Dana 53R, 2050 Axle Disassemly Service Manual - 044718

© 2050 Series
DANA
Posi-Torq Limited Slip Differential
Off-Highway Products
Reference 21D and 53R Axle Series
Service Manual #0097 Revision A 5.09
Dana Off-Highway Products, LLC

©
DANA
FOREWORD
This manual has been prepared to provide the customer and maintenance personnel with information and
instructions on the maintenance and repair of Dana Products.
Extreme care has been exercised in the design and selection of materials and manufacturing of these units. The
slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated
intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and
trouble-free service.
In order to become familiar with the various parts of the product, its principle of operation, troubleshooting, and
adjustments, it is urged that mechanics study the instructions in this manual carefully and use them as a reference
when performing maintenance and repair operations.
NOTE: Always furnish serial and model numbers when ordering parts.
www.DANA.com/OFFHIGHWAY
1-704-878-5850 i
DANA 2050 Series Differential Manual ©
DANA
Introduction and General Description
SAFETY PRECAUTIONS
To reduce the chance of personal injury and/or property damage, the following instructions must be carefully
observed. Proper service and repair are important to the safety of the service technician and the safe, reliable
operation of the machine.
It is important to note that this manual contains safety guidelines for Disassembly and Assembly of the 2050
Series Differential. It describes safety instructions included throughout this manual, lists safety precautions to
follow when assembling or disassembling of the 2050 Series Differential, and describes safety practices.
Safety instructions are noted throughout this manual. Each safety instruction is given as a WARNING or a CAU-
TION and is accompanied by a safety symbol in the left-hand margin as shown below:
WARNING
Failure to observe a safety instruction noted by WARNING could result in severe
injury or death.
CAUTION
Failure to observe a safety instruction noted by CAUTION could result in injury
or damage to the equipment.
Used throughout this manual, NOTES provide useful, additional data. They are never used to communicate
safety hazards.
DANA Off-Highway Products, LLC www.DANA.com/OFFHIGHWAY

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DANA
Table of Contents
Foreword ........................................................................................................................ i
Safety Precautions.......................................................................................................... ii
Chapter 1
1.1 Customer Support ...................................................................................................... 1-2
1.2 Introduction................................................................................................................ 1-3
1.3 Application Policy ..................................................................................................... 1-3
1.4 POSI-TORQ Differential Description ....................................................................... 1-4
Chapter 2
Specifications
2.1 Recommended Lubricants for DANA Off-Highway Drive Axles ............................ 2-3
Initial Fill.............................................................................................................. 2-3
Service Fill............................................................................................................ 2-3
2.2 Cleaning and Inspection ............................................................................................ 2-8
Cleaning ............................................................................................................... 2-8
Bearings ............................................................................................................ 2-8
Housings ........................................................................................................... 2-8
Inspection.............................................................................................................. 2-9
Bearings ............................................................................................................ 2-9
Oil Seals, Gaskets, and Retaining Rings ........................................................... 2-9
Gears and Shafts ............................................................................................... 2-9
Housing and Covers .......................................................................................... 2-9
2.3 Differential Reassembly .......................................................................................... 2-10
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DANA
Table of Contents
Chapter 3
Disassembly
3.1 Disassembly of the Standard Differential ................................................................. 3-3
3.2 Disassembly of the POSI-TORQ with Springs

(or without Springs) Differential............................................................................. 3-12
3.3 Disassembly of the No Spin Differential ................................................................ 3-18
3.4 Disassembly of the Hydraloc Differential .............................................................. 3-23
3.5 Cleaning and Inspection.......................................................................................... 3-30
Cleaning............................................................................................................. 3-30
Bearings .............................................................................................................. 3-30
Housings ............................................................................................................. 3-30
Inspection........................................................................................................... 3-31
Bearings .............................................................................................................. 3-31
Oil Seals, Gaskets, and Retaining Rings............................................................. 3-31
Gears and Shafts ................................................................................................. 3-31
Housing and Covers............................................................................................ 3-31
Chapter 4
Assembly
4.1 Assembly of the Standard Differential...................................................................... 4-3
Guidelines for Thread Locking Compound Application....................................... 4-3

Pinion Shaft and Bearing Cage Reassembly ....................................................... 4-4
4.2 Ring Gear to Pinion Mounting Distance Procedure.................................................. 4-9
Differential Pinions and Cross Reassembly ...................................................... 4-14

4.3 Assembly of the POSI-TORQ with Springs
4.4 Assembly of the No Spin Differential..................................................................... 4-25
4.5 Assembly of the Hydraloc Differential ................................................................... 4-30

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Chapter 1
Introduction
Page
1.1 Customer Support ...................................................................................................... 1-2
1.2 Introduction................................................................................................................ 1-3
1.3 Application Policy ..................................................................................................... 1-3
1.4 POSI-TORQ Differential Description ....................................................................... 1-4
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DANA
1.1 Customer Support

DANA Off-Highway Products, LLC; places a top priority on customer service. We
understand that superior service is paramount to obtaining - and keeping - our valuable
customers. Our continuous commitment to this strong customer support structure involves so
much more than improvements to quality, production, delivery, and cost.
It's our job to keep your off-highway vehicles up and running. We take great pride in our
comprehensive cradle-to-grave service, value-added support, fast emergency response,
systems integration, supply chain management, and regional supply capabilities.
Contact us if you have questions or comments regarding DANA Off-Highway products or services.
Key Contacts
DANA Off-Highway Products Telephone Contact Center Information:
Asia Pacific (China): 86 2 153 831100
Asia Pacific (Korea): 82 2 563 9451
Europe (Italy): 39 0464 580227
North America (USA): 803-438-0705 Ext. 7789
South America (Brazil): 55 15 3238 6092
DANA OFF-HIGHWAY PRODUCTS DIVISION

139 E. Broad St.
Statesville, NC 28677
Telephone: 704.878.5850 Fax: 704.878.5633

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DANA
1.2 Introduction
This manual provides important information to familiarize you with a safe disassembly and
assembly procedure for the 2050 Series Differential.
This manual has been prepared to provide the customer and the maintenance personnel with
information and instructions on the maintenance and repair of the DANA Off-Highway product.
Extreme care has been exercised in the design, selection of materials, and manufacturing of these
units. The slight outlay in personal attention and cost required to provide regular and proper
lubrication, inspection at stated intervals, and such adjustments as may be indicated will be
reimbursed many times in low-cost operation and trouble-free service.
In order to become familiar with the various parts of the product, its principle of operation,
troubleshooting, and adjustments, it is urged that the mechanic study the instructions in this manual
carefully and use it as a reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only DANA Off-Highway-

approved parts as listed in the applicable parts manual should be used. Use of "will-fit" or non-
approved parts may endanger proper operation and performance of the equipment. DANA Off-
Highway products does not warrant repair or replacement parts, nor failures resulting from the use
of parts which are not supplied by, or approved by, DANA Off-Highway Products, LLC.
NOTE: Always furnish the distributor with the serial and model number when ordering
parts.
This manual is divided into four chapters:
CHAPTER 1 - INTRODUCTION
CHAPTER 2- SPECIFICATIONS
CHAPTER 3- DISASSEMBLY
CHAPTER 4- ASSEMBLY
1.3 Application Policy

Capability ratings, features, and products vary depending upon the model and type of service.
Applications approval must be obtained from DANA Off-Highway Products, LLC. We reserve the
right to change or modify our product specifications, configurations, or dimensions at any time
without notice.
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1.4 POSI-TORQ Differential Description

The DANA Off-Highway Products POSI-TORQ Differential with springs and the POSI-TORQ
Differential without springs are designed to prevent the severe loss of traction which occurs when
one wheel encounters adverse tractive conditions such as slippery, wet, or muddy conditions and
the uneven terrain often encountered in off-road vehicle operations. This terrain can cause the
vehicle to become immobile because of the spinning of one wheel.
The DANA Off-Highway Products POSI-TORQ Differential with springs, uses clutch plates
(which may optionally be spring-loaded) to inhibit spinning and send torque to the high-traction
wheel. With the spring-loaded POSI-TORQ, the wheel with the best traction can have up to five
times the torque of the wheel with poor traction (5:1 bias ratio) at low torque levels. The use of
clutches in the differential provides high-torque bias while maintaining a smooth differential
action. This eliminates the drive line shock inherent in locking-type differentials.
Features:
•Increases traction in adverse driving conditions over a standard differential.
•Reduces tire wear.
•Eliminates shock loadings caused by locking differentials.
•Improves steering over a locking differential.
•Directs torque away from a slipping wheel to the wheel with the most traction.
•Provides up to five times the torque to the tractive wheel as to the slipping wheel at low torque
levels.
•Uses a quiet, four pinion gear differential with each pinion backed by a replaceable thrust
washer to reduce maintenance costs.
•Available in two versions - without springs and with springs, depending on application
requirements.
•Available on many DANA Off-Highway Products axle models.

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Chapter 2
Specifications
Page
2.1 Recommended Lubricants for DANA Off-Highway Drive Axles ............................ 2-3
Initial Fill.............................................................................................................. 2-3
Service Fill............................................................................................................ 2-3
2.2 Cleaning and Inspection ............................................................................................ 2-8
Cleaning ............................................................................................................... 2-8
Bearings ............................................................................................................ 2-8
Housings ........................................................................................................... 2-8
Inspection.............................................................................................................. 2-9
Bearings ............................................................................................................ 2-9
Oil Seals, Gaskets, and Retaining Rings ........................................................... 2-9
Gears and Shafts ............................................................................................... 2-9
Housing and Covers .......................................................................................... 2-9
2.3 Differential Reassembly .......................................................................................... 2-10
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Specifications
NOTES
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2.1 Recommended Lubricants for DANA Off-Highway Drive

Axles
Initial Fill
Use grade 85W140 qualified API GL-5SP/MIL-PRF 2105E in all places gear lubricant is specified
in MS-8 engineering standard. This lubricant is preferred for initial fill for most ambient
temperatures (See Figure A). Other lubricants approved to specifications are acceptable for initial
fill or top off.
Service Fill
Multipurpose gear lubricants approved to the specifications are recommended. Multigrade gear
lubricants are classified on the basis of their viscosities at various temperatures.
Listed below are the recommended multigrade viscosities for use at the prevailing operating
temperatures in DANA Off-Highway Drive Axles.
Figure A
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DANA
Specifications
OFF-HIGHWAY SYSTEMS
TECHNICAL SERVICE BULLETIN
No. 279 Mo – Yr (R)
) 12/05
5
RECOMMENDED LUBRICANTS FOR OHS DRIVE AXLES
Recommendations: Extreme pressure gear lubricant is recommended for use in all drive-steer and rigid
drive axles except where explicitly stated differently by Off-Highway Systems Engineering.
Mineral Based: Acceptable lubricants must meet API GL-5/MT-1 or MIL-PRF2105E qualifications.
The highest viscosity grade must be used given the prevailing ambient temperatures from the chart below.
Synthetics: Synthetic lubricants are recommended providing they meet API GL-5/MT-1
qualifications. The highest viscosity grade must be used given the prevailing ambient
temperatures from the chart below.
In general synthetic oils have a lower pressure viscosity response than mineral oil lubricants. As the contact
pressure between the gears increases, this produces a thickening of the mineral oil at the contact point.
This increase in viscosity helps to maintain lubricant film thickness reducing the possibility of surface and
spalling fatigue. Synthetic lubricants do not thicken as much under pressure unless specifically formulated
to do so. Before using a synthetic lubricant in heavy applications, the customer must check with the
lubricant supplier on the issue of high-pressure lubricant applications.
Normal Oil Change Intervals: Oil change intervals for mineral based lubricants in normal
environmental and duty cycle conditions is 1000 hours in all off-highway applications and 10,000 miles in
on-highway applications. Severe or sustained high operating temperature or very dusty atmospheric
conditions will result in accelerated deterioration or contamination. Judgement must be used to determine
the required change intervals for extreme conditions.
Extended Oil Change Interval: Extended oil service may result when using synthetic lubricants.
Appropriate change intervals must be determined for each application by measuring oxidation and wear
metals over time to determine a baseline. Wear metal analysis can provide useful information, but an axle
should not be removed from service based solely on this analysis. Vehicles, which are prone to high levels
of ingested water in the axle, or water as a result of condensation should not use extended drain intervals.
Friction Modifiers: Friction modifiers may be used with the lubricant to reduce Posi-Torq (limited slip)
differential noise or liquid cooled brake noise. If friction modifiers are used, follow instructions on TSB 278.
The use of aftermarket lubricant additives other than those specified is not
recommended and may reduce the life of the axle and void the warranty!
V is c o s ity B a s e d o n P r e v a ilin g A m b ie n t T e m p e r a t u r e
SAE 140
80W 140 / 85W 140
SAE 90
80W 90
75W 90
75W
DEG. C. -4 0 -3 0 -2 0 -1 0 0 10 20 30 40 50
F. –40 -2 2 -4 14 32 50 68 86 104 122

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1-704-878-5850 2-5
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Specifications

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Figure B
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DANA
Specifications
2.2 Cleaning and Inspection

Cleaning
Clean all parts thoroughly using solvent-type cleaning fluid. It is recommended that parts be
immersed in cleaning fluid, and moved up and down slowly until all old lubricant and foreign
material is dissolved and parts are thoroughly cleaned.
WARNING
Care should be exercised to avoid skin rashes, fire hazards, and inhalation of vapors when using
solvent-type cleaners.
Bearings
Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to
dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles.
Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free
compressed air. Be careful to direct air stream across bearing to avoid spinning. Do not spin
bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process.
Housings
Clean interior and exterior of housings, bearing caps, etc., thoroughly. Cast parts may be cleaned in
hot solution tanks with mild alkali solutions, providing these parts do not have ground or polished
surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. This
will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in solution tanks
must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be
cleaned with a steam cleaner.
WARNING
Care should be exercised to avoid skin rashes and inhalation of vapors when using alkali
cleaners.
Thoroughly dry all parts cleaned immediately by using moisture-free compressed air or soft,
lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated oil, or
laping compound.

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Inspection
The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement
of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a
later date.
Bearings
Carefully inspect all rollers, cages, and cups for wear, chipping, or nicks to determine fitness of
bearings for further use. Do not replace a bearing cone or cup individually without replacing the
mating cup or cone at the same time. After inspection, dip bearings in clean light oil and wrap in
clean lintless cloth or paper to protect them until installed.
Oil Seals, Gaskets, and Retaining Rings

Replacement of spring-loaded oil seals, gaskets, and snaprings is more economical when unit is
disassembled than to risk premature problems at a future time. Loss of lubricant through a worn
seal may result in failure of other more expensive parts of the assembly. Sealing members should
be handled carefully, particularly when being installed. Cutting, scratching, or curling under lip of
seal seriously impairs its efficiency. At reassembly, lubricate lips of oil seals with E.P. Multi
Purpose Grease, Grade # 2.
Gears and Shafts

If this magna-flux process is available, use this process to check parts. Examine teeth, and ground
and polished surfaces on all gears and shafts carefully for wear, pitting, chipping, nicks, cracks, or
scores. If gear teeth are cracked or show spots where case hardening is worn through, replace with
new gear. Small nicks may be removed with suitable hone. Inspect shafts to make certain they are
not sprung or bent, or that the splines are twisted, and that the shafts are true. Differential pinions
and side gears must be replaced as sets. Differential ring gear and bevel pinion must also be
replaced as a set if either is damaged.
Housing and Covers

Inspect housing, covers, planet spider, and differential case to be certain they are thoroughly
cleaned and that mating surfaces, bearing bores, etc., are free from nicks or burrs. Check all parts
carefully for evidence of cracks or conditions which would cause subsequent oil leaks or failures.
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DANA
Specifications
2.3 Differential Reassembly

The reassembly instructions describe the procedure to be followed when reassembling and
installing components of the axle. Instructions covering reassembly of opposite side are identical
unless otherwise noted.
NOTE: Class 8.8, 10.9, 12.9, and grade 5 and grade 8 fastening hardware has been used in
the production of the axle assemblies covered in the manual. A table of proper
torque values for the fastener classes above is provided within this manual. The
class of hardware may be determined by the markings contained on the head of
each capscrew. Class 12.9 or grade 8 torque values need to be used on all socket
head capscrews used with this assembly. Torque values specified in the text of this
manual are for classes 8.8, 10.9, 12.9, and grade 5 and grade 8 hardware used in
production. On all axles being overhauled, bolts and capscrews should be identified
as described above and torque value chart consulted for correct torque.
THREAD LOCKING COMPOUND

Guidelines for application where to apply:
1. Bolts, capscrews, and studs (anchor end).
2. Nuts, apply compound to the male thread of the mating fastener.
3.Apply compound to coat the full length and circumference of thread engagement.
4. Remove excess compound from mating parts after fastener installation.

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PINION DEPTH SETTING PROCEDURE

The function of the pinion setting gauge is to
measure the distance from the centerline of
the differential bearing bores to the ground
surface on the gear end of the pinion. This
measurement when subtracted from the value
etched on the ring gear will
indicate the size of the shim pack required to
position the pinion gear in proper relation to
the ring gear.
A ring gear to pinion distance will be etched

on the outer diameter of the ring gear. Add
0.4649 in. (11.808 mm) to it. 0.4649 in.
(11.808 mm) is half the thickness of the
gauge bar). Record this value. This value
may be different on each ring and pinion set
due to manufacturing variations.
Use a file and emery cloth to remove all burrs and nicks from machined bearing surfaces of carrier housing.
Paint bearing surfaces with bearing contact checking compound.
Insert an extension depth micrometer (Starrett #44B-6RC and extension #99347 7 in. [178 mm] or equivalent is
recommended) into the guide bore of the micrometer arbor and slide clamps over base of micrometer. With the
thumb screws reacting on base, secure micrometer.
NOTE: The micrometer extension must pass freely through the micrometer bar guide bore and base of the
micrometer must rest on the micrometer arbor when mounted.
Mount adapter discs on micrometer arbor and set in position in carrier housing. Exercise care to be sure that
micrometer and extension do not contact any part of the carrier in this operation. Apply pressure by hand and
rotate adapter discs slightly to obtain a contact with bearing surfaces.
Remove checking gauge assembly and check for full bearing contact on bearing surfaces.
If contact is full and proper, again position checking gauge assembly in carrier and check distance to ground sur-
face on pinion. Do not apply pressure to arbor or micrometer. Turn micrometer carefully and evenly until the flat
tip of the micrometer extension contacts the ground surface of the pinion squarely. Subtract this reading from the
value previously recorded. This equals the amount of shims to be added between the inner pinion bearing cup
and the carrier housing.
EXAMPLE:
5.289 in. (134.341 mm) Value etched on ring gear.
+0.469 in. (011.913 mm) Constant (1/2 thickness of gauge bar).
5.758 in. (146.253 mm) Total
-5.728 in. (145.491 mm) Initial micrometer reading.
0.030 in. (0.762 mm) Add this value in shims under inner pinion bearing cup.
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Specifications
GEAR TOOTH CONTACT CHART - LH

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GEAR TOOTH CONTACT CHART - RH
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Specifications
FASTENER TORQUE CHART
STANDARD FASTENERS
Lubricated and Plated Bolts, CapScrews, and Studs
Grade 5 Grade 8
3 Radial Dashes on Bolt Head 6 Radial Dashes on Bolt Head
Size LBF/FT [Nm] LBF/FT [Nm]
1/4-20 10 14 11 15
1/4-28 11 15 13 18
5/16-18 16 22 30 41
5/16-24 20 27 32 43
3/8-16 25 34 36 49
7/16-14 41 56 57 77
7/16-20 45 61 64 87
1/2-13 63 85 88 119
1/2-20 70 95 99 134
9/16-18 100 136 141 191
5/8-11 124 168 175 237
5/8-18 141 191 198 268
3/4-10 220 298 310 420
3/4-16 245 332 347 470
METRIC FASTENERS
Lubricated and Plated Bolts, CapScrews, and Studs
Class 8.8 Class 10.9 Class 12.9
8.8 on Bolt Head 10.9 on Bolt Head 12.9 on Bolt Head
Size LBF/FT [Nm] LBF/FT [Nm] LBF/FT [Nm]
M4 2.2 3 3.2 4.4 7.4 10
M5 4.4 5.9 6.4 8.7 7.4 10
M6 7.4 10 11 15 13 18
M8 18 25 26 36 32 43
M10 36 49 51 72 62 84
M12 63 85 92 125 107 145
M14 100 135 147 200 173 235
M16 155 210 229 310 269 365
M18 221 300 317 430 369 500
M20 313 425 450 610 524 710
M22 428 580 605 820 708 960
M24 538 730 774 1050 900 1220

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PLUG AND ELASTIC STOP NUT TORQUE CHARTS
O-RING PLUGS
Size P/N LBF/FT [Nm]

5/16-24 24K-1 5 7
3/8-24 24K-2 8 11
7/16-20 24K-3 10 14
1/2-20 24K-4 13 18
9/16-18 24K-5 15 20
3/4-16 24K-6 25 34
7/8-14 24K-7 35 47
1 1/16-12 24K-8 50 68
1 3/16-12 24K-9 60 81
1 5/16-12 24K-10 75 102
1 5/8-12 24K-11 85 115
1 7/8-12 24K-12 85 115
PIPE PLUGS
Size (NPTF) LBF/FT [Nm]

1/16-27 7 9
1/8-27 10 14
1/4-18 20 27
3/8/-18 30 41
1/2-14 35 47
3/4-14 45 61
1-11 1/2 55 75
1 1/4-11 1/2 65 88
ELASTIC STOP NUTS
Size LBF/FT [Nm]

1-20 200 270
1 1/4-18 250 340
1 1/2-18 350 475
1 3/4-12 450 610
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Specifications
Standard Differential Exploded View
Figure C

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Standard Differential Parts List

Table 2.1
ITEM DISCRIPTION QTY ITEM DISCRIPTION QTY

1 Differential Adjusting Nut 2 18 Case Bolt Washer 8
Locks
2 Adjusting Nut Lock Bolt 2 19 Bearing Retainer Ring 1

Lockwasher
3 Adjusting Nut Lock Bolt 2 20 Inner Pinion Bearing 1
4 Differential Adjusting Nut 2 21 Pinion - See Item 52 1
5 Differential Bearing Cup 2 22 Differential Carrier Capscrew 4
6 Differential Bearing Cone 2 23 Differential Carrier Capscrew 4

Lockwasher
7 Ring Gear Bolt Nut 12 24 Differential Carrier Cap 1

Assembly Includes Items 22
and 23
8 Differential Case Flanged 1 25 Center Pinion Bearing Cone 1

Half - See Item 54
8A Dowel Pin Flanged Half 4 26 Center Pinion Bearing Cup 1
8A Dowel Pin Plain Half 4 27 Pinion Bearing Spacer Kit 1
9 Ring Gear - See Item 52 1 28 Bearing Cage Shim - .007 AR
10 Ring Gear Bolt 12 28A Bearing Cage Shim - .010 AR
11 Side Gear Thrust Washer 2 29 Pinion Bearing Cage 1

Assembly - Includes Items 26
and 30
12 Pinion Thrust Washer 4 30 Outer Pinion Bearing Cup 1
13 Pinion and Side Gear Kit 1 31 Outer Pinion Bearing Cone 1

Included in Item 15
14 Pinion Gear Spider 1 32 Not Used On This Model
15 Side Gear - See Item # 13 2 33 Capscrew Plug - Bearing 2

Cage Puller
16 Differential Case Plain Half - 1 34 Not Used On This Model

See Item 54
17 Differential Case Capscrew 8 35 Seal - Inner Pinion - See Item

46
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Specifications
Table 2.1

36 Retainer - Oil Seal - See Item 46 Oil Seal - Inner 1
51
37 Oil Seal Retainer 8 47 Grease Seal - Outer 1

Lockwasher
38 Oil Seal Retainer Capscrew 8 48 Flange 1
39 Not Used On This Model 49 Nut - Pinion Shaft 1
40 Not Used On This Model 50 Dust Shield - Flange 1
41 Pinion Dust Shield - See Item 51 Retainer - Oil Seal 1

50
42 Not Used On This Model 51A Grease Fitting 2
43 Flange - See Item 48 52 Ring Gear and Pinion Set 1

Includes Item 9 and 21
44 Not Used On This Model 53 Differential Body Sub 1

to 15 and 54
45 Nut - Pinion Shaft - See Item 1 54 Differential Case Assembly - 1

49 Includes Items 8, 8A, 16,
16A, 17, and 18
AR = As Required
N.I. = Not Illustrated

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Posi-Torq Differential Exploded View
Figure D
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Specifications

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Posi-Torq Differential Parts List

Table 2.2

1 Differential Adjusting Nut 2 20 Ring Gear - See Item 50
Lock
2 Nut Lock Capscrew 2 21 Flange Half Case - See Item

Lockwasher 51
3 Adjusting Nut Lock 2 22 Differential Case Bolt 8

Capscrew Washers
4 Differential Case Bolt 4 23 Differential Case Bolt 8
5 Differential Case Bolt 4 24 Ring Gear Bolt Nut 12

Washer
6 Plain Half Case - See Item 51 1 25 Ring Gear Bolt 12
7 Outer Clutch Disc 8 26 Inner Pinion Bearing 1

Retainer Ring
8 Inner Clutch Disc 6 27 Inner Pinion Bearing 1
9 Differential Side Gear and 1 28 Pinion - See Item 50

Pinion Gear Kit - Includes
Item 17
10 Thrust Plate 2 29 Carrier Cap Capscrew 4
11 Spacer - Shim As Required 2 30 Carrier Cap Lockwasher 4

.075 Thick
11A Spacer - Shim As Required 2 31 Differential Bearing Cone 2

.065 Thick
12 Spring Pack Assembly 2 32 Differential Bearing Cup 2
13 Inner Spacer 4 33 Differential Adjusting Nut 2
14 Middle Spacer 4 34 Differential Carrier Cap 1

and 23
15 Outer Spacer 4 35 Center Pinion Bearing Cone 1
16 Pinion Gear Thrust Washer 4 36 Center Pinion Bearing Cup 1
17 Differential Pinion Gear - 1 37 Pinion Bearing Cone Spacer 1

Part of Item 9 Kit
18 Needle Roller 216 38 Pinion Bearing Shim - .007 AR
19 Pinion Gear Spider 1 38A Pinion Bearing Shim - .010 AR
1-704-878-5850 2-21
DANA
Specifications
Table 2.2

39 Pinion Bearing Cage 1 46 Outer - Pinion Oil 1
40 Outer Pinion Bearing Cup 1 47 Dust Shield 1
41 Outer Pinion Bearing Cone 1 48 Universal Flange 1
42 Seal - Inner Pinion Oil 1 49 Flange Nut 1
43 Pinion Oil Seal Retainer 1 50 Ring Gear and Pinion Set 1

43A Fitting - Grease (N.I.) 2 51 Differential Case Assembly - 1

Includes Items 4 to 6 and 21
to 23
44 Retainer Capscrew 8 52 Differential Body Assembly - 1

Lockwasher Includes Items 4 to 9, 13 to
19, and 21 to 23
45 Retainer Capscrew 8 53 Pinion Bearing Cage and Cup 1

and 40
45A Retainer Capscrew (N.I.) 2 54 Kit - Differential Bearing 1

Includes Items 27, 31, 32, 35,
36, 37, 40, and 41
AR = As Required

2-22 1-704-878-5850
©
DANA
No Spin Differential Exploded View
Figure E
1-704-878-5850 2-23
DANA
Specifications
No Spin Differential Parts List

Table 2.3

1 Lock - Differential Adjusting 2 17 Pinion - See Item 44 1
Nut
2 Adjusting Nut Lock 2 18 Differential Carrier Capscrew 4

Lockwasher Lockwasher
3 Adjusting Nut Lock 2 19 Differential Carrier Capscrew 4

Capscrew
4 Differential Adjusting Nut 2 20 Differential Carrier, Cap and 1

Sleeve Assembly Includes
Items 18, 19, and 20A
5 Differential Bearing Cup 2 20A Trunnion Sleeve Included in 1

Item 20
6 Differential Bearing Cone 2 20B Differential Puller Capscrew 4

(not shown)
7 Ring Gear Bolt Nut 12 21 Inner Pinion Bearing Cone 1
8 Differential Case Flanged 1 22 Inner Pinion Bearing Cup 1

Half - See Item 46
9 Ring Gear - See Item 44 1 23 Pinion Bearing Spacer Kit 1
10 Ring Gear Bolt 12 24 Bearing Cage Shim - .007 AR
10A Spacer - No Spin 1 24A Bearing Cage Shim - .010 AR
11 Differential No Spin 1 25 Pinion Bearing Cage and Cup 1

Assembly Assembly Includes Items 22
and 26
11A Spacer - No Spin 1 26 Outer Pinion Bearing Cup 1
12 Differential Case Plain Half - 1 27 Outer Pinion Bearing Cone 1

See Item 46
13 Differential Case Bolt 8 28 Not Used On This Model
13A Differential Case Bolt 4 29 Capscrew - Bearing Cage and 2

Retainer Puller
14 Case Bolt Washer 12 30 Not Used On This Model 1
15 Bearing Retainer Ring 1 31 Seal - Inner Pinion 1
16 Inner Pinion Bearing 1 32 Pinion Oil Seal Retainer 1

2-24 1-704-878-5850
©
DANA
Table 2.3

32A Fitting - Grease 2 40 Not Used On This Model
33 Oil Seal Retainer 8 41 Pinion Shaft Nut 1

Lockwasher
34 Oil Seal Retainer Capscrew 8 42 Not Used On This Model
35 Seal - Outer Pinion 1 43 Not Used On This Model
36 Not Used On This Model 44 Ring Gear and Pinion Set - 1

37 Pinion Dust Shield 1 45 Differential Body Sub 1

and 10A to 14
38 Not Used On This Model 46 Differential Case Assembly -

Includes Items 8, 12, 13A,
and 14
39 Flange 1
AR = As Required
1-704-878-5850 2-25
DANA
Specifications
Hydraloc Differential Assembly Exploded View
Figure F

2-26 1-704-878-5850
©
DANA
Hydraloc Differential Assembly Parts List

Table 2.4

1 Differential Carrier Assembly 1 24 Spacer Kit 1
2 Diff Carrier & Cap Assembly 1 25 Cone Bearing - Outer 1

includes items 3 & 4
3 Washer 4 26 Seal - Outer 1
4 Capscrew 4 27 Seal - Inner 1
5 Ring & Pinion Gear Set 1 28 Input Flange 1

(includes items & 7
6 53R Ring Gear 1 29 Nut - Pinion Shaft 1
7 Spiral Bevel Pinion 1 30 Dust Shield 1
8 Cone - Bearing 2 31 Retainer Seal 1
9 Cup - Bearing 2 32 Cap Screw 3
10 Nut - Diff Adjusting 1 33 Fitting Assy - Pressure Port 1
11 Ring Piston 2 34 Lock Washer 2
12 Inner Pinion Bearing 1 35 Cap Screw 2
13 Bearing Cage Shim - .007 AR 36 Cap Screw 20
14 Bearing Cage Shim - .010 AR 37 Washer 20
15 Bearing Cage Assembly 1 38 Hex Nut 20

includes items 16-18
16 Bearing Cage 1 39 Fitting King Pin 2
17 Cup Bearing -Inner 1 40 Cap Plug 4
18 Cup Bearing - Outer 1 41 Snapring 1
19 Pinion Oil Seal Retainer 1 42 Nut - Diff Adjusting 1
20 Lock Washer 8 43 Lock - Diff Adj Nut 1
21 Hex Bolt 8 44 Lock Washer 1
22 Hex Bolt 2 45 Cap Screw 1
23 Cone Bearing - Center 1
AR = As Required
1-704-878-5850 2-27
DANA
Specifications
Hydraloc Differential Body Assembly Exploded View and Parts List
Figure G
Table 2.5

1 Differential Case Assy 1 14 Plate - Friction 11
includes items 2 thru 5
2 Differential Case Plain Half 1 15 Piston 1
3 Clutch Housing 1 16 Ring - Backup Inner 1
4 Diff Case - Flange Half 1 17 Ring - Backup Outer 1
5 Cap Screw 2 18 Seal Ring 1
6 Thrust Washer 1 19 Seal Ring 1
7 Thrust Washer 1 20 Plug 1
8 Washer - Side Pinion 4 21 Washer 12
9 Pinion - Diff Side 4 22 Cap Screw 12
9A Differential Side Kit 1 23 Spacer - Inner 4

includes items 9,11 & 12
10 Cross Differential 1 24 Roller Needle 216
11 Gear Differential Side 1 25 Spacer - Center 4
12 Gear Differential Side 1 26 Spacer - Outer 4
13 Plate - Reaction 12

2-28 1-704-878-5850
©
DANA
Chapter 3
Disassembly
Page
3.1 Disassembly of the Standard Differential.................................................................. 3-3
3.2 Disassembly of the POSI-TORQ with Springs (or without Springs) Differential .. 3-12
3.3 Disassembly of the No Spin Differential................................................................. 3-18
3.4 Disassembly of the Hydraloc Differential ............................................................... 3-23
3.5 Cleaning and Inspection .......................................................................................... 3-30
Cleaning ............................................................................................................. 3-30
Bearings .......................................................................................................... 3-30
Housings ......................................................................................................... 3-30
Inspection............................................................................................................ 3-31
Bearings .......................................................................................................... 3-31
Oil Seals, Gaskets, and Retaining Rings ......................................................... 3-31
Gears and Shafts ............................................................................................. 3-31
Housing and Covers ........................................................................................ 3-31
1-704-878-5850 3-1
DANA
Disassembly
NOTES
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3-2 1-704-878-5850
©
DANA
3.1 Disassembly of the Standard Differential

The instructions contained herein cover the disassembly of the standard differential assembly in a
sequence that would normally be followed after the unit has been removed from the axle housing
for a complete overhaul.
WARNING
Maintain secure control of differential at all times. Serious injury may occur from
pinch points and unstable parts.
CAUTION
Cleanliness is of extreme importance in the repair and overhaul of this unit.
Before attempting any repairs, the exterior of the unit must be thoroughly cleaned
to prevent the possibility of dirt and foreign matter entering the mechanism.
Mount differential on differential overhaul stand.
Figure 1
Check and record ring gear backlash with a dial

indicator. This information is necessary for
reassembly unless a new gear set is installed.
Figure 2
1-704-878-5850 3-3
DANA
Disassembly
Mark carrier cap and carrier housing to ensure

correct match in reassembly.
Figure 3
Remove adjusting nut lock capscrews and

washers on both sides.
Figure 4
Remove carrier cap capscrews and washers on

both sides.
Figure 5

3-4 1-704-878-5850
©
DANA
Remove carrier caps.
Figure 6
Remove adjusting nuts and taper bearing cups.
Figure 7
Remove differential assembly from carrier.
Figure 8
1-704-878-5850 3-5
DANA
Disassembly
Remove companion flange nut.
Figure 9
Remove flange.
Figure 10
Remove oil seal retainer bolts.
Figure 11

3-6 1-704-878-5850
©
DANA
Remove oil seal retainer.
Figure 12
Use threaded holes and bolts to remove pinion and

bearing cage assembly.
Figure 13
Remove pinion and bearing cage assembly. Retain

shim pack for possible reuse at reassembly.
Figure 14
1-704-878-5850 3-7
DANA
Disassembly
Press pinion shaft and center bearing from outer

bearing and bearing cage.
Figure 15
Press center bearing from pinion shaft.
Figure 16
Remove inner pinion bearing retainer ring.
Figure 17

3-8 1-704-878-5850
©
DANA
Press inner bearing from pinion shaft.
Figure 18
Remove pinion bearing cups only if they are to be

replaced or if the bearing cage is damaged.
Figure 19
Remove body bolts from plain half.
Figure 20
Mark plain and flange half case to ensure correct

reassembly.
Figure 21
1-704-878-5850 3-9
DANA
Disassembly
Remove plain half case.
Figure 22
Remove side gear.
Figure 23
Remove differential pinions, washers, and cross

as an assembly.
Figure 24
Remove side gear.
Figure 25

3-10 1-704-878-5850
©
DANA
Remove thrust washer.
Figure 26
Remove ring gear bolts and nuts.
Figure 27
Remove ring gear. If the plain or flange half case

bearings are to be replaced, remove with a
suitable bearing puller.
Figure 28
1-704-878-5850 3-11
DANA
Disassembly
3.2 Disassembly of the POSI-TORQ with Springs (or without

Springs) Differential
The instructions contained herein cover the disassembly of the POSI-TORQ with Springs (or
without Springs) differential assembly in a sequence that would normally be followed after the unit
has been removed from the axle housing for a complete overhaul.
NOTE: Spring-loaded differentials are optional. The differential shown in this text is
spring-loaded. Disassembly and reassembly are identical except where springs are
shown.
Remove body bolts from flange half.
Figure 29
Remove flange half.
Figure 30

3-12 1-704-878-5850
©
DANA
Remove inner and outer clutch discs.
Figure 31
Remove side gear.
Figure 32
Remove thrust plate.
Figure 33
1-704-878-5850 3-13
DANA
Disassembly
Remove spring pack spacer.
Figure 34
Remove spring pack.
Figure 35
Remove differential pinions, washers, and cross

as an assembly.
Figure 36
NOTE: There are two rows of needle rollers under each pinion gear. Be careful to retain all
needle rollers for reassembly.

3-14 1-704-878-5850
©
DANA
Remove pinion gear thrust washer.
Figure 37
Remove pinion gear outer spacer.
Figure 38
Remove pinion gear from pinion gear spider.
Figure 39
NOTE: There are two rows of needle rollers under each pinion gear. Be careful to retain all
needle rollers for reassembly.
Remove pinion gear inner spacer.
Figure 40
1-704-878-5850 3-15
DANA
Disassembly
Remove flange half spring pack.
Figure 41
Remove spring pack spacer.
Figure 42
Remove thrust plate.
Figure 43
Remove side gear.
Figure 44

3-16 1-704-878-5850
©
DANA
Remove inner and outer clutch discs.
Figure 45
Figure 46

Figure 47
1-704-878-5850 3-17
DANA
Disassembly
3.3 Disassembly of the No Spin Differential

The instructions contained herein cover the disassembly of the No Spin differential assembly in a
Remove body bolts from flange half of case and

remove case half.
Figure 48
Remove No Spin spacer.
Figure 49
Remove axle gear.
Figure 50

3-18 1-704-878-5850
©
DANA
Remove spring.
Figure 51
Remove spring retainer.
Figure 52
Remove spider case half.
Figure 53
1-704-878-5850 3-19
DANA
Disassembly
Remove cross.
Figure 54
Remove spider case half.
Figure 55
Remove spring retainer.
Figure 56

3-20 1-704-878-5850
©
DANA
Remove spring.
Figure 57
Remove axle gear.
Figure 58
Remove No Spin spacer.
Figure 59
1-704-878-5850 3-21
DANA
Disassembly
Figure 60

Figure 61

3-22 1-704-878-5850
©
DANA
3.4 Disassembly of the Hydraloc Differential

The instructions contained herein cover the disassembly of the Hydraloc differential assembly in a
WARNING
CAUTION
NOTE: Perform the first three disassembly steps of the Standard Differential, then
continue with the following Hydraloc disassembly procedure.
Remove adjusting nut lock capscrews and

washers on both sides.
Figure 62
1-704-878-5850 3-23
DANA
Disassembly
Remove pressure port.
Figure 63
Remove three seal retainer screws and using a flat

tip screwdriver to gently pry off seal retainer.
Figure 64
Remove carrier cap capscrews and washers on

both sides.
Figure 65

3-24 1-704-878-5850
©
DANA
Remove carrier caps.
Figure 66
Remove adjusting nuts, taper bearing cups and

differential assembly from carrier.
Figure 67
NOTE: Refer to the Standard Differential disassembly procedure for disassembly of the
pinion. Continue with the following procedure for disassembly of the Hydraloc
plain and flange case halves.
Mark plain, flange half, and clutch housing case to

ensure correct reassembly.
Figure 68
1-704-878-5850 3-25
DANA
Disassembly
Remove plain half case bolts and plain half case.
Figure 69
Remove thrust washer.
Figure 70
Remove side gear.
Figure 71
Remove differential pinions, washers, needle

rollers, spider gears, and cross as an assembly.
Figure 72

3-26 1-704-878-5850
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DANA
NOTE: Disassemble cross assembly as instructed for the Posi-Torq differential.
Remove side gear.
Figure 73
Remove side gear thrust washer.
Figure 74
Remove ring gear.
Figure 75
1-704-878-5850 3-27
DANA
Disassembly
Remove two capscrews that will allow separation

of the differential case (flange half) from the
clutch housing.
Figure 76
Lift clutch housing using threaded lifting eyes.
Figure 77
Position differential flange half on bench as

shown. Use compressed air to push piston out of
bore.
Figure 78
Remove piston.
Figure 79

3-28 1-704-878-5850
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DANA
Remove outer piston seal and backup ring.
Figure 80
Remove inner piston seal and backup ring.
Figure 81
Remove reaction and friction plates. .
Figure 82
NOTE: Remove ring gear as instructed in the disassembly of the Standard Differential.
Remove plug and seal rings.
Figure 83
1-704-878-5850 3-29
DANA
Disassembly
3.5 Cleaning and Inspection

Cleaning
Clean all parts thoroughly using solvent-type cleaning fluid. It is recommended that parts be
immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign
material is dissolved and parts are thoroughly cleaned.
WARNING
Care should be exercised to avoid skin rashes, fire hazards, and inhalation of
vapors when using solvent-type cleaners.
Bearings
Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to
dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles.
Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free
compressed air. Be careful to direct air stream across bearing to avoid spinning. Do not spin
bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process.
Housings
Clean interior and exterior of housings, bearing caps, etc., thoroughly. Cast parts may be cleaned in
hot solution tanks with mild alkali solutions providing these parts do not have ground or polished
surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. This
will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in solution tanks
must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be
cleaned with a steam cleaner.
WARNING
Care should be exercised to avoid skin rashes and inhalation of vapors when
using alkali cleaners.
Thoroughly dry all parts cleaned immediately by using moisture-free compressed air or soft,
lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated oil, or
laping compound.

3-30 1-704-878-5850
©
DANA
Inspection
The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement
of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a
later date.
Bearings
Carefully inspect all rollers, cages, and cups for wear, chipping, or nicks to determine fitness of
bearings for further use. Do not replace a bearing cone or cup individually without replacing the
mating cup or cone at the same time. After inspection, dip bearings in clean light oil and wrap in
clean lintless cloth or paper to protect them until installed.
Oil Seals, Gaskets, and Retaining Rings

Replacement of spring-loaded oil seals, gaskets, and snaprings is more economical when unit is
disassembled than to risk premature to replace these parts at a future time. Loss of lubricant
through a worn seal may result in failure of other more expensive parts of the assembly. Sealing
members should be handled carefully, particularly when being installed. Cutting, scratching, or
curling under lip of seal seriously impairs its efficiency. At reassembly, lubricate lips of oil seals
with E.P. Multi Purpose Grease, Grade # 2.
Gears and Shafts

If this magna-flux process is available, use this process to check parts. Examine teeth and ground
and polished surfaces on all gears and shafts carefully for wear, pitting, chipping, nicks, cracks, or
scores. If gear teeth are cracked or show spots where case hardening is worn through, replace with
new gear. Small nicks may be removed with suitable hone. Inspect shafts to make certain they are
not sprung or bent, or that the splines are twisted, and that the shafts are true. Differential pinions
and side gears must be replaced as sets. Differential ring gear and bevel pinion must also be
replaced as a set if either is damaged.
Housing and Covers

Inspect housing, covers, planet spider, and differential case to be certain they are thoroughly
cleaned and that mating surfaces, bearing bores, etc., are free from nicks or burrs. Check all parts
carefully for evidence of cracks or conditions which would cause subsequent oil leaks or failures.
1-704-878-5850 3-31
DANA
Assembly
Chapter 4
Assembly
Page
4.1 Assembly of the Standard Differential...................................................................... 4-3
Guidelines for Thread Locking Compound Application....................................... 4-3

Pinion Shaft and Bearing Cage Reassembly ....................................................... 4-4
4.2 Ring Gear to Pinion Mounting Distance Procedure.................................................. 4-9
Differential Pinions and Cross Reassembly ...................................................... 4-14

4.3 Assembly of the POSI-TORQ with Springs
4.4 Assembly of the No Spin Differential..................................................................... 4-25
4.5 Assembly of the Hydraloc Differential ................................................................... 4-30

4-1 1-704-878-5850
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DANA
NOTES
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1-704-878-5850 4-2
DANA
Assembly
4.1 Assembly of the Standard Differential

The instructions contained herein cover the assembly of the standard differential assembly in a
sequence that would normally be followed after the unit has been removed and completely
overhauled.
WARNING
CAUTION
NOTE: At reassembly, apply thread locking compound where noted.
Guidelines for Thread Locking Compound Application

1. On bolts, cap screws, and studs (anchor end), apply compound on female threaded component
part.
2. On nuts, apply compound to the male thread of the mating fastener.

3. Apply ample compound to coat the full length and circumference of thread engagement.
4. Remove excess compound from mating parts after fastener installation.
NOTE: All parts must be lubricated with DANA Off-Highway Products recommended axle
lubricant when reassembling. No part should be reassembled dry.

4-3 1-704-878-5850
©
DANA
Pinion Shaft and Bearing Cage Reassembly

Press inner pinion bearing on pinion shaft with
snapring and radius toward pinion.
Figure 1
Install inner bearing to pinion shaft retainer ring.
Figure 2
Press center taper bearing on shaft with large

diameter of taper toward pinion gear.
Figure 3
1-704-878-5850 4-4
DANA
Assembly
NOTE: A pinion bearing spacer and shim kit is provided for repair of carrier assemblies.
This kit consists of two spacers and a quantity of shims. If the pinion, pinion
bearings, or housing was not changed, use the original bearing spacer for
reassembly.
Install pinion bearing spacer.
Figure 4
Install inner and outer taper bearing cups in pinion

bearing cage.
Figure 5

4-5 1-704-878-5850
©
DANA
Position pinion bearing cage assembly on pinion

shaft. Position outer pinion bearing cone on
pinion shaft and press into place.
Figure 6
Keep pinion and cage assembly in press with

approximately 1500 lbs force (1105 N•m) of press
pressure exerted on driver. Wrap several turns of
soft wire or cord around pinion cage and pull in
horizontal line with spring scale. While pulling in
straight line (90 degrees from centerline of shaft),
read spring scale and measure rotating torque.
Figure 7
Multiply reading on spring scale by one-half diameter in inches, of bearing cage to obtain preload
torque. Correct preload torque of new bearings is 18 to 30 lbf•in.
(2 to 3.4 N•m) and correct preload torque of used bearings is 5 to 15 lbf•in. (0.6 to 1.7 N•m). If
preload is not within these limits, remove shims to increase preload or add shims to decrease
preload.
NOTE: This is a preliminary check. Final bearing preload check must be made with pinion
shaft and bearing cage assembly in differential carrier housing.
1-704-878-5850 4-6
DANA
Assembly
Install bearing cage and pinion shaft assembly in

differential carrier assembly without bearing cage
shims. Use eight pinion oil seal retainer bolts with
lock washers to pull pinion shaft assembly fully
into carrier assembly. Make sure oil passages are
aligned.
Figure 8
NOTE: Install three flat washers on each bolt to prevent them from bottoming.
Temporarily install companion flange on end of

pinion shaft without installing pinion oil seal
retainer. Install companion flange retaining tool
on companion flange and torque flange nut to 800
lbf•ft (1084.7 N•m).
Figure 9
Remove companion flange retaining tool and use

"inch-pound" torque wrench to check bearing
preload.
Figure 10
If bearing preload for new bearings is not between 18 and 30 lbf•in. (2 to 3.4 N•m) and if bearing
preload for used bearings is not between 5 and 15 lbf•in. (0.6 to 1.7 N•m), disassemble parts and
add shims to decrease preload or remove shims to increase preload.

4-7 1-704-878-5850
©
DANA
Use a file and emery cloth to remove all burrs and

nicks from machined bearing surfaces of carrier
housing.
Figure 11
Paint bearing surfaces with bearing contact

checking compound.
Figure 12
1-704-878-5850 4-8
DANA
Assembly
4.2 Ring Gear to Pinion Mounting Distance Procedure
NOTE: The following procedures are for all differentials.
A pinion setting gauge must be used to achieve a precise mounting distance between the ring gear,
differential carrier housing, and pinion.
The gauge should be used if either carrier housing and/or ring and pinion is changed.
The use of the gauge will determine the amount of shims to be used under the pinion bearing cage
to achieve an exact mounting distance between the ring gear and pinion.
By using the gauge and adding the proper thickness of shims, an optimum tooth contact is obtained.
The following procedure is used to achieve a proper ring gear-to-pinion mounting distance using a
pinion setting gauge.
Locating position of the pinion as described produces a proper tooth contact with the ring gear
when it and the differential assembly are assembled and adjusted to proper backlash setting.
Pinon setting gauge can be purchased from:

Service Tools
2013 Fourth Street, N.W., Owatonna, Minn. 55060.
Kit No. VME 10004-2.
The function of the pinion setting gauge is to

measure the distance from the centerline of the
differential bearing bores to the ground surface on
the gear end of the pinion. This measurement,
when subtracted from the value etched on the ring
gear, indicates the size of the shim pack required
to position the pinion gear in proper relation to the
ring gear.
Figure 13
On the outer diameter of the ring gear, a ring gear-to-pinion distance is etched. Add 0.4649 in.
(11.808 mm) to the etched distance. The 0.4649 in. (11.808 mm) measurement represents half the
thickness of the gauge bar. Record this value. This value may be different on each ring and pinion
set due to manufacturing variations.

4-9 1-704-878-5850
©
DANA
Insert extension depth micrometer (Starrett #44B-6RC) and extension (#99347) 7 in. (178 mm) or
equivalent into the guide bore of the micrometer arbor and slide clamps over base of micrometer.
With the thumb screws reacting on the base, secure the micrometer.
NOTE: The micrometer extension must pass freely through the micrometer bar guide bore
and base of the micrometer must rest on the micrometer arbor when mounted.
Mount adapter discs on micrometer arbor and set in position in carrier housing. Make sure that the
micrometer and the extension do not contact any part of the carrier in this operation. Apply
pressure by hand and rotate adapter discs slightly to obtain a contact with bearing surfaces.
Remove checking gauge assembly and check for full bearing contact on bearing surfaces.
If contact is full and proper, position the checking gauge assembly again in the carrier and check
the distance to the ground surface on the pinion.
NOTE: Do not apply pressure to arbor or micrometer.
Turn micrometer carefully and evenly until the flat tip of the micrometer extension contacts the
ground surface of the pinion squarely. Subtract this reading from the value previously recorded and
this equals the amount of shims to be added between the inner pinion bearing cup and the carrier
housing.
Example:
5.289 in. (134.341 mm) Value etched on ring gear.
+0.4649 in. (11.81 mm) Constant (1/2 in. thickness of gauge bar).
5.758 in. (146.253 mm) Total

-5.728 in. (145.491 mm) Initial micrometer reading.
0.030 in. (0.762 mm) Add value in shims under inner pinion bearing cup.
Mount adapter discs on micrometer arbor and set

in position in carrier housing as shown.
Figure 14
NOTE: Exercise care to be sure that micrometer and extension do not contact any part of
the carrier in this operation.
1-704-878-5850 4-10
DANA
Assembly
NOTE: Apply pressure by hand and rotate adapter discs slightly to obtain a contact with
bearing surfaces.
Remove checking gauge assembly and check for

full bearing contact on bearing surfaces.
Figure 15
If contact is full and proper, position the checking

gauge assembly again in the carrier and check the
distance to the ground surface on the pinion.
Figure 16
Remove bolts holding pinion bearing cage and pinion in differential carrier and remove bearing
cage and pinion assembly. Install required shim pack and reinstall cage and pinion assembly in
carrier. Tighten cage screws 125 to 140 lbf•ft torque (170 to 190 N•m) temporarily.
After adding required amount of shims, mount checking gauge assembly again and take a check
reading. The reading should now be 5.758 in., plus or minus 0.002 in. In other words, the reading
should be equal to the value etched on the ring gear, within 0.002 in.

4-11 1-704-878-5850
©
DANA
Remove bolts holding pinion cage in housing.

Remove pinion and cage assembly. Apply Loctite
#515 to shim and joining surfaces. Reinstall
pinion and cage assembly being sure all oil
passages are aligned. Apply a light coat of Loctite
#515 to the outer diameter of the pinion shaft oil
seal. Press seal in retainer with lip of seal toward
pinion bearing. Coat outer bearing cage surface
with Loctite #515 and install oil seal retainer.
Figure 17
NOTE: If applicable, grease the seal at every normal service interval and more often when
used in submerged or severe conditions.
Apply Loctite #262 thread locking compound to

threaded holes and install retainer bolts and
washers. Tighten bolts 125 to 140 lbf•ft torque
(170 to 190 N•m).
Figure 18
Apply Dow-Corning RTV-Q3-7069 Sealant to

pinion spline locations shown on assembly
instruction sheet (Figure B). Install flange,
washer, and nut. Tighten nut to 800 lbf•ft torque
(1085 N•m) minimum.
Figure 19
1-704-878-5850 4-12
DANA
Assembly
Check ring gear mounting surface of flanged half

of differential case for burrs. Make certain this
surface is smooth and clean. lnstall ring gear.
lnstall bolts so internal diameter of ring gear
prevents turning of hex head.
Figure 20
NOTE: Heat ring gear prior to installation to facilitate assembly.
Install ring gear bolt nuts and tighten 300 to 330 lbf•ft torque (406.8 to 447.4 N•m) for non-splined
ring gear to non-splined half case. Tighten 125 to 140 lbf•ft (170 to 190 N•m) for splined ring gear
to splined half case.
NOTE: Ring gear should be timed to case with single X mark on case aligning with double
XX mark on ring gear.
Install thrust washer.
Figure 21
Check depth and condition of four dowel pins.

Install side gear.
Figure 22

4-13 1-704-878-5850
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DANA
Differential Pinions and Cross Reassembly
NOTE: All parts must be lubricated with DANA Off-Highway Products recommended axle
lubricant when reassembling. No part should be reassembled dry.
Install pinion gear and pinion thrust washer on

each end of the spider.
Figure 23
Place spider assembly on side gear.
Figure 24
Position side gear on spider assembly.
Figure 25
1-704-878-5850 4-14
DANA
Assembly
WARNING
Maintain secure control of differential at all times. Serious injury may occur from pinch points
and unstable parts.
Install thrust washer with grease in case half over

dowel pins.
Figure 26
Apply Loctite #262 to threaded holes in case

halves. Align match mark on plain half case with
mark on flanged half case.
Figure 27
WARNING
Maintain secure control of differential at all times. Serious injury may occur from pinch points
and unstable parts.
Install case half bolts and tighten 360 to 400 lbf•ft

torque (488.1 to 542.3 N•m).
Figure 28

4-15 1-704-878-5850
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4.3 Assembly of the POSI-TORQ with Springs (or without

Springs) Differential
Figure 29
NOTE: Coat all clutch plates and side gear surfaces with Dow-Corning Molykote G-N
Paste.
lnstall one outer clutch plate (teeth on the outer

diameter). lnstall one inner clutch plate (teeth on
the inner diameter). Alternate inner and outer
clutch plates until four outer and three inner plates
are installed. Start with an outer plate and end
with an outer plate.
Figure 30
NOTE: The inner disc lubrication slots must be aligned.
Install side gear, aligning outer splines with clutch

plate splines.
Figure 31
1-704-878-5850 4-16
DANA
Assembly
NOTE: A check must be made to determine the distance between the side gear and the flat
surface of the half case. This distance is the "A" dimension shown in following
figure. A 1000 pound force (4448 N•m) must be applied to the side gear to flatten
the clutch plates. A press is one method that can be used. Also (as shown in the
following figure), a 1/2-in. (12.7 mm) bolt and 1/2-in. (12.7 mm) thick washer top
and bottom may be used. Install as shown and tighten nut 30 to 50 lbf•ft torque
(40.7 to 67.7 N•m). This is equivalent to 1000 lbs. (4448 N•m) force. A flat bar is
used to support the depth micrometer. Measure the distance as shown and subtract
the thickness of the support bar to get dimension "A." If dimension "A" is between
1.4510 and 1.4605 in. (36.9 to 37.1 mm), use a 0.065 in. (1.65 mm) thickness spring
pack spacer. If dimension "A" is between 1.4606 to 1.4710 in. (37.1 to 37.4 mm), use
a 0.0750 in.(1.91 mm) thickness spring pack spacer. This procedure is used on both
flanged and plain half cases. Keep selected spring pack spacers with its respective
half case for reassembly.
Figure 32

4-17 1-704-878-5850
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Install thrust plate.
Figure 33
Install spring pack spacer.
Figure 34
After the proper spring pack spacer is determined,

build up the plain half case parts on the flanged
half case.
Figure 35
1-704-878-5850 4-18
DANA
Assembly
Install flange half spring pack. Springs are stacked

one on top of each other, arched toward the spider.
Figure 36
Place components in order shown.
Figure 37

4-19 1-704-878-5850
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Position inner needle roller bearing spacer on

differential spider with radius toward spider
shoulder.
Figure 38
NOTE: Be careful to retain all needle rollers.
Using a rubber band to facilitate reassembly,

install one row of needle roller bearings.
Figure 39
Install center roller bearing spacer. This spacer is

a loose fit with the spider leg.
Figure 40
1-704-878-5850 4-20
DANA
Assembly
Using another rubber band, install outer row of

needle spider roller bearings as shown.
Figure 41
Position pinion gear on needles as shown.

Remove first rubber band. Slide pinion gear over
second row of needles. Remove second rubber
band.
Figure 42
Install outer roller bearing spacer and pinion

thrust washer. Use a rubber band on each end of
the spider, after pinion installation, to keep pinion
gear in place until assembly is installed into flange
half case. This spacer is a close fit with the spider
leg.
Figure 43

4-21 1-704-878-5850
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DANA
Install pinion gear thrust washer.
Figure 44
Remove rubber bands holding pinion gears into

position on differential spider. Place spider
assembly on side gear.
Figure 45
Install spring pack with all springs stacked one on

top of each other, arched toward the spider.
Figure 46
1-704-878-5850 4-22
DANA
Assembly
Install spring pack spacer on spring pack.
Figure 47
Position spring pack thrust plate.
Figure 48
Position side gear on thrust plate.
Figure 49
NOTE: Coat all clutch plates and side gear surfaces with Dow-Corning Molykote G-N
Paste.

4-23 1-704-878-5850
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Install one outer disc and one inner disc on the

side gear. Alternate discs until a quantity of four
outer discs and three inner discs are installed. Start
with an outer disc and end with an outer disc.
Align outer clutch disc teeth to facilitate assembly
into plain half case.
Figure 50
NOTE: The inner disc lubrication slots must be aligned.
NOTE: Apply Loctite #262 to threaded holes in case halves.
Align match mark on plain half case with mark on

flanged half case. Install plain half case over
clutch plates and side gear.
Figure 51
WARNING
torque (488.1 to 542.3 N•m).
Figure 52
1-704-878-5850 4-24
DANA
Assembly
4.4 Assembly of the No Spin Differential

The instructions contained herein cover the assembly of the No Spin differential assembly in a
sequence that would normally be followed after the unit has been disassembled and completely
overhauled.

Figure 53
Install No Spin spacer.
Figure 54
Install axle gear.
Figure 55
Install spring.
Figure 56

4-25 1-704-878-5850
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DANA
NOTE: Before installing spring retainer, be sure to first align splines of spider case half and
spring retainer.
Figure 57
Install aligned spring retainer and spider case half as

one unit (only spring retainer shown here).
Figure 58
Install spider case half.
Figure 59
1-704-878-5850 4-26
DANA
Assembly
Install cross.
Figure 60
NOTE: Spider case halves only fit together one way. Exercise care to align keys/keyways of
each half before fitting halves together.
.
Figure 61
Install spider case half.
Figure 62

4-27 1-704-878-5850
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DANA
NOTE: Before installing spring retainer, be sure to first align splines of spider case half and
spring retainer.
Figure 63
Install aligned spring retainer and spider case half as

one unit (only spring retainer shown here).
Figure 64
Install spring.
Figure 65
1-704-878-5850 4-28
DANA
Assembly
Install axle gear.
Figure 66
Install No Spin spacer.
Figure 67
WARNING

torque (488.1 to 542.3 N•m).
Figure 68

4-29 1-704-878-5850
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DANA
4.5 Assembly of the Hydraloc Differential

The instructions contained herein cover the disassembly of the Hydraloc differential assembly in a
WARNING
CAUTION
CAUTION
Gears with different plant identity codes are not interchangeable and are not to be
intermixed at assembly.
Install plug and seal rings.
NOTE:Clean threads of plug with alcohol and

use Loctite® 620 for sealant on plug and hole.
Figure 69
Install inner and outer clutch discs. Installing a

reaction disc first, then alternating with the
friction discs.,
Figure 70
1-704-878-5850 4-30
DANA
Assembly
Install inner piston seal and backup ring. .
Figure 71
Install outer piston seal and backup ring.
Figure 72
Install piston.
Figure 73
Lower the differential case (flange half) onto

clutch housing and install two capscrews.
Figure 74

4-31 1-704-878-5850
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DANA

Figure 75
Install ring gear bolt nuts and tighten 350 to 388 lbf•ft torque (474.5 to 526 N•m)
CAUTION
Align both friction and reaction plate lube grooves with each other.
NOTE: Apply MS330 oil to both sides of clutch plates, back face of side gears and pinions.
Install side gear thrust washer.
Figure 76
Install side gear.
Figure 77
1-704-878-5850 4-32
DANA
Assembly
Install differential pinions, washers, and cross as

an assembly.
Figure 78
Install side gear.
Figure 79
Install thrust washer
Figure 80

4-33 1-704-878-5850
©
DANA

torque (484 to 524.7 N•m).
Figure 81
Install differential into carrier, and position

differential bearing cup and adjusting nut on one
side of differential and lift slightly with hoist.
Position bearing cup and adjusting nut on carrier.
Repeat procedure and install opposite bearing cup
and adjusting nut. Turn adjusting nuts by hand to
be sure of proper thread alignment. .
Figure 82
Install differential adjusting nuts.
Figure 83
NOTE: Refer to the Standard Differential assembly located in the Ring Gear to Pinion
Mounting Distance Procedure, for the proper adjusting nut and cap block
installation procedure.
1-704-878-5850 4-34
DANA
Assembly
Place retainer carefully over the rotary seal rings

and install three seal retainer capscrews using
thread locking compound.
Figure 84
Inspect and replace worn or damaged O-ring and

fitting. Install pressure port and tighten 75 to 85
lbf•ft (101 to 115 N•m).
Figure 85
Install carrier caps, washers, and capscrews.

Torque capscrews 475 to 525 lbf•ft torque (645 to
710 N•m).
Figure 86
Apply thread locking compound to adjusting nut

lock capscrews and washers on both sides. Torque
capscrews 72 to 80 lbf•ft torque (97 to 108 N•m).
Figure 87
NOTE: Refer to figures 92 and 93 for setting backlash and preload. The
following steps are for all differentials.

4-35 1-704-878-5850
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Position differential assembly into carrier.
Figure 88
Position differential bearing cup and adjusting nut

on one side of differential and lift slightly with
hoist. Position bearing cup and adjusting nut on
carrier. Repeat procedure and install opposite
bearing cup and adjusting nut. Turn adjusting nuts
by hand to be sure of proper thread alignment.
Figure 89
NOTE: Coat internal threads in housing with Loctite Sealer #262.
Position bearing caps on bearings and adjusting

nuts, making sure match marks made during
disassembly are properly aligned. Install cap bolts
and tighten lightly.
Figure 90
Tighten bearing adjusting nuts to adjust bearings

to zero endplay.
Figure 91
1-704-878-5850 4-36
DANA
Assembly
Use a dial indicator as shown. Move ring gear by

loosening one adjusting nut and tightening
opposite adjusting nut. Adjust position until gear
backlash is to backlash specifications (see Figure
B on page 2-7 for new gear setting), or adjust to
backlash noted at disassembly for used gears.
Figure 92
When proper backlash is achieved, tighten opposite adjusting nut to set preload on taper bearings.
Using only thumb and forefinger, move ring gear. When ring gear becomes difficult to move,
preload on bearing is set.
Tighten differential cap bolts 475 to 525 lbf•ft

torque (645 to 712 N•m). Recheck ring and pinion
backlash and bearing preload to be sure backlash
is within specifications.
Figure 93
Tighten adjusting nut lock capscrew and washer

72 to 80 lbf•ft torque (97 to 108 N•m) on both
sides.
Figure 94

4-37 1-704-878-5850

Dana 53R, 2050 Axle Disassemly Service Manual - 044718

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© 2050 Series

Service Manual #0097 Revision A 5.09

Dana Off-Highway Products, LLC

DANA Off-Highway Products, LLC www.DANA.com/OFFHIGHWAY

1.1 Customer Support ...................................................................................................... 1-2

1.2 Introduction................................................................................................................ 1-3

1.3 Application Policy ..................................................................................................... 1-3

1.4 POSI-TORQ Differential Description ....................................................................... 1-4

Initial Fill.............................................................................................................. 2-3

Service Fill............................................................................................................ 2-3

2.2 Cleaning and Inspection ............................................................................................ 2-8

Cleaning ............................................................................................................... 2-8

Bearings ............................................................................................................ 2-8

Housings ........................................................................................................... 2-8

Bearings ............................................................................................................ 2-9

Oil Seals, Gaskets, and Retaining Rings ........................................................... 2-9

Gears and Shafts ............................................................................................... 2-9

Housing and Covers .......................................................................................... 2-9

2.3 Differential Reassembly .......................................................................................... 2-10

3.2 Disassembly of the POSI-TORQ with Springs

3.3 Disassembly of the No Spin Differential ................................................................ 3-18

3.4 Disassembly of the Hydraloc Differential .............................................................. 3-23

3.5 Cleaning and Inspection.......................................................................................... 3-30

Bearings .............................................................................................................. 3-30

Housings ............................................................................................................. 3-30

Bearings .............................................................................................................. 3-31

Oil Seals, Gaskets, and Retaining Rings............................................................. 3-31

Gears and Shafts ................................................................................................. 3-31

Housing and Covers............................................................................................ 3-31

Guidelines for Thread Locking Compound Application....................................... 4-3

Differential Pinions and Cross Reassembly ...................................................... 4-14

4.4 Assembly of the No Spin Differential..................................................................... 4-25

4.5 Assembly of the Hydraloc Differential ................................................................... 4-30

DANA Off-Highway Products, LLC www.DANA.com/OFFHIGHWAY

1.2 Introduction................................................................................................................ 1-3

1.3 Application Policy ..................................................................................................... 1-3

1.4 POSI-TORQ Differential Description ....................................................................... 1-4

1.1 Customer Support

Asia Pacific (China): 86 2 153 831100

Asia Pacific (Korea): 82 2 563 9451

Europe (Italy): 39 0464 580227

North America (USA): 803-438-0705 Ext. 7789

South America (Brazil): 55 15 3238 6092

DANA OFF-HIGHWAY PRODUCTS DIVISION

DANA Off-Highway Products, LLC www.DANA.com/OFFHIGHWAY

Whenever repair or replacement of component parts is required, only DANA Off-Highway-

This manual is divided into four chapters:

1.3 Application Policy

1.4 POSI-TORQ Differential Description

•Increases traction in adverse driving conditions over a standard differential.

•Reduces tire wear.

•Eliminates shock loadings caused by locking differentials.

•Improves steering over a locking differential.

•Available on many DANA Off-Highway Products axle models.

DANA Off-Highway Products, LLC www.DANA.com/OFFHIGHWAY

Initial Fill.............................................................................................................. 2-3

Service Fill............................................................................................................ 2-3

2.2 Cleaning and Inspection ............................................................................................ 2-8

Cleaning ............................................................................................................... 2-8

Bearings ............................................................................................................ 2-8

Housings ........................................................................................................... 2-8

Bearings ............................................................................................................ 2-9

Oil Seals, Gaskets, and Retaining Rings ........................................................... 2-9