dana spicer fa drive axles service manual for f155-s and f170
Contents
1. 100 0 800 0 Lor 600 0 LEL O IO O oc L TOO TSL 900 0 00 0 00 0 Leo lt 00 0 s lt o LOO O TOL O LTL SOO O est 900 0 tOc 800 0 LET 600 0 Tec OIO O ez lt t LOO soc cIO O SOO Ot lt vyoo o 970 00 Ot lt IOO O0 sco 100 O Leo cOO O Let 00 0 lt lt 900 0 100 0 600 O Tec OIO O TIIO O soc cIO O Ott 100 700 0 So 00 0 Leo coo 0t eco 100 0 r lt o cOO O BLO 00 0 yoo o lt lt r 900 0 100 0 coc 800 0 Tec OLO O oc LIO O soc 10 0 Ott 10 O Ott TIOO SLO 00 O Leo lt 00 0 eco 0 sco LOO O Leo cOO O SLO 00 O LECL 00 0 UuUsSZE L00 0 800 0 LECT 60070 lt L LOO soc cLoo Ott tIO O S E TIO O Isc SIO O Leo 000 sco TOO O eco TOO O Leo cOO O SLO O0O0 O voo o Let SOO O est 900 0 800 0 Lom 600 0 Tec OIO O soc cIO O Ott 10 O oct LASKO Ise SIO O Sor 9IO O eco LOO O eco LOO O Leo cOO O 97 0 00 0 TOO O LTI SOO O cst 900 0 Z L00 02. Loc 00 0 Tec OrO O oLc t LOO Ott tIO O Ott ISt SIO O 9100 LY0 O LOO O Leo cOO O 00 0 lt TOO O Let 00 0 cel 900 0 Z LOO O 800 0 Lc 600 0 Tec OILO O L LOO soc TOO Oct t 1070 Isc SIO O Sor 9100 ctt LIO O Let 8 L070 sco LOO O Leo cOO O 97 0 00 0 GNIADIWOLLOS 000 SHHONDdO L 000 0 Let 00 0 900 0 L00 0 coc 800 0 Lom 600 0 ONDTAVW NOINId MAN Tec It TOO soc lt Ott IO O sec stoo Sor 9IO O ctv LI0 O Lev 8IO O csv 6100 NOINId MAN OL ATO LAVHO ONLLLHS NOINId NOINId GTO 15 DIFFERENTIAL ASSEMBLY Differential Gear Thrust Washer Differential Side Gear Differential Pinion Mate Thrust Washer Differential Pinion Mate i Differential Bearing Cap Bolt a 115 135 Lb Ft 155 183 N m Differential Bearing Cap Washer Cott il M otter lt a me Ring Differential Case Cap Half Differential Case Nut 75 90 Lb Ft 00 120 N m ass Differential Bearing Cup Correct rivet head shape when properly compressed 5 4 5 1 If ring gear was remove
3. 800 0 Z O0 0 lt O r tO00 0 sos lt I0 0 ez lt TIO O Iro Ot vec OIO O Tec OrO Oct LTT 6000 LTT 6000 goc 800 0 SLI L00 0 SZ L00 O lt r 900 0 est 900 0 Let 00 0 00 0 So 00 0 t00 0r lt TOO O TSO 2 00 O TOO O SOO O lt lt r 900 0 LLO O c rec OIO Ot rec OrO Oc LTT 600 0 LTT 6000 coc 800 O coc 800 0 LO00 O cst 900 0 900 0 LTT 00 0 700 0 00 O Leo lt 00 0 sco 000 sco eco LOO O I SO Leo cOO O SLO 00 0 LTI 00 0 Let SOO O est 900 0 lt lt L 900 0 Z LO0O0 O L00 0 800 0 LTT 600 0 0 100 0 00 0 sco I0O O Leo 9 0 00 O ceri 900 0 L00 0 coc 800 0 LTT 60070 300 0 SZ 00 0 cst 900 0 t00 0 SO cOO O SLO 00 0 est 900 0 Z LOO O 800 0 Loc 00 0 Tec OIO O 100 0 900 0 Let 00 0 00 0 97 0 00 0O 00 0 Let S00 O
4. 1 Remove pinion bearing cage mounting bolts 6 2 Remove pinion bearing cage and cage assembly from carrier housing If difficulty is encountered in removing pinion assembly from carrier place a brass 7 drift on inner end of pinion and tap lightly NOTE Retain shims for possible use during 8 reassembly 9 3 Mount pinion assembly in a soft jawed vise or fixture holding yoke or pinion stationary Remove roll pin nut and spacer 11 4 Remove the end yoke or drive gear using a suitable press 5 Remove pinion from cage assembly 10 End Yoke Assembly Located between pinion bearings is a selective spacer used for pinion bearing preload Retain this spacer for possible use in reassembly Remove old pinion seal and discard Always replace it with a new seal at time of reassembly Lift out the outer pinion bearing cone Remove inner pinion bearing cup using a suitable adapter and press or puller Remove roller bearing from end of pinion Remove inner bearing cone from pinion Pinion Disassembly Complete CLEANING AND INSPECTION CLEANING 1 Parts should be cleaned with emulsion cleaners or troleum base cleaning solvent NOTE Alkaline type solutions may cause damage to machined surfaces and should be avoided 2 Make sure interior of axle housing is clean prior to reas sembly 3 Cleanall gasket surfaces of old material DRYING Inspect gears for excessive wear or damage Replace Use
5. 55060 Telephone 1 800 533 0492 Fax Number 1 800 578 7375 23 DANA SPICER Drivetrain Products Axles Driveshafts Off Highway Transmissions LONG Thermal Products Transmission Oil Coolers Engine Oil Coolers VICTOR REINZ Sealing Products Gaskets and Seals Cylinder Head Cover Modules Thermal Acoustic Protective Shielding Dana Aftermarket Group PO Box 321 Toledo Ohio 43697 0321 Warehouse Distributors 1 800 621 8084 OE Dealers 1 877 777 5360 WWW spicerparts com AXSM 8663 Printed in U S A Copyright Dana Limited 2012 All rights reserved Dana Limited SPICER
6. LUBRICANT LEVEL Tighten the inner adjusting nut to 120 140 Lb Ft 165 190 N m while rotating the hub to seat the bearings Back off the adjusting nut 1 2 turn and follow the proedure outlined in step 5 6 Install lock against inner wheel nut with locking portion positioned on either the flat side of inner nut or peak of inner nut as shown 7 Install outer wheel nut and torque to 250 275 Lb Ft 340 373 N m Rotate wheel in both directions Wheel must rotate freely with out binding 8 Bend one tang of lock over flat portion of outer wheel to secure 9 Remove old axle flange gasket and clean mating sur faces of hub and axle flange 10 Install new axle flange gasket 11 Install axle shaft Torque axle nuts to specifications See Axle Torque Specifications pg 21 INSTALLATION OF DIFFERENTIAL CARRIER INTO AXLE HOUSING Thoroughly clean the inside of the carrier housing and inspect the housing mounting surface for nicks and general cleanliness Stone the surface if neces sary to remove burrs or nicks Bolt holes must also be checked to see that they are free of contami nants Loctite 518 Gasket Eliminator Figure 15 Apply 125 inch 3 175 mm diameter bead of Loctite 518 gasket eliminator onto the axle housing mounting flange and around each bolt hole See Figure 15 Thread two studs into the axle housing 180 apart This will eliminate rotation of the carrier assembly af
7. Pinion Bearing Cage Bearing Cone Pinion Oil Seal Outer Pinion Bearing Cup Optional Pinion Bearing Cage Bolt 160 180 Lb Ft End Yoke 217 244 N m Assembly Flanged Hex Nut 700 900 Lb Ft 950 1 220 N m REMOVAL OF DIFFERENTIAL CARRIER FROM AXLE HOUSING NOTE Steam clean axle assembly 1 Block wheels 2 Remove axle housing drain plug and drain lubricant 3 Disconnect drive shafts at the rear U joint NOTE If end yoke and or seal is to be replaced loosen yoke nut at this time 4 Remove axle shaft flange nuts 5 Hold a large brass drift or a brass hammer against the center of the axle shaft flange Strike the drift with sharp blows from a large hammer or sledge until the axle shaft separates from the hub A CAUTION Do not strike the flange directly with a steel hammer or sledge This may crack and splinter material possibly causing serious or fatal injury Do not pry or chisel axle flange away from hub or damage to sealing surfaces could occur 6 Remove axle shafts 7 Support the differential carrier assembly on a roller jack Secure as necessary to prevent it from falling off the jack when removed from the housing 8 Use a breaker bar to loosen the differential carrier to housing mounting bolts Remove all bolts except top two These two bolts will prevent the carrier assembly from falling 9 Separate differential carrier from the housing Be certain carrier is balanced pro
8. ER OR ALTER BRAKE LININGS IN ANY MANNER WITHOUT PROPER PROTECTIVE EQUIPMENT FOLLOW 0 S H A STANDARDS FOR PROPER PROTECTIVE DEVICES TO BE USED WHEN WORKING WITH BRAKE MATERIALS AXLE COMPONENTS Axle Shaft Housing Vent Plug Fill Plug 35 45 Lb Ft Differential Bearing Cap Hex Bolt 7 9 Lb Ft 12 N m P Magnetic d Nn SN lt Nap Oil Scoop gS a Adjusting Ring NN N Differential Bearing Cup Differential Bearing Cap Bolt 115 135 Lb Ft 155 185 N m Differential Bearing Cap Washer Differential Pinion Mate Thrust Washer Differential Pinion Mate MN Differential Cross Shaft Differential Side Gear Differential Bearing Cone Differential Case Bolt Differential Case Flange Half Iona S Differential Gear i SS o ange Ha Pinion Up Components Thrust Washer EN JR e Ring Gear CD Ring Gear Rivet amp 5 Cotter Pin Carrier Housing Ring Gear Bolt Kit Oil Deflector Adjusting Ring 300 320 Lb Ft p Lock 406 434 N m ni Pinion Position Shi Differential Case Nut 75 90 Lb Ft 100 120 N m Differential Case Cap Half qo Carrier Mounting Bolt 1 f 100 120 Lb Ft lt gt e No SPIN Differential 136 162 N m Pinion 5 Outer Pinion Inner Pinion Bearing Cone 4 Inner Pinion Bearing Cup Pinion Bearing Spacer Selective
9. S OF OPTIONAL VEHICLE SERIAL NUMBER OPTIONAL l bana PART The axle assembly tag contains the following items NUMBER CUSTOMER PART NUMBER Dana part number julian date code axle model and MODEL ratio Optional items include customer part number line set number and the last six digits of the vehicle QQeRDOQD 0 Model serial number ADM F178 5 L _ _ _ __ SER 3 RW 97170 622110 3 73 RI 4400 JULIAN DATE Axle Assembly Tag CODE LINE SET NUMBER LAST SIX DIGITS OF OPTIONAL VEHICLE SERIAL NUMBER OPTIONAL MODEL IDENTIFICATION NUMBERING SYSTEM Load Carrying Capacity 155 15 500 Lbs 170 17 000 Lbs N No SPIN option P s IN Options Gearing Type S Single Reduction No SPIN is a registered trademark of Tractech GEAR SET IDENTIFICATION Manufacturer s Date Date gear set was made Spicer Trademark Dana Diamond and location of SPICER PINION TRADEMARK ETCH manufacturing facility 15 029GP100 Part number of pinion TYPICAL V 260 029 GR107 Part number of ring gear TYPICAL eu 25 Tooth Combination i e 41 11 Indicates the pinion TOOTH PART SPICER MATCHED COMBINATION NUMBER CODE TRADEMARK DATE SET NUMBER has 11 teeth and the ring gear has 41 teeth which results in a 3 73 1 ratio Matched Set Number Spicer ring gears and pinions are manufactured as matched sets Both ring gear and pinion are marked with a c
10. Spicer Drive Axles SPICER Service Manual Spicer Drive Axles AXSM 8663 September 2007 TABLE OF CONTENTS Axle Identification csscsssscsssscssssssssessssscssecsnsecssesssessssssecsssees 1 Identification esses teen ette tennis 2 Model Identification Numbering System Gear Set Axle Lubricant Recommendations 3 General Precautions l 4 Axle Components nui rasa e pen apii qae dut 5 Removal 6 Differential Carrier from Axle Housing Differential from Carrier Differential Disassembly 7 Pinion Above Center 8 Pinion Disassembly 9 Cleaning and Inspection u 10 Pinon ASSERIDD anie Dinan Pt tae asa Pinion POSION ee omm NM md 15 Pinion Setting 14 Differential Assembly uisi dbi tiet nite iacent 16 Differential Installation 17 Ring Gear and Pinion Tooth Contact Pattern 18 Wheel Bearing Adjustment s 19 Installation of Differential Carrier Into Axle Housing 20 Axle Torque Specifications ics a 21 Recommended Service Tools a 22 GENUINE SPICER SERVICE PARTS Should an axle assembly require replacement component parts it is recommended that Spic
11. age Install outer pinion bearing cup into pinion bearing cage Use a feeler gauge or shim stock 0015 Approx to ensure bearing cups are completely seated in bearing bores This is necessary for proper pinion position PINION ASSEMBLY Inner Pinion Bearing Cone Pinion Bearing 3 Pinion Bearing Cage Outer Pinion Bearing Cone Pinion Oil Seal Flanged Hex Nut 700 900 Lb Ft 950 1 220 N m End Yoke Assembly Feeler Gauge Place pinion bearing spacer that was removed during disassembly onto pinion Place pinion bearing cage onto inner pinion bearing cone Install outer pinion bearing cone and washer on to pinion Inspect end yoke or flange for grooves in seal surface caused by contaminants If grooves can be detected with fingernail then end yoke must be repaired with a CR approved repair sleeve replaced Install end yoke onto pinion without seal to allow proper setting of bearing preload Torque pinion nut to 700 900 Lb Ft 950 1 220 N m See Figure 8 PINION ASSEMBLY Yoke Installation Tool d 1009 Figure 8 To measure preload with spring scale clamp the end yoke horizontally in a soft jawed vise Attach one end of cord to a bolt hole in the pinion bearing cage and attach the other end of the cord to the spring scale Rotate pinion cage and attach the other end of cord to the spring scale Rotate pinion bearing cage by pulling scale Read scale durin
12. d from the differential case reinstall it at this time Bolt ring gear to differential case in two places 180 apart before compressing rivet this will eliminate ring gear runout Use a hydraulic or mechanical press and riveting fixture 6 Pressure requirement per rivet is 45 50 tons or 41 45 metric tonnes NOTE Ring gear and pinion must be replaced as a 7 matched set only 2 Press differential bearing cones onto differential 8 case halves Place differential bearing cups on 16 Ring Gear lt 7 Differential Cross Shaft Differential Bearing P Hex Bolt 7 9 Lb Ft 9 12 N m Washers Oil Scoop Ys n ag Misi Ring Differential Bearing Cone Differential Case Bolt 9 Differential Case Flange Half Ring Gear Rivet Ring Gear Bolt Kit 300 320 Lb Ft 406 434 N m Optional cones during remainder of assembly to prevent damage of bearings Apply a small amount of gear lubricant to all mating surfaces This will aid in assembly by keeping parts together and providing initial lubrication Place differential gear thrust washer and differential side gear in differential case flange half Assemble differential pinion mates and differential pinion mate thrust washers onto differential cross shaft Place assembly into differential case flange half Place remaining differential side gear and differential side gear thrust washer in position on differen
13. e GENERAL PRECAUTIONS A IMPORTANT READ THIS SECTION BEFORE STARTING ANY SERVICE PROCEDURES GENERAL AXLE DESCRIPTION This manual covers maintenance and rebuild proce dures for the Spicer F155 S and F170 S rear drive axle assemblies The Spicer Heavy Duty Single Reduction rear drive axle is a full floating axle assembly with a hypoid gear carrier assembly using a High Strength Low Alloy HSLA steel axle housing The hypoid pinion is straddle mounted with two tapered roller bearings behind the pinion teeth for thrust and radial loads A pilot bearing is located on the nose of the pinion for radial load The differential itself uses four precision forged pinion mate gears a forged cross and precision forged side gears Safety glasses should be worn at all times when assembling or disassembling axles SAFTEY PRECAUTIONS Proper service and repair of vehicle components is important to the safe and reliable operation of all motor vehicles This applies particularly to driving axles such as the ones described in this manual The procedures recommended and described in this manual are tested effective methods for performing service operations Follow each procedure closely making use of both the text and illustrations Some of these service procedures show the use of certain tools designed specifically for the operation being performed They are shown as a preferred means of performing the operation It is not practical
14. e a soft hammer or H D plastic head hammer to strike punch NOTE Do not use a chisel to remove rivet heads damage to differential case may result See Figure 5 Differential Disassembly Complete INCORRECT PROCEDURE Ring Gear Figure 5 PINOIN ABOVE CENTER APPLICATIONS The F155 S and F170 S axle assemblies may be specified for pinion above center applications such as motor homes buses or other rear engine chassis vehicles The following modifications to the carrier assemblies have been made to insure proper lubrication when axle assembly is mounted with pinion above center The F155 S and the F170 S need to have two oil scoops and an additional oil passage in the pinion bearing cage as shown in the illustration to the right Mounting screws for the oil scoop must be cleaned and coated with 271 Loctite or its equivalent The 3 8 inch oil scoop mounting bolts must be tightened to 34 38 Lb Ft 46 51 N m torque See Figure 6 Oil Scoops p Pinion Position Shim s a Pinion Pilot Bearing Carrier Mounting Bolt 100 120 Lb Ft 136 162 N m Pinion Bearing Preload a 320 Outer Pinion Bearing Cup ay Dog PINION DISASSEMBLY Inner Pinion Bearing Cone Ox Pinion Bearing Cup y Pinion Bearing Cage Outer Pinion Bearing Cone up Pinion Oil Seal 7 Flanged Hex Nut 700 900 Lb Ft 1 220 N m H Pinion Bearing Cage Bolts 160 180 Lb Ft 217 244 N m
15. e lubricant be drained and all parts be inspected for water damage and or contamination Reassemble the carrier to the housing and refill with specifed gear lubricant PETROLEUM BASED SYNTHETIC BASED APPLICATION PETROLEUM BASED SYNTHETIC BASED MILES INTERVAL MILES INTERVAL On Highway 100 000 1 Year 250 000 3 Year Severe Service and 50 000 1 Year 100 000 1 Year On Off Highway Severe service includes any applications operating at or near maximum GVW or GCW ratings This includes normally wet or dusty environments or consistent heavy load and low speed applications Includes Semi Synthetic blends that meet MIL L 2105D specifications AFTER OVERHAUL OR CHANGE INTERVALS Fill the axle assembly to the bottom of housing fill hole as shown in the illustration below It is recommended that following an overhaul each side of the axle be jacked up seperately to approximately six inches and held into position for one minute This procedure will allow adequate lubricant to flow into the wheel ends and help eliminate the possibility of premature damage to wheel bearings and seals Lower the vehicle to the floor and allow ten minutes for lube to return to normal level Check and refill assembly to bottom of fill hole to replace the lubricant that was directed into the wheel ends NOTE Lubricant close enough to the bottom of the fill hole to be seen or touched is not sufficient Lubricant must be level with the fill hol
16. er Heavy Axle Service Parts be used Spicer Heavy Axle Service Parts are manufactured under the same rigid specification as are original equipment axle components This assures the customer who uses genuine Spicer service parts maxi mum reliability for a Spicer Heavy Axle assembly They may be obtained through your vehicle manufacturer SPICER The use of non original Spicer service parts may cause premature component failure and may void the warranty The items included in this book are currently being offered as service parts at the time of printing The part numbers and illustrations are provided specifically for reference purposes only Therefore Spicer reserves the right to update this manual without notice or liability AXLE IDENTIFICATION All axle assemblies are identified with two tags One located on the differential carrier and the other located on the right hand side of the axle housing JULIAN DATE CODE 97 1070 The differential carrier tag contains the following Dana part number julian date code and ratio Optional MODEL YEAR DAY OF YEAR items include customer part number line set number and the last six digits of the vehicle serial number DANA PART NUMBER CUSTOMER PART NUMBER OPTIONAL P CARRIER CAQ OX JULIAN DATE ili T SER SPICER 97070 620112 RATIO 444 RI 4242 l Carrier Tag LINE SET l NUMBER LAST SIX DIGIT
17. ere is backlash between the ring gear and pinion See Figure 13 Figure 13 5 Loosen adjusting ring on tooth side of ring gear 1 notch and tighten adjusting ring on flange side of ring gear 1 notch Repeat process until backlash is eliminated Tighten adjusting ring on tooth side of the ring gear 2 or 3 notches or until proper backlash and side bearing preload are established 6 Check ring gear and pinion backlash in four equally spaced positions around the ring gear with a dial indicator as shown Acceptable backlash tolerance is 006 012 See Figure 14 NOTE 080 mm between the four positions remove the If backlash tolerance varies more than 005 differential and determine the cause 7 Once backlash is set torque the differential bearing cap bolts to 115 135 Lb Ft 155 185 N m Check backlash after torquing cap bolts Figure 14 Differential Installation Complete RING GEAR AND PINION TOOTH CONTACT PATTERN The procedures to the right are to be used to establish proper gear tooth pattern after assembly of the carrier is complete NOTE If matched sets are being reused measure and record backlash before disas sembly and reassemble to the same backlash This will match ring and pinion gears to the established wear patterns Hand rolled pat terns will cover less area than the gear pattern wow n n PROFILE established by previous service HEEL STEP 1 Paint 1 4 ring gear
18. g fourth revolution Scale reading must be between 3 9 Ibs See Figure 9 Figure 9 12 Measure torque to rotate with an inch pound torque wrench Torque measurementsshould be taken every fourth revolution and should read between 10 50 in lbs of bearing preload See Figure 10 NOTE If bearing preload does not fall within allowed limits preload can be increased by using a thinner spacer and decreased by using a thicker spacer 001 change in preload spacer thickness will change torque to rotate approximately 30 in Ibs Figure 10 NOTE Individual carriers may vary slightly Pinion bearing preload spacers are available in several thicknesses Refer to service parts booklet for kits of commonly used preload spacers Always measure each spacer before assembly to ensure correct thickness NOTE Closer adjustment can be made by sanding the next thicker spacer to desired thickness using emery cloth on a flat surface CAUTION Wash spacer thoroughly of emery cuttings before installing on pinion NOTE Spicer recommends that new torque prevail ing nuts be used 13 Apply Loctite 680 green to threads 14 Install new pinion oil seal Apply a small amount of light greas e to the seal lip Prior to installing yoke 15 Use torque multiplier and torque flanged hex nut to 700 900 Lb Ft 950 1 220 N m Pinion Assembly Complete Ring gears and pinions are supplied in
19. inion Bearing Cage Bolts 9 16 12 8 160 180 217 244 Differential Bearing Cap Bolts 9 16 18 8 115 135 155 183 Differential Case Nuts 1 2 8 75 90 100 120 Carrier Mounting Bolts 1 2 13 8 100 120 136 162 Differential Case Oil Scoop Bolts 1 4 20 8 7 9 9 12 Axle Flange to Wheel Hub Nuts 9 16 18 5 95 115 129 155 Axle Specifications Item U S Metric Pinion Bearing Preload Pull Scale 3 9 Lbs 1 4 4 0 Kg Torque Wrench 10 30 Lb in 1 1 3 4 N m Differential Ring Gear to Pinion Backlash 008 012 23 55 mm Ring Gear Rivet Pressure 45 50 tons 41 45 tonnes Lubrication Lube Capacity Approx 25 pints 11 liters Pinion Nominal Dimension 3 4725 88 20 mm Pinion bearing preload is established prior to installation of pinion seal Capacity will vary depending on the housing angle in each vehicle Fill to lower edge of fill hole in rear of axle housing as shown on page 3 RECOMMENDED SERVICE TOOLS ORDER NUMBER ILLUSTRATION DESCRIPTION DST1001 Nia CARRIER STAND TORQUE MULTIPLIERS DST1002 Maximum 1 000 Lb Ft DST1003 Maximum 2 000 Lb Ft DST1004 Maximum 4 000 Lb Ft DST1005 Maximum 12 000 Lb Ft DST1006 De Q8 YOKE REMOVER BAR TYPE 22 RECOMMENDED SERVICE TOOLS ORDER NUMBER ILLUSTRATION DESCRIPTION DST1000 1 SEAL INSTALLATION TUBE HANDLE DST 1020 PINION SEAL INSTALLER ALL SERVICE TOOLS AVAILABLE FROM OTC DIVISION Service Tools 655 Eisenhower Drive Owatonna MN
20. matched sets only Matching numbers on both the pinion and ring gear are etched for verification If a new gear set is being used verify the numbers of each pinion and ring gear before proceeding with assembly See Gear Set Identification pg 2 Pinion Positon Shims Aay SS Pinion a Mounting Distance aa Ring Gear Pinion position is based on the nominal mounting distance measured from the centerline of the ring gear to the nose of the pinion This dimension is controlled by selectively shimming between the pinion cage assembly and the carrier housing The nominal dimen sion is 3 976 in 100 990 mm NOTE Be sure mounting surfaces and shims are free of burrs and dirt prior to assembly as they will affect pinion position 1 To establish the correct nominal dimension by using a pinion setting gauge install pinion and cage assembly into the carrier housing without shims Tighten pinion cage bolts to correct torque specifi cations See Axle Torque Specifications pg 21 Failure to tighten properly may result in incorrect gear adjustment 2 Attach the step plate clamp assembly to the carrier mounting flange Locate step plate clamp screw over center of pinion Install step plate under clamp screw and tighten to hold step plate securely in position NOTE Be s
21. nd adjust the thickness of the shims to compensate for the difference of these two figures as shown in table on next page For example if the old pinion is etched 2 and the new pinion is 2 subtract 004 in from the thickness of the original shims used to position the pinion If either or both the pinions are etched beyond the values on this chart follow the same procedure to establish correct pinion position For example if the old pinion is etched 12 and the new pinion is etched 9 add 021 inch to the thickness of the original shims After determining the new total build up of pinion position shims round the figure off to the nearest multiple of 005 inch Use the Pinion Setting Chart on the next page as a guideline to set the pinion PINION SETTING CHART ctt LIO O Sor 9100 ISt SIO O Ott tIO Ot soc 0 LTT 6000 0 Leo lt 00 0 oop 9100 rss SIO Ot OSt vIO Oct soc lt 10 0 6ZLc LIO Oc coc 800 0 O70 00 0c sco IO0 0 Ise SIO O t VIO O Ott IO O vec Oro oc SLE 1000 Leo lt 00 0 gsc vrIO O Ott IO Ot soc Tec OIO Ot LTT 600 0 est 900 0 eco I00 0 Ott IO O soc clLoor Iro or LTT 6000 EOT 8000 ctr S00 0r soc 0 100 rec 0100 goc
22. orresponding number i e 401 which identifies them as a matched set A gear set that does not have the same match set BACKAS numbers should not be run together If either ring gear SIGH or pinion require replacement a new matched set must be used Backlash Etch Indicates backlash setting for assembly Pinion Etch Indicator for proper pinion position shim stack up See Pinion Position Section AXLE LUBRICANT RECOMMENDATIONS To ensure proper lubrication and operating temperature correct lubricants and lubricant levels must be obtained RECOMMENDED LUBRICANTS Mineral or Synthetic based hypoid gear lubricants that meet or exceed military specification MIL L 2105D and API service classification GL 5 are the minimum require ments for use in Spicer Medium and Heavy Duty Drive Axles The table below indicates which SAE viscosities are recommended for various temperature ranges the vehicle will encounter SAE 85W 140 SAE 80W 140 SAE 80W SAE 75W 140 SAE 75W 90 SAE 75W C 40 26 12 0 4 15 27 38 F 40 15 10 32 40 60 80 100 F Ambient Air Temperature SERVICE Recommended lubricant change intervals are dependent on the application and operating environment The following chart should be used to establish proper change intervals SUBMERSION OR DEEP WATER FORDING In the event the axle assembly should become submerged in water particularly if over the vent or breather it is recommended that th
23. perly on jack and remove top two carrier to housing mounting bolts Remove differential carrier assembly from the axle housing Mount carrier assembly in a suitable rebuild stand Refer to Recommended Service Tools pg 22 Differential Carrier Removal Complete REMOVAL OF DIFFERENTIAL FROM CARRIER 1 Remove adjusting ring locks from bearing caps 2 Match mark one differential bearing cap and leg with center punch or chisel for correct reassembly See Figure 1 Loosen four bearing cap retainer bolts OW Loosen adjusting rings relieving bearing preload Remove four bearing cap retainer bolts Remove bearing caps Remove adjusting rings Carefully lift the ring gear and differential subassembly out of the carrier NOTE Use care not to damage the ring gear and pinion If either ring gear or pinion show signs of damage they must be replaced as a matched set Removal of Differential Complete Differential Side Gear Differential Pinion Mate Thrust Washer Differential Pinion Mate n Differential Bearing Cap Bolt 115 135 Lb Ft 155 185 N m St Cap Washer Adjusting Ring Lock 75 90 Lb Ft 100 120 N m Differential Bearing Cup 1 Match mark differential case halves with punch or chisel for correct alignment during reassembly See Figure 2 Figure 2 2 Remove differential case nuts and lift off the differential ca
24. se half 5 Remove thrust washer and differential side gear 4 Lift out cross shaft pinion mates and thrust washer 5 Remove second differential side gear and thrust washers Washer Ring Gear X Oil Scoop YS _ S Differential Gear Thrust Washer gt N adjusting ae Rin Differential Bearing 8 lt Differential Case Nut 4 ew Se o 2 Half DIFFERENTIAL DISASSEMBLY N P Hex Bolt 7 9 Lb Ft AN 9 12 N m 9 Differential Bearing 5 p d Differential Bearing Cone Differential Case Bolt Differential Case Flange Half Ring Gear Bolt Kit 300 320 Lb Ft 406 434 N m Differential Cross Shaft Optional Figure 3 6 If differential side bearings are to be replaced remove old bearings using suitable puller See Figure 3 NOTE Inspect all parts including the machined surfaces of the case itself DIFFERENTIAL DISASSEMBLY IMPORTANT If any gears are to be replaced they must be replaced in sets Inspect thrust washers for scoring and excessive wear Replace all worn or damaged parts 7 When it is necessary to remove ring gear from differential case carefully center punch each rivet head Use a 9 16 drill bit and drill through rivet heads See Figure 4 CORRECT PROCEDURE Ring Gear Figure 4 8 Next use a round type punch to drive out the remaining portion of the rivet A CAUTION Always us
25. soft clean lintless towels or rags to dry components gears that are pitted scored broken or worn after cleaning Bearings should not be dried by spinning with compressed air This can damage mating surfaces SHAFTS due to the lack of lubrication After drying parts should be coated with a light coat of lubricant or rust inhibitor to prevent damage from corrosion If parts are to be stored for a prolonged period they should be wrapped in wax paper INSPECTION Inspect shafts for nicks or scoring Prior to reassembly inspect parts for signs of excessive wear or damage Replacement of these parts can prevent SPLINES premature failure and costly downtime Inspect all splines for excessive wear distortion from twisting and cracking BEARINGS Bearing surfaces should be inspected for pitting excessive HOUSINGS wear or overheating THRUST WASHERS Inspect housing for stripped threads and bending fatigue Inspect thrust washers for scoring and cracking Carrier Mounting Bolt 100 120 Lb Ft 136 162 N m Outer Pinion Bearing Cup Pinion Bearing Cage Bolts ae Pinion Position Shim s 0 p Pinion Pilot Bearing 160 180 Lb Ft 217 244 N m Figure 7 Press inner pinion bearing cone onto pinion Press pinion pilot bearing onto nose of pinion Stake nose of pinion in 6 places using a center punch or equivalent tool See Figure 7 Install inner pinion bearing cup into pinion bearing c
26. tched with 0 If the pinion is marked 3 the shim required between pinion gearing cage assembly and carrier housing would be 003 in 076 mm thinner than if pinion was etched 0 PINION POSITION 5 Pinion shims are available in the following thick nesses Inches MM 005 127 010 254 030 762 6 Position shims carrier housing so oil return holes align properly Use a minimum of three shims in a pack If the pack is made of different shim thick nesses install the thinnest shims on both sides of NOTE Be sure mounting surfaces and shims are free of dirt and nicks prior to assembly or leaks will occur and pinion position can be affected 7 Install pinion and pinion cage assembly into carrier NOTE Studs can be used to assist in alignment 8 Tighten pinion cage to carrier bolts See Axle Torque Specifications Chart pg 21 9 An alternative to using the pinion setting gauges is to follow the procedure described in the following section Pinion Position Complete the pack for maximum sealing PINION SETTING CHART When a new gear set is being installed use a microme ter to measure the thickness of the old pinion position shims Measure each shim separately and add together to get the total thickness of the original build up NOTE If old shims are bent or mutilated they should be replaced If a new gear set is being used notice the or 0 etching on both the old and the new pinions a
27. ter it makes contact with the gasket material Install the carrier assembly into the axle housing If reinstalling used bolts clean the mounting bolts and coat with Loctite 277 and install Tighten bolts evenly in a crossing pattern Torque bolts 100 120 Lb Ft 136 162 N m Allow one hour cure time for gasket material before adding hypoid gear lubricant 20 6 Remove the old axle flange gasket and clean mating surfaces of the hub and axle flange 7 Install the new axle flange gasket 8 Install the axle shafts to proper location Torque the axle flange nuts to vehicle manufacturers specifications 9 Clean drain plug and install Torque drain plug to 35 45 Lb Ft 47 61 N m Fill unit to proper level with hypoid gear lubricant 10 Install fill plug and torque to 35 45 Lb Ft 47 61 N m NOTE Lubricant close enough to bottom of fill hole to be seen or touched is not sufficient Lubricant must be level with the fill hole Pints Liters F155 S amp F170 S 11 Lube capacity will vary depending upon the housing angle in each vehicle Capacities given above are for an angle of 4 degrees Fill to the lower edge of the fill hole in the axle housing as shown above Pour 1 Pint 0 5 Liter of gear lube into the filler hole in top of Inter axle Differential cover AXLE TORQUE SPECIFICATIONS Hex Head Fasteners Position Thread Grade Lb Ft N m Flanged Hex Nut 1 3 4 12 8 700 900 950 1 220 P
28. tial pinion mates Assemble case halves making sure match marks are lined up Install differential case bolts and torque differential case nuts evenly to 75 90 Lb Ft 100 120 N m Differential Assembly Complete DIFFERENTIAL INSTALLATION Oil Scoop _ Mounting Gg Figure 12 1 Assemble oil scoop onto differential case See Figure 12 Clean and coat bolts with Loctite 277 or its equivalent Assemble and torque bolts to 7 9 Lb Ft 9 12 N m A CAUTION Differential assembly must be aligned within bearing bores before preload is applied or damage to bearings could occur 2 Install ring gear and differential assembly into carrier housing Tilt differential slightly so ring gear clears straddle bearing support CAUTION To avoid damage of the ring gear and pinion care should be used when installing the ring gear differential assembly into the carrier housing 3 Be sure side bearing cups are seated on bearing cones Assemble differential bearing caps with match marks in proper location Clean differential bearing cap bolts and washers and coat threads with Loctite 277 or its equivalent Install bearing cap bolts and tighten enough to eliminate visible space between differential bearing cap and carrier housing Do not torque the cap bolts at this time 4 Install adjusting rings Tighten both adjusting rings until end play is eliminated and th
29. to anticipate and advise the service trade of all possible alternative methods and of all possible hazard ous consequences that could occur Accordingly anyone who uses a service procedure or tool different than shown must insure that their safety and the vehicle s safety will not be jeopardized by the service method selected END YOKES AND FLANGES A CAUTION Hammering on end yokes can close in the bearing bores or misalign yoke lugs and result in early failures of journal needle bearings or other driveline components Serious damage can also be done internally to the ring and pinion set or pinion bearings by hammering on external parts End yokes or companion flanges should be removed or installed using the recommended methods outlined in this manual CLEANLINESS Axle components should be steam cleaned prior to removal from the vehicle Dirt is abrasive and will cause premature wear of otherwise serviceable parts Service personnel should use a wash tank for thorough cleaning of parts just prior to reassembly CAUTION BRAKE LININGS CONTAIN NON ASBESTOS FIBERS BREATHING BRAKE DUST MAY BE HAZARDOUS TO YOUR HEALTH AND MAY CAUSE SERIOUS RESPIRATORY OR OTHER BODILY HARM AVOID CREATING DUST DO NOT REMOVE BRAKE DRUM WITHOUT PROPER PROTECTIVE EQUIPMENT DO NOT WORK ON LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT DO NOT REPLACE LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT DO NOT ATTEMPT TO SAND GRIND CHISEL FILE HAMM
30. ure lugs on bottom of step plate straddle the bearing staking indentions on end of pinion or PINION POSITION N gt LU AN om Figure 11 false reading may occur Also make sure differential side bearing bores are clean and free of nicks 3 Remove any burrs and wipe clean differential bearing I D s Turn micrometer 90 deg to step plate Install assembled pinion setting gauge into bearing bores of carrier housing until fully seated Adjust micrometer so it is directly over end of step plate Run the micrometer thimble down to measure the distance between the center of the ring gear and the step plate See Figure 11 Make a note of this dimension NOTE Because the step plate must be taken into consideration the thickness of the step plate 400 in 10 16 mm needs to be added to the measured value for the correct micrometer distance 4 the machined end of each pinion either a plus minus or a zero 0 will be etched See Gear Set Identification pg 2 This number represents the amount in thousandths of an inch 001 to be added or subtracted from the nominal dimension for the best running position for that particular gear set EXAMPLE If pinion is etched 3 the required mounting distance is more than nominal by 003 in 076 mm This means the pinion would require 003 in 076 mm thicker shim between pinion bearing cage assembly and carrier housing that a pinion e
31. with marking compound on both the drive and coast side Baer DRIVE SIDE COAST SIDE STEP 2 Rotate ring gear at least one complete revolution in CONVEX CONCAVE both directions while load is being applied CORRECT GEAR PATTERNS FOR GLEASON CUT GEARS LIGHTLY HEAVILY LOADED LOADED NOTE Tooth contact pattern on this axle model can be moved only by adjusting backlash The contact pattern can be moved in the direction of heel to toe and toe to heel Depth of the pattern cannot be adjusted If an acceptable tooth contact pattern cannot be established within limits of backlash contact Spicer Service at 1 800 666 8688 WHEEL BEARING ADJUSTMENT NOTE Wheel bearings should be adjusted following vehicle manufacturers recommended maintenance schedule 1 Block wheels not being adjusted to insure that E E vehicle will not roll Release emergency brake 2 Raise wheel to be adjusted off of the ground Make certain wheel rotates freely 5 Remove axle shaft 4 Remove outer adjusting nut and lock if tabs are broken 5 Torque inner wheel nut to 50 Lb Ft 68 N m while rotating wheel one direction then the other direc tion Back off inner nut 1 4 turn NOTE When replacing wheel bearings new bearings must be re seated to insure maximum service reliabil ity After the hub and bearings are assembled in place on the spindile install the inner adjusting nut
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