Spicer Convertible Tandem Axles User Manual
Spicer
®
Drive Axles
Service Manual
Spicer® Convertible Tandem Axles
AXSM0510
October 2011
Forward
S21-170
S23-190
S23-170D
S23-190D
Rear
S21-060B
S23-070B
S23-090B
General Information
General Information
The description and specifications contained in this service publication are current at the time of printing.
Dana reserves the right to discontinue or to modify its models and/or procedures and to change specifications at any
time without notice.
Any reference to brand names in this publication is made simply as an example of the types of tools and materials recommended
for use and should not be considered an endorsement. Equivalents, if available, may be used.
Important Notice
General Information
This symbol is used throughout this
manual to call attention to procedures
where carelessness or failure to follow
specific instructions may result in
personal injury and/or component
damage.
Departure from the instructions, choice
of tools, materials and recommended
parts mentioned in this publication
may jeopardize the personal safety
of the service technician or vehicle
operator.
Always use genuine Spicer replacement parts.
WARNING: Failure to follow indicated
procedures creates a high risk of personal
njury to the servicing technician.
i
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
cover ed in the service procedures.
Tip: Helpful removal and installation
procedures to aid in the service of this unit.
i
General Information
ii
Table of Contents
Table of Contents
General Information
Important Notice . . . . . . . . . . . . . . . . . . . . . i
Introduction
Model Listing . . . . . . . . . . . . . . . . . . . . . . . . 1
Model Information . . . . . . . . . . . . . . . . . . . . 1
Model Identification . . . . . . . . . . . . . . . . . . . 2
Parts Identification . . . . . . . . . . . . . . . . . . . . 2
Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . 2
Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Ring Gear and Pinion . . . . . . . . . . . . . . . . . 3
Inspection
Failure Analysis . . . . . . . . . . . . . . . . . . . . . . 5
How to Diagnose a Failure . . . . . . . . . . . . . 5
Document the Problem . . . . . . . . . . . . . . . . 5
Make a Preliminary Investigation. . . . . . . . . 6
Prepare the Parts for Inspection . . . . . . . . . 6
Find the Cause of the Failure . . . . . . . . . . . 6
Correct the Cause of the Problem . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspect Axle Housing. . . . . . . . . . . . . . . . . . 6
Inspect Components . . . . . . . . . . . . . . . . . . 7
Adjust Tooth Contact Position
Adjust Ring and Pinion Tooth Contact
Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
New Gearing - Correct Pattern . . . . . . . . . 31
Used Gearing - Correct Pattern . . . . . . . . . 31
Adjust Contact Pattern . . . . . . . . . . . . . . . 31
Adjust Ring Gear Position (Backlash) . . . . 32
Wheel Differential Lock
Parts Exploded View . . . . . . . . . . . . . . . . . 33
Install and Adjust Wheel Differential Lock . 34
Housing Assembly Forward
Parts Exploded View . . . . . . . . . . . . . . . . . 35
Bowl Tag Housing Assembly . . . . . . . . . . . 36
Parts Exploded View . . . . . . . . . . . . . . . . . 36
Install Bowl Tag Housing Cover . . . . . . . . 37
Axle Assembly Procedure . . . . . . . . . . . . . 37
Bowl Tag Axle Conversion Process
Axle Disassembly Procedure . . . . . . . . . . 39
Axle Assembly Procedure . . . . . . . . . . . . . 39
Housing Breather . . . . . . . . . . . . . . . . . . . . 41
Differential Carrier Assembly
Exploded Parts View . . . . . . . . . . . . . . . . . . 9
Remove Differential Carrier . . . . . . . . . . . . .10
Standard Differentials . . . . . . . . . . . . . . . . .10
Install Differential Carrier . . . . . . . . . . . . . .10
Drive Pinion Assembly
Parts Exploded View . . . . . . . . . . . . . . . . . .11
Pinion Removal . . . . . . . . . . . . . . . . . . . . . .12
Drive Pinion Overhaul and Assembly . . . . .14
Wheel Differential Assembly
Exploded Parts View . . . . . . . . . . . . . . . . . .19
Remove Wheel Differential Carrier
Disassembly (All Standard Models) . . . . . .20
Forward Carrier Disassembly . . . . . . . . . . .22
Forward Carrier Assembly . . . . . . . . . . . . .23
Set Backlash and Bearing Preload . . . . . . .25
Wheel End Seal
Parts Exploded View . . . . . . . . . . . . . . . . . 43
Remove and Overhaul Wheel End Seal . . 44
Install Wheel End Seal . . . . . . . . . . . . . . . . 44
Adjust Wheel Bearing . . . . . . . . . . . . . . . . 44
Three-piece Dowel-type Lock
Washer System . . . . . . . . . . . . . . . . . . . . . 45
Three-piece Tang-type Lock
Washer System . . . . . . . . . . . . . . . . . . . . . 45
Four-piece Tang/Dowel-type
Lock Washer System . . . . . . . . . . . . . . . . 46
Replace Seal . . . . . . . . . . . . . . . . . . . . . . . 46
Guidelines for Reusing Yoke . . . . . . . . . . . 47
Verify Wheel Endplay Procedure . . . . . . . . 48
Readjust Wheel Endplay Procedure . . . . . 48
Lubricate Wheel End . . . . . . . . . . . . . . . . . 49
Wheel Ends with an Oil Fill Hole . . . . . . . . 49
Wheel Ends Without Oil Fill Hole . . . . . . . . 50
Service Kit . . . . . . . . . . . . . . . . . . . . . . . . . 51
iii
Table of Contents
General Lubrication Information
Approved Lubricants . . . . . . . . . . . . . . . . . .53
Recommendations for Viscosity/
Ambient Temperature . . . . . . . . . . . . . . . . .53
Lube Change Intervals . . . . . . . . . . . . . . . .53
Lubricant Chart . . . . . . . . . . . . . . . . . . . . . .54
Change Lube . . . . . . . . . . . . . . . . . . . . . . .55
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Standpipes . . . . . . . . . . . . . . . . . . . . . . . . .56
Theory of Operation
Power Divider Operation (Power Flow
and Torque Distribution) . . . . . . . . . . . . . . .57
Operate Wheel Differential Assembly . . . . 59
Control Systems for Differential Lock . . . . 59
Direct Driver-controlled System . . . . . . . . . 59
Wheel Differential Lock System . . . . . . . . 60
Wheel Differential Lock . . . . . . . . . . . . . . . 61
Differential Lock Engaged . . . . . . . . . . . . . 62
Differential Lock Disengaged . . . . . . . . . . 62
Differential Lock Engagement Indicator . . 62
Proper Vehicle Towing
Without Wheel Differential Lock . . . . . . . . 63
With Wheel Differential Lock . . . . . . . . . . . 63
Fastener Torque Specifications . . . . . . . 65
iv
Introduction
Introduction
Dana Commercial Vehicle Systems Division, presents this
publication to aid in maintenance and overhaul of Spicer
tandem drive axles.Introduction
Instructions contained cover the models listed. Their design is
common, with differences in load capacity. Capacity variations
are achieved by combining basic differential carrier assemblies with different axle housings, axle shafts and wheel
equipment.
Model Listing
Model Information
The following models are included in this publication:
Heavy Singles
S21-170 S26-190
S21-170D S26-190D
S23-170 S30-590
S23-170D S30-190
S23-190 S30-190D
Introduction
S23-190D S35-590
S25-170
S26-170
Bowl Tag Axles
Forward Rear
S21-170 S21-160B
S23-170 S23-070B
S23-170D S23-070B
S23-190D S23-090B
D - Dual Drive Forward Axle
with Inter-Axle Differential
G - Single Rear Axle (Global)
R - Dual Drive Rear Axle
S - Single Rear Axle (N.A.)
GAW Rating
x 1000 lbs. (N. America) "-"
x 1 Tn. (Europe) "."
Gear Type
1 - Standard Single Reduction
2 - Dual Range
3 - Planetary Double Reduction
4 - Open
5 - Helical Reduction
S 23-1 7 0 D
Options
B - Bowl Tag
C - Controlled Traction
D - Differential Lock
E - High Entry Single
H - Heavy Wall
I - Integral Brake
L - Limited-Slip
P - Lube Pump
R - Retarder Ready
W - Wide-Track
Design Level
Head Assembly Series
1
Model Identification
PT. NO
.
HSG. CAP.
LB
S.
H
SG
. I.D. NO.
H
OU
SI
N
G MA
D
E I
N
Spicer®
Drive Axle
Introduction
4
3
CUST. PART NO.
2
SPEC. SERIAL NO.
Spicer
5
®
MODEL PART NO. RATIO
1
MADE IN:
1 - Country or origin
2 - Axle model identification
3 - Specification number assigned to the axle built by Spicer.
Identifies all component parts of the axle including
special OEM requirements such as yokes or flanges.
6
Spicer
7
CUST. PART NO.
SPEC. SERIAL NO.
MODEL PART NO. RATIO
MADE IN:
®
Rear Axle (Top View)
4 - OEM part number assigned to the axle build
5 - Carrier assembly serial number assigned by the
manufacturing plant
6 - Axle gear ratio
7 - Carrier assembly production or service part number
Parts Identification
Axle Housing
1 - ID Tag
2
Axle Shaft
2
1
2 - Axle shaft part number
Introduction
Introduction
Ring Gear and Pinion
Note: Ring gear and drive pinion are matched parts and must
be replaced in sets.
1 - Part number
2 - Number of ring gear teeth
3 - Manufacturing numbers
4 - Matching gear set number
5 - Number of pinion teeth
6 - Date code
7 - Indicates genuine Spicer parts
8 - Heat code
3
Introduction
4
Inspection
Inspection
Inspection
Failure Analysis
Failure analysis is the process of determining the original
cause of a component failure in order to keep it from Inspection
happening again. Too often, when a failed component is
replaced without determining its cause, there will be a recurring failure. If a carrier housing is opened, revealing a ring
gear with a broken tooth, it is not enough to settle on the broken tooth as the cause of the carrier failure. Other parts of the
carrier must be examined. For a thorough understanding of
the failure and possible insight into related problems, the
technician needs to observe the overall condition of the vehicle.
No one benefits when a failed component goes on the junk
pile with the cause unknown. Nothing is more disturbing to a
customer than a repeat failure. Systematically analyzing a failure to prevent a repeat occurrence assures quality service by
avoiding unnecessary downtime and further expense to the
customer.
The true cause of a failure can be better determined by
knowing what to look for, determining how a piece of the
equipment was running, and learning about previous problems. In the case of a rebuilt rear axle, mismatched gears may
have been installed.
The more successful shops prevent repeat equipment failures
by developing good failure analysis practices. Knowing how
to diagnose the cause of a premature failure is one of the
prerequisites of a good heavy-equipment technician.
Document the Problem
Here are some guidelines for starting to learn about a failure.
• Talk to the operator of the truck.
• Look at the service records.
• Find out when the truck was last serviced.
Ask the following questions:
• In what type of service is the truck being used?
• Has this particular failure occurred before?
• How was the truck working prior to the failure?
You need to be a good listener. Sometimes insignificant or
unrelated symptoms can point to the cause of the failure.
Ask the following questions:
• Was the vehicle operating at normal temperatures?
• Were the gauges showing normal ranges of operation?
• Was there any unusual noise or vibration?
After listening, review the previous repair and maintenance
records. If there is more than one driver, talk to all of them
and compare their observations for consistency with the
service and maintenance records. Verify the chassis Vehicle
Identification Number (VIN) number from the vehicle identification plate, as well as the mileage and hours on the vehicle.
How to Diagnose a Failure
The following five steps are an effective approach to good
failure diagnostics.
1. Document the problem.
2. Make a preliminary investigation.
3. Prepare the parts for inspection.
4. Find the cause of the failure.
5. Correct the cause of the problem.
5
Inspection
WARNING
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.
• Look for leaks, cracks or other damage that can
point to the cause of the failure.
• Make note of obvious leaks around plugs and seals.
A missing fill or drain plug would be an obvious
cause for concern.
• Look for cracks in the carrier housing (harder to see,
but sometimes visible).
• Does the general mechanical condition of the vehicle
indicate proper maintenance or are there signs of
neglect?
• Are the tires in good condition and do the sizes
match?
• If equipped with a torque-limiting device, is it working properly?
During the preliminary investigation, write down anything
out of the ordinary for later reference. Items that appear
insignificant now may take on more importance when the
subassemblies are torn down.
Prepare the Parts for Inspection
After the preliminary investigation, locate the failure and prepare the part for examination. In carrier failure analysis, it may
be necessary to disassemble the unit.
• When disassembling subassemblies and parts, do
not clean the parts immediately since cleaning may
destroy some of the evidence.
• When tearing down the drive axle, do it in the recommended manner. Minimize any further damage to the
unit.
• Ask more questions when examining the interior of
the carrier. Does the lubricant meet the manufacturer
specifications regarding quality, quantity and viscosity? 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 failure is caused by a lack of lubrication, you must determine if
there was an external leak. Obviously, if there is an external
leak, just replacing the failed gear is not going to correct the
situation.
Another important consideration is to determine the specific
type of failure which can be a valuable indicator for the cause
of failure. The following pages show different types of failures
and possible causes. Use this as a guide in determining types
of failures and to correct problems.
Correct the Cause of the Problem
Once the cause of the problem has been determined, refer to
the appropriate service manual to perform the repairs.
Inspection
Clean
1. Wash steel parts with ground or polished surfaces
in solvent. There are many suitable commercial
solvents available. Kerosene and diesel fuel are
acceptable.
Gasoline is not an acceptable solvent because of its
extreme combustibility. It is unsafe in the workshop environment.
2. Wash castings or other rough parts in solvent or
clean in hot solution tanks using mild alkali solutions.
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.
• If parts are to be stored: Coat with oil, wrap in
corrosion resistant paper and store in a clean,
dry place.
Inspect Axle Housing
6
Inspection
Inspection
CAUTION
1
2
1 - Axle housing
2 - Machined surface
Axle housing inspection and repairs are limited to the
following checks or repairs.
• Visually inspect axle housing for cracks, nicks, and
burrs on machined surfaces.
• Check carrier bolt holes and studs for foreign
material.
• Replace damaged fasteners. Look for loose studs or
cross threaded holes.
Any damage which affects the alignment or structural integrity 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.
• Check all seals and gaskets.
Note: Replace conventional gaskets with silicone rubber
gasket compound (included in many repair kits). The
compound provides a more effective seal against lube
seepage and is easier to remove from mating surfaces
when replacing parts.
• Bearings for loose fit on drive pinion, pilot bearing,
and differential bearings.
• All fasteners for rounded heads, bends, cracks, or
damaged threads.
• Inspect machined surfaces of cast or malleable
parts. They must be free of nicks, burrs, cracks,
scoring, and wear.
• Look for elongation of drilled holes, wear on surfaces 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.
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
In addition, inspect the following for damage:
• Differential gearing.
signs of excessive heat in the axle and are usually
related to low lubrication levels or improper lubrication practices.
7
Inspection
8
Carrier Assembly
Differential Carrier Assembly
1
2
3
Exploded Parts View
Carrier Assembly
1 - Carrier fasteners
2 - Carrier assembly
3 - Single axle assembly
9
Carrier Assembly
1 - Apply silicone gasket in this pattern
Remove Differential Carrier
Note: The removal of the forward carrier does not require dis-
connecting of the inter-axle driveline and removal of the
output shaft yoke assembly as most other Spicer tandems require.
Standard Differentials
1. Block the vehicle.
2. Drain axle lubricant.
3. Disconnect driveline.
4. Disconnect lead wires to the selector switch and air
line at shift cylinder.
5. Remove axle shafts.
WARNING:
WARNING
Do not lie under carrier after fasteners are removed. Use
transmission jack to support differential carrier assembly
prior to loosening fasteners.
6. To remove axle shaft, remove axle stud nuts.
(If used, remove lock washers and taper dowels.)
Install Differential Carrier
IMPORTANT
Before installing carrier assembly, inspect and thoroughly
clean interior of axle housing using an appropriate solvent
and clean rag.
1. Apply Spicer approved RTV compound on axle
housing mating surface as shown in the illustration.
Completely remove all old gasket material prior to
applying new material. Compound will set in 5 minutes. Install carrier before compound sets or reapply.
1
7. Remove axle shafts.
Note: All models in this publication use axle shafts with
unequal lengths. Axle shafts may also be location specific with various wheel equipment. Do not misplace axle
shafts from their intended location. Identify left and right
shafts for reference during reassembly.
TIP: If necessary, loosen dowels
drift in the center of the shaft head and striking drift
with a sharp blow with a hammer.
CAUTION:
CAUTION
Do not strike the shaft head with a steel hammer. Do not use
chisels or wedges to loosen shaft or dowels.
8. Remove carrier cap screws, nuts, and lock washers.
9. Remove differential carrier assembly.
by holding
a brass
TIP: To assist in installing complete differential carrier use two pieces of threaded rod (M16 X 1.5)
threaded into carrier cap screw holes. Rod should be
approximately 6" long. Use these to pilot the carrier
o the housing.
int
2. Install carrier to housing, lock washers, cap screws
and nuts. Torque to proper specification. Torque to
250–290 lb-ft. (339–393 N•m).
3. Install axle shafts and axle stud nuts. (If used, also
install lock washers and tapered dowels.)
4. Add axle lubricant. Fill to bottom of filler hole.
5. Connect driveline, making sure all yokes are in
phase. Lubricate u-joints.
10
Drive Pinion
Drive Pinion Assembly
1
2
3
4
5
6
7
8
9
10
Parts Exploded View
Drive Pinion
1 - Pinion pilot bearing
2 - Pinion
3 - Pinion bearing cone - inner
4 - Pinion bearing cup - inner
5 - Pinion bearing spacer
6 - Pinion bearing cup - outer
7 - Pinion bearing cone - outer
8 - Oil seal
9 - Yoke
10 - Pinion nut
11
Drive Pinion
1
1
1 - Threaded Jack Holes
1
1
1 - Slots
CAUTION
Pinion Removal
1. If a pilot web is used, remove the web cap screws.
a. For S190 disassembly, install a M10 x 1.50 bolt
in the threaded jack holes found in-between the
pilot web cap screws.
b. For S190 disassembly, use the pry slots pro-
vided at each end of the pilot web.
2. Before the pinion nut can be loosened, you must destake the nut from the slot of the pinion.
3. To de-stake the nut, use a chisel or drift with a round
tip. The flange of the nut must be pushed far enough
outward so that the staked area will not interfere with
the pinion threads when the nut is removed. See diagram below.
Failure to de-stake the pinion nut will result in damage to
the drive pinion threads when removed. The pinion nut
should never be reused, always replace with new.
1
12
2
3
1 - Round Tipped Chisel
2 - Machined Slot In Pinion
3 - Nuts Staking Flange
4. Remove the pinion nut.
Drive Pinion
Drive Pinion
1 - Carrier Assembly
2 - Press
3 - Pinion
4 - Wood Block
2
1
3
4
1 - Press
1
IMPORTANT
5. Place carrier assembly into a press, place a 2" x 6" x
6" wood block under the pinion. This will ensure that
when the pinion is pressed free from the bearings
the pinion will not be damaged.
The bearing spacer will be reused or used as a starting
point when resetting the pinion bearing preload. Do not discard this part.
6. Use the proper pressing tool to press the end of the
pinion until free from the pinion bearings.
13
Drive Pinion
1
1 - Press
IMPORTANT
Drive Pinion Overhaul and Assembly
The preload of the bearings on the drive pinion is adjusted by
a spacer between the inner and outer bearing cones and the
helical gear. The preload is adjusted by changing the thickness
of the spacer. A thicker spacer will decrease the preload, a
thinner spacer will increase the bearing preload.
The following procedure covers both the forward and rear axle
carrier overhaul and assembly.
Note: See carrier disassembly for instructions on pinion and
yoke removal.
1. If the model of axle uses a pilot bearing, remove the
bearing using a split-type puller. Use two procedure
steps to remove each bearing.
a. Mount the puller vertically to separate the bear-
ing from the pinion. This action will force the
puller halves behind the bearing race and start
moving the bearing from the pinion.
2. Remove the inner pinion bearing cone from the pinion using a split-type puller. Use two procedure
steps to remove each bearing.
a. Mount the puller vertically to separate the bear-
ing from the pinion. This action will force the
puller halves behind the bearing race and start
moving the bearing from the pinion.
b. Mount the puller horizontally to press the bear-
ing from the pinion.
b. Mount the puller horizontally to press the bear-
ing from the pinion.
Use the correctly sized spacer. Do not use shim stock or
14
Drive Pinion
JD
77
8
5
405
DANA
86
L
7
0
3
8
grind spacers. These practices can lead to loss of bearing
preload and gear or bearing failure.
To prevent bearing damage, use suitable sleeve that only
contacts the inner race of bearing cone.
3. Use a press sleeve to install the inner bearing cone
and pilot bearing, if used, onto the pinion. Apply
pressure until the bottom of the cone touches the
shoulder of the pinion. Apply lubricant to the cone of
the bearing.
6-39
4. If removed, install the inner and outer bearing cups
into the carrier.
If replacement of the output shaft side gear
c.
bearing cup is necessary, use either of the following methods:
Weld: Place a weld bead around the inside of
the cup, when the weld cools the cup will fall
out.
Hammer: Use a rolling head prybar to get under
the cup and then, with a hammer and drift from
the back side of carrier, tap out bearing cup.
d. To install the outer bearing cup, place the carrier
in a press with the top of the carrier facing up.
e. Place the cup in the bore, use a sleeve or bear-
ing driver tool to press the cup until it is fully
seated. Use a feeler gage to make sure the cup
is fully seated.
Drive Pinion
a. To install the inner bearing cup, place the carrier
in a press with the bottom of the carrier facing
up.
b. Place the cup in the bore, use a sleeve or bear-
ing driver tool to press the cup until it is fully
seated. Use a feeler gage to make sure the cup
is fully se
ated.
Note: If a press is not available, use a sleeve or bearing driver
and a hammer to install the cups.
5. Place the pinion on a 6”
the carrier over the pinion.
lower
x 6” x 6” block of wood and
6. Install the pinion spacer.
15
Drive Pinion
Note: If you are using the same drive pinion, use the same
spacer that was originally installed in the assembly. If
the drive pinion is to be replaced, the original spacer will
be used as the starting point of adjustment.
7. Install the outer bearing cone.
9. Align a 6” x 6” x 6” wood block under the drive pin-
ion, then lower the carrier and pinion assembly into
a press so that it is supported by the block.
10. Remove the pinion nut.
11. Place a press sleeve over the top of the outer bearing
cone. Use the press to apply 5 tons of force. It is
important to rotate the carrier slightly to make sure
that the rollers of the bearing are properly seated.
8. Install a pinion nut finger tight. This will hold the pinion in place while it is positioned into the press.
16
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