1. Manuals
  2. Brands
  3. DANA Manuals
  4. Industrial Equipment
  5. Spicer AXSM0056
  6. Service manual

DANA Spicer AXSM0056 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Spicer
Single Drive Axles
®
Service Manual
AXSM0056
September 2013
S170 Series
S190 Series
S590 Series

Advertisement

Table of Contents
loading

Related Manuals for DANA Spicer AXSM0056

Summary of Contents for DANA Spicer AXSM0056

  • Page 1 Spicer Single Drive Axles ® Service Manual AXSM0056 September 2013 S170 Series S190 Series S590 Series...
  • Page 2 General Information The description and specifications contained in this service publication are current at the time of printing. Dana reserves the right to discontinue or to modify its models and/or procedures and to change specifications at any time without notice.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Carrier Assembly page 7 Wheel Differential Drive Assembly Pinion page 23 page 12 Seals Housing page 47 Breather page 46 Lubrication page 54 Wheel Differential Lock Wheel page 40 End Seal page 47...
  • Page 4 General Information Introduction ..............1 Model Identification ............. 2-3 Failure Analysis ............4-5 Inspection ................6 Differential Carrier Assembly - Parts........7 Remove Differential Carrier .......... 8-9 Install Differential Carrier ..........10 Remove Wheel Differential (All Standard Models) ..11 Pinion Removal ............12-13 Pinion Assembly - Parts Exploded View ......14 Drive Pinion Overhaul and Assembly ......15-19 Wheel Differential - Parts Exploded View ......

  • Page 5: Introduction

    General Information Introduction Model Information Dana Commercial Vehicle Systems Division, presents this publication to aid in maintenance and overhaul of Spicer The following models are included in this publication: tandem drive axles. Heavy Singles Instructions contained cover the models listed. Their design is...

  • Page 6: Model Identification

    General Information Model Identification Drive Axle Spicer ® CUST. PART NO. SPEC. SERIAL NO. MODEL PART NO. RATIO MADE IN: Spicer ® CUST. PART NO. SPEC. SERIAL NO. MODEL PART NO. RATIO MADE IN: Rear Axle (Top View) 1 - Country or origin 4 - OEM part number assigned to the axle build 2 - Axle model identification 5 - Carrier assembly serial number assigned by the...
  • Page 7 General Information Ring Gear and Pinion Note: Ring gear and drive pinion are matched parts and must be replaced in sets. 41-8 6-39 1 - Part number 2 - Number of ring gear teeth 3 - Manufacturing numbers 4 - Matching gear set number 5 - Number of pinion teeth 6 - Date code 7 - Indicates genuine Spicer parts...

  • Page 8: Failure Analysis

    Inspection Failure Analysis Document the Problem Failure analysis is the process of determining the original cause of a component failure in order to keep it from Here are some guidelines for starting to learn about a failure. happening again. Too often, when a failed component is •...
  • Page 9 Inspection Make a Preliminary Investigation Find the Cause of the Failure These steps consist of external inspections and observations Here begins the real challenge to determine the exact cause of that will be valuable when combined with the results of the the failure.

  • Page 10: Inspection

    Inspection Inspection Clean Note: Replace conventional gaskets with silicone rubber gasket compound (included in many repair kits). The Wash steel parts with ground or polished surfaces compound provides a more effective seal against lube in solvent. There are many suitable commercial seepage and is easier to remove from mating surfaces solvents available.

  • Page 11: Differential Carrier Assembly - Parts

    Differential Carrier Assembly Differential Carrier Assembly - Parts 1 - Carrier fasteners 2 - Carrier assembly 3 - Single axle assembly...

  • Page 12: Remove Differential Carrier

    Differential Carrier Assembly Remove Differential Carrier Note: The removal of the forward carrier does not require dis- connecting of the inter-axle driveline and removal of the output shaft yoke assembly as most other Spicer tan- dems require. Standard Differentials Block the vehicle. Drain axle lubricant.

  • Page 13: Carrier Assembly

    Carrier Assembly After July 2013 Mount the differential carrier in a head stand with 8B. Using a long flat blade screwdriver on a pry bar, the wheel differential facing upward. back off one of the wheel diff. bearing adjusters and remove. Note: For easier disassembly, loosen but do not remove the pinion nut.

  • Page 14: Install Differential Carrier

    Differential Carrier Assembly Install Differential Carrier IMPORTANT Before installing carrier assembly, inspect and thoroughly clean interior of axle housing using an appropriate solvent and clean rag. 1. Apply Spicer approved RTV compound on axle housing mating surface as shown in the illustration. Completely remove all old gasket material prior to applying new material.

  • Page 15: Remove Wheel Differential (All Standard Models)

    Carrier Assembly Remove Wheel Differential (All Standard Models) Carrier Disassembly Remove the shift fork and sliding clutch assembly. For models having the wheel differential lock option or a Note: Do not disassemble the shift fork from the sliding carrier thrust bolt, refer to the following procedure. These clutch unless parts are to be replaced.

  • Page 16: Pinion Removal

    Drive Pinion Pinion Removal If a pilot web is used, remove the web capscrews. Before the pinion nut can be loosened, you must de-stake the nut from the slot of the pinion. For S190 disassembly, install a M10 x 1.50 bolt in the threaded jack holes found in- between the pilot web capscrews.
  • Page 17 Drive Pinion Place carrier assembly into a press, place a 2" x 6" x 6" wood block under the pinion. This will ensure IMPORTANT that when the pinion is pressed free from the bear- ings the pinion will not be damaged. The bearing spacer will be reused or used as a starting point when resetting the pinion bearing preload.

  • Page 18: Pinion Assembly - Parts Exploded View

    Drive Pinion Pinion Assembly - Parts Exploded View 1 - Pinion pilot bearing 5 - Pinion bearing spacer 9 - Yoke 2 - Pinion 6 - Pinion bearing cup - outer 10 - Pinion nut 3 - Pinion bearing cone - inner 7 - Pinion bearing cone - outer 4 - Pinion bearing cup - inner 8 - Oil seal...

  • Page 19: Drive Pinion Overhaul And Assembly

    Drive Pinion Drive Pinion Overhaul and Assembly The preload of the bearings on the drive pinion is adjusted by Remove the inner pinion bearing cone from the pin- a spacer between the inner and outer bearing cones and the ion using a split-type puller. Use two procedure helical gear.
  • Page 20 Drive Pinion If replacement of the output shaft side gear bearing cup is necessa ry, use either of the fol- IMPORTANT lowing methods: Use the correctly sized spacer. Do not use shim stock or Weld: Place a weld bead around the inside of grind spacers.
  • Page 21 Drive Pinion Note: If you are using the same drive pinion, use the same Align a 6” x 6” x 6” wood block under the drive pin- spacer that was originally in stalled in the assembly. If ion, then lower the carrier and pinion assembly into the drive pinion is to be replaced, the original spacer will a press so that it is supported by the block.
  • Page 22 Drive Pinion 12. With 5 tons of force on the press, you should be able 14. Install the drive yoke and pinion nut. to feel a small amount of drag from the bearing as you rotate the carrier. If the carrier turns with no drag at all, the pinion spacer thickness should be decreased by using a thinner spacer.
  • Page 23 Drive Pinion 17. Now remove the pinion nut and yoke and install the pinion seal. Use Spicer’s seal drive (part number WARNING 210749) and drive adapter (part number 131472). Failure to stake the pinion nut properly may result in the nut coming loose during service.

  • Page 24: Wheel Differential - Parts Exploded View

    Wheel Differential Wheel Differential - Parts Exploded View Before July 2013 After July 2013 1 - Threaded bearing adj - flange half 8 - Differential spider 14 - Bearing adjuster - plain half 2 - Bearing cone - flange half 9 - Side gear 15 - Bearing cup - plain half 3 - Bearing cup - flange half...

  • Page 25: Forward Carrier Assembly

    Wheel Differential Wheel Differential Disassembly - Forward Carrier Assembly Before July 2013 IMPORTANT Remove the side gear thrust washers, side pinions During the following procedures, place the and differential spider from the plain half case. differential assembly on a malleable surface to prevent damage when removing components.

  • Page 26: Wheel Differential Assembly

    Wheel Differential Remove the bearing cones from the plain and flange halves in two steps: Mount the puller vertically to split the bearing. This action will start the bearing moving off the differential case. Mount the puller horizontally to remove the cone.

  • Page 27: Wheel Differential Assembly - Forward Carrier Assembly

    Wheel Differential Wheel Differential Assembly - Forward Carrier Assembly Assemble the side pinions onto the wheel differential spider. Apply a thin coat of oil to the mating surfaces IMPORTANT of the side pinion and differential spider. Install the wheel differential nest on top of the side gear. To prevent bearing damage, use suitable sleeve that only contacts the inner race of the cone.
  • Page 28 Wheel Differential Use a rubber mallet to seat the ring gear to the plain Install the ring gear capscrews. half. 10. Tighten the ring gear capscrews with an impact gun Install the flange half of the case. Align the capscrew and then use a torque wrench to torque to the proper holes.

  • Page 29: Install Wheel Differential Assembly - Forward Carrier Assembly

    Wheel Differential Install Wheel Differential Assembly - Forward Carrier Assembly Set Backlash and Bearing Preload Connect the adjuster plates using the threaded rod, washers and nuts. Tighten the nuts on the rod to Note: To install the wheel differential assembly, properly setup hold the threaded cups in place.
  • Page 30 Wheel Differential Make sure that the bearings cage is parallel to the Turn the plain half adjuster ring until there is zero edge of the threaded cup. preload on the bearings. This is done by turning the adjuster plate clockwise until you feel the threaded cup gain resistance.
  • Page 31 Wheel Differential Use a rubber mallet to fully seat the threaded bearing 12. Install the carrier differential bearing caps and cap- cups. screws. Make certain there is no gap between the carrier cap and the carrier surface. With a dial indicator, check the ring and pinion back- 13.
  • Page 32 Wheel Differential 15. Measure the ring gear total radial runout. Indicator 18. With the carrier mounted in a head stand, roll the reading should not exceed 0.010" (0.25 mm). carrier on its side. 16. Measure the ring gear total backface runout. Indicator reading should not exceed 0.010"...
  • Page 33 Wheel Differential 21. Use the correct socket and a breaker bar to rotate the 22. When contact pattern is correct, use a punch with a differential. The differential should be hard to turn. round head to stake the threaded bearing cups in Rotate the pinion until the ring gear rotates 3 or 4 place.

  • Page 34: Forward Carrier Assembly

    Wheel Differential Wheel Differential Disassembly - Forward Carrier Assembly After July 2013 IMPORTANT 3. Remove the side gear thrust washers, side pinions During the following procedures, place the and differential spider from the plain half case. differential assembly on a malleable surface to prevent damage when removing components.
  • Page 35 Wheel Differential Remove the bearing cones from the plain and flange halves in two steps: Mount the puller vertically to split the bearing. This action will start the bearing moving off the differential case. Mount the puller horizontally to remove the cone.

  • Page 36: Wheel Differential Assembly - Forward Carrier Assembly

    Wheel Differential Wheel Differential Assembly - Forward Carrier Assembly 4. Assemble the side pinions and thrust washers onto the wheel differential spider. Apply a thin IMPORTANT coat of oil to the mating surfaces of the side pinion and differential spider. Install the To prevent bearing damage, use suitable sleeve that only wheel differential nest on top of the side gear contacts the inner race of the cone.
  • Page 37 Wheel Differential Use a rubber mallet to seat the ring gear to the plain Install the ring gear capscrews. half. 10. Tighten the ring gear capscrews with an impact gun Install the flange half of the case. Align the capscrew and then use a torque wrench to torque to the proper holes.
  • Page 38 Wheel Differential 11. Lower assembled differential assembly in to the carrier using a hoist and a strap. Be careful not to damage the differential bearings lowering the assembly. 12. Install the bearing cup and bearing adjuster to the flange half side first. 1 - Flange Half 2 - Plain Half 13.

  • Page 39: Install Wheel Differential Assembly - Forward Carrier Assembly

    Wheel Differential Install Wheel Differential Assembly - Forward Carrier Assembly Backlash and Bearing Preload 1. Turn the flange half bearing adjuster in until the ring Tighten the plain half adjuster two lug notches. gear contacts the pinion (zero backlash) then back Start with the notch at the top, count two notches the adjuster out two notches of the adjuster lugs.
  • Page 40 Wheel Differential 6. Install the carrier differential bearing caps and cap- 9. Measure the ring gear total radial runout. Indicator screws. Make certain there is no gap between the reading should not exceed 0.010" (0.25 mm). carrier cap and the carrier surface. 10.
  • Page 41 Wheel Differential 13. Make a sling out of a strap and position around the plain half of the wheel differential. 14. Connect the end of the strap to a hoist and apply pressure to the sling. 15. Use the correct socket and a breaker bar to rotate the differential.

  • Page 42: Adjust Tooth Contact Position

    Ring Gear Adjust Tooth Contact Position Adjust Ring and Pinion Tooth Contact Pattern Used Gearing - Correct Pattern Used gearing will not usually display the square, even con- Note: Rear axle gearing is shown in the following instruc- tact pattern found in new gear sets. The gear will normally tions.
  • Page 43 Ring Gear Adjust Ring Gear Position (Backlash) If the gear pattern shows incorrect face width contact, change backlash by adjusting the ring gear. If the pattern is too close to the edge of the tooth toe, move the ring gear away from the pinion to increase backlash. Loosen the bearing adjuster on the teeth side of the ring gear several notches.

  • Page 44: Wheel Differential Lock - Parts Exploded View

    Wheel Differential Lock Wheel Differential Lock - Parts Exploded View 1 - Sliding clutch 5 - Piston 9 - Switch 2 - Spring 6 - O-ring 10 - Roll pin 3 - Shift Fork 7 - Piston cover 4 - Push rod 8 - Washer...

  • Page 45: Install And Adjust Wheel Differential Lock

    Wheel Differential Lock Install and Adjust Wheel Differential Lock Note: With differential carrier completely assembled and adjusted, install differential lock as follows: 1. If shift fork and sliding clutch are disassembled, engage fork with the clutch hub and install spring pin in the fork leg.

  • Page 46: Housing And Output Shaft Assembly - Parts Exploded View

    Output Shaft Assembly & Rear Cover Housing and Output Shaft Assembly - Parts Exploded View 1 - Jam nut 6 - Breather hose 10 - Stud 2 - Locking ring 7 - Carriage capscrew 11 - Drain plug 3 - Spindle nut 8 - Nut 12 - Axle shaft 4 - Axle housing...

  • Page 47: Replace Seal

    Seal - Replace Replace Seal Spicer strongly recommends using seal drivers when installing Remove the new seal from its package and install new seals. Use the proper driver to make sure that the seal is with the proper driver : square and installed to the proper depth.
  • Page 48 Seal - Replace Guidelines for Reusing Yoke CAUTION Do not use the yoke if it has any damage on the seal surface (nicks or scratches). The surface of the yoke and the lips of the seal form a critical interface which retains the axle’s lubricant while sealing the axle from outside contaminants.

  • Page 49: Service Kit

    Seal - Replace Service Kit R-Pinion Location Tool 210749 131472...

  • Page 50: Housing Breather

    Housing Breather Housing Breather Spicer has an axle breather that consists of a fitting, hose Insert hose onto fitting, long end down. and clamp assembly. This breather design has improved resistance to water ingestion, clogging caused by dirt, ice or snow buildup around the base of the breather.

  • Page 51: Wheel End Seal - Parts Exploded View

    Wheel End Seal Wheel End Seal - Parts Exploded View 1 - Installation tool 2 - Seal 3 - Rear hub...

  • Page 52: End Seal

    Wheel End Seal Remove and Overhaul Wheel End Seal Install Wheel End Seal WARNING Before installation, lubricate the following with the same lubricant used in the axle sump. Never work under a vehicle supported by only a jack. Always support vehicle with stands. Block the wheels and •...

  • Page 53: Adjust Wheel Bearing

    Wheel End Seal Adjust Wheel Bearing WARNING CAUTION Do not mix spindle nuts and lock washers from different Never use an impact wrench to adjust wheel bearings. A systems. Mixing spindle nuts and lock washers can cause torque wrench is required to assure that the nuts are prop- wheel separation.
  • Page 54 Wheel End Seal b. Install the outer nut on the spindle and tighten Four-piece Tang/Dowel-type Lock Washer System to 350 lbs. ft. (475 N•m). c. Verify endplay. Three-piece Tang-type Lock Washer System 1 - Inner Nut 2 - Dowel Pin 3 - Dowel-type Lock Washer 4 - Tang-type Lock Washer 1 - Inner Nut...

  • Page 55: Verify Wheel Endplay Procedure

    Wheel End Seal Verify Wheel Endplay Procedure Readjust Wheel Endplay Procedure Verify that endplay meets specification using a dial indicator. An indicator with 0.001" (0.03 mm) resolution is required. Excessive Endplay— If end-play is greater than 0.005" Wheel endplay is the free movement of the tire and wheel (.127 mm), remove the outer nut and pull the lock washer assembly along the spindle axis.

  • Page 56: Lubricate Wheel End

    Wheel End Seal Lubricate Wheel End Wheel Ends with an Oil Fill Hole Rotate the wheel end hub until the oil fill hole is up. CAUTION Rem ove the oil fill plug. Before operating the axle, the wheel hub cavities and bear- ings must be lubricated to prevent failure.
  • Page 57 Wheel End Seal Wheel Ends Without Oil Fill Hole Raise the left side of the axle 6" or more. Hold axle in this position for one minute. With axle level and wheel ends assembled, add lubri- cant through filler hole in axle housing cover until Lower the left side.

  • Page 58: General Lubrication Information

    MILSPEC, as demonstrated by extensive laboratory and field testing. For a complete list of Spicer approved synthetic lubricants contact your local Dana representative. See back cover of this manual for appropriate phone number. Makeup Lube—Maximum amount of non-synthetic makeup lube is 10%.

  • Page 59: Lube Change Intervals

    Lubrication Lube Change Intervals This product combines the latest manufacturing and part Severe Service Lubrication Change Intervals – Severe service washing technology. When filled with an Spicer approved applications are those where the vehicle consistently synthetic lubricant at the factory, the initial drain is not operates at or near its maximum GCW or GVW ratings, dusty required.

  • Page 60: Change Lube

    Lubrication Change Lube Drain Note: Lube fill capacities (see chart) are basic guidelines and will vary based on the angle the axle is installed in a par- Drain when the lube is at normal operating temperature ticular chassis. Torque fill plug to 40–60 lbs. ft. (150°–200°F).

  • Page 61: Standpipes

    Lubrication Standpipes Drive axles are lubricated with oil drawn from a large sump integral to the assembly. Most axle designs attempt to posi- tion vital components such as pinion bearings in close prox- S190 imity to this sump, keeping them bathed in a generous supply of oil at all times.
  • Page 62 Lubrication 12° Installation Tandem Rear Axles Installation 5-10% 10-15% 15-20% Angle* Grade Grade Grade 0° – – – 3° – – 1.00" 5° – 1.00" 1.75" 7° – 1.75" 2.00" 1 - Oil Filler Hole 10° – 2.00" 2.25" 2 - Lost Oil Capacity 13°...

  • Page 63: Drive Pinion

    Towing Guide Proper Vehicle Towing Without Wheel Differential Lock With Wheel Differential Lock Lift the drive wheels completely off of the ground or damage Follow this procedure to remove all axle shafts preventing will occur. gear rotation with the drive wheels and possible lubrication damage: Engage the wheel differential lock, indicator light is WARNING...

  • Page 64: Power Divider Operation (Power Flow And Torque Distribution)

    Theory of Operation Power Divider Operation (Power Flow and Torque Distribution) In operation, the power divider accepts torque from the The inter-axle differential compensates for minor variations vehicle driveline and distributes it equally to the two axles. in speed between the two axles, the same way the wheel differential works between the two wheels of a single drive This assembly is of the two-gear design consisting of an axle.
  • Page 65 Theory of Operation With Lockout Engaged Note: Varied road surface conditions can result in unequal (Inter-Axle Differential is Not Operating) torque distribution between the two axle assemblies. Lockout should only be engaged when both axles are rotat- ing at the same speed. Operation should be limited to low- traction situations and should be disengaged when normal CAUTION CAUTION...

  • Page 66: Operate Wheel Differential Assembly

    Theory of Operation Operate Wheel Differential Assembly The Spicer wheel differential lock is driver-controlled and Direct Driver-controlled System operated by a carrier mounted air-actuated shift unit. In The driver manually locks and unlocks the wheel differen - operation, it po sitively locks the wheel differential to pro - tial, using a cab-mounted electric switch (or air valve).

  • Page 67: Direct Driver-Controlled System

    Theory of Operation Direct Driver-Controlled System 1 - Cab-mounted control val ve (plunger in—valve open) 9 - Forward rear axle wheel differential lock air shift cylinder 2 - Dry air supply tank 80–120 PSI (part of axle assembly) 3 - Preferably equal in length 10 - Wheel differential lock indicator switch 4 - Power supply (part of axle assembly)

  • Page 68: Wheel Differential Lock

    Theory of Operation Wheel Differential Lock The Spicer Wheel Differential Lock is an optional feature for The wheel differential lock co nsists of three major assem- spicer Axles. In operation, it positively locks the wheel differ - blies . ential, to provide improved traction under adverse road •...
  • Page 69 Theory of Operation Differential Lock Engaged Differential Lock Engagement Indicator Air pressure applied to the shift cylinder moves the piston, Differential lock engagement is detected by a switch (elec- push rod, shift fork and the sliding curvic clutch engages tric) mounted on the differential carrier. An actuator, the fixed curvic clutch.

  • Page 70: Pinion Assembly - Parts Exploded View

    Parts Identification Pinion Assembly - Parts Exploded View 1 - Pinion pilot bearing 5 - Pinion bearing spacer 9 - Yoke i n i i n i i r a r e t i n i 3 - Pinion bearing cone - inner 7 - Pinion bearing cone - outer 4 - Pinion bearing cup - inner 8 - Oil seal...

  • Page 71: Wheel Differential - Parts Exploded Views

    Parts Identification Wheel Differential - Parts Exploded View Before July 2013 After July 2013 1 - Threaded bearing adj - flange half 8 - Differential spider 13 - Bearing adjuster - plain half 2 - Bearing cone - flange half 9 - Differential case - RH (plain half) 14 - Bearing cup - plain half 3 - Differential case LH (flange half)

  • Page 72: Wheel Differential Lock Assembly - Parts Exploded Views

    Parts Identification Wheel Differential Lock Assembly - Parts Exploded View 1 - Sliding clutch 5 - Piston 9 - Switch 2 - Spring 6 - O-ring 10 - Roll pin 3 - Shift Fork 7 - Piston cover 4 - Push rod 8 - Washer...

  • Page 73: Housing And Output Shaft Assembly - Parts Exploded View

    Parts Identification Housing and Output Shaft Assembly - Parts Exploded View 1- Jam Nut 5 - Breather 9 - Lock washer 2 - Locking ring 6 - Breather hose 10 - Stud 3 - Spindle nut 7 - Carriage capscrew 11 - Drain plug 4 - Axle housing 8 - Nut...

  • Page 74: Fastener Torque Specifications

    Fastener Torque Specifications Fastener Torque Specifications Location Size Lbs. Ft. • POWER DIVIDER Input Cage Locking Bolt M8 x 1.0 x 30 20 ± 5 25 ± 5 IAD Shift End Cap 2.375 - 16 UN-2A 65 ± 10 85 ± 15 Power Divider Cover Capscrews M14 x 1.5 x 45 175 ±...
  • Page 76 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.

Table of Contents