Spicer D170, D190, D590 User Manual

Spicer

®

Tandem Drive Axles

Service Manual

AXSM0057
September 2013

D170 Series

D190 Series

D590 Series

General Information

General Information

The description and specifications contained in this service publication are current at the time of printing.

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

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

Important Notice

This symbol is used throughout this
manual to call attention to procedures
where carelessness or failure to follow
specific instructions may result in
personal injury and/or component
damage.

Departure from the instructions, choice
of tools, materials and recommended
parts mentioned in this publication
may jeopardize the personal safety
of the service technician or vehicle
operator.

Always use genuine Spicer replacement parts.

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 installation
procedures to aid in the service of this unit.

Table of Contents

Table of Contents

Wheel
Differential
Assembly
page 36

Carrier
Assembly
page 23

Table of Contents

Drive
Pinion
page 25

Power
Divider
page 12

Seals
page 68

Wheel
End Seal
page 68

Wheel
Differential
Lock
page 57

Output Shaft
Assembly &
Rear Cover
page 58

Inter-Axle
Lockout
page 11

Differential
Carrier
Assembly
page 8

Housing
Breather
page 67

Lubrication
page 75

General Information

Introduction .....................................................................1

Model Identification .........................................................2

Parts Identification ..........................................................2

Failure Analysis ...............................................................4

Prepare the Parts for Inspection ......................................5

Inspection ........................................................................6

Endplay Procedure ...........................................................7

Check Input Shaft Endplay (Forward Axle) .......................7

Check Output Shaft Endplay (Forward Axle) ....................7

Differential Carrier Assembly - Parts................................8

Remove Differential Carrier - (Forward and Rear) ............9

Install Differential Carrier (Forward and Rear) ................10

IAD Differential Lock Disassembly ................................. 11

Inter-Axle Lockout .........................................................11

Power Divider - Parts Exploded View ............................. 12

Power Divider Disassembly -

Forward Carrier Assembly ...................................13-14

Pump Disassembly ........................................................ 15

Lube Manifold Disassembly ........................................... 16

Manifold Assembly ........................................................17

Pump Assembly ............................................................. 18

Power Divider Assembly .......................................... 19-22

Carrier Disassembly -

Forward Carrier Assembly .................................. 23-24

Pinion Removal ........................................................ 25-26

Forward Axle Pinion Assembly -

Parts Exploded View .................................................27

Rear Axle Pinion Assembly -

Parts Exploded View .................................................27

Drive Pinion Overhaul and Assembly -

Forward and Rear Carrier Assembly ................... 28-34

Wheel Differential - Parts Exploded View ...................... 35

Wheel Differential Disassembly - Before July 2013

Forward Carrier Assembly .................................. 36-37

Wheel Differential Assembly -

Forward Carrier Assembly ..................................38-40

Install Wheel Differential Assembly -

Forward Carrier Assembly .................................. 41-45

Wheel Differential Disassembly - After July 2013

Forward Carrier Assembly .................................. 46-47

Wheel Differential Assembly -

Forward Carrier Assembly .................................. 48-50

Install Wheel Differential Assembly -

Forward Carrier Assembly .................................. 51-53

Adjust Tooth Contact Position .................................. 54-55

Wheel Differential Lock - Parts Exploded View.............. 56

Install and Adjust Wheel Differential Lock ......................57

Housing and Output Shaft Assembly -

Parts Exploded View ................................................ 58

Remove Output Shaft Assembly ...............................59-60

Overhaul and Assemble Output Shaft Assembly ....... 61-62

Measure ....................................................................... 63

Replace Seal ................................................................. 64

Guidelines for Reusing Yoke .......................................... 65

Service Kit .................................................................... 66

Housing Breather ...........................................................67

Wheel End Seal - Parts Exploded View ......................... 68

Remove and Overhaul Wheel End Seal .......................... 69

Adjust Wheel Bearing............................................... 70-71

Verify Wheel Endplay Procedure ....................................72

Readjust Wheel Endplay Procedure ................................72

Lubricate Wheel End -

Wheel Ends with an Oil Fill Hole ................................73

Wheel Ends Without Oil Fill Hole ...............................74

General Lubrication Information -

Approved Lubricants .................................................75

Recommendations for Viscosity/Ambient

Temperatur e .............................................................75

Lube Change Intervals ...................................................76

Change Lube

Drain ....................................................................... 77

Fill ........................................................................... 77

Standpipes .............................................................. 78-79

Proper Vehicle Towing ................................................... 80

Power Divider Operation

(Power Flow and Torque Distribution) ................. 81-82

Operate Wheel Differential Assembly ............................ 83

Control Systems for Differential Lock ............................ 83

Direct Driver - Controlled System.................................. 84

Wheel Differential Lock ............................................85-86

Power Divider - Parts Exploded View .............................87

Forward Axle Pinion Assembly -

Parts Exploded View ................................................ 88

Rear Axle Pinion Assembly -

Parts Exploded View ................................................ 89

Wheel Differential -

Parts Exploded View ................................................ 90

Wheel Differential Lock -

Parts Exploded View .................................................91

Housing and Output Shaft Assembly -

Parts Exploded View ................................................ 92

Fastener Torque Specifications ..................................... 93

General Information

Introduction

Dana Commercial Vehicle Systems Division, presents this
publication to aid in maintenance and overhaul of Spicer
tandem drive axles.

Instructions contained cover the models listed. Their design is
similar, with primarily differences in load capacity. Capacity
variations are achieved by combining basic differential carrier
assemblies with different axle housings, axle shafts and wheel
equipment.

The suffix letter “P” in the model number indicates optional
lube pump. The pump is designed to provide additional lubrication
to the inter-axle differential and related parts.

Model Listing

General Information

Model Information

The following models are included in this publication:

Heavy Tandems

D40-170 D46-590HP

D40-170(P) D50-170

D40-170D(P) D52-190P

D46-170 D52-190DP

D46-170(P) D52-590P

D46-170D(P) D60-190P

D46-170H D60-590P

D46-170H(P) D70-190P

D46-170DH(P)

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

D 46-1 7 0 D

Options

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

Drive Axle

General Information

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.

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 Axle Shaft

®

S.

Spicer

O.

P. LB

PT. N

.

E IN

. NO

HSG. CA

. I.D

MAD

HSG

OUSING

H

1 - ID Tag

1

2 - Axle shaft part number

2

2

Ring Gear and Pinion

Note: Ring gear and drive pinion are matched parts and

must be replaced in sets.

General Information

127381

1

SPICER

7

7

5

41-8

127

SPICER

1

8

8-41

127

127428

NL2

2

G

0H

17

3

General Information

L7038

G

17

OF

6

8

6

3

4

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

L

6-39

JD77

85405

86

DANA

7

0

3

8

4

3

Failure Analysis

Inspection

Failure analysis is the process of determining the original
cause of a component failure in order to keep it from
happening again. Too often, when a failed component is
replaced without determining its cause, there will be a recurring
failure. If a carrier housing is opened, revealing a ring
gear with a broken tooth, it is not enough to settle on the broken
tooth as the cause of the carrier failure. Other parts of the
carrier must be examined. For a thorough understanding of
the failure and possible insight into related problems, the
technician needs to observe the overall condition of the vehicle.

No one benefits when a failed component goes on the junk
pile with the cause unknown. Nothing is more disturbing to a
customer than a repeat failure. Systematically analyzing a failure
to prevent a repeat occurrence assures quality service by
avoiding unnecessary downtime and further expense to the
customer.

The true cause of a failure can be better determined by
knowing what to look for, determining how a piece of the
equipment was running, and learning about previous problems.
In the case of a rebuilt rear axle, mismatched gears may
have been installed.

The more successful shops prevent repeat equipment failures
by developing good failure analysis practices. Knowing how
to 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.

4

Inspection

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 carrie r 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.

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
ure is caused by a lack of lubrication, you must determine if
there was an external leak. Obviously, if there is an external
leak, just replacing the failed gear is not going to correct the
situation.

Another important consideration is to determine the specific
type of failure which can be a valuable indicator for the cause
of failure. The following pages show different types of failures
and possible causes. Use this as a guide in determining types
of failures and to correct problems.

Correct the Cause of the Problem

Once the cause of the problem has been determined, refer to
the appropriate service manual to perform the repairs.

failed part and finding that the fail-

Inspection

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.

5

Inspection

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.

WARNING

Gasoline is not an acceptable solvent because of its
extreme combustibility. It is unsafe in the workshop envi­ronment.

2. Wash castings or other rough parts in solvent or

clean in hot 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

Axle housing inspection and repairs are limited to the
following checks or repairs.

• Visually inspect axle housing for

burrs on machined surfaces.

• Check carrier bolt holes and studs for foreign

material.

• Replace damaged fasteners. Look for loose studs or

cross threaded holes.

CAUTION

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.

cracks, nicks, and

Note: Replace conventional gaskets with silicone rubber

gasket compound (included in many repair kits). The
compound provides a more effective seal against lube
seepage and is easier to remove from mating surfaces
when replacing parts.

1

2

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

of excessive heat in the axle and are usually

signs
related to low lubrication levels or improper lubrica­tion practices.

In addition, inspect the following for damage:

• Differential gearing.

• Bearings for loose fit on drive pinion, pilot bearing,

and differential bearings.

• All fasteners for rounded heads, bends, cracks, or
damaged threads.

• Inspect machined surfaces of cast or malleable
parts. They must be free of nicks, burrs, cracks,
scoring, and wear.

• Look for elongation of drilled holes, wear on sur­faces machined for bearing fits and nicks or burrs in
mating surfaces.

Inspect Primary Gearing

Before reusing a primary gearset, inspect teeth for signs of
excessive wear. Check tooth contact pattern for evidence of
incorrect adjustment.

6

Inspection

Endplay Procedure

Check Input Shaft Endplay (Forward Axle)

Note: Before disassembling the power divider, measure and

record input shaft endplay.

1. Position dial indicator at yoke end of input shaft.

2. Push in on input shaft and zero the dial indicator.

3. Using a pry bar, move input shaft axially and mea­sure/record endplay.

Adjustment

Correct endplay for a new assembly is 0.001" to 0.005". See
the “Input Shaft Endplay" procedure in the "Power Divider
Assembly” section for proper endplay adjustment procedure.

Check Output Shaft Endplay (Forward Axle)

1. Position dial indicator at yoke end of output shaft.

2. Push in on output shaft and zero the dial indicator.

3. Using a pry bar, move output shaft axially and mea­sure/record endplay.

Adjustment

Correct endplay for a new assembly is 0.001" to 0.045". The
maximum endplay for a used assembly is no more than

0.045". If endplay is incorrect, contact Dana.

Inspection

7

Differential Carrier Assembly

Differential Carrier Assembly - Parts

1

1 - Carrier fasteners
2 - Carrier assembly
3 - Forward axle assembly
4 - Rear axle assembly

4

3

1

2

2

8

Differential Carrier Assembly

Remove Differential Carrier (Forward and Rear)

Note: The removal of the forward carrier does not require

disconnecting 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. Rear Only: Disconnect inter-axle driveline.

4. Front Only: Disconnect main driveline.

5. Front Only: Disconnect differential lockout air line.

6. Disconnect lead wires to the selector switch and air
line at shift cylinder.

7. Remove axle shafts.

WARNING

Do not lie under carrier after fasteners are removed. Use
transmission jack to support differential carrier assembly
prior to loosening fasteners.

8. To remove axle shaft, remove axle stud nuts.
(If used, remove lock washers and taper dowels.)

9. 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 by holding a brass
drift in the center of the shaft head and striking drift
with a sharp blow with a hammer.

CAUTION

Do not strike the shaft head with a steel hammer. Do not
use chisels or wedges to loosen shaft or dowels.

10. Remove carrier capscrews, nuts, and lock washers.

11. Remove differential carrier assembly.

Differential Carrier

Assembly

9

Differential Carrier Assembly

Install Differential Carrier (Forward and Rear)

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
applyi ng new m aterial. Compound will set in
5 minutes. Install carrier before compound sets or
reapply.

1

Tip: To assist in installing co mplete differential car-

rier use two pieces of threaded rod (M16 X 1.5)
threaded into carrier capscrew holes. Rod sh ould be
approximately 6" long. Use these to pilo
into the housing.

2. In stall carrier to housing, lo ck washers, capscrews
and nuts. To rque to proper specification. Torque to
250–290 lbs. ft. (339–393 N•m).

3. Install axle shafts and axle stud nuts. (If used, also

lock washers and tapered dowels. )

inst all

4. Add axle lub ricant. Fill to bottom of filler hole.

5. Rear Only: Connect inter-axle driveline, making sure
all yokes are in phase. Lubricate u-joints.

6. Front Only: Connect main driveline, making sure all
yokes are in phase. Lubricate u-joints.

7. Front Only: Connect differential lockout air line.

t the carrier

1 - Apply silicone gasket in this pattern

10

IAD Differential Lock Disassembly

Inter-Axle Lockout

Inter-Axle Lockout

Integral Shift Cylinder with Welded Push Rod Assembly

2

3

4

5

1 - Compression spring
2 - Shift fork assembly
3 - Piston
4 - O-ring
5 - Piston cover

1

Disassembly

1. With the axle installed in vehicle, place differential
lock selector valve in the disengaged or unlocked
position.

2. Disconnect the differential lockout air line.

3. Remove the piston cover.

4. Remove the piston and o-ring assembly with pliers.

Note: In order to remove the shift fork and push rod parts,

first remove the power divider cover. See the Power
Divider section.

Assembly

1. Assemble the o-ring onto the piston. Apply silicone
grease to the o-ring.

2. Gently push the piston o-ring assembly into the lock­out cylinder bore. Make sure the piston assembly is
pushed in all the way.

3. Install the piston cover. Tighten by hand and then
torque from 50-75 lbs. ft. (68-102 N•m).

4. Connect the differential lock air line.

Power Divider

5. Cycle the lockout to make sure there ar
and the system is operating properly.

e no leaks

11

Power Divider - Parts Exploded View

1

2

3

19

20

21

22

25

26

23

24

Power Divider

4

5

6

27

28

43

42

41

29

44

10

11

13

35

High Entry Input

Shaft Assembly

14

15

16

36

17

18

7

8

9

11

31

12

32

33

34

39

40

37

30

38

1 - Output shaft nut
2 - Output yoke
3 - Output seal
4 - Output shaft bearing snap ring
5 - Outer bearing cup
6 - Outer bearing cone
7 - Inner bearing cone
8 - Inner bearing cup
9 - Output shaft
10 - Seal manifold
11 - Clamp
12 - Seal manifold feed tube
13 - Sump screen
14 - Output side gear bearing cup
15 - Output side gear bearing cone

12

16 - Pin
17 - Output side gear
18 - Pump
19 - Inter-axle differential
20 - Helical side gear
21 - Thrust washer
22 - Lockout sliding clutch
23 - Shift fork spring
24 - Shift fork assembly
25 - V-ring
26 - Input shaft
27 - Input shaft
28 - Input shaft bearing cone
29 - Carrier housing
30 - Locking capscrew

31 - Input cover
32 - Input cover capscrew
33 - Bearing cup and cage
34 - Input seal
35 - Input yoke
36 - Input nut
37 - Piston
38 - O-ring
39 - Piston

cover
40 - Pinion cover
41 - Input cover capscrew
42 - Input cover
43 - Carrier housing

Power Divider

Power Divider Disassembly - Forward Carrier Assembly

Use these instructions with the carrier assembly in or out of
the vehicle.

1. Disconnect the main driveline.

2. Disconnect the lockout airline.

3. Drain the axle lubricant into a clean oil pan.

4. Remove the input yoke nut and yoke.

5. 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 input shaft threads when the nut is removed. See
diagrams below.

CAUTION

Failure to de-stake the pinion nut will result in damage to
the drive pinion threads when removed. The pinion nut
should never be reused, always replace with new.

1

CAUTION

During removal of the power divider cover, the inter-axle
differential (IAD), in put shaft assembly or IAD shift system
may fall from the carrier if not careful. Use caution to pre­vent injury or damage.

Power Divider

8. For High Entry Applications Only:
Remove the input shaft and gear assembly. Proceed
to step 13.

2

1 - Round Tipped Chisel
2 - Machined Slot In Pinion
3 - Nuts Staking Flange

6. Remove the input seal.

Note: Do not reuse the seals after disassembly.

7. Remove the power divider cover assembly.
tabs provided to free the cover from the carrier
assembly.

3

Use the

9. Remove the input shaft, sliding clutch, shift fork and
spring as an assembly.

13

Power Divider

10. Remove the thrust washer and helical side gear.

11. Remove the inter-axle differential assembly.

12. Remove the output side gear and pump assembly.

14. Input cage is threaded in to the PDU cover, use the
proper tool to remove the cage from the cover.

15. Use a suitable bearing puller to replace the input
bearing cup.

Note: In August of 2006 the piloted input adjuster design was

implemented. The lockin and fastener was replaced with
a 12mm stud and jam nut. It is not recommended that
the piloted designed adjuster and cover be mixed with
the non-piloted design.

Cover Pilot

13. To replace the input bearing cup, back off the
bearing cage locking fastener or jam nut and stud.

14

Adjuster Pilot

Pump Disassembly

For output side gear and/or pump replacement, follow the
procedure below.

1. Remove the output side gear bearing cone, if
required.

1

2

Power Divider

3. Remove pump from the output side gear.

Power Divider

4. Remove the output side gear bearing cup from the
carrier with the proper bearing puller tool.

1 - Press
2 - Press Tool

2. Remove pump locking dowel pin from the hole in the
output side gear hub.

15

Power Divider

Lube Manifold Disassembly

1. Disconnect the hose from the lube manifold.

2. Remove the manifold assembly by prying it out
around the inner diameter.

IMPORTANT

Once removed, the seal manifold assembly cannot be
reused. This component should always be replaced with
new. Use the same removal procedure for the output side
gear seal removal on the non-pump models.

Note: Seals are not sold separately from the manifold.

1

1 - Barbed Nipple

16

Manifold Assembly

Power Divider

1. Install the manifold assembly into the output side
gear bore in the carrier. Make sure the barbed nipple
is lined up with the open ing in the carrier casting.

1

1 - Barbed Nipple

Note: For non-pump manifold installation, it is important to

line up the oil inlet path hole in the manifold with the oil
path opening in the carrier manifold casting.

1

Power Divider

1 - Manifold Oil Inlet Hole

5. Attach the suction screen to the end of the hose.

2. Install the hose clamp on the hose, push the hose
onto the barbed fitting and slide the clamp over the
barbed nipple.

3. Route the suction end of the hose through the holes
in the carrier casting to the bottom of the carrier.

4. Fully press the manifold assembly into position.

Note: Use care when pressing the manifold assembly to avoid

damaging the seals and barbed nipple. Do not over­press plastic.

If the unit does not have a pump, go to the Power Divider
Assembly section

If the unit contains a pump, go to the Pump Assembly section.

.

17

Pump Assembly

Power Divider

Use these instructions with the carrier assembly in or out of
the vehicle.

If the unit does not have a pump, go to the Power Divider
Assembly section.

Note: Keep work area clean. Dirt is an abrasive and will cause

premature wear of the otherwise serviceable parts.

Note: For non-pump models, see page 17 for output side gear

seal manifold installation.

Note: Only service the power divider if the differential carrier

is secured in a stand or while the axle is still attached to
the housing.

CAUTION

During installation of power divider cover, the inter-axle
differential (IAD), input shaft assembly or IAD shift system
parts may fall from the carrier if not careful. Use caution to
prevent injury or damage.

1. Install the pump into the output side gear so that the
pump shaft is facing toward the teeth end of the side
gear.

2. Install the pump locking
the output side gear hub. Make sure the pin is lined
up with the machined slot in the pump body.

1

1 - Machined Slot
2 - Pin

dowel pin into the hole in

2

18

Power Divider Assembly

Power Divider

1. Install output side gear bearing cone and press until
fully seated. Use proper press tools.

1

2

1 - Press
2 - Press Tool

2. Fully press the output side gear bearing cup into the
carrier seat.

Note: Install

5. Install the helical side gear so that the clutch teeth

in the same direction as removed.

are facing upward in the carrier.

Power Divider

IMPORTANT

When inserting the input shaft assembly through the IAD
components, turn the shaft as necessary to align the slot of
the input shaft with the pump drive shaft. The keyway on the
threaded end of the input shaft is aligned with the pump
driver slot. This can be used as a visual aid during assem­bly.

3. Install the output side gear. Apply a thin layer of oil to
the output side gear boss before installing into the
seal.

Note: For non-pump models, fill bore of output side gear

models with synthetic grease.

4. Install the inter-axle differential.

6. Install helical side gear thrust washer.

19

Power Divider

Helical Gear Bushing Replacement:

a. If bushing removal is needed, the bushings

must exit from the thrust side of the helical side
gear.

1

1 - Tap out bushings

b. Install bushings in helical side gear. Bushing

must be installed from the thrust side of the
helical side gear. See illustration for installation
depth.

1

2

9. Install the sliding clutch so that the teeth are facing
up.

10. If removed, press the new input bearing cone in
place until seated using the proper press sleeve or
bearing installer.

1

5

3

4

6

1 - Press
2 - Sleeve
3 - 1st bushing (press to shoulder)
4 - Shoulder
5 - Sleeve
6 - 2nd bushing (recess 1.25 to 1.75 mm)

7. Install the helical side gear thrust washer.

8. Install the v-ring seal to the sliding clutch.

1.25 to 1.75 mm

1 - Press
2 - Press Tool
3 - Bearing
4 - Input shaft

11. For High Entry Applications Only:
Install shaft/gear assembly. Proceed to step 13.

20

Power Divider

12. Assemble the sliding clutch, shift fork and fork
spring to the input shaft and install assembly into
carrier. Make sure that the shift fork rod is piloted in
the carrier bore.

IMPORTANT

Before installing input cover, inspect and thoroughly clean
mating surfaces using an appropriate solvent and clean
rag.

14. Install input cover and capscrews. Torque to the
proper specifications. See the Torque Chart on page
D-1. Tighten fasteners in a criss cross pattern.

Power Divider

15. Install input shaft bearing adjuster, adjust inward
until snug against the bearing cone.

Note: Completely remove all old gasket material prior to

applying new Loctite.

13. Apply a bead of Loctite 518 to the carrier surface as
shown in the illustration.

190 Cover

Input Shaft Endplay

16. Back off input bearing cage one notch and check
endplay. Endplay should be between 0.001" to 0.005"
(0.03 to 0.13 mm). Rota
proper setting.

1

1 - One Notch

te cage in or out to get

170 Cover

21

Power Divider

17. A. For axles built before August 2006. Line up cage
slot with locking fastener. Turn in input cage locking
fastener and torque to the proper specifications.
See Torque Chart.

B. For axles built after August 2006 using the
piloted adjuster and cover. Torque locking stud to

20 ft. lbs. then torque jam nut to 65 ft. lbs.

Stud

Jam Nut

18. Install input seal using proper installation tool.

21. Verify that the endplay is between 0.001" to 0.005"
(0.03 to 0.13 mm). If not, readjust until the proper
specification is

achieved.

Note: High entry models should be set to an endplay of 0.001"

to 0.005".

22. Use a punch with a round tip to stake the pinion nuts
flange into the machined slot in the pinion shaft. See
diagram below.

CAUTION

19. Install yoke and slinger assembly.

20. Install input shaft flanged nut and torque to the
proper specifications. See Torque Chart.

Note: A torque multiplier is recommended. If difficulty achiev-

ing correct torque, torque the nut with the truck wheels
on the ground and with the axle shaft installed.

The stake must be deep enough to enter the machined slot
of the input shaft. See diagram below.

1

2

1 - Round Tipped Chisel
2 - Nuts Staking Flange
3 - Machined Slot In Pinion

WARNING

3

Failure to stake the pinion nut properly may result in the nut
coming loose during service. The pinion nut should never
be reused, always replace with new.

22

Carrier Assembly

Carrier Disassembly - Forward Carrier Assembly

For models having the wheel differential lock option, refer to
the following procedure. These parts must be removed first
before further disassembly of the wheel differential can take
place.

1. For ease of service, mount differential carrier in head
stand with the differential lock facing up.

2. Remove the threaded cylinder cap.

4. Remove the shift fork and sliding clutch assembly.

Note: Do not disassemble the shift fork from the sliding

clutch unless parts are to be replaced. To disassemble,
use a pin punch to remove spring pin from the fork leg.
The sliding clutch can now be removed from the fork.

Carrier Assembly

5. Remove the shift fork spring.

3. Remove the piston push rod from the shift fork.

Note: Omit this step if the ring gear is to be replaced. If the

ring gear is to be reused, check the tooth contact pattern
and ring gear backlash before disassembling the carrier
assembly. When checking the backlash, a yoke or helical
gear must be installed and to
cation to get an accurate reading. Best results are
obtained when tooth contact patterns are maintained in
used gearing.

rqued to the proper specifi-

23

Carrier Assembly

After July 2013

6.

Mount the differential carrier in a head stand with
the wheel differential facing upward.

Note: For easier disassembly, loosen but do not remove the

pinion nut.

7. Remove the carrier differential bearing cap
capscrews, flat washers and bearing caps.

8B. Using a long flat blade screwdriver on a pry bar,
back off one of the wheel diff. bearing adjusters
and remove.

9. Using a chain hoist and the proper strap, lift the
ring gear and wheel differential assembly from
the carrier.

Before July 2013

8A. Use Spicer’s wheel diff. bearing adjustment tool
(part number 513061) to back off the threaded
cups and remove.

1

1 - Threaded bearing cup
2 - Adjustment plate

24

2

Pinion Removal

1. For D170 assembly, remove the pinion cover. Use a
flat chisel to remove the cover from the carrier.

2. If a pilot web is used, remove the web capscrews.

a. For D190 disassembly, install a M10 x 1.5
bolt in the threaded jack holes found in-between
the pilot web capscrews.

Drive Pinion

b. For S190 disassembly, use the pry slots pro­vided at each end of the pilot web.

1

1

1 - Slots

1

1 - Threaded Jack Holes

3. Before the pinion nut can be loosened, you must de­stake the nut from the slot of the pinion.

1

Drive Pinion

4. 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 on next page.

25

Drive Pinion

CAUTION

Failure to de-stake the pinion nut will result in damage to
the drive pinion threads when removed. The pinion nut
should never be reused, always replace with new.

1

2

3

1 - Round Tipped Chisel
2 - Machined Slot In Pinion
3 - Nuts Staking Flange

7. Use the proper pressing tool to press the end of the
pinion until free from the pinion bearings.

1

1 - Press

5. Remove the pinion nut.

6. 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.

2

1

3

4

8. Forward Axles Only: Remove the pinion spacer and
the helical gear.

IMPORTANT

The bearing spacer will be reused or used as a starting
point when resetting the pinion bearing preload. Do not dis­card this part.

26

1 - Carrier Assembly
2 - Press
3 - Pinion
4 - Wood Block

Drive Pinion

Forward Axle Pinion Assembly - Parts Exploded View

1

2

1 - Pinion pilot bearing
2 - Pinion
3 - Pinion bearing cone - inner

4 - Pinion bearing cup - inner
5 - Pinion helical gear
6 - Pinion bearing spacer

Rear Axle Pinion Assembly - Parts Exploded View

2

3

1

2

2

3

4

5

6

7

8

9

7- Pinion bearing cup - outer
8 - Pinion bearing cone - outer
9 - Pinion nut

Drive Pinion

4

5

6

7

8

9

10

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

27

Drive Pinion

Drive Pinion Overhaul and Assembly - Forward and Rear Carrier 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
bearing 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
steps to remove each bearing.

split-type puller. Use two procedure

a. Mount the puller vertically to separate the
bearing 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
bearing from the pinion.

b. Mount the puller horizontally to press the
bearing from the pinion.

1

1 - Press

28

Drive Pinion

IMPORTANT

Use the correctly sized spacer. Do not use shim stock or
grind spacers. These practices can lead to loss of bearing
preload and gear or bearing failure.

To prevent bearing damage, use suitable sleeve that only
contacts the inner race of bearing cone.

3. Use 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.

854

05

6-39

DANA

JD7

86

7

c. If replacement of the output shaft side gear
bearing cup is necessary, use either of the following
methods:

L

7

0

3

8

3. If removed, install the inner and outer bearing cups
into the carrier.

a. To install the inner bearing cup, place the carrier
in a press with the bottom of the carrier facing
up.

b. Place the cup in the bore, use a sleeve or
bearing driver tool to press the cup until it is
fully seated. Use a feeler gage to make sure the
cup is fully seated.

Weld: Place a weld bead around the inside of
the cup, when the weld cools the cup will fall
out.

Hammer: Use slipper to get under the cup and
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
bearing 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

Note: If a press is not available, use a sleeve or bearing driver

and a hammer to install the cups.

29

Drive Pinion

5. For Forward Carriers Only: Install the helical with
the larger boss side facing down in the carrier. Align
the helical gear between the inner and outer bearing
cups.

1

7. To align the splines of the helical gear to the
pinion, use a old pinion nut with a metal ring welded
to the top, thread onto the pinion. Then lift the pinion
while aligning the two splined surfaces.

8. Install the pinion spacer.

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.

1 - Large - Long Boss

6. Place the pinion on a 6 x 6 x 6 block of wood and
lower the carrier over the pinion.

30

Drive Pinion

9. Install the outer bearing cone.

10. Install a pinion nut finger tight. This will hold the pin­ion in place while it is positioned into the press.

11. Align a 6" x 6" x 6" wood block under the drive pin­ion, then lower the carrier and pinion assembly into
a press so that it is supported by the block.

12. Remove the pinion nut.

13. 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.

Drive Pinion

31

Drive Pinion

14. With 5 tons of force on the press, you should be able
to feel a small amount of drag from the bearing as
you rotate the carrier. If the carrier turns with no
drag at all, the pinion spacer thickness should be
decreased by using a thinner spacer. If the carrier is
hard to turn, the spacer thickness must be
increased.

16. Run the nut down with an impact gun. The pinion
should still have the same slight drag that was
obtained in the press.

17. Secure the carrier in a head stand, rotate carrier so
the pinion nut can be torqued.

15. Remove the carrier from the press and reinstall the
pinion nut.

32

Drive Pinion

TIP: A torquing wedge can be made to hold the heli-

cal gear from turning while the nut is torqued.

18. Install the wedge between the carrier wall and the
teeth of the helical gear.

20. Use an lbs. in. torque wrench and correct socket to
check the rolling torque of the pinion. Read torque
while rotating the assembly. Record the rotating
torque, not the breakaway torque. Torque must be
between 20 to 50 lbs. in. If the torque recorded is not
within the specified torque, the pinion spacer must
be changed. Repeat Steps 6-17.

21. Once

the proper rolling torque is achieved, use a
punch with a round head to stake the nut collar into
the slot in the pinion.

1

1 - Wedge

19. Torque the nut to 800-1000 lbs. ft.
(1084-1355 N•m).

TIP: If you are unable to torque the yoke nut cor­rectly, try torquing the nut with the truck wheels on
the ground and with the axle shafts installed.

Drive Pinion

Note: Always use a new nut and coat threads with Loctite 277

if not pre-coated.

33

Drive Pinion

CAUTION

The stake must be deep enough to enter the machined slot
of the pinion. See diagram below.

1

2

1 - Round Tipped Chisel
2 - Nuts Staking Flange
3 - Machined Slot In Pinion

3

24. Use a dead blow mallet to seat the cover.

25. If a pilot bearing web is used, lineup the web to
the locating sleeves and tap in place with a rubber
mallet.

1

WARNING

Failure to stake the pinion nut properly may result in the nut
coming loose during service. The pinion nut should never
be reused, always replace with new.

22. For D170 assembly, install the pinion cover. Apply a
bead of Loctite 518 sealant to the outer flange of the
cover.

23. Install the cover, making sure that the cover is paral­lel to the carrier opening.

1

1 - Locating Sleeves

26. Install capscrews and torque to the proper specifica­tions. See the Torque Chart.

34

Wheel Differential

Wheel Differential - Parts Exploded View

Before July 2013 After July 2013

1

2

3

12

4

5

7

8

6

9

11

6

15

14

4

9

11

Wheel Differential

19

18

2

3

5

17

7

8

6

16

16

6

1 - Threaded bearing adj - flange half
2 - Bearing cone - flange half
3 - Bearing cup - flange half
4 - Ring gear and pinion set
5 - Bolt
6 - Output side gear
7 - Side pinion thrust washer

10

8 - Differential spider
9 - Side gear
10 - Differential case - RH (plain half)
11 - Differential case - RH (plain half)
wheel diff lock
12 - Bearing cone - plain half
13 - Threaded bearing adj - plain half

10

14 - Bearing adjuster - plain half
15 - Bearing cup - plain half
16 - Side gear thrust washer
17 - Side pinion thrust washer
18 - Bearing cup - flange half
19 - Bearing adjuster - flange half

35

Wheel Differential

Wheel Differential Disassembly - Forward Carrier Assembly

Before July 2013

IMPORTANT

During the following procedures, place the
differential assembly on a malleable surface to prevent
damage when removing components.

1. Remove the differential case capscrews.

3. Remove the side gear thrust washers, side pinions

and differential spider from the plain half case.

2. Remove the flange half differential case and bearing
assembly. Use a screwdriver at the spider arm
machined slots of the case to loosen the flange from
the ring gear.

1

1 - Spider Arm Slots

4. Place a block under the plain half, use a rubber mal­let to remove the ring gear.

5. Remove the bearing cones from the case halves
using suitable pullers.

36

Wheel Differential

6. Remove the bearing cones from the plain and flange
halves in two steps:

a. Mount the puller vertically to split the bearing.

This action will start the bearing moving off the
differential case.

Wheel Differential

b. Mount the puller horizontally to remove the

cone.

37

Wheel Differential

Wheel Differential Assembly - Forward Carrier Assembly

IMPORTANT

To prevent bearing damage, use suitable sleeve that only
contacts the inner race of the cone. A used bearing race
would be a suitable tool. This tool should have a slit cut if
the ID is the same as the flange OD.

1. Press the new bearing cone on the plain half and
flange half bearing boss using the proper press
sleeve or bearing installation tool.

4. Assemble the side pinions and thrust washers
onto the wheel differential spider. Apply a thin
coat of oil to the mating surfaces of the side
pinion and differential spider. Install the
wheel differential nest on top of the side gear

5. Install the flange half side gear and thrust washer.
Apply a thin coat of oil to the mating surfaces.

2. Place the plain half side of the differential case on a
malleable surface.

3. Install the side gear and thrust washer. Apply a thin

coat of oil to the mating surfaces of the side gear
thrust washer and plain half.

6. Install the ring gear. Align the capscrew holes.

1

1 - Match spacing of holes on each side of
spider slots

38

Wheel Differential

7. Use a rubber mallet to seat the ring gear to the plain
half.

8. Install the flange half of the case. Align the capscrew
holes.

9. Install the ring gear capscrews.

10. Tighten the ring gear capscrews with an impact gun
and then use a torque wrench to torque to the proper
specifications. See the Torque Chart.

Wheel Differential

39

11. Lower assembled differential assembly in to the
carrier using a hoist and a strap. Be careful not
to damage the differential bearings lowering
the assembly.

Wheel Differential

12. Install the bearing cup and bearing adjuster
to the flange half side first.

1

1 - Flange Half
2 - Plain Half

13. Install the bearing cup and bearing adjuster to the
plain half side. Use a long screwdriver or bar to lift
the differential up while installing the cup and
bearing adjuster.

2

40

Wheel Differential

Install Wheel Differential Assembly - Forward Carrier Assembly

Backlash and Bearing Preload

Note: To install the wheel differential assembly, properly
setup the gear pattern and set the differential bearing
preload. This will require the use of the following Spicer
tools or equivalent. These tools will allow you to align
the bearing adjuster assembly to the carrier. This tool
(part number 513061) will also gage the adjustment for
the differential bearing preload and assist in setting the
backlash. Below you will find detailed instructions
explaining each procedure.

1. The bearing adjustment tool is made up of a threaded
rod, two nuts, two washers and two adjustment plates.
Fit one adjustment plate to the plain half threaded cup.
Fit the other adjustment plate to the flange half cup.
The adjustment rings will fit into slots of the threaded
bearing cups stamped adjustment ring.

2. Connect the adjuster plates using the threaded rod,
washers and nuts. Tighten the nuts on the rod to
hold the threaded cups in place. Carefully lower the
wheel differential and ring gear assembly into the
carrier.

Wheel Differential

1

1 - Threaded bearing cup
2 - Adjustment plate

Note: There are two ways to make sure that the threaded cups

2

are seated properly. If there is a misalignment, reinstall
the differential assembly at a slightly different angle.

3. Make sure there is no gap between the carrier
threads and the cup threads.

1

1 - No gap

41

Wheel Differential

4. Make sure that the bearings cage is parallel to the
edge of the threaded cup.

1

1

1 - Parallel

5. Use a ratchet or breaker bar and a 1¼" deep wall
socket to turn the flange half threaded bearing cup in
until the ring gear contacts the pinion (zero back­lash). Back the cup out two notches of the adjust­ment plate.

6. Turn the plain half adjuster ring until there is zero
preload on the bearings. This is done by turning the
adjuster plate clockwise until you feel the threaded
cup gain resistance. The threaded bearing cup
should only be slightly snugged to achieve a zero
preload condition.

1

1 - Flange Half
2 - Plain Half

2

7. Obtain two notches of preload by tightening the plain
half adjustment ring two notches. Start with the
notch at the top, count two notches counter-clock­wise on the adjuster ring, turn the adjuster ring so
that the notch is facing straight up.

1 - Two Notches

1

42

Wheel Differential

8. Use a rubber mallet to fully seat the threaded bearing
cups.

9. With a dial indicator, check the ring and pinion back­lash. Set the backlash from 0.010" to 0.012". This
will give you room to adjust the contact pattern, if
necessary.

12. Install the carrier differential bearing caps and cap­screws. Make certain there is no gap between the
carrier cap and the carrier surface.

13. Use an impact gun to snug all carrier
cap fasteners.

Wheel Differential

10. Remove the adjuster plates and threaded rod
assembly.

11. Apply a 1/8” bead of Loctite 540 to the exposed
threads of the bearing adjuster.

Apply Loctite 5 40

14. Recheck the backlash. For new gearing, the backlash
should be between 0.008" and 0.018" (0.20 and 0.46
mm).

Note: For used gearing, the backlash should be reset to what

it was at the time of disassembly.

Note: If you have too much backlash, move the ring gear

closer to the pinion. Count the number of notches you

off the plain half threaded cup. Each notch equals

back
about 0.003" (0.08 mm) of backlash.

IMPORTANT

In order to maintain the differential bearing preload, you
will need to turn the flange half threaded cup the same
amount in the same direction. If you need more backlash,
reverse the procedure.

43

Wheel Differential

15. Measure the ring gear total radial runout. Indicator
reading should not exceed 0.010" (0.25 mm).

16. Measure the ring gear total backface runout.
Indicator reading should not exceed 0.010"
(0.25 mm).

18. With the carrier mounted in a head stand, roll the
carrier on its side.

19. Make a sling out of a strap and position around the
plain half of the wheel differential.

17. Check the ring gear tooth pattern. Paint 5 or 6 ring
gear teeth 180 degrees apart on the ring gear.

20. Connect the end of the strap to a hoist and apply
pressure to the sling.

44

Wheel Differential

21. Use the correct socket and a breaker bar to rotate the
differential. The differential should be hard to turn.
Rotate the pinion until the ring gear rotates 3 or 4
times in both directions. See page 30, “Adjust Tooth
Contact Position” for descriptions of correct pattern
position for new and used gearing.

22. When contact pattern is correct, use a punch with a
round head to stake the threaded bearing cups in
place. Stake the outer edge of the bearing adjust­ment ring into the machined slots in the carrier bear­ing bore on both sides. Must be staked at two
locations. Rotate cup if necessary to provide sur­faces for staking.

1

1 - Two Stake Locations

3

Wheel Differential

1

2

1 - Machined slot
2 - Bearing Adjustment Ring
3 - Round Head Punch

45

Wheel Differential

Wheel Differential Disassembly - Forward Carrier Assembly

After July 2013

IMPORTANT

During the following procedures, place the
differential assembly on a malleable surface to prevent
damage when removing components.

1. Remove the differential case capscrews.

3. Remove the side gear thrust washers, side pinions

and differential spider from the plain half case.

2. Remove the flange half differential case and bearing
assembly. Use a screwdriver at the spider arm
machined slots of the case to loosen the flange from
the ring gear.

1

1 - Spider Arm Slots

4. Place a block under the plain half, use a rubber mal­let to remove the ring gear.

5. Remove the bearing cones from the case halves
using suitable pullers.

46

Wheel Differential

6. Remove the bearing cones from the plain and flange
halves in two steps:

a. Mount the puller vertically to split the bearing.

This action will start the bearing moving off the
differential case.

b. Mount the puller horizontally to remove the cone.

Wheel Differential

47

Wheel Differential

Wheel Differential Assembly - Forward Carrier Assembly

IMPORTANT

To prevent bearing damage, use suitable sleeve that only
contacts the inner race of the cone. A used bearing race
would be a suitable tool. This tool should have a slit cut if
the ID is the same as the flange OD.

1. Press the new bearing cone on the plain half and
flange half bearing boss using the proper press
sleeve or bearing installation tool.

4. Assemble the side pinions and thrust washers
onto the wheel differential spider. Apply a thin
coat of oil to the mating surfaces of the side
pinion and differential spider. Install the
wheel differential nest on top of the side gear.

5. Install the flange half side gear and thrust washer.
Apply a thin coat of oil to the mating surfaces.

2. Place the plain half side of the differential case on a
malleable surface.

3. Install the side gear and thrust washer. Apply a thin

coat of oil to the mating surfaces of the side gear
thrust washer and plain half.

6. Install the ring gear. Align the capscrew holes.

1

1 - Match spacing of holes on each side of
spider slots

48

Wheel Differential

7. Use a rubber mallet to seat the ring gear to the plain
half.

8. Install the flange half of the case. Align the capscrew
holes.

9. Install the ring gear capscrews.

10. Tighten the ring gear capscrews with an impact gun
and then use a torque wrench to torque to the proper
specifications. See the Torque Chart.

Wheel Differential

49

11. Lower assembled differential assembly in to the
carrier using a hoist and a strap. Be careful not
to damage the differential bearings lowering
the assembly.

Wheel Differential

12. Install the bearing cup and bearing adjuster
to the flange half side first.

1

1 - Flange Half
2 - Plain Half

13. Install the bearing cup and bearing adjuster to the
plain half side. Use a long screwdriver or bar to lift
the differential up while installing the cup and
bearing adjuster.

2

50

Wheel Differential

Install Wheel Differential Assembly - Forward Carrier Assembly

Backlash and Bearing Preload

1. Turn the flange half bearing adjuster in until the ring
gear contacts the pinion (zero backlash) then back
the adjuster out two notches of the adjuster lugs.

1

1 - Flange Half
2 - Plain Half

2

3. Tighten the plain half adjuster two lug notches.

Start with the notch at the top, count two notches
counterclockwise on the adjuster so that the
notch is facing straight up. You now have a
two notch preload.

1 - Flange Half
2 - Plain Half

4. Use a rubber mallet to make certain that both

bearing adjusters are fully seated.

Wheel Differential

2

1

2. Tighten the plain half adjuster until the bearing cup
just starts to turn. This is a zero bearing preload.

5. With a dial indicator, check the ring and pinion

backlash. Set the backlash from 0.010" to 0.012".
This will give you room to adjust the contact pattern,
if necessary.

51

Wheel Differential

6. Install the carrier differential bearing caps and cap­screws. Make certain there is no gap between the
carrier cap and the carrier surface.

7. Use an impact gun to snug all carrier
cap fasteners.

9. Measure the ring gear total radial runout. Indicator
reading should not exceed 0.010" (0.25 mm).

10. Measure the ring gear total backface runout.
Indicator reading should not exceed 0.010"
(0.25 mm).

8. Recheck the backlash. For new gearing, the backlash
should be between 0.008" and 0.018" (0.20 and 0.46
mm).

Note: For used gearing, the backlash should be reset to what

it was at the time of disassembly.

Note: If you have too much backlash, move the ring gear

closer to the pinion. Count the number of notches you
back off the plain half threaded cup. Each notch equals
about 0.003" (0.08 mm) of backlash.

IMPORTANT

In order to maintain the differential bearing preload, you
will need to turn the flange half threaded cup the same
amount in the same direction. If you need more backlash,

everse the procedure.

r

11. Check the ring gear tooth pattern. Paint 5 or 6 ring
gear teeth 180 degrees apart on the ring gear.

12. With the carrier mounted in a head stand, roll the
carrier on its side.

52

Wheel Differential

13. Make a sling out of a strap and position around the

plain half of the wheel differential.

14. Connect the end of the strap to a hoist and apply

pressure to the sling.

Wheel Differential

15. Use the correct socket and a breaker bar to rotate the

differential. The differential should be hard to turn.
Rotate the pinion until the ring gear rotates 3 or 4
times in both directions.

53

Adjust Tooth Contact Position

Ring Gear

Adjust Ring and Pinion Tooth Contact Pattern

Note: Rear axle gearing is shown in the following instruc-

tions. Correct tooth contact patterns and adjustments
are the same for forward and rear axles.

2

1

1 - Face width
2 - Tooth depth
3 - Heel
4 - Top land
5 - Root
6 - Toe

1. Identify if new or used gearing.

2. Check tooth contact pattern (new or used gearing).

3

4
5
6

Used Gearing - Correct Pattern

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.

Adjust used gear sets to display the same contact pattern
observed before disassembly. A correct pattern is up off the
toe and centers evenly along the face width between the top
land and root. Otherwise, the length and shape of the pat­tern are highly variable 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

New Gearing - Correct Pattern

Paint six ring gear teeth 180° apart with marking compound
and roll the gear to obtain a contact pattern. The correct
pattern is slightly below center on the ring gear tooth with
lengthwise contact up off the toe. The length of the pattern
in an unloaded condition is approximately one-half to two­thirds of the ring gear tooth in most models and ratios.

The pattern could vary in length and should cover 1/2 tooth
or more (face width). The pattern should be evenly centered
between toot
tooth toe.

h top land and root and should be up off the

54

Adjust Ring Gear Position (Backlash)

If the gear pattern shows incorrect face width contact,
change backlash by adjusting the ring gear.

If the pattern is too close to the edge of the tooth toe, move
the ring gear away from the pinion to increase backlash.

1. Loosen the bearing adjuster on the teeth side of
the ring gear several notches.

Ring Gear

Ring Gear

2. Loosen the opposite adjuster one notch.

3. Return to adjuster on teeth side of ring gear and
tighten adjuster until it contacts the bearing cup.

4. Continue tightening the same adjuster 2 or 3
notches and recheck backlash.

If the pattern is concentrated at the heel (too far up the
tooth), move the ring gear toward the pinion to decrease
backlash.

1. Loosen the bearing adjuster on the teeth side of
the ring gear several notches.

2. Tighten the opposite adjuster one notch.

3. Return to adjuster on teeth side of ring gear and
tighten adjuster until it

4. Continue tightening the same adjuster 2 or 3
notches and recheck backlash.

contacts the bearing cup.

55

Wheel Differential Lock

Wheel Differential Lock - Parts Exploded View

1 - Sliding clutch
2 - Spring
3 - Shift Fork
4 - Push rod

10

3

1

4

5

6

7

8

5 - Piston
6 - O-ring
7 - Piston cover
8 - Washer

2

9

9 - Switch
10 - Roll pin

56

Wheel Differential Lock

Install and Adjust Wheel Differential Lock

Note: With differential carrier completely assembled and

adjusted, install differential lock as follows:

1. If shift fork and sliding clutch are disassembled,
engage fork with the clutch hub and install spring pin
in the fork leg. See illustration below for fork mounting
position on clutch.

2. Position compression spring, shift fork and clutch in
shift opening of the carrier. Align pilot hole of shift
fork with the pilot hole of carrier.

3. Install pushrod through shift fork, compression
spring and carrier pilot hole.

Wheel Differential

4. Lubricate piston and o-ring with silicone grease.
Install shift piston assembly into cylinder. Position
piston with small diameter hub toward closed end of
cylinder.

5. Install piston cover o-ring.

6. Install piston cover and torque to 50–75 lbs. ft.

(68–102 N•m).

7. Install selector switch and torque to 10–12 lbs. ft.

(14 –16 N•m).

8. Check selector switch operation. Check switch
electrically with an ohmmeter. Switch should be
closed when clutches are engaged and open when
disengaged.

57

Output Shaft Assembly & Rear

Cover

Housing and Output Shaft Assembly - Parts Exploded View

1

2

3

4

5

6

7

8

10

9

16

11

13

12

14

17

18

15

27

26

19

25

24

21

20

22

23

Welded Rear Cover

1 - Output shaft nut
2 - Output yoke
3 - Output seal
4 - Snap ring
5 - Outer bearing cup
6 - Outer bearing cone
7 - Inner bearing cone
8 - Inner bearing cup
9 - Output shaft

58

10 - Rear cover
11 - Rear cover capscrew
12 - Fill plug
13 - Rear cover nut
14 - Washer
15 - Stud
16 - Spindle nut - Outer
17 - Locking ring
18 - Spindle nut - Inner

19 - Axle housing
20 - Breather
21 - Breather hose
22 - Carrier capscrew
23 - Nut
24 - Washer
25 - Stud
26 - Drain plug
27 - Axle shaft

Remove Output Shaft Assembly

Output Shaft Assembly & Rear

Cover

Note: For forward axle rear covers that are removable the out-

put shaft may be removed when the cover is in or out of
the axle assembly.

1. Disconnect the inter-axle driveline at the forward
axle rear cover position.

2. Remove yoke nut (shoulder nut).

3. Remove yoke from output shaft using appropriate
tool.

1

1 - Yoke Puller Tool

TIP: A yoke puller tool may be made from the center
section of most gear puller tools, or may be pur­chased from your tool distributor.

4. Remove oil seal.

6. Remove output shaft and outer bearing cup as an
assembly.

6

1

2

3

4

5

1 - Snap Ring
2 - Outer Bearing Cup
3 - Output Shaft Assembly
4 - Inner Bearing Cup
5 - Rear Cover Assembly
6 - Output Seal

Output Shaft Assembly &

Rear Cover

5. Remove snap ring.
TIP: It may be helpful to loosely reinstall the yoke

and shoulder nut giving the technician more of an
area to grip when removing the output shaft.

7. Remove the inner bearing cup from rear cover
assembly. This may be removed from inside the axle
housing when the carrier is removed, or by removal
of the forward axle rear cover

.

59

Output Shaft Assembly & Rear

Cover

8. Remove both inner and outer bearing from output
shaft.

1

1 - Press

9. Remove output shaft inner bearing cup.

Note: Components such as the inter-axle driveline, yoke, oil

seal and output shaft assembly should have been
removed according to normal service procedures.
Removing the differential assembly from the axle
housing is not necessary, but would ease the removal
process of the inner bearing cup from the cover bore.

a. Using a bearing puller tool, remove the inner bearing

cup.

b. Visually inspect the inner-machined bore surface of

the welded-on cover for nicks and burrs. Repair if
necessary.

60

Output Shaft Assembly & Rear

Cover

Overhaul and Assemble Output Shaft Assembly

Note: Lubricate the parts with gear lube during assembly.

1. The output shaft bearings are assembled with both
bearing cones back to back. Use a press and a sleeve
to install one bearing at a time.

CAUTION

To prevent bearing damage, use a suitable sleeve that only
contacts the bearing race.

2. Apply pressure until the inner bearing cone touches
the shoulder of the output shaft.

3. Apply pressure until the back of the outer bearing
cone touches the back of the inner bearing.

Note: Axle housings with welded-on covers procured through

service will include the inner bearing cup as part of the
“service” axle housing assembly. Go to Step 6 if the inner
cup has already been installed.

4. Lightly coat the output bore of the axle housing
cover with a 9.5 mm (.38") wide application of Loc­tite 680 where the bore contacts the inner
cup. Do not apply Loctite outside of this area—to the
bearing rollers or outboard of the inner cup bore.
Improper application of the Loctite could lock the
rollers or cause excessive pre-load.

bearing

7. Using a sleeve and driver (hammer), install the outer
bearing cup into the housing assembly over the out­put shaft bearing cone.

8. Using snap ring pliers, install the snap ring that fas-

the outer bearing cup into the welded-on cover

tens
assembly.

9. Check the endplay of the output shaft. New assem­blies should measure 0.001" to 0.045" (0.03 to 1.143
mm).

Note: Use the bearing cup driver to insure seating of snap

ring after installation with snap ring pliers.

1

2

3

4

5

6

Output Shaft Assembly &

Rear Cover

CAUTION

Add Loctite adhesive to the inner bearing surface of the
housing and NOT to the bearing race itself. If added to the
race, excessive adhesive could get on the surface of the
outer bearing race journal during installation and cure the
outer cap in place with excessive pre-load.

5. Using a sleeve and driver (hammer), install the inner
bearing cup.

6. Put the output shaft and bearing assembly into the
axle housing assembly.

7

1 - Press
2 - Plate
3 - Sleeve
4 - Press Bearing on Second
5 - Press Bearing on First
6 - Output Shaft
7 - Plate

61

Output Shaft Assembly & Rear

Cover

1 - Snap Ring
2 - Bearing Cup
3 - Output Shaft Assembly
4 - Inner Bearing Cup
5 - Rear Cover Assembly
6 - Output Seal

6

1

2

3

4

5

10. Bolted rear cover only: If removed, install cover and
fasten with nuts, capscrews and lock washers.
Tighten to proper torque specifications. See the
Torque Chart.

Note: Use Spicer approved RTV compound on axle housing
mating surface. Completely remove all old gasket material
prior to applying new material. Compound will set in
20 minutes. Install axle housing cover and output shaft
assembly before compound sets or reapply.

11. Install the output seal.

12. Install output yoke.

Note: Use of a torque multiplier is recommended.

TIP: If you can't get the correct torque on yoke nut,
try torquing the nut with the truck wheels on the
ground and with the axle shafts installed.

13. Install axle shafts and axle stud nuts (If used, also
install lock washers and taper dowels).

14. Connect inter-axle driveline. Make sure driveline is
properly phased. Lubricate u-joints.

15. Add axle lubricant. Fill to bottom of filler hole.

IMPORTANT

When axle has been disassembled or housing, axle shafts
or wheel equipment replaced, check axle assembly for
proper differential actions before operating vehicle. Wheels
must rotate freely and independently.

Road test vehicle to bring axle lubricant up to temperature.
Recheck joints, drain and fill plugs for leakage. Retighten as
necessary.

62

Output Shaft Assembly & Rear

Measure

Correct endplay for a new assembly is 0.001" to 0.045" [0.03
to 1.143 mm]. The maximum endplay for a used assembly
is no more than 0.045" (1.143 mm). If endplay is incorrect,
contact Dana.

1. Install oil seal.

2. Install yoke.

3. Install yoke nut. One of the following options may be
utilized:

a. Install a new nut with the pre-applied thread
adhesive compound. Tighten the nut to the
specified torque. See the Torque Chart.

Cover

Output Shaft Assembly &

Rear Cover

b. If a new nut with pre-applied thread adhesive
compound is unavailable, apply Loctite 277 or
271 (available in 0.5 ml tube—P/N 129293)
to the nut along two threads, for at least two
flats (120°) of the nut midway through the
thickness (see illustration). Tighten the nut
to the specified torque. See the Torque Chart.

63

Seal - Replace

Replace Seal

Spicer strongly recommends using seal drivers when installing
new seals. Use the proper driver to make sure that the seal is
square and installed to the proper depth.

CAUTION

CAUTION

Oil seals can be easily damaged prior to installation. Use
care when handling the new seal to prevent damage or con­tamination. Leave the seal in its package until installation.
On new yokes, leave the protector on the yoke until it is
installed on the shaft to prevent damage or contamination.

1. Inspect axle endplay at the yoke (see page 10). Service
if beyond specified limit.

2. Remove the old yoke using appropriate tool. A yoke
puller tool may be made from the center section of
most gear puller tools, or may be purchased from
your local tool distributor.

1

Do not use any silicone or permatex-type bore sealant with
this seal.

5. Remove the new seal from its package and install
with the proper driver:

D - Input Driver - 210749

D - Input Insert - 131472

D - Output Driver - 131471

R - Pinion Driver - 210749

R - Pinion Insert - 131472

WARNING

Due to the resiliency of the plastic driver, hammer rebound
may occur when the seal is seated. Keep clear of the hammer
rebound path!

6. Handle the seal by its outside diameter avoiding any
contact with the seal lips. During installation, use the
proper driver to make sure that the seal is mounted
properly.

1 - Yoke Puller Tool

3. Remove seal. Use care when removing the old seal
to prevent damage to the housing seal bore.

4. Inspect the seal bore area for any damage (nicks,
gouges, corrosion). Carefully remove any slight
damage with a crocus cloth. Clean the bore area to
remove any loose debris.

64

7. Use a rubber mallet to drive the seal tool in until the
flange bottoms on the housing cover bore face. The
flange will locate the seal at the proper depth.

Seal - Replace

Guidelines for Reusing Yoke

CAUTION

Do not use the yoke if it has any damage on the seal surface
(nicks or scratches).

The surface of the yoke and the lips of the seal form a critical
interface which retains the axle’s lubricant while sealing the
axle from outside contaminants. The condition of the yoke
hub’s surface is a very important factor in determining seal
life.

Carefully inspect the seal surface area of the yoke hub for
signs of wear and damage. Do not reuse the yoke if there is
noticeable wear, such as heavy grooving, beyond normal polishing
from the seal lips.

Note: Do not rework the yoke with abrasives such as emery
paper or crocus cloth. Clean the surface of the yoke as
necessary using chemical cleaners. Remove all trace of
the chemicals from the yoke after cleaning.

CAUTION

Do not use wear sleeves. Wear sleeves increase the yoke
hub surface diameter and cause premature seal wear and
repeat seal failure.

Seal - Replace

65

Service Kit

Seal - Replace

Location

Tool

D-Input

210749

D-Output R-Pinion

210749

131472

131471

131472

66

Housing Breather

Housing Breather

Spicer has an axle breather that consists of a fitting, hose
and clamp assembly. This breather design has improved
resistance to water ingestion, clogging caused by dirt, ice or
snow buildup around the base of the breather. See installation
instructions below (all views from rear).

1. Install fitting in breather hole.

2. Tighten fitting finger tight.

4. Insert hose onto fitting, long end down.

Housing Breather

3. Using a 3/4” wrench:

• Metal only: Rotate the fitting at least 1/2 turn

until nipple points to rear.

5. Push hose firmly against fitting. Rotate hose to point
down.

• Plastic only: Tighten until one thread is showing.

67

Wheel End Seal - Parts Exploded View

Wheel End Seal

1

2

3

1 - Installation tool
2 - Seal
3 - Rear hub

68

Wheel End Seal

Remove and Overhaul Wheel End Seal

WARNING

Never work under a vehicle supported by only a jack.
Always support vehicle with stands. Block the wheels and
make sure the vehicle will not roll before releasing the
brakes.

IMPORTANT

Wheel end seals can be easily damaged during handling.
Leave the seal in its package until installation to
prevent damage or contamination.

1. Remove outer bearing and wheel.

2. Remove oil seal.

3. Remove inner bearing.

4. Remove old wear sleeve (2-piece design only) with a
ball peen hammer and discard.

Wheel End Seal

Install Wheel End Seal

1. Before installation, lubricate the following with the
same lubricant used in the axle sump.

• Inner bearing

• Wheel seal (follow the directions provided by the

seal supplier)

2. Place seal on installation tool.

3. Drive seal with installation tool onto hub.

IMPORTANT

Do not cut through the old wear sleeve. Damage to the
housing may result.

5. Inspect spindle journal and hub bore for scratches or
burrs. Recondition with an emery cloth as required.

Note: Deep gouges can be repaired by filling gouge with hard-

ening gasket cement and smoothing with emer

6. Clean hub cavity and bearing bores before reassem­bly. Be sure to remove contaminants from all
recesses and corners.

7. Clean bearings thoroughly with solvent and examine
for damage. Replace damaged or worn bearings.

IMPORTANT

Always use the seal installation tool specified by the seal
manufacturer. Using an improper tool can distort or damage
the seal and cause premature seal failure.

y cloth.

69

Adjust Wheel Bearing

Wheel End Seal

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 three­piece tang-type wheel nut system and is not designed to
bear against the inner nut.

1. Inspect the spindle and nut threads for corrosion
and clean thoroughly or replace as required.

Note: Proper assembly and adjustment is not possible if the

spindle or nut threads are corroded.

2. Inspect the tang-type washer (if used). Replace the
washer if the tangs are broken, cracked, or damaged.

3. Install the hub and drum on the spindle with care to
prevent damage or distortion to the wheel seal.

CAUTION

CAUTION

Never use an impact wrenc

h to adjust wheel bearings. A
torque wrench is required to assure that 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 lbs. ft. (68 N•m) while
rotating the wheel hub.

10. Back off the inner nut exactly 1/4 turn.

Note: This adjustment procedure allows the wheel to rotate

freely with 0.001"–0.005" (0.025 mm–0.127 mm)
endplay.

11. Install the correct lock washer for the wheel nut sys­tem being used.

Three-piece Dowel-type Lock Washer System

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 h

ub 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 lbs. ft. (271 N•m) while rotating the wheel
hub.

1

2

3

4

1 - Inner Nut
2 - Dowel Pin
3 - Dowel-type Lock Washer
4 - Outer Nut

a. Install the Dowel-type lock washer on the spindle.

Note: If the dowel pin and washer are not aligned, remove

washer, turn it over and reinst all. If required, loosen the
inner nut just enough for alignment.

CAUTION

Never tighten the inner nut for alignment. This

can preload
the bearing and cause premature
failure.

70

Wheel End Seal

b. Install the outer nut on the spindle and tighten
to 350 lbs. ft. (475 N•m).

c. Verify endplay.

Three-piece Tang-type Lock Washer System

1

2

3

1 - Inner Nut
2 - Tang-type Lock Washer

0.123" (3.124 mm) thick
3 - Outer Nut

a. Install the Tang-type lock washer on the spindle.

CAUTION

Never tighten the inner nut for alignment. This can preload
the bearing and cause premature failure.

Four-piece Tang/Dowel-type Lock Washer System

3

4

5

1

2

1 - Inner Nut
2 - Dowel Pin
3 - Dowel-type Lock Washer
4 - Tang-type Lock Washer

0.0478" (1.2065 mm) thick
5 - Outer Nut

a. Install the Dowel-type lock washer on the spindle.

Note: If the dowel pin and washer are not aligned, remove

washer, turn it over and

reinst all. If required, loosen the

inner nut just enough for alignment.

IMPORTANT

Wheel End Seal

b. Install the outer nut on the spindle and tighten to
250 lbs. ft. (339 N•m).

c. Verify endplay.

d. After verifying endplay, secure wheel nuts by
bending one of the locking washer tangs over
the outer wheel nut and another tang over the
inner wheel nut.

e. Go to step 12.

Never tighten the inner nut for alignment. This can preload
the bearing and cause premature failure.

b. Install the Tang-type lock washer on the spindle.

c. Install the outer nut on the spindle and tighten to
250 lbs. ft. (339 N•m).

d. Verify endplay.

e. After verifying endplay, secure the outer nut by
bending (180° apart) two opposing tangs of the
locking washer over the outer nut.

12. Install the following:

• New gasket at axle shaft flange

• Axle shaft

• Axle flange nuts and tighten to specified torque

13. Lubricate axle wheel ends.

71

Verify Wheel Endplay Procedure

Wheel End Seal

Verify that endplay meets specification using a dial indicator.
An indicator with 0.001" (0.03 mm) resolution is required.
Wheel endplay is the free movement of the tire and wheel
assembly along the spindle axis.

Correct endplay is 0.001"–0.005" (0.025–0.125 mm).

1. Attach a dial indicator with its magnetic base to the
hub or brake drum as shown below.

2. Adjust the dial indicator so that its plunger or pointer
is against the end of the spindle with its line of action
approximately parallel to the axis of the spindle.

3. Grasp the wheel assembly at the 3 o’clock and
9 o’clock positions. Push the wheel assembly in and
out while oscillating it to seat the bearings. Read
bearing endplay as the total indicator movement.

CAUTION

If endplay is not within specification, readjustment is
required.

Readjust Wheel Endplay Procedure

Excessive Endplay— If end-play

(.127 mm), remove the outer nut and pull the lock washer
away from the inner nut, but not off the spindle. Tighten the
inner nut to the next alignment hole of the dowel-type washer
(if used). Reassemble the washer and re-torque the outer nut.
Verify endplay with a dial indicator.

Insufficient Endplay— If endplay is not present, remove the
outer nut and pull the lock washer 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). Reassem­ble the washer and re-torque the outer nut. Verify endplay
with a dial indicator.

Fine Tuning the Endplay— If, after performing the
readjustment procedures, endplay is still not within the

0.001"–0.005" (0.025–0.127 mm) range, disassemble and
inspect the components. If parts are found to be
replace the defective parts, reassemble and repeat wheel
bearing adjustment procedure. Verify endplay with a dial
indicator.

is greater than 0.005"

defective,

72

Wheel End Seal

Lubricate Wheel End

CAUTION

Before operating the axle, the wheel hub cavities and
bearings must be lubricated to prevent failure.

When wheel ends are serviced, follow Spicer’s wheel end
lubrication procedure before operating the axle.

Spicer axles may be equipped with either of two wheel end
designs:

• Wheel ends with an oil fill hole.

• Wheel ends without an oil fill hole.

Wheel End Seal

Wheel Ends with an Oil Fill Hole

1. Rotate the wheel end hub until the oil fill hole is up.

2. Remove the oil fill plug.

3. Pour 1/2 pint of axle sump lubricant into each hub
through the wheel end fill hole.

4. Install oil fill plug and tighten to specified torque.

1

2

1 - Wheel End Oil Fill Hole
2 - Proper Lubricant Level
3 - Lubricant Flow from Sump

3

73

Wheel End Seal

Wheel Ends Without Oil Fill Hole

1. With axle level and wheel ends assembled, add lubri­cant through filler hole in axle housing cover until
fluid is level with the bottom of filler hole.

2. Raise the right side of the axle 6" or more. Hold axle
in this position for one minute.

3. Lower the right side.

1

2

1 - With axle on level surface, fill housing with oil to bottom of plug
2 - Temperature sensor mounting hole
3 - Oil will run into wheel end
4 - Oil will run into wheel end
5 - Tilt housing side to side (1 minute per side)
6 - Recheck oil level in axle

4. Raise the left side of the axle 6" or more. Hold axle in
this position for one minute.

5. Lower the left side.

6. With axle on a level surface, add lubricant through
housing cover oil filler hole until fluid is level with the
bottom of the hole.

Note: Axles without wheel end fill holes will require approxi-

mately 2.5 additional pints of lubricant to bring the lube
level even with the bottom of fill hole.

3

4

74

General Lubrication Information

Lubrication

The ability of a drive axle to deliver quiet, trouble-free operation
over a period of years is largely dependent upon the use
of good quality gear lubrication in the correct quantity. The
most satisfactory results can be obtained by following the
directions contained in this manual.

The following lubrication instructions represent the most current
recommendations from Dana.

Approved Lubricants

General—Gear lubrications acceptable under military specifi­cation (MILSPEC) MIL-L-2105D (Lubricating Oils, Gear,
Multipurpose) are approved for use in Spicer Drive Axles.
The MIL-L-2105D specification defines performance and
viscosity requirements for multigrade oils. It supersedes both
MIL-L-2105B, MIL-L-2105C and cold weather specification
MIL-L-10324A. This specification applies to both petroleum­based and synthetic based gear lubricants if they appear on
the most current “Qualified Products List” (QPL-2105) for
MIL-L-2105D.

Note: The use of separate oil additives and/or friction modifiers
are not approved in Spicer Drive Axles.

Synthetic based—Synthetic-based gear lubricants exhibit
superior thermal and oxidation stability, and generally
degrade at a lower rate when compared to petroleum-based
lubricants. The performance characteristics of these lubricants
include extended change intervals, improved fuel economy,
better extreme temperature operation, reduced wear and
cleaner component appearance. The family of Spicer gear
lubricants represents a premium quality synthetic lube
which fully meets or exceeds the requirements of
MIL-L-2105D. These products, available in both 75W-90
and 80/W-140, have demonstrated superior performance in
comparison to others qualified under the MILSPEC, as demonstrated
by extensive laboratory and field testing. For a complete
list of Spicer approved synthetic lubricants contact
your local Dana representative. See back cover of this
manual for appropriate phone number.

Recommendations for Viscosity/Ambient
Temperature

The following chart lists the various SAE Grades covered by
MIL-L-2105D and the associated ambient temperature range
from each. Those SAE grades shown with an asterisk (*) are
available in the Spicer family of synthetic gear lubricants.
The lowest ambient temperatures covered by this chart are

-40°F and -40°C. Lubrication recommendations for those
applications which consistently operate below this temperature
range, must be obtained through Dana by contacting
your local Dana representative.

Grade Ambient Temperature Range

75W -40°F to -15°F (- 40°C to -26°C)

75W-90* -40°F to 100°F (-40°C to 38°C)

75W-80 -40°F to 80°F (-40°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.

to 21°C)

Lubrication

Makeup Lube—Maximum amount of non-synthetic makeup

lube is 10%. For additional lubrication information, see
TCMT-0021.

75

Lube Change Intervals

Lubrication

This product combines the latest manufacturing and part
washing technology. When filled with a Spicer approved

synthetic lubricant at the factory, the initial drain is not
required.

Change the lubricant within the first 5,000 miles of operation
when not using a Spicer approved synthetic lubricant
in either a new axle or after a carrier head replacement.

Base subsequent lubricant changes on a combination of
the following chart and user assessment of the application
and operating environment.

Synthetic or Lubricant SAE Change Interval for Line Haul Change Interval for Vocational
Mineral

Synthetic* SHAES-256 SAE 75W-90 500,000 miles (800,000 Km) 120,000 miles (193,000 Km)
or 5 years or 1year

Synthetic** SHAES-256 SAE 75W-90, 250,000 miles (400,000 Km) 60,000 miles (96,500 Km)
75W-140 or 3 years or 1 year

Mineral MIL-L-2105E/J02360, 75W, 75W-90, 120,000 miles (193,000 Km) 60,000 miles (96,500 Km)
Base API GL-5 Gear Oil, 75W-140, 80W- or 1 year or 1 year
MIL-PRF-2105E 90, 85W-140

Severe Service Lubrication Change Intervals – Severe service
applications are those where the vehicle consistently
operates at or near its maximum GCW or GVW ratings, dusty
or wet environments, or consistent operation on grades
greater than 8%. For these applications, the ON/OFF HIGHWAY
portion of the chart should be used. Typical applications
are construction, logging, mining and refuse removal.

Note: Clean metallic particles from the magnetic filler plug
and drain plugs. Clean or replace the breather yearly to
avoid lube contamination due to water ingestion.

* Axles using LMS wheel end system

** Axles using adjustable wheel bearing system

For additional lubrication information, see TCMT-0021.

76

Change Lube

Lubrication

Drain

Drain when the lube is at normal operating temperature
(150°–200°F). It will run freely and minimize the time neces­sary to fully drain the axle, this insures the axle is flushed.

Unscrew the magnetic drain plug on the underside of the axle
housing and allow the lube to drain into a suitable container.

Note: Dispose of all used lubricants properly by following dis-

posal methods approved for mineral or synthetic based
oils.

After initial oil change, inspect drain plug for large quantities
of metal particles. These are signs of damage or extreme wear
in the axle. Clean the drain plug and replace it after the lube
has drained completely. Inspect breather for clogging or cor­rosion. Clean or replace as necessary.

Fill

Front Axle

a. With vehicle on level ground, remove the filler hole

plug from the axle housing cover and fill the axle
with approved lubricant until level with the bottom of
the hole.

Note: Lube fill capacities (see chart) are basic guidelines and

will vary based on the angle the axle is installed in a par­ticular chassis. Torque fill plug to 40–60 lbs. ft.
(54–82 N•m).

TIP: The axle can be filled through the axle housing breather
hole. Fill until lube level is even with the bottom of filler hole in

axle housing rear cover.

1 - With axle on level surface, fill housing with oil to bottom
of plug
2 - Temperature sensor mounting hole

Lubrication

Rear Axle

a. Remove the fill

cover and fill the axle with the approved lubricant
until level with the bottom of the hole.

b. If wheel ends were removed, follow instructions in

wheel end servicing page 40.

Correct lube level at bottom of filler hole.

Always use the filler hole as the final reference. If lube is level
with the bottom of the hole, the axle is properly filled.

er hole plug from the axle housing

77

Standpipes

Lubrication

Drive axles are lubricated with oil drawn from a large sump
integral to the assembly. Most axle designs attempt to posi­tion vital components such as pinion bearings in close prox­imity to this sump, keeping them bathed in a generous supply
of oil at all times.

When drive axles are installed at severe angles in vehicle
chassis, the position of these components is changed relative
to the oil sump. The same effect is present when the vehicle
travels up a steep grade. Oil in the sump remains level while
the axle itself tilts up or down. This makes it possible for bear­ings and gears located well forward in the assembly to
“starve” for lubrication even though the axle is filled to the
base of the fill plug hole as recommended by the manufac­turer.

Axles should be modified with standpipes to raise lube levels
whenever chassis installation angles exceed 10° and when the
vehicle must negotiate continuous or lengthy grades on a rou­tine basis.

The chart gives
operating in consistently mountainous areas.

S170

Axle Installation
Angle

12° Rear 29*

10° Rear 30*

8° Rear 31

6° Forward

4° Forward

standpipe recommendations for vehicles

Axle Location Quantity

(pints)

39

Rear

Rear

32

41

33.5

S190

Axle Installation
Angle

12° Rear 29*

10° Rear 30*

8° Rear 31

6° Forward

4° Forward

2° Forward

0° Forward

*Does not allow for standpipe.

Capacities do not include wheel equipment requirements.
An additional 1-2 pints is required in each wheel hub.

Tandem Forward Axles

Installation
Angle*

0° – – –

3° – – 2.00"

5° – 1.00" 2.25"

7° – 1.25" 2.50"

10° 1.50" 1.75" 2.75"

Axle Location Quantity

Rear

Rear

Rear

Rear

5-10%
Grade

10-15%
Grade

(pints)

42.5
32

44.5

33.5

47
35

50
36

15-20%
Grade

2° Forward

Rear

0° Forward

Rear

*Does not allow for standpipe.

Capacities do not include wheel equipment requirements.
An additional 1-2 pints is required in each wheel hub.

78

43
35

45
36

13° 1.75" 2.00" 3.00"

15° 2.50" 2.50" 3.25"

*Pinion pointing upward

Lubrication

Tandem Rear Axles

Installation
Angle*

0° – – –

3° ––1.00"

5° – 1.00" 1.75"

7° – 1.75" 2.00"

10° – 2.00" 2.25"

13° 1.00" 2.25" 2.75"

15° 2.00" 2.50" 3.25"

*Pinion pointing upward

Horizontal Mounting

5-10%
Grade

10-15%
Grade

15-20%
Grade

12° Installation

2

1

1 - Oil Filler Hole
2 - Lost Oil Capacity

12° Installation with Standpipe

2

1

Lubrication

1 - Oil Filler Hole
2 - Additional Oil Capacity

2

1 - Oil Filler Hole
2 - Lost Oil Capacity

Note: Grades must be continuous or lengthy in nature. Moni-

tor oil temperatures before installing standpipes. Axles

1

should operate at approximately 100°F (38°C) over
ambient temperature and not exceed 240°F (116°C).

Final Check

Prior to putting vehicle back into service, run the vehicle to
bring axle lube up to temperature. Check filler and drain plugs
and axle joint for leakage. Re-tighten to specifications as nec­essary.

79

Proper Vehicle Towing

Towing Guide

Without Wheel Differential Lock

Lift the drive wheels completely off of the ground or damage
will occur.

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 over­heat resulting in axle damage or failure.

If it is impossible to lift the drive wheels, remove all axle
shafts to prevent gear rotation and cap the wheel hubs to pre­vent loss of lubricant and a possible road hazard. See the fol­lowing section Proper Vehicle Towing with Wheel Differential
Lock for removal procedure.

With Wheel Differential Lock

Follow this procedure to remove all axle shafts preventing
gear rotation with the drive wheels and possible lubrication

ge:

dama

1. Engage the wheel differential lock, indicator light is
on (move vehicle to verify engagement).

2. Shift transmission into neutral.

3. With vehicle stationary, release the air pressure on
the wheel differential lock shift system and apply the
parking brake.

4. Disconnect the air supply and fitting at the shift
cylinder.

5. Install the shipping capscrew 128642 (0.250 X 18 X

1.5") NPSM screw. GM models require part number
128274 (M12 X 1.5 X 38mm) screw. Tighten cap­screw to manually engage the wheel differential lock
until the indicator light is on and the differential lock
is completely engaged.

6. Remove the axle shafts.

7. Install temporary cover on hub to prevent contami­nation entering and also to prevent the loss of lubri­cant.

80

Theory of Operation

Power Divider Operation (Power Flow and Torque Distribution)

In operation, the power divider accepts torque from the
vehicle driveline and distributes it equally to the two axles.

This assembly is of the two-gear design consisting of an
input shaft, inter-axle differential, output shaft and two
constant-mesh helical gears.

With Lockout Engaged
(Inter-Axle Differential is Operating)

5

The inter-axle differential compensates for minor variations
in speed between the two axles, the same way the wheel
differential works between the two wheels of a single drive
axle. This unit also acts as a central point in distribution of
torque to the two axles.

The power divider also includes a driver-controlled, air­operated lockout. When lockout is engaged, it mechanically
prevents inter-axle differentiation for better performance
under poor traction conditions.

1

2

3

Theory of Operation

1 - Input torque
2 - Lockout disengaged
3 - Forward axle torque is transmitted from the helical side
gear through the pinion helical gear, drive pinion, ring gear,
wheel differential and axle shafts.

4

4 - Rear axle torque is transmitted from the output shaft side
gear through the output shaft, inter-axle driveline, drive
pinion, ring gear, wheel differential and axle shafts.
5 - Input torque (power flow) from the vehicle driveline is
transmitted to the input shaft and the inter-axle differential
spider. The differential distributes torque equally to both

axles.

81

Theory of Operation

With Lockout Engaged
(Inter-Axle Differential is Not Operating)

Lockout should only be engaged when both axles are rotat­ing at the same speed. Operation should be limited to low­traction situations and should be disengaged when normal
traction returns. Failure to do so will result in poor handling
and damage to the axle components.

5

Note: Varied road surface conditions can result in unequal

torque distribution between the two axle assemblies.

CAUTIONCAUTION

Prolonged operation with the lockout engaged can dam­age axle and driveline components.

1

2

3

1 - Input torque
2 - Lockout engaged
3 - Forward axle torque is transmitted from the helical side
gear through the pinion helical gear, drive pinion, ring gear,
wheel differential and axle shafts.

82

4

4 - Rear axle torque is transmitted from the output shaft side
gear through the output shaft, inter-axle driveline, drive
pinion, ring gear, wheel differential and axle shafts.
5 - Input torque (power flow) from the vehicle driveline is
transmitted directly to the helical side gear and the output
shaft. A positive drive is provided to both axles for
maximum traction under adverse road conditions.

Operate Wheel Differential Assembly

Theory of Operation

The Spicer wheel differential lock is driver-controlled and
operated by a carrier mounted air-actuated shift unit.
In operation, it positively locks the wheel differential to
provide improved traction under adverse road conditions.

Control Systems for Differential Lock

Two systems may be used to control the differential lock
operation.

Transmission Low Range Interlock Control System

The wheel differential is locked manually with the transmission
in Low Range. It is unlocked by the driver or unlocked
when the transmission is shifted out of Low Range.

Note: The interlock system is preferred for vehicles equipped
with an air-shifted, Low Range transmission. It is
designed to ensure the differential lock is not left
engaged (and to prevent accidental engagement)
when transmission is in high range.

Direct Driver-Controlled System

The driver manually locks and unlocks the wheel
differential, using a cab-mounted electric switch (or air
valve). The following description assumes the system
includes a cab-mounted electric switch and a solenoid
valve as shown in the illustration. An air valve may be
substituted for these components.

Operation is as follows:

1. With control switch in the “unlock” position, the
wheel differential functions normally.

2. When the control switch is placed in the “lock” position,
the air supply solenoid valve opens and air
pressure activates the shift cylinder. The shift fork is
moved to engage the curvic clutches, which, in turn,
lock the wheel differential.

3. When the control switch is placed in the “unlock”
position, air pressure supply to the shift cylinder is
shut off and air pressure is released from the cylinder.
A compression spring moves the shift fork to disengage
the curvic clutch and unlock the wheel differential.

Theory of Operation

83

Direct Driver-Controlled System

Theory of Operation

1

12

11

10

9

1 - Cab-mounted control valve (plunger in—valve open)
2 - Dry air supply tank 80–120 PSI
3 - Preferably equal in length
4 - Power supply
5 - Fuse or circuit breaker
6 - Indicator light or audible signal
7 - Wheel differential lock indicator switch
(part of axle assembly)
8 - Rear axle wheel differential lock air shift cylinder
(part of axle assembly)

13

14

3

9 - Forward rear axle wheel differential lock air shift cylinder
(part of axle assembly)
10 - Wheel differential lock indicator switch
(part of axle assembly)
11 - Indicator light of audible signal
12 - Fuse or circuit breaker
13 - Power supply
14 - 66468 Quick release valve (optional) located on frame rail
and within 10 feet of tubing from control valve

2

5

6

4

7

8

84

Wheel Differential Lock

Theory of Operation

The Spicer Wheel Differential Lock is an optional feature for
Spicer Axles. In operation, it positively locks the wheel differential,
to provide improved traction under adverse road conditions.

The differential lock is driver-controlled through an electric
switch or air valve mounted in the cab. The locking mechanism
is air-operated to engage a mechanical clutch and lock
the wheel differential. It is spring-operated to disengage the
lock and permit the wheel differential to function normally.

The wheel differential lock consists of three major assemblies.

• Shift Cylinder Assembly: Operates a shift fork and

push rod assembly.

• Shift Fork and Push Rod Assembly: Engages and

disengages the differential lock curvic clutch assembly.

• Curvic Clutch Assembly: Consists of a sliding clutch

splined to a axle shaft and a fixed clutch which is
splined to the differential case hub.

The differential lock also includes a selector switch (electric)
which senses clutch engagement and sends an electrical signal
to a cab mounted indicator light (or an audible signal
device).

Theory of Operation

9

3

1

4

5

2

6

7

8

1 - Sliding clutch 5 - O-ring 9 - Pin
2 - Spring 6 - Piston cover 10 - Carrier
3 - Clutch fork 7 - Washer
4 - Piston and rod 8 - Switch

10

85

Theory of Operation

Differential Lock Engaged

Air pressure applied to the shift cylinder moves the piston,
push rod, shift fork and the sliding curvic clutch engages
the fixed curvic clutch.

The sliding clutch is splined to the axle shaft. The fixed
clutch is splined to the differential case hub. Engaging the
two clutches locks the wheel differential thus preventing
wheel differential action.

Differential Lock Disengaged

When air pressure at the shift cylinder is released, a com­pression spring (mounted on the push rod) moves the push
rod, shift fork and sliding clutch as an assembly. The slid­ing clutch moves out of engagement with the fixed clutch.
The wheel differential is unlocked and operates normally.

5

4

1

2

3

Differential Lock Engagement Indicator

Differential lock engagement is detected by a switch (elec­tric) mounted on the differential carrier. An actuator,
mounted in the piston cover, operates the switch.

When the shift fork moves to engage the differential lock,
the push rod actuator moves away from the switch, allows
the switch to close
cab-mounted indicator light (or an audible signal).

When the shift fork moves to disengage the differential
lock, the compression spring also moves the push rod
actuator to contact the switch. The switch is opened and
turns off the cab-mounted indicator light (or the audible
signal).

and send an electrical signal to turn on a

5

4

1

2

3

6

Differential Lock Engaged

1 - Spring is compressed
2 - Shift fork
3 - Piston and rod
4 - Selector switch
5 - Air pressure applied engages clutches
6 - Fixed clutch splined to differential case
7 - Sliding clutch splined to axle shaft and engaged with
fixed clutch

86

7

6

Differential Lock Disengaged

1 - Spring is decompressed
2 - Shift fork
3 - Piston and rod
4 - Selector switch
5 - Air pressure applied disengages clutches
6 - Fixed clutch splined to differential case
7 - Sliding clutch splined to axle shaft

7

Power Divider - Parts Exploded View

1

2

3

4

5

19

20

21

22

25

23

24

27

26

28

43

42

Parts Identification

6

7

8

29

30

31

40

37

38

41

39

44

High Entry Input

Shaft Assembly

9

10

14

15

16

17

18

Parts Identification

32

12

11

33

11

13

34

35

36

1 - Output shaft nut
2 - Output yoke
3 - Output seal
4 - Output shaft bearing snap ring
5 - Outer bearing cup
6 - Outer bearing cone
7 - Inner bearing cone
8 - Inner bearing cup
9 - Output shaft
10 - Seal manifold
11 - Clamp
12 - Seal manifold feed tube
13 - Sump screen
14 - Output side gear bearing cup

15 - Output side gear bearing cone
16 - Pin
17 - Output side gear
18 - Pump
19 - Inter-axle differential
20 - Helical side gear
21 - Thrust washer
22 - Lockout sliding clutch
23 - Shift fork spring
24 - Shift fork assembly
25 - V-ring
26 - Input shaft
27 - Input shaft
28 - Input shaft bearing cone

29 - Carrier housing
30 - Locking capscrew
31 - Input cover
32 - Input cover capscrew
33 - Bearing cup and cage
34 - Input seal
35 - Input yoke
36 - Input nut
37 - Piston
38 - O-ring
39 - Piston cover
40 - Pinion cover
41 - Input cover capscrew
42 - Input cover
43 - Carrier housing

87

Parts Identification

Forward Axle Pinion Assembly - Parts Exploded View

1

1 - Pinion pilot bearing
2 - Pinion
3 - Pinion bearing cone - inner

2

4 - Pinion bearing cup - inner
5 - Pinion helical gear
6 - Pinion bearing spacer

2

3

4

5

6

7

8

9

7- Pinion bearing cup - outer
8 - Pinion bearing cone - outer
9 - Pinion nut

88

Parts Identification

Rear Axle Pinion Assembly - Parts Exploded View

2

3

1

2

4

5

6

7

8

9

10

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

Parts Identification

89

Parts Identification

Wheel Differential - Parts Exploded View

Before July 2013 After July 2013

1

2

3

4

5

7

8

6

9

11

12

6

14

13

10

4

9

11

3

15

2

8

6

10

18

17

5

16

7

15

6

1 - Threaded bearing adj - flange half
2 - Bearing cone - flange half
3 - Differential case LH (flange half)
4 - Ring gear and pinion set
5 - Bolt
6 - Side gear
7 - Side pinion

90

8 - Differential spider
9 - Differential case - RH (plain half)
10 - Differential case - RH (plain half)
wheel diff lock
11 - Bearing cone - plain half
12 - Threaded bearing adj - plain half

13 - Bearing adjuster - plain half
14 - Bearing cup - plain half
15 - Side gear thrust washer
16 - Side pinion thrust washer
17 - Bearing cup - flange half
18 - Bearing adjuster - flange half

Parts Identification

Wheel Differential Lock - Parts Exploded View

1 - Sliding clutch
2 - Spring
3 - Shift Fork
4 - Push rod

10

3

4

5

6

7

8

9

5 - Piston
6 - O-ring

1

2

Parts Identification

9 - Switch

10 - Roll pin
7 - Piston cover
8 - Washer

91

Parts Identification

Housing and Output Shaft Assembly - Parts Exploded View

1

2

3

4

5

6

7

8

10

9

11

16

13

12

14

17

18

15

27

26

19

25

24

21

20

22

23

Welded Rear Cover

1 - Output shaft nut
2 - Output yoke
3 - Output seal
4 - Snap ring
5 - Outer bearing cup
6 - Outer bearing cone
7 - Inner bearing cone
8 - Inner bearing cup
9 - Output shaft

92

10 - Rear cover
11 - Rear cover capscrew
12 - Fill plug
13 - Rear cover nut
14 - Washer
15 - Stud
16 - Spindle nut - Outer
17 - Locking ring
18 - Spindle nut - Inner

19 - Axle housing
20 - Breather
21 - Breather hose
22 - Carrier capscrew
23 - Nut
24 - Washer
25 - Stud
26 - Drain plug
27 - Axle shaft

Fastener Torque Specifications

Fastener Torque Specifications

Location Size Lbs. Ft. N•m

POWER DIVIDER

Input Cage Locking Bolt M8 x 1.0 x 30 13 ± 17 17 ± 23

Input Cage Locking Stud M12 x 1.75 15 ± 20 20 ±27

Locking Stud Jam Nut M12 x 1.75 60 ±65 81 ± 88

IAD Shift End Cap 2.375 - 16 UN-2A 65 ± 10 85 ± 15

Power Divider Cover Capscrews M14 x 1.5 x 45 175 ± 10 235 ± 10

Input Shaft Nut M48 x 1.5 900 ± 100 1220 ± 135

WHEEL DIFFERENTIAL AND GEARING

Front Pinion Helical Nut M48 x 1.5 900 ± 100 1220 ± 135

Output Shaft Nut M42 x 1.5 900 ± 100 1220 ± 135

Rear Pinion Nut M48 x 1.5 900 ± 100 1220 ± 135

Ring Gear, Diff. Case Bolts M20 x 1.5 x 55 500 ± 25 675 ± 30

CARRIER

Carrier Diff. Bearing Cap M18 x 1.5 x 85 265 ± 15 360 ± 20

Carrier to Housing Capscrews M16 x 1.5 x 85 250 ± 15 335 ± 20

M16 x 1.5 x 55 250 ± 15 335 ± 20

Carrier to Housing Nuts M16 x 1.5 250 ± 15 335 ± 20

Specifications

Fastener Torque

Pilot Bearing Web M16 x 1.5 x 70 210 ± 10 285 ± 15

Differential Lock Switch M14 x 1.5 10 ± 1 15 ± 3

Differential Lock End Cap 2.375 - 16 UN-2A 65 ± 10 85 ± 15

HOUSING

Rear Cover Capscrews M16 x 1.5 x 70 250 ± 15 335 ± 20

M16 x 1.5 x 55 250 ± 15 335 ± 20

Rear Cover Nuts M16 x 1.5 250 ± 15 335 ± 20

Magnetic Plug (Fill) 1 x 11.5 NPTF 50 ± 5 72 ± 5

Drain Plug 0.750 - 14 NPTF 50 ± 5 72 ± 5

Housing Breather 0.375 - 18 NPTF 20 - 26 27 - 35

Temperature Sending Plug 0.500 - 20 NPTF 50 ± 5 72 ± 5

Axle Shaft to Wheel Hub Nut 0.625 - 18 180 ± 10 245 ± 15

0.750 - 16 315 ± 30 425 ± 40

Wheel Diff. Lock Caps 2.37-16UN 2A 65 ± 10 85 ± 15

93

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

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-0057 09/13