Dana® Spicer ®Axles

In Axle Speed Sensor

Service Manual AXSM-0034 December 2003

For the most current information, visit the Roadranger web site at www.roadranger.com
 General Information

General Information
The description and specifications contained in this service
publication are current at the time of printing. Dana Corpora-
tion reserves the right to discontinue or to modify its models
and/or procedures and to change specifications at any time
without notice.
Any reference to brand names in this publication is made sim-
ply as an example of the types of tools and materials recom-
mended for use and should not be considered an
endorsement. Equivalents, if available, may be used.

Important Notice

This symbol is used throughout this WARNING: Failure to follow indicated

manual to call attention to procedures procedures creates a high risk of personal
where carelessness or failure to follow injury to the servicing technician.
specific instructions may result in personal
injury and/or component damage.
CAUTION: Failure to follow indicated procedures
may cause component damage or malfunction.
Departure from the instructions, choice of
tools, materials and recommended parts
IMPORTANT: Highly recommended procedures
mentioned in this publication may
for proper service of this unit.
jeopardize the personal safety of the
service technician or vehicle operator.
NOTE: Additional service information not covered
in the service procedures.

TIP: Helpful removal and installation procedures

to aid in the service of this unit.

Always use genuine Dana replacement parts.

 Table of Contents

Introduction Drive Axle Sensor Assembly ......................................17

Purpose of Manual ...................................................... 1
Sensor Types .............................................................. 1
Basis: Dana Model 402 Drive Axle ............................... 1
Scope of Manual ......................................................... 1
Sensor Service Requirements ....................................17
Axle Shaft Configuration .............................................18
Identifying Installed Sensors ......................................18
Vehicle Preparation.................................................... 18
Carrier Head Removal.................................................18

Drive Axle Sensor Service

Sensor Operation
Sensor Operation ........................................................ 2
Mechanical Configuration............................................. 2
Electrical ...................................................................... 2
Steer/Trailer Axle Sensor System................................ 3
Speed Sensor Operating Principle............................... 4
Output Voltage vs. Wheel Speed .................................. 4
Axle Configuration
Servicing the Differential............................................ 19
Drive Sensor Disassembly .........................................19
Connector Service ..................................................... 19
Drive Axle Sensor Replacement .................................21
Drive Axle Sensor Installation .................................... 21
Checking Sensor Continuity .......................................21
Carrier Head Installation .............................................22
Checking Sensor Continuity .......................................22
Terminal Assembly ....................................................23
Packard Metri-Pack Connectors ................................23
Terminal Seating and Removal ..................................24

Steer Axle Features ..................................................... 6

Trailer Axle Features.................................................... 6
Drive Axle Features ...................................................... 7
Connector Service
Axle Models ................................................................ 8
Replacing Terminals ...................................................25
Splicing Wire .............................................................26
Diagnostics Steer Axle Sensor ...................................................... 27

Diagnostics .................................................................. 9
Drive Axle Troubleshooting ....................................... 11
Troubleshooting ........................................................ 13
Steer/Trailer Troubleshooting .................................... 13

Steer/Trailer Axle Sensor Service

Sensor Service Requirements ................................... 14
Identifying Installed Sensors ..................................... 14
Vehicle Preparation ................................................... 14
Steer and Trailer Axle Service ................................... 14
Preparation ................................................................ 15
Steer Sensor Disassembly ........................................ 15
Feed through Cable Removal .................................... 15
Pro-Torq Spindle Nut Service.................................... 15
Removing Pro-Torq Spindle Nut ............................... 15
Installing Pro-Torq Spindle Nut ................................. 15
Feed Through Cable Replacement ............................. 16
Sensor Installation .................................................... 16
Hub Cap Installation .................................................. 16
 Introduction

Purpose of Manual
Dana speed sensors are used in truck anti-lock brake systems
(ABS) to monitor and report individual wheel speeds to the
ABS electronic controller. This manual describes the operation
of Dana in-axle speed sensors and provides information for
diagnostics and service of these components.
Dana in-axle sensors are multi-point, variable reluctance
devices. They provide individual wheel speed data at a rate of
100 pulses per wheel revolution. The multi-point principle
permits generation of high quality output signals which are
less dependent on mechanical configuration than are single
point sensors.
Sensor Types
There are two types of Dana in-axle speed sensors: an internal
rotor style for drive axles, and an external rotor style for use in
steer and trailer axle applications.
Scope of Manual
Since Dana in-axle speed sensors are used with various man-
ufacturers’ ABS installations, references are somewhat gen-
eral in terms of ABS operation.
Here are other details of the scope of this manual:
Sensor and Associated Wiring Only. ABS components other
than the sensor and associated wiring are outside the scope
of this manual. Diagnostic and service information covering
the electronic control unit and modulating valves are covered
separately in documentation supporting the full ABS installa-
tion.
Applications. Dana speed sensors are suitable for use in all
truck ABS systems with class 6, 7, and 8 air brakes.
Restricted Applications. Dana speed sensors are not
designed for use in the following applications:

Basis: Dana Model 402 Drive Axle • Two speed drive axles

Drive axle illustrations and certain details of axle assembly are • Axles with differential lock or CTD

Introduction
based upon drive axle sensors installed in Dana Model DS/RS • Tire Pressure Control Systems Steer Axles
402 Tandem Drive Axle. Sensors that are installed in drive
axles other than the Dana 402 may involve different service
procedures. One significant area of difference could be in the
axle shafts – particularly shaft length and spline configuration.
Since axle shaft placement is an important factor in proper
speed sensor operation, make sure you are alert to possible
differences when servicing vehicles equipped with drive axles
other than the Dana 402.

1
 Sensor Operation

Sensor Operation
In-axle speed sensors are designed for extended, trouble-free Electrical
operation. During the anticipated axle service life, no adjust-
ment or maintenance is required. Sensors operate in an oil
Speed sensors are variable reluctance devices that convert
bath or oil splash environment and are compatible with all
axle rotation to an AC signal. See Figure 3. The multi-point
lubricants meeting MIL L-2015C/D.
principle permits generation of a high quality output signal
which is less dependent on the mechanical configuration than
Mechanical Configuration are single point sensors.

The sensor operates like a small electric generator. The stator

Figures 1 and 2 show the components of the drive and steer/
teeth and rotor teeth interact to produce magnetic flux varia-
trailer sensor assemblies. Each of the components shown
tion within the pick up coil. This flux variation induces an AC
may be obtained as a separate service item. The drive sensor
voltage in the coil. The voltage varies with wheel speed and
is common to all drive axles but a variety of rotors, axle
will be within the range shown in Output Voltage vs. Wheel
shafts, and bearing adjusters are available depending on the
Speed on page 4.
application. Similarly, there is a single steer/trailer sensor but
a variety of hub caps and spindles.

Drive Axle Sensor System

2
3

1. Axle Shaft 4. Plated Connector

2. Speed Senor with Rotor 5. ABS Harness Connector
3. Differential Bearing Adjuster

2
 Sensor Operation

Steer/Trailer Axle Sensor System

2 3 4 5

Sensor Operation
7 6

1. Hub Cap Assembly 5. Connector Shell-Shroud

2. Jam Nut 6. ABS Harness
3. Feed Through Cable 7. Pro-Torq Spindle Nut
4. Connector Shell -Tower 8. Speed Sensor

3
 Sensor Operation

Speed Sensor Operating Principle

Steer Axle Working Air Gap

Sensor 0.006 Pilot Plate 0.006
Rotor

Stator
w/teeth
0.012 Magnet Coil 0.012

Bronze
Drive Axle Working Thrust
Washer Stator
Sensor Air Gap

0.010 0.010

Rotor Coil Magnet

Output Voltage vs. Wheel Speed

20.00

Upper Limit

15.00

Mean
RMS
Output 10.00
Voltage

Lower Limit
5.00

0.00
0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00

Miles per hour

4
 Sensor Operation

No Polarity Connectors
The sensor output signal is non-polar. In attaching sensor The figure below shows the different connectors used with
wires, either wire may be connected to either terminal. Dana speed sensors. See Section 7 Connector Service for
more information on splicing and terminal crimping.
Electrical Interface
The quality of the sensor signal depends both on the mechan-
ical installation as well as the quality of the wire connections.
In all servicing, pay close attention to the quality and integrity
of the wires, connectors, splices, and terminal crimps. Check
wires and terminals for breaks, corrosion, or indications of
wear. Observe wire routing to make sure there are no sharp
bends or places where mechanical connections are pinching a
wire.

Connectors

4 To ABS
Harness

Drive Sensor
3 To ABS
Connectors Harness
2

Sensor Operation
5
1

To
Sensor
7
Steer/Trailer
To
Sensor Connectors
Sensor 8

10
1. Ring Terminals 6. Connector Shell-Shroud
2. 1-1/8" Hex Bulkhead Connector 7. Connector Shell-Tower
3. Terminals 8. Terminals
4. Connector Shell 9. Feed Through Cable
5. Terminals 10. Ring Terminals

5
 Axle Configuations

Steer Axle Features

There are four differences on steer axles that carry speed sen-
sors:
Drilled Center Axis
The center axis of each steer axle spindle carries the feed
through cable that connects the speed sensor to the ABS wir-
ing harness.
Pro-Torq Spindle Nut
The Pro-Torq spindle nut controls bearing endplay and
replaces the cotter key on the steer axle end. The Pro-Torq nut
includes a matching keeper ring. The nut does not require the
use of a washer. See Steer Axle Service for installation proce-
dures and other important information on the Pro-Torq spin-
dle nut.
Pro-Torq Spindle Nut
Trailer Axle Features
Trailer axle and steer axle sensor units are identical, and trailer
axles have the same features as the steer axle features. Other
trailer axle differences include:
Wheel End Plug
Trailer axles carry an adaptive plug that inserts into the spin-
dle.
Cable Length and Fitting
Depending upon the application, the feed through cable may
emerge from the trailer axle in different locations and require
a longer cable length and a fitting to secure the cable at the
outlet.

Hub Cap
A unique hub cap incorporates the 100 tooth outer ring for
matching with the inner disk on the sensor. The hub cap
includes a removable fill plug and markings to show lubricant
level.
Oil Level
The steer sensor displaces normal oil volume. Additional time
may be needed for oil to reach the required level on the initial
fill.

6
 Axle Configurations

Drive Axle Features

Truck axles that carry Dana speed sensors have a number of
features that differ from conventional axles.
Speed sensor equipped drive axles have four unique features:
Axle Shafts
For drive axle shaft configurations see:
• Illustration for Dana Model DA/RA402
• Illustration for Dana Model 23105A
• Illustration for Dana Model DA/RA404
To ensure proper sensor operation following axle assembly,
make sure axle shafts are installed according to specifica-
tions.
Differential Bearing Adjusters
The differential bearing adjusters have different inside diame-
ters to accommodate the speed sensors. The locks are
shorter to clear the sensors. The bearing adjuster outside
diameters are the same as conventional adjusters.
Carrier Castings
Carrier castings are modified to allow installation of sensors;
the plain half of the carrier has a wire channel or trough to
accommodate wire routing between the sensor and the plated
connector. Also, there is a relief cut out in the axle housing to
allow space for the raised terminals on the speed sensor.
Sensor Splines
The internal sensor splines will differ with various Dana axle
models. Refer to the Illustrated Parts List BRIP-0100 for
information on various models.

Axle Configurations
6"
4"
Front

Long Arm Side of Housing D-Head Short Arm Side of Housing

¥ Long Arm Side of Housing • Short Arm Side of Housing
Plain Half
¥ Plain HalfofofCarrier
Carrier Flanged Half
¥ Flanged Half ofofCarrier
Carrier
¥ Equal Shaft
Equal ShaftLength
Length ¥ Equal ShaftLength
Equal Shaft Length
41 Splines,
¥ 41 11"Long
Splines, 11" Long ¥ 4141Splines,
Splines, 11" Long
11"Long
¥ 6"6" Connector Wires
Connector Wires ¥ 4"4"Connector Wires
Connector Wires

Short Arm Side of Housing R-Head Long Arm Side of Housing

¥ Short Arm Side of Housing ¥ Long Arm Side of Housing
Flanged Half
¥ Flanged HalfofofCarrier
Carrier Plain Half of Carrier
¥ Plain Half of Carrier
¥ Equal ShaftLength
Equal Shaft Length Equal Shaft
¥ Equal Shaft Length
Length
¥ 4141Splines,
Splines, 11" Long
4" Long ¥ 4141Splines, 4" Long
Splines, 11" Long
4" Connector Wires 6" Connector Wires

Model DA/RA402

7
 Axle Configurations

Axle Models

6"
4"
Front

Short Arm Side of Housing Long Arm Side of Housing

¥ Short Arm Side of Housing ¥ Long Arm Side of Housing
Flanged Half
¥ Flanged HalfofofCarrier
Carrier PlainHalf
¥ Plain Half of
ofCarrier
Carrier
Longer Shaft
¥ Longer Length
Shaft Length Shorter Shaft
¥ Shorter Shaft Length
Length
¥ 3636Splines, 10.236"
Splines, 10.236" Long
Long ¥ 3636Splines,
Splines, 10.236" Long
10.236"Long
¥ 4"4"Connector Wires
Connector Wires ¥ 6"6"Connector Wires
Connector Wires

Model 23105A

4" 4"

Front

Long Arm Side of Housing D-Head Short Arm Side of Housing

¥ Long Arm Side of Housing ¥ Short Arm Side of Housing
Plain Half
¥ Plain HalfofofCarrier
Carrier Flanged Half
¥ Flanged HalfofofCarrier
Carrier
Longer Shaft
¥ Longer ShaftLength
Length ¥ Shorter
Shorter Shaft Length
ShaftLength
41 Splines,
¥ 41 11"Long
Splines, 11" Long ¥ 4141Splines,
Splines, 11" Long
11"Long
¥ 4"4" Connector Wires
Connector Wires ¥ 4"4"Connector Wires
Connector Wires

Short Arm Side of Housing R-Head Long Arm Side of Housing

¥ Short Arm Side of Housing
Flanged Half of Carrier
¥ Long Arm Side of Housing
Plain Half of Carrier
¥ Flanged Half of Carrier ¥ Plain Half of Carrier
Shorter Shaft
¥ Shorter ShaftLength
Length Longer Shaft
¥ Longer ShaftLength
Length
¥ 41 Splines,11"
41 Splines, 4"Long
Long ¥ 41 Splines,11"4"Long
41 Splines, Long
4" Connector Wires 4" Connector Wires

Model DA/RA404

8
 Diagnostics

Diagnostics
While the approach will vary by system and by service tool, Loss of Signal/ Noisy Signal Faults
In the absence of visible damage to a sensor, connector or
system operating faults are normally diagnosed through the
wire, likely causes of a loss of signal could be:
ABS controller. In case of a sensor problem, the controller will
identify both the sensor location one of three possible prob- • Incorrect or improperly installed drive axle shaft
lems: • Damaged or improperly installed steer axle hub cap
• Continuity faults
If circuit troubleshooting is necessary, consider the following
• Loss of signal causes:
• Noisy signal • Shorted sensor terminals
Continuity Faults • Broken or faulty connector
To troubleshoot a continuity fault, consider the following
• Shorted wires
causes:
• Shorted or broken ECU connection
• Corroded or bent connector terminals
• Shorted sensor coil
• Broken or pinched wire in between the sensor and
the Electronic Control Unit
See Sensor Signal Faults illustration. For additional guidelines
• Loose sensor terminal screws see Drive Axle Troubleshooting and Steer/ Trailer Trouble-
shooting.
• Sensor terminals shorted to the ground
• Open or broken sensor coil

See Possible Continuity Faults in this publication. For addi-

Diagnostics
tional guidelines see Drive Axle Troubleshooting and Steer/
Trailer Troubleshooting.

9
 Diagnostics

Input
Failure
Broken or
Pinched Wire
Open
Sensor
Coil

Terminals
Broken Loose Shorted to
Connection Corroded or Bent Ground
Terminals Screws

ECU and ABS Harness Connector Sensor

Possible Continuity Faults

Input
Failure
Wires Shorted
Together
Shorted
Sensor

Shorted Terminals
Connection Touching
Faulty
Connector

ECU and ABS Harness Connector Sensor

Possible Sensor Signal Faults

10
 Diagnostics

Drive Axle Troubleshooting Continuity Failure

Below is a drive axle sensor troubleshooting flow chart. Here
are some additional tips:
A continuity failure can be caused by a connector failure, or by
a broken or pinched wire. The problem may be in the wiring
harness or within the axle. It is also possible, but very
unlikely, that the cause of the continuity fault is an open sen-
sor coil or a faulty Electronic Control Unit.

ABS System
identifier symbol
problem and location.

Which type?

Which type? No signal

output
Continuity
Inspect axle shaft and
wheel bearings. Check continuity
Check runout first if this error
Check resistance
also occurrs
across connector
terminals

Runout OK?

Diagnostics
Check axle
Yes No shafts
1250
Remove
* Runout nominal?
head OK?
assembly
OK?
Short Short Short
Yes No

Remove
* Remove
* Check
Remove
* Use
resistance
head head head correct
of either
assembly assembly assembly shaft
side to
ground.
Should
be open

* See Carrier Troubleshooting Flow Chart

Yes No
Open?

Repair harness Remove

*
between ECU head
and Sensor assembly

Drive Axle Troubleshooting

11
 Diagnostics

Continuity Testing Check Drive Sensor Operation

There are two tests of drive sensor continuity: between the With the drive wheels jacked off the ground and the transmis-
two connector terminals, and between each terminal and the sion in neutral, check for sensor operation by spinning a
outside of the housing. Make the tests as follows: wheel and reading voltage across the terminals of the plated
connector on the differential carrier. Any voltage reading indi-
1. If head assembly is still installed on the vehicle, dis-
cates that the sensor is functioning and properly engaged by
connect the sensor from the ABS harness.
the axle shaft splines.
2. Using the standard ohmmeter, measure resistance
Loss of Signal
between the connector terminals. Resistance at the
Loss of signal without a corresponding continuity fault indi-
connector should read 1125 to 1375 ohms.
cates a problem with the axle shaft.
3. Select a clean, dry, unpainted location on the outside
of the housing. Measure resistance between each Consider Axle Shaft Engagement
connector terminal and the carrier casting surface. Improper axle shaft installation could produce drive sensor
Each terminal should show a resistance greater than faults. “Drive Axle Features” on page 7. Possible errors
1 megohm (i.e. infinite resistance). include:
• Installing a conventional shaft instead of the shaft
See flow charts for specific troubleshooting steps. specified for use with speed sensors. (An incorrect
shaft could possibly deliver drive torque but fail to
* Continued from engage sensor).
Figure 10
• Interchanging the long arm and extended short arm
shafts.
Refer to axle
service manual
Axle shafts can be pulled for verification of proper spline con-
figuration. See Drive Axle Sensor Service section for instruc-
Check resistance across
sensor screws
tions.
Noisy Signal Fault
Yes 1250 No Before looking for a cause, clear the error from the controller
nominal? and verify it re-occurs. A noisy speed signal can be caused by
a bent shaft or by a bent or distorted sensor. Also, check the
Remove connector Remove sensor
lead wires screws axle shaft for excessive runout. (Maximum allowed runout at
the sensor splines is 0.015").
Check continuity Replace sensor Avoid Axle Disassembly
to ground
Even when a troubleshooting routine points to a problem at
Reconnect
the sensor, eliminate all other possible causes before remov-
Yes No
Open? connector leads ing the head assembly. For example, although a faulty Elec-
tronic Control Unit is an unlikely trouble source, it only
Replace Verify resistance requires a few minutes to connect a new one and be certain of
connector at connectors
proper Electronic Control Unit operation. If external checks
fail to isolate the problem, the only alternative is to remove the
Verify isolation
head assembly. Look for a bent or distorted housing or a
severely worn differential. See the Carrier Troubleshooting
Reassemble head
flow chart for lists the troubleshooting sequence.

Carrier Troubleshooting

12
 Diagnostics

Troubleshooting Loss of Signal Fault

If there is concurrent loss of signal and continuity faults, solve
the continuity problem first before solving the signal problem.
Steer/Trailer Troubleshooting Loss of signal without a corresponding continuity fault indi-
Compared to the drive axle, the steer sensor allows cates a hub cap problem such as an improper rotor or
easier access to components for testing. If sensor disassem- improper placement of the rotor teeth and the stator teeth.
bly is required, see the Steer/Trailer Axle Service section for
Noisy Signal Fault
instructions. In addition to the basic diagnostics provided by
Before looking for a cause, clear the error from the controller
the ABS system, here are some additional guidelines:
and verify that it re-occurs. A noisy steer sensor signal can be
Check Sensor Operation caused by a loose wheel bearing or by a damaged hub cap.
To check sensor operation, connect AC voltmeter leads to Verify the bearing endplay is no more than 0.010 inches (if the
sensor connector (voltmeter may be connected anywhere Pro-Torq spindle nut is properly adjusted, the endplay should
along the two wires connected to the sensor terminals.) Turn- be 0 to 0.003 inches). See below for instructions on installing
ing a wheel by hand should produce an AC signal. Any signal or adjusting the Pro-Torq spindle nut.
indicates both a functioning sensor and continuity up to the
testing point. No signal could mean either a non-functioning
sensor or a continuity fault.
Continuity Fault
A continuity fault can be caused by a connector failure, or by a
broken or pinched wire. Check continuity at all points on the
signal path. Resistance should read 1125 to 1375 ohms

Diagnostics
across sensor terminals.The problem may be in the vehicle
wiring harness or within the sensor feed through cable. It is
also possible, although highly unlikely, that the cause of the
continuity fault is an open sensor coil or a faulty Electronic
Control Unit.

Use Raised Nubs

to Indicate 1/3 Turn
Back Off

Bottom Legs Point

Away From Nut Notches Allow Insertion
of Screwdriver for
Removal and Assembly

Pro-Torq Spindle Nut

13
 Steer/Trailer Axle Service

Sensor Service Requirements

There are a number of important differences in axles that Vehicle Preparation
carry Dana speed sensors. In general, more care is required
during disassembly and assembly to avoid damage to sensi-
Make sure the vehicle and all components are properly sup-
tive electronic components. Before beginning any service pro-
ported. Follow prescribed safety procedures to protect against
cedures, read through these instructions carefully to spot
injury. For best results when servicing steer axle, the axle
important steps and precautions.
should be raised off the ground. Sensor radial alignment is
less effective when the front tires are supporting the vehicle.
Identifying Installed Sensors
Steer and Trailer Axle Service
Axles equipped with Dana speed sensors have a cable con-
nection to the ABS system. To check for steer or trailer axle
See the exploded view of steer and trailer axle components
sensors, look for a cable feeding out from inside the wheel
below for assistance in servicing the sensor assembly compo-
area and following the brake air line back to an ABS connector.
nents.

Steer/ Trailer Sensor Components

9
8 10

11
12

6
5
4
3
2

1. 1/2" Hub Cap Bolt 7. Ring Terminals

2. Hub Cap Assembly 8. Cable Clamp
3. 7/8" Jam Nut 9. 1/2" Cap Screw
4. Speed Sensor 10. 1/2" Washer
5. Keeper Ring 11. Feed Through Cable
6. Spindle Nut 12. Knuckle Cap

14
 Steer/Trailer Axle Service

Preparation Pro-Torq Spindle Nut Service

Check Endplay
Prepare for speed sensor service as follows:
Excessive axle endplay (over 0.010") could be a possible
1. Jack up the axle to take load off tires.
cause of a noisy sensor signal. A properly seated spindle nut
2. Drain lubricant. is designed to set endplay in the specified range of 0.001" –
0.003". The steer axle speed sensor can accommodate end-
Steer Sensor Disassembly play variance up to 0.010". If system diagnostics indicate a
noisy signal, check axle endplay before removing the spindle-
Remove steer sensor as follows (see the Steer/Trailer Sensor nut.
Components illustration for reference):
1. Unbolt hub cap assembly and remove. Removing Pro-Torq Spindle Nut
2. Inspect sensor components for wear or damage. Pay To remove Pro-Torq spindle nut (6), first remove the keeper
particular attention to the rotor and the inside of the
ring (5). Use a screwdriver to carefully pry the keeper ring
hub cap.
from the undercut groove on either side of the spindle nut
3. Disconnect wires (7) at sensor terminals. until the keeper ring is released. See the Pro-Torq Spindle Nut
4. Unscrew jam nut (3) holding sensor (4) in place. illustration for reference.
5. Remove sensor (4).
CAUTION: Do not attach, loosen, or tighten the
Pro-Torq spindle nut with the keeper ring in place.

Steer/Trailer Axle Service

Feed through Cable Removal
If steer sensor feed through cable (11) requires removal, pro-
ceed as follows:
1. Make sure the cable is disconnected at ABS sensor
harness. This connection will be found inside the
frame rail near the point where the air hose goes
through a bulkhead fitting.
2. To allow the long end of the feed through cable to be
pulled out of the steering knuckle, unplug the termi-
nals from the ABS harness connector.
3. Remove the cap screw (9) holding the cable clamp
(8) to the knuckle cap (12).
4. Loosen the feed through nut at the end of the steer
spindle.
5. Pull the feed through cable (11) out of the spindle.
Trailer Axle Cable
To remove feed through cable from trailer axle, follow the
same steps as above, but allow for variation in cable connec-
tion to the ABS harness.
The keeper ring is a locking device and must be
removed before any adjustment of the nut.
Installing Pro-Torq Spindle Nut
Install spindle nut as follows:
1. Remove the keeper ring (5) from the nut as
described above. Do not use a washer with the Pro-
Torq spindle nut. Use of a washer will impair the
bearing-seating action of the nut and interfere with
sensor clearance.
2. To seat the steer axle bearing, thread the Pro-Torq
nut (6) onto the axle spindle. While rotating the
wheel, torque the nut to 150 lbs. ft. (204 N•m).
3. After seating the bearing, back the nut off one full
turn.
4. To achieve the proper endplay, rethread the Pro-Torq
nut until hand tight. Torque to 75 lbs. ft. (102 N•m).
5. Back off 1/3 turn, or one raised face mark on surface
of the Pro-Torq nut. Wheel should turn freely.
6. Check endplay using a dial indicator. Endplay should
be within 0.001"- 0.003".

15
 Steer/Trailer Axle Service
CAUTION: After seating the bearing at 150 lbs. ft.,
the Pro-Torq spindle nut must be backed off. Fail-
ure to back off the nut will cause the bearing to
run hot and fail prematurely or to be damaged.
The final adjustment of 75 ft. lbs of adjusting
torque with a 1/3 turn backoff will insure the nec-
essary 0.001" – 0.003" endplay.
7. Insert the keeper ring (5) into the undercut groove of
the spindle nut as shown in the Pro-Torq Spindle nut
illustration. Engage the mating teeth of the keeper
and the nut. Compress and insert the keeper arms
one at a time into the undercut groove of the nut.
Position the keeper ring as required to align teeth.
Do not turn the spindle nut to align teeth.
Feed Through Cable Replacement
To replace steer/trailer sensor feed through cable (11):
1. Use compressed air or other appropriate means to
clean out rifled hole through spindle. Make sure
there are no chips or burrs which could damage the
cable.
2. If not already included, mount new o-ring on feed
through cable. O-ring must be slid over the long wire
end of the cable.
3. Carefully feed the long wires into the threaded end of
the steering knuckle. Use a screwdriver to push the
terminals to the rear side of the king pin.
4. Thread the feed through cable connector into place
Torque to 21-25 ft.lbs. (28-34 N•m).
5. Select the side of the axle beam which will allow the
best routing of the connector cable. Also select the
the best mounting location for the cable clamp (8).
On steer axle, check the wire routing by moving the
wheel through full stop-to-stop turns. Make sure the
connector cable is not kinked or stretched and is not
pinched as the wheel turns.
6. Fasten the selected capscrew (9) and washer (10)
holding the cable clamp (8) to the knuckle cap (12).
Torque to 22-28 lbs. ft. (30 -38 N•m).
7. Insert terminals on long end of feed through cable
into ABS connector shell. Push terminals in until
they are firmly seated. Tug back on the wires to make
sure they are properly engaged. To avoid damage,
wrap end of wire.
16
8. Tie wrap cable along air supply line. Do not tie too
tightly.
Sensor Installation
1. Mount sensor assembly (4) onto the steer knuckle.
Align the key way to make sure the sensor terminals
are positioned at 6 o’clock.
2. Install jam nut (3) onto the threaded end of the feed
through cable. Torque to 21-25 lbs. ft. (28-34 N•m).
3. Connect the two short wires (7) to sensor terminals.
Make sure wires are separated and that signal can-
not short across sensor terminals or to the sensor
body. Torque to 10-15 lbs. in. (1.1-1.7 N•m).
Hub Cap Installation
Install hub cap as follows:
1. Inspect hub cap assembly to make sure inside of
hub cap is clean.
2. Position hub cap over speed sensor so oil fill hole is
facing up and positioned between the wheel mount-
ing bolts. Install gasket and hub cap assembly and
manually spin tire for a few complete rotations to
properly center hub cap. Torque hub cap bolts to 8-
10 lbs. ft. (11-14 N•m) following star pattern.
3. Check for sensor output by attaching voltmeter leads
to connector end of feed through cable. With voltme-
ter leads connected, spin tire by hand. Any voltage
reading indicates good operation.
4. Fill hub cap to indicated level with specified lubri-
cant. Because speed sensor restricts flow, additional
time is required for lubricant to fill bearing. Tempo-
rarily install oil fill hole, plug, then rotate tire and
recheck oil level. After oil checks at the desired level,
torque oil fill hole plug to 8-10 lbs. ft. (10.9-13.6
N•m).
CAUTION: Failure to properly center the hub cap
may result in grooving of the interior of hub cap
surfaces. Do not use air tools or overtighten hub
cap bolts.
 Drive Axle Sensor Assembly

Drive Axle Sensor Assembly

Service procedures in this section are limited to the drive axle
speed sensors and associated components. Before beginning
any service procedures, read through these instructions care-
fully to spot important steps and precautions.
The sections “Carrier Head Removal” and “Carrier Head
Installation” provide only abbreviated procedures. For com-
plete instructions on axle service, refer to appropriate service
manuals.
Sensor Service Requirements
Compared with conventional axle service, there are important
differences in drive axles that carry Dana speed sensors. In
general, more care is required during disassembly and
assembly to avoid damages to electronic components.

Drive Axle Configurations

6"
4"
Front

Drive Axle Sensor

Long Arm Side of Housing D-Head Short Arm Side of Housing
¥ Long Arm Side of Housing • Short Arm Side of Housing

Assembly
Plain Half
¥ Plain HalfofofCarrier
Carrier Flanged Half
¥ Flanged Half ofofCarrier
Carrier
¥ Equal Shaft
Longer Length
Shaft Length Shorter Shaft Length
¥ Equal Shaft Length
¥ 41 Splines,11"
41 Splines, Long
11"Long ¥ 4141Splines,
Splines, 11" Long
11"Long
¥ 6" Connector Wires
4" Connector Wires ¥ 4"4"Connector Wires
Connector Wires

Short Arm Side of Housing R-Head Long Arm Side of Housing

¥ Short Arm Side of Housing
Flanged Half of Carrier Half Side
PlainArm
¥ Long of Housing
of Carrier
¥ Flanged Half of Carrier ¥ Plain Half of Carrier
ShorterShaft
¥ Equal ShaftLength
Length Longer Shaft Length
¥ Equal Shaft Length
¥ 41 Splines, 4" Long
41 Splines, 11" Long ¥ 4141Splines,
Splines, 4"
11"Long
Long
4" Connector Wires 4" Connector Wires

Eaton Model 402 Drive Axle, D-Head Sensors

Model DA/RA404

17
 Drive Axle Sensor Assembly

Axle Shaft Configuration Carrier Head Removal

Figure 18 shows the relationships between axle shafts and
front and rear differentials for the Dana Model DA/RA404 Tan-
dem Drive Axle. Note that the short arm side of the housing
uses the shorter shaft length.
Shaft configuration will vary for other drive axles. When reas-
sembling drive axles, make sure to follow specifications for
placement of short arm and long arm shafts.
Identifying Installed Sensors
To begin service:
1. Prevent vehicle movement by setting the parking
brake and blocking the wheels.
2. Raise the drive axle and support with a jack stand of
adequate capacity.
WARNING: Never work under a vehicle supported
only by a a jack. Do not lie under carrier after fas-
teners are removed. Use transmission jack to sup-
port differential carrier assembly.

There are obvious external connections on drive axles that Disassemble carrier DA402 as follows:
carry Dana speed sensors. To verify these service procedures
1. Drain axle lubricant.
apply, check for two 1-1/8" plated hex connectors on and near
the differential carrier mounting flange. To prepare for axle 2. Disconnect inter-axle driveline.
disassembly, unplug the ABS sensor cable from both of the
3. Remove output shaft nut, flat washer, and yoke.
plated connectors on each drive axle.
4. Disconnect differential lockout air line.
CAUTION: In disassembling drive axle, do not
5. Disconnect main driveline.
unscrew the plated connectors. These connectors
house fixed wires which will be damaged if they are 6. Remove stud nuts.
not first disconnected inside the head assembly.
7. Use a heavy hammer on the axle shaft end bell to
The plated connectors do not need to be removed in
loosen the taper bushings (if present) and free the
order to disassemble the carrier from the axle hous-
shaft. To avoid damage to the sensor, apply only the
ing.
minimum force needed to free the shaft from the
carrier.
Vehicle Preparation 8. Remove nuts and lockwashers fastening carrier to
housing. Remove differential carrier assembly from
Make sure the vehicle and all components are properly sup- axle housing.
ported. Follow prescribed safety procedures to protect against
injury.

18
 Drive Axle Sensor Assembly

Servicing the Differential

The figure below shows the drive axle sensor assembly.
Drive Sensor Disassembly
The design of the drive axle sensor allows replacement of sev-
eral individuals components without needing to disassemble
the complete sensor system. For example:
• The differential bearing adjuster (3) does not need to
be removed in order to replace any other compo-
nent.
• The sensor and rotor (2) can be replaced without
removing or replacing the plated connector (4).
At every stage of drive axle service, try to isolate the problem
to specific components in order to avoid unnecessary disas-
sembly.
Remove drive axle sensor as follows:
1. Disconnect two wires from sensor terminals.
2. Carefully inspect wires and connector (4). If connec-
tor is intact and if there is no prior indication that
connectors and wire require replacement, do not
unscrew plated connector (4). The sensor (2) may
be replaced without replacing connector and wire.
3. Remove four screws from face of sensor (2).
4. Remove sensor (2) from differential bearing adjuster
(3).
Connector Service
If plated connector was damaged during axle disassembly or
if there is indication of wiring fault, the connector assembly
must be replaced.

Drive Axle Sensor System

2
3

Drive Axle Sensor

Assembly
4

1. Axle Shaft 4. Plated Connector

2. Speed Sensor 5. ABS Harness Connector
3. Differential Bearing Adjuster

19
 Drive Axle Sensor Assembly

There are two different connectors with two different length of If sensor assembly is to be replaced, install new sensor before
terminal wires: finishing installation of new connector. The final position of
the sensor terminals must be fixed before wires can be sealed
• See “Drive Axle Features” on page 7 for examples.
in place. Step 8 under the Drive Axle Sensor Installation sec-
tion completes the installation of the new connector.
To install new connector (4):
1. Clean threaded hole in carrier and wire path to allow
proper seal for new connector. (Male threads on the
new connector have microencapsulated Loctite.)
2. Insert connector and torque to 20-28 lbs. ft. (27-38
N•m).
3. Route wires to the sensor location.

Short Arm Side Connector

Installed
Position of
Axle Shaft Sensor Terminals
Positioned Near
Connector Hole

Axle Housing

4 inch Long Wires

Axle Connector Hole

Carrier is not on Carrier
Mounting Surface
Short Arm Side
(edge view of bearing adjuster)

Long Arm Side Connector

Wires Seated
in Channel
Sensor Terminals
Positioned Near Carrier
Mounting Surface

Connector Hole
is on Carrier
Mounting Surface 6 Inch Long
Wires

Long Arm Side

(face view of bearing adjuster)

20
 Drive Axle Sensor Assembly
Drive Axle Sensor Replacement
In replacing drive axle sensors, observe the following condi-
tions:
Two Identical Sensors
Speed sensors for both sides the differential are identical.
Inspect Bearing Adjuster Surfaces
Clean and inspect the bearing surface that mates with the sen-
sors. If there is roughness or indication of wear exceeding
0.003", replace the bearing adjuster. See Axle Service manual.
Normal Head Assembly
The speed sensor replacement instructions which follow
assume that the carrier has been serviced and reassembled in
an appropriate manner for the drive axle. These instructions
assume that individual differential bearing preloads have
already been completed and the bearing adjusters are
installed and locked in position.
CAUTION: Differential bearing adjusters must be
set and locked before sensors are installed. To
avoid damage to sensors, no bearing adjustment
can be made after sensors are installed.
Drive Axle Sensor Installation
Except for the wires between the sensor and the plated con-
nector, procedures for installing both drive axle speed sensors
are identical. The instructions which follow cover the long arm
(plain half) side speed sensor and require careful routing of
the 6" long connector wires to prevent pinching between the
head and housing.
1. Lubricate interior rotor with axle lube or grease.
Check that the rotor turns freely by hand.
2. Mate the rotor and the sensor assembly.
3. Align the sensor/rotor assembly with the face of the
adjuster so the terminals are nearest the carrier
mounting service. See the Long and Short Arm Con-
nector illustrations.
4. Orient the sensor to line up the holes in the sensor
with the threaded holes in the adjuster. Rotate the
sensor in either direction to get the fit that keeps the
terminals near the carrier mounting surface. This
final adjustment should only require a slight shift in
sensor position.
5. Apply Loctite to the four mounting screws. Install
the screws and tighten in a "star" pattern to maintain
sensor alignment. Torque to 28-32 lbs. in. (3.2-3.6
N•m). (A preferred tightening approach is the "turn
of bolt" method: torque screws finger tight then
tighten additional 1/4 turn.)
6. Attach the two round terminals to sensor. Either wire
can connect to either sensor blade. Make sure the
terminals are not bridged and connectors are not
touching. Torque to 10-15 lbs. in. (1.1-1.7 N•m).
7. Before sealing wires in place, check sensor continu-
ity by measuring the resistance between pins on the
outside of the connector. Resistance between con-
nector pins should be 1125 to 1375 ohms.
8. Check wire routing. Make sure wire is seated in the
cast-in channel and will not get pinched when the
head is reassembled to the housing. Seal wire in
place with RTV.
To replace sensor on the short arm (flanged half) side, repeat
above steps. Since connector location is inside the mounting
surface, there is less concern for pinching of the shorter 4"
connector wires. However, before final assembly, check wire
Drive Axle Sensor
position and routing to make sure that it is not crimped or
pinched.
Assembly
Checking Sensor Continuity
Before reassembling head, check sensor continuity using the
following two tests:
1. Measure the resistance between pins on outside of
connector. Resistance should be 1125 to 1375
ohms.
2. Perform a continuity check between each connector
pin and the carrier casting surface (i.e., note that
there are four checks per axle, two on each connec-
tor). The carrier surface should be checked at an
unpainted, clean, and dry location. The continuity
check should show infinite resistance, or more than
1 megohm.
21
 Drive Axle Sensor Assembly
Carrier Head Installation
To install carrier head, proceed according to normal axle ser-
vice instructions. To accommodate drive axle speed sensors,
not the following precautions:
Avoid Sensor Damage
When mating the head to the housing, take care to make sure
the cover clears the terminals on both sensors.
Axle Shaft Assembly
As shown in the Drive Axle Sensor System illustration, the
axle shaft for ABS applications have splines that differ from
conventional shafts. The sensors rotors will serve as guides
for the axle splines and should make shaft installation easier,
but use care to avoid damage to sensor.
22
Checking Sensor Continuity
As a final check of sensor continuity, repeat the following two
checks on the installed and reassembled axle:
1. Perform a continuity check on each of the two con-
nector pins. Using a standard ohmmeter, measure
the resistance between connector pins. Resistance
should be 1125 to 1375 ohms. Also, perform conti-
nuity check between each connector pin and the car-
rier casting surface should be checked at an
unpainted, clean, and dry location. Resistance
between each pin and the housing should be greater
than 1 megohm (infinite resistance).
 Connector Service

Terminal Assembly
Speed sensors are electro-mechanical devices that require Packard Metri-Pack Connectors
good electrical signal paths. Proper installation and mainte-
nance of sensor wires and connectors are essential to proper
The illustration below shows the Packard connectors and ter-
operation of Dana sensors. This section covers recommended
minals used with Dana speed sensors. When replacing any
procedures for using connectors, replacing terminals, and
component, make sure the new part is identical to the one
making wire splices.
being removed.

4 To ABS
Harness

Drive Sensor To ABS

Connectors 3
Harness
2

Connector Service
5
1

To
Sensor
7
Steer/Trailer
To
Sensor Connectors
Sensor 8

10

1. Ring Terminals 6. Connector Shell-Shroud

2. 1-1/8’ Hex Bulkhead Connector 7. Connector Shell-Tower
3. Terminals 8. Terminals
4. Connector Shell 9. Feed Through Cable
5. Male Terminals 10. Ring Terminals

23
 Connector Service

Terminal Seating and Removal

To remove terminal:
The connector joining the drive axle sensor to the ABS har- 1. Pull terminal to rear of connector.
ness is the "pull-to-seat" type. The illustration below shows
2. Insert pick under terminal lock tang.
the cross section of the connector.
3. While pick is depressing lock tang, push terminal out
To seat terminal, pull gently on wire until terminal clicks into through front of connector.
place.
The illustration below shows the "push-to-seat" connector
used on the steer axle sensor connection to the ABS harness.

Pull to Seat Connector

LL
PU
1. To Remove, 2. Push Terminal
Use Pick Out from
to Unseat Wire End
Terminal

Push to Seat Connector

2. Pull Out Terminal 1. To Remove, Use

from Connector Pick to Unseat
Terminal

24
 Connector Service

Replacing Terminals
3. For a "pull-to-seat" terminal, feed plain wire through
The illustration below shows the steps to put a new terminal connector before attaching terminal.
on a wire. Note the wings: one set crimps the core, one set
4. Position wire in terminal. First crimp core wings,
crimps the insulation, and the weather boot. To replace a ter-
then crimp insulation wings.
minal:
5. After making a hand crimp, the terminal should be
1. Make sure the insulation is removed cleanly and the
soldered.
wire strands are undamaged.
2. Install new weather boot on wire. Make sure boot is
placed in proper direction.

Take Care Not To

Cut Wire Strands
Crimp Insulation
Second
Crimp Core
Minimize Wire First
Wire Loss

Connector Service
Cutting Off Defective Removing Insulation
Positioning Strip
Terminals in Terminal

Solder all
Hand-Crimped Terminals

25
 Connector Service

Splicing Wire
The illustration below shows the steps to splice two sections
of wire.

Remove installation cleanly and take care not to damage wire

strands. After hand crimping splice clip, the joint should be
soldered. Cover entire splice with splice tape, making sure
tape extends over insulation on both sides of splice.

Take Care Not To

Cut Wire Strands

Tightly Crimp
Spliced Wires
Position Both
Wire Ends
in Splice Clip
Removing Insulation

Tape or 2" of Heat Shrink

Tubing Extends onto Insulation
on Both Sides of Splice

Cover Entire Splice

Solder All Hand Splices with Splice Tape or
Heat Shrink Tubing

26
 Connector Service

Steer Axle Sensor

FRONT
OF
VEHICLE

Sensor Jam Nut

Size Head Lbs. Ft. Nm
9/16"-18 7/8" Hex 21-25 28-34

Connector Service
Pro-Torque Spindle Nut
Size Head (For Fastening
1-1/2 - 18 2-1/2" Hex Instructions see page 19)

Hub Cap Bolt Terminal Screw Feed Through Cable

Size Head lbs. ft. Nm Size Head lbs. in. Nm Size Head lbs. ft. Nm
5/16"-18 1/2" Hex 8-10 11-14 5/64 Allen 10-15 1.1-1.7 9/16-18 11/16" Hex 21-25 28-34

27
 Connector Service

Drive Axle Sensor

Sensor Fastener
Size Head Tighten to:
#10-24 x 7/8 " 1/
8 " Allen Finger tight + 1/4 turn

Terminal Screw
Size Head Lbs. in. Nm
5
#6-32 x 1/4" /64" Allen 10-15 1.1-1.7
Carrier Connector
Size Head Lbs. in. Nm
1
/4"-18 PTF 1-1/8 " Hex 20-28 27-38

Correct tightening torque values are extremely important to assure long sensor life and dependable performance. Under tight-
ening of attaching parts is just as harmful as over tightening.
Exact compliance with recommended torque values will assure the best results.
The data includes fastener size, head type, and torque tightening values.

28
Copyright Eaton and Dana Corporation,
2002. EATON AND DANA CORPORATION
hereby grants its customers, vendors, or
distributors permission to freely copy,
reproduce and/or distribute this document
The Roadranger® System is an unbeatable combination of the best
in printed format. THIS INFORMATION IS
NOT INTENDED FOR SALE OR RE-
products from Eaton and Dana – partnering to provide you the most
SALE, AND THIS NOTICE MUST REMAIN advanced, most trouble-free drivetrain in the industry. And it’s backed by
ON ALL COPIES. the Roadrangers – the most experienced, most expert, most accessible
drivetrain consultants in the business.
For spec’ing or service assistance, call 1-800-826-HELP (4357) 24 hours
a day, 7 days a week, (Mexico: 001-800-826-HELP (4357)) for more time
on the road. Or visit our web site at www.roadranger.com.

AXSM-0034
12/03 PDF
Printed in USA