Spicer Drive Axles User Manual
Spicer® Drive Axles
Service Manual
Spicer® Drive Axles
AXSM-8663
September 2007
TABLE OF CONTENTS
Axle Identification .................................................................... 1
Identification ............................................................................. 2
Model Identification Numbering System
Gear Set
Axle Lubricant Recommendations......................................... 3
General Precautions ................................................................. 4
Axle Components ..................................................................... 5
Removal ...................................................................................... 6
Differential Carrier from Axle Housing
Differential from Carrier
Differential Disassembly ......................................................... 7
Pinion Above Center Applications........................................ 8
Pinion Disassembly .................................................................. 9
Cleaning and Inspection ......................................................... 10
Pinion Assembly ........................................................................ 11
Pinion Position .......................................................................... 13
Pinion Setting Chart ................................................................. 14
Differential Assembly............................................................... 16
Differential Installation ............................................................ 17
Ring Gear and Pinion Tooth Contact Pattern .................... 18
Wheel Bearing Adjustment ..................................................... 19
Installation of Differential Carrier Into Axle Housing ....... 20
Axle/Torque Specifications .................................................... 21
Recommended Service Tools ................................................. 22
GENUINE SPICER SER VICE PARTS
Should an axle assembly require replacement component
parts, it is recommended that Spicer Heavy Axle Service
Parts be used. Spicer Heavy Axle Service Parts are
manufactured under the same rigid specification as are
original equipment axle components. This assures the
customer who uses genuine Spicer service parts, maximum reliability for a Spicer Heavy Axle assembly. They
may be obtained through your vehicle manufacturer.
The use of non-original Spicer service parts may cause
premature component failure and may void the warranty.
The items included in this book are currently being offered
as service parts at the time of printing. The part numbers
and illustrations are provided specifically for reference
purposes only. Therefore, Spicer reserves the right to
update this manual without notice or liability.
i
All axle assemblies are identified with two tags. One
located on the differential carrier, and the other located
on the right hand side of the axle housing.
The differential carrier tag contains the following:
Dana part number, julian date code, and ratio. Optional
items include customer part number, line set number, and
the last six digits of the vehicle serial number.
MODEL YEARMODEL YEAR
MODEL YEAR
MODEL YEARMODEL YEAR
DD
ANA PANA P
ARAR
D
ANA P
AR
DD
ANA PANA P
ARAR
NUMBERNUMBER
NUMBER
NUMBERNUMBER
AXLE IDENTIFICATION
JULIAN DJULIAN D
JULIAN D
JULIAN DJULIAN D
99
9
99
TT
T
TT
AA
TE CODETE CODE
A
TE CODE
AA
TE CODETE CODE
7 07 0
7 0
7 07 0
CUSCUS
TT
OMEROMER
CUS
T
OMER
CUSCUS
TT
OMEROMER
PP
ARAR
T NUMBERT NUMBER
P
AR
T NUMBER
PP
ARAR
T NUMBERT NUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
77
7
77
00
0
00
DD
AA
Y OF YEARY OF YEAR
D
A
Y OF YEAR
DD
AA
Y OF YEARY OF YEAR
DD
ANA PANA P
D
ANA P
DD
ANA PANA P
NUMBERNUMBER
NUMBER
NUMBERNUMBER
ARAR
AR
ARAR
TT
T
TT
CUSCUS
TT
OMEROMER
CUS
T
OMER
CUSCUS
TT
OMEROMER
PP
ARAR
T NUMBERT NUMBER
P
AR
T NUMBER
PP
ARAR
T NUMBERT NUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
MODELMODEL
MODEL
MODELMODEL
JULIAN DJULIAN D
JULIAN D
JULIAN DJULIAN D
CODECODE
CODE
CODECODE
Carrier Tag
LINE SETLINE SET
LINE SET
LINE SETLINE SET
NUMBERNUMBER
NUMBER
LASLAS
T SIX DIGITS OFT SIX DIGITS OF
LAS
T SIX DIGITS OF
LASLAS
T SIX DIGITS OFT SIX DIGITS OF
VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER
VEHICLE SERIAL NUMBER
VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
NUMBERNUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
The axle assembly tag contains the following items:
Dana part number, julian date code, axle model, and
ratio. Optional items include customer part number,
line set number, and the last six digits of the vehicle
serial number.
AA
TETE
A
TE
AA
TETE
Axle Assembly Tag
LASLAS
T SIX DIGITS OFT SIX DIGITS OF
LAS
T SIX DIGITS OF
LASLAS
T SIX DIGITS OFT SIX DIGITS OF
VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER
VEHICLE SERIAL NUMBER
VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
LINE SETLINE SET
LINE SET
LINE SETLINE SET
NUMBERNUMBER
NUMBER
NUMBERNUMBER
(OPTIONAL)(OPTIONAL)
(OPTIONAL)
(OPTIONAL)(OPTIONAL)
JULIAN DJULIAN D
JULIAN D
JULIAN DJULIAN D
CODECODE
CODE
CODECODE
AA
TETE
A
TE
AA
TETE
1
MODEL IDENTIFICATION NUMBERING SYSTEM
FF
amilamil
yy
F
amil
y
FF
amilamil
FF
F
FF
1 1
1
1 1
77
7
77
00
0
00
S NS N
S N
S NS N
yy
Load Carr Load Carr
Load Carr
Load Carr Load Carr
(1 (1
55
5 = 15 = 1
5
5 = 1
55
5 = 15 = 1
77
0 = 10 = 1
7
0 = 1
77
0 = 10 = 1
5,55,5
5,5
5,55,5
77
7
77
(1
(1 (1
(1 (1
(1
(1 (1
ying Capacitying Capacit
ying Capacit
ying Capacitying Capacit
00 Lbs.)00 Lbs.)
00 Lbs.)
00 Lbs.)00 Lbs.)
,000 Lbs.),000 Lbs.)
,000 Lbs.)
,000 Lbs.),000 Lbs.)
OpOp
Op
OpOp
(N= No-SPIN(N= No-SPIN
(N= No-SPIN
(N= No-SPIN(N= No-SPIN
yy
y
yy
tionstions
tions
tionstions
Gearing TGearing T
Gearing T
Gearing TGearing T
(S= Single R(S= Single R
(S= Single R
(S= Single R(S= Single R
® ®
®
® ®
opop
tion)tion)
op
tion)
opop
tion)tion)
ypeype
ype
ypeype
educeduc
educ
educeduc
GEAR SET IDENTIFICATION
tion)tion)
tion)
tion)tion)
* No-SPIN® is a registered trademark of Tractech
Manufacturer's Date- Date gear set was made.
Spicer Trademark- Dana Diamond and location of
manufacturing facility.
029GP100- Part number of pinion. (TYPICAL)
029GR107- Part number of ring gear. (TYPICAL)
Tooth Combination(i.e. 41-11)- Indicates the pinion
has 11 teeth and the ring gear has 41 teeth which
results in a 3:73:1 ratio.
Matched Set Number- Spicer ring gears and pinions
are manufactured as matched sets. Both ring gear and
pinion are marked with a corresponding number (i.e.
401), which identifies them as a matched set.
A gear set that does not have the same match set
numbers should not be run together. If either ring gear
or pinion require replacement,
a new matched set must
be used.
41-11
TOOTH
COMBINATION
TRADEMARK
PART
NUMBER
SPICER
CODE
HEAT
SPICER
TRADEMARK
PINION
ETCH
MFG.
DATE
L10
BACKLASH
ETCH
+15
260
MATCHED
SET NUMBER
401
Backlash Etch- Indicates backlash setting for assembly.
Pinion Etch- Indicator for proper pinion position shim
stack up. See Pinion Position Section.
2
AXLE LUBRICANT RECOMMENDATIONS
To ensure proper lubrication and operating temperature,
correct lubricants and lubricant levels must be obtained.
RECOMMENDED LUBRICANTS
Mineral or Synthetic based hypoid gear lubricants that
meet or exceed military specification MIL-L-2105D, and
API service classification GL-5, are the minimum requirements for use in Spicer Medium and Heavy Duty Drive
Axles.
The table below indicates which SAE viscosities are
recommended for various temperature ranges the vehicle
will encounter.
Ambient Air Temperature
APPLICATION
On Highway 100,000 1 Year 250,000 3 Year
* Severe Service
and 50,000 1 Year 100,000 1 Year
On-Off Highway
PETROLEUM BASED SYNTHETIC BASED**
MILES INTERVAL MILES INTERVAL
* Severe service includes any applications operating at
or near maximum GVW or GCW ratings. This
includes normally wet or dusty environments, or
consistent heavy load and low speed applications.
** Includes Semi-Synthetic blends that meet
MIL-L-2105D specifications.
AFTER OVERHAUL OR CHANGE INTERVALS
Fill the axle assembly to the bottom of housing fill hole
as shown in the illustration below. It is recommended
that following an overhaul, each side of the axle be
jacked up seperately to approximately six inches and held
into position for one minute. This procedure will allow
adequate lubricant to flow into the wheel ends and help
eliminate the possibility of premature damage to wheel
bearings and seals. Lower the vehicle to the floor and
allow ten minutes for lube to return to normal level.
Check and refill assembly to bottom of fill hole to replace
the lubricant that was directed into the wheel ends.
SERVICE
Recommended lubricant change intervals are dependent
on the application and operating environment. The
following chart should be used to establish proper
change intervals.
SUBMERSION OR DEEP WATER FORDING
In the event the axle assembly should become
submerged in water, particularly if over the vent or
breather, it is recommended that the lubricant be
drained and all parts be inspected for water damage
and/or contamination. Reassemble the carrier to the
housing and refill with specifed gear lubricant.
NOTE: Lubricant close enough to the bottom of the fill hole to be seen or touched
is not sufficient. Lubricant must be level with the fill hole.
3
GENERAL PRECAUTIONS
READ THIS SECTION BEFORE STARTING
GENERAL AXLE DESCRIPTION
IMPORTANT
ANY SERVICE PROCEDURES
This manual covers maintenance and rebuild procedures for the Spicer F155-S and F170-S rear drive axle
assemblies.
The Spicer Heavy Duty Single Reduction rear drive axle
is a full floating axle assembly, with a hypoid gear carrier
assembly, using a High Strength Low Alloy (HSLA) steel
axle housing. The hypoid pinion is straddle mounted
with two tapered roller bearings behind the pinion teeth
for thrust and radial loads. A pilot bearing is located on
the nose of the pinion for radial load. The differential
itself uses four precision forged pinion mate gears, a
forged cross, and precision forged side gears.
Safety glasses should be worn
at all times when assembling
or disassembling axles.
Accordingly, anyone who uses a service procedure or
tool different than shown must insure that their safety,
and the vehicle's safety, will not be jeopardized by the
service method selected.
END YOKES AND FLANGES
CAUTION: Hammering on end yokes can close
in the bearing bores or misalign yoke lugs and result
in early failures of journal needle bearings or other
driveline components. Serious damage can also be
done internally to the ring and pinion set or pinion
bearings by hammering on external parts. End yokes
or companion flanges should be removed or installed
using the recommended methods outlined in this
manual.
SAFTEY PRECAUTIONS
Proper service and repair of vehicle components is
important to the safe and reliable operation of all motor
vehicles. This applies particularly to driving axles such as
the ones described in this manual. The procedures
recommended and described in this manual are tested,
effective methods for performing service operations.
Follow each procedure closely, making use of both the
text and illustrations. Some of these service procedures
show the use of certain tools designed specifically for
the operation being performed. They are shown as a
preferred means of performing the operation. It is not
practical to anticipate and advise the service trade of all
possible alternative methods, and of all possible hazardous consequences that could occur.
CLEANLINESS
Axle components should be steam cleaned prior to
removal from the vehicle. Dirt is abrasive and will cause
premature wear of otherwise serviceable parts.
Service personnel should use a wash tank for thorough
cleaning of parts just prior to reassembly.
CAUTION
BRAKE LININGS CONTAIN NON-ASBESTOS FIBERS
BREATHING BRAKE DUST MAY BE HAZARDOUS TO YOUR HEALTH AND
MAY CAUSE SERIOUS RESPIRATORY OR OTHER BODILY HARM.
AVOID CREATING DUST
DO NOT REMOVE BRAKE DRUM WITHOUT PROPER PROTECTIVE EQUIPMENT.
DO NOT WORK ON LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT.
DO NOT REPLACE LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT.
DO NOT ATTEMPT TO SAND, GRIND, CHISEL, FILE, HAMMER OR ALTER BRAKE
LININGS IN ANY MANNER WITHOUT PROPER PROTECTIVE EQUIPMENT.
FOLLOW 0.S.H.A. STANDARDS FOR PROPER PROTECTIVE DEVICES TO BE USED
WHEN WORKING WITH BRAKE MATERIALS.
4
Axle Shaft
AXLE COMPONENTS
Differential Bearing Cap Bolt
(115-135 Lb-Ft)
(155-183 N-m)
Differential Bearing
Cap Washer
Differential Pinion Mate
Differential Cross Shaft
Differential Side Gear
Differential Gear
Thrust Washer
Cotter
Pin
Adjusting Ring
Lock
Differential Case Nut
(75-90 Lb-Ft)
(100-120 N-m)
Fill Plug
(35-45 Lb-Ft)
(47-61 N-m)
Differential Pinion Mate
Thrust Washer
Vent Plug
Magnetic Drain Plug
(35-45 Lb-Ft)
(47-61 N-m)
Ring Gear Rivet
Carrier Housing
Housing
Hex Bolt
(7-9 Lb-Ft)
(9-12 N-m)
Washer
Oil Scoop
Differential Case
Flange Half
Ring Gear
Ring Gear Bolt Kit
(300-320 Lb-Ft)
(406-434 N-m)
Pinion Position Shim(s)
Pinion Pilot Bearing
Differential Bearing Cap
Adjusting Ring
Differential Bearing Cup
Differential Bearing Cone
Differential Case Bolt
Pinion-Up Components
Oil Scoop
Oil Deflector
Differential Case
Cap Half
No-SPIN® Differential
(Optional)
Carrier Mounting Bolt
(100-120 Lb-Ft)
(136-162 N-m)
Inner Pinion Bearing Cone
Pinion
Inner Pinion Bearing Cup
Pinion Bearing Spacer
(Selective)
Pinion Bearing Cage
Outer Pinion Bearing Cup
Pinion Bearing Cage Bolt
5
(160-180 Lb-Ft)
(217-244 N-m)
Outer Pinion
Bearing Cone
Pinion
Oil Seal
End Yoke
Assembly
Flanged Hex Nut
(700-900 Lb-Ft)
(950-1,220 N-m)
REMOVAL OF DIFFERENTIAL
CARRIER FROM AXLE HOUSING
NOTE: Steam clean axle assembly.
1. Block wheels.
2. Remove axle housing drain plug and drain lubricant.
3. Disconnect drive shafts at the rear U-joint.
NOTE: If end yoke and/or seal is to be replaced,
loosen yoke nut at this time.
4. Remove axle shaft flange nuts.
5. Hold a large brass drift or a brass hammer against
the center of the axle shaft flange. Strike the drift
with sharp blows from a large hammer or sledge
until the axle shaft separates from the hub.
CAUTION: Do not strike the flange directly
with a steel hammer or sledge. This may crack and
splinter material, possibly causing serious or fatal
injury. Do not pry or chisel axle flange away from
hub or damage to sealing surfaces could occur.
6. Remove axle shafts.
7. Support the differential carrier assembly on a roller
jack. Secure as necessary to prevent it from
falling off the jack when removed from the housing.
8. Use a breaker bar to loosen the differential carrier-
to-housing mounting bolts. Remove all bolts except
top two. These two bolts will prevent the carrier
assembly from falling.
9. Separate differential carrier from the housing. Be
certain carrier is balanced properly on jack, and
remove top two carrier-to-housing mounting bolts.
Remove differential carrier assembly from the axle
housing.
Mount carrier assembly in a suitable rebuild stand.
(Refer to Recommended Service Tools, pg. 22).
Differential Carrier Removal Complete
REMOVAL OF DIFFERENTIAL FROM CARRIER
1. Remove adjusting ring locks from bearing caps.
2. Match mark one differential bearing cap and leg with
center punch or chisel for correct reassembly. See
Figure 1.
3. Loosen four bearing cap retainer bolts.
4. Loosen adjusting rings, relieving bearing preload.
5. Remove four bearing cap retainer bolts.
6. Remove bearing caps.
7. Remove adjusting rings.
8. Carefully lift the ring gear and differential
subassembly out of the carrier.
NOTE: Use care not to damage the ring gear and
pinion. If either ring gear or pinion show signs of
damage, they must be replaced as a matched set.
Removal of Differential Complete
FF
F
FF
igurigur
igur
igurigur
e 1e 1
e 1
e 1e 1
6
Cotter Pin
Differential Gear Thrust Washer
Differential Side Gear
Differential Pinion Mate Thrust Washer
Differential Pinion Mate
Differential Bearing Cap Bolt
(115-135 Lb-Ft)
(155-183 N-m)
Differential Bearing
Cap Washer
DIFFERENTIAL DISASSEMBLY
Differential Bearing Cap
Hex Bolt
(7-9 Lb-Ft)
(9-12 N-m)
Ring Gear
Ring Gear Rivet
Differential Cross Shaft
Washer
Oil Scoop
Differential
Bearing Cone
Differential Case Bolt
Differential Case Flange Half
Ring Gear Bolt Kit
(300-320 Lb-Ft)
(406-434 N-m)
Adjusting
Ring
Adjusting Ring
Lock
Differential
Bearing Cup
Differential Case Cap Half
Differential Case Nut
(75-90 Lb-Ft)
(100-120 N-m)
1. Match mark differential case halves with punch or
chisel for correct alignment during reassembly. See
Figure 2.
(Optional)
FF
igurigur
e 2e 2
F
igur
e 2
FF
igurigur
e 2e 2
2. Remove differential case nuts and lift off the
differential case half.
3. Remove thrust washer and differential side gear.
4. Lift out cross shaft, pinion mates and thrust washer.
5. Remove second differential side gear and thrust
washers.
FF
igurigur
e 3e 3
F
igur
e 3
FF
igurigur
e 3e 3
6. If differential side bearings are to be replaced,
remove old bearings using suitable puller. See
Figure 3.
NOTE: Inspect all parts, including the machined
surfaces of the case itself.
7
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