Spicer S140 User Manual

Spicer

Single Drive Axles

Service Manual

S140 Series AXSM0030 September 2013

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.

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.

Any reference to brand name 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.

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

NOTE:

covered in the service procedures.

TIP: Helpful removal and installation procedures to aid in the service of this unit.

Refer to the OEM vehicle specifications

OEM

Always use genuine Spicer replacement parts.

General Information

General Information ..........................................................i

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

Ring Gear and Pinion .......................................................3

Inspection ........................................................................4

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

Differential Carrier Assembly ...........................................8

Differential Carrier Assembly -

Parts Exploded View ....................................................9

Remove Differential Carrier ............................................ 10

Install Differential Carrier ............................................... 11

Remove Wheel Differential ............................................. 12

Pinion - Parts Exploded View ......................................... 13

Pinion Removal .............................................................. 14

Drive Pinion ...................................................................15

Pinion Installation ..........................................................16

Wheel Differential Assembly - Parts Exploded ...............18

Disassemble, Overhaul, and

Assemble Wheel Differential ..................................... 19

Measure and Adjust Carrier Assembly ...........................24

Adjust Ring and Pinion Tooth Contact Pattern ............... 26

Install Axle Housing Breather .........................................28

Wheel End Seal - Parts Exploded View ......................... 29

Remove and Overhaul Wheel End Seal .......................... 30

Adjust Wheel Bearing.....................................................31

Wheel End .................................................................... 33

Lubricate Wheel End ..................................................... 34

Lubrication ................................................................... 36

Change Lube ................................................................ 38

Proper Vehicle Towing ....................................................39

Torque Chart ................................................................. 40

Introduction

Dana Commercial Vehicle Division, presents this publication to aid in maintenance and overhaul of Spicer single drive axles. Instructions contained cover the models listed. Their design is common, with differences in load capacity. Capacity variations are achieved by combining basic differential carrier assemblies with different axle housings, axle shafts and wheel equipment.

Model Listing

Rear Axle Load Capacity

S19-140 19,000

S17-140 17,000

Model Information

S 19 - 1 4 0 L

S - S i n gle R e a r Axle

G A W R at in g x 1000 l bs .

Gea r Ty p e

1 - S t a n d a r d S i n gle R e d u c t i o n 2 - D u a l R a n g e 3 - Pla n e t a r y Do uble R ed uc ti on 4 - C o n t r olled Tr act io n Differ en tial 5 - H elical R e d u c t i o n

O p t i o n s

L - L imit e d - S lip W - W i d e -t r ack F - Rolled Ove r R - P a r k i n g B r ake

D e s i g n L evel

H ead A s s e mbl y S e r i e s

Model Identification

Drive Axle

Introduction

Spicer

CUST. PART NO.

SPEC. SERIAL NO.

MODEL PART NO. RATIO

MADE IN:

1 - Country of 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

Part Identification

Axle Housing Axle Shaft

CUST. PART NO.

SPEC. SERIAL NO.

MODEL PART NO. RATIO

MADE IN:

Spicer

Introduction

Spicer

PT. NO. HSG. CAP. LBS.

. I.D. NO.

ADE IN HSG HOUSING M

1 - ID Tag 2 - Axle shaft part number

Introduction

Ring Gear and Pinion

Note: Ring gear and drive pinion are matched parts and must be replaced in sets.

127381

L7038

SPICER

41-8

NL2

8-41

127428

127

SPICER

1 - Part number 2 - Number of ring gear teeth 3 - Manufacturing numbers

6-39

JD77

85405

4 - Matching gear set number 5 - Number of pinion teeth

7 - Indicates genuine Spicer parts 8 - Heat Code

6 - Date code

Inspection

Failure Analysis

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

ut determining its cause, there will be a recurring failure.

witho 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. 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

cause unknown. Nothing is more disturbing to a

case of

a rebuilt rear axle, mismatched gears may have

pile with th customer than a repeat failure. Systematically analyzing a failure to prevent a repeat occurrence assures quality 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 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 technicia

Other parts

of the carrier must be

ser

vice by

a good heavy-equipment

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. Ask: In what type of service is the truck being used?

5. Ask: Has this particular failure

Ask: How was the truck working p

You need to be a good listener. Sometimes, insignificant or unrelated symptoms can point to the cause of the failure:

7. Ask: Was the vehicle operating at normal temperatures?

8. Ask: Were the gauges showing normal ranges of operation?

9. Ask: Was there any unusual noise or vibration?

After listening, review the previous repair and maintenance records. If th and compare their observations for consistency with the service and maintenance records. Verify the chassis Vehicle

entificat

Id cation plate, as well as the mileage and hours on the vehicle.

Make a Preliminary Investigation

These steps consist of external inspections and that will be valuable when combined with the results of the parts examination.

1. Look for leaks, cracks or other damage that can

2. Make note of obvious leaks around

3. Look for cracks in the carrier housing (harder to see,

4. Does the general mechanical condition of the vehicle

5. Are the tires in good condition and do the

6. If equipped with a torque-limiting device, is it work-

ere is more than one driver, talk to all of them

ion Number (VIN) number from the vehicle identifi-

point to the cause of

A missing fill or drain plug would be an obvious cause for concern.

metimes visible).

but so

indi

cate proper maintenance or are there signs of

neglect?

match?

ing properly?

the failure.

occurred before?

rior to the failure?

obser

vations

plugs and seals.

sizes

Inspection

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.

2. Look at the service records.

3. Find out when the truck was last serviced.

During the preliminary investigation, wr of the ordinary for later reference. Items that appear insignificant now may take on more importance when the subassemblies are torn down.

ite down anything out

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 necessar

y to disassemble the unit.

1. When disassembling subassemblies and parts, do not clean the parts immediately since destroy some of the evidence.

2. When tearing down the drive axle, do it in the recom-

ded manner. Minimize any further damage to the

men unit.

Ask more questions when examining the interior of

3. the carrier specifications regarding quality, quantity and viscosity? As soon as you have located the failed part, take time

. Does the lubricant meet the manufacturer

to analyze

the data.

cleaning may

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 fail-

ure is caused by a lack of lubricati 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 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.

n, you must determine if

to determine the

specific

Correct the Cause of the Problem

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

Inspection

Clean

1. Wash steel parts with ground or polished surfaces in solvent. There are many suita vents available. Kerosene and diesel fuel are acceptable.

WARNING

Gasoline is not an acceptable solvent because of its

e combustibility. It is unsafe in the workshop envi-

extr ronment.

2. Wash castings or other rough parts in solvent or clean in hot solution tanks usi tions.

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

ion.

solut

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 sion resistant paper and store in a clean, dry place.

ble commercial sol-

ng mild alkali solu-

with oil, wrap in

corro-

Inspect Axle Housing

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

• Visually inspect axle housing for cracks, nicks and burrs on

• Check carrier bolt holes and studs for foreign material.

• Replace damaged fasteners. Look for loose bolts cross-threaded holes

Any damage which affects the alignment or structural integrity of the housing requires housing replacement. Do not

r by bending or straightening. This process can affect

repai the material’s properties and cause it to fail completely under load.

• Check all seals and gaskets.

Note: Replace

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

machined surfaces.

conventional

CAUTION

gaskets with silicone rubber gas-

mating surfaces

Inspection

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 signs of 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, and differential bearings.

All fasteners for rounded heads, bends, cracks or

• dama

excessive heat in the axle

ged threads.

and are usually

Inspection

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

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

aces.

, cracks,

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.

Differential Carrier Assembly

1 - Carrier fastener 2 - Carrier assembly

Differential Carrier

Assembl

Differential Carrier Assembly

Differential Carrier Assembly - Parts Exploded View

20B

20A

1 - Pinion Nut 2 - End Yoke and Slinger 3 - Oil Seal 4 - Outer Pinion Bearing Cone 5 - Outer Pinion Bearing Cup 6 - Pinion Spacer 7 - Inner Pinion Bearing Cup 8 - Inner Pinion Bearing Cone 9 - Drive Pinion 10 - Carrier Housing 11 - Diff Case Dowels 12 - Ring Gear 13 - Ring Gear Bolts 14 - Flange Half Bearing Cone 15 - Flange Half Bearing Cup

16 - Flange Half Bearing Adjuster 17 - Side Pinion Thrust Washer 18 - Side Pinion 19 - Side Gear 20A,B - Differential Shaft 21 - Pin 22 - Capscrew 23 - Flat Washer 24 - Flange Half Cap 25 - Plain Half Cap 26 - Cotter Pin 27 - Side Gear Thrust Washer 28 - Plain Half Diff Case 29 - Plain Half Bearing Cone 30 - Plain Half Bearing Cup 31 - Plain Half Bearing Adjuster 32 - Pipe Plug

Differential Carrier Assembly

Remove Differential Carrier

Standard Differentials

1. Block the vehicle.

2. Drain axle lubricant. Remove bottom two (2) capscrews.

3. Disconnect driveline.

4. Remove axle shafts. (If used, remove lock washers and tap

Do not lie under carrier after fasteners are removed. Use transmi prior to loosening fasteners.

ssion jack to support differential carrier assembly

r dowels.)

WARNING

CAUTION

Do not strike the shaft head with a steel hammer. Do not

use chi

els or wedges to loosen shaft or dowels.

5. Remove carrier capscrews and washers.

6. Remove differential carrier assembly.

Differential Carrier

Assembl

Differential Carrier Assembly

Install Differential Carrier

IMPORTANTIMPORTANT

Before installing carrier assembly, inspect and thoroughly clean interior of axle housing using an appropriate solvent and clean rag.

1. Apply Spicer approved RTV compound on axle housing mating surface as shown in the illustration. Completely remove all old gasket material prior to applying new material. Compound will set in 20 minutes. Install carrier before compound sets or reapply.

1 - Apply RTV gasket in this pattern

TIP: To assist in installing complete differential carrier use two pieces of threaded rod (M14 X 2) threaded into carrier capscrew holes. Rod should be approximately 4" (102 mm) long. Use these to pilot the carrier into the housing.

2. Install carrier to housing, lock washers and capscrews. Torque to proper specification. Torque to 142–158 lbs. ft. (193–214 N•m).

3. Install axle shafts and axle

d axle lubricant. Fill to bottom of filler hole in car-

4. Ad rier.

5. Connect main driveline and lubricate joints.

stud nuts.

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