service manual: g & m models two speed rear
Contents
1. com 1 9 og Ld LOW RANGE In low range engine power is transmitted to the hypoid ring gear as before It then flows to the ring gear internal spur teeth which transfers it to the planet gears that are attached to the differential case Because the sun gear is clutched to a stationary retainer plate it cannot rotate and acts as a reaction member for the planet gears This causes the planet gears to rotate around the sun gear driving the differential case at a speed slower that the ring gear creating the additional low range reduction ratio and further multiplying engine torque From this point power flows in the same sequence as when the axle is in high range AXLE COMPONENTS Axle Shaft Sun Gear Hex Bolt 255 275 Lb Ft 298 539 N m Vent Plug Fill Plug 3 35 45 Lb Ft 47 61 N m Temperature e Sensor Plug 35 45 Lb Ft Sun Gear 47 61 N m Retainer Plate Adjusting Ring Differential Bearing Cup Differential Bearing Cone Ring Gear Bolt See Torque Specifications Magnetic Drain Plug 35 45 Lb Ft 47 61 N m Za Differential Support Case Differential Case Planetary e Planet Gear Shaft NS p Pl net Gear Mounting Plate Planet Gear2. lt 1491000 Zr S OO O TSL 900 0 Lc Tec soc Ie IO 00 0 800 0 600 0 cIO O 000 lt TOO O 97 0 00 0 Leo c00 0 eco I00 0 eco IOO Oc Leo cOO0 Ot 97 0 00 0 Zot soo O lt S 900 0 82I Z00 O0 800 0 LET 600 0 Tc OIO O OL LIO Oc soc cIO Oc Ore elo oF 00 0 220 00 0 Leo lt 00 0 sco 100 0 sco reo zO 000 lt rOO O Lot SOO 0 lt S TT 900 0 L00 0 EOT 800 O Lec 600 0 Tec OIO O eZ lt LLOO soc cIOO c Ott tIO O Ott TO O SLO 00 0 Leo c00 0 eco 1000 Leo 920 lt 00 0 00 0 cOO0 O c OO0 O est 900 0 34L 00 0c 800 0 600 0 Tec OIO O soc o LO gsc cIOO Leo cooo eco I00 0 Leo cOO0 O 940 lt 00 O rOO O Let SOO 0 est 900 0 100 0 com 800 0 Lom 600 0 Tec OIO Oc 6SZZ ILTO O soc cloor Ott I10 O v Ise SIOO c 990177 9
3. NOTE When replacing wheel bearings new bearings must be re seated to insure maximum service reliability After the hub and bearings are assembled in place on the spindile install the inner adjusting nut Tighten the LUBRICANT LEVEL inner adjusting nut to 120 140 Lb Ft 163 190 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 vehicle manufacturers specifications Wheel Bearing Adjustment Complete 23 AXLE TORQUE SPECIFICATIONS Item Model U S Metric Pinion Bearing Preload Torque Wrench M 20 50 Lb in 2 5 5 7 N m Differential Ring Gear to Pinion Backlash M 008 016 20 41 mm Lubrication Lube Capacity G 25 0 pints 11 8 liters Lube Capacity Approx M 35 0 pints 16 6 liters Pinion bearing preload is established prior to installation of pinion seal Capacity will va
4. differential carrier assembly is bolted The banjo housing is the vehicle load carrying member and the differential carrier assembly is the torque transmitting portion of the axle It consist of a primary hypoid gear set for high range operation and a secondary planetary type spur gear set which is combined with the primary gear set for low range operation Range changes are easily made by means of a hand control button mounted on the gear shift lever See Two Speed Operating Instructions Pg 25 The control button causes the planetary sun gear to act as a sliding clutch member and moves it in and out of engagement with two clutching plates to complete range changes I TT TT HIGH RANGE In high range the sun gear locks the planet gears with the planet plate and the ring gear The unit then functions as a single reduction axle Power flows in the pinion to the ring gear through the differential case to the differential cross shaft The cross shaft transfers it through the differential pinion mates to the left and right differential side gears and finally to the axle shafts POWER FLOW DIAGRAMS
5. 9000 Zot 000 tooo 00 0 Leo lt 00 0 sco Leo 7 0 TOO O 9es TIO O Ott eloo soc clo O 6Lc IIO O tec LTT 600 0 800 0 1000 est 900 0 Ler 000 lt O 000 c00 0 lt I00 0 sco LOO O cr Leo cOO Oc SLO OO Oc O Let 00 0 Ott IO O soc cIO 0 ITOO PST 0T0 0 LTT 6000 EOT 80070 Z00 0 lt S IT 900 0 S00 0 0 00 0 Leo C00 0 eco TOO O eco IO00 O LSO 00 0 000 lt 00 0 00 0 lt S ua 900 0 soc cI0 0 IIO O vec OIO O LTT 600 0 coc 800 0 1000 900 0 Let 000 lt 700 0 920 5 00 0 Leo lt 00 0 sco eco TO00 O O cOO O c 00 0 lt O c LECL SOO Oc est 900 0 SLE Z amp 00 0 LILO O Tec OILO O LTE 600 0 800 0 L00 0 900 0 S00 0 TOO O 97 0 00 0 Leo c00 0 sco I00 0 LOO O Leo 97 0 lt Ze LY Too O 00 0
6. Sooo 9000 L00 0 coc 800 0 vec OIO O LTT 600 0 coc 800 0 8Z IL L00 0 est 900 0 col rOO O SLO 00 0 Leo c00 0 eco Eco TOO O Leo cOO0 O c SLO 00 O Let est Ip lt lt 00 0 1000 800 0 600 0 LOC 600 0 coc 800 0 1000 est 900 0 Let sooo ZOT v0O O 00 0 Leo Tooo sco sco TO0 O Leo 970 000 Let celi coc Lom roc SOO O 9000 1000 800 0 6000 OIO O 0Z 8000 SZ L00 0 TSL 900 0 Let S00 0 97 0 L SO 00 0 T000 Sco I00 0 Seco tOO O Leo cOO O GLO 00 0 TOL TOO O Let TSL ft Oc ccc roc oLc SOOO 9000 1000 8000 6000 1000 cst 900 0 S00 0 00 0 00 0 SZO c00 0 1000 Teo coo O 000 Let SQ0 O cst 900 0 1000 Oc 800 0 Loc 600 0 tec OIO O LTO O soc cI0 O c cel 900 0 Z IL SOO O lt BLO 00 0 Leo c00 0 eco I00 0 eco
7. assembly 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 HAMMER OR ALTER BRAKE LININGS IN ANY MANNER WITHOUT PROPER PROTECTIVE EQUIPMENT FOLLOW 0 5 STANDARDS FOR PROPER PROTECTIVE DEVICES TO BE USED WHEN WORKING WITH BRAKE MATERIALS TWO SPEED AXLE FEATURES This Spicer axle assembly consist of a full float cold formed and welded banjo type housing member to which the
8. Adjusting Ring Retainer Hex Bolt Retainer Plate Bolt 30 40 Lb Ft See Torque Specifications 41 54 N m Install ring gear support case assembly into carrier housing The ring gear side of the support case must be tipped to clear the pinion roller bearing retainer plate Care should be taken to avoid damage of ring and pinion gear teeth and bearings Place bearing cups into position Assemble differential bearing caps Install bearing Once proper backlash is established torque bearing cap bolts to Model 220 250 Lb Ft 298 339 N m M Model 290 350 Lb Ft 393 475 N m Install adjusting ring retainers washers and bolts Torque retainer bolts to 30 40 Lb Ft 41 54 N m cap bolts finger tight only Install adjusting rings NOTE Assemble adjusting rings so that the side with two 3 Tighten adjusting ring on back side of ring gear shoulders is facing out to ensure clearance for the bearing until there is zero 0 backlash between the ring Inside face has only one shoulder See Figure 11 gear and pinion Proper Adjusting Ring Installation 4 Next tighten adjusting ring on the tooth side of ring gear until cup is seated Continue to tighten adjusting ring until backlash has returned to Outside Face measurement taken prior to disassembly pm Ring 5 Check ring gear and pinion backlash in four Relief for equally spaced positions around the ring gear with Clearance a dial i
9. Differential Bearing Cap Bolt See Torque Specifications Differential Cross Shaft Differential Bearing Cap Washer Differential Case Cap Half 0 9 on Differential Case Bolt MS Differential Gear Thrust Washer See Torque Specifications lt gt Hex Bolt me Pen Nm amp A OW Differential Pinion Mate Washer 6 Differential Pinion Mate Thrust Washer Adjusting Ring Y lt Retainer Shift Fork Assembly Differential J Pinion e Set Screw Shift Housing Seal Support Case 59 Pinion Pilot Bearing Cap Bolt See Torque Specifications Pinion Pilot Bearing Cap Pinion Oil Slinger Pinion Pilot Bearing Oil Slinger Seal Inner Pinion Bearing Cone Inner Pinion Bearing Cup Optional No SPIN Pinion Bearing Spacer Selective Carrier Housing O See Torque Specifications 0 Co N Carrier Mounting Bolt Outer Pinion Bearing Cup Outer Pinion Bearing Cone Pinion Oil Seal End Yoke Assembly Flanged Hex Nut 700 900 Lb Ft 6 949 1 220 N m 1 Shift the axle into low range See Two Speed Operating Instructions Pg 25 2 Remove the drain plug and drain lubricant 5 Remove the shift unit from carrier assembly NOTE Shift unit contains lube Provide container to catch lubricant NOTE For servicing the shift unit refer to Vehicle Service Manual 4 Disconnect drive shaft at rear u joint NOTE If ring or pinion be
10. Pinion Pilot Bearing Cap 0 Pinion Pilot Bearing Pinion Retainer Plate Bolt See Torque Specifications Inner Pinion Bearing d Inner Pinion Bearing Cup Pinion Bearing Spacer Selective Carrier Mounting Bolt See Torque Specifications 1 Assemble the proper pinion position spacer oil slinger seal and inner bearing cone onto the pinion 2 Press pinion pilot bearing on the pinion 5 Stake pinion pilot bearing onto pinion in six places using a center punch or equivalent tool See illustration on right NOTE Make sure all carrier bores are free from all nicks dirt or any other contamination 4 Install the inner and outer bearing cups into the carrier Oil Slinger Selective 6 Slinger Seal 9 Op Oo PINION ASSEMBLY Carrier Housing Flanged Hex Nut 700 900 Lb Ft 949 1 220 N m Outer Pinion Bearing Cone Pinion Oil Seal S End Yoke Assembly Use a feeler gauge or shim stock to ensure bearing cups are completly seated in bearing bores 0015 approx This is necessary for proper pinion position See Figure 8 Install inner pinion oil slinger seal into the carrier with the tabs locking into the oil channel Make sure the flat side of the seal is seated against the bottom of the bearing cup bore so that the lip side will be against the pinion oil slinger Install pinion into carrier using slow steady move ment when sliding through i
11. cap for proper wrench rotate pinion noting rolling torque Rolling spotface and chamfer at the four bolt holes as shown in torque of pinion should read between 20 50 in Ib Figure 10 If spotface and chamfer are not present 2 3 5 7 N m machine as required 030 chamfer X 45 for holes and 1 25 spotface X 030 To increase preload decrease thickness of preload deep at four places spacer to decrease preload increase thickness of preload spacer Every 001 025 mm change in 14 Rotate carrier to Chamfer 030 x 45 thickness of preload spacer changes torque to vertical position rotate by approximately 30 in Ib with yoke down Install pinion pilot NOTE A pinion bearing spacer selective is used to bearing cap using develop pinion bearing preload See list in next column for available thicknesses Measure the spacer with a or available P necessary micrometer before assembly to insure correct thickness 15 Install four retainer 12 Remove flanged hex nut washer and end yoke bolts Torque to Apply a light coat of lubricant to the lip of the seal and assemble into housing Model 70 80 Lb Ft 95 108 N m 030 Deep x 1 25 Spotface M Model 110 125 Figure 10 Lb Ft 149 169 N m 15 Assemble end yoke washer and new flanged hex nut Torque to 700 900 Lb Ft 949 1 220 N m Recheck torque to rotate Pinion Assembly Complete Ring gears and pinions are supplied in matched sets only Matching
12. carrier bearing bore Pinion Disassembly Complete CLEANING AND INSPECTION CLEANING 1 Parts should be cleaned with emulsion cleanersor 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 priorto reas sembly RVA y JO 5 Clean all gasket surfaces of old material DRYING Inspect gears for excessive wear or damage Replace Use 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 O o THRUST WASHERS Inspect housing for stripped threads and bending fatigue Inspect thrust washers for scoring and cracking
13. determine the position of the pinion mounting distance PINION SETTING 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 Pinion position spacers selective are available in the following thicknesses Inches MM 052 1 321 055 1 397 058 1 473 061 1 549 064 1 626 067 1 702 070 1 778 073 1 854 076 1 930 079 2 007 082 2 083 NOTE Measure the new pinion position spacer with a micrometer before assembly to insure correct thickness 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 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
14. numbers on both the pinion and ring gear are etched for verification If a new gear set is being used verify the number of each pinion and ring gear before proceeding with assembly See Gear Set Identification Ps 2 Beginning with carriers GGA 1007032 and MJA 1007160 a new method of setting pinion position has been adopted A number is etched on the machined surface under the roller bearing retainer plate on each carrier This number is used in conjunction with the number etched on each pinion to determine the proper pinion bearing spacer selective for proper assembly t eliminates the need for measuring with special gauge tools See Figure 7 Figure 7 Pinion position is based on the mounting distance measured from the centerline of the ring gear to the back of the pinion head See Illustration top of next column This dimension is controlled by shimming between the oil slinger seal and pinion head with a pinion position spacer selective On the nose 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 thou sandths of an inch 001 to be added or subtracted from the nominal mounting dimension for the best running position for that particular gear set PINION POSITION Pinion Oil Slinger N TIHNA Nominal Mounting Distance Centerline of Ring Gear A plus number etched on the pinion would mean that
15. through your vehicle manufac turer The use of non original Spicer service parts may Assembly Continued Pinion yen n d n dini 16 Differential 454 4a5 4 18 Ring Gear and Support 19 Differential Support Case Installation 20 Ring Gear and Tooth Contact Pattern 21 Sun Gear Retainer lnstallation 22 Installation of Carrier into Axle Housing 22 Wheel Bearing Adjustment s 25 Axle Torque Specifications 24 Two Speed Operating Instructions 25 Export Improvement for M230 T Model 26 Recommended Service Tools 27 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 JULIAN DATE CODE 5 DAY OF YEAR 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 Two types of tags may be found on the axle an aluminum tag tha
16. 100 sco 100 0 97 0 00 0 TOO O c S00 0 900 0 LOO Ot coc 800 0 Lom 600 O Lat Sc OLOO SLT soc cIO Oc Ott Ott TIO O 9017 9100 ctv LIO O ZOT O Let S 00 0O 900 0 00 0 800 0 Lom 600 0 Lec OIO O ola LIO O soc O Ott I10 O oct f TO O SIO O ctv LIO O LSY 8100 eco LOO O AIADINO LLOS 000 SHHONDdO 000 0 Lot soo oO cer 900 0 coc 800 0 Lom Tec OLO O ec LIIO O DNDIDIVIA NOINId MAN NOINId MAN OL GTO LYVHD ONLLLAS NOINId O Kot O Ott I10 O Tse 9017 9IO O Let 8T10 0 tSv 6100 NOINId ATO 17 DIFFERENTIAL ASSEMBLY Differential Case Planetary Half Differential Pinion Mate M Differential Pinion Mate Thrust Washer gt Differential Case Cap Half Differential Gear Thrust Washer Differential Case Bolt See Torque Specifications 1 Apply a small amount of lubricant to all mating surfaces This will keep the thrust washers in place during assembly and provide for initial lubrication Combe 2 Place thrust washer and differential side gear in me
17. EL M190 T lt lt MJAABO00 0 9 DANA PART Axle Assembly Tag NUMBER MODEL IDENTIFICATION NUMBERING SYSTEM 190 H T Nominal Load Gearing Type Options Carrying Capacity T Two Speed No SPIN Differential 155 15 500 Lbs 175 17 500 Lbs 190 19 000 Lbs 210 21 000 Lbs 220 22 000 Lbs 230 25 000 Lbs No SPIN is a registered trademark of Tractech Same as 185 18 500 Lbs GEAR SET IDENTIFICATION HEAT MFG LOCATION CODE ee PART TOOTH SET NUMBER NUMBER COMBINATION COMBINATION i 260 ae 2 PINION CODE ETCH NUMBER pana MFG LOCATION Manufacturer s Date Date gear set was made pinion are marked with a corresponding number i e Spicer Trademark Company logo and location of WIRT sed HER egi manufacturing facility A gear set that does not have the same match set numbers should not be run together If either ring gear Part number Ring Gear GGAGR 104 TYPICAL or pinion require replacement a new matched set must Tooth Combination i e 41 11 Indicates the pinion has 11 teeth and the ring gear has 41 teeth which results in 3 73 1 ratio be used Backlash Etch Indicates backlash setting for assembly Matched Set Number Spicer ring gears and pinions are Pinion Etch Indicator for proper pinion position shim manufactured as matched sets Both ring gear and AXLE LUBRICANT RECOMMENDATIONS
18. S Safety glasses should be worn at all times when assembling or disassembling axles SAFETY 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 method selected REBUILD FACILITIES A suitable holding fixture or carrier overhaul stand is desireable but not necessary to rebuild these units Alternatley a sturdy shop table of approximately 50 inches in height can be used with suitable means to hold the carrier securely for rebuild operations A light chain hoist should be used to relocate the carrier housing and to install or remove the ring gear and support case
19. Spicer Drive Axles SPICER Service Manual Spicer Drive Axles AXSM 8810 January 1998 6155 G175 T M190 T M210 T M220 T M230 T Two Speed Axles TABLE OF CONTENTS Axle Identification n yana dyana danan 1 Model Identification Numbering System 2 Gear Set Identification ee 2 Axle Lubricant Recommendations 5 General Precautions scccssssssssssssessssecsssesssssssseesssessseessseee 4 Safety Rebuild Facilities End Yokes and Flanges Cleanliness Features Power Flow Diagrams e 5 Axle COMPONENTS 6 Removal of Differential Carrier from Axle Housing 7 Disassembly Differential Cartier 8 Ring Gear and Support Case 9 Differential Lu nnn 10 e Tl Cleaning and Inspection ttai 12 Assembly PINON ODIUM 15 Pinion POSION didi omini ek 15 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 assembly They may be obtained
20. 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 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 SAE 85W 140 SAE 80W 140 80W SAE 75W 140 SAE 75W 90 SAE 75W will encounter C 40 26 12 0 4 15 27 438 C F2 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 PETROLEUM BASED SYNTHETIC BASED APPLICATION MILES INTERVAL MILES INTERVAL 3 Year 1 Year On Highway Severe Service and On Off Highway 1 Year 250 000 1 Year 100 000 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 2105 D specifications 3 SUBMERSION OR DEEP WATER FORDING In the event the carrier housing should become submerged in water particularly if over the vent plug it is recommend
21. arings are to be removed break loose pinion nut at this time 5 Remove axle shaft cap screws and lock washers or stud nuts and cone locks Remove axle shafts If gasket is assembled between the hub and shaft discard the old gasket and replace with a new one at time of reassembly 4 4i DZ p Ld nl Figure 1 REMOVAL OF DIFFERENTIAL CARRIER FROM AXLE HOUSING N Support the carrier on a roller jack Remove the carrier to housing bolts Break carrier loose from housing with use of pry bars behind carrier flange mounting face See Figure 1 Removal of Carrier from Axle Housing Complete DISASSEMBLY OF DIFFERENTIAL CARRIERS 4A 4B 5 6 Sun Gear Retainer Plate Retainer Plate Bolt See Torque Specifications Place the carrier in a suitable holding fixture such as a carrier repair stand If ring gear and pinion are to be reused measure gear backlash prior to disassem bly For double reduction models remove the two bolts and the double reduction plate Proceed to step 7 For two speed models remove the shift fork spring and seal from the carrier housing New Style Remove set screw and shift fork shaft Remove shift fork Proceed to step 7 Old Style Remove the shift fork shaft snap ring using suitable snap ring pliers Be sure to retrieve the retaining ring so that it will not be lost in the differential carrier Remove sealer from s
22. ce the planetary gears in position on the planetary gear shafts NOTE Remove any burrs from planet gear mounting plate 6 Position the planetary gear mounting plate on the planetary gear shafts and dowels with the cham Ring Gear See Torque Specifications Differential Support Case Differential Thrust Plate Planetary Gear Shafts Planetary Gear Mounting Plate fered teeth facing the planet gears Tap the plate with a soft hammer if necessary to seat the plate against the differential subassembly NOTE Be sure that the planetary gear shafts and dowel pins are flush to below flush prior to installing thrust plate 7 Apply lubricant to each side of the differential thrust plate and position the thrust plate on the planetary gear mounting plate 8 Place the support case on the ring gear and line up the bolt holes If old ring gear is used make sure match marks are aligned NOTE See Pg 26 for M230 T export model assembly instructions of ring gear bolts and retainers 9 Install and tighten the ring gear bolts alternately and evenly Torque bolts to G Model 110 125 Lb Ft 149 169 N m M Model 160 180 Lb Ft 217 244 N m Ring Gear and Support Case Assembly Complete DIFFERENTIAL SUPPORT CASE INSTALLATION Carrier Housing Differential Bearing Cap Sun Gear Retainer Plate Support Case and Differential Assembly Differential Bearing Cap Bolt See Torque Specifications
23. e SS Un differential case planetary half 5 Assemble differential components and place into differential case planetary half 4 Place side gear and thrust washer in position on differential pinion mates 5 Position differential case cap half onto above assembly making sure match marks line up See iio Figure 6 4 Install differential case bolts 230 export model has 12 bolts Tighten alternately and evenly Torque bolts to Model 70 80 Lb Ft 95 108 N m M Model 110 125 Lb Ft 149 169 N m Differential Assembly Complete lt Differential Q 1 RING GEAR AND SUPPORT CASE ASSEMBLY Planetary Gears Differential Subassembly Differential Support Case Differential Gear Thrust Washer Install differential bearing cones onto hub of support cases NOTE To protect bearings during the following steps install bearing cups on bearing cones 2 Apply lubricant to thrust washer surface and install in differential support case Install differential assembly into differential support case Rotate differential assembly to assure proper installation Install ring gear on differential support case aligning bolt holes Make sure ring gear is seated NOTE If old ring gear is used make sure match marks are aligned 5 Lubricate and install the four planetary gear shafts in the holes of the differential subassembly Pla
24. ed 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 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 PATENTED PRESSURIZED LUBRICATION SYSTEM The lube system for our two speed axle line is unique in the industry It s closed and pressurized so that oil constantly flows to critical components The tapered roller bearings act as a pump which provides pressurized lube through the internal channels in the carrier to the differential bearings planetary gears and differential gears GENERAL PRECAUTIONS IMPORTANT READ THIS SECTION BEFORE STARTING ANY SERVICE PROCEDURE
25. ee M230 T export model assembly instructions of Sun Gear Retainer Pg 27 1 Install sun gear retainer plate with chamfered teeth facing out and four bolts For double reduction models Install the two bottom bolts only Torque bolts to 220 250 Lb Ft 298 539 N m NOTE If lock plates will not fit correctly over bolts and retainer plate tighten the bolt until lock plate can be installed 2 Install sun gear For double reduction models Install the double reduction plate install two bolts and torque to 220 250 Lb Ft 298 339 N m For two speed models slide shift fork into carrier housing and position on sun gear Install shift fork shaft through hole in carrier housing and shift fork Figure 12 Insert and tighten set screw 30 40 Lb Ft 41 54 N m Install shift fork seal and spring See Figure 12 Sun Gear Retainer Installation Complete INSTALLATION OF 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 necessary to remove burrs or nicks 2 Apply an 1 8 bead of Loctite 518 gasket elimina 3 tor onto the axle housing mounting flange and around each bolt hole See Figure 13 Loctite 518 Gasket Eliminator Figure 13 Thread 2 studs into the axle housing 180 apart This will eliminate rotation of the carrier assembly after it makes contact
26. etary gear shafts halves iy im fhe sane 6 Turn assembly over and support on differential Figure 2 subassmbly dowel pins CAUTION Care must be taken to keep differential um BERO e of S ESO subassembly properly positioned in support case to C T prevent damage when removing ring gear l 7 Rotate ring gear to make sure support case is seated squarely on differential subassembly Using a soft hammer tap each side of ring gear alternatley to remove from support case half 8 Lift support case form differential subassembly Figured Remove thrust washer from differential subassembly 2 Remove ring gear bolts Remove differential 9 If either the left or right differen support case from ring gear using pry bars NOTE It is recommended that whenever the ring gear tial support case bolts are removed they be replaced with a new set bearings are to 3 Remove aluminum differential thrust plate be replaced remove them NOTE Thrust plate may be retained in support case due to oil rentention It should be removed and cleaned using a suitable before reassembly puller See Figure 3 4 Remove planetary gear mounting plate Use care to Figure 3 avoid damage to surfaces of plate and planetar 5 P P y Ring Gear and Support Case Disassembly Complete gear shafts 9 DIFFERENTIAL DISASSEMBLY Differential Case Cap Half Dif
27. ferential Pinion Mate Differential Pinion Mate Thrust Washer Differential Case Flange Half 7 Differential Gear Thrust Washer Differential Case Bolt See Torque Specifications NOTE Differential case halves are matched and marked during the manufacturing process No further marking C N necessary See Figure 4 di n n Com kan 1 Remove differential case bolts and lift off right hand N df ez LJ MI case half 2 Remove thrust washer and differential side gear 5 Lift out cross shaft differential pinions and thrust washers NOTE Inspect all parts inlcuding the matched surfaces of the case itself Where necessary replace all worn parts If excessive wear is noticed on all parts it is Figure 4 suggested that the complete differential assembly be replaced If any gears are to be replaced they must be replaced in sets Inspect thrust washers for scoring and excessive wear replace if necessary 4 Lift out differential side gear and thrust washer Differential Disassembly Complete Pinion Pilot Bearing Cap o Pinion Pilot Bearing T 6 Slinger Seal Retainer Plate Bolt See Torque Specifications Inner Pinion Bearing Cone Inner Pinion Bearing Cup Pinion Bearing Spacer Selective Carrier Mounting Bolt See Torque Specifications 1 Turn the carrier to a vertical position and remove the four pilot bearing cap bolts Lift the pilot bearing cap fr
28. ft lbs DST1004 Maximum 4 000 ft lbs DST1005 Maximum 12 000 ft lbs DST1006 YOKE REMOVER BAR TYPE DST1009 AS INSTALLER DIFFERENTIAL YOKE 1 VAS 28 RECOMMENDED SERVICE TOOLS ORDER NUMBER ILLUSTRATION DESCRIPTION DST1000 1 SEAL INSTALLATION TUBE HANDLE DST1000 2 PINION SEAL INSTALLER ALL SERVICE TOOLS AVAILABLE FROM OTC DIVISION Service Tools 655 Eisenhower Drive Owatonna MN 55060 Telephone 1 800 533 0492 Fax Number 1 800 578 7375 29 lt pana 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 8810 Printed in U S A Copyright Dana Limited 2012 All rights reserved Dana Limited
29. hift fork shaft holes Remove shift fork shaft by using a drift and hammer Support Case and Differential Assembly Adjusting Ring Retainer He Carrier Housing Differential Bearing Cap Differential Bearing Cap Bolt See Torque Specifications x Bolt 30 40 Lb Ft 41 54 N m NOTE Shaft will only drive out in one direction 7 Remove sun gear 8 Remove four sun gear retainer bolts and sun gear retainer plate NOTE For ease of disassembly the ring gear bolts can be loosened at this time 9 Remove adjusting ring retainers 10 Remove four differential bearing cap bolts 11 Back out either adjusting ring to relieve preload 12 Remove bearing caps 13 Remove adjusting rings 14 Lift the ring gear and differential sub assembly out of carrier The ring gear side of the subassembly must be tipped up for the ring gear to clear the pinion roller bearing retainer NOTE Use care to avoid damage to the ring gear and pinion Differential Disassembly Complete RING GEAR AND SUPPORT CASE DISASSEMBLY Ring Gear See Torque Specifications Planetary Gears Differential Support Case Differential Subassembly Differential Thrust Plate Differential Support Case Planetary Gear Shafts Differential Bearing Cone AT A gt Dre Planetary Gear Mounting Plate Differential Gear Thrust Washer 1 Prior to disassembly match mark support case 5 Remove planetary gears and plan
30. ndicator NOTE If backlash does not vary more than 003 in and the average backlash is between 008 016 in or 20 Figure 11 40 mm the setting is acceptable Ring Gear and Support Case Assembly Complete 20 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 m terns will cover less area than the gear pattern TENE PROFILE established by previous service HEEL STEP 1 Paint 1 4 ring gear with marking compound both the drive and coast side ROOT EN 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 21 SUN GEAR RETAINER INSTALLATION NOTE S
31. nner bearing cup and seal The pinion should be restrained from end movement by using a retaining strap See Figure 9 PINION ASSEMBLY 8 Rotate carrier to a vertical position Place pinion Pinion bearing spacers selective are available in the bearing spacer selective on pinion Install outer following thicknesses bearing cone onto pinion inches MM Inches MM NOTE The reason for not assembling a new pinion oil 700 17780 714 18 156 seal at this time is due to the possibility of having to 701 17 805 715 18 161 adjust pinion preload or pinion position It would be 702 17831 716 18 186 necessary to again remove the seal and as mentioned 703 17856 717 18 212 whenever seals are removed they are to be discarded 704 17882 718 18 237 because of possible damage 705 18 907 719 18 263 9 Inspect end yoke seal surface for grooves caused by 706 18 932 20 18 288 seal lip If grooves can be detected with a fingernail 707 18 958 721 18 313 yoke should be replaced or have repair sleeve 708 18 983 722 18 339 RORIS 709 18 009 725 18 364 10 Assemble end yoke washer and old flanged hex nut 710 18 034 724 18 390 onto pinion Torque nut to 700 900 Lb Ft 949 71 18 059 725 18 415 1 220 N m The old nut can be used during this 712 18 085 726 18 440 adjustment phase of the assembly saving the new 73 18 110 727 18 466 one for final assembly 11 Remove pinion retainer strap Using an in lb torque NOTE Inspect pinion pilot bearing
32. number must be added to the nominal mounting distance to get the required mounting distance 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 thinner shim between pinion and oil slinger seal than a pinion etched with O to allow for this difference To achieve proper pinion position decrease the pinion position spacer thickness by 003 in 076 mm Similarily if the pinion is marked 3 the shim required between pinion and oil slinger seal would be 003 in 076 mm thicker than if pinion was etched 0 to allow for this distance To acheive proper pinion position increase the pinion position spacer thickness by 003 in 076 mm The number etched on the carrier also refers to the mounting distance based on a 0 etched pinion This number represents thicness in thousandths of the pinion position spacer selective required for a 0 etched pinion PINION POSITION The following examples illustrate how the carrier etch and the pinion etch interact EXAMPLE A EXAMPLE B Number etched on nose of pinion 3 2 Number etched on carrier 63 61 Add or subtract pinion etch from carrier etch to get correct pinon 063 061 postion spacer 003 1 002 060 063 Select pinion postion spacer that is closest to the calculated value from table NOTE The pinion position spacer functions as a selective shim to
33. om the roller bearing and carrier housing tapping with soft hammer from underneath side if necessary 2 Turn the nose of the carrier to a horizontal position to remove the flanged hex nut Hold the end yoke stationary and remove the flanged hex nut and washer Figure 5 5 Remove the end yoke using a suitable puller See Figure 5 4 Replace flanged hex nut finger tight Tap pinion free of bearing with soft hammer 5 Supporting pinion from inside carrier remove flanged hex nut PINION DISASSEM BLY T Position Spacer Selective Carrier Housing Outer Pinion Bearing Cup Flanged Hex Nut 700 900 Lb Ft 949 1 220 N m 6 Remove pinion 7 Near the spline end of the pinion and between the pinion bearings is a selective pinion bearing spacer used for pinion bearing preload Retain this spacer for possible use in reassembly 8 Remove pinion pilot bearing from end of pinion 9 Remove inner bearing cone from pinion Remove the pinion oil seal Discard the seal and replace it with a new one at time reassembly Remove the outer pinion bearing cone 11 Rotate carrier to pinion nose down position Remove the pinion oil slinger seal from the carrier and discard Install a new seal at the time of reassembly 12 With nose of the carrier down remove the outer pinion bearing cup 15 Turn the carrier over and remove the inner bearing cup CAUTION Do not nick the
34. rt Case Assembly Complete EXPORT IMPROVEMENT FOR M230 T MODEL SUN GEAR RETAINER INSTALLATION 1 Install sun gear retainer plate Apply Loctite 277 to threads of bolts with a grooved head and install Torque bolts to 220 250 Lb Ft 258 559 N m O NOTE Figures 18 19 for proper assembly 2 Install sun gear lock plates over bolts NOTE If lock plates will not fit correctly over bolts and retainer plate tighten the bolt until lock plate can be installed E clip 3 Install E clips to grove in head of bolt 4 Install sun gear Lock Plate 5 Slide shift fork into carrier housing and position on sun gear Install shift fork shaft through hole in carrier housing and shift fork TTTT Sun Retainer Plate 6 Insert and tighten set screw 50 40 Lb Ft 41 54 N m 4 Install shift fork seal and spring NOTE Continue assembly with Installation of Carrier mem igure into Axle Housing procedures outlined on Pg 22 Sun Gear Retainer Installation Complete Sun Gear Lock Plate Sun Gear Retainer Plate TO Set Screw Grooved Retainer Bolt Figure 19 27 RECOMMENDED SERVICE TOOLS ORDER NUMBER ILLUSTRATION DESCRIPTION DST1001 CARRIER STAND TORQUE MULTIPLIERS DST1002 Maximum 1 000 ft lbs DST 1003 Maximum 2 000
35. ry 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 Fasteners Position Model Thread Grade Lb Ft N m Flanged Hex Nut G M 1 1 4 12 700 900 949 1 220 Fill amp Magnetic Drain Plugs M 3 4 14 8 35 45 47 61 Adjusting Ring Retainer Bolts M 3 8 16 8 30 40 41 54 Differential Case Bolts G 7 16 14 8 15 135 156 183 1 2 13 8 70 80 95 108 Carrier Mounting Bolts G 1 2 13 8 100 120 136 163 5 8 11 8 240 260 325 352 Ring Gear Bolts G 1 2 13 8 110 125 149 169 M 9 16 12 8 160 180 217 244 Differential Bearing Cap Bolts G 5 8 18 8 220 250 298 339 3 4 16 8 290 350 393 475 Pinion Pilot Bearing Retainer Bolt G 7 16 14 8 70 80 95 108 M 1 2 13 8 110 125 149 169 Sun Gear Retainer Bolt G M 5 8 18 8 255 275 345 575 On models equipped with Sun Gear Lock Plate See Page 27 Retainer Bolt Torque is 220 250 Lb Ft 298 339 N m TWO SPEED OPERATING INSTRUCTIONS The Spicer two speed rear axle may be specified in combination with four and five speed manual transmissions There are 8 10 possible gear selections The axle can be spit shifted or shifted to high when road speed is achieved By studying Figure 14 and using the following shift sequences you can refine and make using the Spicer two speed axle an automatic occurance LOW TO HIGH SHIFTING With accelerator down move the axle selector switch
36. t is riveted on the axle assembly or a coated mylar tag The aluminum differential carrier tag contains the following items serial number according to the julian date code the Dana part number and ratio The mylar differential carrier tag contains the following Dana part number julian date code and ratio Optional items JULIAN DATE CODE DANA PART NUMBER SPICER SN 97070 RATIO 0 00 Carrier Tag DANA PART NUMBER CUSTOMER PART NUMBER OPTIONAL MODEL TUM Mode MISB T Sui mU 9 d 478 JULIAN DATE Axle Assembly Tag CODE LINE SET NUMBER LAST SIX DIGITS OF OPTIONAL VEHICLE SERIAL NUMBER OPTIONAL AXLE IDENTIFICATION include customer part number line set number and the last six digits of the vehicle serial number The aluminum axle assembly tag contains the following items serial number according to the julian date Dana part number and the model The mylar 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 DANA PART NUMBER CUSTOMER PART NUMBER OPTIONAL P CARRIER M1JRERB888 BX BU lJ II SER SPICER 3707 000000 RATIO R1 4040 Carrier Tag LINE SET NUMBER LAST SIX DIGITS OF OPTIONAL VEHICLE SERIAL NUMBER OPTIONAL JULIAN DATE CODE SPICER SN 97070 MOD
37. 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 esr 610 0 Let 810 0 ctt LIO O 9O0t 9IO0 0 ISt SLUGS Ott r100 ETOO soc cIO 0 II0O 0 Tec OIO O LTT 6000 8000 L00 0 cst 900 0 93 0 000 Let 8100 cer LI10 0 9017 9100 Tse stoo ese VIO O Ott SOt 100 CIO O LIO O rec OIO O LTT 6000 0Z 8000 1000 900 0 Let 000 Teo c00 0 eco 100 O ctv LIO O 9017 910 0 Ise SIO O ewe vIO O Ott 100 SOt ZLc cIO O LLOO vec OIO O LTZ 600 0 800 0 EFL LOO O 900 0 Let 5000 ZO TT 00 0 sco I00 0 0 sco L00 O LSO amp 00 0 90177 910 0 Ist SIO O 5 FIO 0 Ott 100 soc cIO 0 6LT rec IIO O OIO O LTT 600 0 800 0 Eb 1000 est 9000 Lc SOO O vooo SLO 00 0 eco LOO O Leo cOoO0 Oc 970 000 sec SIO O TIO O Ott IO O soc cIO 0 6ZLc IIO O vec LTT OIO O 6000 EOT 800 0 1000 est
38. to HI RANGE Release accelerator When shift is complete depress accelerator HIGH TO LOW SHIFTING With accelerator down move the axle selector switch to LO LO RANGE Rapidly release and depress accelerator When shift is complete depress accelerator SPLIT SHIFTING THE TRANSMISSION AND AXLE Upshifting While shifting transmission up to the next higher gear Figure 14 Move axle selector switch to LO before engaging clutch Downshifting With the accelerator down move the axle selector Switch to HI pre select Shift transmission down to the next lower gear 25 EXPORT IMPROVEMENT FOR M230 T MODEL RING GEAR BOLT RETAINER INSTALLATION 1 Follow Ring Gear and Support Case Assembly procedures 1 thru 8 2 Insert ring gear bolts through ring gear bolt retainers See Figure 15 Ring Gear Bolt Retainer Figure 15 5 Apply a thin layer of Loctite 277 on the threads of the ring gear bolts and install as shown in Figure 16 Tabs 26 4 Torque the ring gear bolts to 160 180 Lb Ft 217 244 N m 5 Bend tabs on retainers over flats of bolts See Figure 17 CAUTION If tabs on retainers do not align with flats on bolts tighten bolts to next flat that will align with tab Bent Tab Figure 17 NOTE Continue assembly with Differential Support Case Installation procedures outlined on Pg 20 Ring Gear and Suppo
39. with the gasket material 22 Install the carrier assembly into the axle housing Clean the mounting bolts and coat with Loctite 277 red or its equivalent and install Tighten bolts evenly in cross pattern See torque specifica tions for carrier mounting bolts 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 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 Fill unit to proper level with hypoid gear lubri cant 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 Installation of Carrier Complete WHEEL BEARING ADJUSTMENT NOTE Wheel bearings should be adjusted following vehicle manufacturers recommended maintenance J 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
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