DANA Spicer Drive Axles Service Manual

Spicer

Drive Axles

Service Manual

AXSM0029 September 2007

General Information

The description, testing procedures, and specifications contained in this service publication were current at the time of printing.

Dana reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice and without incurring obligation.

The recommendations of the vehicle manufacturer should be considered as the primary source of service information regarding this Spicer product. This manual is intended to be used as a supplement to such information.

Any reference to brand names in this publication is made simply as an example of the types of tools and materials recommended for use and, as such, should not be considered as an endorsement. Equivalents, if available, may be used.

IMPORTANT NOTICE

This symbol is used throughout this publication to call your attention to areas in which carelessness or failure to follow specific procedures may result in personal injury and/or component malfunction or damage.

Anyone departing from the instructions contained in this publication through procedures used or choice of tools, materials and parts may jeopardize his personal safety and/or the safety of the vehicle user.

Always use genuine Spicer replacement parts.

WARNINGS: Used in areas where failure to follow listed procedures creates a high

probability of personal injury to the servicing technician.

CAUTIONS: Used in areas

where failure to procedures may cause personal

injury due to component damage or subsequent malfunction.

follow listed

Table of Contents

Electric Shift System

Introduction

Electric Shift System . . . . . . . . . . . . . . . . . . . . . . . . . 1

Mechanical Operation . . . . . . . . . . . . . . . . . . . . . . . . 2

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Shift Unit Removal/Disassembly

Remove Shift Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Remove Slider Block . . . . . . . . . . . . . . . . . . . . . . . . . 8

Remove Circuit Board and Motor . . . . . . . . . . . . . . . 9

Remove Gear and Cam Pins . . . . . . . . . . . . . . . . . . 10

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Shift Unit Assembly/Installation

Install Cam Pins and Gear . . . . . . . . . . . . . . . . . . . . 11

Install Slider Block. . . . . . . . . . . . . . . . . . . . . . . . . . 12

Install Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Install Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . 14

Install Shift Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Shift Unit Retrofit Kits

Retrofitting Instructions. . . . . . . . . . . . . . . . . . . . . . 16

Air Shift System

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Air Shift Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Description and Operation (Shift Unit) . . . . . . . . . . 20

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Shift Unit Removal/Disassembly

Remove Shift Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Disassemble Shift Unit . . . . . . . . . . . . . . . . . . . . . . 22

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Shift Unit Assembly/Installation

Assemble Shift Unit. . . . . . . . . . . . . . . . . . . . . . . . . 24

Install Shift Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Air Shifter Valve Removal/Disassembly

Remove/Disassemble Air Shifter Valve . . . . . . . . . . 26

Inspection/Lubrication . . . . . . . . . . . . . . . . . . . . . . 26

Air Shifter Valve Assembly/Installation

Assemble/Install Air Shifter Valve . . . . . . . . . . . . . . 27

Servicing Other Electric System Components

Installation of Improved Motor Housing Cover

(Production units effective December 1989) . . . . . . 17

Speedometer Adapter . . . . . . . . . . . . . . . . . . . . . . . 18

Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Servicing Other Air System Components

Quick Release Valve . . . . . . . . . . . . . . . . . . . . . . . . 28

Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Servicing Other Air System Components

Additional Service Information . . . . . . . . . . . . . . . . 29

Parts Information . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Introduction

Electric Shift System

The service procedures and specifications in this publication cover the current Spicer 2-Speed Axle Shift Systems.

Maintenance and overhaul instructions for the Spicer 2-Speed Axle carriers are covered in the publications listed on the back cover.

This manual includes information on two types of Shift Systems currently in use for Spicer 2-Speed Axles; Electric and Air.

Spicer 2-Speed Axles are driver-controlled by means of a shift unit operated from the vehicle cab. These shift units are activated by air or electric power depending on the convenient source in the chassis.

Because of this variation, this publication is divided into two major segments: Electric Shift System for hydraulic-brake chassis and Air Shift System for air-brake chassis.

Electrical Operation

Note: For component identification and wiring schematic,

refer to illustrations on pages 1, 2, 3, and 4.

Unit in Low Range Shifting to High Range

Current flows through upper contact cont

acts of high-range switch, and motor to ground which starts the motor rotating. Current also continues from common motor terminal through low-range switch and to ground through the resistor.

When motor starts, rotation of the gear allows cam ramp to apply pressure on low-range cam pin, which allows low range switch to open. The path to ground (through resistor) is open and the diode prevents speedometer adapter solenoid from being energized.

Motor rotation continues to shift axle to high range. As shift is completed, cam ramp of gear releases high-speed cam pin to open high-range switch and creates an open circuit to turn off power to motor. Motor rotation is stopped quickly by means of dynamic braking through resistor.

of control switch, closed

If, during rotation, driver decides to switch back to low range,

continues to turn.

motor

ELECTRIC SHIFT UNIT CUTAWAY

Motor

Circuit Board

Assembly Cam Pin (Low Range)

Switch Spring

Gear

Gear Pin (Eccentric)

Wiring Harness and Connector

Black Wire

Green Wire Red Wire Worm Gear

Cam Pin (High Range)

Slider Block

Flat Washer (0.100",

2.54 mm thick)

Opening of high-range switch has no effect since motor is now being powered by the circuit from control switch, through diode and low-range switch to ground at motor. In this instance, motor continues to turn until cam pin opens low-range switch to turn off power to motor.

Unit in High Range Shifting to Low Range

Current flows through control switch lower contact to energize speedometer adapter solenoid and through the diode and low-range switch to common motor terminal and ground at motor. Motor starts rotating. Current also flows through closed contact of high-range switch and to ground through resistor. Once gear rotates enough to apply cam pin pressure on the high switch, circuit to ground through resistor is open

As moto

r rotation continues to shift axle to low range, gear rotates and releases cam pin on low-range switch to open switch and open motor circuit. Motor power is turned off. Once again, the resistor portion of the circuit provides braking to stop motor quickly.

If, during motor rotation, driver decides to shift back to high range, the motor continues to turn. Opening of low-range switch has no effect since motor is now being powered through control switch. In this instance, motor continues to turn until gear rotation opens high-range switch to open motor circuit.

The shift unit always remains synchronized with position of driver's control switch.

Electric Shift System

Mechanical Operation

Low to High Range or High to Low Range

When shifting axle range either up or down, motor starts and turns worm gear shaft. The gear assembly (which is meshed with worm gear) turns and moves eccentric pin in slot area of slider block.

Since driving torque holds shift fork and swivel block of the slider block assembly in place, linear motion of slider block is translated into compression of the internal spring.

ELECTRIC SHIFT UNIT

Housing Cover

Cover Gasket Nut (Circuit Board)

Circuit Board Assembly

Red Wire

Black Wire

Green Wire

Cam Pin

Motor Housing

Gear Washer

Gear

Gear Pin

Gear Shaft

As motor shuts off at 180º of gear rotation, a break in torque by driver allows spring force (stored in the slider block assembly) to move the swivel pin and shift fork in appropriate direction for axle range change.

When opposite axle range is selected by driver, the process is repeated by motor turning another 180º in same direction. In this case though, eccentric pin movement creates block spring compression in the opposite direction.

Cover Screw

Cover Gasket (See Note below)

Wiring Harness and Connector

Board Flat Washer

Nut (Gear Shaft)

Worm Gear

Motor Screw

Motor Assembly

Nut

Cable Clip

Motor Lead Wire

General Information

Slider Block & Shaft Assembly

Base Housing

Dowel Pin

Seal & Spring

Note: The new improved housing cover does not require a

gasket (see page 17).

Electric Shift Unit Assembly

Housing Screw

Flat W

Nut

asher (0.100", 2.54 mm thick)

Stud

Shift System Electrical Wiring Schematic

Electric Shift System

Circuit Board

Resistor

Up-High

Power Source (Ignition or Accessory Switch)

Circuit Breaker

Speedometer Adapter

Wiring Harness

Range

Down-Low

Range

Electrical Shift System Major Components

Switch Knob

Control Switch

Wiring Harness Connector

Ground

Motor

Housing Cover

Ground

Black

Green

Red

Shift Unit Switch

Black

Ground

High Range NC NO

Switches

Low Range NO NC

Diode

Plug and Cable Assembly

Electric

Shift Unit

Speedometer

Adapter

Front Wiring Harness

Rear Wiring Harness

Circuit Breaker or Fuse

Electric Shift System

Slider Block Inspection Procedure

Bottom of Base Housing

General Information

• Remove shift unit from axle.

• Move slider block from side to side. Make sure slider block moves freely in housing.

Electric Shift System

Troubleshooting

Troubleshooting Guide

This chart begins with an improperly operating shift unit. Use with illustrations on pages 3, 4 and 6 to help isolate the problem. Follow the possible solutions as an aid to system repair.

Axle doesn’t shift ranges.

• Check the circuit breaker.

• Is the circuit breaker closed?

NoYes

Check for power at the shift unit connector.

• Is there a voltage reading of 9V or more?

Remove shift unit from axle and apply voltage.

• Does unit shift properly?

Inspect slider block from bottom of shift unit. See page 4

• Check to see if slider block is loose or missing.

• Is slider block in good operating condition?

Inspect appearance of shift fork and check fit with depth card.

• Does the fork match the depth card output? (See page 6)

• Reset circuit breaker or replace fuse.