Spicer DS404 Reinforcing Instructions - Manual

Spicer ®
Axles & Brakes
P/N: SHAIS132
DS404 Housing Cover Weld Reinforcing Instructions
Subject of Instruction Sheet: The procedure below has been created to assist a mechanical technician in the proper
repair of a cracked rear cover weld and the installation of a reinforcement bracket on DS404 housings in Peterbilt vehicles
using an Air Leaf Suspension. This is the
only approved method for this repair. Any other method of repair may result in
damage to the axle, axle housing, or other vehicle components and could affect performance and safety. Failure to follow
all steps of this procedure will result in a poor repair and the crack could occur again.
Affected Models:
DS404 Drive Housing Used in Peterbilt Air Leaf Suspension Vehicles. See chart below.
Axle Model
Wall
Thickness
Suspension Type and
Timing
Production
Housing P/N On
Tag
Production
Brackets Welded
By:
DS404 3/8" (9.5mm) Air Leaf - Before 3/99 319402 Peterbilt
DS404 3/8" (9.5mm) Air Leaf - From 3/99 - 6/00 319954 Dana
Reinforcing Bracket Part Number 302527
Welding Equipment and Specifications :
Mig (wire) Welding
Welding Gas – recommended – 80% Argon, 20% C-O2 Gas Flow Setting – 50-60 cfh.
Wire Size – ER70S-3 or ER70S-6 .035”
First and second passes cover weld, approximate settings – 30 volts, 180 amps.
Third filler pass, cover weld, approximate settings – 26 volts, 140 amps.
Apply three weld passes to the cover and two to the bracket. The first pass should be centered over the fit-up line and
penetrate the failure area. The second pass should be placed slightly above the first. Blend the weld smoothly ( without
significant cross section enlargement ) with the housing and first pass. The third pass should penetrate the lower half of
the second pass to the edge of the housing cover. Avoid any significant overlap of weld or undercut. When making the
second and third passes the weld direction should be reversed. Always start the weld at one end, never in the middle the
intended weld area. See illustrations below for more information.
Arc (stick) Welding
Miller DC type stick welder set at 140 -150 amp setting.
Use E7018 1/8 inch Electrode for all three passes. Note** Remove slag between
passes. E7018 rod must be stored in
heated rod oven. Apply three weld passes to the cover and two to the bracket. The first pass should be centered over the
fit-up line and penetrate the failure area. The second pass should be placed slightly above the first. Blend the weld
smoothly ( without significant cross section enlargement ) with the housing and first pass. The third pass should penetrate
the lower half of the second pass to the edge of the housing cover. Avoid any significant overlap of weld or undercut.
When making the second and third passes the weld direction should be reversed. Always start the weld at one end, never
in the middle the intended weld area. See illustrations below for more information. When welding the second and third
passes, reverse the direction of the weld. Never start or stop a weld close to the 12:00 position.