Spicer Drive Axles Service Manual Axle Shift Systems, 2-Speed Single Rear Axles - Manual (Page 19)

16
Electric Shift System
Retrofit Kits
Shift Unit Retrofit Kits
The new Spicer Electric Shift Unit is a completely new design
and shares no common parts with existing shift units. How-
ever, it is completely interchangeable as a unit for service
replacement. Retrofit Kits are available to convert to the new
shift unit.
Note: In some special situations, the new unit cannot be used.
Refer to appropriate Spicer Parts Books for detailed
application and part no. information.
The following instructions are a condensed version for retro-
fitting a new shift unit. Detailed instructions are contained in
the Retrofit Kit.
Retrofitting Instructions
*These parts are included in Retrofit Kit.
1. Remove existing shift unit.
2. Remove and discard seal and spring.
3. Cut existing wiring harness (approx. 6" - 8"). Identify
wires (Low Range, High Range and ground).
4. Connect new wiring harness to existing harness,
using connectors* furnished in kit.
5. Connect new wiring harness to new shift unit.*
Check shift unit operation before mounting on differ-
ential carrier. Operate driver control switch in low
and high range and observe new shift unit operation.
If shift unit does not operate, unplug new harness
connector and test for power and voltage continuity
at connector terminals.
If shift unit operates, install on carrier as follows:
6. Use new seal and spring assembly.* Mount seal on
carrier studs.
7. Install shift unit. Install flat washers and nuts.
Torque nuts.
Note: Make sure to use the mounting washers* (0.100",
2.54 mm thick) furnished with kit.
8. Attach cable clip* to harness near motor and fasten
to motor stud with nut*. Torque clip nut.
9. Secure harness to chassis with tie wraps.* Leave
adequate slack to allow for axle movement.
IMPORTANT: Shift Unit Replacement.
Before installing a rebuilt or new shift unit, check fit of shift
fork to slide block pivot using a “Fit-up” Card or Template
(PN 128039). These cards are furnished with new shift units
retrofit and slide block kits. Instructions are contained on
the card (see illustration) (also see page 6 instructions).
EXISTING WIRING HARNESS NEW HARNESS*
Ground to Green Wire (Ground)
) w o L ( e ri W k c a l B o t w o L
) h g i H ( e ri W d e R o t h g i H
Connectors (3)
Tie Wraps (2)
Shift
Unit
Assembly
Flat Washer (2)
(0.100", 2.54mm thick)
Cable
Clip
Clip
Nut
Wiring
Harness
Spring
Seal
COMPONENTS OF TYPICAL RETROFIT KIT
IMPORTANT
Procedure:
1. Shift axle to high range so fork is
square to axle face.
2. Remove shift unit and rubber boot.
3. Drop card over shift unit as shown
in (fig. 1) until card touches carrier
surface or interferes with fork.
4. If no interference, fork is OK.
Go to step #6.
5. If card interferes at A or B, care-
fully grind fork to fit template.
6. Replace boot and reassemble unit.
Dana service keeps
you on the road.
For technical assistance call
1-877-777-5360
anywhere in North America
Part no. 128039
10M/1290/MP
Copyright Dana 1991
All right reserved
2-Speed Shift Fork Fit-Up Card
Printed in U.S.A.