Spicer S170, S190, S590 User Manual

Spicer

Single Drive Axles

Service Manual

AXSM0056 September 2013

S170 Series

S190 Series

S590 Series

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

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

Model Identification

Drive Axle

General Information

CUST. PART NO.

SPEC. SERIAL NO.

Spicer

MODEL PART NO. RATIO

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.

CUST. PART NO.

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

. NO

. I.D

USING

1 - ID Tag

. LB

Spicer

. DE IN

Axle Shaft

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

SPICER

41-8

127

SPICER

8-41

127

127428

NL2

General Information

L7038

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

6-39

JD77

85405

DANA

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.

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.

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 - 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.

Differential Carrier Assembly

Differential Carrier Assembly - Parts

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

Differential Carrier

Assembl

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.

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.

1 - Threaded bearing cup 2 - Adjustment plate

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 - 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.

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.

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 - Threaded Jack Holes

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

vided at each end of the pilot web.

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

4. Remove the pinion nut.

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.

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 - Press

Pinion Assembly - Parts Exploded View

Drive Pinion

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

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 - Press

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

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 .

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.

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

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 - Locating Sleeves

CAUTION

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

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

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