Service Manual
Contents
1. Disassemble Overhaul and Assemble Wheel Differential S110 aaeeei 21 Disassemble Wheel Differential A 21 Disassemble Overhaul and Assemble Wheel Differ ential S130 WEE 26 Disassemble Wheel Differential A 26 Measure and Adjust Carrier Assembly 32 Adjust Backlash and Preload AAA 32 Change Backlash Setting A 33 Measure Ring Gear Runout sses 33 Adjust Ring and Pinion Tooth Contact Pattern 34 Install Axle Housing Breather seese 36 Wheel End Seal Parts Exploded View 37 Remove and Overhaul Wheel End Seal 38 Adjust Wheel Bearing A 39 Wheel EE 41 Verify Wheel End play Procedure AAA 41 Adjust End play with Tire and Wheel Assembly 41 Adjust End play with Wheel Hub 44 Readjust Wheel End play Procedure 44 Lubricate Wheel End nsss 42 lee EEN 44 Approved Lubricants AAA 44 Recommendations for Viscosity Ambient Temp 44 Lube Change Intervals seneese 45 Change Lube Lies unes nn matters nt 46 CITE 46 e 46 Proper Vehicle TOWING ecececeeeteeeeeeees 47 With Truetrac Limited Slip Differential 47 Re te e EE 48 T rgue Chart EE 49 Introduction Introduction Dana Commercial Vehicle Division presents this publication to aid in maintenance and overhaul of Spicer single drive axles Instructions contained cover the models listed Their design is common with differences in load capacity Capacity variations are achieved by combining basic differential carrier asse2. gt D LE el D 2 Gi 5 B Mount puller horizontally to remove cone 8 Remove inner side gear and thrust washer 10 Press new bearing cone on the differential case 27 28 Wheel Differential Assembly 11 Place thrust washer on the side gear Lubricate both sides of the thrust washer before installing ID 12 Install the side gear and thrust washer in the differ ential case 13 Start the full differential shaft into the shaft bores in the case that does not have a locking pin hole Side Pinion and Thrust C qu Full Differential Shaft Locking Pin Holes 14 Install a side pinion and thrust washer and push the shaft through the side pinion Side Pinion and Thrust OOO 15 Install the side pinion and thrust washer to the other side of the full shaft 16 Install a side pinion and thrust washer on the half shaft side Side Pinion and Thrust Washer 17 Install the half shaft so that the pin is facing upward and push it in until it stops Half Differential 1 Pin Hole Shaft Facing Upward Wheel Differential Assembly 18 The end of the half shaft should fit into the slot of 21 Next the two locating dowel pins that are pressed the full shaft at the same time as the hole in the case into the ring gear must be removed le in the half shaft dE DESSERT Note The dowel can only be pressed in one direct
3. utes Install carrier before compound sets or reap ply 1 Apply RTV gasket in this pattern TIP To assist in installing complete differential carrier use two pieces of threaded rod M14 X 2 threaded into carrier capscrew holes Rod should be approximately 4 102 mm long Use these to pilot the carrier into the housing 2 Install carrier to housing lock washers and cap screws Torque to proper specification Torque to 142 158 lbs ft 193 214 Nem 3 Install axle shafts and axle stud nuts 4 Add axle lubricant Fill to bottom of filler hole in car rier 5 Connect main driveline and lubricate joints i ai CH Ki DA Le 2 ai Differential Carrier Assembly Remove Wheel Differential Note Omit this step if the gear set is to be replaced If gear 3 Remove capscrews and bearing caps Back off bear set is to be reused check tooth contact pattern and ring ing adjusters and remove adjusters and bearing gear backlash before disassembling differential carrier cups When checking backlash a yoke must be installed and torqued to get an accurate reading Best results are obtained when established wear patterns are maintained in used gearing 1 Mount differential carrier in repair stand 4 Lift ring gear and differential assembly out of carrier Note For easier disassembly loosen but do not remove pin ion self locking nut 2 Punch mark bearing caps If reusing ge
4. F to 80 F 40 C to 21 C 75W 90 40 F to 100 F 40 C to 38 C 75W 140 40 F and above 40 C and above 80W 90 15 F to 100 F 26 C to 38 C 80W 140 15 F and above 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 Severe Service Lubrication Change Intervals Severe ser washing technology When filled with a Spicer approved vice applications are those where the vehicle consistently synthetic lubricant at the factory the initial drain is operates at ornearts maximum GEW or GVW ratings dusty not required or wet environments or consistent operation on grades greater than 8 For these applications the ON OFF HIGH WAY portion of the chart should be used Typical applications are construction logging mining and refuse removal This product combines the latest manufacturing and part m E E T D Change the lubricant within the first 5 000 miles of opera tion when not using a Spicer approved synthetic lubricant in either a new axle or after a carrier head replacement Note Clean metallic particles from the magnetic filler plug Base subsequent lubricant changes on a combination of and drain plugs Clean or replace the breather yearly to the following chart and user assessment of the application avoid lube contamination due to water ingestion and operating
5. adjust the contact pattern by changing the ring gear position e Ring gear position controls the backlash This adjustment moves the contact pattern along the face width of the gear tooth Note This is a shimless pinion designed carrier If the pattern shows an incorrect pinion cone position check to make sure the inner pinion cup is fully seated Use a feeler gauge Adjust Tooth Contact Pattern Adjust Ring Gear Position Backlash If the ring 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 ae 7 Wi 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 the ring gear and tighten adjuster until it contacts the bearing cup 4 Continue tightening the same adjuster two 2 or three 3 notches and recheck backlash If the pattern is concentrated at the heel too far up the tooth move the ring gear toward the pinion to decrease backlash a aes E a e kel KZ be Q e gt D iv KH ze 5 Loosen the bearing adjuster on the teeth side of the ring gear several notches 6 Tighten the opposite adjuster one notch 7 Return to adjuster on teeth side of ring gear and tighten adjuster until it contact
6. Oil Fill Hole Before operating the axle the wheel hub cavities and bear l ings must be lubricated to prevent failure When wheel ends are serviced follow Spicer s wheel end lubrication procedure before operating the axle Ton H t og Spicer axles may be equipped with either of two 2 wheel end designs e Wheel ends with an oil fill hole e Wheel ends without an oil fill hole Wheel Ends with an Oil Fill Hole 1 Remove the oil fill plug 2 Pour half 1 2 a pint of axle sump lubricant into each hub through the wheel end fill hole 3 Install oil fill plug and tighten to specified torque Wheel End without Oil Fill Hole 1 Wheel end oil fill hole 2 Proper lubricant level por 3 NL me Fhe 1 Lubricant flow from sump 42 Wheel Adjustment Wheel Ends without Oil Fill Hole 1 With axle level and wheel ends assembled add lubri cant through filler hole in carrier until fluid is level with the bottom of filler hole 2 Raise the right side of the axle six 6 inches 152 mm or more Hold axle in this position for one 1 minute 3 Lower the right side 4 Raise the left side of the axle six 6 inches 152 mm or more Hold axle in this position for one 1 minute 5 Lower the left side 6 With axle on alevel surface add lubricant through carrier oil filler hole until fluid is level with the bot tom of the hole Note Axles without wheel end fill
7. holes will require approxi mately 2 5 additional pints of lubricant to bring the lube level even with the bottom of fill hole 1 Oil will run into wheel end 2 Oil will run into wheel end 43 Lubrication Lubrication The ability of a drive axle to deliver quiet trouble free opera tion 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 cur rent recommendations from Dana Approved Lubricants General Gear lubrications acceptable under military specifi cation MILSPEC MIL L 2105D Lubricating Oils Gear Mul tipurpose are approved for use in Spicer Drive Axles The MIL L 2105D specification defines performance and vis cosity 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 modifi ers 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
8. 0A Differential Shaft 20B Differential Stub Shaft 21 Pin 22 Capscrew 23 Flat Washer 24 Flange Half Cap 25 Plain Half Cap 26 Cotter Pin 27 Side Gear Thrust Washer 28 Plain Half Diff Case 29 Plain Half Bearing Cone 30 Plain Half Bearing Cup 31 Plain Half Bearing Adjuster 32 Pipe Plug 33 Optional Truetrac KI D e n D 3 2 lt Differential Carrier Assembly Remove Differential Carrier Standard Differentials 1 Block the vehicle 2 Drain axle lubricant Remove bottom two 2 cap screws 3 Disconnect driveline 4 Remove axle shafts If used remove lock washers and taper dowels A warning Do not lie under carrier after fasteners are removed Use transmission jack to support differential carrier assembly prior to loosening fasteners A CAUTION Do not strike the shaft head with a steel hammer Do not use chisels or wedges to loosen shaft or dowels 5 Remove carrier capscrews and washers 6 Remove differential carrier assembly 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 20 min
9. 1 Nem Drive Pinion 7 Measure torque to rotate the pinion with an inch 10 Handle the seal by its outside diameter avoiding any pound torque wrench Torque measurements should contact with the seal lips During installation use the be taken every fourth 4th revolution and should proper driver to make sure that the seal is mounted a read between 20 40 in Ibs 2 3 4 5 Nem of bearing properly S preload 14 U D Use a rubber mallet to drive the seal tool in until the 5 flange bottoms on the housing cover bore face The S flange will locate the seal at the proper depth Note If bearing preload does not fall within allowed limits preload can be increased by using a thinner spacer and decreased by using a thicker spacer 12 Install end yoke Pinion bearing preload spacers are available in the ont jji following thicknesses 27 44 28 00 mm aa EE that pew torgue E ee HERE 13 Use torque multiplier and torque pinion nut to i 625 753 Ibs ft 847 1021 Nem 8 Repeat process until torque to rotate is between 20 40 in Ibs 2 3 4 5 Nem After proper preload is achieved remove yoke and install new seal with 2 Oil Seal proper service tool 1 Seal Driver 3 Pinion Cage A CAUTION Do not use any silicone or permatex type bore sealant with this seal 9 Remove the new seal from its package and install with the proper driver R Pinion Use drive 126917 only A WARNING Due to the resiliency of t
10. Spicer Single Drive Axles SPICER Drivetrain Products Service Manual AXSM0055 April 2011 110 Series 130 Series General Information General Information The description and specifications contained in this service Any reference to brand name in this publication is made sim publication are current at the time of printing ply as an example of the types of tools and materials recom mended for use and should not be considered an Dana reserves the right to discontinue or to modify its endorsement Equivalents if available may be used models and or procedures and to change specifications at any time without notice Important Notice This symbolis 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 Helpful removal and inst
11. al Assembly 17 Install and hand tighten all new ring gear capscrews 18 The interface of the ring gear to differential case is a press fit Put the assembly in a press with the ring gear facing upward Make certain that the ring gear is flush and square to the differential case before pressing Press until ring gear bottoms out on the case A IMPORTANT DO NOT use the capscrews to draw the ring gear into place Only use a press 24 19 Press new ring gear bearing cone A IMPORTANT When pressing differential case bearing cones note that the bearing is beyond flush with the top of the case The cone must be fully seated 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 bear ing boss OD 20 Tighten and torque ring gear capscrews in an alter nating pattern 140 160 lbs ft 190 217 Nem Wheel Differential Assembly 21 Install differential case assembly into carrier Be careful not to damage the differential bearings lower ing the assembly 22 Lubricate the differential bearings and install bearing cups and differential bearing adjusters gt D LE el D 2 Gi 5 25 Wheel Differential Assembly Disassemble Overhaul and Assemble Wheel Differential 130 Disassemble Wheel Differential 1 Remove capscrews fas
12. allation procedures to aid in the service of this unit Refer to the OEM vehicle specifications Always use genuine Spicer replacement parts ep D 5 ei 5 E 2 E 5 Table of Contents GereralInformationt s sushi i Important Nolte sena E O R i HE OdUOTION WEE 1 Model OSUN EE 1 Model Information 0 ce eccececeseeseeeseeeeceeseeseteneeeaes 1 Model Identification sssrin 2 Part Identification 2 Ring Gear and RGL 3 INSECTES Re nn saad 4 Failure Analysis 4 How to Diagnose a Falure ee eeseeeeseeeeeeeeeeeeees 4 Ee Prepare the Parts for Inspection 5 Find the Cause of the Failure n se 5 Correct the Cause of the Problem eccerre 5 IMS POCtON euer eege ee ins 6 Inspect Axle HOUSING AAA 6 Inspect Components 00 cceceeeeteeeeeeeeteeeteeeeeteeeteees 7 Inspect Primary Gearing 0 cceeeeeseeeeeeeeeteeeeeeees 7 Differential Carrier Assembly sse 8 S110 Carrier Assembly eds ve LMP denges 9 S130 Carrier Assembly rentes 11 Remove Differential Carrier ccsseseseeen 12 Standard Differentials 12 Install Differential Carrier seses 13 Remove Wheel Differential 14 Pinion Parts Exploded View aeee 15 Pinion Removal seu sus Mae este aliens 16 Drive TE 17 Rear Axle Pinion Assembly Parts Exploded View 17 Pinion Installation E 18 Final BUIG UP oarenien eet AA AN 18 Wheel Differential Assembly Parts Exploded 20
13. and thrust washers A IMPORTANT Do not press on the wheel differential shaft to free the ring gear from the case Pressing on the wheel differential shaft may cause it to bend and or fatigue 21 22 Wheel Differential Assembly 6 Remove inner side gear and thrust washer 7 Remove bearing cones from ring gear and differen tial case in two steps a Mount puller vertically to split bearing This action will start moving bearing off case and gear b Mount puller horizontally to remove cone 8 Press new bearing cone on differential case 9 Place thrust washer on side gear Lubricate both sides of the thrust washer Install on side gear MH ID aD See Wheel Differential Assembly 10 Install inner side gear and thrust washer in differen 14 Make certain the hole in the shaft and case line up tial case and install the locking pin 15 Install outer side gear Note No thrust washer is used at this location 11 Start wheel differential shaft in differential case with the locking pin hole facing up gt D 2 O D 2 Gi 5 12 Install the first side pinion thrust washer and gear 16 L i t bly aligning the ri Push shaft through washer and side pinion SSES EH gear capscrew holes 13 Install second side pinion and thrust washer Push shaft through washer and side pinion until it is flush to the outside of the case 23 Wheel Differenti
14. ar set also punch mark bearing adjusters for reference during assembly 1 Punch Marks Differential Carrier Assembly Pinion Parts Exploded View DI bs D i Q KI D 1 Pinion Nut 7 Pinion Spacer 2 End Yoke 8 Inner Pinion Bearing Cup 3 Slinger 9 Inner Pinion Bearing 4 Oil Seal 10 Drive Pinion 5 Outer Pinion Bearing Cone 11 Carrier 6 Outer Pinion Bearing Cup Differential Carrier Assembly Pinion Removal 1 Remove yoke nut 2 Remove yoke using a yoke puller service tool 1 Yoke puller 3 Remove oil seal 4 Place carrier in a press with threaded end of pinion face up 5 Place a wood block under pinion to avoid damage to gear teeth NU D 1 Press Outer bearing Inner bearing Wood block Drive pinion D a A WH h Bearing preload spacer 6 Press pinion through outer bearing and out of carrier casting 7 Remove bearing preload spacer and save for use in reassembly 8 Remove inner bearing cone from pinion using a split type puller Use two procedure steps to remove each bearing a Mount puller vertically to separate the bearing This action will force puller halves under bearing and start moving bearing off pinion o 4 bei D ba Q N e bei Q SS Ei D D wn ao Ki 2 e bei S o o D QD R ing 1 Press 9 If bearings are
15. based lubricants The performance characteristics of these lubri cants include extended change intervals improved fuel econ omy 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 dem onstrated by extensive laboratory and field testing For a com plete list of Spicer approved synthetic lubricants contact your local Dana representative See back cover of this manual for appropriate phone number Makeup Lube Maximum amount of non synthetic makeup lube is 10 44 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 tempera ture 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 80 40
16. ce Dowel type Lock Washer System 1 Inner nut 2 Dowel pin 3 Dowel type lock washer 4 Outer nut e 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 reinstall 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 39 gt GEI 3 o 3 Wheel Adjustment Systems Install the outer nut on the spindle and tighten to 350 Ibs ft 475 Nem Verify end play see Verify Wheel End Play Proce dure Three piece Tang type Lock Washer System 1 Inner nut 2 Tang type lock washer 123 thick 3 Outer nut Install the Tang type lock washer on the spindle IMPORTANT Never tighten the inner nut for alignment This can preload the bearing and cause premature failure 40 Install the outer nut on the spindle and tighten to 250 Ibs ft 339 Nem Verify end play see Verify Wheel End Play Proce dure After verifying end play secure wheel nuts by bend ing one of the locking washer tangs over the outer wheel nut and another tang over the inner wheel nut Go to step 12 Four piece Tang Dowel type Lock Washer System 1 Inner nut 2 Dowel pin 3 Dowel type lock washer 4 Tang type lock washer 0478 thick 5 Outer nut Install the Dowel ty
17. e bottom of the hole 3 If wheel ends were removed follow instructions in the wheel end servicing section Always use the filler hole as the final reference If lube is level with the bottom of the hole the axle is properly filled Note Lube fill capacities are basic guidelines and will vary based on the angle the axle is installed in a particular chassis Torque fill plug to 40 60 Ibs ft 64 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 side of carrier Proper Vehicle Towing Proper Vehicle Towing 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 This 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 Differential Lock for removal procedure With Truetrac Limited Slip Differential These differentials perform like conventional open differen tials under normal driving conditions until traction control is needed Then t
18. e pinion are matched parts and must be replaced in sets EJ E 2 e z E 5 1 Part number 4 Matching gear set number 7 Indicates genuine Spicer parts 2 Number of ring gear teeth 5 Number of pinion teeth 8 Heat Code 3 Manufacturing numbers 6 Date code General Information Inspection Failure Analysis Failure analysis is the process of determining the original cause of acomponent failure in order to keep it from happen ing 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 bro ken 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 fail ure 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 know ing what to look for determining how a piece o
19. e 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 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 the nuts are properly 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 0 001 005 0 025 mm 0 127 mm end play 11 Install the correct lock washer for the wheel nut sys tem being used Three pie
20. environment Synthetic or Lubricant SAE Change Interval for Line Haul Change Interval for Voca Mineral tional Synthetic SHAES 256 SAE 75W 90 500 000 miles 800 000 Km or 120 000 miles 193 000 Km 5 years or lyear Synthetic SHAES 256 SAE 75W 90 250 000 miles 400 000 Km or 60 000 miles 96 500 Km or 1 75W 140 3 years year Mineral MIL L 2105E J02360 75W 75W 90 120 000 miles 193 000 Km or 60 000 miles 96 500 Km or Base API GL 5 Gear Oil 75W 140 80W 1 year 1 year MIL PRF 2105E 90 85W 140 Axles using LMS wheel end system Axles using adjustable wheel bearing system 45 Lubrication Change Lube Drain 1 Drain when the lube is at normal operating tempera ture 150 200 F 66 93 C It will run freely and minimize the time necessary to fully drain the axle this insures the axle is flushed 2 Remove the bottom two carrier to housing cap screws 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 3 Inspect breather for clogging or corrosion Clean or replace as necessary 46 Fill 1 Reinstall bottom two carrier to housing capscrews use Loctite 270 and torque to 142 158 lbs ft 193 214 Nem 2 Remove the filler hole plug from the side of the car rier and fill the axle with the approved lubricant until level with th
21. f the equip ment 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 prac tices Knowing how to diagnose the cause of a premature fail ure 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 fail ure diagnostics 1 Document the problem Make a preliminary investigation Prepare the parts for inspection Find the cause of the failure Or an Le Jo Correct the cause of the problem Document the Problem Here are some guidelines for starting to learn about a failure including questions to ask 1 Talk to the operator of the truck 2 Look at the service records 3 Find out when the truck was last serviced 4 Ask In what type of service is the truck being used 5 Ask Has this particular failure occurred before 6 Ask How was the truck working prior to the failure You need to be a good listener Sometimes insignificant or un related symptoms can point to the cause of the failure 7 Ask Was the vehicle operating at normal tempera tures 8 Ask Were the gauges showing normal ranges of operation 9 Ask Was there any unusual noise or vibration After listening review the previous repair and maintenance records If there is more than
22. he imbalanced gear forces automatically apply resistance to the wheel or axle with the lesser traction Planetary pinion gears are supported in pockets of the case Each pinion meshes with its side gear and with a mating pin ion of the opposite planetary gear set When the vehicle experiences unequal side to side traction for instance on wet muddy icy or sand gravel terrain the pinions resist rotation in the case and transfer torque from one side gear to the other All mating pinions tend to separate from each other and from the side gears and they wedge into their case pockets This provides a friction force that retards or prevents the wheel with lesser traction from rotating and spinning out 47 D Le GS D lt OD 2 o 2 gt le Torque Flow Torque Flow While driving with equal load on and equal traction under both drive wheels the Truetrac differential provides equal torque to each wheel 1 Torque flow distribution while operating with equal loading and ground coefficient With unequal load and or traction on each drive wheel a major portion of the torque will be transferred from one side to the other to reduce the chance of a one wheel spin out 1 4 1 T
23. he plastic driver hammer rebound may occur when the seal is seated Keep clear of the ham mer rebound path Wheel Differential Assembly Wheel Differential Assembly Parts Exploded AN DAA UNS 20 Diff Case Bearing Adjuster Diff Bearing Cup Diff Case Bearing Cone Differential Case Side Gear Thrust Washer Side Gear Differential Shaft Side Pinion Side Pinion Thrust Washer Pin Ring Gear Ring Gear Bolt Ring Gear Bearing Cone Ring Gear Bearing Cup Ring Gear Bearing Adjuster Locating Dowels Wheel Differential Assembly Disassemble Overhaul and Assemble Wheel Differential 110 Disassemble Wheel Differential 1 Remove capscrews fastening ring gear to differential A CAUTION ase The differential case and gears will fall after separation Support the case so that it will not cause damage to the dif ferential or bodily injury 3 Lift out outer side gear Es D o O D D 5 2 2 The ring gear to differential case interface is a press fit Place the assembly in a press with the case fac ing downward Support the assembly on either side 4 Remove differential shaft locking pin with pliers of the ring gear Thread a capscrew back into one of the case holes by hand Press down on the head of the capscrew you may need to press in more than one position to free the ring gear from the case 1 Locking pin 5 Remove shaft side pinions
24. ion Press Align Pin the dowels towards the inside of the gear Holes Fit End ON Into Slot 19 Install the locking pins to both sides of the differen tial case gt D 2 O D 2 Gi 5 22 Press the dowel pins into the holes that the shaft locking pins were installed 20 Install outer side gear Note No thrust washer is used at this location 23 Lower the ring gear onto the case assembly aligning the locking dowels 29 Wheel Differential Assembly 24 Install and hand tighten all new ring gear cap screws 25 The interface of the ring gear to differential case is a press fit Put the assembly in a press with the ring gear facing upward Make certain that the ring gear is flush and square to the differential case before pressing Press until ring gear bottoms out on the case A IMPORTANT DO NOT use the capscrews to draw the ring gear into place Only use a press 30 26 Press new ring gear bearing cone IMPORTANT When pressing differential case bearing cones note that the bearing is beyond flush with the top of the case The cone must be fully seated 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 bear ing boss OD 27 Tighten and torque ring gear capscrews in an alter nating pattern See the To
25. mblies with different axle housings axle shafts and wheel equipment Model Listing Rear Axle Load Capacity 10 110 10 000 12 110 12 000 z 514 110 14 000 2 16 130 16 000 Model Information S14 110L th agains S Single Rear Axle B Bus Specific D Differential Lock GAW Rating x 1000 Ibs H Heavy Wall Integral Brake Gear Type L Limited Slip 1 Standard Single Reduction R Retarder Parking Brake Ready 2 Dual Range W Wide track 3 Planetary Double Reduction F Roll Over 4 Controlled Traction Differential 5 Helical Reduction Dee ig MEENE Head Assembly Series Introduction Model Identification Drive Axle Data plate is located on the axle centerline 4 5 LE CUST PART NO Spicer ei O SPEC SERIAL NO O MODEL PARTNO RATIO R j 2 men as e 1 7 Rear Axle Front View 1 Country of origin 4 OEM part number assigned to the axle build 2 Axle model identification 5 Carrier assembly serial number assigned by the 3 Specification number assigned to the axle built by Spicer manufacturing plant Identifies all component parts of the axle including special 6 Axle gear ratio special OEM requirements such as yokes or flanges 7 Carrier assembly production or service part number Part Identification Axle Housing Axle Shaft 1 ID Tag 2 Axle shaft part number Introduction Ring Gear and Pinion Note Ring gear and driv
26. not clean the parts immediately since cleaning may destroy some of the evidence 2 When tearing down the drive axle do it in the recom mended manner Minimize any further damage to the unit 3 Ask more questions when examining the interior of the carrier Does the lubricant meet the manufacturer 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 in correcting 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 solven
27. ock and With indicator mounted at bottom push pull at sides of 9 o clock positions Push the wheel assembly in and drum out while oscillating it to seat the bearings Read bearing end play as the total indicator movement Readjust Wheel End play Procedure Excessive End play If end play is greater than 005 127 mm remove the outer nut and pull the lock washer away from the inner nut but not off the spindle Tighten the If end play is not within specification readjustment is inner nut to the next alignment hole of the dowel type washer required if used Reassemble the washer and retorque the outer nut Verify end play with a dial indicator Adjust End play with Tire and Wheel As Insufficient End play If end play is not present remove the sembly outer nut and pull the lock washer away 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 retorque the outer nut Verify end play with a dial indicator Fine Tuning the End play If after performing the readjust ment procedures end play is still not within the 001 005 025 127 mm range disassemble and inspect the compo nents If parts are found to be defective replace the defective parts reassemble and repeat wheel bearing adjustment pro cedure Verify end play with a dial indicator 41 Wheel Adjustment Lubricate Wheel End Wheel End with
28. one driver talk to all of them and compare their observations for consistency with the ser vice and maintenance records Verify the chassis Vehicle Identification Number VIN number from the vehicle identifi cation plate as well as the mileage and hours on the vehicle Make a Preliminary Investigation These steps consist of external inspections and observations that will be valuable when combined with the results of the parts examination 1 Look for leaks cracks or other damage that can point to the cause of the failure 2 Make note of obvious leaks around plugs and seals A missing fill or drain plug would be an obvious cause for concern 3 Look for cracks in the carrier housing harder to see but sometimes visible 4 Does the general mechanical condition of the vehicle indicate proper maintenance or are there signs of neglect 5 Are the tires in good condition and do the sizes match 6 If 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 insignifi cant now may take on more importance when the subassem blies 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 1 When disassembling subassemblies and parts do
29. orque flow distribution with less load over or ground coefficient under left wheel 48 Torque Chart Torque Chart Location Thread Size Class Grade Torque Specification Pinion Shaft End Nut M36X1 5 10 9 625 753 lbs ft 847 1021 Nem Bing Gear to Case Capscraw M14X2 S110 10 9 140 160 Ibs ft 190 217 Nem M16X2 S130 10 9 225 10 Ibs ft 305 13 Nem Carrier Cap Capscrew M14X2 10 9 130 150 Ibs ft 176 203 Nem Head to Housing Capscrew M14X2 10 2 140 160 Ibs ft 190 217 Nem ABS Set Screw 312 18 18 26 Ibs ft 25 35 Nem 49 e lt Ke D Q gt D For spec ing or service assistance call 1 877 777 5360 or visit our website at www dana com Dana Commercial Vehicle Products Group 3939 Technology Drive Maumee Ohio USA 43537 DANA 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 0055 04 11
30. pe lock washer on the spindle Note If the dowel pin and washer are not aligned remove washer turn it over and reinstall 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 Install the Tang type lock washer on the spindle Install the outer nut on the spindle and tighten to 250 Ibs ft 339 Nem Verify end play see Verify Wheel End Play Proce dure After verifying end play secure the outer nut by bending 180 apart two opposing tangs of the locking washer over the outer nut Install the following e New gasket at axle shaft flange e Axle shaft e Axle flange nuts and tighten to specified torque Lubricate axle wheel ends Wheel Adjustment Wheel End Verify Wheel End play Procedure Adjust End play with Wheel Hub Verify end play meets specification using a dial indicator An indicator with 001 03 mm resolution is required Wheel end play is the free movement of the tire and wheel assembly along the spindle axis Correct end play is 001 005 025 125 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 3 o cl
31. r bearing Or O1 Ser Pa 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 7 Clean hub cavity and bearing bores before reassem bly Be sure to remove contaminants from all recesses and corners 8 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 tool can distort or dam age the seal and cause premature seal failure 38 Wheel Adjustment Systems 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 dam aged 3 Install the hub and drum on the spindle with care to prevent damage or distortion to th
32. rque Chart on page 50 for torque specifications Wheel Differential Assembly 28 Install differential case assembly into carrier Be careful not to damage the differential bearings lower ing the assembly 29 Lubricate the differential bearings and install bearing cups and differential bearing adjusters be o EI iv iv Ss EN Wheel Differential Assembly Measure and Adjust Carrier Assembly Adjust Backlash and Preload 4 Use a rubber mallet to make certain that both bear ing adjusters are fully seated 1 Turn the flange half bearing adjuster in until the ring gear contacts the pinion zero backlash then back the adjuster out two 2 notches from the adjuster lugs 5 Measure backlash Make sure it is within specifica tion of 006 018 15 46 mm TIP To give yourself room to adjust contact pattern set it between 012 014 30 36 mm 1 Flange half 2 Plain half 2 Tighten the plain half adjuster until the bearing cup just starts to turn this is a zero bearing preload 3 Tighten the plain half adjuster two lug notches Start with the notch at the top count two notches coun terclockwise on the adjuster turn the adjuster so that the notch is facing straight up You now have a two notch preload ANS DCS 1 Lugs 2 One notch ER Wheel Differential Assembly Change Backlash Setting Measure Ring Gear Runout If you have too much backla
33. s the bearing cup 8 Continue tightening the same adjuster two 2 or three 3 notches and recheck backlash 35 Housing Breather Install Axle Housing Breather 4 Insert hose onto fitting long end down 1 Install fitting in breather hole 2 Tighten fitting finger tight KK GC 5 Push hose firmly against fitting Rotate hose to point down gE 3 Torque to 5 Ibs ft 7 Nem and align the nose of the breather to the rear GC 36 o Oo Kl E ui rT o Wheel End Seal Installation tool 2 Seal 1 Wheel End Seal Parts Exploded View 3 Rear hub 37 Wheel End Seal Remove and Overhaul Wheel End Seal Install Wheel End Seal A WARNING 1 Before installation lubricate the following with the 8 same lubricant used in the axle sump Never work under a vehicle supported by only a jack Always support vehicle with stands Block the wheels and e Inner bearing make sure the vehicle will not roll before releasing the e Wheel seal follow the directions provided by brakes the seal supplier 2 Place seal on installation tool 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 nut and locking washer Remove inner nut Remove outer bearing and wheel Remove oil seal Remove inne
34. sh the ring gear needs to move Measure Ring Gear Total closer to the pinion Back off the plain half adjuster counting 1 Measure ring gear total radial runout Indicator the number of notches you back it off each notch equals reading should not exceed 010 25 mm about 003 08 mm of backlash O O j T To AAR In order to maintain the differential bearing preload you YDA gt Y er will need to turn the flange half bearing adjuster the same Chi all L amount in the same direction If you need more backlash Bs Ig lt D F i EWS yy D reverse this procedure ONE AAN Le 1 Install carrier bearing caps and torque carrier cap de al bolts to 130 150 Ibs ft 176 203 Nem 2 Recheck backlash If the bearing adjusters were not in straight or fully seated the backlash will change 2 Measure ring gear total backface runout Indicator reading should not exceed 010 25 mm gt D LE el D 2 Gi 5 a Used Gearing Reset to backlash recorded before disassembly b New Gearing Backlash should be between 006 and 018 15 46 mm 3 Check ring gear tooth contact pattern Paint ring gear teeth and check tooth contact pattern Correct tooth patterns see Adjust Tooth Contact Pattern 4 Install bearing adjuster cotter pins 33 Adjust Tooth Contact Pattern Adjust Ring and Pinion Tooth Contact Pattern 1 Face width 2 Tooth depth 3 Heel 4 Top land 5 Roo
35. t 6 Toe 1 Identify if new or used gearing 2 Check tooth contact pattern new or used gearing New Gearing Correct Pattern e Paint six ring gear teeth 180 apart 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 1 2 to two thirds 2 3 of the ring gear tooth in most models and ratios The pattern could vary in length and should cover half 1 2 of the tooth or more face width The pat tern should be evenly centered between tooth top land and root and should be up off the tooth toe Kg 34 Used Gearing Correct Pattern e Used gearing will not usually display the square even contact pattern found in new gear sets The gear will normally have a pocket at the heal end of the gear tooth The more use a gear has had the more the line becomes the dominant characteristic of the pattern e Adjust used gear sets to display the same contact pattern observed before disassembly A correct pat tern 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 pattern are highly vari able and is considered acceptable as long as it does not run off the tooth at any point 1 Pattern along the face width could be longer Adjust Contact Pattern e f necessary
36. t There are many suitable commercial sol vents available Kerosene and diesel fuel are accept able A WARNING Gasoline is not an acceptable solvent because of its extreme combustibility It is unsafe in the workshop envi ronment 2 Wash castings or other rough parts in solvent or clean in hot solution 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 If parts are to be reused immediately Lightly oil e f parts are to be stored Coat with oil wrap in corro sion resistant paper and store in a clean dry place Inspect Axle Housing Axle housing inspection and repairs are limited to the follow ing 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 mate rial e Replace damaged fasteners Look for loose bolts 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 gas ket compound included in man
37. tening ring gear to differential case 2 The ring gear to differential case interface is a press fit Place the assembly in a press with the case fac ing downward Support the assembly on eitiher side of the ring gear Thread a capscrew back into one of the case holes by hand Press down on the head of the capscrew you may need to press in more than one position to free the ring gear from the case A IMPORTANT Do not press on the wheel differential shaft to free the ring gear from the case Pressing on the wheel differential shaft may cause it to bend and or fatigue 26 A CAUTION The differential case and gears will fall after separation Support the case so that it will not cause damage to the dif ferential or bodily injury Remove the outer side gear Remove the differential shaft locking pins by turning the differential case opening facing down Use a hammer to lightly tap on the side of the case to free the locking pins The locking pins are slip fit and should fall from the case easily Wheel Differential Assembly 6 Remove the half shafts first and then remove their 9 Remove bearing cones from ring gear and differen side pinions and thrust washers tial case in two steps A Mount puller vertically to split bearing This action will start moving the bearing off case and gear J Ha Oo Differential Shaft 7 Remove the full shaft side pinions and thrust wash ers
38. ter Pinion Bearing Cup Pinion Spacer Inner Pinion Bearing Cup Inner Pinion Bearing Cone Drive Pinion 10 Carrier Housing 10A Carrier Housing Assembly 10B Switch 10C Capscrew 10D Backing Ring 11 Ring Gear 12 Ring Gear Bolt 13 Ring Gear Bearing Cone 14 Ring Gear Bearing Cup DAN DAA Go No Carrier Assembly 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Ring Gear Bearing Adjuster Side Pinion Thrust Washer Side Pinion Side Gear Differential Shaft Pin Capscrew Fat Washer Flanged Half Cap Plain Half Cap Cotter Pin Side Gear Thrust Washer Differential Case Differential Case Bearing Cone Differential Bearing Cup Differential Case Bearing Adjuster Pipe Plug Optional Truetrac 130 Carrier Assembly Pinion Nut End Yoke Slinger Outer Pinion Bearing Cone Outer Pinion Bearing Cup Pinion Spacer Inner Pinion Bearing Cup Inner Pinion Bearing Cone Drive Pinion 10 Carrier Housing 10A Carrier Housing Assembly 10B Switch 10C Capscrew 10D Backing Ring 11 Diff Case Dowels 12 Ring Gear 13 Ring Gear Bolt 14 Flange Half Bearing Cone 15 Flange Half Bearing Cup 1 2 3 4 5 6 7 8 9 Carrier Assembly 10 10A Optional 10A includes items 10B 10C and 10D 16 Fland Half Bearing Adjuster 17 Side Pinion Thrust Washer 18 Side Pinion 19 Side Gear 2
39. to be replaced remove bearing cups from carrier casting at this time Pinion removal complete Drive Pinion Drive Pinion Rear Axle Pinion Assembly Parts Exploded View i o D 5 1 Pinion Nut 6 Outer Pinion Bearing Cup 2 End Yoke 7 Pinion Spacer 3 Slinger 8 Inner Pinion Bearing Cup 4 Oil Seal 9 Inner Pinion Bearing Cone 5 Outer Pinion Bearing Cone 10 Drive Pinion Drive Pinion Pinion Installation Final Buildup Note Do not install oil seal in carrier until bearing preload is correctly adjusted 1 Press inner bearing cone on pinion A IMPORTANT To prevent bearing damage use suitable sleeve that only contacts inner race of bearing cone 2 Install preselected bearing spacer Press inner and outer bearing cups into the carrier until seated Use a feeler gage 0015 038 mm approx to make sure that bearing cups are fully seated in bearing bores Apply lubricant to both cup and cone Place carrier housing in press with the pinion sup ported by wood block 6 x 6 x 6 152 x 152 x 152 mm so the inner pinion bearing is mated to the cone Ty LS 4 al 1 Press Outer pinion bearing Wood block Drive pinion aA A Q PP Bearing preload spacer Press outer bearing onto pinion until completely seated Rotate carrier during seating process Use torque multiplier and torque pinion nut to 625 753 Ibs ft 847 102
40. y repair kits The com pound 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 Notches visible steps or grooves created by wear Pitting 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 In addition inspect the following for damage Differential gearing Bearings for loose fit on drive pinion 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 NV W I CR N D ge Se ON LISE Kess A al 1 Carrier fastener 2 Carrier assembly Carrier Assembly 110 Carrier Assembly ACTES RE Le Pinion Nut End Yoke Slinger Outer Pinion Bearing Cone Ou
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