DANA Spicer Drive Axles Service Manual
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DANA Spicer Drive Axles Service Manual

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Spicer
Drive Axles
®
Service Manual
AXSM0029
September 2007

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Summary of Contents for DANA Spicer Drive Axles

  • Page 1 Spicer Drive Axles ® Service Manual AXSM0029 September 2007...
  • Page 2 The description, testing procedures, and specifications contained in this service publication were current at the time of printing. Dana reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice and without incurring obligation.

  • Page 3: Table Of Contents

    Table of Contents Electric Shift System Air Shift System Introduction Air Shift System Electric Shift System ......1 Description .

  • Page 4: Electric Shift System

    Electric Shift System Introduction The service procedures and specifications in this publication If, during rotation, driver decides to switch back to low range, cover the current Spicer 2-Speed Axle Shift Systems. motor continues to turn. ELECTRIC SHIFT UNIT CUTAWAY Maintenance and overhaul instructions for the Spicer 2-Speed Wiring Harness and Connector Axle carriers are covered in the publications listed on the back...

  • Page 5: Mechanical Operation

    Electric Shift System Mechanical Operation As motor shuts off at 180º of gear rotation, a break in torque by driver allows spring force (stored in the slider block Low to High Range or High to Low Range assembly) to move the swivel pin and shift fork in appropriate When shifting axle range either up or down, motor starts and direction for axle range change.
  • Page 6 Electric Shift System Shift System Electrical Wiring Schematic Circuit Board Resistor Ground Up-High Range Power Source Black (Ignition or Switches Down-Low Accessory Switch) Switch Knob Range Motor High Range Ground Range NO NC NC NO Control Switch Housing Circuit Wiring Cover Breaker Harness...
  • Page 7 Electric Shift System Slider Block Inspection Procedure Bottom of Base Housing • Remove shift unit from axle. • Move slider block from side to side. Make sure slider block moves freely in housing.

  • Page 8: Troubleshooting

    Electric Shift System Troubleshooting Troubleshooting Guide This chart begins with an improperly operating shift unit. Use with illustrations on pages 3, 4 and 6 to help isolate the problem. Follow the possible solutions as an aid to system repair. Axle doesn’t shift ranges. •...
  • Page 9 FORWARD-REAR AXLE Procedure: 1. Shift axle to high range so fork is square to axle face. Dana service keeps 2. Remove shift unit and rubber boot. you on the road. Figure 1 3. Drop card over shift unit as shown in (fig.
  • Page 10 Electric Shift System Parts Service Kits Expanded Service Kits Note: The new and improved housing cover does NOT require a gasket (see page 17). SERVICE KIT NO. DESCRIPTION ITEMS INCLUDED 211319 Circuit Board and Cover Kit 1-7, 18-19 113745 Motor and Lube Kit 10, 18-19 113746 Drive Gear and Cam Pin Kit...

  • Page 11: Shift Unit Removal/Disassembly

    Electric Shift System Shift Unit Removal/Disassembly Remove Shift Unit Lift out slider block and shaft assembly. Slider Block Shift axle to low range and park vehicle. Disconnect wiring harness at shift unit. Shaft Assembly Remove nuts, flat washers and shift unit from car- rier.

  • Page 12: Remove Circuit Board And Motor

    Electric Shift System Remove Circuit Board and Motor Remove circuit board mounting washer. Remove cap screws fastening cover to motor hous- ing. Remove Note: Gasket compound may cause cover to stick to housing. Circuit Board If necessary, carefully pry it loose, using a thin-blade Washer screwdriver.

  • Page 13: Remove Gear And Cam Pins

    Electric Shift System Remove Gear and Cam Pins Cleaning Remove gear locknut. Use deep-well socket while After shift unit disassembly, clean all parts (with exception of holding shaft end with locking pliers. the motor and circuit board), in a suitable commercial solvent. Remove ground lead wire.

  • Page 14: Shift Unit Assembly/Installation

    Electric Shift System Shift Unit Assembly/Installation Install Cam Pins and Gear Lubricate both sides of gear washer and gear face that contacts gear washer. Note: Use “Rheolube 362” lubricant during following reas- sembly procedures. Use of other lube types may cause operational problems under certain low temperature conditions.

  • Page 15: Install Slider Block

    Electric Shift System Connect ground lead wire. Install gear locknut. While Also fill the cavity next to the gear with lubricant holding shaft end with locking pliers, torque locknut. (cavity adjacent to motor shaft hole). SLIDER BLOCK LUBRICATION Connect ground Install gear lead wire locknut...

  • Page 16: Install Motor

    Electric Shift System Install Motor With housing mating surfaces clean, apply a contin- uous bead of approved gasket compound around the Apply a continuous bead of approved gasket com- outer edge of the base housing. Align the dowel pin pound on motor base around motor shaft and lead with hole in motor housing and assemble the two wire.

  • Page 17: Install Circuit Board

    Electric Shift System Install Circuit Board Install circuit board on gear shaft and install locknut. Torque locknut. Install circuit board washer on gear shaft and on top of gear locknut. IMPORTANT Install circuit IMPORTANT: If a new housing cover is required, install the board washer improved cover (see page 17 for instructions).

  • Page 18: Install Shift Unit

    Electric Shift System Install Shift Unit Place cover in position on motor housing and install cap screws. Torque cover cap screws. Note: Before installation, place shift unit in low range. This can be accomplished by connecting chassis wiring har- ness to shift unit cover and operating control switch (in cab), or apply 12-volt power supply to low range and Red Wire ground terminals in shift unit cover (see wiring sche-...

  • Page 19: Shift Unit Retrofit Kits

    Procedure: 1. Shift axle to high range so fork is Remove existing shift unit. square to axle face. Dana service keeps 2. Remove shift unit and rubber boot. you on the road. 3. Drop card over shift unit as shown Remove and discard seal and spring.

  • Page 20: Servicing Other Electric System Components

    Electric Shift Sytem Servicing Other Electric System Components Installation of Improved Motor Housing CAUTION Cover (Production units effective Decem- CAUTION: When removing material, use care to avoid filing ber 1989) into the threads of the motor mount fastener. See Detail Below The new cover (PN 113786) has a continuous sealing lip around the outside edge which improves sealing against road Interference Area...

  • Page 21: Speedometer Adapter

    Electric Shift Sytem Speedometer Adapter The speedometer adapter is lubricated and sealed for life of the unit. No maintenance is required. Replace a faulty unit. Install long screw from kit in this location Control Switch For inspection or replacement, the control switch can easily Install 3 previously removed screws be removed by sliding the rubber boot up to the knob, then in these locations...

  • Page 22: Air Shift System

    Air Shift System Air Shift System * For Vehicles Not Equipped with + For Vehicles with Automatic Safety Brakes Transmission Drive Speedometers Axle Shift Unit Quick Release Valve +Speedometer Adapter Exhaust 2-Speed Air Shifter Valve + Pressure Switch (normally closed) * Solenoid Valve White Dry Air Tank...

  • Page 23: Air Shift Unit

    For additional information con- The Air Shift Unit is engineered for efficient performance and tact Dana Service Support. built for reliable, service-free operation. Note: Air Shift Units are also used on Spicer Controlled Trac- Operation of the unit is as follows: The shift unit is mechani- tion Differential and Dual Range Tandem Axles.

  • Page 24: Troubleshooting

    Air Shift System Troubleshooting Check for Air Leaks Make sure valve has a good ground connection to the frame. With power at valve, check operation as follows: A simple method for quickly locating troubles in the system is to listen for possible air leaks and for sound which would indi- Disconnect lead wire and air line outlet at valve cate shift unit operation.

  • Page 25: Shift Unit Removal/Disassembly

    Air Shift System Shift Unit Removal/Disassembly Remove Shift Unit Remove compression spring and piston stop from bore of shift unit housing. Disconnect air line at shift unit cover. Remove nuts, flat washers and piston air shift unit from differential carrier. Compression Note: When shift unit is removed, provide container to catch Spring...

  • Page 26: Lubrication

    Air Shift System Lubrication Parts Inspection Lubricant — Use SAE 10 motor oil* for temperatures above Shift Fork Seal — Inspect shift fork seal for defects and tight 0° F (-18° C). For temperatures below 0° F (-18° C), mix three fit on shift fork.

  • Page 27: Shift Unit Assembly/Installation

    Air Shift System Shift Unit Assembly/Installation Assemble Shift Unit Apply pressure to piston until actuating lever is in alignment with push rod end. Install clevis pin. Note: Prior to assembly, the piston felt oilers should be Release press. soaked in SAE 10 oil for one hour. Lubricate “0” rings with a high viscosity silicone oil or barium grease “0”...

  • Page 28: Install Shift Unit

    Air Shift System Install Shift Unit Lubricate shift fork. Slide seal and spring assembly over fork and place on differential carrier studs. Place shift unit on mounting studs and make certain shift fork actuating lever engages slot in shift fork. Install flat washers and stud nuts.

  • Page 29: Air Shifter Valve Removal/Disassembly

    Air Shift System Air Shifter Valve Removal/Disassembly Remove/Disassemble Air Shifter Valve Inspection/Lubrication Each 50,000 miles, disassemble, inspect and clean, then CAUTION lubricate moving parts with barium-base grease. No other type lubricant should be used. CAUTION: Air supply to valve must be shut off before the valve is serviced.

  • Page 30: Air Shifter Valve Assembly/Installation

    Air Shift System Air Shifter Valve Assembly/Installation Assemble/Install Air Shifter Valve Hold shifter plate in position with one hand, then install spring and shifter knob. Install cover and fas- If housing was removed, install jam nut on shift ten with screw. lever.

  • Page 31: Servicing Other Air System Components

    Air Shift System Servicing Other Air System Components Speedometer Adapter Quick Release Valve The speedometer adapter is lubricated and sealed for life of If quick release valve fails to operate properly, it may be repaired as follows: Disassemble valve. Inspect valve body, the unit.

  • Page 32: Additional Service Information

    Shift Systems Additional Service Information Service information on 2-Speed Axle shifting components may be found in the appropriate Axle Service Publications. Parts Information Complete information for identifying replacement parts for 2- Speed Shift Systems may be found in the appropriate Parts Publications.
  • Page 33 For spec‘ing or service assistance, call 1-877-777-5360 or visit our website at www.dana.com Dana Commercial Vehicle Products Group 3939 Technology Drive Maumee, Ohio, USA 43537 www.dana.com All applications must be approved by the Application Engineering Department. Specifications and/or design are subject to change without notice or obligation.

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