information.
Dana Corporation is not committed or liable for canvassing existing product.