Spicer S135L, S135N, S135S, S150L, S150N User Manual
...
Spicer® Single Drive Axles
Service Manual
Spicer® Drive Axles
AXSM-8941
September 2007
General Information
General Information
The description and specifications contained in this service publication are current at the time of printing. Dana Corporation
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.
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.
Always use genuine Dana replacement parts.
Table of Contents
Table of Contents - Visual
Wheel
Differential
Assembly
page 17
Carrier
Assembly
page 8
Table of Contents
Drive
Pinion
page 12
Housing
Breather
page 26
Lubrication
page 33
Pinion
Seals
page 12
Wheel
End Seal
page 28
Table of Contents
General Information
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . 3
Ring Gear and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection
Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Prepare the Parts for Inspection . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect Axle Housing . . . . . . . . . . . . . . . . . . . . . . 7
Inspect Primary Gearing . . . . . . . . . . . . . . . . . . . 7
Differential Carrier Assembly
Differential Carrier Assembly - Exploded View . . . . . . 8
Removal of Differential Carrier From Axle Housing . . 9
Install Differential Carrier . . . . . . . . . . . . . . . . . . . . . 10
Remove Wheel Differential . . . . . . . . . . . . . . . . . . . . 11
Pinion Assembly
Rear Axle Pinion Assembly - Exploded View . . . . . . 12
Remove Pinion Assembly . . . . . . . . . . . . . . . . . . . . 13
Install Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . 15
Wheel Differential Assembly
Wheel Differential Assembly - Exploded View . . . . . 17
Disassemble, Overhaul and
Assemble Wheel Differential . . . . . . . . . . . . . . . . . . 18
Disassemble Wheel Differential . . . . . . . . . . . . . 18
Overhaul and Assemble Wheel Differential. . . . . 20
Wheel Differential Adjustments
Measure and Adjust Carrier Assembly
(Adjust Backlash and Preload) . . . . . . . . . . . . . . . . . 22
Change Backlash Setting . . . . . . . . . . . . . . . . . . . . . 23
Adjust Tooth Contact Pattern
Adjust Ring and Pinion Tooth Contact Pattern . . . . . 24
Adjust Ring Gear Position (Backlash) . . . . . . . . . . . 25
Table of Contents
Housing Breather
Install New Axle Housing Breather -
(Metal and Plastic) . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Axle Housing
Axle Housing - Exploded View . . . . . . . . . . . . . . . . . .27
Wheel End Seal
Wheel End Seal Parts - Exploded View . . . . . . . . . . .28
Remove and Overhaul Wheel End Seal . . . . . . . . . . .29
Install Wheel End Seal . . . . . . . . . . . . . . . . . . . . 29
Wheel Adjustment Systems
Adjust Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . .30
Wheel Ends
Verify Wheel End-Play Procedure . . . . . . . . . . . . . . .32
Lubrication
Lubricate Wheel End . . . . . . . . . . . . . . . . . . . . . . . . .33
General Lubrication Information . . . . . . . . . . . . . . . .35
Approved Lubricants . . . . . . . . . . . . . . . . . . . . . .35
Recommendations for Viscosity/
Ambient Temperature . . . . . . . . . . . . . . . . . . . . 35
Lube Change Intervals . . . . . . . . . . . . . . . . . . . . . . . .36
Change Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Proper Vehicle Towing
With Truetrac Limited Slip Differential. . . . . . . . 38
Torque Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Parts Identification
Rear Drive Axle Parts - Exploded View . . . . . . . . . . .40
Torque Specifications
Fastener Torque Specifications . . . . . . . . . . . . . . . . .41
Service Tools
Recommended Service Tools . . . . . . . . . . . . . . . . . .42
General Information
Introduction
Dana Corporation presents this publication to aid in maintenance and overhaul of Dana single reduction drive axles.
Instructions contained cover the models listed below. Their
design is common, with differences in load capacity. Capacity
variations are achieved by combining basic differential carrier
assemblies with different axle housings, axle shafts, and
wheel equipment.
Model Listing
The following models are included in this publication:
Dana Single Reduction Axles
With Standard Wheel Differential
S135L S135N S135S
S150L S150N S150S
Spicer
General Information
S 135 S
Gearing Type
S = Single Reduction
L = True Trac Differential
N = No Spin
Nominal Load
Carrying Capacity
135 = 13,500 lbs.
150 = 15,500 lbs.
1
Model Identification
General Information
1
(P) CARRIER #
SER #
620112
360CR100 6X
SPICER
RATIO
3.91
5
1 - Customer part number (optional)
2 - Dana part number
3 - Julian date code
4 - Line set number (optional)
5 - Last six digits of vehicle serial number
(optional)
94070
R1 4242
2
4
Rear Axle
(Top View)
CUST. PART NO.
SPEC. SERIAL NO.
MODEL PART NO. RATIO
MADE IN:
3
®
Spicer
Data plate is
located on the
axle centerline
2
Parts Identification
General Information
Axle Housing
1
360RF100-6
4
SER #
620112
6
RATIO
3.91
2
MODEL
S135-S
94070
R1 4242
Julian Date Code
94 070
Model Year
3
4
5
Day of Year
General Information
1 - Dana part number
2 - Customer part number (optional)
3 - Model
4 - Julian date code
5 - Line set number (optional)
6 - Last six digits of vehicle serial number (optional)
Axle Shaft
1
1 - Axle shaft part number
3
Ring Gear and Pinion
Manufacturer’s Date - Date gear set was made.
General Information
Spicer Trademark - Company logo and location of manufac-
turing facility.
360GP104 - Part number of pinion 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.
1
41-11
41-11
2
3
4
Matched Set Number - Spicer ring and pinions are manufac-
tured as matched sets. Both ring and pinion are marked with a
corresponding number (i.e. 260), which identifies them as a
matched set.
A gear set that does not have the same match set numbers
should not be mated together. If either ring gear or pinion
require replacement, a new matched set must be used.
260
5
6
7
1 - Spicer trademark
2 - Tooth combination
3 - Part number
4 - Heat code
4
260
5 - Spicer trademark
6 - Manufacturer’s date
7 - Matched set number
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.
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.
You need to be a good listener. Sometimes, insignificant or
unrelated symptoms can point to the cause of the failure.
• Ask: Was the vehicle operating at normal tempera-
tures?
• Ask: Were the gauges showing normal ranges of
operation?
• Ask: 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.
Make a Preliminary Investigation
These steps consist of external inspections and observations
that will be valuable when combined with the results of the
parts examination.
• Look for leaks, cracks, or other damage that can
point to the cause of the failure.
• Make note of obvious leaks around plugs and seals.
A missing fill or drain plug would be an obvious
cause for concern.
• Look for cracks in the carrier housing (harder to see,
but sometimes visible).
• Does the general mechanical condition of the vehicle
indicate proper maintenance or are there signs of
neglect?
• Are the tires in good condition and do the sizes
match?
Inspection
3. Prepare the parts for inspection.
4. Find the cause of the failure
5. Correct the cause of the problem.
Document the Problem
Here are some guidelines for starting to learn about a failure,
including questions to ask:
• Talk to the operator of the truck.
• Look at the service records.
• Find out when the truck was last serviced.
• Ask: In what type of service is the truck being used?
• Ask: Has this particular failure occurred before?
• Ask: How was the truck working prior to the failure?
• If equipped with a torque-limiting device, is it work-
ing 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.
5
Prepare the Parts for Inspection
Inspection
After the preliminary investigation, locate the failure and prepare the part for examination. In carrier failure analysis, it may
be necessary to disassemble the unit.
• When disassembling subassemblies and parts, do
not clean the parts immediately since cleaning may
destroy some of the evidence.
• When tearing down the drive axle, do it in the recommended manner. Minimize any further damage to the
unit.
• Ask more questions when examining the interior of
the carrier. Does the lubricant meet the manufacturer
specifications regarding quality, quantity, and viscosity? As soon as you have located the failed part,
take time to analyze the data.
Find the Cause of the Failure
Here begins the real challenge to determine the exact cause of
the failure. Keep in mind that there is no benefit to replacing a
failed part without determining the cause of the failure. For
example, after examining a failed part and finding that the failure is caused by a lack of lubrication, you must determine if
there was an external leak. Obviously, if there is an external
leak, just replacing the failed gear is not going to correct the
situation.
Another important consideration here 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 in correcting 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.
6
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
Note: Replace conventional gaskets with silicone rubber gas-
ket 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
Inspection
2
1 - Axle Housing
2 - Machined Surface
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
signs of excessive heat in the axle and are usually
related to low lubrication levels or improper lubrication practices.
Axle housing inspection and repairs are limited to the following checks or repairs:
• Visually inspect axle housing for cracks, nicks and
burrs on machined surfaces.
• Check carrier bolt holes and studs for foreign material.
• Replace damaged fasteners. Look for loose studs or
cross threaded holes.
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.
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 gear set, inspect teeth for signs of
excessive wear. Check tooth contact pattern for evidence of
incorrect adjustment.
7
Differential Carrier
Differential Carrier Assembly - Exploded View
1
1 - Carrier fasteners
2 - Carrier assembly
3 - Single axle assembly
3
2
8
Differential Carrier
Removal of Differential Carrier From Axle Housing
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 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; 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. Loosen all but the top two carrier-to-housing mounting bolts. Remove all bolts except the top two. These
two bolts will prevent the carrier assembly from falling.
9. Separate the differential carrier from the housing
using the removal slots. Make sure the carrier is balanced properly on jack. Remove the top two carrier
mounting bolts. Remove the differential carrier
assembly from the axle housing.
1
1
1 - Removal slots
10. Mount carrier assembly in a suitable rebuild stand.
Differential Carrier
9
Install Differential Carrier
Differential Carrier
IMPORTANT: Before installing the carrier assembly, inspect
and thoroughly clean interior of axle housing using an appropriate solvent and clean rag.
1. Apply Dana approved RTV compound on axle housing mating surface as shown in the illustration. Completely remove all old gasket material prior to
applying new material. Compound will set in 20 minutes. Install carrier before compound sets or reapply.
1
TIP: To assist in installing complete differential car-
rier use two pieces of threaded rod threaded into
carrier cap screw holes. Rod should be approximately 6" long. Use these to pilot the carrier into the
housing.
2. Install carrier to housing, washers, cap screws, and
nuts. Torque to proper specifications. See torque
chart of page 41.
3. Install axle shafts and axle stud nuts (if used, also
install lock washers and tapered dowels).
4. Add axle lubricant. Fill to the bottom of the fill hole.
5. Connect inter-axle driveline, making sure all yokes
are in phase. Lubricate U-joints.
1 - Apply silicone gasket in this pattern
10
Differential Carrier
Remove Wheel Differential - All Standard Models
1. Mount differential carrier in repair stand.
Note: Omit this step if the gear set is to be replaced. If gear
set is to be reused, check tooth contact pattern and ring
gear backlash before disassembling differential carrier.
When checking backlash, a yoke or helical gear must be
installed and torqued to get an accurate reading. Best
results are obtained when established wear patterns are
maintained in used gearing.
2. If reusing gear set, also punch mark bearing adjusters for reference during assembly.
3. Remove cap screws, flat washers, and bearing caps.
Loosen bearing adjusters and remove adjusters and
bearing cups.
4. Using a chain hoist, lift ring gear and differential
assembly out of carrier.
Differential Carrier
1
11
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