Service Manual
Contents
1. Shift Fork Actuator Assembly Axle Shaft Engaged Clutch Collar Figure 13 26 CARRIER REMOVAL CARRIER REMOVAL Before carrier assembly can be removed from the axle housing the main differential lock must be engaged in the locked position This must be done before the right side axle shaft is removed Engaging locking the main differential allows enough clearance for the clutch collar to clear the carrier to housing mounting flange so removal can be achieved NOTE Locking of the main differential must be done before removing the right side axle shaft If the right side axle shaft was removed for towing purposes reinstall it into the housing using procedure 2 from the Install Axle Shafts After Towing Page 26 AIR PRESSURE METHOD 1 Drain lubricant from the axle assembly 2 Raise the right side rear drive wheel off the floor using a hoist or jack 5 Hold the right side of the vehicle in the raised position by using a jack stand under the right side housing spring seat Disconnect the drive shaft from the input yoke 5 Disconnect air line from the differential lock shift cylinder 6 Connect an auxiliary air supply to the differen tial lock shift cylinder NOTE If an auxiliary air supply is not available con tinue to use the Manual Engaging Method to lock the main diffe2. Capacity for cast housing TORQUE SPECIFICATIONS S230 S SL S260 SB Fasteners Position Thread size Grade Pinion Hex Nut 1 3 4 12 Pinion Bearing Cage Bolts 9 16 12 8 Adjusting Ring Lock Bolts 3 8 16 8 Carrier Mounting Bolts 5 8 1 8 Differential Bearing Cap Bolts 3 4 10 8 Differential Case Bolts 9 16 12 8 Fill Plug 3 4 14 Drain Plug 3 4 M Temperature Sensor Plug 3 4 14 Air Shift Cylinder Bolt 3 8 16 8 Air Shift Cylinder Plug 1 4 18 Electric Switch Unit 9 16 18 Lb Ft N m 900 1 200 1 220 1 627 160 180 217 244 20 30 27 4 240 260 325 352 295 340 397 460 160 180 217 244 35 45 47 61 35 45 47 61 35 45 47 61 30 40 41 54 20 30 27 4 20 30 27 4 NOTE Refer to vehicle manufacturer specifications for axle Flange Wheel Nut fastener torque S230 S SL S260 SB Specifications Position U S Metric Pinion Nominal Dimension 4 5945 in 116 700 mm Bearing Preload Torque Wrench 10 40 Lb in 1 1 4 5 N m Bearing Preload Pull Scale 5 9 Lbs 1 4 4 5 Kg Differential Ring Gear to Pinion Backlash 012 016 in 30 A0 mm Ring Gear Rivet Pressure 45 50 tons 41 45 tonnes Lubrication Approx S230 S SL Lube capacity 48 8 Pts 23 1 Liters S260 SB Fabricated Housing Lube Capacity 52 9 Pts 25 0 Liters S260 SB Cast Housing Lube Capacity 55 2 Pts 26 1 Liters Pinion bearing preload is established prior to installation of pinion seal
3. Pinion Above Center The axle assembly tag contains the following items Dana part number julian date code axle model and ratio Optional items include customer part number line set number and the last six digits of the vehicle serial number MODEL IDENTIFICATION NUMBERING SYSTEM Eng Family Nominal Load Gearing Type Options S Spicer Carrying Capacity S Single Reduction N No SPIN Differential 230 23 000 Lbs L Driver Controlled Diff Lock 260 26 000 Lbs B Bus No SPIN is a registered trademark of Tractech GEAR SET IDENTIFICATION Manufacturer s Date Date gear set was made SPICER PINION ETCH TRADEMARK Spicer Trademark Company logo and location of manufacturing facility C 300GP203 Part number of pinion gear TYPICAL EY um Tooth Combination i e 41 11 Indicates the pinion TOOTH PART HEAT SPICER MFG MATCHED fag the rine pear teeth ic COMBINATION NUMBER CODE TRADEMARK DATE SET NUMBER results in a 3 73 1 ratio 15 Matched Set Number Spicer ring gears and pinions are manufactured as matched sets Both ring gear and pinion are marked with a corresponding number i e 260 which identifies them as a matched set A gear set that does not have the same match set BACKLASH ETCH numbers should not be run together If either ring gear or pinion require replacement a new matched set must be used Backlash Etch Indicates back
4. End Yoke Assembly Washer Inner Pinion Bearing Cup Pinion Preload Spacer Selective Pinion Hex Nut 900 1 200 Lb Ft Pinion Position Shim s 1 220 1 627 N m 1 Press inner pinion bearing cone onto pinion 5 Install outer pinion bearing cup into pinion bearing 2 Press Pilot bearing onto the pinion 3 Stake Pilot bearing in nine places See illustration 6 Use feeler gauge or shim stock 002 in Max to below using a center punch or equivalent tool ensure bearing cups are completely seated in This operation will move gear shaft material outward bearing bores This is necessary for the proper into bearing chamfer pinion position See Figure 5 Figure 5 4 Install inner pinion bearing cup into pinion bearing cage 7 Place the selective preload spacer that was removed during disassembly onto pinion PINION ASSEMBLY 8 Place pinion bearing cage onto inner pinion Method A uses a pull scale and a strong cord approxi bearing mately 8 ft long See Item Tl Method B uses a Lb in torque wrench Both methods measure torque to rotate 9 Install the outer pinion bearing cone onto pinion See Item 12 10 Without installing seal install end yoke onto pinion 5 y P Tl Method To measure torque to rotate with the using yoke installer service tool See Figure 6 This spring scale clamp the end yoke horizontally in a will allow proper setting o
5. 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 22 ALL SERVICE TOOLS AVAILABLE FROM OTC DIVISION Service Tools 655 Eisenhower Drive Owatonna MN 55060 Telephone 1 800 555 0492 Fax Number 507 455 7011 23 DRIVER CONTROLLED DIFFERENTIAL LOCK INTRODUCTION The Spicer driver controlled differential lock provides exceptional traction and pulling power in both slippery driving conditions and heavy duty applications Such applications include pulling double trailers construction and refuse collection In adverse road conditions the Spicer driver controlled differential lock also protects against spin out and shock loading The differential lock is activated by a cab mounted switch The lock operates through an airactuated shift assembly that is located on the right side of the differen tial carrier When the differential lock is engaged an air actuated piston moves the clutch collar along splines of the axle shaft onto mated splines of the differential case See Figure 12 When the differential case and clutch collar splines are engaged the wheel differential is positively locked The shift fork trips an electric switch unit that signals a cab indiactor light for driver verification There is no differ ential action between the rear drive wheels of the axle when the differential is positively locked resulting in maximum tractio
6. 400 461 N m Fill Plug 35 45 Lb Ft 47 61 N m O Temperature ee E Sensor Plug Washer 35 45 Lb Ft A 47 61 N m NS Drain Plug n Differential Bearing Adjusting Ring Differential Case Half Differential Bearing Cap Differential Bearing Cup Differential Bearing Cone Differential Case Flange Half SS S Ring Gear Q Ring Gear Rivet 45 50 tons E Thrust Washer 41 45 metric tonnes Ring Gear Bolt Kit Service Differential Pinion Mate Adjusting Ring Lock Bolt Differential Cross Shaft A 5 9 20 30 Lb Ft Q i Differential Si 2 ifferential Side Gear 27 41 N m CG di Thrust Washer e N Differential Case Bolt 160 180 Lb Ft 217 244 N m No Spin Differential Carrier Mounting Bolt er 240 260 Lb Ft 325 555 N m Inner Pinion Bearing Cone Inner Pinion Bearing Cup f Pinion Preload Spacer Selective Pinion Position Shim Carrier Housing Pinion Bearing Cage Pilot Bearing SS Pinion Outer Pinion Bearing Cup Bearing Cage Bolt 160 180 Lb Ft 217 244 N m Outer Pinion Bearing Cone Pinion Seal 5 End Yoke Assembly D Pinion Hex Nut 900 1 200 Lb Ft K S 1 220 1 627 N m Washer PINION UP AXLE COMPONENTS Axle Shaft Housing Breather Differential Bearing Cap Bolt 295 540 Lb Ft
7. Alkaline type solutions may cause damage to machined surfaces and should be avoided 2 Make sure interior of axle housing is clean prior to reassembly 5 Clean all gasket surfaces of old material DRYING Use soft clean lintless towels or rags to dry compo nents after cleaning Bearings should NOT be dried by spinning with compressed air This can damage mating surfaces 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 Prior to reassembly inspect parts for signs of excessive wear or damage Replacement of these parts can prevent premature failure and costly downtime BEARINGS S C D DO Bearing surfaces should be inspected for pitting excessive wear or overheating THRUST WASHERS A P Inspect thrust washers for scoring and cracking GEARS Inspect gears for excessive wear or damage Replace gears that are pitted scored broken or worn SHAFTS Inspect shafts for nicks or scoring SPLINES twisting and cracking HOUSINGS Inspect housing for stripped threads and bending fatigue 13 lt PINION ASSEMBLY Pinion Bearing Cage Outer Pinion Bearing Cup Bearing Cage Bolt 160 180 Lb Ft 217 244 N m Outer Pinion Bearing Cone Inner Pinion Bearing Cone Pinion Seal
8. If matched sets are being reused measure and record backlash before disassembly and reas semble to the same backlash This will match ring and pinion gears to the established wear patterns Hand rolled patterns will cover less area than the gear pattern established by previous service STEP 1 Paint 1 4 ring gear with marking compound on both the drive and coast side CORRECT GEAR PATTERNS PROFILE TOP LAND Ce LENGTHWISE BEARING ARC W DRIVE SIDE ROOT STEP 2 Apply drag load to ring gear and rotate pinion so that ring gear completes one revolution in each direction LIGHTLY LOADED HEAVILY LOADED HEEL HEEL COAST SIDE CONCAVE DRIVE SIDE CONVEX HEEL COAST SIDE CONCAVE DRIVE SIDE CONVEX INCORRECT GEAR PATTERNS LIGHTLY LOADED HEAVILY LOADED TOE HEEL DRIVE SIDE COAST SIDE CONVEX CONCAVE TOE HEEL HEEL COAST SIDE CONCAVE DRIVE SIDE CONVEX 21 Thoroughly clean the inside of the carrier housing and inspect the housing mounting surface for nicks and general cleanliness Stone the surface if necessary to remove burrs or nicks Bolt holes must also be checked to see that they are free of contaminants Loctite 518 Gasket Eliminator Figure TI Apply an 125 inch 3 175 mm diameter bead of Loctite 518 gasket eliminator onto the axle housing mounting flange and around each bolt
9. Fill Plug 35 45 UR D a ei 400 461 N m m ei Temperature Sensor Plug Washer 35 45 Lb Ft 47 61 N m Drain Plug 35 45 Lb Ft ag 47 61 N m Differential Bearing Cup Differential Bearing Adjusting Ring Differential Bearing Cone Differential Case Bolt 160 180 Lb Ft 217 244 N m Differential Case Half Differential Pinion Mate Thrust Washer Ring Gear Rivet 45 50 tons 41 45 metric tonnes Adjusting Ring Lock Bolt 20 30 Lb Ft 27 41 N m 0 Carrier Mounting Bolt 240 260 Lb Ft 325 353 N m d Pinion Preload Spacer Selective Pinion Position Shim SS Pinion Bearing Cage Op Bearing Cage Bolt o li Pilot Bearing Carrier Mounting Bolt Pinion 240 260 Lb Ft 325 353 N m SCH 244 N m 6 0 0 7 b d Carrier Housing Inner Pinion Bearing Cone 2 Gi P Yoke Assembly A Inner Pinion Bearing Cup TIP 0 M Q Outer Pinion Bearing Cup 160 180 Lb Ft Outer Pinion Bearing Cone Pinion Seal Pinion Hex Nut 7 900 1 200 Lb Ft 1 220 1 627 N m IMPORTANT If the vehicle is equipped with driver controlled differential lock see instructions begining on page 24 To tow a vehicle with driver controlled differential lock see instructions on page 26 NOTE Steam clean axle assembly 1 Block wheels 2 Remove axle housing drain plug and drain lubricant 3 Discon
10. If differential side bearings are to be replaced remove old bearings using a suitable puller See Figure 4 DIFFERENTIAL DISASSEMBLY CORRECT PROCEDURE Ring Gear A CAUTION Always use a soft hammer or H D plastic head hammer to strike punch INCORRECT PROCEDURE Figure 4 NOTE Inspect all parts including the machined surfaces of the case half Ring Gear If any gears are to be replaced they must be replaced in matched sets Inspect thrust washers for scoring and excessive wear Replace all worn or damaged parts NOTE Ring gear bolt kits are available as a replace ment for ring gear rivets see Parts List manual for NOTE Do not use a chisel to remove rivet heads part number information damage to differential case may result 7 When it is necessary to remove ring gear from the biffesisbal Disassembly Compe differential case carefully center punch each rivet head Use a 9 16 inch drill bit Drill through rivet heads to depth shown Next use a rounded type punch to drive out remaining portion of the rivet Carrier Housing Pinion i Op Inner Pinion Bearing Cone Inner Pinion Bearing Cup Pinion Preload Spacer Selective 1 Remove pinion bearing cage mounting bolts 2 Remove pinion assembly from carrier housing If difficulty is encountered in removing pinion assembly from carrier housing place a brass drift on inner end of pinion and tap
11. assembly They may be obtained through your vehicle manufac turer 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 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 The differential carrier tag contains the following Dana part number julian date code and ratio Optional items include customer part number line set number and the last six digits of the vehicle serial number Pinion Below Center DANA PART NUMBER CUSTOMER PART NUMBER OPTIONAL MODEL HEI E Model see 5230 5 SER 96070 620112 478 RI 4042 JULIAN DATE Axle Assembly Tag UNE SET CODE NUMBER LAST SIX DIGITS OF OPTIONAL VEHICLE SERIAL NUMBER OPTIONAL AXLE IDENTIFICATION JULIAN DATE CODE 96 070 MODEL YEAR DAY OF YEAR DANA PART NUMBER CUSTOMER ART NUMBER OPTIONAL P gt CARRIER 308CA101 5X SER SPICER 620112 RATIO JULIAN DATE CODE 9607 4040 Carrier Tag LINE SET NUMBER LAST SIX DIGITS OF OPTIONAL VEHICLE SERIAL NUMBER OPTIONAL
12. cones Assemble differential bearing caps with and the bearing preload match marks in proper location Clean bearing cap 8 bolts and washers and coat threads with Loctite 5 Check ring gear and pinion backlash in four equally 277 Install bearing cap bolts and tighten enough spaced positions around the ring gear with a dial indicator as shown See Figure 10 Acceptable backlash tolerance is 002 from backlash etched on ring gear to draw bolt head into contact with bearing cap eliminating visible space between differential bearing cap and carrier housing Do not torque the cap bolts at this time A CAUTION Differential assembly must be aligned within bearing bores before preload is applied or damage to bearings can occur Figure 10 NOTE If the backlash tolerance does not vary more than 004 in 080 mm the setting is acceptable If backlash does vary more than 004 in 080 mm remove the differential and determine the cause Figure 9 6 Once backlash is set torque the differential bearing cap bolts to 295 340 Lb Ft 397 460 N m Check 3 Install adjusting rings Tighten both adjusting rings backlash after torquing cap bolts until end play is eliminated and there is backlash between the ring gear and pinion See Figure 9 20 RING GEAR AND PINION TOOTH CONTACT PATTERN The following procedures are to be used to establish proper gear tooth pattern after assembly of the carrier is complete NOTE
13. hole See Figure Tl Thread two studs into the axle housing 180 apart This will eliminate rotation of the carrier assembly after 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 cross pattern Torque bolts 240 260 Lb Ft 325 552 N m Allow one hour cure time for gasket material before adding hypoid gear lubricant Remove the old axle flange gasket and clean mating surfaces of the hub and axle flange 22 INSTALLATION OF DIFFERENTIAL 10 CARRIER INTO AXLE HOUSING Install the new axle flange gasket Install the axle shafts to proper location Torque the axle flange nuts to vehicle manufacturers specifications 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 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 CAPACITIES Approximate Pints Liters 5 230 S SL S260 SB S260 SB Lube capacity will vary depending upon the housing angle in each vehicle Capacities given above are for an angle of 4 Fill to the lower edge of the fill hole in the axle housing as shown above Capacity for fabricated housing
14. lightly with hammer NOTE Retain shims for possible use during reassembly 5 Hold yoke stationary Remove nut and washer A torque multiplier may be required to loosen nut 4 Remove the end yoke using a suitable puller See Recommended Service Tools pg 32 5 Remove pinion from cage assembly NOTE It may be necessary to tap outer end of pinion with a soft hammer taking care not to damage threads Outer Pinion Bearing Cone Qo Pinion Seal End Yoke Assembly O Washer E 70 Pinion Position Shim s 22 PINION DISASSEMBLY Pinion Bearing Cage Outer Pinion Bearing Cup Bearing Cage Bolt 160 180 Lb Ft 217 244 N m Pinion Hex Nut 900 1 200 Lb Ft 1 220 1 627 N m 6 Located between the pinion bearings is a selective bearing preload spacer Retain this selective preload spacer for possible use during reassembly 7 Remove the old pinion seal and discard Always use a new seal at the time of reassembly 8 Lift out the outer pinion bearing cone 9 Remove inner pinion bearing cup using a suitable adapter and press or puller A CAUTION Do not nick bearing bore 10 Remove the outer pinion bearing cup use the same procedure as in step 9 Tl Remove pilot bearing from end of pinion 12 Remove inner bearing cone from pinion Pinion Disassembly Complete CLEANING AND INSPECTION CLEANING 1 Parts should be cleaned with emulsion cleaners or petroleum base cleaning solvent NOTE
15. sco LOO 0 Leo OO O Lot SOO O cer 90070 LE 100 0 SOT 800 0 Lor 600 0 tec OIO O ELFU Ott IO O vTIO O sc SIO O Let 810 0 SOS OcO O ONDAAVW NOINId 18 DNDTIVIN NOINId MAN NOINId MAN OL ONLLLAS NOINId QOGNIADINOLLOS 000 SHHONDdOL 0000 DIFFERENTIAL ASSEMBLY Differential Bearing Cone Differential Bearing Cup Thrust Washer Differential Case Half Differential Case Bolt 160 180 Lb Ft Differential Bearing 217 244 N m Adjusting Ring Correct rivet head shape when properly compressed 1 If ring gear was removed from the differential case reinstall it at this time Bolt ring gear to differential case in three places 120 apart before compressing rivet this will eliminate ring gear runout Use a hydraulic or mechanical press and riveting fixture Pressure requirement per rivet is 45 50 U S tons or 41 45 metric tonnes 2 Press bearing cones onto differential case halves Place bearing cups on cones during remainder of assembly to prevent damage of bearings NOTE Ring gear bolt kits are available as a replace ment for ring gear rivets see parts list manual for part number information Differential Bearing Adjusting Ring Differential Bearing Cup Differential Case Flange Half Ring Gear Ring Gea
16. shafts must be removed To remove axle shafts use the following procedures 1 Disengage main differential lock NOTE Differential lock cab light should be off This indicates that the difflock is disengaged 2 Remove both axle shafts from vehicle by normal procedures NOTE Right side axle shaft has two sets of splines need more attention than the conventional axle shaft Install right side axle shaft using the following procedures Push axle shaft into housing until contact is made with the clutch collar Rotate axle shaft while pushing down on flange until splines align Push axle shaft further until contact is made with with differential side gear one for the differential side gear and the other for the Rotate shaft again while pushing down differential lock clutch collar 3 Cover both open axle hubs to prevent contaminants from entering axle and loss of any lubricants INSTALL AXLE SHAFTS AFTER TOWING 1 Remove hub covers from axle 2 With differential lock in disengaged position Install right side axle shaft on flange until splines align Push axle shaft into housing until flange seats against the axle hub 5 Install left side axle shaft into housing using normal procedures 4 Fasten both axle shafts to the hubs and torque to vehicle specifications See Figure 13 RIGHT SIDE AXLE SHAFT OF DIFFERENTIAL LOCK Differential Case Half Side Gear Mated Axle Shaft Splines
17. OM CARRIER 1 Remove adjusting ring locks from bearing caps Loosen four bearing cap retainer bolts 2 Match mark one differential bearing cap and leg with Loosen adjusting rings relieving bearing preload center punch or chisel for correct reassembly See Remove four bearing cap retainer bolts Figure 2 Remove bearing caps Remove adjusting rings 0 x 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 Figure 2 DIFFERENTIAL DISASSEMBLY Differential Bearing Adjusting Ring Differential Bearing Cup Differential Case Half Differential Bearing Cone Differential Bearing Cup Ring Gear Ring Gear Rivet 45 50 tons Differential Pinion Mate Differential Cross Shaft Differential Side Gear Thrust Washer Differential Case Half Differential Case Bolt 160 180 Lb Ft Differential Bearing 217 244 N m Adjusting Ring 1 Match mark differential case halfs with punch or 2 Remove differential case bolts and lift off differential chisel for correct alignment in reassembly case half See Figure 3 3 Remove thrust washer and differential side gear 4 Lift out cross shaft pinion mates and thrust washers 5 Remove second differential side gear and thrust washer 6
18. Spicer Drive Axles SPICER Service Manual Spicer Drive Axles AXSM 8942 September 2007 TABLE OF CONTENTS Axle Identification eos ssec chi Model Identification Numbering System Gear Set Identification Axle Lubricant Recommendations General Precautions Standard Axle Components Pinion Up Axle Components Removal of Differential Carrier from Axle Housing Removal of Differential from Carrier Differential Disassembly Pinion Disassembly Cleaning and Inspection Pinion Pinion Position Differential Assembly Differential Installation Ring Gear and Pinion Tooth Contact Pattern Installation of Carrier into Axle Housing Fastener Torques and Axle Specifications Driver Controlled Differential Lock Driver Controlled Differential Lock Components Towing Procedures Instructions Carrier Removal Removal of Diff Lock Assembly Installation of Diff Lock Assembly Carrier Installation Checking Differential Lock Operation Recommended Service Tools GENUINE SPICER SERVICE PARTS Should an axle assembly require replacement compo nent parts it is recommended that Spicer 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 maximum reliability for a Spicer Heavy Axle
19. ZOO 0 100 0 SL 900 0 Let SOO OT cot vrOO O 97 0 00 0 Leo sco LO0O Or eco LOO 0 Leo cOO O 970 00 0 O Let SOO O est 900 0 100 0 800 0 rec Oro O ZSI 9000 7 Ler S00 0 FOO Or SLO KOO Or Leo OO 0t Seco LOO Or SO LOOO Leo COU Or o0 OO O Or Let S00 07 900 O L00 0 SOT 0007 Lom 600 O LTT 600 0 Let SOO O FOOO 97 0 OO Or Leo ZOO Or Sco LOOO 0 Leo c00 0 97 0 00 0O FOOO Let SOO O Ss LE 900 0 sZt coc 800 0 cc 600 0 tec OIO O KO 97 0 Leo Sco 8000 9000 t00 0 I00 0 eco LOO O SLO 00 O FOO Or LTL SOO O est 900 Or SLE 41000 LECT 60007 Tec OIO O L LOO ZOO Or Let 0 0 9407 g 00 0 Tso eco LOo0O Or eco LOO O 1900 cOO O 00 O Let S00 O cst 900 0 L00 0 800 0 tec OIO O oc L LOO soc cI0O O est 900 0 lt FOO Ot Leo ZOO Or eco I00 Or Leo cOO O 9 0 00 0O ZOL O Let SOO O
20. ar 1 Year On Highway 1 Year Severe Service and 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 environment or consistent high 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 hole GENERAL PRECAUTIONS IMPORTANT READ THIS SECTION BEFORE STARTING ANY SERVICE PROCEDURES GENERAL AXLE DESCRIPTION This manual covers maintenance and rebuild procedures for the Spicer 5230 5 S230 SL and S260 SB rear drive axle assemblies The Spicer Heavy Duty Single Reduction rear drive axle is a full floa
21. electrical connections Lastly if needed remove carrier by procedures outlined in the Carrier Re moval section and follow all assembly steps for installation of the carrier into the housing Differential Lock Check Complete RECOMMENDED SERVICE TOOLS ORDER NUMBER ILLUSTRATION DESCRIPTION DST 1001 Iia CARRIER STAND TORQUE MULTIPLIERS DST1002 K Maximum 1 000 Lb Ft DST1003 Maximum 2 000 Lb Ft DST1004 Maximum 4 000 Lb Ft DST1005 Maximum 12 000 Lb Ft DST1006 D NL YOKE REMOVER BAR TYPE DST1007 INSTALLER DIFFERENTIAL YOKE 1 3 4 12 DST1000 1 SEAL INSTALLATION TUBE HANDLE DST1000 3 c f PINION SEAL INSTALLER Ban gt 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 Distributor 1 800 621 8084 OE Dealers 1 877 777 5360 www spicerparts com AXSM 8942 Printed in U S A Copyright Dana Limited 2012 All rights reserved Dana Limited SPICER
22. est 900 0 SZ 100 0 coc 800 0 Lc 600 0 oc IrO O soc TIO O Ott IO O 21 SOO OT OO Or LOO Or eco LOOO OO Or Let SOO O EA 9000 7 sZt 00 0 SOU Or Loc 600 0 tec OIO O soc TILLOO Occ IOO Ott vIOO TOO Or Leo LOO O Ico COO 0 O Let SOO O Ss 900 0 100 0 coc 800 0 lt lt 600 0 Tec OIO O L LOO Ott 10 O Oct t100 97 0 00 0r Seco LOO Or LOO Or Leo cOO0 O 97 0 OO Or LECL SOO O 900 0 SZ L00 0 SO 80070 Lor 600 0 Tec OIO O Oc L LOO soc cIO O gsc t LOO sc S LO O Leo ZOO Or Leo OO O BLO 00 O SLO OO O TOO O FOO Or LTI SOO O est 900 0 cst 900 0 100 0 41000 coc 800 0 SO 800 0 Lom 600 0 cc 600 0 PST OIO O CLC L LOO L TOO soc cIO O soc cIO O Ott 10 0 Ott IO O ISt SIO O oor 9I10 0 9IO O st 810 0 sco ILOO O LEIL SOO O SL 900 0 sZt 100 0 coc 800 0 Lom 600 O tec OrO O soc cIO O Ott 100 Oct TIO O ccv ZOO SC St 610 0
23. ethod selected END YOKES AND FLANGES 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 HEAITH 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 HAMMER 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 STANDARD AXLE COMPONENTS Axle Shaft Housing Breather Differential Bearing Cap Bolt 295 540 Lb Ft
24. f pinion preload Secure soft jawed vise Attach one end of the cord to a bolt yoke with a Yoke and Flange Holding Bar or an i S Gg hole in the pinion cage wrap cord around pinion equivalent tool Install pinion nut and washer d attach the out d of th d to th Torque pinion nut to 900 1 200 Lb Ft 1 220 spring scale Rotate pinion cage by pulling scale 1 627 N m iL Read scale during fourth revolution Scale reading NOTE Inspect end yoke seal surface for grooves must be between 3 10 Lbs 1 4 4 5 Kg See caused by lip of seal If grooves can be detected with Figure 7 fingernail it should be replaced Figure 7 Continued on Next Page A CAUTION The pinion cage should be rotated periodically while tightening the pinion nut to seat and align the pinion bearings There are two methods of measuring pinion bearing preload and both are acceptable Mechanic s preference and available tools should determine which method is used 12 Method B To measure torque to rotate with the torque wrench assemble pinion cage into the carrier housing and install two mounting bolts to anchor the unit Rotate pinion with the torque wrench See Figure 8 Torque measurement will be taken during fourth revolu tion and must be between 10 40 Lb in 1 1 4 5 N m without pinion seal NOTE When torque to rotate reading does not fall within allowable limits bear
25. g the assembly To ensure the clutch collar and differential case splines have engaged completely rotate right side axle shaft When fully engaged remove shaft from the carrier assembly IMPORTANT Hold air pressure on locked carrier assembly until it has been completely installed into axle housing 6 Install carrier assembly into axle housing and fasten using normal installation procedures Remove auxiliary air supply from shift assembly and connect the vehicle air line to shift cylinder Install axle shafts into housing Use procedures 2 and 3 from the Install Axle Shafts After Towing section Remove jack stands from vehicle and lower to shop floor MANUAL ENGAGING METHOD 1 Align the splines of the clutch collar and the differential case by hand 30 CARRIER INSTALLATION 2 Install a M12 X 1 50 bolt into the shift cylinder airport to manually engage the lock IMPORTANT Hand tighten M12 X 1 50 bolt with a socket See Figure 17 HAND TIGHTEN M12 X 1 50 BOLT USING SOCKET Figure 17 A CAUTION If a high resistance to turn is felt before full engagement of lock stop turning the bolt Over torquing may cause damage to the shift unit Realign splines and continue to tighten 3 To ensure lock is fully engaged rotate the drive pinion 4 Install carrier assembly into axle housing and fasten using normal procedures Remove manual engaging bolt from shift cylinder replace with air shift cyli
26. hift shaft Clean the mating surfaces of the carrier shift cylinder and apply a 125 in 5 175 mm continuous bead of Loctite 518 to the carrier surface See Figure 16 Install the shift cylinder into the carrier Do not allow the cylinder to rotate once it has been seated 29 10 INSTALLATION OF DIFF LOCK ASSEMBLY Install the two shift cylinder washers and bolts and torque 50 40 Lb Ft 41 54 N m Install the threaded plug into the center of the shift cylinder an torque 20 50 Lb Ft 27 41 N m Thread the electric switch unit into the top of the carrier and torque 20 50 Lb Ft 27 41 N m Install the air coupler into the air port Diff Lock Installation Complete Loctite 518 Gasket Eliminator Figure 16 AIR PRESSURE METHOD 1 Install the right side axle shaft through the clutch collar and into the differential side gear of the carrier assembly The axle shaft is used to align splines of the the differential case half and clutch collar Rotate right side axle shaft until splines of clutch collar and the differential case half are aligned A CAUTION Do not use hands to position shift collar while air pressure is being applied to shift cylinder injury could result 3 Connect auxiliary air supply to shift cylinder 4 Apply and hold air pressure to the shift cylinder Applying air will move the shift collar inward and engage the splines with the differential case splines lockin
27. ing preload can be increased by using a thinner spacer or decreased by using a thicker spacer 001 in 025 mm change in preload spacer thickness changes scale reading by approximately 10 165 001 in change in preload spacer will change torque to rotate by approximately 30 Lb in This is only a guide individual carriers may vary slightly The pinion bearing spacers are available in the following thicknesses Measure spacer with micrometers before assembly to ensure correct thickness Inches MM 893 22 982 894 22 708 895 22 733 PINION ASSEMBLY Inches MM 896 22 758 897 22 784 898 22 809 899 22 855 900 22 860 901 22 885 902 22 911 903 22 936 904 22 962 905 22 987 906 23 012 907 25 038 908 25 065 909 25 089 910 25 114 Ku 23 139 916 25 266 NOTE Closer adjustment can be made sanding next thicker spacer to desired thickness using emery cloth on a flat surface Surfaces must be parallel to each other and square to bore diameter A CAUTION Wash spacer thoroughly of emery cuttings before installing on pinion 14 After proper torque to rotate is achieved remove end yoke 15 Clean and dry threads on pinion 16 Install pinion oil seal with Recommended Service Tool See page 32 17 Install end yoke using yoke installer service tool DST1007 See Figure 6 18 Coat threads with Loctite 680 adhesive compound Continued on Next Page PINION POSITION 19 Install pin
28. ion nut and washer Use torque multiplier and torque pinion nut to 900 1 200 Lb Ft 1 220 1 627 N m Pinion assembly is now ready to be installed into carrier housing Pinion Assembly Complete Ring gears and pinions are supplied in 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 When a new gear set is being installed use a micrometer 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 and 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 pinion gears 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 pin
29. ion 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 Lev 8100 IIO O 8000 L00 0 ctv 1100 Fee Oro Oc 100 0 est 900 0 Let SOO Ot oor 9100 LTT 600 0 lt 900 0 GEL SOO O FOO 0 sco IOO O sc sto or KO 800 0 AXES S00 0 Oc 97 0 OO Or Leo OO O Ost FlOOr KAN vIOO vec LTT KO 600 0 8000 L00 0 00 0 celi 900 0 Leo Lot SOO O t BLO OO OT 000 T SO Or LOO O Leo cOoO O 920 00 O 00 O FOO Or Let SOO 0 Ott IOO LTT 60007 SOO OT SZ ZOO Ort CSL 900 Or LCL S00 Ot vOO O 97 0 00 0r Leo OO OT Seco LOO Or eco LOO O Leo 00 0 TOL FOO Or Ze SO0D Or TSL 900 0 soc SO Ip uM cst Let 8000 1000 9000 00 0 lt FOO Ot 970 OO OI Leo TOO O sco I00 0 sco LOO O Leo OO O 97 0 00 O Let S00 O cei 900 0 84 1L
30. l engagement of lock stop turning bolt CARRIER REMOVAL Over torquing may cause damage to the shift unit 4 To ensure lock is fully engaged rotate the drive pinion or the right side wheel 5 Remove axle shafts by normal removal procedures 6 Remove carrier assembly from axle housing Carrier Removal Complete REMOVAL OF DIFF LOCK ASSEMBLY Figure 15 NOTE The carrier should already be removed from the vehicle before proceeding with the disassembly of the diff lock components See Figure 15 1 Remove the electric switch unit from the carrier 2 Remove the bolts and washers from the air shift cylinder 3 Remove air shift cylinder 4 Remove the shift shaft and shift fork by unthreading the shaft 5 Remove compression spring 6 Remove the shift fork and clutch collar from the carrier Diff Lock Removal Complete Place the arms of the shift fork over the clutch collar so that the threaded end of the fork faces the direction shown in Figure 15 Position the shift fork collar assembly into the carrier so the collar fits over the splined differential case While holding the collar in place insert the spring into the shift shaft and thread the shaft into the shift fork Torque the shift shaft 20 30 Lb Ft 27 41 N m Lubricate the O ring of the shift piston and install into the shift cylinder Install the piston so that the metal spacer is visible This area will fit over the s
31. lash setting for assembly Pinion Etch Indicator for proper pinion position shim stack up See Pinion Position Section AXLE LUBRICANT RECOMENDATIONS To ensure proper lubrication and operating temperature correct lubricants and lubricant levels must be obtained RECOMMENDED GEAR LUBRICANTS Mineral or Synthetic based hypoid gear lubricants that meet or exceed military specification MIL L 2105 D and 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 140 gt SAE85W 140 gt SAE80OW SAE 75W 90 0 4 15 27 38 C 40 26 12 F 40 15 10 432440 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 carrier housing should become submerged in water particularly if over the vent or breather it is recommended that the lubricant be drained and all internal parts be inspected for water damage and or contamination Reassemble the carrier to the housing and refill with specified gear lubricant APPLICATION PETROLEUM BASED SYNTHETIC BASED MILES INTERVAL MILES INTERVAL 3 Ye
32. n to the rear drive wheels Normal differential action occurs between the rear drive wheels of the axle when the differential lock is disengaged The cab mounted indicator light should be off at this time DIFFERENTIAL LOCK IDENTIFICATION Ring and Pinion Gears Axle Housing Differential Gears Electric Switch Unit Vehicle Air Supply Inlet Piston Plugged Hole For Manual Engagement Shift Fork Clutch Collar Engaged Right Side Axle Shaft Splines Differential Case Half Figure 12 DRIVER CONTROLLED DIFFERENTIAL LOCK COMPONENTS Double Splined Axle Shaft Diff Lock Side Only Differential Bearing Cap Carrier Assembly Adjusting Splined Differential Ring Lock Case Half Adjusting Ring Lock Bolt Sch 20 50 Lb Ft Differential 27 41 N m e Bearing Cone Differential Bearing Cup i S ke lt Adjusting Ring SE Clutch Collar Mi Shift Fork kee Roll Pin Shift Fork Shaft Roll n Piston Assembly Shift Fork E SS Air Shift Cylinder n Washer zi AN A Shift Fork Shaft Electric Switch Unit S diy y 20 30 Lb Ft P vk 27 41 N m Air Shift Cylinder Bolt 30 40 Lb Ft p 54 NS Air Shift Cylinder Plug 20 30 Lb Ft 27 41 N m 25 TOWING PROCEDURES INSTRUCTIONS REMOVE AXLE SHAFTS BEFORE TOWING If the vehicle is to be towed with the rear axle drive wheels to engaging two sets of splines this axle shaft will on the ground axle
33. nder plug and torque 20 30 Lb Ft 27 41 N m Connect the vehicle air line to the shift cylinder assembly Install axle shafts into the axle housing Use procedures 2 and 3 from the Install Axle Shafts After Towing section page 26 Remove jack stands from under vehicle and lower to shop floor Carrier installation complete CHECKING DIFFERENTIAL LOCK OPERATION IMPORTANT Before testing differential lock operation vehicle must be lowered completely to floor and clear of all obstacles jack stands hoist tools etc 1 Start engine and allow air pressure system to build up to normal operating level Place cab differential lock switch in the unlocked disengaged position Drive vehicle at very slow speed MAX 10 M PH and check differential lock cab light The indicator light should be OFF when lock is in the disengaged unlocked position Continue to drive vehicle at low speed MAX 10 M PH and flip differential lock cab switch to the engaged locked position The indicator light should now come ON 51 IMPORTANT If indicator light remains on when switch is in the unlocked position check to see if the manual engaging bolt was removed from the shift cylinder assembly If engaging bolt remains remove it and replace with shift cylinder plug Retest for correct differential lock operation NOTE If differential lock still does not operate in accordance with above tests check all air and
34. nect 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 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 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 REMOVAL OF DIFFERENTIAL CARRIER FROM AXLE 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 using removal slots See Figure 1 Be certain carrier is balanced properly on jack and remove top two carrier to housing mounting bolts Remove differential carrier assembly from the axle housing Figure 1 10 Mount carrier assembly in a suitable rebuild stand Refer to Recommended Service Tools pg 32 Differential Carrier Removal Complete REMOVAL OF DIFFERENTIAL FR
35. r Rivet 45 50 tons 41 45 metric tonnes Differential Pinion Mate Differential Side Gear Differential Cross Shaft 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 thrust washer and side gear in differential case flange half Assemble pinion mates and thrust washers onto differential cross shaft Place assembly into flange half differential case Place remaining side gear and thrust washer in position on differential pinion mates Assemble case halves making sure match marks are lined up If reinstalling used bolts clean threads and apply Loctite 277 Install differential case bolts and torque evenly to 160 180 Lb Ft 217 244 N m Differential Assembly Complete DIFFERENTIAL INSTALLATION 1 Install ring gear and differential assembly into carrier 4 Loosen adjusting ring on tooth side of ring gear one housing notch and tighten adjusting ring on flange side of CAUTION To avoid damage of ring gear and pinion ring gear one notch Repeat process until backlash care should be used when installing the ring gear differential assembly into the carrier housing is eliminated Tighten adjusting ring on tooth side of the ring gear until the ring gear and pinion backlash matches the backlash etched on the 2 Be sure side bearing cups are seated on bearing ring gear This adjustment sets both the backlash
36. rntial 7 Apply and hold air pressure to the shift cylinder This will move the clutch collar inward and engage splines with the differential case splines locking the assembly 8 To ensure differential clutch collar and case half have engaged completely rotate the drive pinion or the right side wheel 27 NOTE Continue to keep differential lock engaged locked with air pressure until carrier has been completely removed from the axle housing 9 Remove the axle shafts and carrier assembly from the axle housing using the procedures as shown on Page 8 10 When carrier has been removed from the axle housing remove auxiliary pressure from the shift cylinder MANUAL ENGAGING METHOD NOTE Use this method if auxiliary air is unavailabe 1 Follow air pressure engagemant method through step 5 NOTE Refer to Figure 14 for the following steps DIFFERENTIAL LOCK MANUAL ENGAGEMENT DIAGRAM Air Supply C Inlet U C Air Shift Cylinder Manual Engagin M12 X 1 50 Bolt Figure 14 2 Remove plug from the hole in the center of the shift cylinder cover 3 Install an M12 x 1 50 bolt in the cylinder airport same hole the plug was in to manually engage the differential Continued On Next l age NOTE Bolt must be at least 1 75 in long to fully engage differential IMPORTANT Hand tighten the M12 x 1 50 bolt with a socket See Figure 17 on Page 30 A CAUTION If a high resistance to turn is felt before ful
37. ting 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 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 m
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