Spicer Tandem Drive Axle Dual Range Double Planetary User Manual

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Spicer® Tandem Drive Axles

Service Manual

Spicer® Tandem Drive Axles

AXSM-0045 September 2007

Spicer Axle Service and Maintenance Instructions

Tandem Drive Axles

Dual Range and Planetary Double Reduction Gearing

Introduction

Dana Corporation, Axle & Brake Division, presents this publication to aid in maintenance and overhaul of Spicer

tandem drive axles. Service and Maintenance instructions cover Spicer Dual

Range (2-Speed) and Planetary Double Reduction Tandem Axles. Instructions are applicable to both gearing types unless specified otherwise.

Five basic axle series are included in this book. Their design is common with differences in load capacity and two gearing

types.

Load Capacity (lbs.)

Dual Range

34,000 DT340, DT341

38,000 38,000 40,000 40,000 45,000

DT380(P)

* DT381(P)

DT400-P, DT401-P DT402(P) DT451 -P

The suffix letter “P” in the Model No. indicates the axle

is equipped with a gear-driven Lube Pump, designed to

provide additional lubrication to the inter-axle differential and related parts.

Instructions contained herein are applicable to all axle models

unless specified otherwise.

For brake information and axle mounting suspension systems, refer to pertinent truck manufacturer’s literature.

Model Numbers

DP381(P)

Planetary Double Reduction

DP340, DP341 DP380(P)

DP400-P, DP401 -P DP402(P) DP451-P

Typical 3PICER Tandem Drive

Axle (Dual Range illustrated).

Design Variations:

Two design variations of tandem axles are included in this manual. The major difference is in the shaft sp line design. Refer to page 5 for deails.

*NOTE: DS381 (P) axles manufactured

after April 1985 are rated at 40,000 lbs,

Contents

Description and Operation Gearing and Torque Distribution

Lubrication Cleaning, Inspection, Replacement Adjustments

• Wheel Bearings

•Adjust Input Shaft End Play

•Pinion Bearing Preload

•Differential Bearing Preload and Ring Gear Backlash Adjustment

Ring Gear and Pinion Tooth Contact Fastener Tightening Specifications Rear Axle Differential

Carrier Replacement

Forward Axle Differential

Carrier Replacement Power Divider Replacement Power Divider Overhaul

•Remove Power Divider from Differential Carrier

•Disassemble power Divider Cover

•Disassemble Inter-axle Differential

*Service Bulletin Supplement

(Checking Input Shaft End Play —

●

Disassemble Output Shaft

●

Assemble Output Shaft

●

Assemble Inter-axle Differential

●

Assemble Power Divider Cover

●

Install Power Divider on Diff. Carrier

●

Adjust Input Shaft End Play

Differential Carrier Overhaul

●

Disassemble Differential Carrier

●

Disassemble Drive Pinion

•

Disassemble Wheel Differential

●

Assemble Wheel Differential

●

Assemble Drive Pinion

●

Forward Axle- Install Pinion

●

Forward Axle - Install Helical Gear

●

Forward Axle - Install Differential Assembly in Carrier

●

Rear Axle - Install Pinion and Differential in Carrier

Misc. Torque Fastening Chart DuaI Range Axle Shift System

Axle Models with Thrust Button

Price $3.50

Axle and Carrier Assembly Model Identification

Spicer Axle

Spicer

Spicer Axle

Spicer

Axle Specification Number

The complete axle is identified by the specification

number stamped on the rear right-hand side of the axle. housing. This number identifies all component parts of the axle as built by Spicer, including special OEM requirements such as yoke or flange.

In addition, some axles may include a metal identification tag (see illustration).

Metal Identification Tag

Ring Gear and Pinion Identification

Ring Gear and Drive Pinion are matched parts and must

be replaced in sets. Check the appropriate Spicer Axle parts book for part numbers and ordering

instructions. To aid in identifying gear sets, both

parts are stamped with such infor-

mation as number of pinion and

ring gear teeth, individual part

number and matched set number

(refer to adjacent drawing).

Spicer¬Dual Range Tandem Drive Axles

Description and Operation

Spicer Dual Range Tandems are basically 2-Speed, shiftable drive axles. They provide two gearing ratios (low and high ranges) and are designed for heavy-duty service in on-off highway operations. Low range for deep gear reduction and slow speed hauling off highway. High range for cruising speeds on highway.

The complete tandem axle assembly includes two axle units, each with double gear reduction capability coupled by a 2-gear S

power divider.

Power Divider

In operation, the power divider accepts the torque from the vehicle

drivelne and distributes it equally to the two axles. This assembly is of the two-gear design consisting of an input shaft,

inter-axle differential, output shaft and two constant-mesh helical

gears. The inter-axle differential compensates for axle speed variations in the

same way the wheel differential works between the two wheels of a single drive axle. This unit also acts as a central point in distribution

of torque to the two axles.

The power divider also includes a driver-controlled, air-operated lockout. When lockout is engaged, it mechanically prevents inter-axle differentiation for better performance under poor traction conditions.

Lube Pump

Tandem Axles with suffix letter "P" in Model No. are equipped with a lube pump to provide positive lubrication to the inter-axle differential and other power divider parts. This pump is operated by a drive gear engaged with the input shaft splines. When vehicle is moving in a forward direction, pressurized lube is delivered to the vital power divider parts.

PICER Dual Range Gearing

with Lube Pump

Lube Pump System

The pump lube system

incorporates a magnetic strainer screen. To keep the system clean, the magnet traps minute particles and the screen blocks out large

particles of foreign material.

Dual Range Tandem Shift System

Range selection is accomplished by an air shift system and is drivercontrolled through a cab-mounted air control valve.

The control valve operates two shift units (one for each axle) which mechanically engages or disengages the planetary gearing.

For operation description, refer to Shift System section in this manual.

Forward Axle Shift Unit

Rear Ax/e Shift Unit

Spicer Planetary Double Reduction Axles

Description and Operation

The Planetary Double Reduction Tandem Axle shares its basic design concepts and many components with the Dual Range Tandem. The principle variation

is the permanent engagement of the double reduction feature. A stationary sun gear, fixed in engagement with the low-speed

clutch plate, replaces the sliding

clutch gear and provides continuous

double reduction operation in the

same manner as the dual range

axle when in Low Range.

Torque distribution and power flow

is same as Dual Range Gearing in

Low Range (see page 7).

Design Variations (Dual Range and Planetary Double Reduction Axles)

NOTE: To assist in identifying the axle being serviced, here are the major design variations within the axle series covered by this manual.

D341, 381(P)

401-P, 402(P),

451-P

16 34

44 36

5 pitch

41 39

1-5/8"-18

self-locking or

slotted nut with

roll pin M42 x 1.5

after 7/1 /95

1-1/2"-18

self locking

M36 x 1.5after

7/1/95

Axle Series Output Shaft Splines

Side Gear End Output End

Input Shaft Splines

Input End

Diff. End

Helical Gear Drive Pinion Splines

Forward Axle Rear Axle

Drive Pinion Nut

Forward Axle

Rear Axle

D340, 380(P)

400-P

16 10

16 36

7 pitch

10 10

1-1/2"-18

self-locking

1-1/2"-18

self-locking

Axle Shaft & Side Gear Splines

Lube Pump Drive Shaft.

pump models is equipped with a woodruff key. On late pump models, the key is eliminated. The drive

shaft end has two machined flats and the drive gear

mounting hole is shaped to accommodate these flats.

D340,380(P)-16

D400-P-33

The drive shaft on early

D341-39 D381(P), D402(P) -41 D401-R D451-P -33

Gearing and Torque Distribution

Dual Range Gearing

The gearing for each axle is a combination of a spiral bevel ring gear and pinion and a planetary

unit.

First reduction (High Range) is provided by the spiral bevel gearing.

Second reduction (Low Range) is through the planetary gearing.

Four planetary idler pinions are confined within the ring gear and mesh with the ring gear internal teeth. The planetary gears rotate around a sliding clutch gear.

Each axle is equipped with a shift unit, which operates the sliding clutch gear to provide means for selecting the axle range. Range selection is accomplished through the movement of the sliding clutch gear in and out of engagement with low and high-speed clutch plates.

The sliding clutch gear is locked into the high-speed clutch plate and rotates as part of the differential assembly. The planetary pinions are stationary and the axle uses only the single reduction of the ring gear and pinion. Power flow is through the drive pinion, ring gear, differential unit and axle shafts.

The sliding clutch gear is shifted into engagement with the lowspeed clutch plate (an integral part of the bearing adjuster). The sliding clutch is held stationary and the planetary pinions are forced to rotate around it. Power flow is now

through drive pinion, ring gear,

planetary gearing, differential unit and axle shafts. The axle uses two reductions to multiply torque. The planetary unit adds approximately 36¡/0 more reduction to the primary gear set. Torque is multiplied on an equivalent basis.

Torque Distribution in High Range

Torque (power flow) from the vehicle driveline is transmitted to the input shaft and the inter-axle differential spider. At this point, the differential distributes torque equally to both sides.

For the forward axle, torque is transmitted from the helical-side gear to the pinion helical gear, drive pinion, ring gear, wheel differential and axle shafts.

For the rear axle, torque is transmitted from the output shaft side gear, through the output shaft,

inter-axle driveline, to the drive pinion, ring gear, wheel differential and axle shafts.

INPUT

TORQUE

Torque is transmitted to both axles through inter-axle

differential action.

Torque Distribution in High Range (cent’d)

A lockout mechanism is incorporated in the power divider to enable the vehicle driver to lock out the INPUT

inter-axle differential and provide maximum traction under adverse road conditions.

In operation, an air cylinder (controlled by a cabmounted valve) shifts a sliding clutch. To lock out

inter-axle differential action, the clutch engages the helical-side gear and causes this gear, the input shaft and differential to rotate as one assembly. This action provides a positive drive to both axles.

With lockout engaged, torque is distributed to both axles without differential action. The forward axle pinion and ring gear are driven by the helical-side gear. The rear axle gearing is driven from the output

shaft side gear and inter-axle driveline. NOTE: Varied road surface conditions can result

in unequal torque distribution between the two axle

assemblies.

Torque is transmitted to both axles without inter-axle

differential action.

TORQUE

Torque Distribution in Low Range

INPUT

TORQUE

INPUT

TORQUE

Torque is transmitted to both axles through inter-axle

differential action.

Torque is transmitted to both axles without inter-axle

differential action.

Spicer Tandem Drive Axles

Differential Carrier Assembly Forward Axle

Dual Range DT340, 310(P), 400-P DT341, 381(P), 401-P DT402(P), 451-P

Planetary Double Reduction DP340, 380(P), 400-P DP341, 381(P), 401-P DP402(P), 451-P

IMPORTANT: Seals, Yokes and Slingers.

Before replacing

these parts, refer to

Repair and Replacement Instructions for interchangeability information.

Spicer®Tandem Drive Axles

Differential Carrier Assembly Rear Axle

Dual Range RT340, 341, 380, 381, 400, 401,402, 451 Planetary Double Reduction RP340, 341, 380, 381, 400, 401, 402,451

Lubrication

The ability of a drive axle to deliver quiet, trouble-free operation over a period of years is largely dependent upon the use of good quality gear lubricant in correct quantity. The most satisfactory results can be obtained by following the directions contained in this manual.

The following lubrication instructions represent the most current recommendations from the Axle & Brake Division of

Dana Corporation.

Approved Lubricants

General-Gear

specification (MILSPEC) MIL-L-2105D (Lubricating Oils, Gear, Multipurpose) are approved for use in Spicer Drive Axles. The MIL-L-2105D specification defines performance and viscosity requirements for multigrade oils. It super-

sedes both MIL-L-21 056, MIL-L-2105C and cold weather specification MlL-L-l 0324A. This specification applies to both petroleum-based and synthetic based gear lubricants if they appear on the most current “Qualified Products List” (QPL-2105) forMIL-L-2105D.

Note: The use of separate oil additives and/or friction modifiers are not approved in Drive Axles.

Synthetic

superior thermal and oxidation stability, and generally degrade at a lower rate when compared to petroleum-based

lubricants. The performance characteristics of these lubri-

cants include extended change intervals, improved fuel

economy, better extreme temperature operation, reduced wear and cleaner component appearance. The family of Spicer®gear lubricants represents a premium synthetic lube which fully meets or exceeds the

requirements of MIL-L-2105D. These products, available in both 75W-90 and 80 W-1 40, have demonstrated superior performance in comparison to others qualified under the MILSPEC, as demonstrated by extensive laboratory and field testing. For a complete list of Spicerr®approved synthetic lubricants contact your local Spicer representative. See back cover of this manual for appropriate phone number.

Makeup Lube-Maximum amount of non-synthetic makeup

lube is 100/o.

lubrications acceptable under military

based-Synthetic-based gear lubricants exhibit

quality

Viscosity/Ambient Temperature Recommendations-The

following chart lists the various SAE Grades covered by MIL-L-2105D and the associated ambient temperature range from each. Those SAE grades shown with an asterisk (*) are available in the Spicer family of synthetic gear lubricants.

The lowest ambient temperatures covered by this chart are

-40°F and -40°C. Lubrication recommendations for those applications which consistently operate below this temperature range, must be obtained through the Dana Corporation by contacting your local Spicer representative.

Grade

75W 75W-80

75W-90* 75W-140 80W-90 80W-140* 85W-140

Ambient Temperature Range

-40oF to -15°F (-40oC to -26oC)

-40°F to 80oF (-40°C to 21oC)

-40oF to 100oF (-40oC to 38oC)

-40°F and above (-40oC and above)

-150F to 100oF (-26°C to -38oC)

-150F and above (-26°C and above) 10oF and above (-12°C and above)

Lube Change Intervals

This product combines the latest manufacturing and part washing technology.

synthetic lubricant at the factory, the initial drain is not

required. Change the lubricant within the first 5,000 miles of

operation when not using a approved

lubricant in either a new axle or after a carrier head replacement.

a combination of the following chart and user assessment of the application and operating environment.

Severe Service Lubrication Change Intervals -

service applications are those where the vehicle consistently operates at or near its maximum GCW or GVW

ratings, dusty or wet environments, or consistent operation on grades greater than 8%. For these applications, the ON/OFF HIGHWAY portion of the chart should be used. Typical applications are construction, logging, mining and

refuse removal.

Note:

Remove metallic particles from the magnetic filler plug and drain plugs. Clean or replace the breather at each lubricant change.

When filled with an approved

synthetic

Base subsequent lubricant changes on

Severe

Lubricant Type

Mineral

Based

Spicer - Approved 250,000

Synthetic

Guidelines - Lube Change Intervals for Drive Axles

On Highway

Miles

100,000

Maximum Change

Interval

Yearly

3 Years

On/Off Highway Severe

Service Miles

40,000

100,000

Maximum Change

Interval

Yearly

Lubrication

Changing Lube

Draining

Drain when the lube is at normal operating temperature. It will run freely

and minimize the time necessary to fully drain the axle. Unscrew the magnetic drain plug on the underside of the axle housing

and allow the lube to drain into a suitable container. Inspect drain plug for large quantities of metal particles. After initial oil change, these are signs of damage or extreme wear in the axle, and inspection of the entire unit may be warranted. Clean the drain plug and replace it after the lube has drained completely.

Axles with Lube Pump:

divider cover and inspect for wear material in the same manner as the

drain plug. Wash the magnetic strainer in solvent and blow dry with compressed air to remove oil and metal particles.

Remove the magnetic strainer from the power

CAUTION:

SAFE AREA. WEAR SAFETY

EXERCISE CARE

TO DIRECT COMPRESSED AIR INTO

GLASSES.

Filling

Remove the filler hole plug from the center of the axle housing cover and fill the axle with approved lubricant until level with the bottom of the hole.

Forward axles:

(0.94 liters) of lubricant through filler hole at the top of the differential carrier near the power divider cover.

NOTE: Lube fill capacities in the

adjacent chart are good guidelines

but will vary somewhat on the

basis of the angle the axle is

installed in a particular chassis.

Always use the filler hole as the

final reference. If lube is level with

the bottom of the hole, the axle is

properly filled.

Add two pints

Axle Installation Angles

Axles installed at angles exceeding

10 degrees or operated regularly in areas of continuous and lengthy grades may require standpipes to allow proper fill levels.

For specific recommendations, contact your local Spicer representative.

Lube Capacities*

DO NOT OVERFILL AXLES

63,&(5 Housings (Rectangular Arm)

Dual Range and PDR Tandem Series

340, 341 . . . . . . . . . . . . . . . . . . . . . . . . . . .

380(P), 381 (P) 400-P, 401-P

402( P), 451-P . . . . . . . . . . . . . . . . . . . . .

Forward Axles: Add an additional 2 pints (0.94 liters) axle lubricant

through filler hole at the top of the differential carrier near the power divider cover. (See photo above.)

*Capacities listed are approximate. The amount of lubricant will vary with angle of

axle as installed in vehicle chassis. Figures do not apply to housings not designed or manufactured by Spicer.

Forward

Axle

Pints (liters)

38 (18.0)

37 (17.5)

Rear Axle

Pints (liters)

35 (16.6)

34 (16.1)

Wheel End Lubrication

IMPORTANT: In cases where wheel

equipment is being installed, either new or after maintenance activity, the lube cavities are empty. Bearings and seals must be manually supplied with adequate lubricant or they will be severely damaged before the

normal motion of the vehicle can supply lube to the hub ends of the housing.

To avoid the risk of premature damage to being installed. There are three methods of wheel bearings and seals, they must be doing this. The correct method will depend “prelubed” any time the wheel equipment is

Lubrication When Hubs Have No Filler Holes (Preferred Method*)

(Follow procedure in numerical sequence.)

1. Fill axle with lube through axle housing cover filler hole.

2. Jack up left side of axle.

Maintain this position for one minute to allow lube to

flow into wheel ends at

right side.

on the type of wheel equipment being used.

3. Jack up right side of axle. Maintain this position for one minute to allow

lube to flow into wheel

ends at left side.

4. With vehicle level again, add lube through axle housing cover filler hole. The axle should require two additional pints of

lube to bring level up to bottom of filler hole.

*The above procedure is the preferred method since it optimizes the lube supply to the wheel end components and axle sump.

Alternate Method of Wheel End Lubrication

1. After the wheel hub seal has been installed,

charge the hub cavity with as much axle lubricant as possible.

2. Prelube the bearings with clean axle lubricant at installation.

NOTE: If the hub has no cavity to accept a assembly to prevent spilling lubricant on

precharge of axle lube, the bearings can be

Hubs Equipped with Lube Filler Holes

Pour a pint of standard axle lubricant into

the hub through the cavity filler hole

provided.

prepacked with a good quality grease instead of axle lube. However, excess grease should be removed.

CAUTION: Exercise caution when

mounting a precharged hub and drum

the brake linings.

Cleaning, Inspection, Replacement

“

As the drive axle is disassembled, set all parts aside for thorough cleaning and inspection. Careful inspection will help determine whether parts should be reused. In many cases, the causes of premature wear or drive axle failure will also be revealed.

Cleaning

The differential carrier assembly may be steam-cleaned while mounted in the housing as long as all openings are tightly plugged. Once removed from its housing, do not steam clean differential carrier or any compo-

nents. Steam cleaning at this time could allow water to be trapped in

cored passages, leading to rust, lubricant contamination, and premature

component wear. The only proper way to clean the assembly is to dis-

assemble it completely. Other methods will not be effective except as

preparatory steps in the process. Wash steel parts with ground or polished surfaces in solvent. There are many suitable commercial solvents avail-

able. 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.

Wash castings or other rough parts in solvent or clean in hot solution

tanks using mild alkali solutions. If a hot solution tank is used, make

sure parts are heated thoroughly, before rinsing.

Rinse thoroughly to remove all traces of the cleaning solution. Dry parts

immediately with clean rags.

Lightly oil parts if they are to be reused immediately. Otherwise, coat with oil and wrap in corrosion-resistant paper. Store parts in a clean, dry

place.

Inspection

Inspect steel parts for notches, visible steps or grooves created by wear.

Look for pitting or cracking along gear contact lines. Scuffing, deformation or discoloration are signs of excessive heat in the axle, usually related to low lubricant levels or improper lubrication practices.

Before reusing a gear set, inspect teeth for signs of excessive wear. Check tooth contact pattern for evidence of incorrect adjustment (see Adjustment Section for correct pattern).

Inspect machined surfaces of cast or malleable parts. They must be free of 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 fasteners for rounded heads, bends, cracks or damaged threads. The axle housing should be examined for cracks or leaks. Also look for

loose studs or cross-threaded holes.

Inspect machined surfaces for nicks and burrs.

Repair and Replacement

IMPORTANT: To achieve maximum value from an axle rebuild, replace lower-cost parts, such as thrust washers, seals, etc. These items protect the axle from premature wear or loss of lubricants. Replacing these parts will not increase rebuild cost significantly.

It is also important to replace other parts which display signs of heavy

wear even though not cracked or broken. A significant portion of such a

part’s useful life has been expended and the damage caused, should the part fail, is far in excess of its cost.

Steel Parts —

able. Worn or damaged parts should be discarded without hesitation. Also discard mating parts in some cases. Gear sets for example, must be replaced in sets.

Miscellaneous Parts

of these parts can be reused if damaged. Fasteners using self-locking nylon “patches” may be reused if not damaged, but should be secured by a few drops of Loctite #277 on the threaded surface of the hole during installation and carefully torqued during installation.

Axle Housings

machined surfaces and the replacement of loose or broken studs.

CAUTION: ANY DAMAGE WHICH AFFECTS THE ALIGNMENT OR STRUCTURAL INTEGRITY OF THE HOUSING REQUIRES HOUSING

REPLACEMENT. REPAIR BY WELDING OR STRAIGHTENING

SHOULD NOT BE ATTEMPTED. THIS PROCESS CAN AFFECT THE

HOUSING HEAT TREATMENT AND CAUSE IT TO FAIL COMPLETELY

WHEN UNDER LOAD.

Silicone Rubber Gasket Compound —

uses silicone rubber gasket compound to seal the majority of metal-tometal mating surfaces.

Spicer includes gasket compound and application instructions in many repair parts kits.

It is recommended that this compound be used in place of conventional gaskets. The compound will provide a more effective seal against lube seepage and is easier to remove from mating surfaces when replacing parts.

Gear sets, differential parts and bearings are not repair-

— Seals and washers are routinely replaced. None

— Repairs are limited to removal of nicks or burrs on

For more effective sealing, Spicer

Seals, Yoke & Slinger Service Information

During the 4th Quarter of 1990, Spicer began using new seals and yoke & slingers on the models in this

publication. The new seals and slingers are noticeably different from the current seals and will affect

interchangeability.

● The upgraded Seals can be used on axles originally equipped with the old seals.

● Spicer recommends the replacement of old yoke & slinger assemblies when the new seals are installed. The

old yokes and slingers will work with the new seals, but new yoke and slinger assemblies provide maximum

sealing protection and prevent premature seal wear due to poor yoke condition.

● New yoke and slinger assemblies cannot be used with the old seal design on the tandem forward axles.

● New yoke and slinger assemblies can be used with the old seal on the tandem rear pinions.

● Yoke Assembly & Oil Seal Kits contain oil seal, yoke & slinger and instructions.

● Most non-Spicer aftermarket seals will not be compatible with the new Spicer Yoke and Slinger assemblies.

● Sicer recommends the use of special installation tools conveniently packaged in a single kit (listed below).

•

Refer to Spicer parts Book AXIP-0087 and Spicer Bulletin 90-06 for additional information.

Seal Driver Installation Kit 212139

Includes:

•

126917 Driver (Rear Axle Pinion)

• 127787 Adapter (use with 126917 Driver for Forward Axle Input)

• 127786 Driver (Forward Axle Output)

Adjustments

WARNING: Never work u n-

der a vehicle supported by

Wheel Bearing Adjustment

only a jack. Always support vehicle with stands. Block the wheels and make sure

Wheel bearings should be adjusted at regular intervals

using the following procedure:

the vehicle will not roll before releasing the brakes

Wheel End Seal

Important: Wheel end seals can be easily damaged during handling. Leave the seal in its package until installation to

prevent damage or contamination.

1. Remove:

● The outer bearing and wheel.

● The inner bearing.

● The oil seal or grease retainer and discard.

● The old wear sleeve (2-piece design only) with a ball peen hammer and discard.

Caution: Do not cut through the old wear sleeve. Damage to the housing may result.

2. Inspect:

● The spindle journal and hub bore for scratches or burns. Recondition with emery cloth as required.

Note: Deep gouges can be repaired by filling gouge with hardened gasket and smoothing with emery cloth.

3. Clean

●

The hub cavity and bearing bores before reassembly. Be sure to remove contaminants from all recesses and corners.

● The bearings thoroughly with solvent and examine for damage. Replace damaged or worn bearings.

4. Before installation, lubricate with the same lubricant used in the axle sump.

● The inner bearing.

● The wheel seal following the directors provided by the seal supplier.

IMPORTANT: Always use the seal installation tool specified by the seal manufacturer. Using an improper tool can distort or damage the seal and cause premature seaI failure.

Wheel Bearing Adjustment

1. Identify the wheel nut system being installed. Three systems are available:

● Three piece Dowel-type wheel nut system-fig.1

● Three piece Tang-type wheel nut system-Fig.2

● Four piece Tang/Dowel type wheel nut system-Fig.3

WARNING:

Do not mix spindle nuts and lock washers from different systems. Mixing spindle nuts and lock washers can

cause wheel separation.

NOTE:

The lock washer for a four piece-dowel-type wheel system is thinner than the lock washer for a three piece tang-

type wheel nut system and is not designed to bear against the inner nut.

2. inspect the indle and nut threads for corrosion and ean thoroughly or replace as required. Note: Proper assembly and adjustment is not possible if the spindle or nut threads are corroded.

● Inspect the tang-type washer (if used). Replace the washer if the tangs are broken, cracked, or damaged.

3. Install the hub and drum on the spindle with care to prevent damage or distortion to the wheel seal.

* CAUTION: A wheel dolly is recommended during installation to make sure that the wheel seal is not damaged by the weight of the hub and drum. Never support the hub on the spindle with just the inner bearing and seal. This can damage the seal and cause premature failure.

●

Completely fill the hub cavity between the inner and outer bearing races with the same lubricant used in the axle sump.

4. Before installation, lubricate the outer bearing with the same lubricant used in the axle sump. Note: Lubricate only with clean axle lubricant of the same type used in the axle sump. Do not pack the bearing with

grease before installation. Grease will prevent the proper circulation of axle lubricant and may cause wheel seal failure.

5. ● Install the outer bearing on the spindle.

● Install the inner nut on the spindle.

● Tighten the inner nut to 200 lbs. ft. (271 N. M.) while rotating the wheel hub.

CAUTION: Never use an impact Wrench to adjust wheel bearings. A torque wrench is required to assure that

the nuts are property tightened.

Back-off the inner nut one full turn. Rotate the wheel hub.

Re-tighten the inner nut to 50 lbs. ft. (68 N. M.) while rotating the wheel hub.

Back-off the inner nut exactly 1/4 turn.

Note:

This adjustment procedure allows the wheel to rotate freely with 0.001”-0.005” (0.025mm to 0.1 27mm) end-play.

9. Install the correct lock washer for the wheel nut system being used.

THREE PIECE TANG-TYPE LOCK WASHER SYSTEM (see Fig. 2).

*Install the Tang-type lock washer on the spindle.

IMPORTANT: Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure.

*Install the outer nut on the spindle and tighten to 250 lbs. ft. (339 N.M.).

*Verify end-play (see End Play Verification Procedure)

*After verifying end play, secure wheel nuts by bending one of the locking

washer tangs over the outer wheel nut and another tang over the inner wheel nut as shown in Figure 4. (below)

THREE PIECE DOWEL-TYPE LOCK WASHER SYSTEM (see Fig.1)

* Install the Dowel-type lock washer on the spindle.

Note: If the dowel pin and washer are not aligned,

remove washer, turn it over

and reinstall. If required, loosen the inner nut just enough for alignment.

IMPORTANT: Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure.

*Install the outer nut on the spindle and tighten to 350 lbs. ft. (475 N.M.).

*Verify end-play (see End Play Verification Procedure)

FOUR PIECE TANG/DOWEL-TYPE LOCK WASHER SYSTEM (see Fig. 3)

* First, install the Dowel-type lock washer on the spindle.

Note: If the dowel pin and washer are not aligned, remove washer, turn it over and reinstall. If required loosen the in-

ner nut just enough for alignment.

IMPORTANT:

Never tighten the inner nut for alignment. This can preload the bearing and cause premature failure. * Install the Tang-type lock washer on the spindle. * Install the outer nut on the spindle and tighten to 250

lbs. ft. (339 N m.)

* Verify end-play (see End Play Verification Procedure)

* After verifying end play, secure the outer nut by bending two opposing (180ç apart) tangs of the locking washer

over the outer nut as shown in Figure 5 (below).

10. Install * New gasket at axle shaft flange.

* axle shaft. * Axle flange nuts and tighten to specified torque.

11. Lubricate axle wheel ends (see Wheel End Lubrication Procedure)

End Play Verification Procedure

Verify that end-play meets specification using a dial indicator. An indicator with 0.001" (0.03 mm) resolution is required. Wheel end play is the free movement of the tire and wheel assembly along the spindle axis.

a. Attach a dial indicator with its magnetic base to the hub or brake drum as shown below:

With indicator mounted at bottom,

Push/Pull at sides of drum

End Play Adjustment

with Wheel hub

Fig. 4 End Play Measurement

b. Adjust the dial indicator so that its plunger or pointer is against the end of the spindle with its line of action approximately parallel to the axis of the spindle.

c. Grasp the wheel assembly at the 3 o'clock and 9 o'clock positions. Push the wheel assembly in and out while oscillating it to seat the bearings. Read bearing end play as the total indicator movement.

* CAUTION: If end play is not within specification, readjustment is required.

End Play Re-adjustment Procedure Excessive End Play -

If end play is greater than .005' (.127 mm), remove the outer nut and pull the lock washer away

from the inner nut, but not off the spindle. Tighten the inner nut to the next alignment hole of the dowel-type washer (if

used). Reassemble the washer and torque the outer nut. Verify end play with a dial indicator. Insufficient End Play - If end play is not present, remove the outer nut and pull the lock washer away from the inner

nut, but not off the spindle. Loosen the inner nut to the next adjustment hole of the dowel-type washer (if used). Reassemble the washer and re-torque the outer nut. Verify end play with a dial indicator.

Fine Tuning the End Play -

If, after performing the readjustment procedures, end play is still not within the .001"-.005"

(.025 mm to.127 mm) range, disassemble and inspect the components. If parts are found to be defective, replace the

defective parts, reassemble and repeat wheel bearing adjustment procedure. Verify end play with a dial indicator.

Differential Carrier

Adjustments help provide optimum axle life and performance by correctly

positioning bearings and gears under load.

The tandem axles covered in this manual require the following adjustments:

Bearing Preload:

performed for both pinion and differ-

ential bearings. It maintains proper

gear alignment by creating correct

bearing cone and cup relationship for free rotation under load. The pinion pilot bearing does not require

load adjustment.

Adjust Input Shaft End Play

Specifications: Input shaft end play requirements will vary with operat-

ing conditions, mileage and rebuild procedures. These variations are shown in the following chart.

This adjustment is

a pre-

Ring Gear Tooth Contact: This adjust-

ent positions ring gear and pinion

for best contact under load. Correct in the inter-axle differential. Proper adjustment distributes torque evenly adjustment helps maximize life of all

over gear

gear set life.

teeth and helps maximize

Input Shaft End Play (Forward Axles):

This adjustment controls gear mesh

power divider parts.

Input

New or Rebuild with new parts

0.003" to 0.007"

Shaft End Play Chart

NOTE: Because of manufacturing

variations in individual parts, correctly adjusted end play could

Rebuild with reused parts

0.013" to 0.017"

vary 0.010", after the unit is rotated.

Acceptable End Play Tolerances when measuring as

a regular maintenance procedure with axle in truck.

Up to 0.060" with over 100,000 miles or 1 year service off-road.

NOTE: If end play exceeds limits, disassemble power divider and replace worn parts.

Up to 0.040" with less than 100,000 miles or 1 year service on-road.

Measure and Adjust End Play

IMPORTANT:

Button between the input and output shafts. End play tolerances are the same for axles with or without this Spring and Button. However, end play measurement procedure is different than-described below. Refer to Service Bulletin Supplement at back of this manual for procedure variances.

1. With power divider assembled to differential carrier, measure end pay with dial indicator positioned at yoke end of input shaft. Move input shaft axially and measure end play. If end play is not correct (see chart), adjust as follows.

2. Remove input shaft nut, flat washer and yoke. Remove bearing cover cap screws and lockwashers. Remove cover and shim pack.

3. To increase end play, add shims:

desired end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003" to 0.007"

pleasured endplay (Step)....... . . . . . . . . . . . . . . . . 0.001" - 0.001"

Add shims to provide desired end play . . . . . . . . . . . . . 0.002" to 0.006"

4. To decrease end play, remove shims:

Measured endplay (Step 1l) . . . . . . . . . . . . . . . . . . . . . . . 0.015" - 0.015"

desired end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003" to 0.007"

Remove shims to provide desired end play . . . . . . . . . 0.012" to 0.008"

5. To reassemble input shaft, install the adjusted shim pack and bearing cover. Install cap screws and lockwashers. Torque screws to 75-85 ft-lbs. (101-115 N.m).

NOTE: If difficulty is experienced in achieving correct torque on the input yoke nut, torque the nut with truck on the ground and axle shafts installed.

In September 1988, Spicer added a Spring and a Thrust

6. Install yoke, flat washer and nut. Tighten nut snugly. Tap end of input shaft lightly to seat bearings.

7. Measure input shaft end play with dial indicator. If end play is still incorrect, repeat Steps 2 through 6.

8. With end play correct, seal shim pack to prevent lube Ieakage, then torque input shaft nut and cover cap screws (see chart).

NOTE: When power divider has been disassembled and reassembled, it may be desirable to adjust end play by measuring bearing cover clearance and calculating shim pack size. For procedures, see page 42.

Torque Chart

Input Shaft Nut Ft-lbs.

1-5/8-18 780-960 *M42

X 1.5 840-1020

Bearing Cover Cap Screw

1/2-13 75-85

(Grade 5)

*Metric Nut used on Axles produced after 7/1 /95

N´m

1057-1301 1140-1383

101-115

Adjustments

Pinion Bearing Preload

Most late model axles are provided with a “press-fit” outer bearing on the drive pinion. Some of the early model axles use an outer bearing which slips over the drive pinion. Procedures for adjusting both types of pinion bearing design are contained in this section.

Adjust Pinion Bearing Preload for Axles with

“Press-fit” Outer Pinion Bearings

Trial Build-up

1. Assemble pinion bearing cage,

bearings and spacer (without drive pinion or oil seal). Center bearing

spacer between two bearing cones.

NOTE: When new gear set or

pinion bearings are used, select nominal size spacer from the speci-

fication chart below. If original

parts are used, use spacer removed

during disassembly.

2. With the bearings well lubri-

cated, place the assembly in the

press. Position sleeve so that load is applied directly to the back-face of the outer bearing cone.

3. Apply press load (see chart

below) 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 from 10-20 inch-pounds. This specification is translated into spring scale readings in the chart below.

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.

IMPORTANT: Once correct bear-

ing preload has been established,

note the spacer size used. Select a spacer 0.001” larger for use in the final pinion bearing cage assembly. The larger spacer compensates

for slight “growth” in the bear-

ings which occurs when they are

pressed on the pinion shank. The trial build-up will result in proper pinion bearing preload in three of four cases.

IMPORTANT: 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.

Assemble these Parts for

Trial Build-up.

INNER INNER

BEARING BEARING SPACER

CONE

Axle Models Forward Axles

D340, 380(P), 400-P

D341, 381(P), 401-P, 402(P), 451-P

Rear Axles

(ail models)

CUP

Specifications for Pinion Bearing

Trial Build-up Preload Test

(“Press-fit” Outer Pinion Bearings)

Nominal Bearing

Spacer Thickness

in.

0.638

0.496

0.638

BEARING

(vARIABLE)

16.21

12.60

16.21

13.5-15.5

Press Loads

Tons

17-19

14-15

OUTER BEARING

CUP

Metric Tons

12.2-14.0

15.4-17.2

12.7-13.6

OUTER

BEARING

CONE

Spring

Scale Reading

(without

pinion seal)

(for 10-20

in-lbs. torque)

(1.1-2.3 N•m)

lbs. kgs.

3-7 1.4-3.2

4-8 1.8-3.6

Final Pinion Bearing Preload Test

1. Assemble the complete pinion bearing cage unit as recommended

in the assembly section of this manual.

NOTE:

disassembly during bearing adjustment procedure, use a dummy yoke if available) in place of helical gear.

2. Apply clamp load to the pinion bearing cage assembly. Either install

. the yoke (or helical gear) and torque the pinion nut to specifications or use a press to simulate nut torque (see chart below).

Vise Method

vise, clamping yoke firmly.

Press Method

load is applied directly to the back-face of the outer bearing cone. .

3. Measure Pinion Bearing Preload -

assembly rolling torque. To use the spring scale, wrap soft wire around the bearing cage, attach the scale and pull. Preload is correct when torque required to rotate the pinion bearing cage is from 15 to 35 inch pounds. This specification is translated into spring scale readings in the

chart below.

4. Adjust Pinion Bearing Preload -

preload. Disassemble the pinion bearing cage as recommended in this manual and change the pinion bearing spacer. A thicker spacer will decrease preload. A thinner spacer will increase preload.

IMPORTANT:

grind spacers. These practices can lead to loss of bearing preload and

gear or bearing failure.

Forward axle pinion is equipped with helical gear. For easier

If the yoke and nut are used, mount the assembly in a

- If a press is used, position a sleeve or spacer so that

Use a spring scale to test the

If necessary, adjust pinion bearing

Use the correctly sized spacer. Do not use shim stock or

Specifications for Final Pinion

Bearing Preload Test

("Press-fit" Outer Pinion Bearing)

Nut Torque

Axle Models

Forward Axles

D340, 380(P), 400-P

D341, 381(P), 401-P, 402(P), 451 -P

Rear Axles

(all models)

*Torque nut to 840 ft-lbs. (1139 N´m), then continue tightening nut to align nut slot to nearest hole in pinion shank.

Ft-lbs. SELF-LOCKING N UT

560-700

SELF-LOCKING NUT

780-960

SLOTTED NUT & ROLL PIN

840*

METRIC NUT (After 7-1-95)

840-1020

560-700

METRIC NUT (After 7-1-95)

575-703

N.m

759-949

1057-1301 17-19

1139* 17-19

1140-1383

759-949

774-955

Press Loads

Tons

13.5-15.5 12.2-14.0

17-19

14-15

Metric Tons

15.4-17.2

12.7-13.6

Spring Scale Reading

(without pinion seal)

(for 15-35 in-lbs. torque)

lbs.

5-12

6-14 2.7-6.4

(1.7-4 N.m)

kgs.

2.3-5.4

Adjustments

Adjust Pinion Bearing Preload for Axles with

ñSlip-fitî Outer Pinion Bearings

1. Lubricate bearings and assemble the drive pinion, bearings, and pinion bearing cage as recommended in the assembly section of this

manual. Use the pinion bearing spacer removed from the axle during disassembly. If the original spacer cannot be used, install the nominal spacer recommended in the adjacent chart.

NOTE: Forward axle pinion is equipped with helical gear. For easier disassembly during bearing adjustment procedure, use a dummy yoke

(if available) in place of helical gear.

2. Apply clamp load to the pinion bearings. Install the yoke (or helical

gear) and torque the nut to specification or use a press to simulate nut torque by applying pressure to the assembly (see chart below).

Vise Method -

in a vise, clamping yoke firmly.

Press Method -

load is applied directly to the back-face of outer pinion bearing.

3. Measure Pinion Bearing Preload - Use a spring scale to test the

assembly rolling torque. To use the spring scale, wrap a soft wire around the bearing cage, attach the scale and pull. Preload is correct when

torque required to rotate the pinion bearing cage is from 15 to 35 inch pounds. This specification is translated into spring scale readings in the

chart below.

4. Adjust Pinion Bearing Preload -

preload. Disassemble the pinion bearing cage as recommended in this manual and change the pinion bearing spacer. A thicker spacer will

decrease preload. A thinner spacer will increase preload.

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.

If the yoke and nut are used, mount the assembly

If a press is used, position a sleeve or spacer so that

If necessary, adjust pinion bearing

Nominal Pinion

Bearing Spacers

Spacer Thickness Axle Model Forward Axles

D340, 380(P), 400-P D341, 381(P), 401-P,

402(P), 451-P

Rear Axles

(all models)

Measuring Bearing Preload with Pinion in Vise.

in. mm

0.638 16.205

0.492 12.497

0.638 16.205

Measuring Bearing Preload with Pinion in Press.

Spring Scale Reading

(without pinion seal)

(for 15-35 in-lbs. torque)

lbs.

5-12

Axle Models

Forward Axles

D340, 380(P), 400-P

D341, 381 (P), 401-P, 402(P), 451-P

Specifications for Final Pinion

Bearing Preload Test

("Press-fit" Outer Pinion Bearing)

Nut Torque

Ft-lbs. N.m

Tons Metric Tons

SELF-LOCKING NUT

560-700

759-949 13.5-15.5 12.2-14.0

SELF-LOCKING NUT

780-960

1057-1301

17-19

SLOTTED NUT & ROLL PIN

840*

11 39*

17-19

Press Loads

15.4-17.2

METRIC NUT (After 7-1-95)

840-1020

1140-1383

17-19

15.4-17.2

Rear Axles

(all models)

560-700

759-949

14-15

12.7-13.6

6-14

METRIC NUT (After 7-1-95)

575-703

*Torque nut to 840 ft-lbs. (1.139 N´m), then continue tightening nut to align nut slot to nearest hole in pinion shank.

774-955

(1.7-4 N.m)

kgs.

2.3-5.4

2.7-6.4

Differential Bearing Preload and Ring Gear Backlash Adjustment

Correct differential bearing preload insures proper location of these bearings under load and helps position the ring gear for proper gear

tooth contact.

(Follow procedures in numerical sequence.)

Adjust Diff. Bearing Preload

1. Lubricate differential bearings. IMPORTANT: When installing

bearing caps and adjuster, exert care not to cross threads.

2. Install adjusters and bearing caps. Tighten bearing cap screws finger-tight. If this is difficult, use a hand wrench.

4. Tighten the bearing adjuster

on the back-face side of the ring gear until there is no backlash.

This can be tested by facing the

ring gear teeth and pushing the

gear away from the body while

gently rocking the gear from side

to side. There should be no free

movement. Rotate the ring gear and check

for any point where the gear may

bind. If such a point exists, loosen and retighten the back side adjuster. Make all further adjustments from the point of tightest mesh.

NOTE: Ring gear position for rear axle is illustrated.

6. Measure backlash with a dial indicator. USED GEARING NEW GEARING

If backlash is incorrect, proceed as described below to readjust.

— Reset to backlash recorded before disassembly.

— Backlash should be between 0.006” and 0.016”.

3. Loosen the bearing adjuster

on the same side as the ring gear teeth until its first thread is visible.

5. At teeth side of ring gear,

tighten adjuster until it contacts the bearing cup. Continue tighten-

ing adjuster two or three notches and this will preload bearings and provide backlash.

Adjust Ring Gear Backlash

add

adjuster on the teeth side of the ring gear several notches. Loosen the opposite adjuster one notch.

Return to adjuster on teeth side of the ring gear and tighten adjuster until it contacts the bearing cup. Continue tightening the same adjuster 2 or 3 notches. Recheck backlash.

backlash: Loosen the

remove

adjuster on the teeth side of the ring gear several notches. Tighten the opposite adjuster one notch.

Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup. Continue tightening the same adjuster 2 or 3 notches. Recheck backlash.

backlash: Loosen the

Moving adjuster one notch is the movement of the lead edge of one adjuster lug to the lead edge of the next lug past a preselected point.

Adjustments

R ing Gear and Pinion Tooth Contact

NOTE: Rear axle gearing is shown in the following instructions. Correct

tooth contact patterns and adjustments are the same for

rear axles.

Check Tooth Contact Pattern (NEW GEAR)

Paint twelve ring gear teeth with marking compound and roll the gear to obtain a contact pattern. The correct pattern is well-centered on the ring gear tooth with lengthwise contact clear of the to the Iength of the

pattern in an unloaded condition is approximately onehalf to two-thirds of the ring gear tooth in most models

and ratios.

forward and

RING GEAR TOOTH NOMENCLATURE

Check Tooth Contact Pattern (USED GEAR)

Used gearing will not usually display the square, even contact pattern found in new gear sets. The gear will normally have a “pocket” at the toward of the gear tooth which tails into a contact line along the root of tooth. The more use a gear has

had, the more the line becomes the dominant

characteristic of the pattern. Adjust used gear sets to display the same contact

pattern observed before disassembly. A correct

pattern is clear of the toe and centers evenly along the face width between the top land and root. Otherwise, the length and shape of the pattern are

highly variable and is considered acceptable as

long as it does not run off the tooth at any point.

CORRECT PATTERN (NEW GEARING)

CORRECT PATTERN (USED GEARING)

●

Pocket may be

extended.

●

Pattern along

face width

could be longer.

the

Adjust Tooth Contact Pattern

If necessary, adjust the contact pattern by moving the ring gear and drive pinion. Ring gear position controls the backlash. This adjustment moves the contact pattern along the face width of the gear tooth. Pinion

position is determined by the size of the pinion bearing cage shim pack. It controls contact on the tooth depth of the gear tooth.

These adjustments are interrelated. As a result, they must be considered together even though the pattern is altered by two distinct operations. When making adjustments, first adjust the pinion, then the

backlash. continue this sequence until the pattern is satisfactory.

Adjust Pinion Position

If the gear pattern shows incorrect tooth depth contact, change drive

pinion position by altering the shim pack. Used gears should achieve

proper contact with the same shims removed from the axle at disassembly.

INCORRECT PATTERN

● Pattern too close to tooth top ‘land and off center.

If the pattern is too close to the top land of the gear tooth, remove pinion shims.

Ž Pattern’ too close or off tooth root.

If the pattern is too close to the root of the gear tooth, add pinion shims.

NOTE: Check ring gear backlash after each shim change and adjust if necessary to maintain the 0.006” to

0.016” specifications.

If the gear pattern shows incorrect face width contact, change backlash.

INCORRECT PATTERN

● Pattern too close to edge of tooth toe.

With the pattern concentrated at the toe (too far

down the tooth), add backlash by loosening the bearing adjuster on the teeth side of ring gear several notches. Loosen the opposite adjuster one notch.

Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup. Continue tightening the same adjuster 2 or 3

notches. Recheck backlash.

• Pattern too far along tooth toward tooth heel.

If the pattern is concentrated at the heel (too

far up the tooth), remove backlash by loosening the bearing adjuster on the teeth side of ring gear several notches. Tighten the opposite adjuster one notch

Return to adjuster on teeth side of ring gear and tighten adjuster until it contacts the bearing cup. Continue tightening the same adjuster 2 or 3

notches. Recheck backlash.

Fastener Tightening Specifications

Specifications are for all axle models unless specified otherwise.

—

●

Correct tightening torque values are extremely important to assure long Spicer Axle life and dependable performance. Under-tightening of attaching parts is just as harmful as over-tightening.

●

Exact compliance with recommended torque values will assure the

best results.

●

The data includes fastener size, grade and torque tightening values. Axle models are included to pinpoint identification of fasteners for your particular axle.

●

To determine bolt or cap screw grade, check for designation stamped on bolt head (see illustration).

NOTE 1: METRIC NUTS used on Axles produced after 7-1-95. Reference chart on page 76

REFERENCE MISC. TORQUE FASTENING CHART ON PAGE 76

Grade

Dual Range

DT340, DT380(P), DT400-P DT341, DT381(P), DT401-P DT402(P), DT451-P

Planetary Double Reduction

DP340, DP380(P), DP400-P, DP341 , DP381(P), DP401-P, DP402(P), DP451-P

REFERENCE MISC. TORQUE FASTENING CHART ON PAGE 76

NOTE 1: METRIC NUTS used on Axles produced after 7-1-95. Reference chart on page 76

Fastener Tightening Specifications:

Specifications

Rear Axles

are for all axle models unless specified otherwise.

Dual Range RT340, 341,380, Planetary Double Reduction

381,400,401,402,451

RP340, 341, 380, 381,400, 401, 402, 451

●

Correct tightening torque values are extremely important to assure long Spicer Axle life and dependable performance. Under-tightening of attaching parts is just as harmful as over-tightening.

●

Exact compliance with recommended torque values will assure the best results.

●

The data includes fastener size, grade and torque tightening values. Axle models are included to pinpoint identification of fasteners for your particular axle.

●

To determine bolt or cap screw grade, check for designation stamped

on bolt head (see illustration). REFERENCE MISC. TORQUE FASTENING CHART ON PAGE 76

NOTE 1: METRIC NUTS used on Axles produced after 7-1-95. Reference chart on page 76

Bolt head markings

for grade identification

Grade 5

Grade 8

Rear Axle Differential Carrier Replacement

Remove Differential Carrier Assembly from Axle Housing

Install Differential Carrier Assembly

IMPORTANT: Before installing carrier assembly, inspect and thoroughly clean interior of axle housing.

NOTE: Use silicone rubber gasket compound on axle hous-

ing mating surface as shown in the illustration. Compound

will set in 20 minutes. Install

carrier before compound sets or reapply.

1. Install differential carrier assembly in axle housing. Install stud nuts and lockwashers. Tighten to correct torque

IMPORTANT:

axle shafts or wheel equipment replaced, check axle assembly for proper differential action before operating vehicle. Wheels must rotate freely and independently.

(see chart pg. 76).

When axle has been disassembled or housing, gears,

2. Install axle shafts and stud nuts. (If used, also install lockwashers and taper dowels.)

3. Connect inter-axle driveline.

4. Fill axle with correct lube (see

Lubrication Section).

5. Dual Range Axle Only. Install shift unit, nuts and lockwashers.

Torque nuts to 55-61 ft.-lbs. (74-82

N•m). Connect air line.

Axle Housing Silicone Gasket

Compound Pattern.

Forward Axle Differential Carrier Replacement

Remove Differential Carrier Assembly from Axle Housing

IMPORTANT: D341, 381(P),

WARNING: THE OUTPUT SHAFT REAR BEARING RETAINING WASHER IS FREQUENTLY LOST WHEN THE DIFFERENTIAL CARRIER ASSEMBLY IS REMOVED. IT MAY ADHERE TO THE YOKE, TO THE

FACE OF THE OUTPUT SHAFT BEARING, FALL ON THE FLOOR OR INTO THE HOUSING. LOCATE THIS WASHER BEFORE CONTINUING! IF IT IS NOT REINSTALLED, THE END OF THE YOKE WILL WEAR THE OUTPUT SHAFT BEARING VERY QUICKLY. IF IT IS LEFT IN THE HOUSING, IT CAN BE

PICKED UP BY THE RING GEAR MOTlON AND CAUSE PREMATURE AXLE FAILURE.

(Follow procedure in numerical sequence.)

401-P, 402(P), 451-P models do NOT use an output shaft Rear Bearing Retaining Washer

NOTE 1: Flat washer

not used on axles with metric threaded nuts.

Install Differential Carrier Assembly

IMPORTANT:

D341, 381(P), 401-P, 402(P), 451-P models do NOT use an output shaft Rear Bearing Retaining Washer

WARNING: WHEN INSTALLING DIFFERENTIAL CARRIER ASSEMBLY, IT IS IMPORTANT TO

FOLLOW CORRECT PROCEDURES TO ASSURE USEFUL LIFE. FAILURE TO CORRECTLY INSTALL REAR BEARING AND RETAINING WASHER COULD RESULT IN PREMATURE AXLE FAILURE.

IMPORTANT: Before installing carrier assembly, inspect and thoroughly clean interior of axle housing. NOTE: Use silicone rubber

gasket compound on axle housing mating surface as shown in the illustrations. Compound will set in 20 minutes. Install carrier and axle

housing cover before compound

sets or reapply.

SILICONE GASKET COMPOUND

PATTERN. DIFFERENTIAL CARRIER PATTERN. HOUSING COVER

MATING SURFACE.

SILICONE GASKET COMPOUND

MATING SURFACE.

(Follow procedure in numerical sequence.)

1. Apply silicone gasket compound. Install differential carrier assembly

in axle housing. Install nuts and “

2. install cover and fasten with nuts, cap screws and lockwashers. Tighten to correct torque. If removed

lockwashers. Tighten to correct

torque. Reference torque chart

page 76.

5. Install a new output shaft’

seal in the axle housing cover * until flush with chamfer in bore.

Lubricate the seal inner diameter to prevent damage during yoke installation.

6. Slide the rear bearing retaining washer over the splines of the

outer shaft until it seats flush against the output shaft bearing.

IMPORTANT:

401-P, 402(P), 451-P models do

NOT use an output shaft Rear Bearing Retaining Washer.

Location

of hole in

rear cover.

Axle Housing Cover and Output Shaft Bearing Parts.

install bearing parts (see steps 3 through 6).

-3. Install output shaft rear bearing.

Tap the outer race (with a sleeve or drift) until it is seated firmly in the

machined pocket of the cover.

Secure with snap ring.

4. Lubricate and install the rear bear-

ing sleeve on the output shaft. Make certain it fits snugly against the shoulder at the forward edge of the

shaft splines.

7. Install output yoke, flat washer and self-locking nut. Tighten to correct torque. Ref. chart on page 26, 76.

*D341, 381 (P),

NOTE:

Flat washer not used with

metric threaded nuts.

If removed,

8. Install axle shafts, and stud nuts (if used, also install lock-

washers and taper dowels).

9. Connect main and inter-axle

drivelines.

10. Fill axle with correct lubricant

11. Connect differential lockout

air line.

12.

Dual Range Axle only — Install shift unit, nuts and lockwashers. Torque nuts to 55-61 ft.-lbs. (74-82

N.m). Connect air line.

(see Lubrication Section).

*IMPORTANT See page 15 for service information on Seals, Yokes & Slingers.

IMPORTANT: When axle has been disassembled or housing, gears,

axle shafts or wheel equipment replaced, check axle assembly for proper differential action before operating vehicle. Wheels must rotate freely and independently.

Power Divider Replacement

(with differential carrier assembled to axle housing)

Removing and Installing Power Divider.

The power divider can be replaced with the axle assembly in or out

of chassis and with differential carrier assembled to axle housing.

WARNING: DURING REMOVAL AND INSTALLATION, THE

POWER DIVIDER ASSEMBLY MUST BE SUPPORTED AS A SAFETY PRECAUTION. DURING REMOVAL OR INSTALLATION, THE lNTER-

AXLE DIFFERENTIAL MAY FALL FROM

CARRIER. EXERCISE CAUTION TO PREVENT DAMAGE OR INJURY.

With axle out of chassis, use chain hoist. Fasten chain to input yoke to remove power divider.

NOTE: Lifting mechanism may create nicks and

burrs on input yoke. Remove if present.

With axle installed in chassis, use a transmission jackãor a chain hoist and a sling. Wrap sling strap around power divider and attach to chain

hoist hook as shown in photos.

Removing Power Divider with Chain Hoist and Sling.

Remove Power Divider from Differential Carrier

CAUTION:

AXLE DIFFERENTIAL MAY FALL FROM CARRIER. EXERT CAUTION TO PREVENT DAMAGE OR INJURY.

6. Pull power divider assembly forward until it is completely free of carrier, then remove the assembly.

7. Inter-axle Differential. With

ential can be lifted off output shaft side gear (see photo on page 33). NOTE: Late Model Axles may be equipped with a Spring and Thrust

Button mounted between input and output shafts (see Service Bulletin

Supplement at back of this manual).

8. Output Shaft.

inter-axle driveline. Remove nut, flat washer and output shaft yoke. Pull output shaft assembly out of carrier (see photo on page 33).

9. Axle Housing Cover and Output Shaft Bearing Parts.

remove these parts following instructions on page 30.

DURING REMOVAL of POWER DIVIDER, THE lNTER-

power divider removed, the inter-axle differ-

If necessary, remove output shaft as follows: Disconnect

If necessary,

Install Power Divider on Differential Carrier

ïwith carrier assembled to axle housing)

NOTE: Lubricate all parts before installation.

1. Axle Housing Covet and Output Shaft Bearing Parts.

install these parts following instructions on page 31.

If removed,

2. Output Shaft.

lubricate "O" rings, then install shaft assembly in differential carrier and housing cover. Lubricate seal lip. Make sure yoke is clean and dry, then install yoke, flat washer and self-locking nut. Torque nut to 480-600 ft.-lbs. (650-813 Nm),

If removed,

NOTE:

equipped with a spring and thrust button mounted in end of output shaft. (see page 74).

3. Inter-axle Differential.

this assembly on output shaft side gear (with nuts facing away from side gear).

Late Model Axles may be

Install

CAUTION: DURING INSTALLATION OF POWER DIVIDER, THE

INTER-AXLE DIFFERENTIAL MAY FALL FROM CARRIER. EXERT

CAUTION TO PREVENT DAMAGE OR INJURY.

5. Make certain dowel pins are installed in carrier (see drawing above),

then install power divider assembly.

Use a transmission jack or a chain hoist and sling (see photo).

During installation, rotate input shaft to engage input shaft splines with

inter-axle differential. After installation, again rotate input shaft to check for correct assembly. Output shaft should turn when input shaft is rotated.

6. Install power divider cover cap screws and lockwashers. On pump

models only, install socket-head cap screw in correct location (see drawing on preceding page). Torque cap screw to 110-125 ft.-lbs.

(149-170 Nm).

7. Check and Adjust Input Shaft Play.

to differential carrier. Check end play with dial indicator. If necessary adjust end play (see page 19 or Service Bulletin Supplement Page 74). After input shaft end play is within specifications complete assembly procedure follows:

8. Connect drivelines. Connect lockout air line.

9. Fill axle to proper lube level (see Lubrication Section).

IMPORTANT:

shafts or wheel equipment replaced, check axle assembly for proper differential action before operating vehicle. Wheels must rotate freely and independently.

When axle has been disassembled or housing, gears, axle

With power divider assembled

Silicone Gasket Compound

4. Power Divider Assembly.

silicone rubber gasket compound on differential carrier mating surface as shown in the illustration.

NOTE: Compound will set in 20 minutes. Install power divider before compound sets or reapply.

Installing Power

with Chain Hoist and Sling.

Divider Assembly

Use

Measuring Input Shaft End Play with Dial Indicator.

Power Divider Overhaul

Remove Power Divider from Differential Carrier

(with carrier removed from axle housing)

NOTE: It is assumed that the differential carrier and

have been removed from axle housing (see page 30) prior to starting

the following procedures:

1. Mount differential carrier in

repair stand. Loosen input shaft nut.

2. Remove power divider cover cap screws and lockwashers.

CAUTION: DURING REMOVAL

OF POWER DIVIDER, THE INTER-AXLE DIFFERENTIAL MAY FALL OFF INPUT SHAFT FROM DIFFERENTIAL CARRIER. EXERT CAUTION TO PREVENT DAMAGE OR INJURY.

3. Attach chain hoist to input yoke

and lift power divider off carrier. If

power divider does not separate easily, strike the cover near the dowel pin locations with a mallet

(see illustration). NOTE: Lifting mechanism may

create nicks or burrs on input yoke. Remove if present.

power divider assembly

Power Divider Cover Dowel Pin Location.

Pump model illustrated

4. Inter-axle Differential. Lift differential assembly off output shaft side gear.

NOTE: Late Model Axles may be equipped with a Spring and Thrust Button mounted between input and output shafts (see Service Bulletin at back of this manual).

NOTE: For instructions on removing axle housing cover and output shaft rear bearing parts, see page 30.

5. Output Shaft.

remove the output shaft assembly.

Tilt carrier and

Output Shaft Side Gear Bearing

Cup. If replacement is necessary,

use puller to remove bearing cup from carrier.

Disassemble Power Divider Cover

1. Remove snap ring from machined groove at rear of input shaft.

WARNING: SNAP RING IS

SPRING STEEL AND

OFF WEAR SAFETY GLASSES WHEN REMOVING. WITH SNAP RING REMOVED, THE HELlCAL SIDE GEAR MAY FALL OFF SHAFT. EXERT CARE TO PREVENT DAMAGE OR INJURY.

Slide helical-side gear off input shaft, then remove bronze thrust washer and "D" washer from shaft.

MAY POP

2. Axles with Lube Pump.

point in disassembly, it is desirable

to remove lube pump drive gear

nut. Hold input shaft yoke to secure drive gear, then loosen and remove drive gear nut.

3. Remove nut, flat washer and

yoke from input shaft.

NOTE:

nuts do not use a flat washer.

Axles with metric threaded

At this

4. Remove cap screws, lockwashers and input bearing cover and shim pack.

5. Slide input shaft assembly out of cover. Remove bearing spacer from shaft (used only on D340, 380, 380-P, 400-P).

6. NOTE: Remove Lockout,

Sliding Clutch and Shift Fork.

Starting with axles built early in

1991, the sliding clutch and helical

slide gear curvic teeth diameter

was increased to provide g rester

tooth engagements. For additional

parts and service information, refer to Spicer Bulletin 91-01.

Power Divider Overhaul

Disassemble Power Divider Cover (Cont'd)

Step 6 (cont'd).

To remove the "larger-diameter" sliding clutch,

lockout (see Shift System Section). Then remove the sliding clutch and shift fork (with the two parts engaged). Grasp the assembly

by hand and maneuver the assembly past restrictions in the power divider cover.

To remove the "smaller-diameter"

sliding clutch,

model axles), the clutch can be disengaged and removed without removal of the lockout and shift fork.

first remove the

(used on earlier

7. Remove oil seal from input bearing cover. Remove bearing

cup from cover.

8. Remove input shaft bearing

cone. Temporarily place lockout sliding clutch over rear of input shaft, teeth toward bearing cone. Place shaft in press and remove bearing cone.

9. Axles with Lube Pump:

drive gear locknut previously removed (step 2) and working

through power divider cover input

shaft bore, gently pry oil pump drive gear from its shaft. See steps 10 thru 12 for pump disassembly.

12. Unscrew and remove

magnetic screen from power divider cover.

With

10. Remove oil pump cover cap

screws and lockwashers. Remove

pump cover and "O" ring.

11. *NOTE: When used, remove

woodruff key from gear shaft,

Remove pump gears from power

divider cover.

Disassemble Inter-axle Differential

Punch mark differential case halves for correct position during reassembly.

Remove locknuts and bolts. Separate case halves and remove thrust washers, side pinions, bushings, and spider.

NOTE: Side Pinion Bushings.

Not used on tandems built after November 1, 1991. Use when originally equipped. Current production Inter-Axle Differential Assemblies are only serviced as a complete assembly.

"Non-Current Production" Inter-Axle Differential.

Disassemble Output Shaft

1. Mount shaft assembly in vise, using brass vise jaw protectors. Remove outer snap ring, side gear and bearing cone assembly. If replacement is necessary, remove inner snap ring.

WARNING:

SPRING STEEL AND MAY POP OFF. WEAR SAFETY GLASSES WHEN REMOVING.

NOTE 1:

bushing less output shaft 128736. Do not attempt to install bushings in shafts with P/Nês 128736 or 129194* stamped into them. Ref. bulletin AXIB-93-06 *(output shaft w/metric threads used in axles after 1-3-95)

SNAP RING IS

Starting in June 1993, production axles were made with

2. Remove output shaft "O" rings.

If replacement is necessary, remove bushing mounted in end of output shaft. (NOTE 1)

3. Remove bearing cone from side gear using press and split-type puller.

NOTE:

output shaft rear bearing parts, see page 30.

For instructions covering

Removing Bearing Cone from

Output Shaft Side Gear.

Power Divider Overhaul

Assemble Output Shaft

NOTE: Lubricate parts with gear lube during assembly.

1. Press bearing cone on output

shaft side gear.

IMPORTANT: Provide protection

against possible gear teeth damage during press operation.

2. Mount output shaft in vise.

Lubricate and install "O" rings. If removed, install bushing in end of output shaft.

3. If removed, install inner snap

ring on shaft, then install side gear and bearing cone assembly, and outer snap ring.

WARNING:

SPRING STEEL AND MAY POP

OFF. WEAR SAFETY GLASSES WHEN INSTALLING.

Assemble Inter-axle Differential

1. Install bushings, side pinions and thrust washers on inter-axle differential spider.

2. Install spider assembly in one

differential case half, align punch

marks and install other case half. Secure assembly with bolts and locknuts. Tighten to correct torque (17-23 ft-lbs., 23-31 N´m).

NOTE: Side Pinion Bushings.

Not used on tandems built after November 1, 1991. Use when originally equipped.

SNAP RING IS

NOTE:

be equipped with a spring and thrust button mounted between the input shaft and output shaft (see page 74).

Late Model Axles may

Assembling Non-Current Production Inter-Axle Differentials.

NOTE 1:

bushingless output shaft 128736. Do not attempt to install bushings in shafts with P/NÍs 128736 or 129194* stamped into them. Ref. bulletin AXIB-93-06 *(output shaft w/metric threads used in axles after 1-3-95)

Starting in June 1993, production axles were made with

Assemble Power Divider Cover

LOCKOUT. FOR DESIGN VARIATIONS REFER TO LOCKOUT SERVICE INSTRUCTIONS.

1. *See note on exploded view. Install pump gears in power divider cover (position gear with long shaft in opening adjacent to input shaft).

2. Install "O" ring in pump cover,

making sure "O" ring is seated

firmly in cover. If removed, install

dowel pins. Install pump cover on power divider cover and secure with cap screws and lockwashers. Tighten to correct torque (85-105

IN-LBS., 10-12 Nm).

3. Install Pump Drive Gear.

Install

drive gear on pump shaft end.

NOTE:

Some pump drive shafts use

a woodruff key. When key is used.

place key in shaft slot. Position

gear on shaft engaging key. Then

install gear with driver and hammer. NOTE: Install and tighten drive

gear nut after input shaft is assembled to power divider cover (see step 10).

4. Install magnetic screen in power divider cover. Tighten to correct torque (40-60 Ft-lbs., 54-81 Nm).

Power Divider Overhaul

Assemble Power Divider (Cont'd)

7. Install bronze bushings in

5. Press bearing cone on input

shaft. IMPORTANT: To prevent bearing

damage, be careful to use sleeve that only contacts the inner race of bearing cone.

SEAL INSTALLATION

IMPORTANT: Before installing

seal, refer to page 15 for service

information on SeaIs, Yokes &

Slingers.

6. Press oil seal in cover using a seal driver or suitable sleeve.

Press bearing cup in input bearing cover.

IMPORTANT: For correct cup installation, use appropriate sleeve. Take care to make sure cup is not cocked and is firmly seated all around.

NOTE 1:

1/3/95 have a "step" at the end of

Inner Bore. Bushings must be installed from the Curvic Tooth side of the Helical Gear inward towards this step. Press bushing flush against the shoulder of the step.

Helical Gears made after

helical-side gear.

8. NOTE:

power divider cover (see photo

above) to make sure it is in place and firmly seated. If loose, seat by tapping with a hammer. Replace

plug if necessary. Assemble lockout shift fork and

sliding clutch with clutch teeth facing the helical-side gear, then install this assembly in power divider cover.

NOTE: At this point in reassembly, assemble and install lockout (see Shift System Section).

Check expansion plug in

9. Slide input shaft and bearing assembly into power divider cover from the front side. Engage shaft splines in lockout clutch.

Install bearing spacer on input shaft (used only on D340, 380, 380-P, 400-P). Temporarily install

input bearing cover assembly, cap screws and lockwashers.

NOTE: Do not install any shims under bearing cover at this time. Correct shim pack will be determined after the power divider is installed on differential carrier (Refer to "Adjust Input Shaft End

play" page 42).

IMPORTANT: For Axles with

Spring and Thrust Button between input shaft and output shaft:

preliminary adjustment of input shaft end play, install a 0.045"

(0.024 mm) shim pack under

bearing cover (see Service Bulletin Supplement, page 74).

Tighten bearing cover cap screws finger-tight. Install input yoke, flat washer and nut. Temporarily tighten nut snugly.

10. lMPORTANT - Axles with

Lube Pump: Install and tighten

lube pump drive gear locknut, holding input shaft to secure gear. Torque nut to 35-45 ft-lbs, (47-61 Nm).

11. Slide "D" washer over input

shaft up to base of sliding clutch

splines. NOTE: Make sure flat part of

washer inside diameter engages shaft properly.

Install bronze washer, Install helical gear. Secure with snap ring.

WARNING: SNAP RING IS

SPRING STEEL AND MAY POP OFF. WEAR SAFETY GLASSES WHEN INSTALLING.

12. Install power divider cover assembly on differential carrier

(see page 41).

For

Install Power Divider on Differential Carrier

(with carrier removed from axle housing)

NOTE: The following instructions pertain to installation of power divider

on differential carrier with carrier removed from axle housing.

NOTE: Before installing power divider, install related parts as follows:

1. Output Shaft Side Gear Bearing

Cup.

If removed, press bearing cup in carrier. Use a press and appropriate sleeve or use a brass drift and a mallet. Tap bearing cup into its' bore making certain cup is

evenly and firmly seated.

NOTE: Late Model Axles may be equipped with a spring and thrust button mounted between the input shaft and output shaft (see page 74).

2. Output Shaft. Lubricate "O" rings, then install output shaft assembly in carrier.

3. Inter-axle Differential.

differential assembly on output shaft side gear (with nuts facing

away from output shaft side gear).

Install

4. Apply silicone gasket compound on carrier mating surface (see illustration).

5. Install Power Divider.

chain hoist to input yoke and install power divider assembly.

During installation, rotate input shaft to engage input shaft splines with inter-axle differential. After installation, again rotate input shaft. Output shaft should turn when input shaft is rotated if assembly is correct.

NOTE: Lifting mechanism may create nicks and burrs on input yoke. Remove if present.

Attach

6. If removed, install dowel pins in carrier. Install power divider

cover cap screws and lock-

washers. (On pump models only, place socket-head cap screw at location shown on drawing. Torque cap screws to 110-125 ft-lbs. (149-170 Nm).

7. Adjust Input Shaft End Play.

Adjust end play with the power

divider assembled to the differen-

tial carrier. (See page 42.)

Power Divider Overhaul

Adjust Input Shaft End Play

NOTE: After power divider overhaul and installation in power divider, check and adjust input shaft end play.

Correct end play when new parts are used in overhaul is 0.003î to

0.007î, with reused parts 0.01 3ñ to 0.01 7ñ. Refer to page 19 for other variations.

Measure and Adjust End Play

IMPORTANT: In September 1988, Spicer added a Spring and a Thrust Button between the input and output shafts. End play tolerances are the

same for axles with or without this Spring and Button. However, end play

measurement procedure is different than described below. Refer to Service Bulletin Supplement at back of this manual for procedure variances.

1. Remove input shaft nut, fiat washer and yoke. Remove input bearing

cover cap screws and lockwashers. Remove bearing cover (and shim

pack if installed).

2. Reinstall bearing cover without shims. Hold in position with hand pressure and measure clearance between power divider cover and bearing cover, using a feeler gauge.

3. The bearing cover clearance measured in Step 2 plus 0.005" will equal shim pack thickness required for desired end play (rebuild with new parts). Add 0.015" to shim pack for rebuild with used parts.

4. Install shim pack and bearing cover. Install cap screws and lockwashers. Torque screws to 75-85 ft-lbs. (101-115 Nm).

5. Install yoke, flat washer and nut. Tighten nut snugly. Tap end of input shaft lightly to seat bearings.

6. Check input shaft end play with dial indicator positioned at yoke

end of input shaft. Move input shaft axially and measure end play. If end play is correct, seal shim pack to prevent lube leakage then torque

input shaft nut and cover cap screws (see chart).

7. If end play is incorrect, change shim pack size, as follows:

Add shims to increase end play.

Example: Desired end play (New Parts) . . . . . . . . . . . . . . 0.003" to 0.007"

Measured end play (Step 6) . . . . . . . . . . . . . . . 0.001" - 0.001"

Add shims to provide desired end play . . . . . 0.002" to 0.006"

Remove shims to decrease end play.

Example: Measured end play (Step 6) . . . . . . . . . . . . . . . 0.015" - 0.015"

Desired end play (New Parts) . . . . . . . . . . . . . . 0.003" to 0.007"

Remove shims to provide desired end play . . 0.012" to 0.008"

8. To add or remove shims, remove input shaft nut, flat washer and yoke. Remove cap screws, lockwashers and bearing cover. Add or remove shims as required.

9. Install bearing cover, cap screws and lockwashers. Install yoke, flat

washer and nut. Seal shim pack to prevent lube leakage then torque

input shaft nut and cover cap screws (see chart).

Measuring Bearing Cover Clearance.

Installing Bearing Cover and Shim Pack.

Measuring End Play with Dial Indicator.

Tightening Yoke Nut.

Input Shaft Nut

1-5/8-18 *M42 X 1.5

Bearing Cover Cap Screw

1/2-13

(Grade 5) ñMetric Nut used on Axles produced after 7/1 /95

Torque Chart

Ft-lbs.

780-960 840-1020

75-85

1057-1301 1140-1383

101-115

NOTE: If difficulty is experienced

in achieving correct torque on the

input yoke nut, torque the nut with

truck on the ground and axle shafts

installed.

Differential Carrier Overhaul

(Forward and Rear Axles)

Disassemble Differential Carrier (with power divider removed)

NOTE: If the gear set is to be reused, check tooth contact pattern and ring gear backlash before beginning disassembly. Best overhaul results are obtained when used gearing is adjusted to

established wear patterns. Omit this step if the gear set is to be replaced.

When reusing the

the left-hand bearing cap, adjuster and lock as a unit. This will help return the gear set to its original adjustment during reassembly.

1. Mount the differential carrier in

a repair stand.

gear set, remove

run in

Rear Axle

Forward Axle

NOTE:

loosen but do not remove pinion self-locking nut. When forward axle pinion is equipped with slotted nut, remove roll pin with a pin punch then loosen nut.

For easier disassembly,

2. Dual Range Axles Only:

Remove shift fork seal and spring. Remove expansion plugs, then working at the lower (or small) plug hole, drive out the shift fork shaft.

WARNING: WHEN USING A

DRIFT, PUNCH OR SIMILAR TOOL, WEAR SAFETY GLASSES.

3. Dual Range Axles Only:

engage shift fork yoke from sliding collar. Then remove clutch and shift fork.

Planetary Double Reduction Axles: A sun gear is used in place

of sliding clutch gear. To remove sun gear, remove cap screws and the retainer which holds gear in

position, then remove sun gear.

Dis-

4. If reusing gear set, punch mark

bearing adjusters for reference

during assembly.

5. On teeth-side of ring gear, cut lockwire and remove bearing cap screws. Remove cap, adjuster and lock.

Differential Carrier Overhaul

(Forward and Rear Axles)

Disassemble Differential Carrier (Cont'd)

6. On back-side of ring gear, cut

lockwire and remove bearing cap screws. If the gear set is to be reused, remove bearing cap, adjuster and lock as an assembly. This will facilitate correct positioning of ring gear during

reassembly.

9. Forward Axle:

nut. When pinion is equipped with a slotted nut, remove roll pin with a pin punch then remove nut.

Remove helical drive gear, using

suitable puller if necessary.

NOTE: Remove outer pinion

bearing cone if "slip-fit" type.

Remove pinion

7. Remove bearing cups, then lift ring gear and differential assembly

out of carrier.

10. Forward Axle:

bearing cage cap screws and lockwashers. Remove pinion and cage assembly from carrier. Remove shim pack.

Remove pinion

8. Rear Axle:

bearing cage cap screws, then drive pinion, cage and yoke assembly out of carrier.

IMPORTANT: Do not allow pinion to drop on hard surface. Remove shim pack.

IMPORTANT: Forward and Rear Axle:

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.

Remove pinion

Disassemble Drive Pinion

NOTE: Sicer drive axles may be equipped with either "slip-fit" or "press-fit" outer pinion bearings.

procedures are contained in this section for disassembly of both types.

IMPORTANT: During the following yoke removal procedure, the drive

pinion may fall out of bearings and cage. Do not allow pinion to drop on hard surface.

1. Rear Axle Pinion Yoke:

Remove yoke. If pinion nut was not loosened during earlier disassembly, clamp assembly in vise

jaws, use brass pads to prevent

damage. Loosen and remove pinion nut

and flat washer.

NOTE: Flat washers are not used

with metric threaded nuts. Metric nuts went into production on 7-1-95.

Removing "Sllp-Fit" Outer Bearing

Cone (Rear Axle illustrated).

2. Forward and Rear Axle Pinion

Bearing Cage:

"press-fit" bearing cone, support cage and press pinion out of bearing cage and bearing cone.

For pinion with "slip-fit" bearing

cone, the cage, outer bearing and

pinion can usually be disassem-

bled easily without a press. If difficulty is experienced, use a press.

For pinion with

3. Rear Axle Pinion Oil Seal and

Outer Bearing Cone:

seal and bearing cone from cage.

Discard oil seal. Remove bearing

cups with suitable puller.

Removing Bearing Cage (Rear

Axle illustrated).

Remove oil

Differential Carrier Overhaul

Disassemble Drive Pinion (Cont'd)

(Forward and Rear Axles)

4. Remove and retain

bearing spacer from pinion.

5. Remove pilot bearing and inner bearing cone from pinion, using a split-type puller. Use two procedure steps-to remove each bearing (see photos above).

First, mount puller vertically to split the bearing.

This action will force

bearing off pinion.

The same procedure inner bearing cone.

puller halves under bearing and start moving

can be used to remove pilot bearing and pinion

Second, mount puller horizontally to press pinion out of bearing.

Disassemble Wheel Differential

3. Remove ring gear.

NOTE: A soft-faced hammer or

mallet may be required to dislodge

gear from its mounting.

1. Remove nuts and bolts fasten-

ing ring gear and support cases.

Remove small support case and

thrust washer.

4. To remove differential assembly, place support case assembly on a bench or on the floor. Position case on its side, then slowly roll the case and slide differential assembly out of the case.

5. Remove thrust washer from

support case.

6. Invert differential assembly to remove idler pins, then remove idler pinions.

7. Punch mark differential cases

for correct location in reassembly.

Remove cap screws and separate

case halves.

Differential Carrier Overhaul

Disassemble Wheel Differential (Cont'd)

(Forward and Rear Axles)

8. Lift out thrust washer and side

gear.

11. First, try to lift off high-speed clutch plate by hand. If it cannot be

removed easily, press off plate as follows:

9. Lift out spider, side pinions and 10. Remove side gear and thrust thrust washers.

a. Insert properly sized adapters

(round metal stock) into two

idler pin holes and invert the case assembly in a press. The clutch plate should be down.

The adapter length should

provide space for removal of the plate.

Setup for Removing High-Speed Clutch Plate

12. Remove bearing cones from

support cases using suitable puller

(see photo).

NOTE: Holes are provided in case to enable removal of bearing cone with a pin punch (see photo). Tap alternately through each hole until cone is removed.

WARNING: WHEN USING A

DRIFT, PUNCH OR SIMILAR

TOOL, WEAR SAFETY GLASSES.

washer.

b. Use bar stock to block the center

hole in the clutch plate and press against it with the press ram.

C. Continue to press until the plate

breaks loose from the plate dowel pins.

Removing Bearing from Small Support Case using Puller.

Assemble Wheel Differential

NOTE: Lubricate internal parts with gear lube during reassembly.

1. Press bearing cones on support

cases (see photos). IMPORTANT: To prevent bearing

cone damage, use suitable sleeve that only contacts the inner race of the cone.

Pressing Bearing Cone on Large Support Case

2. Position high-speed clutch plate with chamfered end of clutch teeth

toward idler pinions. Press clutch plate on case.

IMPORTANT: It is important that the ends of the dowel pins are recessed 1/8" below surface of the clutch plate. If pins extend beyond plate

surface, press pins to proper depth. Don't press them in too far.

Pressing Bearing Cone on Small Support Case

3. Place thrust washer and side gear in differential case.

Differential Carrier Overhaul

Assemble Wheel Differential (Cont'd)

(Forward and Rear Axles)

4. Assemble side pinions and

thrust washers on spider. Place this assembly in differential case.

7. Install idler pins and pinions.

5. Place side gear and thrust

washer in position on side pinions.

8. Place thrust washer in support case.

6. Align punch marks and place

plain case on case (with pins). install cap screws and torque to 90-110 ft-lbs. (122-149 Nm).

NOTE: Turn side gear hub to check

for free differential rotation. Rota-

tion may require up to 50 ft-lbs.

(65 Nm).

9. During installation of ring gear,

temporarily use two bolts in mount-

ing holes to assure bolt hole alignment. Place ring gear on support case (see photo), then remove the

two bolts.

10. To install differential assembly, place support case and ring gear

assembly on a bench or the floor.

Position case on its side. Carefully lift and slide differential assembly into case. Engage idler pinions with ring gear teeth to complete the installation.

NOTE: During differential installation, be sure thrust washer stays in its proper mounting position.

11. Install thrust washer and small

support case over differential assembly.

12. Carefully install ring gear bolts, making certain flat on bolt head is

seated against the outside diameter of the support case. Install nuts and torque to 110-130 ft-lbs. (149-176 Nm).

NOTE: Temporarily install sliding clutch (or sun gear) and check planetary for free rotation.

Assemble Drive pinion ("press-fit” outer pinion bearing)

Forward Axle Pinion Illustrated.

*D341, 381 (P), 401-P, 402(P), 451-P use self-locking or slotted nut and roll pm. Metric threaded nuts used on axles starting 7-1-95

D340, 380(P), 400-P use self-locklng nut only.

Rear Axle Pinion Illustrated.

NOTE:Spicer drive axles may be equipped with either “slip-fit” or “press-fit” outer pinion bearings. Procedures are contained in this section for assembly of both types.

NOTE: Lubricate parts with gear lube during reassembly.

PINION PILOT BEARING

BEARING BEARING CONE SPACER (INNER) (VARIABLE) SHIM

DRIVE PINION

BEARING BEARING CUP CONE (INNER)

BEARING CAGE CAGE CUP

LOCKWASHER

BEARING

(OUTER)

CAGE CAP SCREW

(OUTER)

OIL SEAL & RETAINER

INPUT YOKE

FLAT WASHER

/ FLAT WASHER NOT USED

WITH

. .

METRIC THREADED NUTS.

PINION NUT

1. Using appropriate sleeve, press bearing cups in cage (see adjacent

drawings). NOTE: On rear axles, do not install

oil seal in cage until bearing

preload is correctly adjusted. IMPORTANT: After bearing cups

are installed, preselect pinion bearing spacer using the “trial build-up” procedure described in

the Adjustments Section of this

manual.

Forward Axle Pinion. Press Bearing Cups in Cage.

“A" Cups must be firmly seated in cage

Check with feeler gauge (0.001”) after installation.

NOTE:

Install cups one at a time

Rear Axle Pinion. Press Bearing Cups in Cage.

“A" -

Cups must be firmly seated in cage. Check with feeler gauge (0.001”) after installation.

NOTE: Install cups one at a time

Differential Carrier Overhaul (Forward and Rear Axles)

Assemble Drive Pinion

2. Press pilot bearing on pinion.

IMPORTANT: To prevent bearing

damage, use suitable sleeve that only contacts inner bearing race.

("press-fit" outer pinion bearing) (Cont'd)

3. Stake pilot bearing using staking

tool. This is essential to retain the bearing.

NOTE: During pinion bearing in-

stallation, locate each part in same position that was used in "Trial Build-up" Preload Test.

4. Press inner bearing cone on

pinion. IMPORTANT: To prevent bearing

damage, use suitable sleeve that only contacts inner race of bearing cone.

5. Install preselected bearing

spacer on pinion.

8. Rear Axle Only. With pinion

installed and bearing preload adjustment complete, install oil seal with a press. **

** IMPORTANT: Refer to page 15 for service information on Seals, Yokes & Slingers.

* Flat washer not used on axles with metric threaded nuts.

6. Install bearing cage on drive

pinion.

9. Rear Axle Only. Prior to installation of yoke, lubricate oil seal and

make sure yoke is clean and dry. Install yoke, flat washer* and nut.

Torque nut to correct specification.

7. Press outer bearing cone on

pinion.

IMPORTANT:

damage, use suitable sleeve that only contacts inner race of bearing cone.

IMPORTANT: At this stage of

assembly, "final-check" pinion bear-

ing preload. See Adjustment Section of this manual.

NOTE: After tightening pinion

nut, recheck pinion bearing rolling torque. See Adjustment Section for "Press-fit' outer pinion bearing.

10. Forward Axle Pinion Helical Gear and Nut:

installed during pinion installation (see page 54).

To prevent bearing

These parts are

Assemble Drive Pinion (*"Slip-fit" outer pinion bearing)

1. Using appropriate sleeve, press

bearing cups in cage.

Press pilot bearing in pinion.

IMPORTANT:

damage, use suitable sleeve that only contacts inner bearing race.

To prevent bearing

3. Stake pilot bearing using staking

tool and press. This is essential to

retain the bearing.

6. Install bearing cage on drive pinion.

4. Press inner bearing cone on pinion.

IMPORTANT: To prevent bearing

damage, use suitable sleeve that

only contacts inner race of bearing cone.

7. Install pinion outer bearing cone.

NOTE: At this stage in assembly,

check pinion bearing preload described in Adjustment Section of

this manual for "slip-fit" outer pinion

bearing. oil seal until adjustment is complete.

Rear Axle:

Do not install

5. Install bearing spacer on pinion.

NOTE:

bearings are used, select nominal size spacer (see chart page 22). If original parts are used, use spacer

removed during disassembly.

Installation of these parts is the same for "slip-fit" and "press-fit" bearings. See page 52 (step 8 and

9) for instructions. NOTE: For "slip-fit" bearings,

to simplify seaI installation. Nut: See page 54 for instructions.

When new gear set or pinion

Rear Axle Oil Seal and Yoke:

pinion may be temporarily removed

9. Forward Axle Helical Gear and

Differential

Carrier Overhaul

Forward Axle -

Install

1. Output Shaft Side Gear Bearing Cup. If removed, press bearing

cup in carrier.

Torque Chart

Bearing Cage Cap Screw

Size

9/16-12

(Grade 8)

Forward Axle -

Ft-lbs. N.m

155-175

Nominal Shim Pack

In.

0.024

210-237

0.609

Install Helical Gear

Pinion

2. Place shim pack on carrier, making certain that holes in shims are aligned with carrier holes.

NOTE:

install same quantity and size of shims removed during disassembly. When installing a new gear set, use nominal shim pack (see chart).

If gear set is to be reused,

3. Install drive pinion assembly. Install bearing cage cap screws and lockwashers. Torque cap screws (see chart).

NOTE: The forward axle pinion is equipped with a helical gear. For easier disassembly during carrier adjustment procedure, use a dum-

my yoke (if available) in place of helical gear.

1. Install helical gear on pinion, positioned as shown in the illustration. Install self-locking nut or slotted nut. Torque nut properly

(see chart), using a suitable fixture

to hold helical gear.

NOTE: On axles equipped with slotted nut and roll pin, do not

install roll pin until carrier adjustments are completed.

Torque Chart

Pinion SELF-LOCKING NUT

Size

(D340, 380(P), 400-P)

1-1/2-18

(D341 ,381 (P), 401-P, 402(P), 451-P)

1-518-18 (D341 , 402(P), 451(P)

produced after 7-1-95 M42

(D341, 381(P), 401-P, 402(P), 451-P)

1-518-18

*IMPORTANT:

(1139 Nm), then continue tightening nut to align slot with the nearest hole in pinion shank. Install roll pin.

Ft-lbs.

560-700

780-960

X 1.5 840-1020

Pinion SLOTTED NUT

& ROLL

840*

Torque to 840 ft-lbs.

759-949

1057-1301

1140-1383

1139*

Pinion Helical Gear Mounting Position

NOTE: See Torque Chart for

Pinion Nut Variations

POSITION LARGE CHAMFER

TOWARD BEARING CONE

Installing Pinion Helical Gear.

Forward Axle --

1. Lubricate bearings during the

following assembly procedure:

Place ring gear and differential

assembly in carrier. Insure that

ring gear and drive pinion mesh properly.

During installation, tilt carrier to allow support case pilot to rest in carrier bore, then install bearing cup as shown in photo, Also install

bearing cup on opposite side of differential.

Install Differential Assembly in Carrier

If the same gear set is used,

install the assembled bearing cap,

adjuster and lock on the backface

side of the ring gear. Otherwise install adjuster and cap separately.

NOTE: When installing cap, it may

be necessary to tap it lightly with a hammer. Be sure cap is fully seated and threads are aligned properly. If

trouble is encountered, check for

cross-threading of bearing adjuster and carrier threads.

On teeth side of ring gear, install the other adjuster and bearing cap, observing same precautions to avoid cross-threading.

3. Install and tighten bearing cap

screws finger-tight. If this is difficult, use hand wrench.

4. At the teeth-side of ring gear,

position bearing adjuster until its first thread is visible.

At the back-side of ring gear, tighten adjuster until there is no

backlash.

NOTE: With bearing adjusters and caps assembled to carrier, the carrier assembly is now ready for adjustment of bearing preload, ring gear backlash and gear toothe contact (see page 57).

Differential Carrier Overhaul

Rear Axle

- Install Pinion

Nominal Shim Pack

0.023

1. Place shim pack on carrier

making photo).

NOTE: If the gear set is to be reused, use same quantity and size shims removed during disassem-

bly. If a new gear set is to be in-

stalled, install a nominal shim pack

(see chart).

Rear Axle - Install Differential in Carrier

sure lube hole is clear (see

0.584

2. Install drive pinion assembly. NOTE: Make certain lube holes

in carrier, shims and cage are aligned. install bearing cage cap screws and lockwashers. Torque cap screws to 110-125 ft-lbs. (149-170 Nm).

NOTE: Lubricate bearings during

the following assembly procedure:

1. Place ring gear and differential assembly in carrier. Insure that ring gear and drive pinion mesh properly.

During installation, tilt carrier to allow support case pilot to rest in carrier bore, then install bearing cup as shown in photo.

install bearing cup on opposite

side of differential.

Also

2. If the same gear set is used, install the assembled bearing cap, adjuster and lock on the backface side of the ring gear. Otherwise install adjuster and cap separately.

NOTE: When installing cap, it may be necessary to tap it lightly with a hammer. Be sure cap is fully

seated and threads are aligned properly, If trouble is encountered, check for cross-threading of bearing adjuster and carrier threads.

On teeth side of ring gear, install the other adjuster and bearing cap, observing same precautions to avoid cross-threading.

3. Install and tighten bearing cap screws finger-tight. If this is difficult, use hand wrench.

NOTE: The assembly is now ready for adjustment of differential bearing preloan, ring gear backlash and gear tooth contact (see page

57).

Forward and Rear Axle -- Adjust Differential Bearing Preload:

1. At the teeth-side of ring gear, position bearing adjuster until its first thread is visible.

2. At the back-face side of ring gear, tighten adjuster until there is no backlash.

3. At the teeth-side of ring gear, tighten adjuster until it contacts the bearing cup. Continue tightening adjuster two or three notches. This will preload bearings and provide backlash.

4. Check Ring Gear Backlash. Measure backlash with a dial indicator. Specifications are listed below. Refer to page 23 for detailed instructions on adjusting backlash.

Ring Gear Backlash Specifications USED GEARING NEW GEARING -

- Reset to backlash recorded before disassembly. Backlash should be between 0.006" and 0.016".

5. Check Ring Gear Tooth Contact. Pain ring gear teeth and check

toothe contact pattern. Correct toothe patterns are illustrated below. For checking and adjusting procedures, see page 24.

CORRECT PATTERN (USED GEARING)

CORRECT PATTERN (NEW GEARING)

¥Could vary in length.

● Pocket may be

extended.

¥pattern along the

face width could be longer.

Pattern should cover 1/2 tooth or more (face width).

● pattern should

be evenly centered between tooth top land and root.

Adjusting Bearing Adjuster.

Checking Ring Gear Backlash.

● Pattern should be clear of tooth toe.

6. With ring gear and pinion adjusted correctly, align adjusters and locks, then tighten differential bearing cap screws to correct torque

(see chart page 58). Install cotter pin in one adjuster lock. Install cap screws in opposite adjuster lock and tighten to correct torque (see chart page 58). Lockwire bearing and adjuster lock cap screws.

Differential Carrier Overhaul

Adjust Differential Bearing Preload (Cont'd)

7. For planetary double reduction axles

install sun gear and retainer, then install cap screws that fasten both retainer and adjuster lock cap screws. Tighten screws to correct torque (see chart), and lockwire all cap screws.

8. For dual range axles: Position shift fork in carrier opening, then install sliding clutch.

9. With clutch installed, engage shift fork yoke with clutch collar. Then install shift fork shaft. Install expansion plugs to seal openings.

10. Install shift unit seal and spring.

(on backface side of ring gear),

Installing Shift Fork Shaft.

Differential Bearing Cap Cap Screw

Size

13/16-10

Bearing Adjuster Lock and Sun Gear Retainer Cap Screw

Size

5/8-1 1

Grade

(8)

Grade

(5)

Torque Chart

Ft.-lbs.

370-430

Ft.-lbs.

160-176

501-583

217-239

Dual Range Axle Shift Systems

There are two shift system designs predominantly used to select range of an Spicer dual range tandem axle.

1. Standard System. For range selection, a cab-mounted air

shifter valve operates two air shift units mounted on the axles. The inter-axle differential lockout is of the straight-air type

and air-operated to engage lockout and spring-released to disengage lockout.

2. Axle Range Interlock System. This system has an added

feature to prevent axle shifting when the inter-axle differential is locked out. The axle range air shifter valve for this system includes an Interlock Pin Assembly to provide the interlock feature.

The inter-axle differential lockout is of the straight-air type. It is equipped with an Interlock Control Valve which controls

air pressure delivery to the shifter valve Interlock Pin, Detailed information on these systems is included in this

manual.

“Reverse-Air” Type Inter-axle Differential Lockout. Some

shift systems may include this lockout design. It is springoperated to engage or “Lock” the differential and air-operated

to disengage or “Unlock” the differential.

Dual Range Axle Shift Systems

Standard System for Axle Range Selection and Inter-Ax/e Differential Lockout

(straight-air type)

Air pressure with axle in High Range, Inter-Axle Differential Engaged.

Description

The standard dual range shift system consists of:

A manually-operated, air shifter

valve to change axle range.

A quick release valve which

provides for fast release of air pres-

sure from the axle shift units.

Two air shift units mounted on the axles. These shift units are mechanically connected to the axle shift forks and sliding clutches which, in turn, shift axles into Low or High Range.

For vehicles not equipped with automatic safety brakes,

controlled solenoid valve exhausts

the system and downshifts the axles

when the ignition switch is turned off. The electrical circuit is protected by a circuit breaker.

For vehicles equipped with transmission-drive speedometers, the system

includes a speedometer adapter which compensates speedometer readings when axle is in Low Range. The

adapter is operated by an electrical

switch mounted on or near the quick-

release valve. The switch is normally-

closed and is opened by air pressure.

an ignition-

Pressure switch and speedometer adapter

required for vehicles with transmission

drive speedometers.

With axles in Low Range, the switch is closed and the adapter is energized. The adapter operates with a ratio compatible with the axle Low Range for proper speed readings. With axle in High Range, the air lines are pressurized and the pressure switch is open. The adapter now operates with 1:1 ratio for proper speed readings in High Range.

Axle Shift System Operation

High Range.

moved to the High position, the valve is opened and air pressure is supplied

through the quick release valve to

both axle shift units. When driveline torque is interrupted, the shift units will shift both axles to High Range.

Low Range.

moved to the Low position, the valve is closed. Air pressure in the shift units is exhausted through the quick release valve. When driveline torque is interrupted, both axles are shifted to Low Range and held in this position by shift unit return springs.

When shifter valve is

Solenold valve required for vehicles

not equipped with automatic safety brakes.

Inter-Axle Diff. Lockout System

The lockout air shift system consists of:

1. A manually-operated air shifter

valve which controls engagement or disengagement of the inter-axle differential.

2. A lockout cylinder which operates under air pressure. This cylinder is mechanically-connected to a shift fork and sliding clutch. The clutch engages or disengages a differential helical-side gear to “Lock” or “Unlock” the differential.

Lockout System Operation.

operation description, refer to the following page.

For

Dual Range Axle Shift Systems

"Standard" Lockout

Description: The “standard” lockout unit is of the straight-air type and is air-operated to engage lockout and spring-released to disengage lockout.

The piston is mechanically connected to the shift fork and sliding clutch. The clutch engages or disengages the helical-side gear to lock or unlock the inter-axle differential.

(straight-air type)

Disengage Lockout (Unlock Differential)

When the air shifter valve lever

is moved to the disengaged or “Unlock” position, the valve is closed and air pressure in the

cylinder is exhausted.

Air pressure at piston is released. Spring pressure moves piston, shift fork and sliding clutch. Clutch is disengaged from helical-side gear.

Inter-axle differential is unlocked and functions normally.

Engage Lockout (Lock Differential)

When the air shifter valve Iever is moved to the engaged or “Lock” position, the valve is opened and supplies air to the lockout cylinder.

Air pressure enters cover—moves

piston, shift fork and sliding clutch. Clutch engages helical-side gear. Inter-axle differential is locked out (or not operating).

Axle Range Selection and Inter-Axle Differential Lockout System

(with Axle Range Interlock and Straight-air type Lockout)

Air pressure with axle in High Range,

Inter-Axle Differential Engaged, and

Axle Shifter Valve Lever Blocked.

Pressure switch and speedometer adapter required for vehicles with transmission

drive speedometers.

Description and Operation

The Axle Range Interlock feature in this system is designed to prevent axle shifting when the inter-axle differential is locked out (or when lockout is engaged).

The basic shift system operates the same as the standard shift system to shift axle and engage or disengage lockout. However, it varies by adding an Interlock Pin Assembly to the axle range shifter valve and an Interlock Control Valve to the lockout cylinder. These two components are interconnected with air lines (see illustration above). In operation, the Interlock

Pin Assembly blocks movement of the axle range shifter valve lever when air pressure is present. Refer to the following page for operation description.

Solenoid valve required for vehicles not equipped with automatic safety brakes.

Dual Range Axle ShiFt Systems

Axle Range Interlock Operation

Engage Lockout (Lock Differential) (Axle in High or Low Range)

Disengage

Lockout (Unlock Differential) (Axle in High or Low Range)

Trouble Shooting

Check for Air Pressure and Air Leaks

A simple method for quickly locating troubles in a shift system can be accomplished by listening for possible air leaks and for sound which would indicate mechanical shifting.

Axle Shift System

When system includes a solenoid valve, turn ignition “ON” to energize and open the solenoid valve.

If electrical system is functioning, air pressure should be present at valve outlet connection.

Move axle shifter valve lever to High Range. In this position, air pressure should be present in the entire system. Check for air leaks.

Move axle shifter valve lever to Low Range. In this position, air pressure should be present only up to axle shifter valve.

To check axle for shifting, operate shifter Iever back and forth from “LO” to “HI”. If the shift unit is operating, a definite reaction will be evident by sound of parts movement.

If air pressure is satisfactory and shift unit does not operate, disassemble and inspect shift unit.

Check Pressure Switch.

In Low Range, the pressure switch is

closed and electrical circuit is com-

plete to the speedometer adapter. In High Range, air pressure opens the pressure switch, breaks the electric

circuit to the speedometer adapter. To check pressure switch operation,

shift to High Range and probe switch terminals. No voltage should be

present. Replace a faulty pressure switch as an assembly.

Check Quick Release Valve.

The quick release valve provides a means of quickly exhausting air from system when axle is shifted from High to Low Range.

To check valve operation, listen for audible air exhaust from valve when shifting axle from High to Low Range. Replace a faulty quick release valve as an assembly.

Check Lockout (standard).

With shifter valve in the “Lock” position, air pressure is present in the entire lockout system. Check for air leaks with lockout engaged. Repair leaks.

NOTE:

air pressure present at cover connection, remove and check lockout cylinder.

Check Lockout (with axle range interlock).

With shifter valve in “Lock” position, lockout is engaged and air pressure is present in all lines and components of the lockout and interlock system.

Check for air leaks with lockout

engaged. Repair leaks.

If lockout will not engage with air pressure present at cylinder cover side connection, remove and check cylinder.

Check Interlock Control Valve

Air pressure is present at the

inlet connection at all times. With lockout engaged, the valve

should open and air pressure should be present at the valve side connection.

With lockout disengaged, valve should be closed, blocking air at the side connecton.

Check valve operation in both

lockout positions. If valve operation is faulty, replace the assembly.

Check Interlock Pin Assembly

Air pressure is present at the axle

range shifter valve cover connection when lockout is engaged. Air pressure should operate locking pin to

block movement of the axle shifter valve lever.

To check operation, move the lock-

out shifter lever to the “Lock” position.

If lever operation is not blocked,

check for air pressure at the Interlock

Pin connection. If air pressure is

present, repair Interlock Pin Assembly.

If lockout will not engage with

Check Electrical System

Check Solenoid Valve

When ignition switch is "ON"; solenoid valve is energized and air pressure is available to operate the

system. When ignition switch is “OFF; solenoid valve is de-energized and

exhausts the system which downshifts axle to low range. Check wiring and circuit breaker for defects that would cause shorts or open circuits.

Make sure valve has a good ground connection to the frame. With power at valve, check operation as follows: Disconnect lead wire and air line outlet at valve and install air pressure gauge.

Apply power to valve and observe air gauge reading. Operating pressure should be approximate reservoir pressure.

If gauge indicates approximate pres-

sure, valve is okay.

If gauge indicates low or no pressure,

valve is faulty. Replace valve assembly.

Check Speedometer Adapter

Make sure adapter is grounded to

vehicle chassis.

Check wiring for shorts or grounds

and trace electrical circuit from igni-

tion switch through circuit breaker,

pressure switch to adapter.

Check for power supply at adapter terminal. With axle shifter valve in High Range, pressure switch is open and power is not delivered to adapter. With shifter valve in Low Range, the pressure switch is closed and power is delivered to operate the speedometer adapter. If power supply is okay, adapter is faulty. Replace adapter assembly.

Axle Shift

System Components

Air Shifter

Valves (Standard System)

NOTE: For air shifter valve repair instruction, refer to pertinent manufacturer’s

literature. See instructions

Air Shifter Valve (Axle Range Interlock System)

below for Interlock Pin Assembly repair.

Typical Air Shifter Valve for Standard System, Axle Range Selection and Inter-axle Differential Lockout.

Ax/e Range Selector Name Plate

(Standard System)

Axle Range Interlock Air Shifter Valve.

The Valve for the Interax/e Differential/ Lockout is the same as the Standard System.

Inter-Axle Differential Lockout Name Plate

Axle Range Shifter Valve Interlock Pin Assembly

NOTE: The interlock pin assembly may be disassembled for cleaning and inspection. However, parts are only available as a complete assembly (shifter valve and interlock assembly).

Disassemble Pin.

ring, then remove piston stop, piston and spring from piston housing.

Remove snap

Ax/e Range Selector Name P/ate

(System with Axle Range Interlock)

NOTE: Before reassembly, lubri-

cate “O” rings with a high-viscosity silicone oil or barium grease “O”

ring lubricant.

Assemble Pin.

on piston and piston stop. Insert spring, piston and piston stop in housing and secure with snap ring.

NOTE: Interlock pin and piston must reciprocate freely in the piston housing when compressed against the compression return spring.

NOTE: For ease of assembly,

insert a pin or drill bit (5/64” max. diameter) into the piston stop to guide the piston stop as it is installed into the piston housing.

Install “O” rings

● Planetary Double Reduction Tandem Axles

• Dual Range Tandem Axles with “standard” Axle Range Selection

System. Two “Standard” designs are used on these axles and are identified as

“Standard” “Current” or “Standard” “Non-Current” Models. Both designs are air-operated to engage the lockout and spring-released to disengage the lockout. Spicer Axles may be equipped with either of these lockouts. The “Current” model is interchangeable with the “Non-Current” model

as an assembly. For service information, refer to the following page.

“Standard” “Current” Model Lockout Overhaul

Disassemble and Remove Lockout. NOTE: With axle installed in

vehicle, place differential lock selector valve in the disengaged

(or unlocked) position. Disconnect the air line at the lockout piston housing.

“Standard” “Current” Model Lockout

“Reverse-Air” Lockout.

“Reverse-Air” lockout is springoperated to engage the lockout and air-operated to disengage the

lockout. This model is similar to

the “non-current” “standard”

lockout. It is not available in the new

“current” lockout.

The

Remove cap screws and lockwashers fastening mounting bracket to power divider cover. shoulder washer from push rod. divider cover installed (see Power Remove bracket and piston Divider instructions). housing.

Assemble and Install Lockout

1. With shift fork and sliding clutch

installed, place the shoulder

washer (white plastic) over push

rod. The large diameter side of the

washer must face the power divider cover.

2. Install compression spring on

push rod.

3. Lubricate “O” ring with silicone-

based lubricant and install “O” ring on piston.

4. Place piston assembly on push

rod. The large diameter end of piston must face power divider

cover.

5. Install locknut on push rod and tighten to 13-17 lbs. -ft. (18-23 N•m).

2. Remove locknut, Piston with “O” ring, compression spring and

6. Install piston housing, making sure the housingIScorrectly seated and piloted in the shoulder washer,

7. Place mounting bracket over housing and position on power divider cover. Install. cap screws and lockwashers and tighten to 48-56 Ib.-ft. (65-76 N•m).

NOTE:

apply sealant to air line fitting and

connect air line. When tightening air line, hold piston housing in

mounting position using a wrench applied to the hexagon configuration at outer end of housing.

If axle is installed in vehicle,

NOTE: The shift fork and Push rod cannot be removed with power

NOTE: A new style “Inter-Axle Differential Lockout” was being released as this publication was being printed. If the Inter-Axle Differential Lockout Assembly on your axle is not shown in this publication, call your local

Spicer representative.

Axle Shift Components.

Retrofit “Non-Current” to “Current” Model Lockout

The “current” model (only as an assembly) is interchangeable with the “non-current” lockout. The original shift fork and push rod can

be used for either model lockout

and need not be replaced.

Retrofit Kits are available to convert the “non-current” model to the “current” lockout. Parts (except the

“Standard” "Non-Current” Model Lockout Overhaul

shift fork), included in these kits are shown in the illustration on the preceding page. For additional

information, refer to Spicer Parts Books (see inside back cover).

Disassemble and remove

“non-current” lockout. Refer to

instructions below.

“Standard” “Non-Current” Model Lockout

Assemble and install “current” lockout following instructions on preceding page.

NOTE:

from “non-current” model. They

are too long to use with the new “current” model.

Do not use mounting screws

Service Parts Availability.

“non-current” lockout assembly, body, piston and body cover are no longer available. If any of these

items are not serviceable, replace lockout with the new “current” model per instructions above. For

other parts, a Service Parts Kit

(see illustration) is available to

service the “non-current” lockout.

Disassemble and Remove Lockout

Remove cap screws and lockwashers fastening cover to the body. Remove cover and “O’’ ring.

Remove nut, flat washer and “O’’ ring from push rod.

Assemble and Install Lockout

With shift fork and sliding clutch

installed in power divider cover, assemble and install lockout as follows.

1. Apply silicone gasket compound to mounting surface on power divider cover. See illustration.

2. Install lockout body. Secure with cap screws and lockwashers. Torque cap screws to 48-56 Ibs.-ft.

(65-76 N•m).

NOTE: Before installation, soak piston felt oilers in SAE 30 engine oil and lubricate “O’’ rings with a high-viscosity silicone oil or barium grease “O’’ ring lubricant.

The

*Asterisk Identifies parts included in Service Kit 277207

NOTE: Axles with Lube Pumps:

piston stop located at base of piston. reinstalled in reassembly.

Remove body cap screws and lockwashers, then remove body and piston as an assembly. Remove “O’’ ring and felt oilers from the piston.

3. Install felt oilers and large “O” ring on piston.

Axles with Lube Pump.

installing piston, place piston stop

at base of lockout body.

4. Install compression spring over shift fork push rod. Install piston in

body and secure with “O” ring, flat washer and nut. Torque nut to 20-26 Ibs.-ft. (27-35 N•m).

5. install “O’’ ring in lockout body cover. Install cover and secure with cap screws and lockwashers. Torque cap screws to 96-108

LBS.-IN (10-12 N•m).

Before

These axle models are equipped with a

It is important that this stop be

NOTE: The shift fork and push rod cannot be removed with power divider cover installed (see Power

Divider instructions).

Inter-Axle Differential Lockout (with Interlock Control Valve)

(straight-air type)

Lockout Cylinder

Disassemble Cylinder.

1. Remove cap screws, lockwash-

ers, cover assembly and "O" ring,

2. Remove hex-nut piston and

"O" rings.

3. Remove body cap screws and

lockwashers, then remove body and piston as an assembly.

Assemble Cylinder.

1. Apply gasket compound to

mounting surface on power divider cover.

2. Install lockout body. Secure with cap screws and lockwashers.

Torque cap screws to 48-56 ft-lbs.

(65-76 Nm). NOTE: Before installation, soak

piston felt oilers in SAE 30 engine oil and lubricate "O" rings with a high-viscosity silicone oil or barium grease "O" ring lubricant.

3. Install felt oilers and "O" ring on piston.

Axles with Lube Pump:

installing piston, place piston stop at base of lockout body.

4. Install compression spring over

shift fork push rod. Install piston in body. Install "O" ring over push rod and in piston. Install hex-nut piston and tighten to 20-26 ft-lbs. (27-35 N«m). Install "O" ring on piston.

Before

5. Install "O" ring in lockout body cover. Install cover assembly and

secure with cap screws and lockwashers. Torque cap screws to 96-108 IN-LBS. (10-12 N«m).

6. Adjust interlock control valve.

Interlock Control Valve

Replace faulty valve as an assembly,

Repair and Replacement. Remove Valve.

1. Loosen locknut and unscrew valve body from cylinder cover. Install and Adjust Valve.

NOTE: If button is not assembled to valve stem, install as follows: Insert

valve stem to full depth of the button. Lock in place with set screw. Torque

set screw to 6 IN-LBS. (0.7 Nm).

1. With button assembled to valve, install locknut and Iockwasher on valve body. With lockout cylinder exhausted, screw the valve assembly into the lockout cylinder cover until the valve is seated on hex-nut piston.

2. To adjust, unscrew control valve until the valve air-delivery port is aligned with the lockout cylinder air-inlet port.

NOTE: Do not unscrew valve more than 360 Lock the valve in place with locknut. Torque locknut to 35 IN-LBS.

(3.9 Nm).

Speedometer Adapter

The speedometer adapters are

lubricated and sealed for life of

the unit. No maintenance is

required. Replace a faulty unit.

Solenoid Valve

Replace solenoid valve as an assembly. The valve should

not be serviced.

Quick Release Valve

If quick release

valve fails to

operate properly, it may be

repaired as follows: Disassemble valve.

Inspect valve

body, valve seat

and spring (if

used) for evi-

dence of faulty operation.

faulty parts, then reassemble valve.

Replace

. .

Pressure Switch

Replace pressure switch as an assembly.

Axle Shift System Components

Air Shift Unit

Description and Operation

The Piston Air-Shift Units are

engineered for efficient performante and built for reliable, service-free operation.

Operation of each unit is as follows: The shift units are mechanically connected to the axle shift forks and shift axles into Low or High range.

The unit consists of an air chamber,

piston, compression spring and mechanical linkage. When air is admitted to the chamber or cylinder, the piston travels downward against a compression spring, transferring

motion through a push rod and

actuating lever to the shift fork,

Air Shift Unit-Exploded View (Forward Axle Unit Illustrated)

shifting the axle into High range. Exhaust of air pressure permits the heavy-duty spring to return the axle gearing to Low range.

Air Shift Unit Replacement

Remove Unit

Disconnect air line at shift unit

cover. Remove nuts, flat washers and piston air-shift unit from differ-

ential carrier.

NOTE: When shift unit is removed,

provide container to catch oil that escapes from reservoir. Remove shift fork seal and spring.

Air Shift Unit Overhaul

Install Unit

1. Lubricate

and spring assembly over fork and seal on differential carrier studs.

Shift axle into Low Range.

2. Place shift unit on mounting

studs and make certain shift fork

actuating lever engages slot in shift

fork. Install flat washers and stud

nuts. Tighten nuts to 55-61 ft-lbs.

(74-82 Nm).

shift fork. Slide seal

3. When axle is installed in vehicle, fill shift unit housing to level of filler plug with SAE 10 oil or

automatic transmission fluid (see

Lubrication on

Coat threads of filler plug with

sealer and install plug.

4. Connect air lines to shift unit cover.

following page).

Disassemble Unit

1. Remove cap screws, lock

washers, cover and gasket from housing. Drain lubricant.

2. Remove bolts, locknuts, cover at piston end of housing. Remove "O" ring.

CAUTION: DURING THE FOLLOWING PROCEDURE, THE PISTON WILL POP OUT OF HOUSING UNDER SPRING PRESSURE. EXERCISE CAUTION TO PREVENT POSSIBLE INJURY.

3. Remove locknut, flat washer, and piston from push rod. Remove "O" ring and felt oilers from piston.

4. Remove compression spring and piston stop from bore of shift unit housing.

5. Remove clevis pin, then

push rod from shift unit housing. Remove "O" Ring from push rod.

remove

Parts Inspection

Shift Fork Seal

seal for defects and tight fit on shift fork. A spring is used to assure a closer fit of seal around shift fork. If this spring is not present on axle being serviced, install one when reassembling unit.

"O" Rings, Felt Oilers and Gasket -

Replace "O" rings, felt oilers

and cover gasket when piston airshift unit is disassembled for repair.

Compression Spring -

spring for distortion, cracks, or other visual defects, Replace a faulty spring.

Actuating Lever and Pins -

Inspect lever pins and bearings

for worn or grooved condition.

Inspect actuating lever and pus rod for worn or elongated holes at point where they are connected. Replace faulty parts.

Piston

surface for worn, grooved or damaged condition which will affect the piston movement in cylinder. Replace a faulty piston.

- inspect piston friction

- Inspect shift fork

Inspect

6. Remove actuating lever and pin assembly from shift unit housing.

Do not disassemble actuating lever.

Axle Shift System Components

Air Shift Unit Overhaul (Cont'd)

Assemble Unit

NOTE: Prior to assembly, the

piston felt oilers should be soaked in SAE 10 oil for one hour. Lubricate "O" rings with a high-viscosity silicone oil or barium grease "O" ring lubricant.

Assemble pin to actuating lever

and install this assembly in shift unit housing.

2. Assemble "O" ring and piston

to push rod and fasten with flat washer and locknut. Tighten nut to a torque of 120-150 IN-LBS.

(14-17 Nm). Install felt oilers and "O" ring in piston.

CAUTION: DURING THE

FOLLOWING PROCEDURE USING A PRESS, MAKE CERTAIN COMPONENTS ARE PROPERLY ALIGNED IN PRESS TO PREVENT

POSSIBLE PERSONAL INJURY

OR DAMAGE TO PARTS.

3. Insert

sion spring in shift unit housing.

Place piston and push

piston stop and compres-

rod assembly in housing. Position housing assembly in arbor press.

4. Apply pressure to piston until actuating lever is in alignment

with push rod end. Install clevis

pin. Release press.

5. Place cover gasket in position

on shift unit housing then install cover and bearing assembly and fasten with cap screw and lock-

washers. If necessary, use a sealer on threads of cap screws to prevent any leaking. Tighten screws to a torque of 90-110 IN-LBS.

(10-12 N.m).

6. Place "O" ring in groove of

shift unit housing, then install

housing cover and secure with bolts and locknuts. Tighten locknuts evenly to a torque of 108-132 IN-LBS. (12-15 N.m).

7. Fill shift unit with SAE 10 oil or automatic transmission fluid (see

Lubrication) when axle is installed in vehicle.

Shift Unit Housing in Press.

Installing Push Rod Clevis Pin.

Lubrication

Lubricant-Use SAE

for temperature above 0oF (-18oC).

For temperatures below 0

C), mix three parts of SAE

(-18 10 motor oil with one part of kero-

sene. This cold weather mixture

can be safely used up to 32

C).

*NOTE: Commercially available automatic transmission fluid may

be used in place of SAE 10 motor oil. Automatic transmission fluid can be used for all temperatures. Do not mix kerosene with automatic transmission fluid.

Lubricant Check and Level -

Each 20,000 miles or six months, remove pipe plug in shift unit housing cover to check lubricant level.

Lube should be level with bottom

of filler hole.

Lubricant Change -

a year remove shift unit housing cover and drain old lubricant. Wash parts thoroughly and air dry.

Reinstall cover. Remove pipe plug

in cover. Fill through pipe plug

opening until lube is level with

bottom of filler hole.

10 motor oil*

At least once

Air Shifter Valve

(Optional Axle Range Shifter Valve Mounted on Gear Shift Lever).

CAUTION: AIR SUPPLY TO VALVE MUST BE SHUT OFF BEã

FORE THE VALVE IS SERVICED.

The shifter valve can be disassem-

bled for service without removing

the assembly from the gear shift

lever.

Remove screw from cover, then lift off cover and remove shifter knob, knob spring, shifter plate, "O" ring guide and "O" ring from valve housing,

2. If housing requires replace-

ment, disconnect air lines, loosen

jam nut, then unscrew housing from shift lever.

Inspection and Lubrication

Each 50,000 miles, disassemble, inspect and clean, then lubricate moving parts with barium-base

grease. No other type lubricant should be used.

Assemble and Install Valve

1. If housing was removed, install jam nut on shift lever. Thread housing

on shift lever and tighten jam nut. Connect air lines. Air shift valve knob should be positioned at 9:00 o'clock. Lubricate moving parts with bariumbase grease during assembly.

2. Place shifter plate in mounting

position on valve housing.

Pre-assemble guide and "O" ring, then place this assembly in mounting position in shifter plate.

4. Hold shifter plate in position

with one hand, then install spring and shifter knob. Install cover and fasten with screw.

Service Bulletin Supplement.

Input Shaft End Play for Axle Models equipped with an Input Shaft Axial Spring

and Thrust Button.

In September 1988, Spicer added an Axial Spring and Thrust Button between the input and output shafts. The addition of these parts reduces shaft end play movement by loading the shafts axially in the direction of the yoke.

End play tolerances are the same for axles

with or without the new Spring and Thrust

Button. However, end play measurement procedure is different as described below.

Measure and Adjust Input Shaft End Play.

NOTE: The addition of the Spring and Thrust Button between the input and output shafts necessitates the fabrication of a “U”

bracket to assist in measuring the shaft end play. Proceed as follows:

1. Fabricate a “U” bracket from 1“ flat stock

(minimum thickness 0.125”) as specified in

the illustration.

2. If axle is disassembled,

(0.024 mm) thick shim pack and place shim pack and bearing cover on power divider

cover. Then proceed with Step 3.

If axle is assembled, remove input shaft nut, flat washer and yoke. (NOTE: Axles built with metric threaded nuts do not use flat washers.) Then proceed with Step 3.

build up a 0.045”

Location of Axial Spring and Thrust Button.

Input Shaft End Play Chart

New or Rebuild with new

parts 0.003” to 0.007”

Rebuild with reused parts

0.013" to 0.017"

Acceptable End Play Tolerances when measuring as a

regular maintenance procedure with axle in truck.

Up to 0.060”

100,000 miles or 1 year service off-road.

Up to 0.040”

100,000 miles or 1 year service on-road.

with over

with less than

NOTE:

Because of manufacturing variations in individual parts, correctly adjusted end play could vary 0.010,” after the unit is rotated.

NOTE: If end play exceeds

limits, disassemble power

divider and replace worn

parts.

“U” Bracket Specifications.

NOTE 1: Bushing no longer used in current production axles, see pages 37 & 38.

Measure and Adjust Input Shaft End Play

using two bearing cover cap screws (see illustration). install all other cover cap screws

and torque to 75-85 Ibs.-ft. (101-115 N•m).

4. Position a dial indicator on the end of the

input shaft (see illustration).

5. Insert a pry bar through the “U” bracket

with the end of the bar resting on the end of the input shaft. (see illustration).

6. Zero the dial indicator and lift up on the pry bar to move the input shaft axially until it bottoms out within the bearing cover. Measure the end play.

“U” bracket and bearing cover. Seal shim pack to prevent lube leakage. Reinstall bearing cover and cap screws. Torque cap screws to 75-85 Ibs.-ft. (101-115 N.m). Continue axle

assembly as necessary.

Cont’d.

Install the “U” bracket on bearing cover,

If end play is acceptable (see chart), remove

8. If end play is incorrect, change shim pack size as follows:

Add shims to increase end play.

Desired end play . . . . . . . . . . . . . . . . . . . 0.003” to 0.007”

Measured end play (Step 6). . . . . . . . . . . . 0.001” - 0.001”

Add shims to provide desired end play . . . . 0.002” to 0.006”

Remove shims to decrease end play.

Measured endplay (Step 6). . . . .. . . . . . . . . . 0.015” - 0.015”

Desired end play . . . . . . . . . . . . . . . 0.003” to 0.007”

Remove shims to provide desired end play . . . . . . 0.012“ to 0.008”

Recheck end play and adjust as necessary

until end play is within acceptable tolerance.

10.

When end play is correct, remove “U” bracket and bearing cover. Seal shim pack to prevent lube leakage. Reinstall bearing cover

and cap screws. Torque cap screws to 75-85

Ibs.-ft. (101-115 N.m). Continue axle assembly

as necessary.

Note: Air lockout unit not shown.

“U” Bracket Installation

Dial Indicator Mounting Position and Checking

Input Shaft End Play.

Parts Books

Single Reduction Tandem Drive Axles

■ 34,000 —

■ 34,000

45,000 lbs. (340, 380,400, 341, 381, 401, 402, 403, 451) . . . . . .AXIP-0089

45,000 lbs. (344, 404, 454) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXIP-0200

— 52,000 lbs. (With Controlled Traction Differentials) . . . . . . . . . . . .AXIP-0084

Dual Range, Planetary Double Reduction Tandem Drive Axles

■ 34,000

— 45,000 lbs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXIP-0087

Single Reduction, Dual Range, Planetary Double Reduction Tandem Drive

Axles)

■ 46,000 —

65,000 lbs. (Axle Series 461, 521, 581, 601 ,651, 652) . . . . . . . AXIP-0085

(Diff. Lock Models 461,521, 581) . . . . . . . . . . . . . . AXIP-0085A

Spicer Axle Brakes

■ All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..BRIP-0065

Spicer Steer Axles

■

All Models . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXIP-0074

Service Manuals

Single Reduction Tandem Drive Axles

■ 34,000—

■ 34,000 —

■ 44,000 —

45,000 lbs. (Axle Series 340 —

45,000 lbs.

(Axle Series 344, 404, 454) . . . . . . . . . . . . . . . . . . .AXSM-0046

58,000 lbs. (Axle Series 440, 460

402, 451) . . . . . . . . . . . . . . . . . AXSM-0041

— 651) . . . . . . . . . . . . . . . . . AXSM-0042

Dual Range and Planetary Double Reduction Tandem Drive Axles

■ 34,000 —

■ 44,000 —

45,000 lbs. (Axles Series 340 —

65,000 lbs. (Axle Series 440, 460 —

402, 451) . . . . . . . . . . . . . . . . AXSM-0045

651) . . . . . . . . . . . . . . . . . AXSM-0044

Spicer®Axle Brakes

■ EB & ES Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXSM-0033

Spicer®Steer Axles

■

E-1000I, E-1200I, E-1320I, E-1460I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXSM-0038

■

EFA12F3, 12F4, 13F3, 13F5, 20F4, 22T21T5, 24T21T5 . . . . . . . . . . . . . . .AXSM-0037

These publications may all be ordered through the Spicer publications order system. An order form may be obtained by calling Dana

listed on back cover.

Spicer

Service Support. Phone numbers are

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

Spicer Tandem Drive Axle Dual Range Double Planetary User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual