Disassembly
When changing ratios on the model 44 front drive axle, it may be necessary to change the differential case along with the ring gear and drive pinion. Ratios 2.72 to 1 up to 3.37 to 1 incorporate a thick differential case flange and a thin ring gear. Ratios 3.92 to 1 and up to 4.56 to 1 incorporate a thin differential case flange and a thick ring gear.
1. Remove axle assembly from vehicle, Figs. 1 through 6.
2. Drain fluid from axle.
3. Remove lefthand axle arm assembly.
4. Loosen bolts attaching carrier to axle arm. Remove bolts attaching support arm to the carrier, then the carrier assembly.
5. Place carrier into a suitable holding fixture, then remove and clean all gasket surfaces. Remove bearing caps. Note matched numbers or letters stamped on the cap and carrier assembly. These numbers or letters must be matched during assembly. These numbers may either be stamped vertically, horizontally or in some instances both vertically or horizontally.
6. Mount suitable spreader and adapter tools on to carrier assembly.
7. Position a suitable dial indicator on to carrier, then spread the housing. Do not spread the housing more than .005 inch on 1980 models, .015 inch on 1981 models, or .010 inch on 1982---86 models or .015 inch on 1987 models, except model 28 and 60 monobeam axles. On model 60 monobeam axle, do not spread the carrier more than .015 inch. On model 28 axles, do not spread housing more than .010 inch.
8. Remove differential case from the carrier. It may be necessary to pry the case from the carrier with suitable pry bars.
9. Remove and tag bearing cups to indicate from which side of the carrier they were removed. Remove spreader tool from case.
10. Turn nose of carrier upward. Hold end yoke with a suitable holding tool and remove pinion nut and washer from pinion assembly.
11. Using a suitable tool, remove end yoke. If the yoke shows any sign of wear in the seal contact area, replace yoke.
12. Remove drive pinion by tapping on the drive pinion shaft. Do not damage pinion bearing preload shims located on the splined end of the pinion. If damaged, replace with shims of equal thickness, do not loosen the shims.
13. Using a suitable bearing cup puller and slide hammer, remove drive pinion oil seal from carrier.
14. Remove outer pinion bearing and the oil slinger from the carrier input bore.
15. Remove pinion bearing preload shims. Ensure all shims are removed from the carrier. Replace any damaged shims. Shims are available in thicknesses of .003, .005, .010 and .030 inch.
16. Remove inner pinion bearing cup and baffle. Drive bearing cup out of bore. Oil baffle and shims are located between the inner bearing cup and carrier bore. Do not damage the shims when removing the bearing cup. If any shims are damaged, measure the thickness and replace with shims of equal thickness.
17. Turn nose of carrier downward and remove outer pinion bearing cup. Drive cup from the carrier.
18. Remove differential case bearings and shims from case. Position a suitable step plate under bearing, then install a universal bearing removal tool and remove bearing. Turn case over and remove other bearing in the same manner.
19. Wire shims, bearing cup and cone together and identify from which side of the differential case they were removed. If any shims are damaged, replace with new shims.
20. Place a few shop towels over a vise to prevent the ring gear teeth from being nicked after it is free from the case assembly. Remove the ring gear bolts. Tap ring gear to free it from case. Remove case and ring gear from vise. Whenever removing the ring gear bolts, discard and replace with new bolts upon assembly.
21. Remove bearing and oil slinger from the drive pinion.
22. Inspect all parts for damage and replace as required.
Fig. 1 Disassembled view of Dana/Spicer model 44-9F front drive axle
Fig. 2 Disassembled view of Dana/Spicer model 44-1FS front drive axle
Fig. 3 Disassembled view of Dana/Spicer model 44-1FS-HD front drive axle
Fig. 4 Disassembled view of Dana/Spicer model 50-1FS front drive axle
Fig. 5 Disassembled view of Dana/Spicer model 60 front drive axle
Fig. 6 Disassembled view of Dana/Spicer model 28 front drive axle