dana spicer single drive axles s170, s190, s590
Contents
1. 1 lt 9 1 Cab mounted control val ve plunger in valve open 9 Forward rear axle wheel differential lock air shift cylinder 2 Dry air supply tank 80 120 PSI part of axle assembly 3 Preferably equal in length 10 Wheel differential lock indicator switch 4 Power supply part of axle assembly 5 Fuse or circuit breaker 11 Indicator light of audible signal 6 Indicator light or audible signal 12 Fuse or circuit breaker 7 Wheel differential lock indicator switch 13 Power supply part of axle assembly 14 66468 Quick release valve optional located on frame rail 8 Rear axle wheel differential lock air shift cylinder and within 10 feet of tubing from control valve part of axle assembly 63 Theory of Operation Wheel Differential Lock The Spicer Wheel Differential Lock is an optional feature for spicer Axles In operation it positively locks the wheel differ ential to provide improved traction under adverse road conditions The differential lock is driver controlled through an electric switch or air valve mounted in the cab The locking mecha nism is air operated to engage a mechanical clutch and lock the wheel differential It is spring operated to disengage the lock and permit the whe2. 63 Wheel Differential 1 64 65 Pinion Assembly Parts Exploded View 66 Wheel Differential Parts Exploded Views 67 Wheel Differential Lock Assembly Parts Exploded Views 68 Housing and Output Shaft Assembly Parts Exploded View 69 Fastener Torque Specifications 70 General Information Introduction Dana Commercial Vehicle Systems Division presents this Model Information publication to aid in maintenance and overhaul of Spicer tandem drive axles The following models are included in this publication Heavy Singles Instructions contained cover the models listed Their design is 521 170 528 190 common with differences load capacity Capacity variations are achieved by combining basic differential carrier assemblies 521 1700 526 1900 with different axle housings axle shafts and wheel 523 170 530 590 equipment 523 1700 530 190 523 190 530 1900 S23 190D 530 190E S25 170 S35 590 Model Listing 526 170 es 3 5 S 23 170D L 0ptions D Dual Drive Forward Axle C Controlled Traction with Inter Axle Differential D Differential Lock G Single Rear Axle Global E
3. 1 Jam Nut 5 Breather 9 Lock washer 2 Locking ring 6 Breather hose 10 Stud 3 Spindle nut 7 Carriage capscrew 11 Drain plug 4 Axle housing 8 Nut 12 Axle shaft 69 Fastener Torque Specifications Fastener Torque Specifications Location Size Lbs Ft Nem POWER DIVIDER Input Cage Locking Bolt M8 x 1 0 x 30 20 5 25 5 IAD Shift End Cap 2 375 16 UN 2A 65 10 85 15 Power Divider Cover Capscrews M14 x 1 5 x 45 175 x 10 235 x 10 Input Shaft Nut M48 x 1 5 900 100 1220 135 WHEEL DIFFERENTIAL AND GEARING Front Pinion Helical Nut M48 x 1 5 900 100 1220 135 Output Shaft Nut M42 x 1 5 900 100 1220 135 Rear Pinion Nut M48 x 1 5 900 100 1220 135 Ring Gear Diff Case Bolts M20 x 1 5 x 55 500 25 675 30 CARRIER Carrier Diff Bearing Cap M18 x 1 5 x 85 265 15 360 20 Carrier to Housing Capscrews M16 x 1 5 85 250 15 335 20 M16 x 1 5 x 55 250 15 335 20 Carrier to Housing Nuts M16 x 1 5 250 15 335 20 Pilot Bearing Web M16 x 1 5 x 70 210 10 285 15 Differential Lock Switch M14 x 1 5 10 1 15 3 Differential Lock End Cap 2 375 16 UN 2A 65 10 85 15 HOUSING Rear Cover Capscrews M16 x 1 5 x 70 250 15 335 20 M16 x 1 5 x 55 250 15 335 20 Rear Cover Nuts M16 x 1 5 250 15 335 20 Magnetic Plug Fill 1 11 5 NPTF 50 5 72 5 Drain Plu
4. Qo 1 Input torque 2 Lockout engaged 3 Forward axle torque is transmitted from the helical side gear through the pinion helical gear drive pinion ring gear wheel differential and axle shafts Note Varied road surface conditions can result in unequal torque distribution between the two axle assemblies A CAUTION Prolonged operation with the lockout engaged can dam age axle and driveline components 4 Rear axle torque is transmitted from the output shaft side gear through the output shaft inter axle driveline drive pinion ring gear wheel differential and axle shafts 5 Input torque power flow from the vehicle driveline is transmitted directly to the helical side gear and the output shaft A positive drive is provided to both axles for maximum traction under adverse road conditions 61 oa lt i Er 5 Theory of Operation Operate Wheel Differential Assembly The Spicer wheel differential lock is driver controlled and operated by a carrier mounted air actuated shift unit In operation it positively locks the wheel differential to pro vide improved traction under adverse road conditions Control Systems for Differential Lock Two systems may be used to control the differential lock operation Transmission Low Range Interlock Control System The wheel differential is locked manually
5. Verify endplay Three piece Tang type Lock Washer System 1 Inner Nut 2 Tang type Lock Washer 0 123 3 124 mm thick 3 Outer Nut a Install the Tang type lock washer on the spindle A CAUTION Never tighten the inner nut for alignment This can preload the bearing and cause premature failure b Install the outer nut on the spindle and tighten to 250 Ibs ft 339 Nem c Verify endplay d After verifying endplay secure wheel nuts by bending one of the locking washer tangs over the outer wheel nut and another tang over the inner wheel nut e Go to step 12 50 Four piece Tang Dowel type Lock Washer System 5 9 5 1 Inner Nut 2 Dowel Pin 3 Dowel type Lock Washer 4 Tang type Lock Washer 0 0478 1 2065 mm thick 5 Outer Nut a Install the Dowel type lock washer on the spindle Note If the dowel pin and washer are not aligned remove washer turn it over and reinst all If required loosen the inner nut just enough for alignment A IMPORTANT Never tighten the inner nut for alignment This can preload the bearing and cause premature failure b Install the Tang type lock washer on the spindle Install the outer nut on the spindle and tighten to 250 Ibs ft 339 Nem d Verify endplay e After verifying endplay secure the outer nut by bending 180 apart two opposing tangs of the locking washer over the outer nut 12 Install the following e New gasket a
6. 5 Remove axle shafts A WARNING Do not lie under carrier after fasteners are removed Use transmission jack to support differential carrier assembly prior to lo osening fasteners 6 To remove axle shaft remove axle stud nuts If used remove lock washers and taper dowels 7 Remove axle shafts Note All models in this publication use axle shafts with unequal lengths Axle shafts may also be location spe cific with various wheel equipment Do not misplace axle shafts from their intended location Identify left and right shafts for reference during reassembly TIP If necessary loosen dowels by holding a brass drift in the center of the shaft head and striking drift with a sharp blow with a hammer A CAUTION Do not strike the shaft head with a steel hammer Do not use chisels or wedges to loosen shaft or dowels 8 Remove carrier capscrews nuts and lock washers 9 Remove differential carrier assembly Carrier Assembly After July 2013 6 Mount the differential carrier in a head stand with 8B Using a long flat blade screwdriver a pry bar the wheel differential facing upward back off one of the wheel diff bearing adjusters and remove Note For easier disassembly loosen but do not remove the pinion nut 2 S 1 gt 7 1 3 lt 7 Remove the carrier differential bearing cap capscrews flat washers and bearing caps 9 Using a chain hoist and the prope
7. lash Back the cup out two notches of the adjust ment plate Turn the plain half adjuster ring until there is zero preload on the bearings This is done by turning the adjuster plate clockwise until you feel the threaded cup gain resistance The threaded bearing cup should only be slightly snugged to achieve a zero preload condition 1 Flange Half 2 Plain Half Obtain two notches of preload by tightening the plain half adjustment ring two notches Start with the notch at the top count two notches counter clock wise on the adjuster ring turn the adjuster ring so that the notch is facing straight up FP Ss 1 Two Notches Wheel Differential 8 Use a rubber mallet to fully seat the threaded bearing 12 Install the carrier differential bearing caps and cap cups screws Make certain there is no gap between the carrier cap and the carrier surface oa E oa oa r E 9 With a dial indicator check the ring and pinion back lash Set the backlash from 0 010 to 0 012 This 13 Use an impact gun to snug all carrier will give you room to adjust the contact pattern if cap fasteners necessary 14 Recheck the backlash For new gearing the backlash should be between 0 008 and 0 018 0 20 and 0 46 mm 10 Remove the adjuster plates and threaded rod assembly Note For used gearing the backlash should be reset to what 11 Apply a 1 8 bead of Loctite 540 to the expose
8. Do not pack the bearings with grease before installation Grease will prevent the proper circulation of axle lubricant and may cause wheel seal failure 6 Install the outer bearing on the spindle 7 Install the inner nut on the spindle Tighten the inner nut to 200 Ibs ft 271 Nem while rotating the wheel hub A CAUTION Never use an impact wrench to adjust wheel bearings A torque wrench is required to assure that the nuts are prop erly tightened 8 Back off the inner nut one full turn Rotate the wheel hub 9 Retighten the inner nut to 50 Ibs ft 68 Nem while rotating the wheel hub 10 Back off the inner nut exactly 1 4 turn Note This adjustment procedure allows the wheel to rotate freely with 0 001 0 005 0 025 mm 0 127 mm endplay 11 Install the correct lock washer for the wheel nut sys tem being used Three piece Dowel type Lock Washer System 9 9 2 1 Inner Nut 2 Dowel Pin 3 Dowel type Lock Washer 4 Outer Nut a Install the Dowel type lock washer on the spindle Note If the dowel pin and washer are not aligned remove washer turn it over and reinst all If required loosen the inner nut just enough for alignment A CAUTION Never tighten the inner nut for alignment This can preload the bearing and cause premature failure 49 E 2 E Wheel End Seal b Install the outer nut on the spindle and tighten to 350 Ibs ft 475 Nem
9. High Entry Single R Dual Drive Rear Axle H Heavy Wall S Single Rear Axle N A Integral Brake L Limited Slip GAW Rating P Lube Pump x 1000 Ibs N America R Retarder Ready x 1 Tn Europe W Wide Track Gear Type Design Level 1 Standard Single Reduction 2 Dual Range Head Assembly Series 3 Planetary Double Reduction 4 Open 5 Helical Reduction General Information Model Identification Drive Axle 3 CUST PART NO N Spice SPEC SERIAL NO 2 SEE PARTNO RATIO ju MADE IN 1 Country or origin 2 Axle model identification 3 Specification number assigned to the axle built by Spicer Identifies all component parts of the axle including special OEM requirements such as yokes or flanges Parts Identification Axle Housing 1 ID Tag Rear Axle Top View 4 OEM part number assigned to the axle build 5 Carrier assembly serial number assigned by the manufacturing plant 6 Axle gear ratio 7 Carrier assembly production or service part number Axle Shaft 2 Axle shaft part number General Information Ring Gear and Pinion Note Ring gear and drive pinion are matched parts and must be replaced in sets D D i 3 D 1 Part number 2 Number of ring gear teeth 3 Ma
10. clutch moves out of engagement with the fixed clutch The wheel differential is unlocked and operates normally Ja 25 ain LE 3s LE Differential Lock Engaged 1 Spring is compressed 2 Shift fork 3 Piston and rod 4 Selector switch 5 Air pressure applied engages clutches 6 Fixed clutch splined to differential case 7 Sliding clutch splined to axle shaft and engaged with fixed clutch Differential Lock Engagement Indicator Differential lock engagement is detected by a switch elec tric mounted on the differential carrier An actuator mounted in the piston cover operates the switch When the shift fork moves to engage the differential lock the push rod actuator moves away from the switch allows the switch to close and send an electrical signal to turn on a cab mounted indicator light or an audible signal When the shift fork moves to disengage the differential lock the compression spring also moves the push rod actuator to contact the switch The switch is opened and turns off the cab mounted indicator light or the audible signal Differential Lock Disengaged 1 Spring is decompressed 2 Shift fork 3 Piston and rod 4 Selector switch 5 Air pressure applied disengages clutches 6 Fixed clutch splined to differential case 7 Sliding clutch spl
11. end of cylinder z D 2 ES D et Install piston cover o ring Install piston cover and torque to 50 75 Ibs ft 68 102 Nem N Install selector switch and torque to 10 12 Ibs ft 14 16 Nem Check selector switch operation Check switch electrically with an ohmmeter Switch should be closed when clutches are engaged and open when disengaged 41 Output Shaft Assembly amp Rear Cover Housing and Output Shaft Assembly Parts Exploded View 7 Jam nut 6 Breather hose 10 Stud 2 Locking ring 7 Carriage capscrew 11 Drain plug 3 Spindle nut 8 Nut 12 Axle shaft 4 Axle housing 9 Lock washer 5 Breather 42 Seal Replace Replace Seal Spicer strongly recommends using seal drivers when installing 4 Remove the new seal from its package and install new seals Use the proper driver to make sure that the seal is with the proper driver square and installed to the proper depth R Pinion Driver 210749 R Pinion Insert 131472 A CAUTION Oil seals can be easily damaged prior to installation Use care when handling the new seal to prevent damage or contamination Leave the seal in its package until Due to the resiliency of the plastic driver hammer rebound installation On new yokes leave the protector on the may occur when the seal is seated Keep clear of the ham yoke until it is installed on the shaft to preve
12. gearing When contact pattern is correct use a punch with a round head to stake the threaded bearing cups in place Stake the outer edge of the bearing adjust ment ring into the machined slots in the carrier bear ing bore on both sides Must be staked at two locations Rotate cup if necessary to provide sur faces for staking 4 di SN GEN A Q A H J WC Rur 1 Two Stake Locations at 1 Machined slot 2 Bearing Adjustment Ring 3 Round Head Punch 29 E 1 oa a e Wheel Differential Wheel Differential Disassembly Forward Carrier Assembly 1 After July 2013 1 A IMPORTANT g 5 3 Remove the side gear thrust washers side pinions During e following procedures place ho and differential spider from the plain half case 2 differential assembly on a malleable surface to prevent damage when removing components 1 Remove the differential case capscrews 2 Remove the flange half differential case and bearing assembly Use a screwdriver at the spider arm machined slots of the case to loosen the flange from 4 Place a block under the plain half use a rubber mal the ring gear let to remove the ring gear 5 Remove the bearing cones from the case halves using suitable pullers 1 Spider Arm Slots 30 6 Wheel Differential Remove the bearing cones from the plain and flange halves in
13. noticeable wear such as heavy grooving beyond normal pol ishing from the seal lips Note Do not rework the yoke with abrasives such as emery paper or crocus cloth Clean the surface of the yoke as necessary using chemical cleaners Remove all trace of the chemicals from the yoke after cleaning A CAUTION Do not use wear sleeves Wear sleeves increase the yoke hub surface diameter and cause premature seal wear and repeat seal failure 44 Seal Replace Service Kit Location 210749 Rd 131472 45 Housing Breather Housing Breather Spicer has an axle breather that consists of a fitting hose 4 Insert hose onto fitting long end down and clamp assembly This breather design has improved resistance to water ingestion clogging caused by dirt ice or snow buildup around the base of the breather See installation instructions below all views from rear 1 Install fitting in breather hole IN 2 Tighten fitting finger tight 5 Push hose firmly against fitting Rotate hose to point 2 down oque 3 Using a 3 4 wrench e Metal only Rotate the fitting at least 1 2 turn until nipple points to rear N p e Plastic only Tighten until one thread is showing 46 L 72 3 wi Wheel End Seal Parts Exploded View Wheel End Seal 1 Installation tool 2 Seal 3 Rear hub 47 Wheel End Seal Remove and Overhaul Wheel End S
14. or cracking along gear contact lines Scuffing deformation or discolorations These are signs of excessive heat in the axle and are usually related to low lubrication levels or improper lubrica tion practices ition inspect the following for damage Differential gearing Bearings for loose fit on drive pinion pilot bearing and differential bearings All fasteners for rounded heads bends cracks or damaged threads Inspect machined surfaces of cast or malleable parts They must be free of nicks burrs cracks scoring and wear Look for elongation of drilled holes wear on sur faces machined for bearing fits and nicks or burrs in mating surfaces Inspect Primary Gearing Before reusing a primary gear set inspect teeth for signs of excessive wear Check tooth contact pattern for evidence of incorrect adjustment Differential Carrier Assembly Differential Carrier Assembly Parts 1 Carrier fasteners 2 Carrier assembly 3 Single axle assembly V Differential Carrier Assembly Remove Differential Carrier Note The removal of the forward carrier does not require dis connecting of the inter axle driveline and removal of the output shaft yoke assembly as most other Spicer tan dems require Standard Differentials 1 Block the vehicle Drain axle lubricant Disconnect driveline gt m Disconnect lead wires to the selector switch and air line at shift cylinder
15. to seat the ring gear to the plain 9 Install the ring gear capscrews half 10 Tighten the ring gear capscrews with an impact gun and then use a torque wrench to torque to the proper specifications See the Torque Chart 8 Install the flange half of the case Align the capscrew holes 33 Wheel Differential 11 Lower assembled differential assembly in to the carrier using a hoist and a strap Be careful not to damage the differential bearings lowering the assembly 12 Install the bearing cup and bearing adjuster to the flange half side first 1 Flange Half 2 Plain Half 13 Install the bearing cup and bearing adjuster to the plain half side Use a long screwdriver or bar to lift the differential up while installing the cup and bearing adjuster 34 Wheel Differential Install Wheel Differential Assembly Forward Carrier Assembly Backlash and Bearing Preload 8 1 Turn the flange half bearing adjuster in until the ring 3 Tighten the plain half adjuster two lug notches gear contacts the pinion zero backlash then back Start with the notch at the top count two notches S the adjuster out two notches of the adjuster lugs counterclockwise on the adjuster so that the notch is facing straight up You now have a two notch preload ANS C QEN 1 Flange Half 2 Plain Half 1 Flange Half 2 Plain Half 4 Use arubber mallet to make certain that both bearing adjusters
16. top of the side gear contacts the inner race of the cone A used bearing race would be a suitable tool This tool should have a slit cut if the ID is the same as the flange OD 1 Press the new bearing on the plain half and flange half bearing boss using the proper press sleeve or bearing installation tool 5 Install the flange half side gear Apply a thin coat of oil to the mating surfaces 2 Place the plain half side of the differential case on a malleable surface 3 Install the side gear Apply a thin coat of oil to the mating surfaces of the side gear and plain half 1 Match spacing of holes on each side of Spider slots 23 7 8 24 Wheel Differential Use a rubber mallet to seat the ring gear to the plain 9 half Install the flange half of the case Align the capscrew holes Install the ring gear capscrews 10 Tighten the ring gear capscrews with an impact gun and then use a torque wrench to torque to the proper specifications See the Torque Chart oa ES oa oa a E Wheel Differential Install Wheel Differential Assembly Forward Carrier Assembly 1 Set Backlash and Bearing Preload 2 Connect the adjuster plates using the threaded rod washers and nuts Tighten the nuts on the rod to Note To install the wheel differential assembly properly setup hold the threaded DS in place Carefully lower the the gear pa
17. 13 1 00 2 25 2 75 15 2 00 2 50 3 25 Pinion pointing upward Horizontal Mounting 58 1 Oil Filler Hole 2 Lost Oil Capacity Lubrication 12 Installation 1 Oil Filler Hole 2 Lost Oil Capacity 12 Installation with Standpipe 1 Oil Filler Hole 2 Additional Oil Capacity Note Grades must be continuous or lengthy in nature Moni tor oil temperatures before installing standpipes Axles should operate at approximately 100 F 38 C over ambient temperature and not exceed 240 F 116 C Final Check Prior to putting vehicle back into service run the vehicle to bring axle lube up to temperature Check filler and drain plugs and axle joint for leakage Re tighten to specifications as nec essary Towing Guide Proper Vehicle Towing Without Wheel Differential Lock Lift the drive wheels completely off of the ground or damage will occur A WARNING Do not lift the front wheels non drive wheels This alters the oil s position in the drive axle draining it away from the drive pinion and its bearings If the pinion is rotated under these conditions for any period of time bearings will over heat resulting in axle damage or failure If it is impossible to lift the drive wheels remove all axle shafts to prevent gear rotation and cap the wheel hubs to pre vent loss of lubricant and a possible road hazard See the fol lowing section Proper Vehicle Towing with Wheel Diff
18. 3 Pinion 4 Wood Block 6 Use the proper pressing tool to press the end of the pinion until free from the pinion bearings En var dai Y 1 Press 13 1 lt ay Drive Pinion Pinion Assembly Parts Exploded View 1 Pinion pilot bearing 2 Pinion 3 Pinion bearing cone inner 4 Pinion bearing cup inner Cg 5 Pinion bearing spacer 9 Yoke 6 Pinion bearing cup outer 10 Pinion nut 7 Pinion bearing cone outer 8 Oil seal Drive Pinion Drive Pinion Overhaul and Assembly The preload of the bearings on the drive pinion is adjusted by 2 Remove the inner pinion bearing cone from the pin a spacer between the inner and outer bearing cones and the ion using a split type puller Use two procedure helical gear The preload is adjusted by changing the thickness steps to remove each bearing a Monte puler verily separate the bear ing from the pinion This action will force the The following procedure covers both the forward and rear axle puller halves behind the bearing race and start carrier overhaul and assembly moving the bearing from the pinion Note See carrier disassembly for instructions on pinion and yoke removal 1 If the model of axle uses a pilot bearing remove the bearing using a split type puller Use two procedure steps to remove each bearing a Mount the puller vertically to separate the bear ing from the pinion Thi
19. Best results are obtained when tooth contact patterns are maintained in used gearing 11 Drive Pinion Pinion Removal 1 Ifa pilot web is used remove the web capscrews 2 Before the pinion nut can be loosened you must a For S190 disassembly install a M10 x 1 50 Pe Stake ne Ut iam He ar tha bolt in the threaded jack holes found in between the pilot web capscrews 3 To de stake the nut use a chisel or drift with a round tip The flange of the nut must be pushed far enough outward so that the staked area will not interfere with the pinion threads when the nut is removed See diagram below 1 Threaded Jack Holes b For 5190 disassembly use the pry slots pro vided at each end of the pilot web A CAUTION Failure to de stake the pinion nut will result in damage to the drive pinion threads when removed The pinion nut should never be reused always replace with new 1 Round Tipped Chisel 2 Machined Slot In Pinion 3 Nuts Staking Flange 3 4 Remove the pinion nut 12 Drive Pinion 5 Place carrier assembly into a press place a 2 x 6 x 6 wood block under the pinion This will ensure that when the pinion is pressed free from the bear ings the pinion will not be damaged The bearing spacer will be reused or used as a starting point when resetting the pinion bearing preload Do not da Y 2 discard this part 1 Carrier Assembly 2 Press
20. Helpful removal and installation procedures to aid in the service of this unit Always use genuine Spicer replacement parts Table of Contents Table of Contents Assembly page 23 Housing Breather page 46 Lubrication page 54 Wheel Differential Lock page 40 Ey i 1 N General Information INTO DUCT ON res ua S 1 Model Identification eese 2 3 Failure Analysis 4 5 Inspection 6 Differential Carrier Assembly 7 Remove Differential 8 9 Install Differential 10 Remove Wheel Differential All Standard Models 11 Pinion Removal a SA 12 13 Pinion Assembly Parts Exploded View 14 Drive Pinion Overhaul and Assembly 15 19 Wheel Differential Parts Exploded View 20 Wheel Differential Disassembly Before July 2013 Forward Carrier 21 22 Wheel Differential Assembly Forward Carrier Assembly 23 24 Install Wheel Differential Assembly Forward Carrier Assembly 25 29 Wheel Differential Disa
21. are fully seated 2 Tighten the plain half adjuster until the bearing cup just starts to turn This is a zero bearing preload 5 With a dial indicator check the ring and pinion backlash Set the backlash from 0 010 to 0 012 This will give you room to adjust the contact pattern if necessary 35 Wheel Differential 6 Install the carrier differential bearing caps and cap 9 Measure the ring gear total radial runout Indicator screws Make certain there is no gap between the reading should not exceed 0 010 0 25 mm carrier cap and the carrier surface 10 Measure the ring gear total backface runout Indicator reading should not exceed 0 010 7 Use an impact gun to snug all carrier 0 25 mm cap fasteners 11 Check the ring gear tooth pattern Paint 5 or 6 ring gear teeth 180 degrees apart on the ring gear 8 Recheck the backlash For new gearing the backlash should be between 0 008 and 0 018 0 20 and 0 46 mm Note For used gearing the backlash should be reset to what it was at the time of disassembly Note If you have too much backlash move the ring gear Closer to the pinion Count the number of notches you back off the plain half threaded cup Each notch equals about 0 003 0 08 mm of backlash 12 With the carrier mounted in a head stand roll the A IMPORTANT carrier on its side In order to maintain the differential bearing preload you will need to turn the flange half threaded
22. ay from the inner nut but not off the spindle Loosen the inner nut to the next adjustment hole of the dowel type washer if used Reassem ble the washer and re torque the outer nut Verify endplay with a dial indicator Fine Tuning the Endplay If after performing the readjustment procedures endplay is still not within the 0 001 0 005 0 025 0 127 mm range disassemble and inspect the components If parts are found to be defective replace the defective parts reassemble and repeat wheel bearing adjustment procedure Verify endplay with a dial indicator 51 E m 2 2 E Wheel End Seal Lubricate Wheel End A CAUTION Before operating the axle the wheel hub cavities and bear ings must be lubricated to prevent failure When wheel ends are serviced follow Spicer s wheel end lubri cation procedure before operating the axle Spicer axles may be equipped with either of two wheel end designs e Wheel ends with an oil fill hole e Wheel ends without an oil fill hole 52 Wheel Ends with an Oil Fill Hole 1 2 3 4 Rotate the wheel end hub until the oil fill hole is up Rem ove the oil fill plug Pour 1 2 pint of axle sump lubricant into each hub through the wheel end fill hole Install oil fill plug and tighten to specified torque C ont Ci 09 OT ae S ECIXNNNS Y 1 Wheel End Oil Fill Hole 2 Proper Lubricant Level 3 Lubricant Flow fr
23. contact your local Dana representative See back cover of this manual for appropriate phone number Makeup Lube Maximum amount non synthetic makeup lube is 10 For additional lubrication information see TCMT 0021 54 Recommendations for Viscosity Ambient Temperature The following chart lists the various SAE Grades covered by MIL L 2105D and the associated ambient temperature range from each Those SAE grades shown with an asterisk are available in the Spicer family of synthetic gear lubricants The lowest ambient temperatures covered by this chart are 40 F and 40 C Lubrication recommendations for those applications which consistently operate below this temperature range must be obtained through Dana by contacting your local Dana representative Grade Ambient Temperature Range 75W 40 F to 15 F 40 C to 26 C 75W 90 40 F to 100 F 40 C to 38 C 75W 80 40 F to 80 F 40 to 21 C 75W 140 40 F and ab ove 40 C and above 80W 90 15 F to 100 F 26 C to 38 C 80W 140 15 F and ab ove 26 C and above 85W 140 10 F and above 12 C and above Available in the Spicer family of synthetic gear lubricants Lubrication Lube Change Intervals This product combines the latest manufacturing and part Severe Service Lubrication Change Intervals Severe service washing technology When filled with an Spicer approved applications are those
24. cup the same amount in the same direction If you need more backlash reverse the procedure 36 Wheel Differential 13 Make a sling out of a strap and position around the plain half of the wheel differential oa e ES 1 oa E 14 Connect the end of the strap to a hoist and apply pressure to the sling 15 Use the correct socket and a breaker bar to rotate the differential The differential should be hard to turn Rotate the pinion until the ring gear rotates 3 or 4 times in both directions 37 Ring Gear Adjust Tooth Contact Position Adjust Ring and Pinion Tooth Contact Pattern Note Rear axle gearing is shown in the following instruc tions Correct tooth contact patterns and adjustments are the same for forward and rear axles Zu on c 1 Face width 2 Tooth depth 3 Heel 4 Top land 5 Root 6 Toe 1 Identify if new or used gearing 2 Check tooth contact pattern new or used gearing New Gearing Correct Pattern Paint six ring gear teeth 180 apart with marking compound and roll the gear to obtain a contact pattern The correct pattern is slightly below center on the ring gear tooth with lengthwise contact up off the toe The length of the pattern in an unloaded condition is approximately one half to two thirds of the ring gear tooth in most models and ratios The pattern could vary in length and should cover 1 2 tooth or more face
25. d it was at the time of disassembly threads of the bearing adjuster Note If you have too much backlash move the ring gear foo back off the plain half threaded Each notch equals 509 about 0 003 0 08 of backlash umo oso 5 omo wo A IMPORTANT In order to maintain the differential bearing preload you will need to turn the flange half threaded cup the same amount in the same direction If you need more backlash reverse the procedure Apply Loctite 5 40 27 Wheel Differential 15 Measure the ring gear total radial runout Indicator 18 With the carrier mounted in a head stand roll the reading should not exceed 0 010 0 25 mm carrier on its side 16 Measure the ring gear total backface runout Indicator reading should not exceed 0 010 19 Make a sling out of a strap and position around the 0 25 mm plain half of the wheel differential 20 Connect the end of the strap to a hoist and apply pressure to the sling 17 Check the ring gear tooth pattern Paint 5 or 6 ring gear teeth 180 degrees apart on the ring gear 28 Wheel Differential 21 Use the correct socket and a breaker bar to rotate the differential The differential should be hard to turn Rotate the pinion until the ring gear rotates 3 or 4 times in both directions See page 30 Adjust Tooth Contact Position for descriptions of correct pattern position for new and used
26. e the axle is properly filled 56 Note Lube fill capacities see chart are basic guidelines and will vary based on the angle the axle is installed in a par ticular chassis Torque fill plug to 40 60 Ibs ft 54 82 Nem TIP The axle can be filled through the axle housing breather hole Fill until lube level is even with the bottom of filler hole in axle housing rear cover 1 With axle on level surface fill housing with oil to bottom of plug 2 Temperature sensor mounting hole Lubrication Standpipes Drive axles are lubricated with oil drawn from a large sump integral to the assembly Most axle designs attempt to posi tion vital components such as pinion bearings in close prox imity to this sump keeping them bathed in a generous supply of oil at all times When drive axles are installed at severe angles in vehicle chassis the position of these components is changed relative to the oil sump The same effect is present when the vehicle travels up a steep grade Oil in the sump remains level while the axle itself tilts up or down This makes it possible for bear ings and gears located well forward in the assembly to starve for lubrication even though the axle is filled to the base of the fill plug hole as recommended by the manufac turer Axles should be modified with standpipes to raise lube levels whenever chassis installation angles exceed 10 and when the vehicle must negotiate continuous or lengthy g
27. e pattern is concentrated at the heel too far up the tooth move the ring gear toward the pinion to decrease backlash 1 Loosen the bearing adjuster on the teeth side of the ring gear several notches 2 Tighten the opposite adjuster one notch 3 Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup 4 Continue tightening the same adjuster 2 or 3 notches and recheck backlash 39 Wheel Differential Lock Wheel Differential Lock Parts Exploded View Lj Yo 3 1 Sliding clutch 5 Piston 9 Switch 2 Spring 6 O ring 70 Roll pin 3 Shift Fork 7 Piston cover 4 Push rod 8 Washer 40 Wheel Differential Lock Install and Adjust Wheel Differential Lock Note With differential carrier completely assembled and adjusted install differential lock as follows If shift fork and sliding clutch are disassembled engage fork with the clutch hub and install spring pin in the fork leg See illustration below for fork mounting position on clutch N Position compression spring shift fork and clutch in shift opening of the carrier Align pilot hole of shift fork with the pilot hole of carrier 99 Install pushrod through shift fork compression spring and carrier pilot hole DA Lubricate piston and o ring with silicone grease Install shift piston assembly into cylinder Position piston with small diameter hub toward closed
28. eal Install Wheel End Seal A WARNING 1 Before installation lubricate the following with the Never work under a vehicle supported by only a jack same lubricant used in the axle sump Always support vehicle with stands Block the wheels and Inner bearing make sure the vehicle will not roll before releasing the brakes e Wheel seal follow the directions provided by the seal supplier 2 Place seal on installation tool A IMPORTANT 3 Drive seal with installation tool onto hub Wheel end seals can be easily damaged during handling Leave the seal in its package until installation to prevent damage or contamination 1 Remove outer bearing and wheel Remove oil seal Remove inner bearing gt gt Remove old wear sleeve 2 piece design only with ball peen hammer and discard A IMPORTANT Do not cut through the old wear sleeve Damage to the housing may result 5 Inspect spindle journal and hub bore for scratches or burrs Recondition with an emery cloth as required Note Deep gouges can be repaired by filling gouge with hard ening gasket cement and smoothing with emery cloth 6 Clean hub cavity and bearing bores before reassem bly Be sure to remove contaminants from all recesses and corners 7 Clean bearings thoroughly with solvent and examine for damage Replace damaged or worn bearings A IMPORTANT Always use the seal installation tool specified by the seal manufacturer Using an improper t
29. ed dowels Add axle lubricant Fill to bottom of filler hole Connect driveline making sure all yokes are in phase Lubricate u joints 10 Carrier Assembly Remove Wheel Differential All Standard Models Carrier Disassembly 4 Remove the shift fork and sliding clutch assembly For models having the wheel differential lock option or a Note Do not disassemble the shift fork from the sliding carrier thrust bolt refer to the following procedure These clutch unless parts are to be replaced To disassem parts must be removed first before further disassembly of ble use a pin punch to remove spring pin from the the wheel differential can take place fork leg The sliding clutch can now be removed from the fork 1 For ease of service mount differential carrier in head stand with differential locked with the differ ential lock facing up 9 TV N d S 1 gt 7 1 3 lt 5 Remove the shift fork spring 2 Remove the threaded cylinder cap 5 mc piu Remove the piston push rod from the shift fork Note Omit this step if the ring gear is to be replaced If the ES ring gear is to be reused check the tooth contact pat tern and ring gear backlash before disassembling the SA carrier assembly When checking the backlash a yoke or helical gear must be installed and torqued to the proper specification to get an accurate reading
30. el differential to function normally 3 4 S P 2 The wheel differential lock consists of three major assem blies e Shift Cylinder Assembly Operates a shift fork and push rod assembly e Shift Fork and Push Rod Assembly Engages and disengages the differential lock curvic clutch assembly e Curvic Clutch Assembly Consists of a sliding clutch splined to an axle shaft and a fixed clutch which is splined to the differential case hub The differential lock also includes selector switch elec tric which senses clutch engagement and sends an electri cal signal to a cab mounted indicator light or an audible signal device 5 6 AS q 8 f 7 8 1 Sliding clutch 5 O ring 9 Pin 2 Spring 6 Piston cover 10 Carrier 3 Clutch fork 7 Washer 4 Piston and rod 8 Switch 64 Theory of Operation Differential Lock Engaged Air pressure applied to the shift cylinder moves the piston push rod shift fork and the sliding curvic clutch engages the fixed curvic clutch The sliding clutch is splined to the axle shaft The fixed Clutch is splined to the differential case hub Engaging the two clutches locks the wheel differential thus preventing wheel differential action Differential Lock Disengaged When air pressure at the shift cylinder is released a com pression spring mounted on the push rod moves the push rod shift fork and sliding clutch as an assembly The slid ing
31. erential Lock for removal procedure With Wheel Differential Lock Follow this procedure to remove all axle shafts preventing gear rotation with the drive wheels and possible lubrication damage 1 Engage the wheel differential lock indicator light is on move vehicle to verify engagement Shift transmission into neutral With vehicle stationary release the air pressure on the wheel differential lock shift system and apply the parking brake Disconnect the air supply and fitting at the shift cylinder Install the shipping capscrew 128642 0 250 X 18 X 1 5 NPSM screw GM models require part number 128274 M12 X 1 5 X 38mm screw Tighten cap screw to manually engage the wheel differential lock until the indicator light is on and the differential lock is completely engaged Remove the axle shafts Install temporary cover on hub to prevent contami nation entering and also to prevent the loss of lubri cant 59 e a 17 Theory of Operation Power Divider Operation Power Flow and Torque Distribution In operation the power divider accepts torque from the vehicle driveline and distributes it equally to the two axles This assembly is of the two gear design consisting of an input shaft inter axle differential output shaft and two con stant mesh helical gears With Lockout Engaged Inter Axle Differential is Operating 1 Input torque 2 Lockou
32. g 0 750 14 NPTF 50 5 72 5 Housing Breather 0 375 18 NPTF 20 26 27 35 Temperature Sending Plug 0 500 20 NPTF 50 5 72 5 Axle Shaft to Wheel Hub Nut 0 625 18 180 10 245 15 0 750 16 315 30 425 x 40 Wheel Diff Lock Caps 2 37 16UN 2A 65 x 10 85 15 70 For spec ing or service assistance call 1 877 777 5360 or visit our website at www dana com Dana Commercial Vehicle Products Group 3939 Technology Dri spem m SPICER Drivetrain Products www dana com All applications must be approved by the Application Engineering Department Specifications and or design are subject to change without notice or obligation Printed in USA AXSM 0056 09 13
33. iagnose the cause of a premature failure is one of the prerequisites of a good heavy equipment technician How to Diagnose a Failure The following five steps are an effective approach to good failure diagnostics 1 Document the problem 2 Make a preliminary investigation 3 Prepare the parts for inspection 4 Find the cause of the failure 5 Correct the cause of the problem Document the Problem Here are some guidelines for starting to learn about a failure Talk to the operator of the truck Look at the service records e Find out when the truck was last serviced Ask the following questions n what type of service is the truck being used e Has this particular failure occurred before How was the truck working prior to the failure You need to be a good listener Sometimes insignificant or unrelated symptoms can point to the cause of the failure Ask the following questions e Was the vehicle operating at normal temperatures e Were the gauges showing normal ranges of operation e Was there any unusual noise or vibration After listening review the previous repair and maintenance records If there is more than one driver talk to all of them and compare their observations for consistency with the service and maintenance records Verify the chassis Vehicle Identification Number VIN number from the vehicle identification plate as well as the mileage and hours on the vehicle Make a Preliminary Invest
34. igation These steps consist of external inspections and observations that will be valuable when combined with the results of the parts examination e look for leaks cracks or other damage that can point to the cause of the failure e note of obvious leaks around plugs and seals A missing fill or drain plug would be an obvious cause for concern e for cracks in the carrier housing harder to see but sometimes visible e Does the general mechanical condition of the vehicle indicate proper maintenance or are there signs of neglect e Are the tires in good condition and do the sizes match e f equipped with a torque limiting device is it work ing properly During the preliminary investigation write down anything out of the ordinary for later reference Items that appear insignificant now may take on more importance when the subassemblies are torn down Prepare the Parts for Inspection After the preliminary investigation locate the failure and pre pare the part for examination In carrier failure analysis it may be necessary to disassemble the unit e When disassembling subassemblies and parts do not clean the parts immediately since cleaning may destroy some of the evidence e When tearing down the drive axle do it in the recom mended manner Minimize any further damage to the unit e Ask more questions when examining the interior of the carrier Does the lubricant meet the manufactu
35. ined to axle shaft 65 Parts Identification Pinion Assembly Parts Exploded View 1 Pinion pilot bearing 2 Pinion 3 Pinion bearing cone inner 4 Pinion bearing cup inner 66 5 Pinion bearing spacer 9 Yoke 6 Pinion bearing cup outer 70 Pinion nut 7 Pinion bearing cone outer 8 Oil seal Parts Identification Wheel Differential Parts Exploded View Before July 2013 After July 2013 6 R g N 5 2 p 55 P 1 Threaded bearing adj flange half 8 Differential spider 13 Bearing adjuster plain half 2 Bearing cone flange half 9 Differential case RH plain half 14 Bearing cup plain half 3 Differential case LH flange half 10 Differential case RH plain half 15 Side gear thrust washer 4 Ring gear and pinion set wheel diff lock 16 Side pinion thrust washer 5 Bolt 11 Bearing cone plain half 17 Bearing cup flange half 6 Side gear 12 Threaded bearing adj plain half 18 Bearing adjuster flange half 7 Side pinion 67 Parts Identification Wheel Differential Lock Assembly Parts Exploded View 1 Sliding clutch 5 Piston 9 Switch 2 Spring 6 O ring 10 Roll pin 3 Shift Fork 7 Piston cover 4 Push rod 8 Washer 68 Parts Identification Housing and Output Shaft Assembly Parts Exploded View 5 2
36. ing system rm mn 5 For additional lubrication information see TCMT 0021 55 Lubrication Change Lube Drain Drain when the lube is at normal operating temperature 150 200 F It will run freely and minimize the time neces sary to fully drain the axle this insures the axle is flushed Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container Note Dispose of all used lubricants properly by following dis posal methods approved for mineral or synthetic based oils After initial oil change inspect drain plug for large quantities of metal particles These are signs of damage or extreme wear in the axle Clean the drain plug and replace it after the lube has drained completely Inspect breather for clogging or cor rosion Clean or replace as necessary Fill Front Axle a With vehicle on level ground remove the filler hole plug from the axle housing cover and fill the axle with approved lubricant until level with the bottom of the hole Rear Axle a Remove the filler hole plug from the axle housing cover and fill the axle with the approved lubricant until level with the bottom of the hole b If wheel ends were removed follow instructions in wheel end servicing page 40 Correct lube level at bottom of filler hole Always use the filler hole as the final reference If lube is level with the bottom of the hol
37. n place while it is positioned into the press 17 18 Drive Pinion 12 With 5 tons of force on the press you should be able 14 Install the drive yoke and pinion nut to feel a small amount of drag from the bearing as you rotate the carrier If the carrier turns with no drag at all the pinion spacer thickness should be decreased by using a thinner spacer If the carrier is hard to turn the spacer thickness must be increased 15 Torque the nut to 800 1000 Ibs ft 1084 1355 Nem 16 Use an in lbs torque wrench and correct socket to check the rolling torque of the pinion Read torque while rotating the assembly Record the rotating torque not the breakaway torque Torque must be between 20 to 50 Ibs in If the torque recorded is not within the specified torque the pinion spacer must be changed Repeat Steps 6 17 13 Remove the carrier from the press Secure the car rier in a head stand Drive Pinion 17 Now remove the pinion nut and yoke and install the pinion seal Use Spicer s seal drive part number 210749 and drive adapter part number 131472 A WARNING Failure to stake the pinion nut properly may result in the nut coming loose during service The pinion nut should never be reused always replace with new 20 pilot bearing web is used lineup the web to the locating sleeves and tap in place with a rubber mallet 18 Reinstall the yoke and pi
38. na Approved Lubricants General Gear lubrications acceptable under military specifi cation MILSPEC MIL L 2105D Lubricating Oils Gear Multipurpose are approved for use in Spice r Driv e Axles The MIL L 2105D specification defines performance and viscosity requirements for multigrade oils It supersedes both MIL L 2105B MIL L 2105C and cold weather specification MIL L 10324A This specification applies to both petroleum based and synthetic based gear lubricants if they appear on the most current Qualified Products List QPL 2105 for MIL L 2105D Note The use of separate oil additives and or friction modifiers are not approved in Spicer Drive Axles Synthetic based Synthetic based gear lubricants exhibit superior thermal and oxidation stability and generally degrade at a lower rate when compared to petroleum based lubricants The performance characteristics of these lubricants include extended change intervals improved fuel economy better extreme temperature operation reduced wear and cleaner component appearance The family of Spicer gear lubricants represents a premium quality synthetic lube which fully meets or exceeds the requirements of MIL L 2105D These products available in both 75W 90 and 80 W 140 have demonstrated superior performance in comparison to others qualified under the MILSPEC as demonstrated by extensive laboratory and field testing For a complete list of Spicer approved synthetic lubricants
39. nion nut Torque to 800 1000 Ibs ft 19 Once the proper rolling torque is achieved use a punch with a round tip to stake the pinion nuts flange into the machined slot in the pinion shaft See diagram below 1 Locating Sleeves 21 Install capscrews and torque to the proper specifica tions See the Torque Chart et A CAUTION The stake must be deep enough to enter the machined slot of the pinion See diagram below TIP If you are unable to torque the yoke nut cor rectly try torquing the nut with the truck wheels on the ground and with the axle shafts installed 1 Round Tipped Chisel 3 2 Nuts Staking Flange 3 Machined Slot In Pinion 19 Wheel Differential Wheel Differential Parts Exploded View Before July 2013 1 Threaded bearing adj flange half 2 Bearing cone flange half 3 Bearing cup flange half 4 Ring gear and pinion set 5 Bolt 6 Output side gear 7 Side pinion thrust washer 20 After July 2013 8 Differential spider 9 Side gear 10 Differential case RH plain half 11 Differential case RH plain half wheel diff lock 12 Bearing cone plain half 13 Threaded bearing adj plain half 14 Bearing adjuster plain half 15 Bearing cup plain half 16 Side gear thrust washer 17 Side pinion thrust washer 18 Bearing cup flange half 19 Bearing adjuster flange half Wheel Differen
40. nt damage mer rebound path or contanunation 5 Handle the seal by its outside diameter avoiding any 1 Remove the old yoke using appropriate tool A yoke contact with the seal lips During installation use the puller tool may be made from the center section of proper driver to make sure that the seal is mounted most gear puller tools or may be purchased from properly your local tool distributor 6 Use arubber mallet to drive the seal tool in until the flange bottoms on the housing cover bore face The flange will locate the seal at the proper depth 2 Remove seal Use care when removing the old seal to prevent damage to the housing seal bore 3 Inspect the seal bore area for any damage nicks gouges corrosion Carefully remove any slight damage with a crocus cloth Clean the bore area to remove any loose debris A CAUTION Do not use any silicone or permatex type bore sealant with this seal 43 Seal Replace Guidelines for Reusing Yoke A CAUTION Do not use the yoke if it has any damage on the seal surface nicks or scratches The surface of the yoke and the lips of the seal form a critical interface which retains the axle s lubricant while sealing the axle from outside contaminants The condition of the yoke hub s surface is a very important factor in determining seal life Carefully inspect the seal surface area of the yoke hub for signs of wear and damage Do not reuse the yoke if there is
41. nufacturing numbers 4 Matching gear set number 5 Number of pinion teeth 6 Date code 7 Indicates genuine Spicer parts 8 Heat code Failure Analysis Failure analysis is the process of determining the original cause of a component failure in order to keep it from happening again Too often when a failed component is replaced without determining its cause there will be a recurring failure If a carrier housing is opened revealing a ring gear with a broken tooth it is not enough to settle on the broken tooth as the cause of the carrier failure Other parts of the carrier must be examined For a thorough understanding of the failure and possible insight into related problems the technician needs to observe the overall condition of the vehicle No one benefits when a failed component goes on the junk pile with the cause unknown Nothing is more disturbing to a customer than a repeat failure Systematically analyzing a failure to prevent a repeat occurrence assures quality service by avoiding unnecessary downtime and further expense to the customer The true cause of a failure can be better determined by knowing what to look for determining how a piece of the equipment was running and learning about previous problems In the case of a rebuilt rear axle mismatched gears may have been installed The more successful shops prevent repeat equipment failures by developing good failure analysis practices Knowing how to d
42. om Sump Wheel End Seal Wheel Ends Without Oil Fill Hole 4 Raise the left side of the axle 6 or more Hold axle in 1 With axle level and wheel ends assembled add lubri This pos Mon for ang mingite z cant through filler hole in axle housing cover until 5 Lower the left side pn 6 With axle level surface add lubricant through 2 Raise the right side of the axle 6 or more Hold axle housing cover oil filler hole until fluid is level with the c5 in this position for one minute bottom of the hole D 3 Lower the right side Note Axles without wheel end fill holes will require approxi mately 2 5 additional pints of lubricant to bring the lube level even with the bottom of fill hole 1 With axle on level surface fill housing with oil to bottom of plug 2 Temperature sensor mounting hole 3 Oil will run into wheel end 4 Oil will run into wheel end 5 Tilt housing side to side 1 minute per side 6 Recheck oil level in axle 53 Lubrication General Lubrication Information The ability of a drive axle to deliver quiet trouble free operation over a period of years is largely dependent upon the use of good quality gear lubrication in the correct quantity The most satisfactory results can be obtained by following the directions contained in this manual The following lubrication instructions represent the most current recommendations from Da
43. ool can distort or damage the seal and cause premature seal failure 48 Wheel End Seal Adjust Wheel Bearing A WARNING Do not mix spindle nuts and lock washers from different systems Mixing spindle nuts and lock washers can cause wheel separation Note The lock washer for a four piece tang dowel type wheel nut system is thinner than the lock washer for a three piece tang type wheel nut system and is not designed to bear against the inner nut 1 Inspect the spindle and nut threads for corrosion and clean thoroughly or replace as required Note Proper assembly and adjustment is not possible if the spindle or nut threads are corroded 2 Inspect the tang type washer if used Replace the washer if the tangs are broken cracked or damaged 3 Install the hub and drum on the spindle with care to prevent damage or distortion to the wheel seal A CAUTION A wheel dolly is recommended during installation to make sure that the wheel seal is not damaged by the weight of the hub and drum Never support the hub on the spindle with just the inner bearing and seal This can damage the seal and cause premature failure 4 Completely fill the hub cavity between the inner and outer bearing races with the same lubricant used in the axle sump 5 Before installation lubricate the outer bearing with the same lubricant used in the axle sump Note Lubricate only with clean axle lubricant of the same type used in the axle sump
44. opicer Single Drive Axles lt pana gt SPICER Drivetrain Products Service Manual AXSM0056 September 2013 5170 Series 190 Series 5590 Series General Information General Information The description and specifications contained in this service publication are current at the time of printing Dana reserves the right to discontinue or to modify its models and or procedures and to change specifications at any time without notice Any reference to brand names in this publication is made simply as an example of the types of tools and materials recommended for use and should not be considered an endorsement Equivalents if available may be used Important Notice This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and or component damage Departure from the instructions choice of tools materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator WARNING Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician CAUTION Failure to follow indicated procedures may cause component damage or malfunction IMPORTANT Highly recommended procedures for proper service of this unit Note Additional service information not covered in the service procedures Tip
45. r strap lift the ring gear and wheel differential assembly from the carrier Before July 2013 8A Use Spicer s wheel diff bearing adjustment tool part number 513061 to back off the threaded cups and remove 1 Threaded bearing cup 2 Adjustment plate Differential Carrier Assembly Install Differential Carrier A IMPORTANT Before installing carrier assembly inspect and thoroughly clean interior of axle housing using an appropriate solvent and clean rag 1 Apply Spicer approved RTV compound on axle housing mating surface as shown in the illustration Completely remove all old gasket material prior to applying new material Compound will set in 5 minutes Install carrier before compound sets or reapply 1 e 3 T ren PN P XA M 4 n ac ds wo ve r vs os Nes J LI ye e ha OY aa 1 Apply silicone gasket in this pattern TIP To assist in installing complete differential carrier use two pieces of threaded rod M16 X 1 5 threaded into carrier capscrew holes Rod should be approximately 6 long Use these to pilot the carrier into the housing Install carrier to housing lock washers capscrews and nuts Torque to proper specification Torque to 250 290 Ibs ft 339 393 Nem Install axle shafts axle stud nuts If used also install lock washers and taper
46. r to get under the cup and then with a hammer and drift from the back side of carrier tap out bearing cup To install the outer bearing cup place the carrier in a press with the top of the carrier facing up Place the cup in the bore use a sleeve or bear ing driver tool to press the cup until it is fully seated Use a feeler gage to make sure the cup is fully seated Note If a press is not available use a sleeve or bearing driver and a hammer to install the cups 5 Place the pinion on a 6 x 6 x 6 block of wood and lower the carrier over the pinion Install the pinion spacer Drive Pinion Note If you are using the same drive pinion use the same spacer that was originally in stalled in the assembly If the drive pinion is to be replaced the original spacer will be used as the starting point of adjustment 9 Align a 6 x 6 x 6 wood block under the drive pin ion then lower the carrier and pinion assembly into a press so that it is supported by the block ww TT P SN y 27 lt I 7 Install the outer bearing cone 10 Remove the pinion nut 11 Place a press sleeve over the top of the outer bearing cone Use the press to apply 5 tons of force It is important to rotate the carrier slightly to make sure that the rollers of the bearing are properly seated et 8 Install a pinion nut finger tight This will hold the pin ion i
47. rades on a rou tine basis The chart gives standpipe recommendations for vehicles operating in consistently mountainous areas 170 Axle Installation Axle Location Quantity Angle pints 12 Rear 29 10 Rear 30 8 Rear 31 6 Forward 39 Rear 32 4 Forward 41 Rear 33 5 2 Forward 43 Rear 35 0 Forward 45 Rear 36 Does not allow for standpipe Capacities do not include wheel equipment requirements An additional 1 2 pints is required in each wheel hub S190 Axle Installation Axle Location Quantity Angle pints 12 Rear 29 10 Rear 30 8 Rear 31 6 Forward 42 5 Rear 32 4 Forward 44 5 Rear 33 5 2 Forward 47 Rear 35 0 Forward 50 Rear 36 Does not allow for standpipe Capacities do not include wheel equipment requirements An additional 1 2 pints is required in each wheel hub Tandem Forward Axles Installation 5 10 10 15 15 20 Angle Grade Grade Grade 0 3 x 2 00 5 _ 1 00 2 25 7 1 25 2 50 10 1 50 1 75 2 75 13 1 75 2 00 3 00 15 2 50 2 50 3 25 Pinion pointing upward 57 rm 2 gt Tandem Rear Axles Installation 5 10 10 15 15 20 Angle Grade Grade Grade 0 _ _ _ 3 1 00 5 _ 1 00 1 75 7 1 75 2 00 10 _ 2 00 2 25
48. rer specifications regarding quality quantity and viscos ity As soon as you have located the failed part take time to analyze the data Find the Cause of the Failure Here begins the real challenge to determine the exact cause of the failure Keep in mind that there is no benefit to replacing a failed part without determining the cause of the failure For example after examining a failed part and finding that the fail ure is caused by a lack of lubrication you must determine if there was an external leak Obviously if there is an external leak just replacing the failed gear is not going to correct the situation Another important consideration is to determine the specific type of failure which can be a valuable indicator for the cause of failure The following pages show different types of failures and possible causes Use this as a guide in determining types of failures and to correct problems Correct the Cause of the Problem Once the cause of the problem has been determined refer to the appropriate service manual to perform the repairs Inspection Clean 1 Wash steel parts with ground or polished surfaces in solvent There are many suitable commercial solvents available Kerosene and diesel fuel are acceptable A WARNING Gasoline is not an acceptable solvent because of its extreme combustibility It is unsafe in the workshop environment 2 Wash castings or other rough parts in solvent or Clean in hot sol
49. s action will force the puller halves behind the bearing race and start moving the bearing from the pinion b Mount the puller horizontally to press the bear ing from the pinion lt b Mount the puller horizontally to press the bear ing from the pinion 1 Press 15 Drive Pinion A IMPORTANT Use the correctly sized spacer Do not use shim stock or grind spacers These practices can lead to loss of bearing preload and gear or bearing failure To prevent bearing damage use suitable sleeve that only contacts the inner race of bearing cone 3 Use apress sleeve to install the inner bearing cone and pilot bearing if used onto the pinion Apply pressure until the bottom of the cone touches the shoulder of the pinion Apply lubricant to the cone of the bearing 4 removed install the inner and outer bearing cups into the carrier a To install the inner bearing cup place the carrier in a press with the bottom of the carrier facing up b Place the cup in the bore use a sleeve or bear ing driver tool to press the cup until it is fully seated Use a feeler gage to make sure the cup is fully seated 6 16 C If replacement of the output shaft side gear bearing cup is necessary use either of the fol lowing methods Weld Place a weld bead around the inside of the cup when the weld cools the cup will fall out Hammer Use rolling head pryba
50. ssembly After July 2013 Forward Carrier Assembly 30 31 Wheel Differential Assembly Forward Carrier Assembly 32 34 Install Wheel Differential Assembly Forward Carrier Assembly 35 37 Adjust Tooth Contact Position 38 39 Wheel Differential Lock Parts Exploded View 40 Install and Adjust Wheel Differential Lock 41 Housing and Output Shaft Assembly Parts Exploded View sese 42 Replace Seal seen 43 44 SEIGE Kill een te 45 Housing Breather ses 46 Wheel End Seal Parts Exploded View 47 Remove and Overhaul Wheel End Seal 48 Adjust Wheel Bearing nn 49 50 Verify Wheel Endplay Procedure 51 Lubricate Wheel 52 53 General Lubrication Information 54 Lube Charige Intervals c u ott 55 Change hanen 56 Standpipes sse 57 58 Proper Vehicle Towing 59 Power Divider Operation Power Flow and Torque Distribution 60 61 Operate Wheel Differential Assembly 62 Direct Driver Controlled
51. t axle shaft flange e Axle shaft e Axle flange nuts and tighten to specified torque 13 Lubricate axle wheel ends Wheel End Seal Verify Wheel Endplay Procedure Verify that endplay meets specification using a dial indicator An indicator with 0 001 0 03 mm resolution is required Wheel endplay is the free movement of the tire and wheel assembly along the spindle axis Correct endplay is 0 001 0 005 0 025 0 125 mm 1 Attach a dial indicator with its magnetic base to the hub or brake drum as shown below 2 Adjust the dial indicator so that its plunger or pointer is against the end of the spindle with its line of action approximately parallel to the axis of the spindle 3 Grasp the wheel assembly at the o clock and 9 o clock positions Push the wheel assembly in and out while oscillating it to seat the bearings Read bearing endplay as the total indicator movement A CAUTION If endplay is not within specification readjustment is required Readjust Wheel Endplay Procedure Excessive Endplay If end play is greater than 0 005 127 mm remove the outer nut and pull the lock washer away from the inner nut but not off the spindle Tighten the inner nut to the next alignment hole of the dowel type washer if used Reassemble the washer and re torque the outer nut Verify endplay with a dial indicator Insufficient Endplay If endplay is not present remove the outer nut and pull the lock washer aw
52. t disengaged 3 Forward axle torque is transmitted from the helical side gear through the pinion helical gear drive pinion ring gear wheel differential and axle shafts 60 Loa d rd The inter axle differential compensates for minor variations in speed between the two axles the same way the wheel differential works between the two wheels of a single drive axle This unit also acts as a central point in distribution of torque to the two axles The power divider also includes a driver controlled air operated lockout When lockout is engaged it mechanically prevents inter axle differentiation for better performance under poor traction conditions 4 Rear axle torque is transmitted from the output shaft side gear through the output shaft inter axle driveline drive pinion ring gear wheel differential and axle shafts 5 Input torque power flow from the vehicle driveline is transmitted to the input shaft and the inter axle differential spider The differential distributes torque equally to both axles Theory of Operation With Lockout Engaged Inter Axle Differential is Not Operating Lockout should only be engaged when both axles are rotat ing at the same speed Operation should be limited to low traction situations and should be disengaged when normal traction returns Failure to do so will result in poor handling and damage to the axle components DID MT m A F
53. tial Wheel Differential Disassembly Forward Carrier Assembly Before July 2013 ES 1 g 5 3 Remove the side gear thrust washers side pinions 10109109 procedures neos and differential spider from the plain half case gt differential assembly on a malleable surface to prevent damage when removing components 1 Remove the differential case capscrews 2 Remove the flange half differential case and bearing assembly Use a screwdriver at the spider arm machined slots of the case to loosen the flange from the ring gear 4 Place a block under the plain half use a rubber mal let to remove the ring gear 5 Remove the bearing cones from the case halves using suitable pullers 1 Spider Arm Slots 21 Wheel Differential 6 Remove the bearing cones from the plain and flange halves in two steps a Mount the puller vertically to split the bearing This action will start the bearing moving off the differential case b Mount the puller horizontally to remove the cone ca 22 D e k oa D E Wheel Differential Wheel Differential Assembly Forward Carrier Assembly 4 Assemble the side pinions onto the wheel differential spider Apply a thin coat of oil to the mating surfaces A IMPORTANT of the side pinion and differential spider Install the To prevent bearing damage use suitable sleeve that only wheel differential nest on
54. ttern and set the differential bearing preload wheel differential and ring gear assembly into the a This will require the use of the following Spicer tools or carrier equivalent These tools will allow you to align the bear ing adjuster assembly to the carrier This tool part num ber 513061 will also gage the adjustment for the differential bearing preload and assist in setting the backlash Below you will find detailed instructions explaining each procedure 1 The bearing adjustment tool is made up of a threaded rod two nuts two washers and two adjust ment plates Fit one adjustment plate to the plain half threaded cup Fit the other adjustment plate to the flange half cup The adjustment rings will fit into slots of the threaded bearing cups stamped adjust ment ring Note There are two ways to make sure that the threaded cups are seated properly If there is a misalignment reinstall the differential assembly at a slightly different angle 3 Make sure there is no gap between the carrier threads and the cup threads A 1 No gap 1 Threaded bearing cup 2 Adjustment plate 25 26 4 5 Wheel Differential Make sure that the bearings cage is parallel to the edge of the threaded cup O 1 Parallel Use a ratchet or breaker bar and a 1 deep wall socket to turn the flange half threaded bearing cup in until the ring gear contacts the pinion zero back
55. two steps a Mount the puller vertically to split the bearing This action will start the bearing moving off the differential case b Mount the puller horizontally to remove the cone CM ca 31 Wheel Differential Wheel Differential Assembly Forward Carrier Assembly A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts the inner race of the cone A used bearing race would be a suitable tool This tool should have a slit cut if the ID is the same as the flange OD 1 Press the new bearing on the plain half and flange half bearing boss using the proper press sleeve or bearing installation tool 2 Place the plain half side of the differential case on a malleable surface 3 Install the side gear and thrust washer Apply thin coat of oil to the mating surfaces of the side gear thrust washer and plain half 32 4 Assemble the side pinions and thrust washers onto the wheel differential spider Apply a thin coat of oil to the mating surfaces of the side pinion and differential spider Install the wheel differential nest on top of the side gear 5 Install the flange half side gear and thrust washer Apply a thin coat of oil to the mating surfaces 6 Install the ring gear Align the capscrew holes E 1 Match spacing of holes on each side of spider slots D e ES D D e E Wheel Differential 7 Use a rubber mallet
56. ution tanks using mild alkali solu tions Note If a hot solution tank is used make sure parts are heated thoroughly before rinsing 3 Rinse thoroughly to remove all traces of the cleaning solution 4 Dry parts immediately with clean rags 5 Oil parts e fparts are to be reused immediately Lightly oil e fparts are to be stored Coat with oil wrap in corrosion resistant paper and store in a clean dry place Inspect Axle Housing Axle housing inspection and repairs are limited to the following checks or repairs e Visually inspect axle housing for cracks nicks and burrs on machined surfaces e Check carrier bolt holes and studs for foreign material e Replace damaged fasteners Look for loose studs or cross threaded holes A CAUTION Any damage which affects the alignment or structural integ rity of the housing requires housing replacement Do not repair by bending or straightening This process can affect the material s properties and cause it to fail completely under load e Check all seals and gaskets Note Replace conventional gaskets with silicone rubber gasket compound included in many repair kits The compound provides a more effective seal against lube seepage and is easier to remove from mating surfaces when replacing parts 1 Axle housing 2 Machined surface Inspect Components Inspect all steel parts for In add Notches visible steps or grooves created by wear Pitting
57. where the vehicle consistently synthetic lubricant at the factory the initial drain is not operates at or near its maximum GCW or GVW ratings dusty required or wet environments or consistent operation on grades greater than 8 For these applications the ON OFF HIGHWAY Change the lubricant within the first 5 000 miles of operation portion of the chart should be used Typical applications when not using a Spicer approved synthetic lubricant are construction logging mining and refuse removal in either a new axle or after a carrier head replacement Base subsequent lubricant changes on a combination of Note Clean metallic particles from the magnetic filler plug the following chart and user assessment of the application and drain plugs Clean or replace the breather yearly to and operating environment avoid lube contamination due to water ingestion Synthetic or Lubricant SAE Change Interval for Line Haul Change Interval for Vocational Mineral Synthetic SHAES 256 SAE 75W 90 500 000 miles 800 000 Km 120 000 miles 193 000 Km or 5 years or 1year Synthetic SHAES 256 SAE 75W 90 250 000 miles 400 000 Km 60 000 miles 96 500 Km 75W 140 or 3 years or 1 year Mineral MIL L 2105E J02360 75W 75W 90 120 000 miles 193 000 Km 60 000 miles 96 500 Km Base API GL 5 Gear Oil 75W 140 80W or 1 year or 1 year MIL PRF 2105E 90 85W 140 Axles using LMS wheel end system Axles using adjustable wheel bear
58. width The pattern should be evenly centered between tooth top land and root and should be up off the tooth toe 38 Used Gearing Correct Pattern Used gearing will not usually display the square even con tact pattern found in new gear sets The gear will normally have a pocket at the heal end of the gear tooth The more use a gear has had the more the line becomes the domi nant characteristic of the pattern Adjust used gear sets to display the same contact pattern observed before disassembly A correct pattern is up off the toe and centers evenly along the face width between the top land and root Otherwise the length and shape of the pat tern are highly variable and is considered acceptable as long as it does not run off the tooth at any point zu 1 Pattern along the face width could be longer Ring Gear Adjust Ring Gear Position Backlash If the gear pattern shows incorrect face width contact change backlash by adjusting the ring gear If the pattern is too close to the edge of the tooth toe move the ring gear away from the pinion to increase backlash ec D o 1 Loosen the bearing adjuster on the teeth side of the ring gear several notches 2 Loosen the opposite adjuster one notch 3 Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup 4 Continue tightening the same adjuster 2 or 3 notches and recheck backlash If th
59. with the transmis sion in Low Range It is unlocked by the driver or unlocked when the transmission is shifted out of Low Range Note The interlock system is preferred for vehicles equipped with an air shifted Low Range transmis sion It is designed to ensure the differ ential lock is not left engaged and to prevent accidental engage ment when transmission is in high range 62 Direct Driver controlled System The driver manually locks and unlocks the wheel differen tial using a cab mounted electric switch or air valve The following description assumes the system includes a cab mounted electric switch and a solenoid valve as shown in the illustration An air valve may be substituted for these components Operation is as follows 1 With control switch in the unlock position the wheel differential functions normally 2 When the control switch is placed in the lock position the air supply solenoid valve opens and air pressure activates the shift cylinde r The shift fork is moved to engage the curvic clutches which in turn lock the wheel differential 3 When the control switch is placed in the unlock position air pressure supply to the shift cylinder is shut off and air pressure is released from the cylin der A compression spring moves the shift fork to disengage the curvic clutch and unlock the wheel differential Theory of Operation Direct Driver Controlled System
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