Spicer Single Speed Axle User Manual

Spicer® Single Speed Axle

Service Manual

Spicer® 70HD, 276, 80, 286

AXSM-0053
April 2001

INDEX

SECTION 1

GENERAL INFORMATION

PAGE

Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Axle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Servicing Components Not Covered In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Vehicle Storage or Prolonged Inoperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Exploded View of Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Parts Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

SECTION 2

SERVICE TOOLS

Procurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service Tool Part Numbers and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

SECTION 3

CARRIER SECTION - SERVICE PROCEDURES

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Ring Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Servicing Standard Differential Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Case Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Case Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Ring Gear & Pinion Gear Assembly (Theory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Establishing Pinion Gear Depth Using Service Tool Gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Assembly of Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Worksheet for Calculating Ring Gear Backlash & Differential

Bearing Preload Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Applying RTV Silicone Gasket Sealer to Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

SECTION 4

SPECIFICATIONS

Differential Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-l

Axle Lubricant Change Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

i

Wheel Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Submersion or Deep Water Fording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

RTV Silicone Rubber Sealer Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fastener Strength Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Wrench Tightening Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Pinion Bearing and Differential Bearing Preload Specification . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Backlash Specification-Drive Gear to Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Drive Pinion Gear Depth Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Wheel Bearing Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

ii

SECTION 1

GENERAL INFORMATION

IMPORTANT SAFETY NOTICE

Should an axle assembly require component parts replacement, it is recommended that “Original Equip­ment” replacement parts be used. They may be obtained through your local service dealer or other original
equipment manufacturer parts supplier. CAUTION: THE USE OF NON-ORIGINAL EQUIPMENT REPLACEMENT
PARTS IS NOT RECOMMENDED AS THEIR USE MAY CAUSE UNIT FAILURE AND/ OR AFFECT VEHICLE SAFETY.

Proper service and repair is important to the safe, reliable operation of all motor vehicles or driving axles
whether they be front or rear. The service procedures recommended and described in this service manual are
effective methods for performing service operations. Some of these service operations require the use of tools
specially designed for the purpose. The special tool should be used when and as recommended.

CAUTION: EXTREME CARE SHOULD BE EXERCISED WHEN WORKING ON COMPO- NENTS UTILIZING
SNAP RINGS OR SPRING LOADED RETENTION DEVICES. FOR PERSONAL SAFETY, IT IS RECOMMENDED
THAT INDUSTRIAL STRENGTH SAFETY GOGGLES OR GLASSES BE WORN WHENEVER REPAIR WORK IS
BEING DONE ON ANY VEHICLE OR VEHICLE COMPONENTS.

It is impossible to know, evaluate and advise the service trade of all conceivable ways in which service
might be done or of the possible hazardous consequences of each way.

Accordingly, anyone who uses a service procedure or tool which is not recommended must first satisfy
himself thoroughly that neither his safety or vehicle safety will be jeopardized by the service methods he
selects.

WARNING

Some vehicle manufacturers may require the assembly of brake components on Dana axles that utilize

materials containing asbestos fibers.

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

Follow O.S.H.A. standards for proper protective devices to be used when working with asbestos materials.

SILICONE RUBBER SEALANT (RTV) AND LUBRICATING GREASE AND OILS

Silicone rubber sealant is used as a gasket material on Dana axles, as well as various lubricants for
lubricating purposes. Before using any of these materials, one should become familiar with and follow all
safety precautions as recommended by the product manufacturer/supplier. All personnel involved with these
materials should follow good industrial hygiene practices (e.g. before eating, hands and face should be
thoroughly washed. Eating, drinking and smoking should be prohibited in areas where there is potential for
significant exposure to these materials).
When discarding any of the materials, observe all local, state, and federal laws and regulations for proper
disposal procedures.

1-1

Safety Precautions

This symbol warns of possible personal injury.

A serious or fatal injury can
occur . . .

• if you lack proper training

• if you fail to follow proper
procedures

• if you do not use proper
tools and safety equipment

• if you assemble components
improperly

• if you use incompatible
components

• if you use worn-out or
damaged components

• if you use components
in a non-approved
application

SAFETY GLASSES SHOULD BE WORN AT ALL
TIMES WHEN WORKING ON VEHICLES OR
VEHICLE COMPONENTS.

1-2

AXLE IDENTIFICATION

Figure 1-1

Spicer axles are identified with a manufacturing date and complete part numbers stamped on the right­hand tube. The part number may also appear on a metal tag attached to the cover plate by the cover screws,
depending upon the requirements of the vehicle manufacturer.

The part number, consisting of six digits reading from left to right, is the basic number for identifying the
particular axle assembly. The seventh digit following the dash will identify ratio, differential, and end yoke
options used in the assembly. The next group of numbers is the manufacturing date of the axle and is inter­preted as follows. The first number is the month, the second number is the day of the month, the third number
is the year, the fourth is the line that built the axle, and the letter is the shift.

NOTE

It is recommended that when referring to the axle, the complete part number and build date be ob-

tained. To do this, it may be necessary to wipe or scrape off dirt, etc., from the axle housing.

If the axle is unique on design such that the unit cannot be identified in the standard manner as de-

scribed above, refer to the vehicle manufacturer’s service and/or parts manual for proper identification.

SERVICING COMPONENTS NOT COVERED

IN THIS MANUAL

Service procedures for some components may not be covered in this manual because they are unique to
the vehicle application. Refer to the vehicle manufacturer’s service manual for servicing those components.
(e.g. brakes, hubs, rotors, and wheel end components).

VEHICLE STORAGE OR PROLONGED INOPERATION

If the vehicle has not been operated on a regular daily basis, it is recommended that the vehicle be oper­ated at least once every two weeks. The vehicle should be moved far enough to cause the drivetrain compo­nents to make several complete revolutions. This procedure will help assure that all internal components
receive adequate amount of lubrication to help reduce component deterioration caused by an undesirable
environment (e.g. high humidity).

1-3

EXPLODED VIEW OF AXLE ASSEMBLY

Figure 1-2

The model 80 single-speed axle assembly is an integral-type housing. Shown in figure 1-2 is a Model 80

full-float design.

Item Part Description

1 Ring Gear and Drive Pinion Assembly
2 Inner Pinion Bearing Cone
3 Inner Pinion Bearing Cup
4 Pinion Position Shims
5 Pinion Bearing Preload Shims
6 Outer Pinion Bearing Cup
7 Outer Pinion Bearing Cone
8 Thrust Washer

9 Pinion Seal
10 End Yoke and Flinger Assembly
11 Washer
12 Nut
13 Shipping Plug (Shipping purposes only

Removed by vehicle manufacturer)
14 Side Gear Thrust Washer
15 Pinion Mate Gear Thrust Washer
16 Differential Side Gear
17 Differential Pinion Mate Gear
18 Differential Pinion Mate Shaft
19 Differential Outboard Spacer
20 Differential Bearing Cup

Item Part Description

21 Differential Bearing Cone
22 Differential Bearing Preload and

Backlash Shims
23 Ring Gear Screw
24 Differential Case
25 Roll Pin (Pinion Mate Shaft)
26 RTV Sealant

*27 Identification Tag

28 Pill Plug
29 Cover Plate
30 Cover Screw
31 Brake Line Clip
32 Differential Bearing Cap Screw
33 Housing

**34 Differential Bearing Cap

35 Gasket-Axle Shaft Flange
36 Axle Shaft
37 Screw - Axle Shaft Flange

*Specified by vehicle manufacturer.
**Differential bearing caps are part of the housing and
cannot be serviced separately.

1-4

SECTION 2

SERVICE TOOLS

PROCUREMENT

Throughout the manual reference is made to certain tool numbers whenever special tools are required.

These tool numbers

are numbers of Miller Special Tools, 326 15 Park Lane. Garden City, MI 48135. They are used herein for

customer convenience only. Dana makes no warranty or representation to these tools.

Miller Tool Number Description

2 Jaw Puller
DD-914-8 Adapter Ring
DD-914-99 Adapters
DD-914-95 Adapters
D-115 Arbor*
C-4308 Bearing Cup Installer
C-4204 Bearing Cup Installer*
D-4308 Bearing Cup Installer
D-389 Bearing Installer
DD-914-42 Button
DD-914-42 Button
C-3339 Dial Indicator Set
W-129-B Differential Spreader
6776 Dummy Differential Bearing Set*
DD-914-7 Extension
C-4171 Handle
C-1490 Installer

Long Handle break-over bar (wrench)
D-159
6775 Pinion Bearing Cup Remover
D-191 Pinion Height Set*
DD-914 Pinion Yoke Installer
DD-914-P Press
D115-2, 6739 Press
8152 Scooter Gage**
D-131 Slide Hammer

Torque Multiplier***

Torque Wrench
6719 Yoke Holder

* Gage set for setting differential bearing preload , gear backlash, and pinion position.

** Consist of D-106-5 dial indicator and D-115-2 Scooter Block.

*** The Torque Multiplier increases torque (4 to 1) by means of gear ratio:

2-1

1

/2" drive (female), 1/4" drive (male).

NOTES

CARRIER SECTION

DISASSEMBLY

NOTE

The photos or pictures contained herein are
for illustrative and instructional purposes only. The
appearance of your axle assembly and/or
components may vary from that shown. However,
the service procedures described will apply.

If it becomes necessary to disassemble any
parts inside the carrier, it is suggested that the entire
axle be removed from the vehicle and held tight in
a stand or rack.

All dimensions are in inches unless otherwise
stated. Dimensions in parentheses followed by mm
are in millimeters.

WARNING: When removing axle assembly,
make sure vehicle is properly supported.
Improperly supported vehicle can cause
serious injury or death. Follow vehicle
manufacturers recommendations for
proper axle assembly removal
procedures.

SECTION 3

Figure 3-2

Step (3)

CARRIER OVER ,015 (.38 mm). Use dial indicator as
shown.

Mount spreader to housing. DO NOT SPREAD

TOOL: W- 129-B Differential Spreader

C-3339 Dial Indicator Set

Step (1)

lubricant.

Remove cover plate from housing and drain

NOTE

Before removing differential case assembly, make
sure the axle shafts are pulled out far enough for
clearance to allow removal.

Figure 3-1

Step (2)

on caps and carrier. This is important at time of assembly
as they are to be assembled exactly as removed. Letters or
numbers are in vertical and horizontal position.

Remove bearing caps. Note mating letters stamped

Figure 3-3

Step (4)

bars. After differential case has been removed, remove
spreader. Use caution to avoid damage to components.
Tag bearing cups indicating from which side they were
removed from. See note below regarding the use of
bearings.

3-1

Pry differential case from carrier with two pry

NOTE

It is recommended that whenever bearings are
removed, they are to be replaced with new ones,
regardless of mileage.

Figure 3-4

Step (5)

located on each side of the differential bearing bore.
Remove and tag which side they were removed from. Ring
gear side or opposite side. They will be reused during
assembly, unless damaged or worn.

Note the differential bearing outboard spacers

NOTE

Check outboard spacers for damage. (e.g. caused
by worn bearings). If damaged, they should be
replaced with new ones at time of reassembly.

RING GEAR REMOVAL

Figure 3-6

Step (7)

fixture. Remove ring gear screws. Leave 4 screws loosely
assembled 90 degrees apart. Place assembly on a solid
bench. Tap screws alternately and evenly to free ring gear
from differential case. Remove screws and ring gear.
Discard ring gear screws. Ring gear screws are to be
replaced with new ones at time of reassembly.

Place differential case in vise or suitable holding

SERVICING STANDARD

Figure 3-5

Step (6)

as shown. Tag cones indicating from which side they were
removed from.

Remove differential bearing cones with a puller

TOOL: DD-914 Press

DD-914-99 Adapters
DD-914-8 Adapter Ring
DD-914-7 Extension
DD-914-42 Button

DIFFERENTIAL CASE ASSEMBLY

The differential assembly may be serviced at this time, if
required. If differential case, side gears and pinion mate
gears are useable and do not require servicing, proceed to
DRIVE PINION REMOVAL.

CASE DISASSEMBLY

WARNING: When pulling bearings, do
not allow differential assembly to fall. It
can strike legs or feet and may cause
serious injury.

Figure 3-7

Step (8)

3-2

Remove roll pin with a small drift.

Figure 3-8

Step (9)

drift.

Remove differential pinion mate shaft with

Figure 3-9

Step (10)

enter the large opening of the case. Remove pinion mate
gears and spherical washers. After removal of the pinion
mate gears, the side gear and thrust washers can be easily
removed.

Step (11)

required.

Rotate gears until the pinion mate (small gears)

Inspect and replace components as

Figure 3-10

Step (13)

side gear up with fingers. Assemble one pinion mate gear.
Rotate gears until pinion mate gear is directly in the center
of the small opening of the case. Line up the other pinion
mate gear with the gear which has just been assembled.
Rotate gears until the holes of pinion mate gears are in
direct line with the holes of the differential case.

Step (14)

apply a small amount of grease to the new spherical
washers. Assemble washers between the gears and case.
Also line up the holes of the washers with those of the
gears and case. Assemble pinion mate cross shaft, make
sure lock pin hole of the shaft is in verticle position and
lined up with the lock pin hole of the case.

Assemble both side gears into case. Hold top

Aft er making sure the gears are in alignment,

NOTE

Always replace gears as a complete set. Do not
mix new gears with old gears, as this may cause
uneven wear and short gear life.

CASE REASSEMBLY

Step (12)

gear hubs. Assemble new thrust washers onto side gears.

Apply a small amount of grease on both side

Figure 3-11

Step (15) Assemble new roll pin. Peen metal of case over
pin to lock in place.

3-3

DRIVE PINION REMOVAL

Step (16)

and remove pinion nut and washer. NOTE: PINION NUT
HAS 500 LBS. FT. (677.9 Nom) MAX. OF TORQUE FOR
RETENTION.

Secure end yoke or flange with holding wrench,

TOOL: 67 19 Yoke Holder

Torque Multiplier
Long Handle break-over bar (wrench)

WARNING: Gear teeth may have sharp
edges. When handling gears, use care to
avoid personal injury.

NOTE

On the spline end of the pinion, there are bearing
preload shims. These shims may stick to the pinion
or bearing or even fall out. These shims are to be
collected and kept together since they will be used
later in assembly. Try not to mutilate shims. If’ shims
are mutilated, replace with new ones.

Figure 3-12

Step (17)

If end yoke or flange shows wear in the area of the seal
contact surface, it should be replaced.

Remove end yoke or flange with tools as shown.

TOOL: 2 Jaw Puller

Figure 3-13

Step (18) Remove pinion by tapping with a rawhide or
plastic hammer. Catch the pinion with your hand to prevent
it from falling and being damaged.

Figure 3-14

Step (19)

seal. REPLACE WITH NEW ONE AT TIME OF ASSEMBLY.
Remove bearing cone and outer thrust washer.

Pull out pinion seal with puller as shown. Discard

TOOL: D- 131 Slide Hammer

3-4

Figure 3-15

Step (20)

bearing cup. Locate driver on back edge of cup; drive cup
out of carrier. CAUTION: DO NOT NICK CARRIER BORE.

Turn nose of carrier down. Remove outer pinion

TOOL: D-159 Pinion Bearing Cup Remover

C-4171 Handle

Figure 3-1 7

Step (22)

Remove pinion bearing with tools as shown.

TOOL: DD-914-P Press

DD-914-8 Adapter Ring
DD-914-95 Adapters

WARNING: Do not allow gear to fall. It can
strike legs or feet and may cause serious
injury. Gear teeth may have sharp edges.
When handling, use care to avoid cutting
hands.

RING & PINION GEAR

ASSEMBLY THEORY

Figure 3-16

Step (21)

Remove the inner bearing cup with tools as shown.

TOOL: C-4307 Bearing Cup Remover

C-4171 Handle

NOTE:

Shims are located between the bearing cup and
carrier bore and may also include an oil baffle,
depending upon the application. If shims and baffle
are bent or nicked, they should be replaced at time
of assembly.

Figure 3-18 (View of ring 81 pinion set)

Step (23)

sets only. Matching numbers on both the pinion and ring
gear are etched for verification. If a new gear set is being
used, verify the numbers of each pinion and ring gear before
proceeding with assembly.

gear to the button end of the pinion for the Model 80 axle
is 3.500 (88.9 mm).

3-5

Ring gears and pinions are supplied in matched

The nominal distance from the centerline of the ring

On the button end of each pinion, there is etched
a plus (+) number, a minus (-) number, or a zero (0)
which indicates the best running position for each par­ticular gear set. This dimension is controlled by the
shimming behind the inner pinion bearing cup.

For example: If a pinion is etched a plus +3 (m+8),
this pinion would require .003 (.08 mm) less shims
than a pinion etched “0”. This means by removing
shims, the mounting distance of the pinion is in­creased to 3.503 (88.98 mm), which is just what a +3
(m+8) indicates. Or if a pinion is etched -3 (m-8), we
would want to add .003" (.08 mm) more shims than
would be required if the pinion were etched “0”. By
adding .003 (08 mm) shims, the mounting distance
of the pinion was decreased to 3.497 inches (88.82
mm) which is just what a -3 (m-8) indicates.

If the old ring and pinion set is to be reused, mea­sure the old shim pack and build a new shim pack to
this same dimension. If a baffle is used in the axle
assembly, it is considered as part of the shim pack.

To change the pinion adjustments, use different
combination of the pinion shims which come in
different thicknesses.

Old Pinion

Marking

-10 -8 -5 -3 0 +3 +5 +8 +10

+10 +.20 +.18 +.15 +.13 +.10 +.08 +.05 +.03 0

+8 +.18 +.15 +.13 +.10 +.08 +.05 +.03 0 -.03

+5 +.15 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05

+3 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08

0 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10

-3 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13

-5 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15

-5 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18

-10 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18 -.20

New Pinion Marking

Figure 3-20 (Pinion Setting Chart - Metric)

If metric, pinion will be etched (m+ some num­ber). Example (m+5). Use these charts as a guideline
to set pinion.

ESTABLISHING PINION GEAR
DEPTH USING SERVICE TOOL
GAGES.

NOTE

If baffle or slinger is bent or mutilated, it should be
replaced.

Measure each shim separately with a microme­ter and add together to get total shim pack thickness
from the original build-up.

If a new gear set is being used, notice the (+) or
(-) etching on both the old and new pinion and adjust
the thickness of the new shim pack to compensate
for the differences of these two figures.

For example: If the old pinion reads +2 (m+5) and
the new pinion is -2 (m-5), add .004" (. 10 mm) shims
to the original shim pack.

Old Pinion

Marking

-4 -3 -2 -1 0 +1 +2 +3 +4

+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0

+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -.0.001

+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -.0.001 -0.002

+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -.0.001 -0.002 -0.003

0 +0.004 +0.003 +0.002 +0.001 0 -.0.001 -0.002 -0.003 -0.004

-1 +0.003 +0.002 +0.001 0 -.0.001 -0.002 -0.003 -0.004 -0.005

-2 +0.002 +0.001 0 -.0.001 -0.002 -0.003 -0.004 -0.005 -0.006

-3 +0.001 0 -.0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007

-4 0 -.0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

New Pinion Marking

Figure 3-21

View of master pinion bearing, pinion height
block, scooter gage, cross arbor, arbor discs and
master differential bearings.

NOTE

Make sure that all carrier bores are free from all
nicks, dirt or any other contamination.

Figure 3-19 (Pinion Setting Chart - English U.S.
Standard)

3-6

Figure 3-22

Step (24)

carrier as shown. Make sure cup is seated.

Assemble the outer pinion bearing cup into

TOOL: C-4171 Handle

C-4308 Bearing Cup Installer

Figure 3-24

Step (26)

housing. Assemble outer pinion bearing cone, end yoke,
washer, and nut. Torque nut until pinion gear and master
bearing is snug (seated) in housing. The pinion gear should
not have any end play. NOTE: Do not try to rotate pinion
using master bearing.

Assemble pinion with master bearing into

Figure 3-23

Step (25)

Assemble master pinion bearing on pinion.

TOOL: C-4204 Bearing Cup lnstaller

WARNING: Gear teeth may have sharp
edges. When handling gears, use care to
avoid personal injury.

Figure 3-25

Step (27)

cross bores of carrier as shown.

3-7

Place arbor discs (large diameter) and arbor into

TOOL: 6776 Dummy Differential Bearing Set

D-115 Arbor

Figure 3-26

Step (28)

end of the pinion gear and against arbor as shown.

Place pinion height block on top of the button

TOOL: 6775 Pinion Height Set

over top of arbor, it will travel in a clockwise direction.
When indicator is on center of arbor (on top) it will stop
traveling in a clockwise direction. If indicator starts to travel
in a counter-clockwise direction, this means you have
passed the center (top) of the arbor. Record only the reading
when the indicator is at the highest point.

This reading indicates the amount of shims necessary
to obtain the shim pack plus (+) or minus (-) the etching
on the button end of the pinion.

If the etching is zero (0), the shim pack will remain
unchanged.

For example: If the pinion is etched +3 (m+8), this
pinion would require .003" (.08 mm) less shims than a
pinion etched zero (0).

If the pinion is etched -3 (m-8), this would require.
003" (.08 mm) more shims than a pinion etched zero (0).

Figure 3-27

Step (29)

pressure with fingers, making sure the gage is flat on the
pinion block. While pressure is applied, set indicator at
zero “0”.

Place scooter gage on pinion height block. Apply

TOOL: D115-2,6739 Scooter Gage

Figure 3-28

Step (30)

Slide scooter gage over arbor. As gage slides

Figure 3-29

Step (31)

and add together to get total shim pack thickness. If baffle
is required it is to be included in the shim pack. If slinger
is used between the inner bearing cone and thrust face of
pinion, the slinger is also to be measured and included as
part of the total shim pack.

3-8

Measure each shim separately with a micrometer

Figure 3-30

Step (32)

baffle if used) in the inner bearing bore. Drive the
inner bearing cup into the carrier. Make sure cup is
seated.

Place the required amount of shims (and

TOOL: C-4308 Bearing Cup Installer

C-4171 Handle

Figure 3-32

Step (34) Assemble pinion into carrier. Assemble outer
pinion bearing cone, thrust washer, and end yoke onto
pinion spline.

NOTE

Do not assemble preload shims or pinion oil seal at
this time.

Use yoke installer as shown to assemble end
yoke onto spline of pinion.

TOOL: D- 191 Pinion Yoke Installer

6719 Yoke Holder

Figure 3-31

Step (33) Assemble inner bearing cone (and slinger if used)
on pinion. Drive bearing on shaft until it is
completely seated.

TOOL: D-389 Bearing Installer

Figure 3-33

Step (35)

until it requires 10 Lbs. in. 1.13 Nom of torque to rotate
the pinion. Rotate pinion several times before checking
pinion position. This is to seat the bearings and assure a
more accurate reading when checking the pinion depth
setting.

3-9

Assemble washer and pinion nut. Torque nut

TOOL: Torque Wrench

Figure 3-34

Step (36)

cross bore of carrier. Place pinion height block on button
end of pinion. Set dial indicator on height block (high step
of block). Set dial indicator at zero (0). Slide scooter gage
across or over arbor.

point, depending on the etching of the pinion.

Indicator reading within .002 (.05 mm) of etching is
considered acceptable. If pinion position is found to
be within specification, continue with build-up. If pinion
position is not within specification, change shim pack
thickness under inner bearing cup.

Place arbor and discs (large diameter end) into

Indicator will read a plus (+) or minus (-) at its highest

NOTE

Step (37)

of pinion seal and assemble into carrier.

Apply a light coat of hypoid lubricant on the lip

TOOL: 8152 Seal Installer

C-4171 Handle

Figure 3-36

Step (38)

pinion nut. Torque nut to specification.

NOTE: Torque wrench must be capable of 500 lbs. ft. (677.9
N•m) torque.

Assemble pinion, end yoke, washer, and new

TOOL: 6719 Yoke Holder

Torque Wrench

Remove pinion nut, washer, end yoke, and pinion.
Assemble preload shims onto pinion.
NOTE: If old shims are available, measure shim pack and
build up new shim pack using new shims of the same
thickness. If old shim pack is not available for reference,
build shim pack up to .060 (1.52 mm) thick. This will
provide a starting point and may require adjustment.

Figure 3-37

Step (39)

pinion. Torque to rotate pinion should be within
specification. To increase preload, remove shims, to
decrease preload add shims.

Using an in. Lbs. torque wrench as shown, rotate

Figure 3-35

3-10

Figure 3-38

The illustration in figure 338 shows the arrow in the pinion
pointing in two directions. The direction pointing towards
the end yoke indicates that by removing pinion position
shims, the distance from the centerline of the axle to the
pinion button is increased giving a plus reading. The preload
shim pack does not effect the pinion depth setting. Arrows
on the ring gear illustrate the method to increase or
decrease backlash and differential bearing preload.

Figure 3-40

Step (41) Assemble the differential bearing outboard
spacers into the carrier housing, as removed in step 5,
figure 34.

Assemble differential case into carrier (less ring gear).
Mount dial indicator with a magnetic base as shown. Locate
tip of indicator on flat surface of case. Force differential
assembly as far as possible in the direction towards the
indicator. With force still applied, set indicator at zero (0).

TOOL: C-3339 Dial Indicator Set

ASSEMBLY OF DIFFERENTIAL

Figure 3-39

Step (40)

Remove all nicks, burrs, dirt etc., from hubs to allow master
bearings to rotate freely.

Assemble master differential bearings onto case.

TOOL: 6776 Dummy Differential Bearing Set

NOTE

Dial indicator should have a minimum travel capability
of .200 (5.08 mm).

Force the differential assembly as far as it will go in
the opposite direction. Repeat these steps until you have
obtained the same reading. Record the reading of the
indicator on the worksheet, page 313. This reading will be
measurement “A”. After making sure the readings are
correct, remove indicator and differential assembly from
housing. Remove master bearings from hubs and set aside.

Figure 3-41

Step (42)

3-11

Place case assembly in a vise. Be sure flange

face of the case is free of nicks or burrs. Assemble ring
gear to case. Line up holes of the ring gear with those of
the case. Use new ring gear screws. Draw up screws
alternately and evenly. Torque ring gear screws to
specification.

TOOL: Torque Wrench

Figure 3-42

Step (43) Assemble master differential bearings onto case
hubs. Place differential assembly into housing. Set up dial
indicator as shown. Locate tip of indicator on flat surface
of one of the ring gear screws. Force the differential case
assembly (ring gear) away from the pinion gear. With force
still applied to the differential case, set indicator at zero
“0”.

TOOL: C-3339 Dial Indicator Set

Figure 3-44

Step (45)

hub (ring gear side) and opposite side as determined using
the worksheet. Place bearing cone on hub of case. Use
bearing installer to seat bearing cone as shown.

Assemble the required amount of shims onto

TOOL: C- 1490 Installer

C-4171 Handle
DD-914-42 Button

NOTE
Button is used to raise case from bench to protect
bearing cone cage from being damaged when
installing opposite bearing cone.

Figure 3-43

Step (44)

gear into mesh with the pinion gear. Rock ring gear to allow
the teeth of the gear to mesh. Repeat until the same reading
is obtained each time. Record this reading on the
worksheet, page 313. This reading will be measurement
“B”. Remove indicator and differential case assembly from
the carrier. Remove master differential bearings from the
differential case. Refer to the worksheet for calculating
ring gear backlash and differential bearing preload shims,
page 3-13.

Force the differential case assembly and ring

Figure 3-45

Step (46) Install spreader and indicator as shown. DO NOT
SPREAD CARRIER OVER .015 (.38 mm). Remove indicator.

TOOL: W- 129 B Differential Spreader

C-3339 Dial Indicator Set

3-12

WORKSHEET FOR CALCULATING RING GEAR BACKLASH

AND DIFFERENTIAL BEARING PRELOAD SHIMS

(1) Total amount of space measured without ring gear as

shown in step 41, figure 3-40 Measurement A

(2) Total amount of space measured with gear set assembled

in carrier as shown in step 44, figure 3-43 Measurement B

(3) Measurement A minus Measurement B equals calculated Measurement C

After the measurements and calculations have been made, assemble the shim packs using the figures

determined in A, B, & C, and adjusting the pack as described below.

RING GEAR SIDE:

Assemble shim pack to measurement B.

OPPOSITE SIDE OF RING GEAR:

Assemble shim pack to measurement C. Add .010 (.25 mm) for differential bearing preload and backlash.

EXAMPLE

(1) Total amount of space measured without ring gear as

shown in step 41, figure 3-40 Measurement A .105" (2-67 mm)

(2) Total amount of space measured with gear set assembled

in carrier as shown in step 44, figure 3-43 Measurement B .065" (1.65 mm)

(3) Measurement A minus Measurement B equals calculated Measurement C .040" (1.02 mm)

After the measurements and calculations have been made, assemble the shim packs using the figures

determined in A, B, & C, and adjusting the pack as described below.

RING GEAR SIDE:

Assemble shim pack to measurement B, In this example it is .065" (1.65 mm).

OPPOSITE SIDE OF RING GEAR

Assemble shim pack to measurement C. Add .010 (.25 mm) for differential bearing preload and backlash.

.040" + .010" = .050", (1.02 mm + 25 mm = 1.27mm).

3-13

Figure 3-46

Step (47)

bearing cones. Install differential assembly into carrier. Use
a rawhide or plastic hammer to seat differential assembly
into cross bores of carrier. Care should be taken to avoid
nicking the teeth of the ring gear and pinion during
assembly. Remove spreader.

Assemble differential bearing cups to differential

WARNING: When differential assembly is
installed into carrier, use care to avoid
pinching hand or fingers between
differential bearing cup and carrier
housing.
Gear teeth may have sharp edges. When
handling gear, use care to avoid cutting
hands.

Figure 3-48

Step (49)

equally spaced points with dial indicator as shown.
Backlash should be within specification and cannot vary
more than .002 (-05 mm) between points checked.

Check ring gear and pinion backlash in three

TOOL: C-3339 Dial Indicator Set

High backlash is corrected by moving the ring

gear closer to the pinion.

Low backlash is corrected by moving the ring gear

away from the pinion.

These corrections are made by switching shims

from one side of the differential case to the other.

Figure 3-47

Step (48) Install bearing caps. Make sure the letters
stamped on the caps correspond with those on the carrier.
Torque bearing cap screws to specification.

TOOL: Torque Wrench

Figure 3-49

Step (50)

pinion and differential assembly, Torque reading should
be within specifi ication. If preload is to high, remove an
equal amount of shims from both sides of the differential
case hubs. If preload is to low, add an equal amount of
shims to both sides of differential case hubs.

3-14

Using an in. lb. torque e wrench as shown, rotate

NOTE

If shims are added to one side only, it will affect
backlash reading.

APPLYING RTV SILICONE

GASKET SEALER TO COVER PLATE

Figure 3-50

Step (51)

to carrier. Torque screws to specification.

Apply gasket sealer to cover plate and assemble

TOOL: Torque Wrench

NOTE

The cover face of the carrier and the flat surface of
the cover plate must be free of any oil film or foreign
material. Sealant material must meet specifications
as described in the specification section of this
manual.

Apply sealer to cover plate surface. Ensure that
the sealer bead is laid on the inside of the cover
screw holes. The bead is not to pass through the
holes or outside of the holes.

The bead is to be
and 1/8" to 1/4" (3.18 - 6.35 mm) wide.

Allow one hour cure time before filling carrier with
the proper amount of specified lubricant and vehicle
operation.

Assemble axle shafts and wheel end components.
Refer to your vehicle service manual for proper
wheel bearing setting specification.

1

/8" to 1/4" (3.18 - 6.35 mm) high

3-15

NOTES

SECTION 4

SPECIFICATIONS

DIFFERENTIAL LUBRICATION

It is not our intent to recommend any particular brand or make of lubricant for the Spicer hypoid axle. However, an S.A.E.
8OW-90 multi-purpose gear lubricant meeting Mil. Spec. L-2105C, and suitable for 1 A.P.I. Service Classification GL5, is
suggested as a minimum requirement.

IMPORTANT

Motor vehicles are operated under various requirements, conditions, and environments. This manual specifies
the minimum requirements that the lubricants should meet. However, it is recommended that the lubricants
specified by the vehicle manufacturer be used. They may provide additional lubricating characteristics which may
be required for your vehicle’s operation. Contact your local service dealer or refer to your owner’s manual for
obtaining the proper lubricant specification.

AXLE LUBRICANT CHANGE SCHEDULE

The following schedule is a suggested lubricant change schedule. Lubricant in your vehicle may require more frequent

changes depending upon the environment in which it is operated in. Contact your local service dealer or refer to your
owner’s manual for obtaining the proper lubricant change schedule for your vehicle.

Drain lubricant at first oil change and refill with specified lubricant. FOR NORMAL ON HIGHWAY USE, change

lubricant every 100,000 miles or 24 months, whichever comes first. FOR OFF HIGHWAY, SANDY, DUSTY, OR WET
CONDITIONS, change lubricant every 25,000 miles or 6 months, whichever comes first.

Lubricant may be drained by removing the carrier cover plate. This also allows for visual inspection of the internal

components. Follow the service procedure in the manual for reassembly of the cover plate.

WHEEL BEARING LUBRICATION

Wheel bearings are lubricated by packing with grease. For grease packing it is recommended that a 2N.L.G.I. No. 2

lithium EP grease suitable for automotive wheel bearings be used. Contact your local vehicle service dealer or refer to
your owner’s manual for obtaining the proper lubricant specification, and maintenance schedule.

SUBMERSION OR DEEP WATER FORDING

If the vehicle is exposed to water deep enough to cover the hubs, it is recommended that the wheel ends be diassembled

and inspected for water damage and/or contamination.

In the event the carrier housing should become submerged in water, particularly if over the breather, it is recommended

that the hypoid gear lubricant be drained and internal parts be inspected for water damage and/or contamination.

Clean, examine, and replace damaged parts if necessary, prior to assembling the housing cover and refilling with the

specified hypoid lubricant.

NOTE

If the hubs are exposed to deep water, it is possible that the water could enter the carrier at the point the axle
shaft enters the tube in the wheel end. This could also necessitate the draining of the hypoid lubricant as described
above.

It is recommended that whenever bearings are removed, they be replaced with new ones, regardless of
mileage.

1

A.P.I. - American Petroleum Institute

2

N.L.G.I. - National Lubricating Grease Institute

4-1

RTV SILICONE RUBBER SEALER SPECIFICATION

Sealant material must meet specification of 1A.S.T.M. 1, GE 503, Z1, Z2, 23.

FASTENER STRENGTH IDENTIFICATION

IMPORTANT

Whenever fasteners are replaced, it is very important that the fastener be replaced with one of equal or higher
grade and quality. Fasteners should be torqued as recommended or specified for the application.

WARNING

IF FASTENERS OF A LOWER GRADE OR CLASS ARE TORQUED TO THE REQUIREMENTS OF A HIGHER GRADE
OR CLASS FASTENER, IT MAY RESULT IN COMPONENT FAILURE. (E.G. GRADE 5 FASTENER TORQUED TO THE
REQUIREMENTS OF A GRADE 8 FASTENER.)

GRADE 5 GRADE 7 GRADE 8

Customary (Inch) Bolts - Identification marks correspond to bolt strength - Increasing numbers
represent increasing strength.

Metric Bolts - Identification class numbers correspond to bolt strength - increasing numbers
represent increasing strength.

SPECIAL GRADE

(High Strength

Applications)

Figure 4-l

Inch grade fasteners can be identified by the radial lines embossed upon the head of the fastener and will correspond

to the fastener strength by two-lines less than actual grade (i.e. grade 8 fastener will display 6 radial lines on the head).

Metric fastener strength can be identified with the class identification embossed on the head of each fastener.

Increasing numbers represent increasing strength.

1

A.S.T.M. - American Society for Testing and Material

4-2

WRENCH TIGHTENING TORQUE SPECIFICATIONS

LBS. FT. 1 N•m

Cover Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 47.5

Differential Bearing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 108.5

Drive Pinion Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470 637.2

Fill Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 33.9

Ring Gear Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 298.3

PINION BEARING AND DIFFERENTIAL BEARING

PRELOAD SPECIFICATION

LBS. FT. 1 N•m

Torque to Rotate Drive Pinion Only (New bearings only) . . . . . . . . . . . . . . . . . . . . . 20-40 2.26 - 4.52

Torque to Rotate Drive Pinion and Differential Case
Assembly (Less Axle Shafts) (New bearings only) SEE NOTE 1

BACKLASH SPECIFICATION

Drive Gear to Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 005 - .008 (.13 -20 mm)

DRIVE PINION GEAR DEPTH SPECIFICATION

Figure 4-2

The pinion setting dimension is measured from the centerline of differential carrier (center line of ring gear) to face of
pinion (button), plus or minus the etch on the button of the pinion. This dimension must be held within ± .002 in (.05
mm). For example: The model 80 pinion setting dimension is 3.500 (88.9 mm). If the pinion etch is a +2, this dimension
becomes 3.502 (88.95 mm).

WHEEL BEARING SPECIFICATION

SPECIFIED BY VEHICLE MANUFACTURER. CONTACT YOUR LOCAL VEHICLE SERVICE DEALER OR REFER TO YOUR

VEHICLE SERVICE MANUAL FOR OBTAINING THE PROPER WHEEL BEARING SPECIFICATION.

Notes:

(1) Torque to rotate drive pinion only plus 6-8 lbs. in. (.68 - .90 N•m) for ratios 4.63 to 5.13.

4-3

NOTES

Dana Aftermarket Group

For spec‘ing or service assistance, call 1.800.621.8084 or visit our website at www.spicerparts.com

PO Box 321
Toledo, Ohio 43697-0321

Warehouse Distributor: 1.800.621.8084

Dana Commercial Vehicle Products Group

OE Dealers: 1.877.777.5360

3939 Technology Drive
Maumee, Ohio, USA 43537

www.spicerparts.com

www.dana.com

AXSM-0053 Printed in U.S.A.
Copyright Dana Limited, 2012.
All rights reserved. Dana Limited.