Spicer Tandem Drive Axles ® Service Manual AXSM0057 September 2013 D170 Series D190 Series D590 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 names 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 Table of Contents Table of Contents Drive Pinion page 25 Wheel Differential Assembly page 36 Power Divider page 12 Carrier Assembly page 23 Seals page 68 Inter-Axle Lockout page 11 Wheel End Seal page 68 Differential Carrier Assembly page 8 Wheel Differential Lock page 57 Housing Breather page 67 Output Shaft Assembly & Rear Cover page 58 Lubrication page 75
General Information Introduction......................................................................1 Model Identification..........................................................2 Parts Identification...........................................................2 Failure Analysis................................................................4 Prepare the Parts for Inspection.......................................5 Inspection.........................................................................
General Information Dana Commercial Vehicle Systems Division, presents this publication to aid in maintenance and overhaul of Spicer tandem drive axles. General Information Introduction Model Information The following models are included in this publication: Heavy Tandems Instructions contained cover the models listed. Their design is similar, with primarily differences in load capacity.
General Information Model Identification Drive Axle 1 - Country or origin 2 - Axle model identification 3 - Specification number assigned to the axle built by Spicer . Identifies all component parts of the axle including special OEM requirements such as yokes or flanges.
General Information Ring Gear and Pinion Note: Ring gear and drive pinion are matched parts and must be replaced in sets.
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 Make a Preliminary Investigation Find the Cause of the Failure These steps consist of external inspections and observations that will be valuable when combined with the results of the parts examination. Here begins the real challenge to determine the exact cause of the failure. Keep in mind that there is no benefit to replacing a failed part without determining the cause of the failure.
Inspection Inspection 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. Note: Replace conventional gaskets with silicone rubber gasket compound (included in many repair kits). The compound provides a more effective seal against lube seepage and is easier to remove from mating surfaces when replacing parts.
Inspection Endplay Procedure Check Input Shaft Endplay (Forward Axle) Note: Before disassembling the power divider, measure and record input shaft endplay. 1. Position dial indicator at yoke end of input shaft. 2. Push in on input shaft and zero the dial indicator. 3. Using a pry bar, move input shaft axially and measure/record endplay. Check Output Shaft Endplay (Forward Axle) 1. Position dial indicator at yoke end of output shaft. 2. Push in on output shaft and zero the dial indicator. 3.
Differential Carrier Assembly Differential Carrier Assembly - Parts 1 2 4 3 1 1 - Carrier fasteners 2 - Carrier assembly 3 - Forward axle assembly 4 - Rear axle assembly 8 2
Differential Carrier Assembly Remove Differential Carrier (Forward and Rear) Note: The removal of the forward carrier does not require disconnecting of the inter-axle driveline and removal of the output shaft yoke assembly as most other Spicer tandems require. Standard Differentials 1. Block the vehicle. 2. Drain axle lubricant. 3. Rear Only: Disconnect inter-axle driveline. 4. Front Only: Disconnect main driveline. 5. Front Only: Disconnect differential lockout air line. 6.
Differential Carrier Assembly Install Differential Carrier (Forward and Rear) Tip: To assist in installing complet e differential carrier use two pieces of threaded rod (M16 X 1.5) threaded into carrier capsc rew holes. Rod should be approximately 6" long. Use these to pilot the carrier into the housing. IMPORTANT Before installing carrier assembly, inspect and thoroughly clean interior of axle housing using an appropriate solvent and clean rag. 1.
Inter-Axle Lockout IAD Differential Lock Disassembly Inter-Axle Lockout Disassembly Integral Shift Cylinder with Welded Push Rod Assembly 2 4 1 With the axle installed in vehicle, place differential lock selector valve in the disengaged or unlocked position. 2. Disconnect the differential lockout air line. 3. Remove the piston cover. 4. Remove the piston and o-ring assembly with pliers. Note: In order to remove the shift fork and push rod parts, first remove the power divider cover.
Power Divider Power Divider - Parts Exploded View 1 2 44 3 4 5 6 7 19 High Entry Input Shaft Assembly 8 20 21 9 22 27 25 10 14 26 15 16 28 17 11 29 18 12 30 23 31 24 32 11 13 33 34 35 43 42 36 37 41 40 1 - Output shaft nut 2 - Output yoke 3 - Output seal 4 - Output shaft bearing snap ring 5 - Outer bearing cup 6 - Outer bearing cone 7 - Inner bearing cone 8 - Inner bearing cup 9 - Output shaft 10 - Seal manifold 11 - Clamp 12 - Seal manifold feed tube 13 - Sump screen 14 - Outp
Power Divider Power Divider Disassembly - Forward Carrier Assembly Use these instructions with the carrier assembly in or out of the vehicle. Disconnect the main driveline. 2. Disconnect the lockout airline. 3. Drain the axle lubricant into a clean oil pan. 4. Remove the input yoke nut and yoke. 5. To de-stake the nut, use a chisel or drift with a round tip.
Power Divider 10. Remove the thrust washer and helical side gear. 14. Input cage is threaded in to the PDU cover, use the proper tool to remove the cage from the cover. 11. Remove the inter-axle differential assembly. 15. Use a suitable bearing puller to replace the input bearing cup. 12. Remove the output side gear and pump assembly. Note: In August of 2006 the piloted input adjuster design was implemented. The lockin and fastener was replaced with a 12mm stud and jam nut.
Power Divider Pump Disassembly For output side gear and/or pump replacement, follow the procedure below. 1. 3. Remove pump from the output side gear. 4. Remove the output side gear bearing cup from the carrier with the proper bearing puller tool. Remove the output side gear bearing cone, if required. 1 2 Power Divider 1 - Press 2 - Press Tool 2. Remove pump locking dowel pin from the hole in the output side gear hub.
Power Divider Lube Manifold Disassembly 1. Disconnect the hose from the lube manifold. 2. Remove the manifold assembly by prying it out around the inner diameter. IMPORTANT Once removed, the seal manifold assembly cannot be reused. This component should always be replaced with new. Use the same removal procedure for the output side gear seal removal on the non-pump models. Note: Seals are not sold separately from the manifold.
Power Divider Manifold Assembly 1. Install the manifold assembly into the output side gear bore in the carrier. Make sure the barbed nipple is lined up with the open ing in the carrier casting. Note: For non-pump manifold installation, it is important to line up the oil inlet path hole in the manifold with the oil path opening in the carrier manifold casting. 1 Power Divider 1 - Manifold Oil Inlet Hole 5. Attach the suction screen to the end of the hose. 1 1 - Barbed Nipple 2.
Power Divider Pump Assembly Use these instructions with the carrier assembly in or out of the vehicle. 2. Install the pump locking dowel pin into the hole in the output side gear hub. Make sure the pin is lined up with the machined slot in the pump body. If the unit does not have a pump, go to the Power Divider Assembly section. Note: Keep work area clean. Dirt is an abrasive and will cause premature wear of the otherwise serviceable parts.
Power Divider Power Divider Assembly 1. Install output side gear bearing cone and press until fully seated. Use proper press tools. Note: Install in the same direction as removed. 1 2 Install the helical side gear so that the clutch teeth are facing upward in the carrier. 6. Install helical side gear thrust washer. Power Divider 5. 1 - Press 2 - Press Tool 2. Fully press the output side gear bearing cup into the carrier seat.
Power Divider Helical Gear Bushing Replacement: a. 9. If bushing removal is needed, the bushings must exit from the thrust side of the helical side gear. Install the sliding clutch so that the teeth are facing up. 1 1 - Tap out bushings b. Install bushings in helical side gear. Bushing must be installed from the thrust side of the helical side gear. See illustration for installation depth. 1 2 3 10.
Power Divider 12. Assemble the sliding clutch, shift fork and fork spring to the input shaft and install assembly into carrier. Make sure that the shift fork rod is piloted in the carrier bore. 14. Install input cover and capscrews. Torque to the proper specifications. See the Torque Chart on page D-1. Tighten fasteners in a criss cross pattern. Power Divider 15. Install input shaft bearing adjuster, adjust inward until snug against the bearing cone.
Power Divider 17. A. For axles built before August 2006. Line up cage slot with locking fastener. Turn in input cage locking fastener and torque to the proper specifications. See Torque Chart. B. For axles built after August 2006 using the piloted adjuster and cover. Torque locking stud to 20 ft. lbs. then torque jam nut to 65 ft. lbs. 21. Verify that the endplay is between 0.001" to 0.005" (0.03 to 0.13 mm). If not, readjust until the proper specification is achieved.
Carrier Assembly Carrier Disassembly - Forward Carrier Assembly For models having the wheel differential lock option, refer to the following procedure. These parts must be removed first before further disassembly of the wheel differential can take place. For ease of service, mount differential carrier in head stand with the differential lock facing up. 2. Remove the threaded cylinder cap. 3. Remove the piston push rod from the shift fork. Remove the shift fork and sliding clutch assembly.
Carrier Assembly After July 2013 6. Mount the differential carrier in a head stand with the wheel differential facing upward. 8B. Using a long flat blade screwdriver on a pry bar, back off one of the wheel diff. bearing adjusters and remove. Note: For easier disassembly, loosen but do not remove the pinion nut. 7. Remove the carrier differential bearing cap capscrews, flat washers and bearing caps. 9. Before July 2013 8A. Use Spicer’s wheel diff.
Drive Pinion Pinion Removal 1. For D170 assembly, remove the pinion cover. Use a flat chisel to remove the cover from the carrier. b. For S190 disassembly, use the pry slots provided at each end of the pilot web. 1 1 2. If a pilot web is used, remove the web capscrews. a. For D190 disassembly, install a M10 x 1.5 bolt in the threaded jack holes found in-between the pilot web capscrews. 1 1 - Slots 3. Before the pinion nut can be loosened, you must destake the nut from the slot of the pinion. 4.
Drive Pinion 7. CAUTION Use the proper pressing tool to press the end of the pinion until free from the pinion bearings. 1 Failure to de-stake the pinion nut will result in damage to the drive pinion threads when removed. The pinion nut should never be reused, always replace with new. 1 2 3 1 - Round Tipped Chisel 2 - Machined Slot In Pinion 3 - Nuts Staking Flange 1 - Press 8. 5. Remove the pinion nut. 6. Place carrier assembly into a press, place a 2" x 6" x 6" wood block under the pinion.
Drive Pinion Forward Axle Pinion Assembly - Parts Exploded View 2 1 3 2 4 5 6 1 - Pinion pilot bearing 2 - Pinion 3 - Pinion bearing cone - inner 4 - Pinion bearing cup - inner 5 - Pinion helical gear 6 - Pinion bearing spacer 7 8 9 7- Pinion bearing cup - outer 8 - Pinion bearing cone - outer 9 - Pinion nut Rear Axle Pinion Assembly - Parts Exploded View Drive Pinion 2 3 4 1 5 2 1 - Pinion pilot bearing 2 - Pinion 3 - Pinion bearing cone - inner 4 - Pinion bearing cup - inner 5 - Pinion b
Drive Pinion Drive Pinion Overhaul and Assembly - Forward and Rear Carrier Assembly The preload of the bearings on the drive pinion is adjusted by a spacer between the inner and outer bearing cones and the helical gear. The preload is adjusted by changing the thickness of the spacer. A thicker spacer will decrease the preload, a thinner spacer will increase the bearing preload. 2. Remove the inner pinion bearing cone from the pinion using a split-type puller.
Drive Pinion IMPORTANT Use the correctly sized spacer. Do not use shim stock or grind spacers. These practices can lead to loss of bearing preload and gear or bearing failure. To prevent bearing damage, use suitable sleeve that only contacts the inner race of bearing cone. 3. Use a press sleeve to install the inner bearing cone and pilot bearing, if used, onto the pinion. Apply pressure until the bottom of the cone touches the shoulder of the pinion. Apply lubricant to the cone of the bearing.
Drive Pinion 5. For Forward Carriers Only: Install the helical with the larger boss side facing down in the carrier. Align the helical gear between the inner and outer bearing cups. 7. To align the splines of the helical gear to the pinion, use a old pinion nut with a metal ring welded to the top, thread onto the pinion. Then lift the pinion while aligning the two splined surfaces. 8. Install the pinion spacer.
Drive Pinion 9. Install the outer bearing cone. 11. Align a 6" x 6" x 6" wood block under the drive pinion, then lower the carrier and pinion assembly into a press so that it is supported by the block. 10. Install a pinion nut finger tight. This will hold the pinion in place while it is positioned into the press. 12. Remove the pinion nut. Drive Pinion 13. Place a press sleeve over the top of the outer bearing cone. Use the press to apply 5 tons of force.
Drive Pinion 14. With 5 tons of force on the press, you should be able to feel a small amount of drag from the bearing as you rotate the carrier. If the carrier turns with no drag at all, the pinion spacer thickness should be decreased by using a thinner spacer. If the carrier is hard to turn, the spacer thickness must be increased. 16. Run the nut down with an impact gun. The pinion should still have the same slight drag that was obtained in the press. 17.
Drive Pinion TIP: A torquing wedge can be made to hold the helical gear from turning while the nut is torqued. 20. Use an lbs. in. torque wrench and correct socket to check the rolling torque of the pinion. Read torque while rotating the assembly. Record the rotating torque, not the breakaway torque. Torque must be between 20 to 50 lbs. in. If the torque recorded is not within the specified torque, the pinion spacer must be changed. Repeat Steps 6-17. 18.
Drive Pinion 24. Use a dead blow mallet to seat the cover. CAUTION The stake must be deep enough to enter the machined slot of the pinion. See diagram below. 1 2 1 - Round Tipped Chisel 2 - Nuts Staking Flange 3 - Machined Slot In Pinion 3 25. If a pilot bearing web is used, lineup the web to the locating sleeves and tap in place with a rubber mallet. 1 WARNING 1 Failure to stake the pinion nut properly may result in the nut coming loose during service.
Wheel Differential Before July 2013 Wheel Differential Wheel Differential - Parts Exploded View After July 2013 1 2 3 2 3 4 19 18 4 5 5 7 8 17 6 8 7 6 9 12 9 11 15 16 6 16 6 11 14 10 10 1 - Threaded bearing adj - flange half 2 - Bearing cone - flange half 3 - Bearing cup - flange half 4 - Ring gear and pinion set 5 - Bolt 6 - Output side gear 7 - Side pinion thrust washer 8 - Differential spider 9 - Side gear 10 - Differential case - RH (plain half) 11 - Differential case - RH
Wheel Differential Wheel Differential Disassembly - Forward Carrier Assembly Before July 2013 IMPORTANT During the following procedures, place the differential assembly on a malleable surface to prevent damage when removing components. 1. Remove the differential case capscrews. 2. Remove the flange half differential case and bearing assembly. Use a screwdriver at the spider arm machined slots of the case to loosen the flange from the ring gear. 1 1 - Spider Arm Slots 36 3.
Wheel Differential Remove the bearing cones from the plain and flange halves in two steps: a. Mount the puller vertically to split the bearing. This action will start the bearing moving off the differential case. b. Mount the puller horizontally to remove the cone. Wheel Differential 6.
Wheel Differential Wheel Differential Assembly - Forward Carrier Assembly 4. Assemble the side pinions and thrust washers onto the wheel differential spider. Apply a thin coat of oil to the mating surfaces of the side pinion and differential spider. Install the wheel differential nest on top of the side gear 5. Install the flange half side gear and thrust washer. Apply a thin coat of oil to the mating surfaces. 6. Install the ring gear. Align the capscrew holes.
Wheel Differential Use a rubber mallet to seat the ring gear to the plain half. 9. Install the ring gear capscrews. 8. Install the flange half of the case. Align the capscrew holes. 10. Tighten the ring gear capscrews with an impact gun and then use a torque wrench to torque to the proper specifications. See the Torque Chart. Wheel Differential 7.
Wheel Differential 11. Lower assembled differential assembly in to the carrier using a hoist and a strap. Be careful not to damage the differential bearings lowering the assembly. 12. Install the bearing cup and bearing adjuster to the flange half side first. 1 1 - Flange Half 2 - Plain Half 13. Install the bearing cup and bearing adjuster to the plain half side. Use a long screwdriver or bar to lift the differential up while installing the cup and bearing adjuster.
Wheel Differential Backlash and Bearing Preload 2. Note: To install the wheel differential assembly, properly setup the gear pattern and set the differential bearing preload. This will require the use of the following Spicer tools or equivalent. These tools will allow you to align the bearing adjuster assembly to the carrier. This tool (part number 513061) will also gage the adjustment for the differential bearing preload and assist in setting the backlash.
Wheel Differential 4. Make sure that the bearings cage is parallel to the edge of the threaded cup. 6. Turn the plain half adjuster ring until there is zero preload on the bearings. This is done by turning the adjuster plate clockwise until you feel the threaded cup gain resistance. The threaded bearing cup should only be slightly snugged to achieve a zero preload condition. 1 1 2 1 1 - Parallel 5.
Wheel Differential Use a rubber mallet to fully seat the threaded bearing cups. 9. With a dial indicator, check the ring and pinion backlash. Set the backlash from 0.010" to 0.012". This will give you room to adjust the contact pattern, if necessary. 10. Remove the adjuster plates and threaded rod assembly. 11. Apply a 1/8” bead of Loctite 540 to the exposed threads of the bearing adjuster. 12. Install the carrier differential bearing caps and capscrews.
Wheel Differential 15. Measure the ring gear total radial runout. Indicator reading should not exceed 0.010" (0.25 mm). 18. With the carrier mounted in a head stand, roll the carrier on its side. 16. Measure the ring gear total backface runout. Indicator reading should not exceed 0.010" (0.25 mm). 19. Make a sling out of a strap and position around the plain half of the wheel differential. 20. Connect the end of the strap to a hoist and apply pressure to the sling. 17.
Wheel Differential 22. When contact pattern is correct, use a punch with a round head to stake the threaded bearing cups in place. Stake the outer edge of the bearing adjustment ring into the machined slots in the carrier bearing bore on both sides. Must be staked at two locations. Rotate cup if necessary to provide surfaces for staking. Wheel Differential 21. Use the correct socket and a breaker bar to rotate the differential. The differential should be hard to turn.
Wheel Differential Wheel Differential Disassembly - Forward Carrier Assembly After July 2013 IMPORTANT During the following procedures, place the differential assembly on a malleable surface to prevent damage when removing components. 1. Remove the differential case capscrews. 2. Remove the flange half differential case and bearing assembly. Use a screwdriver at the spider arm machined slots of the case to loosen the flange from the ring gear. 1 1 - Spider Arm Slots 46 3.
Wheel Differential Remove the bearing cones from the plain and flange halves in two steps: a. Mount the puller vertically to split the bearing. This action will start the bearing moving off the differential case. b. Mount the puller horizontally to remove the cone. Wheel Differential 6.
Wheel Differential Wheel Differential Assembly - Forward Carrier Assembly 4. Assemble the side pinions and thrust washers onto the wheel differential spider. Apply a thin coat of oil to the mating surfaces of the side pinion and differential spider. Install the wheel differential nest on top of the side gear. 5. Install the flange half side gear and thrust washer. Apply a thin coat of oil to the mating surfaces. 6. Install the ring gear. Align the capscrew holes.
Wheel Differential Use a rubber mallet to seat the ring gear to the plain half. 9. Install the ring gear capscrews. 8. Install the flange half of the case. Align the capscrew holes. 10. Tighten the ring gear capscrews with an impact gun and then use a torque wrench to torque to the proper specifications. See the Torque Chart. Wheel Differential 7.
Wheel Differential 11. Lower assembled differential assembly in to the carrier using a hoist and a strap. Be careful not to damage the differential bearings lowering the assembly. 12. Install the bearing cup and bearing adjuster to the flange half side first. 1 1 - Flange Half 2 - Plain Half 13. Install the bearing cup and bearing adjuster to the plain half side. Use a long screwdriver or bar to lift the differential up while installing the cup and bearing adjuster.
Wheel Differential Wheel Differential Install Wheel Differential Assembly - Forward Carrier Assembly Backlash and Bearing Preload 1. Turn the flange half bearing adjuster in until the ring gear contacts the pinion (zero backlash) then back the adjuster out two notches of the adjuster lugs. 3. Tighten the plain half adjuster two lug notches. Start with the notch at the top, count two notches counterclockwise on the adjuster so that the notch is facing straight up. You now have a two notch preload.
Wheel Differential 6. Install the carrier differential bearing caps and capscrews. Make certain there is no gap between the carrier cap and the carrier surface. 7. Use an impact gun to snug all carrier cap fasteners. 9. Measure the ring gear total radial runout. Indicator reading should not exceed 0.010" (0.25 mm). 10. Measure the ring gear total backface runout. Indicator reading should not exceed 0.010" (0.25 mm). 11. Check the ring gear tooth pattern.
Wheel Differential Wheel Differential 13. Make a sling out of a strap and position around the plain half of the wheel differential. 14. Connect the end of the strap to a hoist and apply pressure to the sling. 15. Use the correct socket and a breaker bar to rotate the differential. The differential should be hard to turn. Rotate the pinion until the ring gear rotates 3 or 4 times in both directions.
Ring Gear Adjust Tooth Contact Position Adjust Ring and Pinion Tooth Contact Pattern Used Gearing - Correct Pattern Note: Rear axle gearing is shown in the following instructions. Correct tooth contact patterns and adjustments are the same for forward and rear axles. 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.
Ring Gear Adjust Ring Gear Position (Backlash) If the 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. Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup. 4.
Wheel Differential Lock Wheel Differential Lock - Parts Exploded View 1 10 3 4 5 2 6 7 8 1 - Sliding clutch 2 - Spring 3 - Shift Fork 4 - Push rod 56 5 - Piston 6 - O-ring 7 - Piston cover 8 - Washer 9 9 - Switch 10 - Roll pin
Wheel Differential Lock Wheel Differential Install and Adjust Wheel Differential Lock Note: With differential carrier completely assembled and adjusted, install differential lock as follows: 1. If shift fork and sliding clutch are disassembled, engage fork with the clutch hub and install spring pin in the fork leg. See illustration below for fork mounting position on clutch. 2. Position compression spring, shift fork and clutch in shift opening of the carrier.
Output Shaft Assembly & Rear Cover Housing and Output Shaft Assembly - Parts Exploded View 1 2 3 4 5 6 7 8 9 10 11 13 21 19 12 20 14 15 22 16 17 18 25 26 24 23 Welded Rear Cover 27 1 - Output shaft nut 2 - Output yoke 3 - Output seal 4 - Snap ring 5 - Outer bearing cup 6 - Outer bearing cone 7 - Inner bearing cone 8 - Inner bearing cup 9 - Output shaft 58 10 - Rear cover 11 - Rear cover capscrew 12 - Fill plug 13 - Rear cover nut 14 - Washer 15 - Stud 16 - Spindle nut - Outer 17 - Lo
Output Shaft Assembly & Rear Cover Remove Output Shaft Assembly Note: For forward axle rear covers that are removable the output shaft may be removed when the cover is in or out of the axle assembly. Disconnect the inter-axle driveline at the forward axle rear cover position. 2. Remove yoke nut (shoulder nut). 3. Remove yoke from output shaft using appropriate tool. Remove output shaft and outer bearing cup as an assembly. 6 1 2 3 Output Shaft Assembly & Rear Cover 1. 6.
Output Shaft Assembly & Rear Cover 8. Remove both inner and outer bearing from output shaft. 1 1 - Press 60 9. Remove output shaft inner bearing cup. Note: Components such as the inter-axle driveline, yoke, oil seal and output shaft assembly should have been removed according to normal service procedures. Removing the differential assembly from the axle housing is not necessary, but would ease the removal process of the inner bearing cup from the cover bore. a.
Output Shaft Assembly & Rear Cover Overhaul and Assemble Output Shaft Assembly Note: Lubricate the parts with gear lube during assembly. 1. The output shaft bearings are assembled with both bearing cones back to back. Use a press and a sleeve to install one bearing at a time. CAUTION Using a sleeve and driver (hammer), install the outer bearing cup into the housing assembly over the output shaft bearing cone. 8.
Output Shaft Assembly & Rear Cover 6 1 2 3 4 5 10. Bolted rear cover only: If removed, install cover and fasten with nuts, capscrews and lock washers. Tighten to proper torque specifications. See the Torque Chart. Note: Use Spicer approved RTV compound on axle housing mating surface. Completely remove all old gasket material prior to applying new material. Compound will set in 20 minutes. Install axle housing cover and output shaft assembly before compound sets or reapply. 11. Install the output seal.
Output Shaft Assembly & Rear Cover Measure Correct endplay for a new assembly is 0.001" to 0.045" [0.03 to 1.143 mm]. The maximum endplay for a used assembly is no more than 0.045" (1.143 mm). If endplay is incorrect, contact Dana. 1. Install oil seal. 2. Install yoke. Output Shaft Assembly & Rear Cover 3. Install yoke nut. One of the following options may be utilized: a. Install a new nut with the pre-applied thread adhesive compound. Tighten the nut to the specified torque. See the Torque Chart. b.
Seal - Replace Replace Seal Spicer strongly recommends using seal drivers when installing new seals. Use the proper driver to make sure that the seal is square and installed to the proper depth. CAUTION Oil seals can be easily damaged prior to installation. Use care when handling the new seal to prevent damage or contamination. Leave the seal in its package until installation. On new yokes, leave the protector on the yoke until it is installed on the shaft to prevent damage or contamination.
Seal - Replace Guidelines for Reusing Yoke CAUTION Do not use the yoke if it has any damage on the seal surface (nicks or scratches). The surface of the yoke and the lips of the seal form a critical interface which retains the axle’s lubricant while sealing the axle from outside contaminants. The condition of the yoke hub’s surface is a very important factor in determining seal life. Carefully inspect the seal surface area of the yoke hub for signs of wear and damage.
Seal - Replace Service Kit D-Input D-Output R-Pinion Location Tool 210749 210749 131471 131472 66 131472
Housing Breather Housing Breather 1. Install fitting in breather hole. 2. Tighten fitting finger tight. 3. 4. Insert hose onto fitting, long end down. 5. Push hose firmly against fitting. Rotate hose to point down. Housing Breather Spicer has an axle breather that consists of a fitting, hose and clamp assembly. This breather design has improved resistance to water ingestion, clogging caused by dirt, ice or snow buildup around the base of the breather.
Wheel End Seal Wheel End Seal - Parts Exploded View 1 2 3 1 - Installation tool 2 - Seal 3 - Rear hub 68
Wheel End Seal Wheel End Seal Remove and Overhaul Wheel End Seal Install Wheel End Seal WARNING 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 1. Before installation, lubricate the following with the same lubricant used in the axle sump. • Inner bearing • Wheel seal (follow the directions provided by the seal supplier) 2. Place seal on installation tool. 3.
Wheel End Seal 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. Note: The lock washer for a four-piece tang/dowel-type wheel nut system is thinner than the lock washer for a threepiece tang-type wheel nut system and is not designed to bear against the inner nut. 1. Inspect the spindle and nut threads for corrosion and clean thoroughly or replace as required.
Wheel End Seal Four-piece Tang/Dowel-type Lock Washer System Wheel End Seal b. Install the outer nut on the spindle and tighten to 350 lbs. ft. (475 N•m). c. Verify endplay. Three-piece Tang-type Lock Washer System 4 3 5 2 1 1 3 2 1 - Inner Nut 2 - Dowel Pin 3 - Dowel-type Lock Washer 4 - Tang-type Lock Washer 0.0478" (1.2065 mm) thick 5 - Outer Nut 1 - Inner Nut 2 - Tang-type Lock Washer 0.123" (3.124 mm) thick 3 - Outer Nut a. Install the Tang-type lock washer on the spindle. a.
Wheel End Seal Verify Wheel Endplay Procedure Verify that endplay meets specification using a dial indicator. An indicator with 0.001" (0.03 mm) resolution is required. Wheel endplay is the free movement of the tire and wheel assembly along the spindle axis. Correct endplay is 0.001"–0.005" (0.025–0.125 mm). 1. Attach a dial indicator with its magnetic base to the hub or brake drum as shown below. 2.
Wheel End Seal Wheel End Seal Lubricate Wheel End Wheel Ends with an Oil Fill Hole CAUTION 1. Rotate the wheel end hub until the oil fill hole is up. Before operating the axle, the wheel hub cavities and bearings must be lubricated to prevent failure. 2. Remove the oil fill plug. When wheel ends are serviced, follow Spicer’s wheel end lubrication procedure before operating the axle. 4. Install oil fill plug and tighten to specified torque.
Wheel End Seal Wheel Ends Without Oil Fill Hole 1. With axle level and wheel ends assembled, add lubricant through filler hole in axle housing cover until fluid is level with the bottom of filler hole. 2. Raise the right side of the axle 6" or more. Hold axle in this position for one minute. 3. Lower the right side.
Lubrication General Lubrication Information 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 This product combines the latest manufacturing and part washing technology. When filled with a Spicer approved synthetic lubricant at the factory, the initial drain is not required. 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.
Lubrication Change Lube Drain Drain when the lube is at normal operating temperature (150°–200°F). It will run freely and minimize the time necessary to fully drain the axle, this insures the axle is flushed. Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container. Note: Lube fill capacities (see chart) are basic guidelines and will vary based on the angle the axle is installed in a particular chassis. Torque fill plug to 40–60 lbs. ft.
Lubrication Standpipes Drive axles are lubricated with oil drawn from a large sump integral to the assembly. Most axle designs attempt to position vital components such as pinion bearings in close proximity to this sump, keeping them bathed in a generous supply of oil at all times. When drive axles are installed at severe angles in vehicle chassis, the position of these components is changed relative to the oil sump. The same effect is present when the vehicle travels up a steep grade.
Lubrication 12° Installation Tandem Rear Axles Installation Angle* 5-10% Grade 10-15% Grade 15-20% Grade 0° – – – 3° – – 1.00" 5° – 1.00" 1.75" 7° – 1.75" 2.00" 10° – 2.00" 2.25" 13° 1.00" 2.25" 2.75" 15° 2.00" 2.50" 3.
Towing Guide Proper Vehicle Towing Without Wheel Differential Lock Lift the drive wheels completely off of the ground or damage will occur. With Wheel Differential Lock Follow this procedure to remove all axle shafts preventing gear rotation with the drive wheels and possible lubrication damage: 1. Engage the wheel differential lock, indicator light is on (move vehicle to verify engagement). Do not lift the front wheels (non-drive wheels).
Theory of Operation Power Divider Operation (Power Flow and Torque Distribution) In operation, the power divider accepts torque from the vehicle driveline and distributes it equally to the two axles. The inter-axle differential compensates for minor variations in speed between the two axles, the same way the wheel differential works between the two wheels of a single drive axle. This unit also acts as a central point in distribution of torque to the two axles.
Theory of Operation With Lockout Engaged (Inter-Axle Differential is Not Operating) Note: Varied road surface conditions can result in unequal torque distribution between the two axle assemblies. Lockout should only be engaged when both axles are rotating at the same speed. Operation should be limited to lowtraction situations and should be disengaged when normal traction returns. Failure to do so will result in poor handling and damage to the axle components.
Theory of Operation Operate Wheel Differential Assembly The Spicer wheel differential lock is driver-controlled and operated by a carrier mounted air-actuated shift unit. In operation, it positively locks the wheel differential to provide improved traction under adverse road conditions. Control Systems for Differential Lock Two systems may be used to control the differential lock operation.
Theory of Operation Direct Driver-Controlled System 1 2 14 11 10 12 5 13 9 1 - Cab-mounted control valve (plunger in—valve open) 2 - Dry air supply tank 80–120 PSI 3 - Preferably equal in length 4 - Power supply 5 - Fuse or circuit breaker 6 - Indicator light or audible signal 7 - Wheel differential lock indicator switch (part of axle assembly) 8 - Rear axle wheel differential lock air shift cylinder (part of axle assembly) 84 3 4 6 7 8 9 - Forward rear axle wheel differential lock air shift c
Theory of Operation Wheel Differential Lock The Spicer Wheel Differential Lock is an optional feature for Spicer Axles. In operation, it positively locks the wheel differential, to provide improved traction under adverse road conditions. The wheel differential lock consists of three major assemblies. • Shift Cylinder Assembly: Operates a shift fork and push rod assembly. The differential lock is driver-controlled through an electric switch or air valve mounted in the cab.
Theory of Operation Differential Lock Engaged Differential Lock Engagement Indicator Air pressure applied to the shift cylinder moves the piston, push rod, shift fork and the sliding curvic clutch engages the fixed curvic clutch. Differential lock engagement is detected by a switch (electric) mounted on the differential carrier. An actuator, mounted in the piston cover, operates the switch. The sliding clutch is splined to the axle shaft. The fixed clutch is splined to the differential case hub.
Parts Identification Power Divider - Parts Exploded View 1 2 44 3 4 5 6 7 19 High Entry Input Shaft Assembly 8 20 21 9 22 27 25 10 14 26 15 16 28 17 11 29 18 12 30 23 31 32 11 Parts Identification 24 13 33 34 35 43 42 36 37 41 40 1 - Output shaft nut 2 - Output yoke 3 - Output seal 4 - Output shaft bearing snap ring 5 - Outer bearing cup 6 - Outer bearing cone 7 - Inner bearing cone 8 - Inner bearing cup 9 - Output shaft 10 - Seal manifold 11 - Clamp 12 - Seal manifold feed
Parts Identification Forward Axle Pinion Assembly - Parts Exploded View 2 1 3 2 4 5 6 1 - Pinion pilot bearing 2 - Pinion 3 - Pinion bearing cone - inner 88 4 - Pinion bearing cup - inner 5 - Pinion helical gear 6 - Pinion bearing spacer 7 8 9 7- Pinion bearing cup - outer 8 - Pinion bearing cone - outer 9 - Pinion nut
Parts Identification Rear Axle Pinion Assembly - Parts Exploded View 2 3 4 1 5 2 5 - Pinion bearing spacer 6 - Pinion bearing cup - outer 7 - Pinion bearing cone - outer 8 - Oil seal 7 8 9 10 9 - Yoke 10 - Pinion nut Parts Identification 1 - Pinion pilot bearing 2 - Pinion 3 - Pinion bearing cone - inner 4 - Pinion bearing cup - inner 6 89
Parts Identification Wheel Differential - Parts Exploded View Before July 2013 After July 2013 1 18 2 17 2 3 3 4 4 5 5 7 8 16 6 8 7 6 9 9 11 12 14 15 6 6 15 11 13 10 10 1 - Threaded bearing adj - flange half 2 - Bearing cone - flange half 3 - Differential case LH (flange half) 4 - Ring gear and pinion set 5 - Bolt 6 - Side gear 7 - Side pinion 90 8 - Differential spider 9 - Differential case - RH (plain half) 10 - Differential case - RH (plain half) wheel diff lock 11 - Bearing co
Parts Identification Wheel Differential Lock - Parts Exploded View 1 10 3 4 5 2 6 7 1 - Sliding clutch 2 - Spring 3 - Shift Fork 4 - Push rod 5 - Piston 6 - O-ring 7 - Piston cover 8 - Washer Parts Identification 8 9 9 - Switch 10 - Roll pin 91
Parts Identification Housing and Output Shaft Assembly - Parts Exploded View 1 2 3 4 5 6 7 8 9 10 11 13 21 19 12 20 14 15 22 16 17 18 25 26 24 23 Welded Rear Cover 27 1 - Output shaft nut 2 - Output yoke 3 - Output seal 4 - Snap ring 5 - Outer bearing cup 6 - Outer bearing cone 7 - Inner bearing cone 8 - Inner bearing cup 9 - Output shaft 92 10 - Rear cover 11 - Rear cover capscrew 12 - Fill plug 13 - Rear cover nut 14 - Washer 15 - Stud 16 - Spindle nut - Outer 17 - Locking ring 18
Fastener Torque Specifications Fastener Torque Specifications Location Size Lbs. Ft. N•m Input Cage Locking Bolt M8 x 1.0 x 30 13 ± 17 17 ± 23 Input Cage Locking Stud M12 x 1.75 15 ± 20 20 ±27 Locking Stud Jam Nut M12 x 1.75 60 ±65 81 ± 88 IAD Shift End Cap 2.375 - 16 UN-2A 65 ± 10 85 ± 15 Power Divider Cover Capscrews M14 x 1.5 x 45 175 ± 10 235 ± 10 Input Shaft Nut M48 x 1.5 900 ± 100 1220 ± 135 Front Pinion Helical Nut M48 x 1.
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.
