Spicer Single Drive Axles ® Service Manual AXSM0055 April 2011 S110 Series S130 Series
General Information General Information The description and specifications contained in this service publication are current at the time of printing. Dana 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 name in this publication is made simply as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents, if available, may be used.
Table of Contents General Information .............................................i Important Notice .......................................................... i Introduction ........................................................1 Model Listing .............................................................. Model Information ...................................................... Model Identification .................................................... Part Identification.................................
Introduction Introduction Dana Commercial Vehicle Division, presents this publication to aid in maintenance and overhaul of Spicer single drive axles. Instructions contained cover the models listed. Their design is common, with differences in load capacity. Capacity variations are achieved by combining basic differential carrier assemblies with different axle housings, axle shafts and wheel equipment.
Introduction Model Identification Drive Axle Data plate is located on the axle centerline 4 5 3 Spicer® CUST. PART NO. SPEC. MODEL PART NO. SERIAL NO. RATIO MADE IN: 2 6 1 7 Rear Axle (Front View) 1 - Country of origin 2 - Axle model identification 3 - Specification number assigned to the axle built by Spicer. Identifies all component parts of the axle including special special OEM requirements such as yokes or flanges.
Introduction Ring Gear and Pinion Note: Ring gear and drive pinion are matched parts and must be replaced in sets.
General Information Inspection Failure Analysis Failure analysis is the process of determining the original cause of a component failure in order to keep it from happening again. Too often, when a failed component is replaced without determining its cause, there will be a recurring failure. If a carrier housing is opened, revealing a ring gear with a broken tooth, it is not enough to settle on the broken tooth as the cause of the carrier failure. Other parts of the carrier must be examined.
Inspection Prepare the Parts for Inspection After the preliminary investigation, locate the failure and prepare the part for examination. In carrier failure analysis, it may be necessary to disassemble the unit. 1. When disassembling subassemblies and parts, do not clean the parts immediately since cleaning may destroy some of the evidence. 2. When tearing down the drive axle, do it in the recommended manner. Minimize any further damage to the unit. 3.
Inspection Inspection Inspect Axle Housing Clean 1. Wash steel parts with ground or polished surfaces in solvent. There are many suitable commercial solvents available. Kerosene and diesel fuel are acceptable. WARNING Axle housing inspection and repairs are limited to the following checks or repairs. • Visually inspect axle housing for cracks, nicks and burrs on machined surfaces. • Check carrier bolt holes and studs for foreign material. • Replace damaged fasteners.
Inspection Inspect Components Inspect all steel parts for: • Notches, visible steps or grooves created by wear. • Pitting or cracking along gear contact lines. • Scuffing, deformation or discolorations. These are signs of excessive heat in the axle and are usually related to low lubrication levels or improper lubrication practices. In addition, inspect the following for damage: Differential gearing • Bearings for loose fit on drive pinion, and differential bearings.
Differential Carrier Assembly Differential Carrier Assembly 1 1 - Carrier fastener 2 - Carrier assembly 8 2
Carrier Assembly S110 Carrier Assembly 21 15 23 12 13 22 14 Carrier Assembly 25 10D 24 20 19 11 18 10C 10B 10, 10A (10A includes items 10B, 10C and 10D) 31 26 17 9 8 16 7 27 6 28 5 29 4 30 3 32 (Optional Truetrac) 2 1 9
Carrier Assembly 1 - Pinion Nut 2 - End Yoke 3 - Slinger 4 - Outer Pinion Bearing Cone 5 - Outer Pinion Bearing Cup 6 - Pinion Spacer 7 - Inner Pinion Bearing Cup 8 - Inner Pinion Bearing Cone 9 - Drive Pinion 10 - Carrier Housing 10A - Carrier Housing Assembly 10B - Switch 10C - Capscrew 10D - Backing Ring 11 - Ring Gear 12 - Ring Gear Bolt 13 - Ring Gear Bearing Cone 14 - Ring Gear Bearing Cup 10 15 - Ring Gear Bearing Adjuster 16 - Side Pinion Thrust Washer 17 - Side Pinion 18 - Side Gear 19 - Differe
Carrier Assembly S130 Carrier Assembly 23 22 24 26 25 20B 19 20A 14 13 10D (Optional) 12 10B (Optional) 32 21 27 31 30 29 28 18 17 10C (Optional) 9 10, 10A (Optional) (10A includes items 10B, 10C and 10D) 8 7 6 5 4 3 2 1 1 - Pinion Nut 2 - End Yoke 3 - Slinger 4 - Outer Pinion Bearing Cone 5 - Outer Pinion Bearing Cup 6 - Pinion Spacer 7 - Inner Pinion Bearing Cup 8 - Inner Pinion Bearing Cone 9 - Drive Pinion 10 - Carrier Housing 10A - Carrier Housing Assembly 10B - Switch 10C - Capscrew
Differential Carrier Assembly Remove Differential Carrier Standard Differentials 1. Block the vehicle. 2. Drain axle lubricant. Remove bottom two (2) capscrews. 3. Disconnect driveline. 4. Remove axle shafts. (If used, remove lock washers and taper dowels.) WARNING WARNING Do not lie under carrier after fasteners are removed. Use transmission jack to support differential carrier assembly prior to loosening fasteners. CAUTION Do not strike the shaft head with a steel hammer.
Differential Carrier Assembly Install Differential Carrier IMPORTANT Before installing carrier assembly, inspect and thoroughly clean interior of axle housing using an appropriate solvent and clean rag. 1. Apply Spicer approved RTV compound on axle housing mating surface as shown in the illustration. Completely remove all old gasket material prior to applying new material. Compound will set in 20 minutes. Install carrier before compound sets or reapply.
Differential Carrier Assembly Remove Wheel Differential Note: Omit this step if the gear set is to be replaced. If gear set is to be reused, check tooth contact pattern and ring gear backlash before disassembling differential carrier. When checking backlash, a yoke must be installed and torqued to get an accurate reading. Best results are obtained when established wear patterns are maintained in used gearing. 1. Punch mark bearing caps.
Differential Carrier Assembly Pinion - Parts Exploded View 11 10 9 Differential Carrier Assembly 8 7 6 5 4 3 2 1 - Pinion Nut 2 - End Yoke 3 - Slinger 4 - Oil Seal 5 - Outer Pinion Bearing Cone 6 - Outer Pinion Bearing Cup 1 7 - Pinion Spacer 8 - Inner Pinion Bearing Cup 9 - Inner Pinion Bearing 10 - Drive Pinion 11 - Carrier 15
Differential Carrier Assembly Pinion Removal 1. Remove yoke nut. 2. Remove yoke using a yoke puller service tool. 6. Press pinion through outer bearing and out of carrier casting. 7. Remove bearing preload spacer and save for use in reassembly. 8. Remove inner bearing cone from pinion using a split-type puller. Use two procedure steps to remove each bearing. a. Mount puller vertically to separate the bearing. This action will force puller halves under bearing and start moving bearing off pinion.
Drive Pinion Drive Pinion Drive Pinion Rear Axle Pinion Assembly - Parts Exploded View 10 9 8 7 6 5 4 3 2 1 1 - Pinion Nut 2 - End Yoke 3 - Slinger 4 - Oil Seal 5 - Outer Pinion Bearing Cone 6 - Outer Pinion Bearing Cup 7 - Pinion Spacer 8 - Inner Pinion Bearing Cup 9 - Inner Pinion Bearing Cone 10 - Drive Pinion 17
Drive Pinion Pinion Installation Final Buildup 3. Press inner and outer bearing cups into the carrier until seated. Use a feeler gage (.0015" [.038 mm] approx.) to make sure that bearing cups are fully seated in bearing bores. Apply lubricant to both cup and cone. 4. Place carrier housing in press with the pinion supported by wood block (6" x 6" x 6" [152 x 152 x 152 mm]), so the inner pinion bearing is mated to the cone.
Drive Pinion 7. 10. Handle the seal by its outside diameter avoiding any contact with the seal lips. During installation, use the proper driver to make sure that the seal is mounted properly. 11. Use a rubber mallet to drive the seal tool in until the flange bottoms on the housing cover bore face. The flange will locate the seal at the proper depth.
Wheel Differential Assembly Wheel Differential Assembly - Parts Exploded 9 8 9 10 S130 8 7 6 6 7 8 10 7 5 8 9 13 9 12 16 9 8 10 1 2 3 11 7 6 4 S110 6 5 8 9 1 - Diff. Case Bearing Adjuster 2 - Diff. Bearing Cup 3 - Diff.
Wheel Differential Assembly Disassemble, Overhaul, and Assemble Wheel Differential - S110 Disassemble Wheel Differential 1. Remove capscrews fastening ring gear to differential case. CAUTION The differential case and gears will fall after separation. Support the case so that it will not cause damage to the differential or bodily injury. Lift out outer side gear. 4. Remove differential shaft locking pin with pliers. Wheel Differential Assembly 3. 2.
Wheel Differential Assembly 22 6. Remove inner side gear and thrust washer. 7. Remove bearing cones from ring gear and differential case in two steps: a. Mount puller vertically to split bearing. This action will start moving bearing off case and gear. b. Mount puller horizontally to remove cone. 8. Press new bearing cone on differential case. 9. Place thrust washer on side gear. Lubricate both sides of the thrust washer. Install on side gear.
Wheel Differential Assembly 10. Install inner side gear and thrust washer in differential case. 14. Make certain the hole in the shaft and case line up and install the locking pin. 15. Install outer side gear. Wheel Differential Assembly Note: No thrust washer is used at this location. 11. Start wheel differential shaft in differential case with the locking pin hole facing up. 12. Install the first side pinion thrust washer and gear. Push shaft through washer and side pinion. 16.
Wheel Differential Assembly 17. Install and hand-tighten all new ring gear capscrews. 19. Press new ring gear bearing cone. 18. The interface of the ring gear to differential case is a press fit. Put the assembly in a press with the ring gear facing upward. Make certain that the ring gear is flush and square to the differential case before pressing. Press until ring gear bottoms out on the case. IMPORTANT IMPORTANT DO NOT use the capscrews to draw the ring gear into place. Only use a press.
Wheel Differential Assembly 21. Install differential case assembly into carrier. Be careful not to damage the differential bearings lowering the assembly. Wheel Differential Assembly 22. Lubricate the differential bearings and install bearing cups and differential bearing adjusters.
Wheel Differential Assembly Disassemble, Overhaul, and Assemble Wheel Differential - S130 Disassemble Wheel Differential 1. 2. Remove capscrews fastening ring gear to differential case. The ring gear to differential case interface is a press fit. Place the assembly in a press with the case facing downward. Support the assembly on eitiher side of the ring gear. Thread a capscrew back into one of the case holes by hand.
Wheel Differential Assembly 6. Remove the half shafts first and then remove their side pinions and thrust washers. 9. Remove bearing cones from ring gear and differential case in two steps: A. Mount puller vertically to split bearing. This action will start moving the bearing off case and gear. 7. Wheel Differential Assembly Half Differential Shaft Remove the full shaft, side pinions and thrust washers. B. Mount puller horizontally to remove cone. 8. Remove inner side gear and thrust washer. 10.
Wheel Differential Assembly 11. Place thrust washer on the side gear. Lubricate both sides of the thrust washer before installing. 15. Install the side pinion and thrust washer to the other side of the full shaft. 12. Install the side gear and thrust washer in the differential case. 16. Install a side pinion and thrust washer on the half shaft side. Side Pinion and Thrust Washer 13. Start the full differential shaft into the shaft bores in the case that does not have a locking pin hole. 17.
Wheel Differential Assembly 18. The end of the half shaft should fit into the slot of the full shaft at the same time as the hole in the case lines up with the hole in the half shaft. Align Pin Holes 21. Next, the two locating dowel pins that are pressed into the ring gear must be removed. Note: The dowel can only be pressed in one direction. Press the dowels towards the inside of the gear. Fit End Into Slot Wheel Differential Assembly 19.
Wheel Differential Assembly 24. Install and hand-tighten all new ring gear capscrews. 25. The interface of the ring gear to differential case is a press fit. Put the assembly in a press with the ring gear facing upward. Make certain that the ring gear is flush and square to the differential case before pressing. Press until ring gear bottoms out on the case. IMPORTANT DO NOT use the capscrews to draw the ring gear into place. Only use a press. 26. Press new ring gear bearing cone.
Wheel Differential Assembly 28. Install differential case assembly into carrier. Be careful not to damage the differential bearings lowering the assembly. Wheel Differential Assembly 29. Lubricate the differential bearings and install bearing cups and differential bearing adjusters.
Wheel Differential Assembly Measure and Adjust Carrier Assembly Adjust Backlash and Preload 1. Turn the flange half-bearing adjuster in until the ring gear contacts the pinion (zero backlash) then back the adjuster out two (2) notches from the adjuster lugs. 2 1 1 - Flange half 2 - Plain half 2. Tighten the plain half-adjuster until the bearing cup just starts to turn, this is a zero bearing preload. 3. Tighten the plain half-adjuster two lug notches.
Wheel Differential Assembly Change Backlash Setting If you have too much backlash, the ring gear needs to move closer to the pinion. Back off the plain half-adjuster, counting the number of notches you back it off (each notch equals about .003" [.08 mm] of backlash). Measure Ring Gear Runout Measure Ring Gear Total 1. Measure ring gear total radial runout. (Indicator reading should not exceed .010" [.25 mm]). 2. Measure ring gear total backface runout. (Indicator reading should not exceed .010" [.
Adjust Tooth Contact Pattern Adjust Ring and Pinion Tooth Contact Pattern Used Gearing - Correct Pattern 2 1 • Used gearing will not usually display the square, even contact pattern found in new gear sets. The gear will normally have a “pocket” at the heal end of the gear tooth. The more use a gear has had, the more the line becomes the dominant characteristic of the pattern. • Adjust used gear sets to display the same contact pattern observed before disassembly.
Adjust Tooth Contact Pattern Adjust Ring Gear Position (Backlash) If the ring gear pattern shows incorrect face width contact, change backlash by adjusting the ring gear. If the pattern is too close to the edge of the tooth toe, move the ring gear away from the pinion to increase backlash. Loosen the bearing adjuster on the teeth side of the ring gear several notches. 2. Loosen the opposite adjuster one notch. 3.
Housing Breather Install Axle Housing Breather 1. Install fitting in breather hole. 2. Tighten fitting finger tight. 3. 36 Torque to 5 lbs. ft. (7 N•m) and align the nose of the breather to the rear. 4. Insert hose onto fitting, long end down. 5. Push hose firmly against fitting. Rotate hose to point down.
Wheel End Seal Wheel End Seal Wheel End Seal - Parts Exploded View 1 2 3 1 - Installation tool 2 - Seal 3 - Rear hub 37
Wheel End Seal Remove and Overhaul Wheel End Seal Install Wheel End Seal WARNING 1. Never work under a vehicle supported by only a jack. Always support vehicle with stands. Block the wheels and make sure the vehicle will not roll before releasing the brakes. IMPORTANT Wheel end seals can be easily damaged during handling. Leave the seal in its package until installation to prevent damage or contamination. 1. Remove outer nut and locking washer. 2. Remove inner nut. 3.
Wheel Adjustment Systems Adjust Wheel Bearing WARNING Do not mix spindle nuts and lock washers from different systems. Mixing spindle nuts and lock washers can cause wheel separation. 1. Inspect the spindle and nut threads for corrosion and clean thoroughly or replace as required. Note: Proper assembly and adjustment is not possible if the spindle or nut threads are corroded. 2. Inspect the tang-type washer (if used). Replace the washer if the tangs are broken, cracked, or damaged. 3.
Wheel Adjustment Systems • Install the outer nut on the spindle and tighten to 350 lbs. ft. (475 N•m). • Verify end-play, see “Verify Wheel End Play Procedure." Four-piece Tang/Dowel-type Lock Washer System Three-piece Tang-type Lock Washer System 3 4 5 2 1 1 2 1 - Inner nut 3 2 - Dowel pin • 1 - Inner nut 3 - Dowel-type lock washer 2 - Tang-type lock washer .123” thick 4 - Tang-type lock washer .0478” thick 3 - Outer nut 5 - Outer nut Install the Tang-type lock washer on the spindle.
Wheel Adjustment Wheel End Verify Wheel End-play Procedure Adjust End-play with Wheel Hub Verify end-play meets specification using a dial indicator. An indicator with .001" (.03 mm) resolution is required. Wheel end-play is the free movement of the tire and wheel assembly along the spindle axis. Correct end-play is .001-.005” (.025-.125 mm). 1. Attach a dial indicator with its magnetic base to the hub or brake drum as shown below. 2.
Wheel Adjustment Lubricate Wheel End IMPORTANT Before operating the axle, the wheel hub cavities and bearings must be lubricated to prevent failure. Wheel End with Oil Fill Hole 1 When wheel ends are serviced, follow Spicer’s wheel end lubrication procedure before operating the axle. Spicer axles may be equipped with either of two (2) wheel-end designs: • Wheel ends with an oil fill hole. • Wheel ends without an oil fill hole . 2 Wheel Ends with an Oil Fill Hole 1. Remove the oil fill plug. 2.
Wheel Adjustment Wheel Ends without Oil Fill Hole 1. With axle level and wheel ends assembled, add lubricant through filler hole in carrier until fluid is level with the bottom of filler hole. 2. Raise the right side of the axle six (6) inches (152 mm) or more. Hold axle in this position for one (1) minute. 3. Lower the right side. 4. Raise the left side of the axle six (6) inches (152 mm) or more. Hold axle in this position for one (1) minute. 5. Lower the left side. 6.
Lubrication Lubrication The ability of a drive axle to deliver quiet, trouble-free operation over a period of years is largely dependent upon the use of good-quality gear lubrication in the correct quantity. The most satisfactory results can be obtained by following the directions contained in this manual. The following lubrication instructions represent the most current recommendations from Dana.
Lubrication Lube Change Intervals Change the lubricant within the first 5,000 miles of operation when not using a Spicer-approved synthetic lubricant in either a new axle or after a carrier head replacement. Base subsequent lubricant changes on a combination of the following chart and user assessment of the application and operating environment.
Lubrication Change Lube Drain Fill 1. Drain when the lube is at normal operating temperature (150°-200°F [66°-93°C]). It will run freely and minimize the time necessary to fully drain the axle, this insures the axle is flushed. 2. Remove the bottom two carrier to housing capscrews and allow the lube to drain into a suitable container. Note: Dispose of all used lubricants properly by following disposal methods approved for mineral- or synthetic-based oils. 3.
Proper Vehicle Towing Proper Vehicle Towing Lift the drive wheels completely off of the ground or damage will occur. WARNING Proper Vehicle Towing Do not lift the front wheels (non-drive wheels). This alters the oil’s position in the drive axle, draining it away from the drive pinion and its bearings. If the pinion is rotated under these conditions for any period of time, bearings will overheat resulting in axle damage or failure.
Torque Flow Torque Flow While driving with equal load on and equal traction under both drive wheels, the Truetrac differential provides equal torque to each wheel. 1 1 - Torque flow distribution while operating with equal loading and ground coefficient With unequal load and/or traction on each drive wheel, a major portion of the torque will be transferred from one side to the other to reduce the chance of a one wheel spin out.
Torque Chart Torque Chart Location Thread Size Class/Grade Torque Specification Pinion Shaft End Nut M36X1.5 10.9 625-753 lbs. ft. (847-1021 N•m) Ring Gear to Case Capscrew M14X2 (S110) M16X2 (S130) 10.9 10.9 140-160 lbs. ft. (190-217 N•m) 225 +/- 10 lbs. ft. (305 +/-13 N•m) Carrier Cap Capscrew M14X2 10.9 130-150 lbs. ft. (176-203 N•m) Head to Housing Capscrew M14X2 10.2 140-160 lbs. ft. (190-217 N•m) ABS Set Screw .312-18 18-26 lbs. ft.
For spec‘ing or service assistance, call 1-877-777-5360 or visit our website at www.dana.com Dana Commercial Vehicle Products Group 3939 Technology Drive Maumee, Ohio, USA 43537 www.dana.com All applications must be approved by the Application Engineering Department. Specifications and/or design are subject to change without notice or obligation.
