SPICER� MODEL 60 MODEL 70 POWR-LOK LIMITED SLIP DIFFERENTIAL SPICER AXLE DIVISION � DANA CORPORATION FORT WAYNE, INDIANA TABLE OF CONTENTS 1 LUBRICATION ................................................................... ......................................... .......................... OPERATION.......................................................................................................................................... 1 TROUBLE SYMPTOMS AND POSSIBLE CAUSES .......................................................................... 1 CHECKING WHEEL TORQUE .............. ............................................... ............................................... 2 DISASSEMBLY - Removal, Inspection and Repair......................................................................... 2 DECREASE WHEEL END TORQUE ...................................... ............................................................. 7 REASSEMBLY ....... ................................................................................................................................ 8 COMPLETE ASSEMBLY REPLACEMENT ................................................ ......................................... 11 IMPORTANT SAFETY NOTICE Should an axle assembly require component parts replacement, it is recommended that "Original Equipment" replacement parts be used. They may be obtained through your local service dealer or other original equip· ment manufacturer parts supplier. CAUTION: THE USE OF NON-ORIGINAL EQUIPMENT REPLACE· MENT PARTS IS NOT RECOMMENDED AS THEIR USE MAY CAUSE UNIT FAILURE AND/OR AFFECT VEHICLE SAFETY. Proper service and repair is important to the safe, reliable operation of all motor vehicles or driving axles whether they be front or rear. The service procedures recommended and described in this service manual are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose. The special tool should be used when and as recommended. It is impossible to know, evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. Accordingly, anyone who uses a service procedure or tool which is not recommended must first satisfy himself thoroughly that neither his safety or vehicle safety will be jeopardized by the service methods he selects. NOTE Throughout this manual. reference is made to certain t.ool numbers whenever special tools are re· quired. These numbers are numbers of Miller Special Tools. 32615 Park Lane, Garden City, Michigan 48135. They are used herein for customer convenience only. Dana makes no warranty or representation to these tools. MODEL 60 AND MODEL 70 POWR-LOK taken during disassembly to note the arrangement LUBRICATION of these components. It is not our intent to recommend any particular The Powr-Lok construction permits differential brand or make of lubricant for Spicer axles. action when required for turning corners and However, a S.A.E 90 weight multipurpose gear transmits equal torque to both wheels when driving lubricant meeting Mil. Spec. L-2105-B, or 80 W 90 straight ahead. However, when one wheel tries to multipurpose gear lubricant meeting Mil. Spec. spin due to leaving the ground, a patch of ice, etc., L-2105-C, and suitable for A.P.l. Service Classificia­ the clut.ch packs automatically provide more torque tion GL-5 is suggested as a minimum requirement.. to Lhe wheel which is not trying to spin. IMPORTANT The Powr-Lok differential resists wheel spin on Limited Slip Differentials impose additional re­ bumpy roads and provides more pulling power when quirements on lubricants which cannot be covered one wheel tries t.o slip. In many cases of differences by the above specifications. Some otherwise good in traction, pulling power will be automatically pro· lubricants produce "chatter" or "bumping" in turn­ vided until both wheels start to slip. ing corners with Limited Slip Differentials. Many In diagnosis of vehicle operators' complaints. it is vehicle manufact.urers find it necessary to specify a important Lo recognize two things. special lubricant or lubricant additive for use with l. If, w1th unequal tract.ion. both wheels slip, t.he Limited Slip Differentials. Check the vehicle Powr-Lok has done aU it can possibly do. manufacturer's lubricant recommendations. 2. In extreme cases of differences in traction, the COLD WEATHER OPERATION wheel with least traction may spin after the If the vehicle is operated below 0°F (-l8°C), it is Powr-Lok has transferred as much torque as advisable to use S.A.E. 80 mult.ipurpose gear lubri­ possible to the non-slipping wheel. cant meeting Mil. Spec. L-2105-B and suitable for A.P.I. Service Classification GL-5. TROUBLE SYMPTOMS AND POSSIBLE CAUSES SUBMERSION OR DEEP WATER FORDING If noises or roughness, such as chatter, are pres­ In the event the gear carrier housing should ent in turning corners, the probable cause is incor­ become submerged in water,part.icularly if over the rect or contaminated lubricant.. (See Lubrication). breathers, it is recommended that the hypoid gear Before any differential is removed and lubricant be drained and internal parts be inspected disassembled for chatter complaints, the correct­ for water damage and/or contaminat.ion. ness of lubricant can and should be determined. Clean, examine and replace damaged parts. if If the vehicle manufacturer recommends a lubri­ necessary, prior to assembling the housing cover cant additive for chatter complaints, add the and refilling with the specified hypoid lubricant. specified type and amount. of additive and recheck for chatter by warming the axle up. and then mak­ NOTE ing a minimum of ten (10) figure eight turns. IT IS RECOMMENDED THAT WHENEVER If this is unsuccessful, or no lubricant additive is BEARINGS ARE REMOVED THEY ARE specified, a complete lubricant drain, flush. and refill TO BE REPLACED WITH NEW ONES. with the specified LimitedSlip differential lubricant REGARDLESS OF MILEAGE. will usually correct chatter. The following procedure is recommended to en­ OPERATION sure flushing the system of old lubricant. A conventional differential transmits all of the 1. Warm the lubricant by vehicle road operation ring gear torque through the differential side gears to or five (5) minut.es of operation in gear at 30 Lhe axle shafts. Torque is at all times equal on the m.p.h. with both rear wheels off the ground. axle shafts, and if one wheelslips, the other wheelcan Vehicle should be on a free wheel hoist. only put out as much torque as the slipping wheel. The Powr-Lok differential has the same power flow as a conventional differential plus a more direct CAUTION flow which automatically takes effect as driving NEVER PLACE THE TRANSMISSION IN conditions demand. This more direct power flow is GEAR WlTII THE ENGl"iE RUNNING WilE� from the differential case to each axle shaft through 0'\JLY 01\E REAR WHEEL OF A LIMITED a clutch plate and ruse arrangement. \ The most common Model 60 & Model 70 Powr­ SUP DIFTERENTIAL EQLIPPED EH ICLE THE VEHICLE \1IGHT Lok consists of five steel clutch members on each IS RAISED. DRI\ E IT­ side of the differential case. SELF OFF OF THE JACK A;-.;D CAUSE Arrangement of these plates and discs is at the op­ DAMAGE OR INJt;RY. tion of the vehicle manufacturer. so care should be 1 MODEL 60 AND MODEL 70 POWR-LOK 2. Drain lubricant while warm. Remove drain Apply a torque wrench to the special tool which is plug or cover plate to drain completely. If cover bolted to the wheel bolts. plate is removed it may be necessary to replace Disregard breakaway torque and observe only the Lhe gaskeL torque required to continuously turn the wheel. 3. Refill axle with specified Limited Slip differen­ If torque reading is less than 40 lbs. ft. (45.2 N •m) tial lubricant. or greater than 200 lbs. ft. (271 N •m) on either wheel 4. Operate the vehicle for approximately ten (10) (with dished plate and dished disc). the Powr-Lok miles, making at least ten (10) figure 8 Lurns to unit should be disassembled and the necessary flush the old lubricant out of Lhe clutch packs. repairs made. Powr-Lok units (with dished plate) should require a minimum of 25 lbs. ft. (33.9 N•m) 5. Repeat. Steps 2, 3, and 4, making sure to re­ or a maximum of 200 lbs. ft. (271 N•m) to rotate. place the cover gasket, if required, in Step #3. 6. It is possible that slight chatter, requiring ad­ DISASSEMBLY ditional vehicle operation, may remain after REMOVAL, INSPECTION AND REPAIRS Step 5. If chatt.er still persists after one hundred OF POWR-LOK DIFFERENTIAL (1 00) miles of vehicle operation. or remains On Spicer axles iL is recommended that the com­ severe after SLep 5 above, disassembly and re­ plete assembly be removed from the vehicle when it pair will be necessary. becomes necessary to service the Limited Slip dif­ ferential. PROPER PROCEDURE FOR CHECKING WHEEL TORQUE Remove wheels. etc. from vehicle. Refer to vehicle manufacturer's recommendations. If inadequaLe or excessive lock-up is suspected, drive the vehicle far enough to warm up the axle Remove axle shafts. lubricant. and exercise the unit by operating the vehicle through at least three (3) figure 8 turns prior to making the following lest as described. With engine shut off, transmission in neutral, and NOTE parking brake off, place a block of wood in front and back of both front wheels. Jack up one rear wheel BRAKE BACKING PLATE CAN NORMALLY until it is completely off the ground and remove hub