Spicer S400 User Manual

Spicer® Tandem Drive Axles

Service Manual

Spicer® Tandem Drive Axles

AXSM-1951 September 1997

S400-S

Axle Identification.................................................................. 1

Model Identification Numbering System ......................... 2

Gear Set Identification ......................................................... 2

Axle Lubricant Recommendations...................................... 3

General Precautions .............................................................. 4

Components

Power Divider ............................................................... 5

Forward Rear ................................................................ 6

Rear Rear....................................................................... 7

Removal of Differential Carrier from Axle Housing ........ 8

Removal of Differential from Carrier ................................. 9

Disassembly

Inter-axle Differential.................................................. 10

Output Shaft ................................................................ 12

Differential .................................................................... 13

Pinion ............................................................................. 14

Cleaning and Inspection ...................................................... 15

Assembly

Pinion ............................................................................. 16

Differential .................................................................... 19

Assembly

Differential Installation ......................................................... 23

Ring Gear and Tooth Contact Pattern .............................. 24

Installation of Inter-axle Differential Into Carrier ........... 25

Yoke Removal and Seal Replacement ................................ 25

Shift Cylinder Service ........................................................... 26

Installation of Differential Carrier Into Axle Housing .... 27

Axle/Torque Specifications.................................................. 28

Recommended Service Tools .............................................. 29

(Continued)

Output Shaft ................................................................ 20

Inter-axle Differential.................................................. 21

GENUINE SPICER SERVICE PARTS

Should an axle assembly require replacement component parts, it is recommended that Spicer Heavy Axle Service Parts be used. Spicer Heavy Axle Service Parts are manufactured under the same rigid specification as are original equipment axle components. This assures the customer who uses genuine Spicer service parts, maximum reliability for a Spicer Heavy Axle assembly. They may be obtained through your vehicle manufacturer.

The use of non-original Spicer service parts may cause premature component failure and may void the warranty.

The items included in this book are currently being offered as service parts at the time of printing. The part numbers and illustrations are provided specifically for reference purposes only. Therefore, Spicer reserves the right to update this manual without notice or liability.

All axle assemblies are identified with two tags. One located on the differential carrier, and the other located on the right hand side of the axle housing.

The differential carrier tag contains the following: Dana part number, julian date code, and ratio. Optional items include customer part number, line set number, and the last six digits of the vehicle serial number.

The axle assembly tag contains the following items: Dana part number, julian date code, axle model, and ratio. Optional items include customer part number, line set number, and the last six digits of the vehicle serial number.

MODEL YEARMODEL YEAR

MODEL YEAR

MODEL YEARMODEL YEAR

ANA PANA P

ANA P

ANA PANA P

NUMBERNUMBER

NUMBER

NUMBERNUMBER

ARAR

AXLE IDENTIFICATION

JULIAN DJULIAN D

JULIAN D

JULIAN DJULIAN D

CUSCUS

CUS

CUSCUS PP

ARAR

T NUMBERT NUMBER

T NUMBER

ARAR

T NUMBERT NUMBER

(OPTIONAL)(OPTIONAL)

(OPTIONAL)

(OPTIONAL)(OPTIONAL)

7 17 1

7 1

7 17 1

OMEROMER

OMER

OMEROMER

TE CODETE CODE

TE CODE

TE CODETE CODE

Y OF YEARY OF YEAR

Y OF YEAR

Y OF YEARY OF YEAR

ANA PANA P

ANA P

ANA PANA P

NUMBERNUMBER

NUMBER

NUMBERNUMBER

ARAR

CUSCUS

OMEROMER

CUS

OMER

CUSCUS

OMEROMER

ARAR

T NUMBERT NUMBER

T NUMBER

ARAR

T NUMBERT NUMBER

(OPTIONAL)(OPTIONAL)

(OPTIONAL)

(OPTIONAL)(OPTIONAL)

MODELMODEL

MODEL

MODELMODEL

Carrier TCarrier T

Carrier T

Carrier TCarrier T

LASLAS

T SIX DIGITS OFT SIX DIGITS OF

LAS

T SIX DIGITS OF

LASLAS

T SIX DIGITS OFT SIX DIGITS OF

VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER

VEHICLE SERIAL NUMBER

VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER (OPTIONAL)(OPTIONAL)

(OPTIONAL)

(OPTIONAL)(OPTIONAL)

agag

LINE SETLINE SET

LINE SET

LINE SETLINE SET NUMBERNUMBER

NUMBER

NUMBERNUMBER (OPTIONAL)(OPTIONAL)

(OPTIONAL)

(OPTIONAL)(OPTIONAL)

JULIAN DJULIAN D

JULIAN D

JULIAN DJULIAN D CODECODE

CODE

CODECODE

TETE

Axle AAxle A

ssemblssembl

Axle A

ssembl

Axle AAxle A

ssemblssembl

LASLAS

T SIX DIGITS OFT SIX DIGITS OF

LAS

T SIX DIGITS OF

LASLAS

T SIX DIGITS OFT SIX DIGITS OF

VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER

VEHICLE SERIAL NUMBER

VEHICLE SERIAL NUMBERVEHICLE SERIAL NUMBER (OPTIONAL)(OPTIONAL)

(OPTIONAL)

(OPTIONAL)(OPTIONAL)

y Ty T

y T

y Ty T

agag

LINE SETLINE SET

LINE SET

LINE SETLINE SET NUMBERNUMBER

NUMBER

NUMBERNUMBER (OPTIONAL)(OPTIONAL)

(OPTIONAL)

(OPTIONAL)(OPTIONAL)

JULIAN DJULIAN D

JULIAN D

JULIAN DJULIAN D CODECODE

CODE

CODECODE

TETE

MODEL IDENTIFICATION NUMBERING SYSTEM

S 400 S N

amilamil

amil

amilamil

(S = Spicer)(S = Spicer)

(S = Spicer)

(S = Spicer)(S = Spicer)

Nominal LoadNominal Load

Nominal Load

Nominal LoadNominal Load CarrCarr

ying Capacitying Capacit

Carr

ying Capacit

CarrCarr

ying Capacitying Capacit

(400 = 40,000 Lbs.)(400 = 40,000 Lbs.)

(400 = 40,000 Lbs.)

(400 = 40,000 Lbs.)(400 = 40,000 Lbs.)

Gearing TGearing T

Gearing T

Gearing TGearing T (S = Single R(S = Single R

(S = Single R

(S = Single R(S = Single R

ypeype

ype

ypeype

educeduc

educ

educeduc

tion)tion)

tion)

tion)tion)

OpOp

tionstions

tions

OpOp

tionstions

(N = *No-SPIN(N = *No-SPIN

(N = *No-SPIN

(N = *No-SPIN(N = *No-SPIN

* No-SPIN® is a registered trademark of Tractech

® ®

DifferDiffer

Differ

DifferDiffer

ential)ential)

ential)

ential)ential)

GEAR SET IDENTIFICATION

Manufacturer's Date- Date gear set was made.

Spicer Trademark- Company logo and location of

manufacturing facility.

Part number of pinion- 390GP100 (TYPICAL)

Tooth Combination(i.e. 41-11)- Indicates the pinion has 11 teeth and the ring gear has 41 teeth which results in a 3:73:1 ratio.

Matched Set Number- Spicer ring gears and pinions are manufactured as matched sets. Both ring gear and pinion are marked with a corresponding number (i.e.

260), which identifies them as a matched set.

A gear set that does not have the same match set numbers should not be run together. If either ring gear or pinion require replacement, a new matched set must be used.

41-11

TOOTH

COMBINATION

TRADEMARK

PART

NUMBER

SPICER

HEAT

CODE

SPICER

TRADEMARK

PINION ETCH

+15

260

MFG. DATE

BACKLASH ETCH

MATCHED

SET NUMBER

L10

260

Backlash etch- Indicates backlash setting for assembly.

AXLE LUBRICANT RECOMMENDATIONS

To ensure proper lubrication and operating temperature, correct lubricants and lubricant levels must be obtained.

RECOMMENDED LUBRICANTS

Petroleum based or synthetic based hypoid gear lubricants that meet or exceed military specification MIL-L2105D, and API service classification GL-5, are the minimum requirements for use in Spicer Medium and Heavy Duty Drive Axles.

The table below indicates which SAE viscosities are recommended for various temperature ranges the vehicle will encounter.

AMBIENT AIR TEMPERATURE

SERVICE

Recommended lubricant change intervals are dependent on the application and operating environment. The following chart should be used to establish proper change intervals.

APPLICATION

On Highway 100,000 1 Year 250,000 3 Year

* Severe Service

and 50,000 1 Year 100,000 1 Year On-Off Highway

PETROLEUM BASED SYNTHETIC BASED**

MILES INTERVAL MILES INTERVAL

* Severe service includes any applications operating

at or near maximum GVW or GCW ratings. This includes normally wet or dusty environment, or consistent high load and low speed applications.

** Includes Semi-Synthetic blends that meet

MIL-L-2105D specifications.

AFTER OVERHAUL OR CHANGE INTERVALS

Fill the axle assembly to the bottom of housing fill hole as shown in the illustration below. It is recommended that following an overhaul, each side of the axle be jacked up separately to approximately six inches and held into position for one minute. This procedure will allow adequate lubricant to flow into the wheel ends and help eliminate the possibility of premature damage to wheel bearings and seals. Lower the vehicle to the floor and allow ten minutes for lube to return to normal level. Check and refill assembly to bottom of fill hole to replace the lubricant that was directed into the wheel ends.

SUBMERSION OR DEEP WATER FORDING

In the event the axle assembly should become submerged in water, particularly if over the vent or breather, it is recommended that the lubricant be drained to prevent water damage and/or contamination. The axle assembly should then be refilled with specified lubricant.

NOTE: Lubricant close enough to the bottom of the fill hole to be seen or touched is not sufficient. Lubricant must be level with the fill hole.

GENERAL PRECAUTIONS

IMPORTANT

READ THIS SECTION BEFORE STARTING

ANY SERVICE PROCEDURES

GENERAL AXLE DESCRIPTION

The Spicer tandem rear axle assemblies consist of two heavy duty, hypoid, single reduction differential carrier assemblies. The forward axle contains a power divider, which does exactly what its name implies. It divides power between the forward rear and rear rear axle assemblies.

The forward axle receives power through a set of helical gears within the power divider. The rear rear axle receives power from the power divider output shaft that extends through the forward axle housing. The complete forward axle differential carrier assembly and power divider can be removed from the axle housing as a unit.

Follow the sections of this manual that cover individual service needs.

Accordingly, anyone who uses a service procedure or tool different than shown must first thoroughly satisfy themselves that their safety, nor the vehicle safety, will be jeopardized by the service method selected.

END YOKES AND FLANGES

CAUTION: Hammering on end yokes could damage the bearing bores or misalign yoke lugs and result in early failures of journal needle bearings or other driveline components. Serious damage can also be done internally to the ring and pinion set or pinion bearings by hammering on external parts. End yokes or companion flanges should be removed or installed using the recommended method such as that described herein.

Safety glasses should be worn

at all times when assembling

or disassembling axles.

SAFTEY PRECAUTIONS

Proper service and repair of vehicle components is important to the safe and reliable operation of all motor vehicles. This applies particularly to driving axles such as the ones described in this manual. The procedures recommended and described in this manual are tested, and effective methods for performing service operations. Follow each procedure closely, making use of both the text and illustrations. Some of these service procedures show the use of certain tools designed specifically for the operation being performed. They are shown as a preferred means of performing the operation. It is not practical to anticipate and advise the service trade of all possible alternative methods, and of all possible hazardous consequences that could result from any particular method.

CLEANLINESS

Axle components should be steam cleaned prior to removal from the vehicle. Dirt is abrasive and can cause premature wear of otherwise serviceable parts. Service personnel should use a wash tank for thorough cleaning of parts just prior to reassembly.

CAUTION

BRAKE LININGS CONTAIN NON-ASBESTOS FIBERS

BREATHING BRAKE DUST MAY BE HAZARDOUS TO YOUR HEALTH AND MAY CAUSE SERIOUS RESPITORY OR OTHER BODILY HARM.

AVOID CREATING DUS T

DO NOT REMOVE BRAKE DRUM WITHOUT PROPER PROTECTIVE EQUIPMENT.

DO NOT WORK ON LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT.

DO NOT REPLACE LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT.

DO NOT ATTEMPT TO SAND, GRIND, CHISEL, FILE, HAMMER OR ALTER BRAKE

LININGS IN ANY MANNER WITHOUT PROPER PROTECTIVE EQUIPMENT.

FOLLOW 0.S.H.A. STANDARDS FOR PROPER PROTECTIVE DEVICES TO BE USED

WHEN WORKING WITH BRAKE MATERIALS.

POWER DIVIDER COMPONENTS

Flange Hex Bolt (160-180 Lb-Ft) (217-244 N-m)

Fill Plug (35- 45 Lb-Ft)

Magnetic Drain Plug (35- 45 Lb-Ft) (47-61 N-m)

Lube Retainer

Hex Bolt (20-25 Lb-Ft)

(27-34 N-m)

Compression Spring

(47-61 N-m)

Inter-axle Differential Case

Inter-axle Differential Bearing Cup

Inter-axle Differential Bearing Cone

Inter-axle Differential Side Gear

Washer

Shift Fork

Inter-axle Differential Assembly

Helical Drive Gear

Needle Bearing

Needle Thrust Bearing Assembly

Input Shaft

Clutch Collar

Input Bearing Cone

Input Bearing Cup

Input Shaft Bearing Shim (Selective)

Input Shaft Bearing Retainer

Input Oil Seal

Yoke Spacer

Shift Shaft

Piston Assembly

Shift Cover O-ring

Shift Cover

Washer

Shift Cover Bolt

(15 - 20 Lb-Ft)

(20-27 N-m)

Input Shaft Bearing

Retainer Bolt

(100-120 Lb-Ft)

(136-163 N-m)

Input Yoke Assembly

Flanged Hex Nut (900-1,200 Lb-Ft) (1,220-1,627 N-m)

FORWARD REAR COMPONENTS

Flanged Hex Nut (900-1,200 Lb-Ft) (1,220-1,627 N-m)

Output Yoke Assembly

Output Oil Seal

Beveled Retaining Ring

Output Shaft Bearing

Output Shaft

Fill Plug (35-45 Lb-Ft) (47-61 N-m)

Temperature Sensor Plug (35-45 Lb-Ft) (47-61 N-m)

Vent Plug

Axle Shaft ( Roadside )

Differential Side Bearing Cap

Axle Housing

Dowel Pin

Differential Gear Thrust Washer

Differential Bearing Cap Bolt (295-340 Lb-Ft) (400-461 N-m)

Flat Washer

Adjusting RingLock

Adjusting Ring Lock Bolt (30-40 Lb-Ft) (41-54 N-m)

Magnetic

Drain Plug

(35-45 Lb-Ft)

(47-61 N-m)

Differential Case Flange Half

Flat Washer

Nut (300-320 Lb-Ft) (407-434 N-m)

Differential Bearing Cone

Differential Bearing Cup

Adjusting Ring

Ring Gear Bolt

Ring Gear

Inner Pinion Bearing Cone

Inner PinionBearing Cup

Pinion Bearing Spacer (selective)

Differential Case Bolt (180-200 Lb-Ft) (244-271 N-m)

Differential Case Cap Half

Differential Side Gear

Differential Cross Shaft

Differential Pinion Mate

Differential Pinion Mate Thrust Washer

Hex Bolt (150 Max. Lb-Ft)

(203 Max. N-m)

Pinion Pilot Bearing Cap

Pinion Pilot Bearing

Pinion

Dowel Pin

Outer Pinion Bearing Cup

Axle Shaft ( Curbside )

Carrier Housing

Carrier Mounting Bolt (240-260 Lb-Ft) (325-353 N-m)

Outer Pinion Bearing Cone

Helical Driven Gear

Flanged Hex Nut (900- 1200 Lb-Ft) (1,220-1,627 N-m)

Housing

REAR REAR COMPONENTS

Temperature Sensor Plug

Differential Bearing Cap Bolt (295-340 Lb-Ft) (400-461 N-m)

Differential Bearing Cap Washer

Adjusting Ring Lock

Adjusting Ring Lock Bolt (30-40 Lb-Ft) (41-54 N-m)

Differntial Pinion Mate Thrust Washer

Differential Bearing Cone

Fill Plug

(35-45 Lb-Ft)

(47-61 N-m)

(35-45 Lb-Ft)

(47-61 N-m)

Differential Pinion Mate

Differential Cross Shaft

Differential Side Gear

Differential Case

Cap Half

Differential Bearing Cup

Adjusting Ring

Vent Plug

Magnetic Drain Plug (35-45 Lb-Ft) (47-61 N-m)

Differential Gear Thrust Washer

Differential Case Bolt (180-200 Lb-Ft) (244-271 N-m)

Hex Bolt (150 Max. Lb-Ft) (203 Max. N-m)

Pinion Pilot Bearing Cap

Dowel Pin

Ring Gear

Ring Gear Bolt

Pinion Pilot Bearing

Pinion

Axle Shaft ( Roadside )

Differential Bearing Cap

Nut (300-320 Lb-Ft) (407-434 N-m)

Ring Gear Flat Washer

Differential Case Flange Half

Inner PinionBearing Cone

Inner Pinion Bearing Cup

Axle Shaft ( Curbside )

Carrier Housing

Carrier Mounting Bolt (240-260 Lb-Ft) (325-353 N-m)

Pinion Bearing Preload Spacer (Selective)

Outer Pinion Bearing Cup

Outer Pinion Bearing Cone

Pinion Oil Seal

End Yoke Assembly

Flanged Hex Nut (900-1,200 Lb-Ft) (1,220-1,627 N-m)

REMOVAL OF DIFFERENTIAL CARRIERS FROM AXLE HOUSINGS

NOTE: Steam clean axle assembly.

1. Block wheels.

2. Remove axle housing and power divider drain plugs

and drain lubricant.

3. Disconnect drive shaft at the rear U-joint.

NOTE: If end yoke and/or seal is to be replaced, loosen yoke nut at this time.

4. Match mark each axle shaft flange to its mating

wheel end and remove axle shaft flange nuts.

IMPORTANT: Axle shafts are of different lengths and should be marked accordingly for proper reassembly.

5. Hold a large brass drift or a brass hammer against

the center of the axle shaft flange. Strike the drift with sharp blows from a large hammer or sledge until the axle shaft separates from the hub.

CAUTION: Do not strike the flange directly with a steel hammer or sledge. This may crack and splinter material, possibly causing serious or fatal injury. Do not pry or chisel axle flange away from hub or damage to sealing surfaces could occur.

10 . Separate differential carrier from the housing using

removal slots. See Figures 1 and 2. Be certaindifferential carrier clears dowel pins and is balanced properly on jack. Remove top two carrier mounting bolts, and remove differential carrier assembly from the axle housing.

Removal slot

Dowel Pin

igurigur

igur

igurigur

e 1e 1

e 1

e 1e 1

Power Divider Drain Plug

Dowel Pin

Removal slot

6. Remove axle shafts. Remember due to different

length axle shafts, each shaft should be marked to mating wheel end for proper reassembly.

7. Disconnect air line from power divider shift cover on

forward rear assembly.

8. Support the differential carrier assembly on a roller

jack. Secure as necessary to prevent it from falling off the jack when removed from the housing.

9. Loosen the differential carrier-to-housing

mounting bolts. Remove all bolts except top two. These two bolts will prevent the carrier assembly from falling.

IMPORTANT: Thread two guide pins into axle housing to relieve weight from output shaft bearing assembly of forward rear during differential carrier removal.

Removal slot

igurigur

e 2e 2

igur

e 2

igurigur

e 2e 2

11 . Mount carrier assembly in a suitable rebuild stand.

(Refer to RECOMMENDED SERVICE TOOLS, pgs. 29-30)

Differential Carrier Removal Complete

REMOVAL OF DIFFERENTIAL FROM CARRIER

The following service procedures apply for both forward rear and rear rear axles, unless otherwise noted.

IMPORTANT: If the ring and pinion is to be reused, ring gear backlash should be checked and recorded before disassembly. Backlash should be reset to this specification after completion of repairs. For backlash specifications refer to DIFFERENTIAL INSTALLATION.

1. Remove adjusting ring bolts and locks from bearing

caps.

2. One differential bearing cap and leg of the carrier is

match marked to aid during reassembly.

See Figure 3.

3. Loosen four bearing cap retaining bolts.

4. Loosen adjusting rings, to relieve bearing preload.

5. Remove four bearing cap retaining bolts and

washers.

igurigur

igur

igurigur

e 3e 3

e 3

e 3e 3

6. Remove bearing caps.

7. Remove adjusting rings and bearing cups.

NOTE: If bearings are to be reused, cups must stay with mated cones. They can not be interchanged.

8. Carefully lift the ring gear and differential subassem-

bly out of carrier.

NOTE: The ring gear side of subassembly must be tipped up for the ring gear to clear the pinion pilot bearing cap.

Removal of Differential Complete

+ 23 hidden pages

Spicer S400 User Manual

TABLE OF CONTENTS

AXLE IDENTIFICATION

AXLE LUBRICANT RECOMMENDATIONS

GENERAL PRECAUTIONS

POWER DIVIDER COMPONENTS

FORWARD REAR COMPONENTS

REAR REAR COMPONENTS

REMOVAL OF DIFFERENTIAL FROM CARRIER