Spicer Single Drive Axles User Manual
Spicer
®
Single Drive Axles
Service Manual
Single Reduction & Single Reduction
with Differential Lock
AXSM0048
September 2008
15040S
17060S/D
19050S
19055S/D
19060S/D
20060S/D/R
21060S/D
21065S/D
21090S/D
22060S/D/R
22065S/D
P20060S/D/R
P22060S/D/R
23070S/D
23080S/D
23085S/D
23090S/D
23105S/D
26080S/D
26085S/D
26090S/D
26105S/D
30105S/D
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.
Important Notice
This symbol is used throughout this
manual to call attention to procedures
where carelessness or failure to follow
specific instructions may result in personal
injury and/or component damage.
Departure from the instructions, choice of
tools, materials and recommended parts
mentioned in this publication may
jeopardize the personal safety of the
service technician or vehicle operator.
Any reference to brand 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.
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.
Always use genuine Spicer replacement parts.
TIP: Helpful removal and installation procedures
to aid in the service of this unit.
i
Table of Contents
Table of Contents
Table of Contents - Visual ............................................ 1
Introduction ................................................................2
Model Identification .................................................... 3
Ring Gear and Pinion .................................................. 4
Failure Analysis ........................................................... 5
Prepare the Parts for Inspection ................................. 6
Inspection ................................................................... 7
Differential Carrier Assembly - Exploded View ............ 8
Remove Differential Carrier ......................................... 9
Install Differential Carrier .......................................... 10
Disassemble Carrier Assembly - (Rear Axles) ........... 11
Rear Axle Pinion Assembly - Exploded View ............. 13
Remove Pinion Assembly ......................................... 14
Disassemble and Overhaul Drive Pinion .................... 15
Replace Pinion Bearing Cage Cups ........................... 17
Adjust Pinion Bearing Preload - (Trial Buildup) ......... 18
Adjust Pinion Bearing Preload - (Final Buildup) ........ 20
Install Drive Pinion Assembly .................................... 24
Install Pinion Oil Seal and Yoke ................................. 25
Wheel differential - Exploded View............................. 26
Remove Wheel Differential - (All Standard Models) ..27
Disassemble, Overhaul and Assemble
Wheel Differential ...................................................... 28
Overhaul and Assemble Wheel Differential ................ 29
Measure and Adjust Carrier Assembly ...................... 31
Change Backlash Setting ........................................... 32
Table of Contents
Adjust Ring and Pinion Tooth Contact Pattern ...........33
Adjust Pinion Position ...............................................34
Differential Lock Shifting Parts - Exploded View ........35
Wheel Differential Locking Axles ...............................36
Install and Adjust Differential Lock - Type 1 Axles .....37
Shift Fork Adjustment - Type 1 Axles .........................39
Install and Adjust Differential Lock - Type 2 Axles .....40
Install and Adjust Wheel Differential Lock .................42
Install New Axle Housing Breather -
(Metal and Plastic) .............................................44
Axle Housing - Exploded View ...................................45
Inter-Axle Speed Sensor Parts - Exploded View ........46
Disassemble and Overhaul Inter-Axle Speed Sensor .47
Install Inter-Axle Speed Sensor .................................48
Wheel End Seal Parts - Exploded View ......................49
Remove and Overhaul Wheel End Seal ......................50
Adjust Wheel Bearing ................................................51
Verify Wheel End-play Procedure ..............................53
Lubricate Information .................................................54
Proper Vehicle Towing ...............................................55
Operate Wheel Differential Assembly .........................56
Wheel Differential Lock ..............................................57
Wheel Differential Lock Operation .............................58
Rear Drive Axle Parts - Exploded View .......................59
Inter-Axle Speed Sensor Parts - Exploded View .. 60-61
Housing and Output Shaft Assembly Parts - Exploded
View ..........................................................................62
Fastener Torque Specifications ............................ 63-65
ii
Table of Contents - Visual
page 44
Carrier
Assembly
page 8
General Information
Inter-Axle
Speed Sensor
page 46
Differential
Assembly
page 11-12
Wheel End Seals
page 49
Drive Pinion
page 13
Seals
page 25
Wheel
Differential
Lock
page 36
Housing Breather
page 44
1
General Information
Introduction
Dana presents this publication to aid in maintenance and
overhaul of Spicer single reduction drive axles. Instructions
contained cover the models listed below. Their design is
common, with differences in load capacity. Capacity
variations are achieved by combining basic differential
carrier assemblies with different axle housings, axle shafts
and wheel equipment. The suffix letter “P” in the model
number indicates a lube pump is standard. Pump models
are equipped with a gerotor pump, designed to provide
additional lubrication to the inter-axle differential and
related parts.
Model Listing
The following models are included in this publication.
Spicer Single Reduction Axles
With Standard With With Wheel
Wheel Differential IASS Differential Lock
15040S – –
17060S _ 17060D
19050S – –
19055S – 19055D
19060S 19060A 19060D
21060S 21060A 21060D
21065S – 21065D
21080S 21080A 21080D
21090S 21090A 21090D
22060S 22060A 22060
5S – 22065D
2206
23070S – 23070D
23080S 23080A 23080D
23085S – 23085D
23090S 23090A 23090D
23105S 23105A 23105D
26080S 26080A 26080D
26090S 26090A 26090D
26105S 26105A 26105D
30105S 30105A 30105D
P22060S - P20060D
P22060S - P22060D
D
(GAWR x 1000 lbs.)
(GCW x 1000 lbs.)
23 080 S
Gearing:
A - Single Reduction with In-Axle
Speed Sensing
B - Bus Specific
D - Single Reduction with
Wheel Differential Lock
H - Heavy Wall
L - Limited Slip
P - Planetary Double Reduction
R - Retarder/Parking Brake Ready
S - Single Reduction
T - 2-Speed
General Information
2
Model Identification
General Information
4
3
CUST. PART NO.
SPEC. SERIAL NO.
Spicer
®
2
MODEL PART NO. RATIO
1
MADE IN:
1 - Country of origin
2 - Axle modle identification
3 - Specification number assigned to the axle
built by Spicer. Identifies all component parts
of the axle including special OEM requirements
such as yoke or flanges.
4 - OEM part number assigned to the axle build
5 - Carrier assembly serial number assigned by
the manufacturing plant
6 - Axle gear ratio
7 - Carrier assembly production or service part number
5
6
7
®
CUST. PART NO.
Spicer
SPEC. SERIAL NO.
MODEL PART NO. RATIO
MADE IN:
Rear Axle (Top View)
Data plate is located on
the axle centerline
Parts Identification
Axle Housing
Spicer
PT. NO.
O.
HSG. CAP. LBS.
ADE IN
HSG. I.D. N
HOUSING M
1 - ID Tag
Axle Shaft
2
®
1
2 - Axle shaft part number
3
General Information
Ring Gear and Pinion
Note: Ring gear and drive pinion are matched parts and must be replaced in sets.
127381
1
SPICER
7
7
5
SPICER
127
1
41-8
8-41
127428
8
NL2
3
L7038
G
17
OF
4
General Information
6
2
8
127
G
0H
6
17
3
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
7
6-39
JD77
85405
86
DANA
0
3
8
4
4
Failure Analysis
Inspection
Failure analysis is the process of determining the original
cause of a component failure in order to keep it from happening again. Too often, when a failed component is replaced
without determining its cause, there will be a recurring failure.
If a carrier housing is opened, revealing a ring gear with a broken tooth, it is not enough to settle on the broken tooth as the
cause of the carrier failure. Other parts of the carrier must be
examined. For a thorough understanding of the failure and
possible insight into related problems, the technician needs to
observe the overall condition of the vehicle.
No one benefits when a failed component goes on the junk
pile with the cause unknown. Nothing is more disturbing to a
customer than a repeat failure. Systematically analyzing a failure to prevent a repeat occurrence assures quality service by
avoiding unnecessary downtime and further expense to the
customer.
The true cause of a failure can be better determined by knowing what to look for, determining how a piece of the equipment was running and learning about previous problems. In
the case of a rebuilt rear axle, mismatched gears may have
been installed.
The more successful shops prevent repeat equipment failures
by developing good failure analysis practices. Knowing how
to diagnose the cause of a premature failure is one of the prerequisites of a good heavy-equipment technician.
How to Diagnose a Failure
The following five steps are an effective approach to good failure diagnostics.
1. Document the problem.
2. Make a preliminary investigation.
You need to be a good listener. Sometimes, insignificant or
unrelated symptoms can point to the cause of the failure.
• Ask: Was the vehicle operating at normal temperatures?
• Ask: Were the gauges showing normal ranges of
operation?
• Ask: Was there any unusual noise or vibration?
After listening, review the previous repair and maintenance
records. If there is more than one driver, talk to all of them
and compare their observations for consistency with the service and maintenance records. Verify the chassis Vehicle
Identification Number (VIN) number from the vehicle identification plate, as well as the mileage and hours on the vehicle.
Make a Preliminary Investigation
These steps consist of external inspections and observations
that will be valuable when combined with the results of the
parts examination.
• Look for leaks, cracks or other damage that can
point to the cause of the failure.
• Make note of obvious leaks around plugs and seals.
A missing fill or drain plug would be an obvious
cause for concern.
• Look for cracks in the carrier housing (harder to see,
but sometimes visible).
• Does the general mechanical condition of the vehicle
indicate proper maintenance or are there signs of
neglect?
• Are the tires in good condition and do the sizes
match?
3. Prepare the parts for inspection.
4. Find the cause of the failure
5. Correct the cause of the problem.
Document the Problem
Here are some guidelines for starting to learn about a failure,
including questions to ask:
• Talk to the operator of the truck.
• Look at the service records.
• Find out when the truck was last serviced.
• Ask: In what type of service is the truck being used?
• Ask: Has this particular failure occurred before?
• Ask: How was the truck working prior to the failure?
5
• 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.
Prepare the Parts for Inspection
Inspection
After the preliminary investigation, locate the failure and prepare the part for examination. In carrier failure analysis, it may
be necessary to disassemble the unit.
• When disassembling subassemblies and parts, do
not clean the parts immediately since cleaning may
destroy some of the evidence.
• When tearing down the drive axle, do it in the recommended manner. Minimize any further damage to the
unit.
• Ask more questions when examining the interior of
the carrier. Does the lubricant meet the manufacturer
specifications regarding quality, quantity and viscosity? As soon as you have located the failed part, take
time to analyze the data.
Find the Cause of the Failure
Here begins the real challenge to determine the exact cause of
the failure. Keep in mind that there is no benefit to replacing a
failed part without determining the cause of the failure. For
example, after examining a failed part and finding that the failure is caused by a lack of lubrication, you must determine if
there was an external leak. Obviously, if there is an external
leak, just replacing the failed gear is not going to correct the
situation.
Another important consideration here is to determine the specific type of failure which can be a valuable indicator for the
cause of failure. The following pages show different types of
failures and possible causes. Use this as a guide in determining types of failures and in correcting problems.
Correct the Cause of the Problem
Once the cause of the problem has been determined, refer to
the appropriate service manual to perform the repairs.
Service Procedure
6
Inspect Assembly
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.
Note: Replace conventional gaskets with silicone rubber gas-
ket compound (included in many repair kits). The compound provides a more effective seal against lube
seepage and is easier to remove from mating surfaces
when replacing parts.
1
2
1 - Axle housing
2 - Machined surface
Inspect all steel parts for:
• Notches, visible steps or grooves created by wear.
• Pitting or cracking along gear contact lines.
• Scuffing, deformation or discolorations. These are
signs of excessive heat in the axle and are usually
related to low lubrication levels or improper lubrication practices.
Inspect Axle Housing
Axle housing inspection and repairs are limited to the following checks or repairs:
• Visually inspect axle housing for cracks, nicks and
burrs on 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.
7
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 -
Parts
Differential Carrier Assembly - Exploded View
2
1
1 - Carrier Fasteners
2 - Carrier Assembly
3 - Single Axle Assembly
3
Service Procedure
8
Remove Differential Carrier
Differential Carrier
Procedure -
1. Block the vehicle.
2. Drain axle lubricant.
3. Disconnect main driveline.
4. Disconnect differential lockout air line.
5. Disconnect lead wires to the selector switch and air
line at shift cylinder.
6. Remove axle shafts.
Diff-Lock Models
• For removal of the locking wheel differential carrier
assembly, the differential lock must be engaged and
held in the engaged position. This can be accomplished by one of two methods; either engage via air
pressure or engage manually.
Engage via Air Pressure
• Using an auxiliary air line, apply 80–120 PSI air pressure to shift cylinder air port to engage clutch.
1
Note: Hand-tighten the bolt, over-torquing may cause damage
to the shift unit. To facilitate hand-tightening, coat bolt
threads with axle lube.
1
2
1—Hand tighten with socket
2—M12 x 1.5 x 38mm bolt – GM only .250 – 18
NPTF – all models except GM
Note: With either method, the axle shaft may have to be
rotated to permit the clutch to become engaged.
WARNING
Do not lie under carrier after fasteners are removed. Use
transmission jack to support differential carrier assembly
prior to loosening fasteners
1—Connect 80-120 PSI air line to cylinder port
Engage Manually
• Install a .250 – 18 NPTF bolt over 1.5" long in the
cylinder air port to manually engage the clutches.
GM models require a M12 X 1.5 X 38mm bolt.
7. To remove axle shaft, remove axle stud nuts. (If
used, remove lock washers and taper dowels.)
8. Remove axle shafts.
Note: All models in this publication use axle shafts with
unequal lengths. Axle shafts may also be location specific with various wheel equipment. Do not misplace axle
shafts from their intended location. Identify left and right
shafts for reference during reassembly.
TIP: If necessary, loosen dowels by holding a brass
drift in the center of the shaft head and strike drift a
sharp blow with a hammer.
CAUTION
Do not strike the shaft head with a steel hammer. Do not
use chisels or wedges to loosen shaft or dowels.
9. Remove carrier cap screws, nuts and lock washers.
10. Remove differential carrier assembly.
9
Differential Carrier
Install Differential Carrier
IMPORTANT
Before installing carrier assembly, inspect and thoroughly
clean interior of axle housing using an appropriate solvent
and clean rag.
Procedure -
1. Apply Spicer approved RTV compound on axle housing mating surface as shown in the illustration. Completely remove all old gasket material prior to
applying new material. Compound will set in 20 minutes. Install carrier before compound sets or reapply.
2
1
1— Apply silicone gasket in this pattern
2— Common stud locations
TIP: To assist in installing complete differential carrier
use two pieces of threaded rod threaded into carrier cap
screw holes. Rod should be approximately 6" long. Use
these to pilot the carrier into the housing.
2. Install carrier to housing, washers, cap screws and
nuts. Torque to proper specifications. See torque
chart of page 66.
3. Install axle shafts and axle stud nuts (if
lock washers and tapered dowels).
install
4. Add axle lubricant. Fill to bottom of filler hole.
used, also
Service Procedure
5. Rear Only: Connect inter-axle driveline, making sure
all yokes are in phase. Lubricate U-joints.
10
Differential Carrier
Disassemble Carrier Assembly - (Rear Axles)
Note: For models having the wheel differential lock option or a
carrier thrust bolt follow the steps below. These parts
must be removed first before further removal of the
wheel differential and/or pinion can take place.
Procedure - Remove Wheel Differential - Models with
Wheel Differential Lock
1. For ease of servicing, mount differential carrier in
stand with differential lock facing up.
Note: To remove the pinion assembly, the shift fork, clutch
hand wheel Diff. assembly, must be removed from carrier. See instructions below.
2. Remove shift cylinder mounting screws, then lift
shift cylinder, piston and o-ring assembly off carrier
and end of push rod.
1
Procedure - Models with Ring Gear Thrust Bolt
1. Loosen thrust bolt jam nut.
Note: If the carrier model has a ring gear thrust bolt installed,
it must be backed away from the ring gear before you
can remove the wheel differential.
2. Back out thrust bolt from the carrier until the end of
the bolt is flush with the inside of the carrier casting.
This will allow enough clearance between the ring
gear and the carrier pilot web.
2
1 - Shift cylinder
3. To disassemble shift cylinder for inspection, first
remove or back off actuator switch. The piston and
o-ring assembly can be removed by inserting a pencil-size tool through the cylinder air port.
4. Grasp push rod end and pull it out of the shift fork,
spring and carrier.
Note: When the push rod is disengaged from the shift fork,
the fork and sliding curvic clutch assembly can be
removed from carrier.
Note: Do not disassemble shift fork from the sliding curvic
clutch unless parts replacement is necessary. To disassemble, use pin punch to remove spring pin from long
leg of fork. The fork can now be disengaged from the
clutch.
5. Remove the snap ring, then lift fixed curvic clutch off
differential case hub spline. Further disassembly of
carrier is the same for axles without differential lock.
1
1 - Thrust bolt
2 - Jam nut
11
Differential Carrier
Procedure - Remove Wheel Differential - All Standard Mod-
els
1. Mount differential carrier in repair stand.
Note: Omit this step if the gear set is to be replaced. If gear
set is to be reused, check tooth contact pattern and ring
gear backlash before disassembling differential carrier.
When checking backlash, a yoke or helical gear must be
installed and torqued to get an accurate reading. Best
results are obtained when established wear patterns are
maintained in used gearing.
3. Remove cap screws, flat washers and bearing caps.
General Information
Loosen bearing adjusters and remove adjusters and
bearing cups.
4. Using a chain hoist, lift ring gear and differential
assembly out of carrier.
2. If reusing gear set, also punch mark bearing adjusters for reference during assembly.
1
1 - Thrust bolt
12
Pinion Assembly
Rear Axle Pinion Assembly - Exploded View
1
2
3
4
5
6
7
9
10
11
12
8
13
1—Pinion pilot bearing
2—Pinion
3—Pinion bearing cone - inner
4—Pinion bearing spacer
5—Pinion bearing cup - inner
6—Shim
7—Pinion bearing cage
8—Cap screw
9—Pinion bearing cup - outer
10—Pinion bearing cone - outer
11—Oil seal
12—Yoke
13—Pinion nut
13
Remove Pinion Assembly
Procedure -
1. Remove pinion bearing cage cap screws. Remove
pinion and cage assembly from carrier. Remove
shim pack.
WARNING
Pinion Assembly
General Information
Do not allow pinion to drop on hard surface
If gear set is to be reused, keep pinion bearing cage shim
pack intact for use in reassembly. If the original shims cannot be reused, record the number and size of shims in the
pack.
14
Pinion Assembly
Disassemble and Overhaul Drive Pinion
The following procedures cover both forward and rear differential drive carrier disassembly.
Rear Axle Pinion Yoke
1. Remove yoke.
CAUTION
If pinion nut was not loosened during earlier disassembly,
clamp assembly in vise jaws, use brass pads to prevent
damage.
2. Loosen and remove pinion nut and flat washer.
Remove yoke from pinion using an appropriate tool.
Forward and Rear Axle Pinion Bearing Cage
3. Press pinion out of bearing cage and bearing cone.
1
5. Remove bearing spacer from pinion.
6. Remove pilot bearing from pinion using a split-type
puller. Use two procedure steps to remove each
bearing.
a. Mount puller vertically to separate the bearing. This
action will force puller halves under bearing and start
moving bearing off pinion.
b. Mount puller horizontally to press pinion out of bear-
ing.
1 - Press Ram
Rear Axle Pinion Oil Seal and Outer Bearing Cone
4. Remove oil seal and bearing cone from cage. Discard oil seal. Remove bearing cups with suitable
puller.
15
7. Remove inner bearing cone from pinion using a
split-type puller. Use two procedure steps to remove
each bearing.
Pinion Assembly
a. Mount puller vertically to separate the bearing. This
action will force puller halves under bearing and start
moving bearing off pinion.
Service Procedure
b. Mount puller horizontally to press pinion out of bear-
ing.
1
1 - Press
16
Replace Pinion Bearing Cage Cups
Pinion Assembly
1. Remove cups.
Front
1 - Cup ( Outer)
2 - Bearing cage
3 - Cup ( inner )
4. Seat cups securely to shoulder. Check clearance
between cup and bearing cage. Must be less than
.001”.
1
Rear
2
3
2
2. Clean and inspect bearing cages for damage, nicks
and burrs.
3. Install inner and outer pinion bearing cups. Use a
press and an appropriate drive sleeve. Make certain
bearing cup is evenly and firmly seated.
1
2
1 - Press ram
2 - Sleeve must apply pressure
to back face of outer bearing cone
17
Pinion Assembly
Adjust Pinion Bearing Preload - (Trial Buildup)
1. Assemble pinion bearing cage, bearings, spacer and
spacer washer (without drive pinion or oil seal). Center bearing spacer between two bearing cones.
Lubricate bearing cups and cones.
Bearing
Cup
Washer
Cage
Cup
Cone
Note: When new gear set or pinion bearings are used, select
nominal size spacer from the specification chart below.
If original parts are used, use spacer removed during
disassembly.
1
2
3. Rotate pinion cage while applying press load to the
assembly and check rolling torque. Wrap soft wire
around the bearing cage, attach spring scale and
pull. Preload is correct when torque required to
rotate the pinion bearing cage is within the specifications listed in the chart below.
CAUTION
Read only the torque value after the bearing cage starts to
rotate.
4. If necessary, adjust pinion bearing preload by changing the pinion bearing spacer. A thicker spacer will
decrease preload. A thinner spacer will increase preload.
Note: Once correct bearing preload has been established,
note the spacer size used. Select a spacer .001" larger
for use in the final pinion bearing cage assembly. The
larger spacer compensates for slight “growth” in the
bearings which occurs when they are pressed on the
pinion shank.
CAUTION
Do not assume that all assemblies will retain proper preload once bearings are pressed on pinion shank. FINAL
PRELOAD TEST MUST BE MADE IN EVERY CASE.
Service Procedure
3
1 - Press ram
2 - Sleeve must apply pressure to
back face of outer bearing cone
3 - Spring scale
2. With the bearings well lubricated, place the assembly
in the press. Position sleeve so load is applied
directly to the back-face of the outer bearing cone.
18
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