Service Manual - Dana Corporation

Procedure -
1. Remove snap ring from machined groove at rear of input
shaft.
WARNING
Snap ring is spring steel and may pop off wear safety
glasses when removing. with snap ring removed, the
helical side gear may fall off shaft. Exert care to prevent
damage or injury,
Slide helical-side gear off input shaft, then remove bronze
thrust washer and "D" washer from shaft.
2. Axles with Lube Pump- At this point in disassembly, it is
desirable to remove lube pump drive gear nut. Hold input
shaft yoke to secure drive gear, then loosen and remove
drive gear nut.
3. Remove nut, flat washer and yoke from input shaft.
Power Divider Overhaul
4. Remove cap screws lock-washers and input bearing cover
and shim pack.
5. Slide input shaft assembly out of cover. Remove bearing
spacer from shaft (used only on D340, 380(P), 400-P).
6. Remove Lockout, Sliding Clutch and Shift Fork.. Starting
with axles built early in 1991, the sliding clutch and helical
slide gear curvic teeth diameter was increased to provide
greater tooth engagements. For additional parts and service
information, refer to Bulletin 91-01.
To remove the larger-diameter sliding clutch, first remove
the lockout (see pages 40-42). Then remove the sliding
clutch and shift fork (with the two parts engaged). Grasp
the assembly by hand and maneuver the assembly past
restrictions in the power divider cover.
To remove the smaller-diameter sliding clutch, (used on
earlier model axles), the clutch can be disengaged and removed
without removal of the lockout and shift fork.
48
Service Procedure