tandem drive axles s400 service manual
Contents
1. 10 Separate differential carrier from the housing using removal slots See Figures 1 and 2 Be certain dif ferential carrier clears dowel pins and is balanced properly on jack Remove top two carrier mounting bolts and remove differential carrier assembly from the axle housing Dowel Pin Removal slot Power Divider Drain Plug Figure 2 11 Mount carrier assembly in a suitable rebuild stand Refer to RECOMMENDED SERVICE TOOLS pgs 29 30 Differential Carrier Removal Complete REMOVAL OF DIFFERENTIAL FROM CARRIER The following service procedures apply for both forward rear and rear rear axles unless otherwise noted IMPORTANT If the ring and pinion is to be reused ring gear backlash should be checked and recorded before disassembly Backlash should be reset to this specification after completion of repairs For backlash specifications refer to DIFFERENTIAL INSTALLATION 1 Remove adjusting ring bolts and locks from bearing caps 2 One differential bearing cap and leg of the carrier is match marked to aid during reassembly See Figure 3 3 Loosen four bearing cap retaining bolts 4 Loosen adjusting rings to relieve bearing preload 5 Remove four bearing cap retaining bolts and washers 6 Remove bearing caps 7 Remove adjusting rings and bearing cups NOTE If bearings are to be reused cups must stay with mated cones They2. 35 45 Lb Ft 47 61 N m Differential Bearing Cap Bolt 295 340 Lb Ft 400 461 N m Differential Bearing Cap Washer Differntial Pinion Mate Thrust Washer Differential Cross Shaft Differential Side Gear Differential Case Cap Half ES 5 Differential Bearing Cone pS 180 200 Lb Ft justing 244 271 N m Adjust OO Differential Bearing Cup Adjusting Ri Adjusting Ring Lock Bolt Justing Sing 30 40 Lb Ft 41 54 N m Du Shaft Curbside 35 45 Lb Ft 47 61 N m Differential Pinion Mate Gear Thrust Washer Differential Case Bolt REAR REAR COMPONENTS Housing Axle Shaft Roadside Nut 300 320 Lb Ft 407 434 N m Ring Gear Flat Washer Ring Gear Differential Case Flange Half Ring Gear Bolt Hex Bolt 2 150 Max Lb Ft 205 Max N m Fa Pinion Pilot Bearing ND Pinion x Inner PinionBearing Cone Pinion Pilot Bearing Cap Inner Pinion Bearing Cu p ig Cup Pinion Bearing Preload Spacer Selective Outer Pinion p dd Bearing Cup Outer Pinion Bearing Cone Carrier Housing P di Carrier Mounting Bolt 240 260 Lb Ft 325 353 N m Flanged Hex Nut 900 1 200 Lb Ft 1 220 1 627 N m REMOVAL OF DIFFERENTIAL CARRIERS FROM AXLE HOUSINGS NOTE Steam clean axle assembly 1 Block wheels 2 Remove axle housing and power divider drain plugs and drain lubricant 5 Disconn
3. p d Output Oil Seal Sia P d Beveled Retaining Ring Die 0 P d Output Shaft Bearing ur O9 ye Output Shaft Fill Plug 7 61 Ny 0 Differential Side Bearing Cap Temperature Sensor Plug Pd 35 45 Lb Ft 47 61 N m Vent Plug Axle Housing Dowel Pin aA Differential Case Bolt Differential Gear Thrust Washer o 3a 180 200 Lb Ft 244 271 N m i Q NN IN NS Differential Case Cap Half V 6 Magnetic Drain Plug 35 45 Lb Ft Differential 47 61 N m paren Bearing Cap Bolt Differential Case Flange Half O Differential Side Gear RU Flat Washer S Differential Cross Shaft 400 461 N m Nut i BN 209 420 melo D Differential Pinion Mate Flat Washer 9 GAN Differential Pinion Mate Adjusting Thrust Washer RingLock gt R SS S Adjusting n Lock Bolt RY Ier oo 503 Me cl Bearing Cone ax N m 30 40 Lb Ft uM 41 54 N m Differential f 2 Pinion Pilot Bearing Cap Bearing Cup Pinion Pilot Bearing O P d Adjusting Ring P Dowel Pin Inner Pinion Bearing Cone Inner PinionBearing Cup Pinion Bearing Spacer selective Outer Pinion P di Bearing Cup C Carrier Mounting Bolt e 240 260 Lb Ft 325 353 N m Pu Axle Shaft Curbside Outer Pinion Bearing Cone Helical Driven Gear Flanged Hex Nut 900 1200 Lb Ft 1 220 1 627 N m Vent Plug Fill 35 45 Lb Ft 47 61 ii Temperature Sensor Plug
4. 26 Lubricate and place piston O ring assembly into shift cylinder with detailed side facing front for the composite piston and the flat face on the aluminum piston See Figure 27 on page 26 Seat piston firmly against shift shaft 27 Install onto the shift cover 28 Clean the shift cover sealing area and the intermedi ate case and apply a 1 16 in bead of Loctite 518 Gasket Eliminator See Figure 22 NOTE Care must be taken to keep Loctite off of piston assembly 29 Install shift cover NOTE If old bolts are used coat threads with Loctite 277 before installing 30 Install four washers and cover bolts Tighten and torque bolts alternately to 15 20 Lb Ft 20 27 N m until cover is seated properly 31 Lube bearing and bearing journals then Install the input shaft into the shift collar and lube input shaft bearing 22 32 Install new oil seal into input shaft bearing retainer 33 Clean the mating surfaces of the bearing retainer and the case Apply a 1 16 in bead of Loctite 518 Gasket Eliminator to cover mounting surface of case and around each bolt hole See Figure 22 34 Install bearing retainer and tighten bolts alternately Torque bolts 100 120 Lb Ft 135 163 N m 35 Inspect input yoke seal surface for grooves If grooves can be detected with fingernail it must be repaired with a CR SPEEDI SLEEVE or replaced 36 Clean and dry threads on input shaft 37 Install end yoke using installer service
5. Output Shaft Removal Complete Housing Output Shaft Bearing Assembly Figure 7 Pinion Mate Thrust Washer Differential Cross Shaft Bolt i Ring Gear Flange Half Differential Case Flat Washer 300 320 Lb Ft XO 407 434 N m Bearing Cup Oo EN 2 2 Bearing Cone 1 Match mark differential case halves with a punch or chisel for correct alignment in reassembly See Figure 8 Figure 8 2 Remove differential case bolts and lift off the differential case half 5 Remove thrust washer and differential gear 4 Lift out cross shaft pinion mates and pinion mate thrust washers 5 Remove second differential gear and thrust washer 6 If differential bearings are to be replaced remove old bearings using a suitable puller See Figure 9 DIFFERENTIAL DISASSEMBLY Bearing Cup Bearing Cone UN A y Differential Case Bolt A RI 180 200 Lb Ft Bw 244 271 N m Plain Half Differential Case LN Differential Gear EM Differential Pinion Mate Gear Thrust Washer Figure 9 NOTE Inspect all parts including the machined surfaces of the case itself IMPORTANT If any gears are to be replaced they must be replaced in sets Inspect thrust washers for scoring and excessive wear Replace all worn or damaged parts 7 When it is necessary to remove ring gear from differential case carefully loosen ring ge
6. Remove rear bearing cup from intermediate case Remove bearing cone from rear differential gearus ing a suitable puller Clean and inspect all components for excessive wear scoring or cracks Replace damaged compo nents with original equipment replacement parts and prepare for reassembly Inter Axle Differential Disassembly Complete OUTPUT SHAFT DISASSEMBLY End Yoke Flanged Hex Nut 900 1 200 Lb Ft 1 220 1 627 N m Output Oil Seal 1 Remove the inter axle drive shaft NOTE Power divider must be engaged so shaft will not rotate 2 Remove output flanged hex nut NOTE Use of torque multiplier is recommended as torque specification on output nut is 900 1 200 Lb Ft 1 220 1 627 N m 5 Remove output yoke using a suitable puller 4 Remove oil seal 5 Remove beveled retaining ring Output Shaft Remover Adapter w Shoulder Facing Out Yoke Installer Service Tool DST1007 Beveled Retaining Ring Output Shaft Housing Output Shaft Bearing Place output shaft remover adapter into housing bore Thread yoke installer service tool onto output shaft See Figure 7 Tighten nut on yoke installer to pull output shaft bearing assembly out of housing If output shaft bearing is to be replaced remove old bearing using a suitable puller or press NOTE It is important to place the Output Shaft Remover Adapter on with the shoulder to the outside See Figure 7
7. can not be interchanged 8 Carefully lift the ring gear and differential subassem bly out of carrier NOTE The ring gear side of subassembly must be tipped up for the ring gear to clear the pinion pilot bearing cap Removal of Differential Complete INTER AXLE DIFFERENTIAL DISASSEMBLY Fill Plug P di 35 45 Lb Ft 47 61 N m Inter axle Differential Case Bearing Cup Bearing Cone Inter axle Differential Side Gear d Inter axle Differential Assembly i Drive Gear ec Needle Bearing Needle Bearing ae Washer Assembly Input Shaft 160 180 Lb Ft 217 244 N m Drain Plug 35 45 Lb Ft 47 61 N m md Lube Retainer Washer Clutch Collar Bolt 20 25 Lb Ft SUR gt Bearing Cone 27 34 N m RQ ps DAMM d Q Shift Fork EM Shim Selective mdi I 7 1 earing Retainer p d Shift Shaft Piston ad Q RD 6 Shift Cover d p oi 100 120 Lb Ft SS Shift Cover 156 163 Input Yoke Assembly Shift Cover Bolt Flanged Hex Nut 15 20 Lb Ft 900 1 200 Lb Ft 20 27 N m 1 220 1 627 N m S 1 Remove intermediate case to carrier bolts Use removal slots to seperate inter axle differential case from carrier See Figure 4 2 With inter axle differential assembly removed remove four bolts and washers of shift cylinder 5 Remove shift cylinder cap and piston NOTE It may be necessary to tap pi
8. inch 076 mm from recorded end play and assemble combination of shims that total proper thickness to establish correct end play EXAMPLE Measurement with dial indicator 080in 2 032 mm Preferred end play 005in 0 076 mm Required shims 077in 1 956 mm 17 Remove input shaft bearing retainer and install shim pack between bearing retainer and input shaft bearing cup Remove input shaft 18 Install shift spring into the bottom of the shift well 19 Check shift fork for excessive wear Replace if necessary 20 Check clutch collar for wear or damage in groove on drive lugs and splines Replace if necessary 21 Apply a thin coat of grease on the clutch collar riding surface area of shift fork INTER AXLE DIFFERENTIAL ASSEMBLY 22 Assemble the shift collar onto the shift fork with flat side of collar up The fork bushing must also face up Install the fork and collar into the case and align the hole of the shift fork over the opening of the spring 23 Apply a thin coat of grease to the small diameter of the shift shaft 24 Insert shift shaft into cylinder and install through the shift fork hole and the spring Make sure shaft is seated into the bottom of the shift cylinder 25 Apply a thin coat of grease to the O ring of the shift piston NOTE Visually inspect the composite shift piston to insure the steel spacer is present on the bottom of the piston See page 26 for more piston information
9. tool NOTE Spicer recommends that new flanged hex nuts be used 38 Apply Loctite 680 green to threads 39 Use torque multiplier and torque input flanged hex nut to 900 1 200 Lb Ft 1 220 1 627 N m Inter axle Assembly Complete Loctite 518 Gasket Eliminator Figure 22 1 Install ring gear and differential assembly into carrier housing Tilt differential slightly so ring gear clears pinion pilot bearing support NOTE Care should be used when installing ring gear and differential into carrier housing so damage to ring gear pinion bearings or bearing bores does not occur 2 Differential bearings should be lubricated and bearing cups should be cleaned and 620 loctite applied to the O D of the bearings Be sure side bearing cups are seated on bearing cones Assemble differential bearing caps with DIFFERENTIAL INSTALLATION Loosen adjusting ring on tooth side of ring gear 1 notch and tighten adjusting ring on flange side of ring gear 1 notch Repeat process until backlash is elminated Tighten adjusting ring on tooth side of ring gear until the ring gear and pinion backlash matches the backlash etched on the ring gear This adjustment sets both the backlash and the bearing preload Check ring gear and pinion backlash in four equally spaced positions aound the ring gear with a dial indicator as shown Acceptable backlash tolerance is 002 from backlash etched on ring gear Se
10. 5 or its equivalent to drain plug threads Insert and torque to 55 45Lb Ft 47 61N m Differential Installation Complete Loctite 518 Gasket Eliminator Figure 29 2 Apply an 1 8 inch bead of Loctite 518 Gasket Eliminator onto the axle housing mounting flange and around each bolt hole See Figure 29 5 Thread 2 studs or guide pins into the axle housing 0 Peer alie NOTE Lubricant close enough to bottom of fill hole to be seen 180 apart This will eliminate rotation of the carrier or touched is not sufficient Lubricant must be level with the fill assembly after it makes contact with the gasket hole material CAPACITIES Approximate NOTE Use guide pins to install forward carrier Axle assembly with output shaft in housing Align splines of Forward Rear output shaft and rear gear of inter axle differential This will help align carrier and output shaft during Rear Rear Lube capacity is based on a 4 installation angle installation and prevent any unnecessary weight on 4 Lube capacity ie based ona 12 installation angle output shaft bearing 4 Install the carrier assembly into the axle housing Clean the mounting bolts and coat with Loctite 277 red or its equivalent and install Tighten bolts evenly in cross pattern Torque bolts 240 260 Lb Ft 330 338 N m 5 Allow one hour cure time for gasket material before adding hypoid gear lubricant 6 Remove the old axle flang
11. 77 777 5360 www spicerparts com AXSM 1951 Printed in U S A Copyright Dana Limited 2012 All rights reserved Dana Limited
12. ADEMARK DATE SET NUMBER results ina 3 73 1 ratio Matched Set Number Spicer ring gears and pinions are manufactured as matched sets Both ring gear and pinion are marked with a corresponding number i e 260 which identifies them as a matched set A gear set that does not have the same match set BACKLASH ETCH numbers should not be run together If either ring gear or pinion require replacement a new matched set must be used Backlash etch Indicates backlash setting for assembly AXLE LUBRICANT RECOMMENDATIONS To ensure proper lubrication and operating temperature PETROLEUM BASED SYNTHETIC BASED APPLICATION W igs INTERVAL _ MILES INTERVAL correct lubricants and lubricant levels must be obtained On Highway 100 000 1 Year 250 000 3 Year Severe Service RECOMMENDED LUBRICANTS and 50 000 1Year 100 000 1 Year Petroleum based or synthetic based hypoid gear lubri On Off Highway cants that meet or exceed military specification MIL L 2105D and API service classification GL 5 are the minimum requirements for use in Spicer Medium and Severe service includes any applications operating at or near maximum GVW or GCW ratings This Heavy Duty Drive Axles includes normally wet or dusty environment or The table below indicates which SAE viscosities are consistent high load and low speed applications recommended for various temperature ranges the vehicle Includes Semi Synthetic blen
13. ITHOUT PROPER PROTECTIVE EQUIPMENT DO NOT WORK ON LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT DO NOT REPLACE LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT DO NOT ATTEMPT TO SAND GRIND CHISEL FILE HAMMER OR ALTER BRAKE LININGS IN ANY MANNER WITHOUT PROPER PROTECTIVE EQUIPMENT FOLLOW 0 S H A STANDARDS FOR PROPER PROTECTIVE DEVICES TO BE USED WHEN WORKING WITH BRAKE MATERIALS POWER DIVIDER COMPONENTS Fill Plug 35 45 Lb Ft d 47 61 N m Inter axle Differential Bearing Cup Inter axle Differential Bearing Cone Inter axle Differential Side Gear Inter axle Differential Assembly P d Helical Drive Gear Flange Hex Bolt 160 180 Lb Ft 217 244 N m Needle Bearing d Needle Thrust d Bearing Assembly Magnetic Drain Plug T 0 Lube uu di t Clutch Coll utch Collar 7 5 d Input Bearing C S nput Bearing Cone P pl Input Bearing Cup Input Shaft Bearing Shift Fork 58 l 9 LC AR Selective P Input Shaft s Op Bearing Retainer Compression Spring ae os o Shift W Piston Input Shaft Bearing Shift Cover O ring P d 0 100 20 Lb d i 136 163 N m Flanged Hex Nut Inout Yoke Aap 900 1 200 Lb Ft Shift Cover Bolt nput Yoke Assembly 1 220 1 627 N m 15 20 Lb Ft 20 27 N m Hex Bolt 20 25 Lb Ft 27 34 N m FORWARD REAR COMPONENTS Flanged Hex Nut 900 1 200 Lb Ft 1 220 1 627 N m Output Yoke Assembly
14. Spicer Tandem Drive Axles SPICER Service Manual Spicer Tandem Drive Axles AXSM 1951 September 1997 5400 5 TABLE OF CONTENTS Axle Identification eene 1 Model Identification Numbering System 2 Gear Set Identification sees 2 Axle Lubricant Recommendations sss 3 General Precautions esistente 4 Components Power Divider 5 Forward Rear ecce teet ER eee 6 Rear 7 Removal of Differential Carrier from Axle Housing 8 Removal of Differential from 9 Disassembly Inter axle 1 10 Output 5 Laioiases aus nowania 12 Differential tet eire endete 15 a a eiui 14 Cleaning and Inspection ee 15 Assembly RS 16 Differential eentttnnntennes 19 GENUINE SPICER SERVICE PARTS Should an axle assembly require replacement component parts it is recommended that Spicer Heavy Axle Service Parts be used Spicer Heavy Axle Service Parts are manufactured under the same rigid specification as are original equipment axle components This assures the customer who uses genuine Spicer service parts maxi mum reliabi
15. ace piston O ring assembly into shift cylinder with detailed side facing front for the Loctite 518 3 Gasket Eliminat composite piston and the flat face on the aluminum i cd piston See Figure 27 Seat piston firmly against Figure 28 shift shaft 5 Clean the shift cover sealing area and the intermedi ate case and apply a 1 16 in bead of Loctite 518 Gasket Eliminator See Figure 28 Composite Shift Piston AluminumShift Piston 4 Install shift cover and tighten bolts to precribed SPA torque 15 20 Lb Ft 20 27N m NOTE If old bolts are to be used coat threads with Loctite 2277 before installing Detail Faces Front Founa oti later 5 Install washers and cover bolts Tighten bolts alternately to 15 20 Lb Ft 20 27 N m until Figure 27 shift cover is seated properly NOTE Care must be taken to keep Loctite off of 6 Connect air line to power divider piston assembly INSTALLATION OF DIFFERENTIAL CARRIER INTO AXLE HOUSING 1 Thoroughly clean the inside of the carrier housing 7 Install the new axle flange gasket ct the 8 Install the axle shafts in proper location Torque and general cleanliness Stone the surface if neces dg BIS Men the axle flange nuts to vehicle manufacturers sary to remove burrs or nicks specifications 9 Clean drain plug and fill unit to proper level with hypoid gear lubricant 10 Apply Loctite 56
16. aced press bearing cups out of carrier casting at this time 0000007 13 Remove pinion pilot bearing with a suitable puller TOTO Pinion Disassembly Complete J 4 Wood Block Press SIR Figure 10 _ Pinion SUOLI ANOVA Wood Block f mmm Figure 10A CLEANING AND INSPECTION CLEANING 1 Parts should be cleaned with emulsion cleaners or petroleum base cleaning solvent NOTE Alkaline type solutions may cause damage to machined surfaces and should be avoided 2 Make sure interior of axle housing is clean prior to reassembly 5 Clean all gasket surfaces of old material DRYING Use soft clean lintless towels or rags to dry Inspect gears for excessive wear or damage Replace components after cleaning Bearings should not be pene P dried by spinning with compressed air This can damage mating surfaces due to the lack of lubrica SHAFTS tion After drying parts should be coated with a light coat of lubricant or rust inhibitor to prevent damage from corrosion If parts are to be stored for a prolonged period they should be wrapped in wax paper INSPECTION Inspect shafts for nicks or scoring Prior to reassembly inspect parts for signs of excessive wear or damage Replacement of these SPLINES parts can prevent premature failure and costly do
17. ange Wheel Nut fastener torque requirements 28 RECOMMENDED SERVICE TOOLS ORDER NUMBER ILLUSTRATION DESCRIPTION DST1001 CARRIER STAND gt TORQUE MULTIPLIERS DST1002 2 Maximum 1 000 Lb Ft DST1003 Maximum 2 000 Lb Ft DST1004 Maximum 4 000 Lb Ft DST1005 Maximum 12 000 Lb Ft DST1006 YOKE REMOVER BAR TYPE DST1007 YOKE INSTALLER 1 3 4 12 DST1008 LONG 2 JAW PULLER 29 RECOMMENDED SERVICE TOOLS DST1000 S400 SERVICE KIT ORDER NUMBER ILLUSTRATION DESCRIPTION B O DST1000 2 INPUT SHAFT SEAL INSTALLER OUTPUT SHAFT SEAL INSTALLER SEAL INSTALLATION HANDLE To be used with seal installers listed below PINION SEAL INSTALLER DST1000 3 DST 1000 4 OUTPUT SHAFT BEARING BEARING ASSEMBLY INSTALLER To be used with 2 jaw puller DST1000 5 OUTPUT SHAFT REMOVER ADAPTER To be used with yoke installer DST 1007 ALL SERVICE TOOLS AVAILABLE FROM OTC DIVISION Service Tools 655 Eisenhower Drive Owatonna MN 55060 Telephone 1 800 533 0492 Fax Number 1 800 578 7375 30 lt gt SPICER Drivetrain Products Axles Driveshafts Off Highway Transmissions LONG Thermal Products Transmission Oil Coolers Engine Oil Coolers VICTOR REINZ Sealing Products Gaskets and Seals Cylinder Head Cover Modules Thermal Acoustic Protective Shielding Dana Aftermarket Group PO Box 321 Toledo Ohio 43697 0321 Warehouse Distributor 1 800 621 8084 OE Dealers 1 8
18. ar nuts with breaker bar in an alternating pattern and remove IMPORTANT Do not damage ring gear when loosening ring gear nuts 8 Inspect ring gear ring gear bolts and ring gear bolt holes for nicks excessive wear and irregularities Differential Disassembly Complete PINION DISASSEMBLY 1 Remove flanged hex nut face up See Figure 10 and 10A NOTE Use of a torque multiplier is recommended 7 Place a wooden block under pinion to avoid damage Torque flanged hex nut to 900 1 200 Lb Ft 1 220 of gear teeth during removal 1 627 Nm 8 Pinion removal 2 Remove end yoke on the rear rear axle using a suitable puller Refer to RECOMMENDED SERVICE TOOLS pgs 29 30 e On the Forward Rear press the pinion through the helical driven gear and inner and outer bearing cones See Figure 10 3 Remove the oil seal on the rear rear axle and s pes discard inner and outer bearing cones See Figure 10 4 Remove the four pinion pilot bearing support bolts Remove the pinion fror the bottom ofthe carrier the pinion piot peaning 10 Remove bearing preload spacer and save for use in 6 Place carrier in press with threaded end of pinion reassembly 11 If the gearset is to be reused remove inner pinion bearing with a suitable puller at this time If the gear set is to be replaced new bearings must be installed _ Pinion 12 If bearings are to be repl
19. ds that meet MIL L 2105D specifications SAE 85W 140 AFTER OVERHAUL OR CHANGE INTERVALS SAE 80W 140 Fill the We bottom E housing fill hole SAE 80W as shown in the illustration below It is recommended SAE80W that following an overhaul each side of the axle be SAE 75W 140 7 jacked up separately to approximately six inches and SAE 75W 90 M held into position for one minute This procedure will SAE 75W allow adequate lubricant to flow into the wheel ends and C 40 26 12 0 4 15 27 438 eliminate the possibility of premature damage to Fe 40 15 10 432 40 60 80 100 F wheel bearings and seals Lower the vehicle to the floor and allow ten minutes for lube to return to normal level AMBIENT AIR TEMPERATURE Check and refill assembly to bottom of fill hole to replace the lubricant that was directed into the wheel SERVICE ends Recommended lubricant change intervals are dependent on the application and operating environment The following chart should be used to establish proper change intervals SUBMERSION OR DEEP WATER FORDING 5 In the event the axle assembly should become sub merged in water particularly if over the vent or breather it is recommended that the lubricant be drained to prevent water damage and or contamination The axle assembly should then be refilled with specified lubricant NOTE Lubricant close enough to the bottom of the fill hole to be se
20. e Figure 24 match marks in proper location Clean bearing cap bolts and washers and coat threads with Loctite 277 red 4 Install bearing cap bolts and tighten enough to eliminate visible space between differential bearing cap and carrier Do not torque bolts at this time NOTE Differential assembly must be aligned within bearing bores before preload is applied or damage to bearings can occur 5 Install adjusting rings Tighten both adjusting rings Figure 24 until end play is eliminated and there is backlash between the ring gear and pinion See Figure 23 NOTE If the backlash tolerance varies more than 003 080mm between the four positions remove the differential and determine the cause 8 Once the backlash is set torque the differential bearing cap bolts to 295 540 Lb Ft 400 461 N m Check backlash after torquing cap bolts Differential Installation Complete Figure 23 25 RING GEAR AND PINION TOOTH CONTACT PATTERN The procedures to the right are to be used to establish STEP 1 Paint 1 4 ring gear with marking compound on proper gear tooth pattern after assembly of the carrier is both the drive and coast side complete STEP 2 Rotate ring gear at least one complete NOTE If matched sets are being reused measure and revolution in both directions while load is record backlash before disassembly and reas being applied semble to the same backlash This will match ring and pinion gears to
21. e gasket and clean mating surfaces of the hub and axle flange 27 AXLE TORQUE SPECIFICATIONS S400 S Specifications Position Metric Pinion Torque Bearing Preload Torque Wrench 10 40 Lb in 1 1 4 5 N m Differential Ring Gear to Pinion Backlash 008 012 in 50 40 mm Lubrication Approx Forward Rear 14 Liters Rear Rear 11 7 Liters Pinion bearing preload is established prior to installation of pinion seal Capacity will vary depending on the housing angle in each vehicle Fill to lower edge of fill hole in rear of axle housing as shown on Page 27 Forward Rear Fasteners Lb Ft N m Position Thread size Flanged Hex Nut 1 3 4 12 Carrier Mounting Bolts 5 8 11 Fill Plugs 3 4 14 Temperature Sensor Plug 1 2 14 Magnetic Drain Plug 3 4 14 Shift Cylinder Cap Bolts 5 16 18 Inter Axle Differential Case Bolts 9 16 12 3 8 16 Grade 8 900 1 200 1 220 1 627 240 260 330 358 35 45 47 61 35 45 47 61 35 45 47 61 15 20 20 27 160 180 217 244 20 25 27 34 Lube RetainerBolts Rear Rear Fasteners Lb Ft N m Position Thread size Flanged Hex Nut 1 3 4 12 Carrier Mounting Bolts 5 8 11 Fill Plug 3 4 M Temperature Sensor Plug 1 2 14 Magnetic Drain Plug 3 4 14 Grade 8 900 1 200 1 220 1 627 240 260 330 358 35 45 47 61 55 45 47 61 35 45 47 61 NOTE Refer to vehicle manufactures specifications for Axle Fl
22. earing preload does not fall within allowed limits preload can be increased by using a thinner spacer and decreased by using a thicker spacer 001 inch change in preload spacer will change torque to rotate approximately 30 16 Figure 18 PINION ASSEMBLY NOTE Individual carriers may vary slighty Pinion bearing preload spacers are available in the following thicknesses inch inch 718 18 24 731 18 57 719 18 26 7352 18 60 20 18 29 733 18 62 721 18 31 734 18 64 722 18 34 735 18 67 25 18 36 56 18 69 724 18 39 737 18 72 725 18 41 58 18 75 726 18 44 739 18 77 727 18 47 40 18 80 28 18 49 741 18 82 729 18 52 742 18 85 7350 18 54 Always measure each spacer before assembly to ensure correct thickness NOTE Closer adjustment can be made by sanding the next thicker spacer to desired thickness using emery cloth on a flat surface CAUTION Wash spacer thoroughly of emery cuttings before installing on pinion 14 Repeat process until torque to rotate is between 10 40 Ib in after preload is achieved remove yoke and install new seal with proper service tool NOTE Acceptable torque to rotate with seal installed is 15 45 Ib in 15 Install yoke using yoke installer See RECOM MENDED SERVICE TOOLS pgs 29 50 NOTE Spicer recommends that new flanged hex nuts be used 16 Apply Loctite 680 green to threads 17 Use torque multiplier and torque flanged hex n
23. ect drive shaft at the rear U joint NOTE If end yoke and or seal is to be replaced loosen yoke nut at this time 4 Match mark each axle shaft flange to its mating wheel end and remove axle shaft flange nuts IMPORTANT Axle shafts are of different lengths and should be marked accordingly for proper reassembly 5 Hold a large brass drift or a brass hammer against the center of the axle shaft flange Strike the drift with sharp blows from a large hammer or sledge until the axle shaft separates from the hub CAUTION Do not strike the flange directly with a steel hammer or sledge This may crack and splinter material possibly causing serious or fatal injury Do not pry or chisel axle flange away from hub or damage to sealing surfaces could occur 6 Remove axle shafts Remember due to different length axle shafts each shaft should be marked to mating wheel end for proper reassembly 7 Disconnect air line from power divider shift cover on forward rear assembly 8 Support the differential carrier assembly on a roller jack Secure as necessary to prevent it from falling off the jack when removed from the housing 9 Loosen the differential carrier to housing mounting bolts Remove all bolts except top two These two bolts will prevent the carrier assembly from falling IMPORTANT Thread two guide pins into axle housing to relieve weight from output shaft bearing assembly of forward rear during differential carrier removal
24. emainder of assembly to prevent damage of bearings 5 Apply a small amount of hypoid axle lubricant to all mating surfaces This will aid in assembly by keeping parts together and providing initial lubrica tion 4 Place gear thrust washer and differential side gear in differential case flange half 5 Assemble pinion mates and pinion mate thrust washers onto differential cross shaft Place assem bly into flange half differential case 6 Place remaining differential side gear and thrust washer in position on differential pinion mates 7 Assemble case halves making sure match marks are lined up 8 Install differential case bolts Tighten alternately and torque evenly to 180 200 Lb Ft 244 27N m NOTE If old bolts are used coat threads with Loctite 277 before installing Differential Assembly Complete OUTPUT SHAFT ASSEMBLY Flanged Hex Nut End Yoke Beveled Retaining Ring Output Shaft 900 1 200 Lb Ft 1 220 1 627 N m Output Oil Seal 1 Press new bearing onto shaft using output shaft bearing installer service tool See Figure 19 NOTE Clean bore of housing to remove old Loctite and oil Bearing Installer Service Tool Figure 19 2 Apply a thin layer of Loctite 620 to the outside diameter of the bearing before assembly into housing NOTE Care must be taken to keep Loctite out of bearing Housing Output Shaft Bearing 3 Install output shaft and bearing assembly into housing u
25. en or touched is not sufficient Lubricant must be level with the fill hole GENERAL PRECAUTIONS A IMPORTANT A READ THIS SECTION BEFORE STARTING ANY SERVICE PROCEDURES GENERAL AXLE DESCRIPTION The Spicer tandem rear axle assemblies consist of two heavy duty hypoid single reduction differential carrier assemblies The forward axle contains a power divider which does exactly what its name implies It divides power between the forward rear and rear rear axle assemblies The forward axle receives power through a set of helical gears within the power divider The rear rear axle receives power from the power divider output shaft that extends through the forward axle housing The complete forward axle differential carrier assembly and power divider can be removed from the axle housing as a unit Follow the sections of this manual that cover individual service needs Safety glasses should be worn at all times when assembling or disassembling axles SAFTEY PRECAUTIONS Proper service and repair of vehicle components is important to the safe and reliable operation of all motor vehicles This applies particularly to driving axles such as the ones described in this manual The procedures recommended and described in this manual are tested and effective methods for performing service operations Follow each procedure closely making use of both the text and illustrations Some of these service procedures show the use of ce
26. er The axle assembly tag contains the following items Dana part number julian date code axle model and ratio Optional items include customer part number line set number and the last six digits of the vehicle serial number DANA PART NUMBER CUSTOMER PART NUMBER OPTIONAL MODEL Axle Assembly Tag CODE SET NUMBER LAST SIX DIGITS OF OPTIONAL VEHICLE SERIAL NUMBER OPTIONAL ceRt 97170 El 273 1 JULIAN DATE AXLE IDENTIFICATION JULIAN DATE CODE MODEL YEAR DAY OF YEAR DANA PART NUMBER CUSTOMER PART NUMBER OPTIONAL P CARRIER 39 CA10 EX SER SPICER 95170 622110 RRTID373 JULIAN DATE Carrier Tag CODE LINE SET NUMBER LAST SIX DIGITS OF OPTIONAL VEHICLE SERIAL NUMBER OPTIONAL MODEL IDENTIFICATION NUMBERING SYSTEM Family Nominal Load Gearing Type Options S Spicer Carrying Capacity S Single Reduction No SPIN Differential 400 40 000 Lbs No SPIN is a registered trademark of Tractech GEAR SET IDENTIFICATION Manufacturer s Date Date gear set was made SPICER TRADEMARK PINION ETCH Spicer Trademark Company logo and location of manufacturing facility C Part number of pinion 390GP100 TYPICAL MA Tooth Combination i e 41 11 Indicates the pinion TOOTH PART HEAT SPICER MATCHED hae the pussy has teeth whieh COMBINATION NUMBER CODE TR
27. et Elimina tor See Figure 19 for correct bead pattern 518 Gasket Eliminator Bead Pattern Figure 19 YOKE REMOVAL AND SEAL REPLACEMENT Disconnect drive shaft at the rear U joint Remove end yoke using the yoke remover tool See Figure 25 Remove oil seal Inspect end yoke seal surface for grooves If grooves can be detected with fingernail it should be repaired with a CR SPEEDI SLEEVE or replaced Clean and dry threads on input ouput shaft or pinion Install oil seal using proper tools Figure 25 Install end yoke using yoke installer See Figure 17 8 Apply Loctite 680 green to threads on page 17 9 Use torque multiplier and torque flanged hex nut to 900 1 200 Lb Ft 1 220 1 627 N m Yoke Removal and Seal Replacement Complete 25 SHIFT CYLINDER SERVICE DISASSEMBLY 1 Disconnect air line from power divider 2 Remove shift cylinder cover bolts and washers WN Remove cover and O ring seal Pull shift cylinder piston assembly from carrier 5 Inspect all components for wear NOTE Do not remove shift fork shaft from assembly Piston Assembly 5 Seal dcm Disassembly Complete e Shift Cover P di Washer Shift Cover Bolt 15 20 Lb Ft 20 27 N m ASSEMBLY NOTE Visually inspect the composite shift piston to insure the steel spacer is present on the bottom of the piston 1 Inspect all new components 2 Lubricate and pl
28. lity for a Spicer Heavy Axle assembly They may be obtained through your vehicle manufacturer Assembly Continued Output saec rossonero 20 Inter axle Differential sss 21 Differential Installation sicutinmaacoarssncinteicunioieass 25 Ring Gear and Tooth Contact Pattern 24 Installation of Inter axle Differential Into Carrier 25 Yoke Removal and Seal Replacement 25 Shift Cylinder Service 26 Installation of Differential Carrier Into Axle Housing 27 Axle Torque Specifications e 28 Recommended Service Tools s 29 The use of non original Spicer service parts may cause premature component failure and may void the warranty The items included in this book are currently being offered as service parts at the time of printing The part numbers and illustrations are provided specifically for reference purposes only Therefore Spicer reserves the right to update this manual without notice or liability All axle assemblies are identified with two tags One located on the differential carrier and the other located on the right hand side of the axle housing The differential carrier tag contains the following Dana part number julian date code and ratio Optional items include customer part number line set number and the last six digits of the vehicle serial numb
29. lock 6 X6 X6 so the inner pinion bearing is mated to the cup See Figure 15 6 Insert original preload spacer and outer pinion bearing onto pinion 7 Press outer pinion bearing onto pinion until completely seated 8 On forward rear press driven gear onto pinion See Figure 16 IMPORTANT The old style driven gear on the 3 2 and 3 42 ratios will have FRONT stamped on the face of the gear This gear must be installed with the word FRONT facing away from the carrier assembly If you do not have this driven gear no special instruc tions apply to the installation of the gear 9 On rear rear carrier inspect end yoke or companion flange for grooves in seal surface If grooves can be ANU mum Vs Figure 16 detected with finger nail then end yoke must be repaired with a C R approved repair sleeve or replaced 10 Use yoke installer service tool and install yoke without seal See Figure 17 11 Use torque multiplier and torque flanged hex nut to PINION ASSEMBLY Yoke Installer Service Tool Figure 17 900 1 200 Lb Ft 1 220 1 627 N m 12 Install pinion pilot bearing cap Tighten and torque four bolts to 150 Lb Ft 205 N m 13 Measure torque to rotate with an inch pound torque wrench Make eight revolutions taking a torque measurement every fourth revolution It should read between 10 40 Ib in of bearing preload See Figure 18 NOTE If b
30. rtain tools designed specifically for the operation being performed They are shown as a preferred means of performing the operation It is not practical to anticipate and advise the service trade of all possible alternative methods and of all possible hazard ous consequences that could result from any particular method Accordingly anyone who uses a service procedure or tool different than shown must first thoroughly satisfy themselves that their safety nor the vehicle safety will be jeopardized by the service method selected END YOKES AND FLANGES A CAUTION Hammering on end yokes could damage the bearing bores or misalign yoke lugs and result in early failures of journal needle bearings or other driveline components Serious damage can also be done internally to the ring and pinion set or pinion bearings by hammering on external parts End yokes or companion flanges should be removed or installed using the recommended method such as that described herein CLEANLINESS Axle components should be steam cleaned prior to removal from the vehicle Dirt is abrasive and can cause premature wear of otherwise serviceable parts Service personnel should use a wash tank for thorough cleaning of parts just prior to reassembly CAUTION BRAKE LININGS CONTAIN NON ASBESTOS FIBERS BREATHING BRAKE DUST MAY BE HAZARDOUS TO YOUR HEALTH AND MAY CAUSE SERIOUS RESPITORY OR OTHER BODILY HARM AVOID CREATING DUST DO NOT REMOVE BRAKE DRUM W
31. se 6 Align the bolt holes of the plastic lube retainer with the case and install the two bolts and washers Tighten and torque lube retainer bolts to 20 25 Lb Ft 27 34 N m 7 Press new needle bearing into 1 0 of drive gear 8 Lubricate needle bearing and carefully lower drive gear into intermediate case until differential gear is seated in inter axle differential 9 Press input shaft front bearing cone onto shaft until seated completely against shoulder Lube the needle thrust bearing lightly and place on front drive gear Ensure that thin bearing race is seated against drive gear and the thrust bearing is seated between the two spacers NOTE To establish proper end play input shaft will be installed into inter axle differential prior to installing shift collar fork and shift shaft 11 Lube and install input shaft turning slightly to engage splines 12 Install new input shaft front bearing cup into input shaft bearing retainer without shims 13 Install bearing retainer onto intermediate housing and bolt into place 14 Thread input flanged hex nut onto input shaft until resistance is felt from locking compound 21 Tap nut lightly with soft hammer 15 Position dial indicator onto end of input shaft See Figure 21 Figure 21 Using suitable pry bar and spacer pry input shaft out and record end play 16 Proper end play for inter axle is 001 to 003 inch 025 to 076 mm Subtract 003
32. sing bearing installer service tool withad equate 2 jaw puller See Figure 20 4 Seat bearing completely in housing and remove excess Loctite 5 Install beveled retaining ring in housing with bevel facing to the rear of the axle Be certain the retainer ring is fully seated Clean and dry threads on output shaft Lubricate bearing with hypoid axle lube Install oil seal using proper service tools Install end yoke using yoke installer service tool v Apply Loctite 680 to threads before installing new flanged hex nut 10 Use torque multiplier and torque flanged hex nut to 900 1 200 Lb Ft 1 220 1 627 N m Output Shaft Installation Complete Bearing Installer Housing Service Tool 2 Jaw Puller Figure 20 20 INTER AXLE DIFFERENTIAL ASSEMBLY 1 Position inter axle differential case on two 4 x 4 blocks for reassembly 2 Install new rear differential bearing cup into case 5 Press new bearing cone onto rear differential gear NOTE Be certain that both cup and cone are seated properly or false reading on end play of inter axle may 4 Apply a light coating of gear lube to rear diff gear bearing hub surface and interior bore then install 5 Lubricate and place inter axle differential assembly inside of plastic lube retainer and install into ca
33. ston lightly with soft mallet to remove Removal slot 4 Remove shift cylinder shaft 5 Remove flanged hex nut INTER AXLE DIFFERENTIAL DISASSEMBLY NOTE Use of a torque multiplier is recommended as torque specification on input flanged hex nut is 900 1 200 Lb Ft 1 220 1 627 N m Refer to RECOM MENDED SERVICE TOOLS pgs 29 30 6 Remove input yoke using a suitable puller See Figure 5 Yoke n d Remover Figure 5 7 Remove bolts from input shaft bearing retainer Use removal slots See Figure 6 to seperate bearing retainer from inter axle differential case and remove retainer Removal slot Removal slot Figure 6 21 Remove input oil seal Press out input shaft bearing cup from bearing retainer Retain shims for possible use during reassembly Early models were not a press fit Remove input shaft assembly Remove input yoke spacer from input shaft Remove front bearing cone from input shaft using suitable puller Remove clutch collar shift fork and spring from assembly Remove needle thrust bearing assembly from top of drive gear Remove drive gear from inter axle differential case Remove two lube retainer bolts Remove lube retainer Remove inter axle differential assembly from case Remove rear Diff gear from inter axle differential Case
34. the established wear patterns TOE Hand rolled patterns will cover less area than the N TOP LAND gear pattern established by previous service PRO HEEL The GLEASON gear set is identified by a 390GA100 y series part number The ORLIKON is identified by a 390GA200 series part number See Gear Set Identifi cation section xis DRIVE SIDE COAST SIDE CONVEX CONCAVE CORRECT GEAR PATTERNS FOR GLEASON CUT GEARS LIGHTLY LOADED HEAVILY LOADED GD OY CORRECT GEAR PATTERNS FOR ORLIKON CUT GEARS LIGHTLY LOADED HEAVILY LOADED ID Ys NOTE Tooth contact pattern on this axle model can be moved only by adjusting backlash The contact pattern can be moved in the direction of heel to toe and toe to heel Depth of the pattern cannot be adjusted If an acceptable tooth contact pattern cannot be established within limits of backlash contact Spicer Service at 1 800 666 8688 24 1 2 Remove yoke nut NOTE Use of torque multiplier is recommended as torque specification on input flanged hex nut is 900 1 200 Lb Ft 1 220 1 627 N m 3 NOTE Spicer recommends that new flanged hex nuts be used Thoroughly clean mating face of carrier and apply Align inter axle differential case with carrier housing and insert bolts and torque to 160 180 Lb Ft 217 244 N m INSTALLATION OF INTER AXLE DIFFERNETIAL TO CARRIER an 1 8 inch bead of Loctite 518 Gask
35. ut to 900 1 200 Lb ft 1 220 1 627 N m Pinion Assembly Complete Pinion Mate Thrust Washer Differential Cross Shaft Ring Gear Flange Half Differential Case S Flat Washer 300 320 Lb Ft 9 o 407 434 N m ev Bearing Cup Bearing Cone 1 If ring gear was removed from the differential case reinstall it at this time e Clean the differential case and ring gear mounting surface e Position the differential case on a work bench with the machine surface down e Place the ring gear on the case with the teeth facing up e Install bolts into the tooth side of the ring gear and install the flat washer and nut onto the differential case side NOTE Bolts have a clearance fit in the differential case and the ring gear mounting holes Bolts require correct torque to ensure proper clamp e When all bolts have been installed tighten opposite one another until one half the pre scribed torque is obtained 150 160 Lb Ft 204 217N m NOTE Bolt heads must be held flat against ring gear while torque is being applied e Repeat the process to full torque specifications 300 320 Lb Ft 407 434 N m DIFFERENTIAL ASSEMBLY Bearing Cup Bearing Cone E Differential Case Bolt 180 200 Lb Ft 244 271 N m Plain Half Differential Case Differential Side Gear e X Differential Pinion Mate Gear Thrust Washer 2 Press bearing cones onto differential case halves Place bearing cups on cones during r
36. wntime Inspect all splines for excessive wear distortion from twisting and cracking BEARINGS Bearing surfaces should be inspected for pitting HOUSINGS excessive wear or overheating O o THRUST WASHERS Inspect housing for stripped threads and bending Inspect thrust washers for scoring and cracking fatigue PINION ASSEMBLY NOTE Alkaline type solutions may cause damage to machined surfaces and should be avoided 5 Stake pilot bearing in nine places using a center punch or equivalent tool See Figure 13 4 Press inner and outer bearing cups into the carrier Feeler Gauge Figure 11 1 Press inner bearing cone onto pinion See Figure 11 2 Press pinion pilot bearing onto the pinion See Figure 12 Figure 14 until seated Use a feeler gauge 0015 inch to make sure that bearing cups are fully seated in bearing bores Apply hypoid gear lubricant to both cup and cone See Figure 14 Pinion Pilot Bearing Outer Pinion Bearing Bearing Preload Spacer n Pinion Figure 12 NOTE Chamfer side of bearing faces the pinion head W Wood Block Pinion Figure 15 NOTE After installing pinion bearing and or helical gear pinion shaft should be turned at least 8 rotations to assure proper alignment of bearing rollers Figure 13 16 5 Place carrier housing in press with the pinion supported by wood b
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