Spicer S170, S190, S590 User Manual

Spicer

®

Single Drive Axles

Service Manual

AXSM0056
September 2013

S170 Series

S190 Series

S590 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 23

Table of Contents

Carrier
Assembly
page 7

Drive
Pinion
page 12

Housing
Breather
page 46

Lubrication
page 54

Wheel
End Seal
page 47

Seals
page 47

Wheel
Differential
Lock
page 40

General Information

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

Model Identification ..................................................... 2-3

Failure Analysis ...........................................................4-5

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

Differential Carrier Assembly - Parts................................7

Remove Differential Carrier .......................................... 8-9

Install Differential Carrier ...............................................10

Remove Wheel Differential (All Standard Models) ..........11

Pinion Removal ......................................................... 12-13

Pinion Assembly - Parts Exploded View ......................... 14

Drive Pinion Overhaul and Assembly .........................15 -19

Wheel Differential - Parts Exploded View ...................... 20

Wheel Differential Disassembly - Before July 2013

Forward Carrier Assembly .................................. 21-22

Wheel Differential Assembly -

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

Install Wheel Differential Assembly -

Forward Carrier Assembly .................................. 25-29

Wheel Differential Disassembly - After July 2013

Forward Carrier Assembly .................................. 30-31

Wheel Differential Assembly -

Forward Carrier Assembly .................................. 32-34

Install Wheel Differential Assembly -

Forward Carrier Assembly .................................. 35-37

Adjust Tooth Contact Position .................................. 38-39

Wheel Differential Lock - Parts Exploded View.............. 40

Install and Adjust Wheel Differential Lock ...................... 41

Housing and Output Shaft Assembly -

Parts Exploded View .................................................42

Replace Seal ............................................................43-44

Service Kit .................................................................... 45

Housing Breather .......................................................... 46

Wheel End Seal - Parts Exploded View ..........................47

Remove and Overhaul Wheel End Seal .......................... 48

Adjust Wheel Bearing...............................................49-50

Verify Wheel Endplay Procedure ....................................51

Lubricate Wheel End ................................................ 52-53

General Lubrication Information .................................... 54

Lube Change Intervals .................................................. 55

Change Lube ................................................................ 56

Standpipes .............................................................. 57-5 8

Proper Vehicle Towing ....................................................59

Power Divider Operation

(Power Flow and Torque Distribution) .................60-61

Operate Wheel Differential Assembly .............................62

Direct Driver-Controlled System .................................... 63

Wheel Differential Lock ............................................64-65

Pinion Assembly - Parts Exploded View ........................ 66

Wheel Differential -

Parts Exploded Views ...............................................67

Wheel Differential Lock Assembly -

Parts Exploded Views .............................................. 68

Housing and Output Shaft Assembly -

Parts Exploded View ................................................ 69

Fastener Torque Specifications ......................................70

Introduction

General Information

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
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

S 23-1 7 0 D

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) "."

Model Information

The following models are included in this publication:

Heavy Singles

S21-170 S26-190

S21-170D S26-190D

S23-170 S30-590

S23-170D S30-190

S23-190 S30-190D

S23-190D S30-190E

S25-170 S35-590

S26-170 - - -

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

General Information

Gear Type

1 - Standard Single Reduction
2 - Dual Range
3 - Planetary Double Reduction
4 - Open
5 - Helical Reduction

Design Level

Head Assembly Series

1

Model Identification

Drive Axle

General Information

4

3

CUST. PART NO.

SPEC. SERIAL NO.

Spicer

®

2

MODEL PART NO. RATIO

1

MADE IN:

1 - Country or origin
2 - Axle model identification
3 - Specification number assigned to the axle built by Spicer.
Identifies all component parts of the axle including
special OEM requirements such as yokes or flanges.

5

6

®

CUST. PART NO.

7

SPEC. SERIAL NO.

MODEL PART NO. RATIO

MADE IN:

Spicer

Rear Axle (Top View)

4 - OEM part number assigned to the axle build
5 - Carrier assembly serial number assigned by the
manufacturing plant
6 - Axle gear ratio
7 - Carrier assembly production or service part number

Parts Identification

Axle Housing

P
A

PT. NO.

. C

G

. NO

HS

. I.D

G

HS

USING

HO

1 - ID Tag

2

. LB

MA

Spicer

.
DE IN

Axle Shaft

2

®

S.

1

2 - Axle shaft part number

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 carrier housing (harder to see,
but sometimes visible).

• Does the general mechanical condition of the vehicle
indicate proper maintenance or are there signs of
neglect?

• Are the tires in good condition and do the sizes
match?

• If equipped with a torque-limiting device, is it work­ing properly?

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

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,
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.

after examining a 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

signs of excessive heat in the axle and are usually
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 gear set, inspect teeth for signs of
excessive wear. Check tooth contact pattern for evidence of
incorrect adjustment.

6

y

Differential Carrier Assembly

Differential Carrier Assembly - Parts

3

1 - Carrier fasteners
2 - Carrier assembly
3 - Single axle assembly

Differential Carrier

Assembl

1

2

7

Differential Carrier Assembly

Remove Differential Carrier

Note: The removal of the forward carrier does not require dis-

connecting of the inter-axle driveline and removal of the
output shaft yoke assembly as most other Spicer tan­dems require.

Standard Differentials

1. Block the vehicle.

2. Drain axle lubricant.

3. Disconnect driveline.

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

5. Remove axle shafts.

WARNING

Do not lie under carrier after fasteners are removed. Use
transmission jack to support differential carrier assembly
prior to lo osening fa steners.

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

7. Remove axle shafts.

Note: All models in this

unequal lengths. Axle shafts may also be location spe ­cific with various wheel equipment. Do not misplace axle
shafts from their intended location. Identify
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.

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

publication use axle shafts with

left and right

CAUTION

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

9. Remove differential carrier assembly.

8

Carrier Assembly

After July 2013

Mount the differential carrier in a head stand with

6.
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.

Carrier Assembly

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.

2

1

1 - Threaded bearing cup
2 - Adjustment plate

9

Differential Carrier Assembly

Install Differential Carrier

IMPORTANT

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

1. Apply Spicer approved RTV compound on axle
housing mating surface as shown in the illustration.
Completely remove all old gasket material prior to
applying new material. Compound will set in 5 minutes.
Install carrier before compound sets or reapply.

1

1 - Apply silicone gasket in this pattern

TIP: To assist in installing complete differential carrier
use two pieces of threaded rod (M16 X 1.5)
threaded into carrier capscrew holes. Rod should be
approximately 6" long. Use these to pilot the carrier
into the housing.

2. Install carrier to housing, lock washers, capscrews
and nuts. Torque to proper specification. Torque to

250–290 lbs. ft. (339–393 N•m).

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

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

5. Connect driveline, making sure all yokes are in
phase. Lubricate u-joints.

10

Carrier Assembly

Remove Wheel Differential (All Standard Models)

Carrier Disassembly

For models having the wheel differential lock option or a
carrier thrust bolt, 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 differential locked 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 torqued to the
proper specification to get an accurate reading. Best
results are obtained when tooth contact patterns are
maintained in used gearing.

11

Pinion Removal

Drive Pinion

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

a. For S190 disassembly, install a M10 x 1.50

bolt in the threaded jack holes found in­between the pilot web capscrews.

1

1

1 - Threaded Jack Holes

b. For S190 disassembly, use the pry slots pro-

vided at each end of the pilot web.

1

2. Before the pinion nut can be loosened, you must
de-stake the nut from the slot of the pinion.

3. To de-stake the nut, use a chisel or drift with a
round tip. The flange of the nut must be pushed far
enough outward so that the staked area will not
interfere with the pinion threads when the nut is
removed. See diagram below.

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 wi

th new.

1 - Slots

1

1

2

3

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

4. Remove the pinion nut.

12

Drive Pinion

5. Place carrier assembly into a press, place a 2" x 6"
x 6" wood block under the pinion. This will ensure
that when the pinion is pressed free from the bear­ings the pinion will not be damaged.

2

1

3

4

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

IMPORTANT

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

Drive Pinion

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

1

1 - Press

13

Pinion Assembly - Parts Exploded View

1

2

Drive Pinion

3

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

14

Drive Pinion Overhaul and Assembly

Drive Pinion

The preload of the bearings on the drive pinion is adjusted by
a spacer between the inner and outer bearing cones and the
helical gear. The preload is adjusted by changing the thickness
of the spacer. A thicker spacer will decrease the preload, a
thinner spacer will increase the bearing preload.

The following procedure covers both the forward and rear axle
carrier overhaul and assembly.

Note: See carrier disassembly for instructions on pinion and

yoke removal.

1. If the model of axle uses a pilot bearing, remove the
bearing using a split-type puller. Use two procedure
steps to remove each bearing.

a. Mount the puller vertically to separate the bear-

ing from the pinion. This action will force the
puller halves behind the bearing race and start
moving the bearing from the pinion.

2. Remove the inner pinion bearing cone from the pin­ion using a split-type puller
steps to remove each bearing.

a. Mount the puller vertically to separate the bear-

ing from the pinion. This action will force the
puller halves behind the bearing race and start
moving the bearing from the pinion.

b. Mount the puller horizontally to press the bear-

ing from the pinion.

. Use two procedure

Drive Pinion

b. Mount the puller horizontally to press the bear-

ing from the pinion.

1

1 - Press

15

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 .

85405

6-39

DANA

JD7

86

7

L

7

0

3

8

c. If replacement of the output shaft side gear

bearing cup is necessa ry, use either of the fol­lowing methods:

Weld: Place a weld bead around the inside of
the cup, when the weld cools the cup will fall
out.
Hamme r: Use a rolling head prybar to get under
the cup and then, with a hammer and drift from
the back side

of carrier, tap out bearing cup.

d. To install the outer bearing cup, place the carrier

in a press with the top of the carrier facing up.

e. Place the cup in the bore, use a sleeve or bear -

ing driver tool to press the cup until it is fully
seated. Use a feeler gage to make sure the cup
is fully seated.

4. 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. Plac e the cup in the bore, use a sleeve or bear-

ing driver tool

to press the cup until it is fully
seated. Use a feeler gage to make sure the cup
is fully seated.

Note: If a press is not available, use a sleeve

or bearing driver

and a hammer to install the cups .

5. Place the pinion on a 6” x 6” x 6” block of wood and
lower the carri er over the pinion .

16

6. Install the pinion spacer.

Drive Pinion

Note: If you are using the same drive pinion, use the same

spacer that was originally in stalled in the assembly. If
the drive pinion is to be replaced, the original spacer will
be used as the starting point of adjustment.

7. Install the outer bearing cone.

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

10. Remove the pinion nut.

11. Place a press sleeve over the top of the outer bearing
cone. Use the press to apply 5 tons of force. It is
important to rotate the carrier slightly to make sure
that the rollers of the bearing are properly seated.

Drive Pinion

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

17

Drive Pinion

12. 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.

14. Install the drive yoke and pinion nut.

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

13. Remove the carrier from the press. Secure the car­rier in a head stand.

16. Use an in. lbs. 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,
be changed. Repeat Steps 6-17.

the pinion spacer must

18

Drive Pinion

17. Now remove the pinion nut and yoke and install the
pinion seal. Use Spicer’s seal drive (part number

210749) and drive adapter (part number 131472).

18. Reinstall the yoke and pinion nut. Torque to 800­1000 lbs. ft.

19. Once the proper rolling torque is achieved, use a
punch with a round tip to stake the pinion nuts
flange into the machined slot in the pini on shaft. See
diagram below.

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.

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

1

1

1 - Locating Sleeves

CAUTION

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

1

2

21. I nstall capscrews and torque to the proper specifica­tions. See the Torque Chart .

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

Drive Pinion

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

3

19

Wheel Differential

Wheel Differential - Parts Exploded View

Before July 2013 After July 2013

12

1

2

3

4

5

7

8

6

9

11

6

15

4

9

11

3

16

2

7

8

6

19

18

5

17

16

6

14

10

10

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

20

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

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

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.

Wheel Differential

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.

21

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

22

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 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. 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. Apply a thin coat of oil to the
mating surfaces of the side gear and plain half.

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

1

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

23

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

24

Wheel Differential

Install Wheel Differential Assembly - Forward Carrier Assembly

Set 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 bear ­ing adjuster assembly to the carrie r. Thi s tool (part num ­ber 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 bearin g adjust ment tool is made up of a
threaded rod, two nuts, two washers and two
ment plates. Fit one adjustment plate to the plain half
threaded cup. Fit the other adjustment plate to th e
flange half cup. The adjustment rings will fit into
slots of the threaded bearing cups stamped adjust ­ment ring.

adjust-

2. Connect the adjuster plates using the t
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

hreaded rod,

1

1 - Threaded bearing cup
2 - Adjustment plate

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

are seated properly. If there is a misalignment, reinstall
the differe

3. Make sure there is no gap between the carrier

2

ntial ass embly at a slightly different angle.

threads and the cup threads.

1

1 - No gap

25

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

2

1 - Flange Half
2 - Plain Half

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

26

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.

27

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 st rap to a hoist and apply
pressure to the sling.

28

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

1

Wheel Differential

2

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

29

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.

Wheel Differential

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.

30

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.

31

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.

Wheel Differential

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

32

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.

33

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

34

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.

35

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.

36

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.

37

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

38

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.

39

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

40

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.

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.

Wheel Differential Lock

41

Output Shaft Assembly & Rear

Cover

Housing and Output Shaft Assembly - Parts Exploded View

4

1

12

11

3

2

10

6

5

7

9

8

1 - Jam nut
2 - Locking ring
3 - Spindle nut
4 - Axle housing
5 - Breather

6 - Breather hose
7 - Carriage capscrew
8 - Nut
9 - Lock washer

10 - Stud
11 - Drain plug
12 - Axle shaft

42

Replace Seal

Seal - Replace

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

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

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

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!

5. 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 mount ed
properly.

6. Use a rubber
flange bottoms on the housing cover bore face. The
flange

mallet to drive the seal tool in until the

will locate the seal at the proper depth.

Seal - Replace

2. Remove seal. Use care when removing the old seal
to prevent damage to th e housing seal bore .

Inspect the seal bore area for any damage (nicks,

3.
gouges, corrosion). Carefully remove any slight
damage with a crocus cloth. Clean the b
remove any loose debris .

CAUTION

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

ore area to

43

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
repeat seal failure.

cause premature seal wear and

44

Seal - Replace

Service Kit

Location

Seal - Replace

R-Pinion

Tool

210749

131472

45

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.

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

3. Using a 3/4” wrench:

• Metal only: Rotate the fitting at least 1/2 turn
until nipple points to rear.

• Plastic only: Tighten until one thread is showing.

46

Wheel End Seal - Parts Exploded View

Wheel End Seal

Wheel End Seal

1

2

3

1 - Installation tool
2 - Seal
3 - Rear hub

47

Remove and Overhaul Wheel End Seal

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.

IMPORTANT

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.

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.

48

Wheel End Seal

Adjust Wheel Bearing

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

Never use an impact
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

wrench to adjust wheel bearings. A

Wheel End Seal

CAUTION

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
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.

hub on the spindle with

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
the bearing and cause premature
failure.

can preload

49

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

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.

50

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

(.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.

end-play is greater than 0.005"

defective,

Wheel End Seal

51

Lubricate Wheel End

Wheel End Seal

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 lubri ­cation 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 Ends with an Oil Fill Hole

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

2. Rem ove 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

52

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

Wheel End Seal

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

53

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 Spice r Driv e 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 ab ove (-40°C and above)

80W-90 -15°F to 100°F (-26°C to 38°C)

80W-140* -15°F and ab ov e (-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)

Makeup Lube—Maximum amount of non-synthetic makeup
lube is 10%. For additional lubrication information, see
TCMT-0021.

54

Lube Change Intervals

Lubrication

This product combines the latest manufacturing and part
washing technology. When filled with an 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.

Lubrication

* Axles using LMS wheel end system

** Axles using adjustable wheel bearing system

For additional lubrication information, see TCMT-0021.

55

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

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

56

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
operating in consistently mountainous areas.

S170

Axle Installation
Angle

12° Rear 29*

10° Rear 30*

8° Rear 31

6° Forward

4° Forward

gives 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

Lubrication

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.

43
35

45
36

13° 1.75" 2.00" 3.00"

15° 2.50" 2.50" 3.25"

*Pinion pointing upward

57

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

2

1 - Oil Filler Hole
2 - Lost Oil Capacity

1 - Oil Filler Hole
2 - Additional 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.

58

Towing Guide

Proper Vehicle Towing

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.

Towing Guide

6. Remove the axle shafts.

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

59

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

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.

60

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.

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

Theory of Operation

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.

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.

61

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 po sitively locks the wheel differential to pro ­vide improved traction under adverse road conditions.

Control Systems for Differential Lock

Two systems may be us ed to control the differential lock
operation.

Transmission Low Range Interlock Control System

The wheel differential is locked manually with the transmis ­sion in Lo w 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 transmis ­sion. It is designed to ensur e the differ ential 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 differen ­tial, using a cab-mounted electric switch (or air valve). The
following description assumes the system includes
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 normall

2. When the control switch is placed in the “lock”
position, the air supply solenoid valve opens and
air pressure activates the shift cylinde r. The shift
fork is moved to engage the curvi c 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 cylin ­der. A compre ssion spring moves the shift fork to
disengage the curvic clutch and unlock the wheel
differential .

y.

a cab-

62

Direct Driver-Controlled System

Theory of Operation

1

12

11

10

9

1 - Cab-mounted control val ve (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

2

5

6

4

7

8

Theory of Operation

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

63

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 differ ­ential, 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 co nsists of three major assem­blies.

• Shift Cylinder Assembly: Operates
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 an 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 electri ­cal signal to a cab mounted in dic ator light (or an audible
signal device) .

a shift fork and

.

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

64

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

Theory of Operation

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

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

65

Parts Identification

Pinion Assembly - Parts Exploded View

1

2

3

4

5

6

7

8

9

10

1 - Pinion pilot bearing 5 - Pinion bearing spacer 9 - Yoke

3 - Pinion bearing cone - inner 7 - Pinion bearing cone - outer

4 - Pinion bearing cup - inner 8 - Oil seal

tun noiniP - 01retuo - puc gniraeb noiniP - 6noiniP - 2

66

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

Parts Identification

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

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

67

Parts Identification

Wheel Differential Lock Assembly - 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

9 - Switch

10 - Roll pin
7 - Piston cover
8 - Washer

68

Parts Identification

Housing and Output Shaft Assembly - Parts Exploded View

4

1

12

11

3

2

10

6

5

7

9

8

Parts Identification

1- Jam Nut
2 - Locking ring
3 - Spindle nut
4 - Axle housing

5 - Breather
6 - Breather hose
7 - Carriage capscrew
8 - Nut

9 - Lock washer
10 - Stud
11 - Drain plug
12 - Axle shaft

69

Fastener Torque Specifications

Fastener Torque Specifications

Location Size Lbs. Ft. N•m

POWER DIVIDER

Input Cage Locking Bolt M8 x 1.0 x 30 20 ± 5 25 ± 5

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

Sp

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

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

70

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-0056 09/13