Spicer Drive Axles Service Manual

Spicer ® 

Drive Axles 

Service Manual 

Spicer 

AXSM-8942 

September 2007 

® Drive Axles

TABLE ABLE OF OF CONTENTS 

CONTENTS 

CONTENTS 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 

Axle Identification 2 

Model Identification Numbering System 3 

Gear Set Identification 3 

Axle Lubricant Recommendations 4 

General Precautions 5 

Standard Axle Components 6 

Pinion-Up Axle Components 7 

Removal of Differential Carrier from Axle Housing 8 

Removal of Differential from Carrier 9 

Differential Disassembly 10 

Pinion Disassembly 12 

Cleaning and Inspection 13 

Pinion Assembly 14 

Pinion Position 17 

Differential Assembly 19 

Differential Installation 20 

Ring Gear and Pinion Tooth Contact Pattern 21 

Installation of Carrier into Axle Housing 22 

Fastener Torques and Axle Specifications 23 

Driver Controlled Differential Lock 24 

Driver Controlled Differential Lock Components 25 

Towing Procedures/Instructions 26 

Carrier Removal 27 

Removal of Diff-Lock Assembly 28 

Installation of Diff-Lock Assembly 29 

Carrier Installation 30 

Checking Differential Lock Operation 31 

Recommended Service Tools 32 

GENUINE GENUINE SPICER SPICER SER SERVICE SER SERVICE 

VICE P PPAR 

P PAR 

AR ARTS AR TS 

Should an axle assembly require replacement component 

parts, it is recommended that Spicer Heavy Axle 

Service Parts be used. Spicer Heavy Axle Service Parts 

are manufactured under the same rigid specification as 

are original equipment axle components. This assures 

the customer who uses genuine Spicer service parts, 

maximum reliability for a Spicer Heavy Axle assembly. 

They may be obtained through your vehicle manufacturer. 

The use of non-original Spicer service parts may 

cause premature component failure and may void the 

warranty. 

1 

The items included in this book are currently being 

offered as service parts at the time of printing. The 

part numbers and illustrations are provided specifically 

for reference purposes only. Therefore, Spicer reserves 

the right to update this manual without notice or 

liability.

All axle assemblies are identified with two tags. One 

located on the differential carrier, and the other located 

on the right hand side of the axle housing. 

The differ differential differ ential carrier carrier t ttag 

t ag contains the following: 

Dana part number, julian date code, and ratio. Optional 

items include customer part number, line set number, and 

the last six digits of the vehicle serial number. 

DANA ANA P PPAR 

P PAR 

AR ART AR 

NUMBER 

NUMBER 

CUS CUS CUSTOMER 

CUS OMER 

PAR AR ART AR T NUMBER 

NUMBER 

(OPTIONAL) 

(OPTIONAL) 

Axle Assembly Tag 

LAS LAS LAST LAS LAS T SIX SIX DIGITS DIGITS OF OF 

OF 

VEHICLE VEHICLE SERIAL SERIAL NUMBER 

NUMBER 

(OPTIONAL) 

(OPTIONAL) 

Pinion Below 

Center 

MODEL 

MODEL 

JULIAN JULIAN D DDATE 

D TE 

CODE 

CODE 

LINE LINE SET 

SET 

NUMBER 

NUMBER 

(OPTIONAL) 

(OPTIONAL) 

2 

MODEL MODEL MODEL YEAR 

YEAR 

DANA ANA P PPAR 

P AR ART AR 

NUMBER 

NUMBER 

AXLE AXLE IDENTIFICA 

IDENTIFICA 

IDENTIFICATION 

IDENTIFICA TION 


D TE CODE CODE 

CODE 

96 96 0 0070 

0 

CUS CUS CUSTOMER 

CUS CUS OMER OMER 

PAR AR ART ART 

T NUMBER 

NUMBER 

(OPTIONAL) 

(OPTIONAL) 

(OPTIONAL) 

Carrier Tag 

LAS LAST LAS T SIX SIX DIGITS DIGITS OF OF 

OF 

VEHICLE VEHICLE SERIAL SERIAL NUMBER 

NUMBER 

(OPTIONAL) 

(OPTIONAL) 

Pinion Above 

Center 

DAY Y OF OF YEAR YEAR 

YEAR 

LINE LINE SET SET 

SET 

NUMBER 

NUMBER 

(OPTIONAL) 

(OPTIONAL) 


D TE 

CODE 

CODE 

The axle axle a aassembl 

a assembl 

ssembl ssembly ssembl y tt 

tag t ag contains the following items: 

Dana part number, julian date code, axle model, and ratio. 

Optional items include customer part number, line set 

number, and the last six digits of the vehicle serial number.

MODEL MODEL MODEL IDENTIFICA 

IDENTIFICA 

IDENTIFICATION IDENTIFICA TION NUMBERING NUMBERING NUMBERING SYSTEM 

SYSTEM 

Family 

(S = Spicer) 

Nominal Load 

Carrying Capacity 

(230 = 23,000 Lbs.) 

(260 = 26,000 Lbs.) 

GEAR GEAR SET SET IDENTIFICA 

IDENTIFICA 

IDENTIFICATION 

IDENTIFICA 

IDENTIFICA TION 

Man Manufactur Man ufactur ufacturer's ufacturer's 

er's Da Date- Da e- Date gear set was made. 

Spicer Spicer Spicer T TTrademark 

T ademark ademark- ademark - Company logo and location of 

manufacturing facility. 

300GP2 00GP2 00GP203- 00GP2 3- Part number of pinion gear. (TYPICAL) 

Too oo ooth oo th Combina Combination(i.e. Combina tion(i.e. 4 441-1 

4 1-1 1-11)- 1-1 1)- Indicates the pinion 

has 11 teeth and the ring gear has 41 teeth which 

results in a 3:73:1 ratio. 

Ma Ma Matched Ma tched Se Se Set Se t Number Number Number- Number - Spicer ring gears and pinions 

are manufactured as matched sets. Both ring gear and 

pinion are marked with a corresponding number (i.e. 

260), which identifies them as a matched set. 

A gear set that does not have the same match set 

numbers should not be run together. If either ring gear 

or pinion require replacement, a new matched set must 

be used. 

Backla Backlash Backla sh Etch- Etch- Indicates backlash setting for assembly. 

Pinion Pinion Etch- 

Etch- Indicator for proper pinion position shim 

stack up. See See Pinion Pinion P PPosition 

P osition Section. Section. 

Section. 

S 230 S L 

Gearing Type 

(S = Single Reduction) 

3 

41-11 

TOOTH 

COMBINATION 

SPICER 

TRADEMARK 

PART 

NUMBER 

Options 

(N = *No-SPIN ® Differential) 

(L = Driver Controlled Diff. Lock) 

(B = Bus) 

HEAT 

CODE 

* No-SPIN ® is a registered trademark of Tractech 

SPICER 

TRADEMARK 

PINION ETCH 

MFG. 

DATE 

L10 

+15 

260 

BACKLASH ETCH 

MATCHED 

SET NUMBER 

260

To ensure proper lubrication and operating temperature, 

correct lubricants and lubricant levels must be obtained. 

RECOMMENDED GEAR LUBRICANTS 

Mineral or Synthetic based hypoid gear lubricants that 

meet or exceed military specification MIL-L-2105D, and 

API service classification GL-5, are the minimum requirements 

for use in Spicer Medium and Heavy Duty Drive 

Axles. 

The table below indicates which SAE viscosities are 

recommended for various temperature ranges the vehicle 

will encounter. 

Cº 

Fº 

-40 

-40 

SAE 140 

SAE 85W-140 

SAE 90 

SAE 80W-140 

SAE 80W 

SAE 75W-140 

SAE 75W-90 

SAE 75W 

-26 

-12 

-15 +10 

0 

+32 +40 

SERVICE 

Recommended lubricant change intervals are dependent 

on the application and operating environment. The 

following chart should be used to establish proper 

change intervals. 

+4 

+15 

+60 

+27 

+80 

AMBIENT AIR TEMPERATURE 

SUBMERSION OR DEEP WATER FORDING 

+38 Cº 

+100 

In the event the carrier housing should become 

submerged in water, particularly if over the vent or 

breather, it is recommended that the lubricant be 

drained and all internal parts be inspected for water 

damage and/or contamination. Reassemble the carrier to 

the housing and refill with specified gear lubricant. 

Fº 

AXLE XLE LUBRICANT RECOMENDATIONS 

4 

PETR 

PETROLEUM PETR OLEUM OLEUM B 

BASED B 

B 

ASED S 

SYNTHETIC S 

YNTHETIC B 

BASED** 

B 

ASED** 

APPLICA 

APPLICA 

APPLICATION 

APPLICA 

APPLICA 

TION 

TION 

MILES MILES INTER 

INTERVAL INTER 

AL MILES MILES MILES INTER 

INTERVAL 

INTER 

INTER 

AL 

On Highway 100,000 1 Year 250,000 3 Year 

* * Severe Service 

and 50,000 1 Year 100,000 1 Year 

On-Off Highway 

* Severe service includes any applications operating at 

or near maximum GVW or GCW ratings. This 

includes normally wet or dusty environment, or 

consistent high load and low speed applications. 

** Includes Semi-Synthetic blends that meet 

MIL-L-2105D specifications. 

AFTER OVERHAUL OR CHANGE INTERVALS 

Fill the axle assembly to the bottom of housing fill hole as 

shown in the illustration below. It is recommended that 

following an overhaul, each side of the axle be jacked up 

seperately to approximately six inches and held into 

position for one minute. This procedure will allow 

adequate lubricant to flow into the wheel ends and help 

eliminate the possibility of premature damage to wheel 

bearings and seals. Lower the vehicle to the floor and 

allow ten minutes for lube to return to normal level. Check 

and refill assembly to bottom of fill hole to replace the 

lubricant that was directed into the wheel ends. 

NO NOTE: NO TE: Lubricant close enough to the bottom of the fill hole to be seen or 

touched is not sufficient. Lubricant must be level with the fill hole.

GENERAL GENERAL PRECAUTIONS 

PRECAUTIONS 

GENERAL AXLE DESCRIPTION 

This manual covers maintenance and rebuild procedures 

for the Spicer S230-S, S230-SL, and S260-SB rear drive 

axle assemblies. 

The Spicer Heavy Duty Single Reduction rear drive axle 

is a full floating axle assembly, with a hypoid gear carrier 

assembly, using a High Strength Low Alloy (HSLA) steel 

axle housing. The hypoid pinion is straddle mounted 

with two tapered roller bearings behind the pinion teeth 

for thrust and radial loads. A pilot bearing is located on 

the nose of the pinion for radial load. The differential 

itself uses four precision forged pinion mate gears, a 

forged cross, and precision forged side gears. 

SAFTEY PRECAUTIONS 

Safety Safety Safety glasses glasses should should be be wor worn wor 

at at all all all times times when when assembling 

assembling 

or or disassembling disassembling axles. 

axles. 

Proper service and repair of vehicle components is 

important to the safe and reliable operation of all motor 

vehicles. This applies particularly to driving axles such as 

the ones described in this manual. The procedures 

recommended and described in this manual are tested, 

effective methods for performing service operations. 

Follow each procedure closely, making use of both the 

text and illustrations. Some of these service procedures 

show the use of certain tools designed specifically for 

the operation being performed. They are shown as a 

preferred means of performing the operation. It is not 

practical to anticipate and advise the service trade of all 

possible alternative methods, and of all possible hazardous 

consequences that could occur. 

IMPOR IMPORTANT 

IMPOR ANT 

READ READ READ THIS THIS SECTION SECTION BEFORE BEFORE ST STAR ST AR ARTING AR TING 

ANY ANY SER SERVICE SER VICE PROCEDURES 

PROCEDURES 

5 

Accordingly, anyone who uses a service procedure or tool 

different than shown must insure that their safety, and 

the vehicle's safety, will not be jeopardized by the service 

method selected. 

END YOKES AND FLANGES 

CA CAUTION: CA UTION: Hammering Hammering on on end end y yyok 

y ok okes ok s can can close 

close 

in in the the bearing bearing bor bores bor s s or or misalign misalign misalign y yyok 

y ok oke ok e lugs lugs and and r rresult 

r sult 

in in in earl early earl y failur failur failures failur failur s of of journal journal needle needle bearings bearings bearings or or o oother 

o other 

ther 

driv driveline driv eline component components. component s. Serious Serious damage damage can can also also be 

be 

done done int internall int internall 

ernall ernally ernall y t tto 

t o the the ring ring and and pinion pinion pinion se se set se t or or pinion 

pinion 

bearings bearings bb 

by bb 

y hammering hammering on on e eext 

e xt xternal xt ernal par par parts. par s. End End y yyok 

y ok okes ok 

or or companion companion companion flange flanges flange flanges 

s should should be be be r rremo 

r emo emoved emo ed or or inst installed inst alled 

using using the the r rrecommended 

r ecommended me methods me thods outlined outlined outlined in in this 

this 

man manual. man manual. 

ual. 

CLEANLINESS 

Axle components should be steam cleaned prior to 

removal from the vehicle. Dirt is abrasive and will cause 

premature wear of otherwise serviceable parts. 

Service personnel should use a wash tank for thorough 

cleaning of parts just prior to reassembly. 

CAUTION 

BR BRAKE BR AKE LININGS LININGS CONT CONTAIN CONT AIN NON-ASBES 

NON-ASBES 

NON-ASBESTOS NON-ASBES 

NON-ASBES OS FIBER FIBERS FIBER FIBER 

BREA BREATHING BREA THING BR BRAKE BR AKE DUS DUST DUS DUST 

T MA MAY MA Y BE BE BE HAZARDOUS HAZARDOUS TT 

TO TT 

O Y YYOUR 

YY 

OUR HEAL HEALTH HEAL TH AND 

AND 

MA MAY MA Y CA CAUSE CA CA USE SERIOUS SERIOUS SERIOUS RESPIR RESPIRATOR 

RESPIR OR ORY ORY 

Y OR OR O OOTHER 

O THER BODIL BODILY BODIL Y HARM. 

HARM. 

AVOID OID CREA CREATING CREA TING DUS DUST DUS 

DO DO DO NO NOT NO REMO REMO REMOVE REMO VE BR BRAKE BR AKE DR DRUM DR DR UM WITHOUT WITHOUT WITHOUT PR PROPER PR PROPER 

OPER PR PROTECTIVE PR TECTIVE EQ EQUIPMENT 

EQ UIPMENT UIPMENT. UIPMENT 

DO DO DO NO NOT NO W WWORK 

W ORK ON ON ON LININGS LININGS WITHOUT WITHOUT PR PROPER PR OPER PR PROTECTIVE PR TECTIVE TECTIVE EQ EQUIPMENT 


DO DO DO NO NOT NO REPLA REPLACE REPLA CE LININGS LININGS WITHOUT WITHOUT WITHOUT PR PR PROPER PR PR OPER PR PROTECTIVE PR TECTIVE EQ EQUIPMENT 


DO DO NO NOT NO A AATTEMPT 

A TTEMPT T TTO 

T O S SSAND, 

S AND, GRIND, GRIND, CHISEL, CHISEL, FILE, FILE, HAMMER HAMMER OR OR AL ALTER AL AL TER BR BRAKE BR AKE 

LININGS LININGS IN IN ANY ANY MANNER MANNER WITHOUT WITHOUT PR PROPER PR PROPER 

OPER PR PROTECTIVE PR TECTIVE EQ EQUIPMENT 

EQ EQUIPMENT 

UIPMENT UIPMENT. UIPMENT 

FOLL OLL OLLOW OLL W 0.S.H.A. 0.S.H.A. S SSTAND 

S AND ANDARDS ANDARDS 

ARDS F FFOR 

F OR PR PROPER PR PR OPER PR PROTECTIVE PR TECTIVE DEVICES DEVICES DEVICES TT 

TO T O BE BE USED 

USED 

WHEN WHEN WHEN W WWORKING 

W WORKING 

ORKING WITH WITH BR BR BRAKE BR AKE MA MATERIALS. 

MA TERIALS.

Adjusting Ring Lock 

Temperature 

Sensor Plug 

(35 - 45 Lb-Ft) 

(47 - 61 N-m) 

Adjusting Ring Lock Bolt 

(20 - 30 Lb-Ft) 

(27 - 41 N-m) 

Axle Shaft 

Fill Plug 

(35-45 Lb-Ft) 

(47 - 61 N-m) 

Differential Case Half 

Differential Bearing Cap 

Carrier Housing 

Breather 

Pilot Bearing 

Housing 

Drain Plug (35 - 45 Lb-Ft) 

(47 - 61 N-m) 

Differential Case Bolt 

(160 - 180 Lb-Ft) 

(217- 244 N-m) 

6 

ST STANDARD ST ANDARD AXLE AXLE COMPONENTS 

COMPONENTS 

Differential Bearing Cap Bolt 

(295 - 340 Lb-Ft) 

(400 - 461 N-m) 

Washer 

Differential Bearing 

Adjusting Ring 

Differential Bearing Cup 

Differential Bearing Cone 

Differential Case Flange Half 

Ring Gear 

Ring Gear Rivet (45-50 tons) 

(41-45 metric tonnes) 

Thrust Washer 

Ring Gear Bolt Kit - Service 

Differential Pinion Mate 

Differential Cross Shaft 

Differential Side Gear 

Thrust Washer 

No-Spin® Differential 

Carrier Mounting Bolt 

(240 - 260 Lb-Ft) 

(325 - 353 N-m) 

Inner Pinion Bearing Cone 

Inner Pinion Bearing Cup 

Pinion Preload Spacer (Selective) 

Pinion Position Shim 

Pinion Bearing Cage 

Outer Pinion Bearing Cup 

Bearing Cage Bolt 

(160-180 Lb-Ft) 

Pinion 

(217- 244 N-m) 

Outer Pinion Bearing Cone 

Pinion Seal 

End Yoke Assembly 

Pinion Hex Nut 

(900 - 1,200 Lb-Ft) 

(1,220 - 1,627 N-m) 

Washer

PINION-UP PINION-UP AXLE AXLE COMPONENTS 

COMPONENTS 

Axle Shaft 

Fill Plug 

(35-45 Lb-Ft) 

(47 - 61 N-m) 

Temperature 

Sensor Plug 

(35 - 45 Lb-Ft) 

(47 - 61 N-m) 

Adjusting Ring Lock 

Differential Bearing Cap 


(20 - 30 Lb-Ft) 

(27 - 41 N-m) 


Breather 


(240 - 260 Lb-Ft) 

(325 - 353 N-m) 

Housing 


7 

Drain Plug (35 - 45 Lb-Ft) 

(47 - 61 N-m) 

Differential Bearing Cap Bolt 

(295 - 340 Lb-Ft) 

(400 - 461 N-m) 

Washer 




Thrust Washer 



(160 - 180 Lb-Ft) 

(217- 244 N-m) 



Thrust Washer 


Ring Gear 



Pilot Bearing 

Pinion 



(240 - 260 Lb-Ft) 

(325 - 353 N-m) 




Pinion Position Shim 



(160-180 Lb-Ft) 

(217- 244 N-m) 



Pinion Seal 


Washer 


(900 - 1,200 Lb-Ft) 

(1,220 - 1,627 N-m)


IMPOR ANT ANT: ANT : If If the the the v vvehicle 

v ehicle is is equipped equipped with with driv driver driv driv er 

contr controlled contr olled differ differential differ ential lock, lock, see see instructions instructions begining 

begining 

on on page page 2 224. 

2 4. TT 

To TT 

o t ttow 

t w a a v vvehicle 

vv 

ehicle with with driv driver driv er contr controlled contr olled 

differ differential differ ential lock, lock, see see instructions instructions on on page page 2 226. 

2 6. 

NO NO NOTE: NO NO TE: St Steam St eam clean clean axle axle a aassembl 

a assembl 

ssembl ssembly. ssembl 

1. 1. Block wheels. 

2. 2. Remove axle housing drain plug and drain lubricant. 

3. 3. Disconnect drive shafts at the rear U-joint. 

NO NOTE: NO TE: If If end end y yyok 

y ok oke ok e and/or and/or seal seal is is t tto 

t o be be r rreplaced, 

rr 

eplaced, 

loosen loosen loosen y yyok 

y ok oke ok e n nnut 

n ut a aat 

a t this this time. 

time. 

4. 4. Remove axle shaft flange nuts. 

5. 5. Hold a large brass drift or a brass hammer against 

the center of the axle shaft flange. Strike the drift 

with sharp blows from a large hammer or sledge 

until the axle shaft separates from the hub. 

CA CAUTION: CA UTION: Do Do no no not no no t strik strik strike strik e the the flange flange dir directl dir ectl ectly ectl 

with with with a a st st steel st eel hammer hammer or or sledge. sledge. This This This ma may ma may 

y cr crack cr ack and 

and 

splint splinter splint er ma material, ma erial, possibl possibly possibl y causing causing serious serious or or fa fatal fa al 

injury injury. injury injury. 

. Do Do no not no not 

t pry pry or or chisel chisel axle axle flange flange a aaway 

aa 

y fr from fr om h hhub 

h ub 

or or damage damage damage t tto 

t o sealing sealing sur surface sur face faces face s could could occur occur. occur 

6. 6. Remove axle shafts. 

7. Support the differential carrier assembly on a roller 

jack. Secure as necessary to prevent it from 

falling off the jack when removed from the housing. 

8 

REMOV REMOVAL REMOV AL OF OF DIFFERENTIAL 

DIFFERENTIAL 

CARRIER CARRIER FROM FROM FROM AXLE AXLE HOUSING 

HOUSING 

8. 8. Use a breaker bar to loosen the differential carrierto-housing 

mounting bolts. Remove all bolts except 

top two. These two bolts will prevent the carrier 

assembly from falling. 

9. 9. Separate differential carrier from the housing using 

removal slots. See See See F FFigur 

F igur igure igur e 1. 1. Be certain carrier is 

balanced properly on jack, and remove top two 

carrier-to-housing mounting bolts. Remove 

differential carrier assembly from the axle housing. 

Remo emo emoval emo al slot slot 

Remo emo emo emoval emo al slot 

slot 

Figur igur igure igur e 1 

1 

10. 0. Mount carrier assembly in a suitable rebuild stand. 

(Refer to Recommended ecommended Service Service T TTools 

T ools ools, ools pg. 32). 

Differ Differ Differential Differ Differ ential Carrier Carrier R RRemo 

R emo emoval emo al al Complet Complet Complete 

Complet Complet

REMOV REMOVAL REMOV REMOVAL 

AL OF OF DIFFERENTIAL DIFFERENTIAL FROM FROM CARRIER 

CARRIER 

1. 1. Remove adjusting ring locks from bearing caps. 

2. 2. Match mark one differential bearing cap and leg with 

center punch or chisel for correct reassembly. See 

See 

Figur igur igure igur e 2. 

2. 

Figur igur igure igure 

e 2 

2 

9 

3. 3. Loosen four bearing cap retainer bolts. 

4. 4. Loosen adjusting rings, relieving bearing preload. 

5. Remove four bearing cap retainer bolts. 

6. 6. Remove bearing caps. 

7. Remove adjusting rings. 

8. 8. 8. Carefully lift the ring gear and differential 

subassembly out of the carrier. 

NO NOTE: NO TE: Use Use car care car e no not no not 

t tt 

to tt 

o damage damage the the ring ring gear gear and 

and 

pinion. pinion. If If either either ring ring gear gear or or pinion pinion sho show sho show 

w signs signs of 

of 

damage, damage, the they the y m mmust 

m ust be be rr 

replaced rr 

eplaced a aas 

a as 

s a a ma ma matched ma tched se set. se t. 

R RRemo 

R emo emoval emo al of of Differ Differential Differ Differential 

ential Complet Complete Complet







(160-180 Lb-Ft) 

(217- 244 N-m) 

1. 1. Match mark differential case halfs with punch or 

chisel for correct alignment in reassembly. 

See See FF 

Figur F igur igure igur e 3. 3. 

3. 

Figur igur igur igure igur e 3 

3 

Thrust Washer 


Thrust Washer 

10 

DIFFERENTIAL DIFFERENTIAL DIFFERENTIAL DISASSEMBL 

DISASSEMBLY 

DISASSEMBL 

DISASSEMBL 





Ring Gear 



2. 2. Remove differential case bolts and lift off differential 

case half. 

3. 3. Remove thrust washer and differential side gear. 

4. 4. Lift out cross shaft, pinion mates, and thrust 

washers. 



5. 5. Remove second differential side gear and thrust 

washer. 

6. 6. If differential side bearings are to be replaced, 

remove old bearings using a suitable puller. 

See See F FFigur 

F igur igure igur e 4. 

4.

DIFFERENTIAL DIFFERENTIAL DIFFERENTIAL DISASSEMBL 

DISASSEMBLY 

DISASSEMBL 


e 4 4 

4 

NO NO NOTE: NO TE: Inspect Inspect all all par parts, par s, including including including the the machined 

machined 

sur surface sur sur face faces faces 

s of of the the ca case ca se half half. half 

If If an an any an y gear gears gear s ar are ar ar e tt 

to tt 

o be be be r rreplaced, 

r eplaced, the they the y m mmust 

m must 

ust be 

be 

replaced eplaced in in ma matched ma tched se sets. se s. Inspect Inspect thrust thrust w wwasher 

w sher shers sher 

for for scoring scoring and and e eexce 

e ce cessiv ce ssiv ssive ssiv e w wwear 

w ear ear. ear . R RReplace 

R eplace all all w wworn 

w orn 

or or damaged damaged par parts. par s. 

NO NOTE: NO TE: Ring Ring gear gear gear bolt bolt kit kits kit s ar are ar ar e a aavailable 

aa 

ailable a aas 

a as 

s a a r rreplace 

rr 

eplace 

ment ment ment for for ring ring ring gear gear riv rivets, riv s, see see P PPar 

P ar arts ar s List List man manual man ual for 

for 

par part par par t n nnumber 

n umber informa information. 

informa information. 

tion. 

7. When it is necessary to remove ring gear from the 

differential case, carefully center punch each rivet 

head. Use a 9/16 inch drill bit. Drill through rivet 

heads to depth shown. Next, use a rounded type 

punch to drive out remaining portion of the rivet. 

11 

CORRECT PROCEDURE 

Ca Case Ca se Ring Ring Gear 

Gear 

CA CAUTION: CA UTION: Alw Always Alw s use use a a soft soft hammer hammer hammer or or H.D. 

H.D. 

pla plastic pla stic head head hammer hammer t tto 

t o strik strike strik e punch. 

punch. 

INCORRECT PROCEDURE 

Ring Ring Gear Gear 

Ca Case Ca se 

NO NOTE: NO TE: Do Do Do no not no t use use use a a chisel chisel t tto 

t o r rremo 

r emo emove emo e riv riv rivet riv t heads, 

heads, 

damage damage t tto 

t o differ differential differ ential ca case ca se ma may ma y rr 

result. r sult. 

Differ Differential Differ ential Disa Disassembly Disa ssembly Complet Complete Complet


Pilot Bearing 

Pinion 




1. 1. Remove pinion bearing cage mounting bolts. 

2. 2. Remove pinion assembly from carrier housing. 

If difficulty is encountered in removing pinion 

assembly from carrier housing, place a brass drift on 

inner end of pinion and tap lightly with hammer. 

NO NOTE: NO TE: R RRetain 

R ain ain shims shims for for possible possible use use during 

during 

rea ea eassembl ea ssembl ssembly. ssembl 

3. 3. 3. Hold yoke stationary. Remove nut and washer. A 

torque multiplier may be required to loosen nut. 

4. 4. Remove the end yoke using a suitable puller. See 

Recommended ecommended Service Service T TTools 

T ools ools, ools pg. 32. 

5. 5. Remove pinion from cage assembly. 

Pinion Position Shim(s) 

NO NOTE: NO NO TE: It It ma may ma y be be nece necessary nece ssary t tto 

t o tt 

tap t ap out outer out er end end of 

of 

pinion pinion pinion with with a a soft soft hammer hammer, hammer , t ttaking 

t aking car care car e no not no t t tto 

t o damage 

damage 

thr threads. thr thr eads. 

12 




(160-180 Lb-Ft) 

(217-244 N-m) 

PINION PINION DISASSEMBL 

DISASSEMBLY 

DISASSEMBL 


Pinion Seal 


Washer 

6. 6. Located between the pinion bearings is a selective 

bearing preload spacer. Retain this selective preload 

spacer for possible use during reassembly. 

7. Remove the old pinion seal and discard. Always use 

a new seal at the time of reassembly. 

8. 8. 8. Lift out the outer pinion bearing cone. 


(900 - 1,200 Lb-Ft) 

(1,220 - 1,627 N-m) 

9. 9. 9. Remove inner pinion bearing cup, using a suitable 

adapter and press or puller. 

CA CAUTION: CA UTION: Do Do Do no no not no not 

t nick nick bearing bearing bearing bor bore. bor e. 

10. 0. Remove the outer pinion bearing cup, use the same 

procedure as in step 9. 

11. 1. Remove pilot bearing from end of pinion. 

12. 2. Remove inner bearing cone from pinion. 

Pinion Pinion Pinion Disa Disassembly Disa Disassembly 

ssembly Complet Complete 

Complet

CLEANING CLEANING AND AND INSPECTION 

INSPECTION 

CLEANING 

1. 1. Parts should be cleaned with emulsion cleaners or 

petroleum base cleaning solvent. 

NO NO NOTE: NO TE: Alk Alkaline Alk aline t ttype 

t ype solutions solutions ma may ma y cause cause damage damage t tto 

t 

machined machined machined sur surface sur surface 

face faces face s and and should should should be be a aavoided. 

a oided. 

2. 2. Make sure interior of axle housing is clean prior to 

reassembly. 

3. 3. Clean all gasket surfaces of old material. 

DRYING 

Use soft, clean, lintless towels or rags to dry components 

after cleaning. Bearings should NOT be dried by 

spinning with compressed air. This can damage mating 

surfaces due to the lack of lubrication. 

After drying, parts should be coated with a light coat 

of lubricant or rust inhibitor to prevent damage from 

corrosion. If parts are to be stored for a prolonged 

period, they should be wrapped in wax paper. 

INSPECTION 

Prior to reassembly, inspect parts for signs of excessive 

wear or damage. Replacement of these parts can 

prevent premature failure and costly downtime. 

BEARINGS 

Bearing surfaces should be inspected for pitting, 

excessive wear, or overheating. 

THRUST WASHERS 

Inspect thrust washers for scoring and cracking. 

13 

GEARS 

Inspect gears for excessive wear or damage. Replace 

gears that are pitted, scored, broken, or worn. 

SHAFTS 

Inspect shafts for nicks or scoring. 

SPLINES 

Inspect all splines for excessive wear, distortion from 

twisting, and cracking. 

HOUSINGS 

Inspect housing for stripped threads and bending 

fatigue.


Pilot Bearing 

Pinion 



1. 1. Press inner pinion bearing cone onto pinion. 

2. 2. Press Pilot bearing onto the pinion. 


Pinion Position Shim(s) 

3. 3. Stake Pilot bearing in nine places (See illustration 

below), using a center punch or equivalent tool. 

This operation will move gear shaft material outward 

into bearing chamfer. 

4. 4. Install inner pinion bearing cup into pinion bearing 

cage. 

14 




(160-180 Lb-Ft) 

(217- 244 N-m) 

PINION PINION ASSEMBL ASSEMBLY ASSEMBL 


Pinion Seal 


Washer 


(900 - 1,200 Lb-Ft) 

(1,220 - 1,627 N-m) 

5. 5. 5. Install outer pinion bearing cup into pinion bearing 

cage. 

6. 6. Use a feeler gauge or shim stock (.002 in. Max.) to 

ensure bearing cups are completely seated in 

bearing bores. This is necessary for the proper 

pinion position. See See F FFigur 


5. 


5 

7. Place the selective preload spacer, that was removed 

during disassembly, onto pinion.

PINION PINION PINION ASSEMBL ASSEMBLY ASSEMBL 

8. 8. Place pinion bearing cage onto inner pinion 

bearing. 

9. 9. Install the outer pinion bearing cone onto pinion. 

10. 0. Without installing seal, install end yoke onto pinion 

using yoke installer service tool. See See F FFigur 

F igur igure igur e 6. 6. This 

will allow proper setting of pinion preload. Secure 

yoke with a Yoke and Flange Holding Bar or an 

equivalent tool. Install pinion nut and washer. 

Torque pinion nut to 900-1,200 Lb-Ft (1,220- 

1,627 N-m). 

NO NOTE: NO TE: Inspect Inspect end end end y yyok 

y ok oke ok e seal seal sur surface sur face for for gr groo gr oo ooves oo 

caused caused b bby 

b y lip lip of of of seal. seal. If If gr groo gr oo ooves oo s s can can be be de de detect de ect ected ect ed with 

with 

fingernail, fingernail, fingernail, it it should should be be r rreplaced. 

r replaced. 

eplaced. 


6 

CA CA CAUTION: CA CA UTION: The The pinion pinion cage cage should should be be r rrotated 

r ed 

periodicall periodicall periodically periodicall periodically 

y while while while tight tightening tight ening the the pinion pinion pinion nn 

nut n ut t tto 

t o sea sea seat sea sea 

and and align align align the the pinion pinion bearings. 

bearings. 

There are two methods of measuring pinion bearing 

preload and both are acceptable. Mechanic's preference 

and available tools should determine which method 

is used. 

15 

Me Method Me thod A A uses a pull scale and a strong cord approximately 

8 ft. long. (See Item 11). Me Method Me Me thod B B uses a Lb-in 

torque wrench. Both methods measure torque to rotate. 

(See Item 12). 

11. 1. Me Method Me thod A: A: To measure torque-to-rotate with the 

spring scale, clamp the end yoke horizontally in a 

soft-jawed vise. Attach one end of the cord to a bolt 

hole in the pinion cage, wrap cord around pinion 

cage and attach the outer end of the cord to the 

spring scale. Rotate pinion cage by pulling scale. 

Read scale during fourth revolution. Scale reading 

must be between 3-10 Lbs (1.4-4.5 Kg) See 

See 

Figur igur igure igur e 7 77. 

7 

Figur igur igur igure igur e 7 

7 

(Continued (Continued on on Ne Next Ne Ne xt P PPage) 

P age)

12. 2. Me Method Me thod B: B: To measure torque to rotate with the 

torque wrench, assemble pinion cage into the carrier 

housing and install two mounting bolts to anchor 

the unit. 

Rotate pinion with the torque wrench. See See F FFigur 

F Figur 

igur igure igur e 8 88. 

8 

Torque measurement will be taken during fourth revolution 

and must be between 10-40 Lb-in (1.1-4.5 N-m) 

without pinion seal. 


8 

NO NOTE: NO TE: When When t ttor 

t tor 

or orque or que t tto 

t o r rrotate 

r e r rreading 

r eading doe does doe s no not no t fall 

fall 

within within within allo allo allowable allo able limit limits, limit s, bearing bearing bearing pr preload pr eload can can be 

be 

incr increa incr ea eased ea sed b bby 

b y using using a a thinner thinner spacer spacer or or decr decrea decr ea eased ea sed b bby 

b 

using using a a thick thicker thick er spacer spacer. spacer . .00 .001 .00 1 in. in. (.0 (.025 (.0 5 mm) mm) change change in 

in 

pr preload pr eload spacer spacer spacer thickne thickness, thickne ss, change changes change s scale scale scale r rreading 

rr 

eading b bby 

b 

appr approxima appr xima xima ximatel xima el ely ely 

y 11 

10 11 

0 0 lbs, lbs, lbs, .00 .00 .001 .00 .001 

1 in. in. change change in in pr preload pr preload 

eload 

spacer spacer spacer will will change change t ttor 

t or orque or que t tto 

t to 

o r rrotate 

r e e b bby 

b by 

y appr approxima appr xima ximatel xima el ely el 

30 0 Lb- Lb- in. in. This This is is onl only onl y a a guide, guide, individual individual carrier carrier carriers carrier s ma may ma 

vary ary slightl slightly. slightl 

The pinion bearing spacers are available in the following 

thicknesses. Measure spacer with micrometers before 

assembly to ensure correct thickness. 

Inche Inches Inche 

MM 

MM 

.893 22.982 

.894 22.708 

.895 22.733 

16 

PINION PINION ASSEMBL ASSEMBLY ASSEMBL 

Inche Inches Inche 

MM 

MM 

.896 22.758 

.897 22.784 

.898 22.809 

.899 22.835 

.900 22.860 

.901 22.885 

.902 22.911 

.903 22.936 

.904 22.962 

.905 22.987 

.906 23.012 

.907 23.038 

.908 23.063 

.909 23.089 

.910 23.114 

.911 23.139 

.916 23.266 

NO NOTE: NO TE: Closer Closer adjustment adjustment can can be be made made made b bby 

b y sanding 

sanding 

ne next ne xt thick thicker thick thick er spacer spacer t tto 

t o de desir de desir 

sir sired sired 

ed thickne thickne thickness thickne ss using using emery 

emery 

clo cloth clo th on on a a fla flat fla t sur surface. sur surface. 

face. Sur Surface Sur face faces face s m mmust 

m must 

ust be be par parallel par allel t tto 

t 

each each o oother 

o other 

ther and and squar square squar e tt 

to t o bor bore bor e diame diameter diame er er er. er 

CA CA CAUTION: CA CA UTION: W WWash 

W sh spacer spacer thor thoroughl thor thoroughl 

oughl oughly oughl y of of emery 

emery 

cut cuttings cut tings befor before befor e inst installing inst inst alling on on pinion. pinion. 

pinion. 

14. 4. After proper torque to rotate is achieved remove 

end yoke. 

15. 5. 5. Clean and dry threads on pinion. 

16. 6. Install pinion oil seal with Recommended ecommended Service Service 

Service 

Tool ool ool ool. ool See page 32. 

17. Install end yoke using yoke installer service tool 

DST1007. See See See F FFigur 

F igur igure igur e 6. 6. 

6. 

18. 8. Coat threads with Loctite #680 adhesive 

compound. 

(Continued (Continued on on Ne Next Ne xt P PPage) 

P age)

PINION PINION PINION POSITION POSITION 

POSITION 

19. 9. Install pinion nut and washer. Use torque multiplier 

and torque pinion nut to 900-1,200 Lb-Ft (1,220- 

1,627 N-m). 

Pinion assembly is now ready to be installed into carrier 

housing. 

Pinion Pinion Assembly Assembly Complet Complete 

Complet 

Ring gears and pinions are supplied in matched sets 

only. Matching numbers on both the pinion and ring 

gear are etched for verification. If a new gear set is 

being used, verify the numbers of each pinion and ring 

gear before proceeding with assembly. 

When a new gear set is being installed, use a micrometer 

to measure the thickness of the old pinion position shims. 

Measure each shim separately and add together to get 

the total thickness of the original build-up. 

NO NOTE: NO NO TE: If If old old shims shims ar are ar are 

e bent bent or or mm 

mutila m utila utilated utila ed the they the y should 

should 

be be r rreplaced. 

r eplaced. 

17 

If a new gear set is being used, notice the (+), (–) or "0" 

etching on both the old and the new pinions, and adjust 

the thickness of the shims to compensate for the 

difference of these two figures (as shown in table on next 

page). 

For example, if the old pinion is etched +2, and the new 

pinion is –2, subtract .004 in. from the thickness of the 

original shims used to position the pinion. 

If either or both the pinion gears are etched beyond the 

values on this chart, follow the same procedure to 

establish correct pinion position. 

For example if the old pinion is etched –12 and the new 

pinion is etched +9, add .021 inch to the thickness of the 

original shims. 

After determining the new total build up of pinion position 

shims, round the figure off to the nearest multiple of .005 

inch. 

Use the Pinion Setting Chart on the next page as a 

guideline to set the pinion.

18 

PINION PINION SETTING SETTING CHAR CHART 

CHAR

DIFFERENTIAL DIFFERENTIAL ASSEMBL ASSEMBLY 

ASSEMBL 





Corr Correct Corr ect riv rivet riv rivet 

et head head shape 

shape 

when when pr properly pr operly compr compressed compr ssed 



(160 - 180 Lb-Ft) 

(217 - 244 N-m) 

Thrust Washer 


Thrust Washer 

1. 1. If ring gear was removed from the differential case, 

reinstall it at this time. Bolt ring gear to differential 

case in three places, 120° apart, before compressing 

rivet; this will eliminate ring gear runout. Use a 

hydraulic or mechanical press and riveting fixture. 

Pressure requirement per rivet is 45-50 U.S. tons or 

(41-45 metric tonnes). 

2. 2. Press bearing cones onto differential case halves. 

Place bearing cups on cones during remainder of 

assembly to prevent damage of bearings. 

NO NO NOTE: NO TE: Ring Ring gear gear bolt bolt kit kits kit s ar are ar e aa 

available a ailable ailable a aas 

aa 

s a a rr 

replace- rr 

eplace 

ment ment for for ring ring gear gear riv rivets, riv riv s, see see see par parts par s list list man manual man manual 

ual for for par part par 

number umber informa information. informa tion. 


19 


Ring Gear 








3. 3. Apply a small amount of gear lubricant to all mating 

surfaces. This will aid in assembly by keeping parts 

together and providing initial lubrication. 

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

flange half. 

5. 5. 5. Assemble pinion mates and thrust washers onto 

differential cross shaft. Place assembly into flange 

half differential case. 

6. 6. 6. Place remaining side gear and thrust washer in 

position on differential pinion mates. 

7. Assemble case halves, making sure match marks are 

lined up. 

8. 8. If reinstalling used bolts, clean threads and apply 

Loctite #277. Install differential case bolts and 

torque evenly to 160-180 Lb-Ft (217- 244 N-m). 

Differ Differential Differ ential Assembly Assembly Complet Complete Complet

1. 1. Install ring gear and differential assembly into carrier 

housing. 

CA CA CAUTION: CA CA UTION: T TTo 

T o a aavoid 

a oid damage damage of of ring ring gear gear and and pinion, 

pinion, 

car care car e should should should be be used used when when inst inst installing inst alling the the ring ring gear 

gear 

differ differential differ ential a aassembl 

a assembl 

ssembl ssembly ssembl y int into int o the the carrier carrier housing. 

housing. 

2. 2. Be sure side bearing cups are seated on bearing 

cones. Assemble differential bearing caps, with 

match marks in proper location. Clean bearing cap 

bolts and washers and coat threads with Loctite 

#277. Install bearing cap bolts and tighten enough 

to draw bolt head into contact with bearing cap, 

eliminating visible space between differential bearing 

cap and carrier housing. Do not torque the cap 

bolts at this time. 

CA CA CAUTION: CA CA UTION: Differ Differential Differ Differential 

ential aa 

assembl a assembl 

ssembl ssembly ssembly 

y m mmust 

m ust be be 

be 

aligned aligned aligned within within bearing bearing bor bores bor s befor before befor befor e pr preload pr eload is is applied applied 

applied 

or or damage damage tt 

to t o bearings bearings bearings can can occur occur. occur 

F igur igure igur igure 

e 9 

9 

3. 3. Install adjusting rings. Tighten both adjusting rings 

until end play is eliminated, and there is backlash 

between the ring gear and pinion. See See F FFigur 


9. 

20 

DIFFERENTIAL DIFFERENTIAL INST INSTALLA INST INSTALLA 

ALLA ALLATION ALLA TION 

4. 4. Loosen adjusting ring on tooth side of ring gear one 

notch and tighten adjusting ring on flange side of 

ring gear one notch. Repeat process until backlash 

is eliminated. Tighten adjusting ring on tooth side 

of the ring gear until the ring gear and pinion 

backlash matches the backlash etched on the 

ring gear. This adjustment sets both the backlash 

and the bearing preload. 

5. 5. 5. Check ring gear and pinion backlash in four equally 

spaced positions around the ring gear with a dial 

indicator as shown. See See F FFigur 

F igur igure igur e 1 110. 

1 0. A AAccep 

A ccep cceptable ccep able 

backla backlash backla sh t ttoler 

t oler olerance oler ance is is +/- +/- +/- .00 .002" .00 .00 2" fr fr from fr fr om backla backlash backla sh 

etched tched on on on ring ring ring gear gear. gear gear 


e 1 110 

1 

NO NOTE: NO TE: If If the the backla backlash backla sh t ttoler 

t oler olerance oler ance doe does doe s no not no t v vvary 

v ary mor more mor 

than than .00 .004 .00 4 in. in. (.0 (.080 (.0 0 mm), mm), the the se setting se ting ting is is accep acceptable. accep accep able. If 

If 

backla backla backlash backla backla sh doe doe does doe does 

s vv 

vary vv 

ary ary mor mor more mor more 

e than than .00 .00 .004 .00 .004 

4 in. in. in. (.0 (.080 (.0 0 0 mm), mm), 

mm), 

remo emo emove emo e the the differ differential differ ential and and de determine de ermine the the the cause. cause. 

cause. 

6. 6. Once backlash is set, torque the differential bearing 

cap bolts to 295-340 Lb-Ft (397-460 N-m). Check 

backlash after torquing cap bolts.

RING RING RING GEAR GEAR AND AND PINION 

PINION 

TOOTH TOOTH CONT CONTACT CONT ACT P PPATTERN 

P TTERN 

The following procedures are to be used to establish 

proper gear tooth pattern after assembly of the carrier is 

complete. 

NO NOTE: NO TE: If If ma ma matched ma tched se sets se s ar are ar e being being rr 

reused, r eused, mea measur mea sur sure sur 

and and r rrecor 

r recor 

ecor ecord ecor d backla backlash backla sh befor before befor e disa disassembl disa disassembl 

ssembl ssembly, ssembl , and and r rrea 

r ea eas- ea s 

semble semble t tto 

t o the the same same backla backlash. backla sh. This This will will ma ma match ma match 

tch ring 

ring 

and and and pinion pinion gear gears gear s t tto 

t o the the e eest 

e st stablished st ablished w wwear 

ww 

ear ear pa patterns. pa erns. 

Hand Hand r rrolled 

r olled pa patterns pa erns will will co cover co er le less le ss ar area ar area 

ea than than the 

the 

gear gear pa pa pattern pa ern e eest 

e st stablished st ablished b bby 

bb 

y pr pr previous pr vious service. 

service. 

STEP 1. Paint 1/4 ring gear with marking compound on 

both the drive and coast side. 

CORRECT CORRECT GEAR GEAR P PPATTERNS 

P TTERNS 

DRIVE SIDE 

(CONVEX) 

LIGHTL LIGHTLY LIGHTL Y L LLOADED 

L ADED 

21 

TOE OE 

HEEL 

HEEL 

LENGTHWISE 

LENGTHWISE 

BEARING BEARING AR ARC AR 

STEP 2. Apply drag load to ring gear and rotate pinion 

so that ring gear completes one revolution in 

each direction. 

TOE TOE 

COAST SIDE 

(CONCAVE) 

DRIVE SIDE 

(CONVEX) 

HEA HEAVIL HEA VIL VILY VIL Y L LLOADED 

L ADED 

HEEL HEEL HEEL 

HEEL 

INCORRECT INCORRECT INCORRECT GEAR GEAR GEAR PP 

PATTERNS PP 

TTERNS 

TOE 

HEEL HEEL 

DRIVE SIDE 

(CONVEX) 

LIGHTL LIGHTLY LIGHTL Y L LLOADED 

LL 

ADED 

COAST SIDE 

(CONCAVE) 

CO COAS CO AS AST AS T SIDE 

SIDE 

TOP OP LAND 

LAND 

ROO OO OOT OO 

TOE 

COAST SIDE 

(CONCAVE) 

HEEL HEEL 

DRIVE SIDE 

(CONVEX) 

PR PROFILE PR PR OFILE 

DRIVE DRIVE SIDE 

SIDE 

HEA HEAVIL HEA VIL VILY VIL Y L LLOADED 

L ADED 

COAST SIDE 

(CONCAVE)

1. 1. Thoroughly clean the inside of the carrier housing 

and inspect the housing mounting surface for nicks 

and general cleanliness. Stone the surface if 

necessary to remove burrs or nicks. Bolt holes must 

also be checked, to see that they are free of 

contaminants. 

Loctit Loctit Loctite Loctit Loctit e 5 5518 

5 

Ga Gask Ga Gask 

sk sket sket 

et Eliminat Eliminat Eliminator Eliminat Eliminat or 

Figur igur igure igur e 1 111 

1 

2. 2. Apply an .125 inch (3.175 mm) diameter bead of 

Loctite 518 gasket eliminator onto the axle housing 

mounting flange and around each bolt hole. See 

See 

Figur igur igure igur e 1 111. 

1 1. 

3. 3. Thread two studs into the axle housing 180 0 apart. 

This will eliminate rotation of the carrier assembly 

after it makes contact with the gasket material. 

4. 4. Install the carrier assembly into the axle housing. 

If reinstalling used bolts, clean the mounting bolts, 

and coat with Loctite #277, and install. Tighten 

bolts evenly in cross pattern. Torque bolts 

240-260 Lb-Ft (325-352 N-m). 

5. 5. Allow one hour cure time for gasket material before 

adding hypoid gear lubricant. 

6. 6. Remove the old axle flange gasket and clean mating 

surfaces of the hub and axle flange. 

22 

INST INSTALLA INST ALLA ALLATION ALLA TION OF OF DIFFERENTIAL 

DIFFERENTIAL 

CARRIER CARRIER INTO INTO AXLE AXLE HOUSING 

HOUSING 

7. Install the new axle flange gasket. 

8. 8. 8. Install the axle shafts to proper location. 

Torque the axle flange nuts to vehicle manufacturers 

specifications. 

9. 9. Clean drain plug and install. Torque drain plug to 

35-45 Lb-Ft (47-61 N-m) Fill unit to proper 

level with hypoid gear lubricant. 

10. 0. Install fill plug and torque to 35-45 Lb-Ft 

(47-61 N-m). 

NOTE : Lubricant close enough to bottom of fill hole to be seen 

or touched is not sufficient. Lubricant must be level with the fill 

hole. 

CAP CAPACITIES CAP CITIES (Appr (Approxima (Appr xima ximate*): xima e*): 

Model Model 

Pint Pint Pints Pint Lit Liter Lit er ers er 

S 230-S/SL 0-S/SL 48.8 8.8 23.1 3.1 

S2 S260-SB S2 0-SB ** 52.9 2.9 25.0 5.0 

S2 S260-SB S2 0-SB *** 55.2 5.2 5.2 26.1 6.1 

* Lube capacity will vary depending upon the housing angle 

in each vehicle. Capacities given above are for an angle of 

4°. Fill to the lower edge of the fill hole in the axle housing 

as shown above. 

** Capacity for fabricated housing 

*** Capacity for cast housing

TORQUE ORQUE SPECIFICA 

SPECIFICATIONS 

SPECIFICA TIONS 

S230-S/SL, S230-S/SL, S260-SB S260-SB Fasteners 

Fasteners 

Position osition Thr Thread Thr ead size 

size Gr Grade Gr ade 

Pinion Pinion He Hex He x Nut Nut 

1 1 3/4 3/4 – – 1 112 

1 

9 9900 

99 

00 - - - 1,2 1,200 1,2 1,200 

00 

Pinion Pinion Bearing Bearing Cage Cage Bolt Bolts Bolt 

Carrier Carrier Mounting Mounting Bolt Bolt Bolts Bolt Bolt 

Differ Differential Differ ential Bearing Bearing Cap Cap Bolt Bolts Bolt 

Differ Differential Differ ential Ca Case Ca se Bolt Bolts Bolt 

FFFill 

FF 

ill Plug 

Plug 

Dr Drain Dr ain Plug 

Plug 

T TTemper 

T emper emperatur emper tur ture tur e Sensor Sensor Plug 

Plug 

Air Air Shift Shift Cylinder Cylinder Bolt 

Bolt 

Electric Electric Switch Switch Unit Unit 

9/1 9/16 9/1 6 – – 1 118 

1 

2 220 

22 

0 0 - - 33 

30 33 

2 227 

22 

7 7 - - 44 

41 44 

23 

8 8 1 1160 

1 0 - - 1 1180 

1 

A AAdjusting 

A djusting Ring Ring Lock Lock Bolt Bolt Bolts Bolt Bolt 

3/8 3/8 – – 1 116 

1 8 8 22 

20 2 0 - - 3 330 

3 

2 2240 

2 0 - - - 2 2260 

2 

1 1160 

1 0 0 - - 11 

180 1 

3 335 

33 

5 - - 4 445 

4 

3 335 

3 5 - - 4 445 

44 

3 330 

3 30 

0 - - - 4 440 

4 

Air Air Shift Shift Cylinder Cylinder Plug Plug 

1/4 1/4 1/4 – – 11 

18 11 

2 220 

2 20 

0 - - - 3 330 

3 

S230-S/SL, S230-S/SL, S260-SB S260-SB S260-SB Specifications 

Specifications 

8 

8 

8 

8 

8 

8 

Lb-Ft Lb-Ft 

N-m N-m 

N-m 

2 2295 

2 5 - - 3 3340 

3 

3 335 

3 5 - - 4 445 

4 

NO NO NOTE: NO NOTE: 

TE: Refer to vehicle manufacturer specifications for axle Flange-Wheel Nut fastener torque. 

Position osition osition U.S. 

U.S. 

Me Metric Me tric 

Pinion 

Pinion 

1,2 1,220 1,2 1,2 0 - - 1,6 1,627 1,6 

217 7 - - 22 

244 2 

2 227 

2 7 - - 4 441 

4 

3 3325 

3 5 5 - - 3 3352 

3 

397 7 - - 4 4460 

4 

217 7 - - 2 2244 

2 

4 447 

4 7 - - 6 661 

6 

44 

47 4 7 - - 6 661 

6 

4 447 

4 7 - - 66 

61 6 

44 

41 44 

1 1 - - 55 

54 55 

22 

27 22 

7 7 - - 4 441 

44 

Nominal Nominal Dimension Dimension 

4.5 4.5 4.5945 4.5 4.5 5 in. in. 

116.7 6.7 6.700 6.7 00 mm 

mm 

Bearing Bearing Bearing Pr Preload Pr eload (T (Tor (T or orque or que WW 

Wrench)* WW 

ench)* 

Bearing Bearing Pr Pr Preload Pr Pr eload (Pull (Pull Scale)* 

Scale)* 

Differ Differential Differ ential 

Ring Ring Gear Gear t tto 

t o Pinion Pinion Backla Backlash Backla sh 

Ring Ring Gear Gear Riv Rivet Riv t Pr Pressur Pr ssur ssure ssur 

45 5 - - - 5 550 

5 0 t ttons 

t ons 41 1 - - 4 445 

4 5 tt 

tonne tt 

onne onnes onne 

Lubrica Lubrica Lubrication Lubrica Lubrication 

tion (Appr (Approx.**) (Appr x.**) 

S2 S230-S/SL S2 0-S/SL Lube Lube capacit capacit capacity capacit capacit 

9/1 9/16 9/1 6 – – 1 112 

1 

5/8 5/8 – – 1 111 

1 

3/4 3/4 – – 1 110 

1 

9/1 9/16 9/1 6 – – 1 112 

1 

3/4 3/4 – – 1 114 

1 

3/4 3/4 – – 1 114 

1 

3/4 3/4 – – 1 114 

1 

3/8 3/8 – – 1 116 

1 

S2 S260-SB S2 0-SB F FFabrica 

F abrica abricated abrica ed Housing Housing Lube Lube Capacit Capacity Capacit 

S2 S260-SB S2 0-SB Ca Cast Ca st Housing Housing Lube Lube Capacit Capacity Capacit 

8 

8 

10 0 - - 4 440 

4 0 Lb-in 

Lb-in 

3 3 - - 9 9 Lbs. 

Lbs. 

.0 .012 .0 2 - - .0 .016 .0 6 in. 

in. 

ALL ALL SER SERVICE SER SER VICE T TTOOLS 

T OOLS A AAVAILABLE 

A AILABLE FR FROM FR OM O OOTC 

O TC DIVISION: 

DIVISION: 

1.1 1.1 - - 4.5 4.5 N-m 

N-m 

1.4 1.4 - - 4.5 4.5 Kg. 

Kg. 

.3 .30 .3 0 - - .4 .40 .4 0 mm 

mm 

48.8 8.8 Pt Pts. Pt s. 23.1 3.1 Lit Lit Liter Lit er ers er 

52.9 2.9 Pt Pts. Pt s. 25.0 5.0 5.0 Lit Liter Lit er ers er 

55.2 5.2 Pt Pts. Pt s. 26.1 6.1 Lit Liter Lit er ers er 

* * Pinion bearing preload is established prior to installation of pinion seal. 

** ** Capacity will vary depending on the housing angle in each vehicle. Fill to lower edge of fill hole in rear of axle housing 

as shown on Page 22. 

Service Tools 

655 Eisenhower Drive 

Owatonna, MN 55060 

Telephone: 1-800-533-0492 

Fax Number: 507-455-7011

INTRODUCTION 

The Spicer driver-controlled differential lock provides 

exceptional traction and pulling power in both slippery 

driving conditions and heavy-duty applications. Such 

applications include: pulling double trailers, construction, 

and refuse collection. In adverse road conditions, the 

Spicer driver-controlled differential lock also protects 

against spin-out and shock loading. 

The differential lock is activated by a cab-mounted 

switch. The lock operates through an air-actuated shift 

assembly that is located on the right-side of the differential 

carrier. When the differential lock is engaged, an airactuated 

piston moves the clutch collar along splines of 

the axle shaft onto mated splines of the differential case. 

See See See F FFigur 

F igur igure igure 

e 11 

12. 11 

2. 2. 

Ring Ring and and Pinion 

Pinion 

Gears 

Gears 

Axle Axle Housing 

Housing 

Differ Differential Differ Differential 

ential 

Gears 

Gears 

DRIVER DRIVER CONTROLLED CONTROLLED DIFFERENTIAL DIFFERENTIAL LOCK 

LOCK 

DIFFERENTIAL LOCK IDENTIFICATION 


1 

24 

When the differential case and clutch collar splines are 

engaged, the wheel differential is positively locked. The 

shift fork trips an electric switch unit that signals a cab 

indiactor light for driver verification. There is no differential 

action between the rear drive wheels of the axle 

when the differential is positively locked, resulting in 

maximum traction to the rear drive wheels. Normal 

differential action occurs between the rear drive wheels 

of the axle when the differential lock is disengaged. The 

cab-mounted indicator light should be off at this time. 

Electric Electric Switch Switch Switch Unit 

Unit 

Differ Differential Differ ential 

Ca Case Ca Ca se Half 

Half 

Vehicle ehicle ehicle Air 

Air 

Supply Supply Inlet Inlet 

Inlet 

Pist Piston Pist on Plugged Plugged Hole Hole Hole (F (For (F or 

Manual Manual Eng Engagement) 

Eng agement) 

Spline Splines Spline 

Right Right Right-Side Right Right -Side 

Axle Axle Shaft 

Shaft 

Shift Shift F FFork 

F ork 

Clutch Clutch Collar 

Collar 

(Eng (Engaged) (Eng (Eng aged)

DRIVER DRIVER DRIVER CONTROLLED CONTROLLED CONTROLLED DIFFERENTIAL DIFFERENTIAL DIFFERENTIAL LOCK LOCK COMPONENTS 

COMPONENTS 

Double Splined Axle Shaft 

(Diff.-Lock Side Only) 


(20 - 30 Lb-Ft) 

(27 - 41 N-m) 

Air Shift Cylinder Bolt 

(30 - 40 Lb-Ft) 

(41 - 54 N-m) 

Adjusting 

Ring Lock 

Piston Assembly 

Air Shift Cylinder 

Washer 


Clutch Collar 

Shift Fork Shaft 

Roll Pin 

Air Shift Cylinder Plug 

(20 - 30 Lb-Ft) 

(27 - 41 N-m) 

Axle Housing Assembly 

Differential 

Bearing Cone 

Differential 

Bearing Cup 

Shift Fork Shaft 

Differential 

Bearing Cap 

25 

Shift Fork 

Roll Pin 

Shift Fork 

Splined Differential 

Case Half 

Spring 

Electric Switch Unit 

(20 - 30 Lb-Ft) 

(27 - 41 N-m) 

Carrier Assembly

REMOVE AXLE SHAFTS BEFORE TOWING 

If the vehicle is to be towed with the rear axle drive wheels 

on the ground, axle shafts must be removed. To remove 

axle shafts use the following procedures: 

1. 1. Disengage main differential lock. 

NO NOTE: NO NO TE: Differ Differential Differ ential lock lock cab cab light light should should should be be off off off. off 

This This This indica indicates indica s tha tha that tha t the the difflock difflock is is disengaged. 

disengaged. 

2. 2. Remove both axle shafts from vehicle by normal 

procedures. 

NO NO NOTE: NO TE: Right Right-side Right -side axle axle shaft shaft ha has ha s t ttwo 

t o se se sets se se s of of spline splines: spline s: 

one one one for for the the differ differential differ ential side side gear gear and and the the o oother 

o ther for for the 

the 

differ differential differ ential lock lock clutch clutch collar collar. collar 

3. 3. Cover both open axle hubs to prevent contaminants 

from entering axle and loss of any lubricants. 

INSTALL AXLE SHAFTS AFTER TOWING 

1. 1. Remove hub covers from axle. 

2. 2. With differential lock in disengaged position, 

Install right-side axle shaft. 

Differ Differential Differ Differential 

ential 

Ca Case Ca se Half 

Half 

TOWING TOWING PROCEDURES PROCEDURES PROCEDURES / / INSTRUCTIONS 

INSTRUCTIONS 

26 

Due to engaging two sets of splines this axle shaft will 

need more attention than the conventional axle shaft. 

Install right-side axle shaft using the following procedures: 

• Push axle shaft into housing until 

contact is made with the clutch collar. 

• Rotate axle shaft while pushing down on 

flange until splines align. 

• Push axle shaft further until contact is 

made with with differential side gear. 

• Rotate shaft again while pushing down 

on flange until splines align. 

• Push axle shaft into housing until flange 

seats against the axle hub. 

3. 3. Install left side axle shaft into housing using normal 

procedures. 

4. 4. 4. Fasten both axle shafts to the hubs and torque to 

vehicle specifications. See See F FFigur 

F igur igure igur e 1 113. 

1 3. 

RIGHT-SIDE AXLE SHAFT OF DIFFERENTIAL LOCK 

Side Side Gear 

Gear 

Mat Mated Mat ed Axle 

Axle 

Shaft Shaft Spline Spline Splines 

Spline 


e 1 113 

1 

Shift Shift F FFork 

FF 

ork 

Actuat Actuator Actuat Actuat or Assembly Assembly 

Assembly 

Axle Axle Shaft 

Shaft 

Eng Engaged Eng Engaged 

aged 

Clutch Clutch Clutch Collar Collar 

Collar

CARRIER CARRIER REMOV REMOVAL REMOV AL 

CARRIER REMOVAL 

Before carrier assembly can be removed from the axle 

housing, the main differential lock must be engaged (in 

the locked position). This must be done before the rightside 

axle shaft is removed. Engaging (locking) the main 

differential allows enough clearance for the clutch collar 

to clear the carrier-to-housing mounting flange so removal 

can be achieved. 

NO NOTE: NO TE: Locking Locking of of the the main main differ differential differ ential m mmust 

m ust be be done done 

done 

befor before befor e r rremo 

r emo emoving emo ving the the right right right-side right -side axle axle axle shaft. shaft. If If the the right- 

right 

side side axle axle axle shaft shaft w wwas 

w s r rremo 

r emo emoved emo ed for for t ttowing 

t wing purpose purposes, purpose s, 

reinst einst einstall einst all it it int into int o the the housing housing using using pr procedur pr ocedur ocedure ocedur e 2. 2. 2. fr from fr om 

the the the "Inst "Inst "Install "Inst "Install 

all Axle Axle Shaft Shafts Shaft s Aft After Aft er T TTowing". 

T wing". P PPage 

P age 2 226. 

22 

6. 

AIR PRESSURE METHOD 

1. Drain lubricant from the axle assembly. 

2. Raise the right-side rear drive wheel off the floor 

using a hoist or jack. 

3. Hold the right-side of the vehicle in the raised 

position by using a jack stand under the rightside 

housing spring seat. 

4. Disconnect the drive shaft from the input yoke. 

5. Disconnect air line from the differential lock 

shift cylinder. 

6. Connect an auxiliary air supply to the differential 

lock shift cylinder. 

NO NOTE: NO NOTE: 

TE: If If an an auxiliary auxiliary air air air suppl supply suppl supply 

y is is no not no t aa 

available aa 

ailableailableconcon- tin tinue tin ue t tto 

t to 

o use use the the the "Man "Manual "Man ual Engaging Engaging Engaging Me Method" Me thod" t tto 

tt 

o lock 

lock 

the the main main differntial. 

differntial. 

7. Apply and hold air pressure to the shift cylinder. 

This will move the clutch collar inward and engage 

splines with the differential case splines, 

locking the assembly. 

8. To ensure differential clutch collar and case half have 

engaged completely, rotate the drive pinion or the 

right-side wheel. 

27 

NO NOTE: NO TE: Contin Continue Contin ue tt 

to t o k kkeep 

kk 

eep differ differential differ ential lock lock engaged 

engaged 

(lock (locked) (lock ed) with with with air air pr pressur pr ssur ssure ssur e until until carrier carrier ha has ha s been 

been 

comple completel comple el ely el y r rremo 

r emo emoved emo ed fr from fr om the the the axle axle housing. housing. 

housing. 

9. Remove the axle shafts and carrier assembly from the 

axle housing using the procedures as shown on 

Page 8. 

10.When carrier has been removed from the axle 

housing, remove auxiliary pressure from the shift 

cylinder. 

MANUAL ENGAGING METHOD 

NO NOTE: NO TE: Use Use Use this this me method me thod if if if auxiliary auxiliary auxiliary air air is is una una unavailabe. una ailabe. 

1. Follow air pressure engagemant method through 

step 5. 

NO NO NOTE: NO NO TE: R RRefer 

R efer t tto 

t o F FFigur 

F igur igure igur e 1 114 

1 4 for for the the follo following follo wing st st steps. st eps. 

Air Air Supply 

Supply 

Inlet 

Inlet 

Air Air Shift 

Shift 

Cylinder ylinder 

Manual Manual Eng Engaging Eng Eng aging 

M1 M12 M1 2 X X 1.5 1.50 1.5 0 Bolt 

Bolt 

DIFFERENTIAL LOCK 

MANUAL ENGAGEMENT DIAGRAM 


e 1 114 

1 

2. Remove plug from the hole in the center of the shift 

cylinder cover. 

3. Install an M12 x 1.50 bolt in the cylinder air-port, 

same hole the plug was in, to manually engage the 

differential. 

Continued Continued Continued Continued Continued On On On On On Ne Ne Next Ne Next 

xt xt xt PP 

Page PP 

age age age age

NO NO NOTE: NO TE: Bolt Bolt mm 

must m ust be be a aat 

aa 

t lea least lea st 1.7 1.75 1.7 5 in. in. long long t tto 

t o full fully full 

engage engage differ differential. differ ential. 


IMPOR ANT ANT: ANT : Hand Hand tight tighten tight en the the M1 M12 M1 M1 2 x x 1.5 1.50 1.5 1.50 

0 bolt bolt bolt with 

with 

a a sock socket. sock t. See See See FF 

Figur F igur igure igur e 1 117 

1 7 on on P PPage 

P Page 

age 3 330. 

3 0. 

CA CAUTION: CA UTION: If If a a high high r rresist 

r sist sistance sist ance t tto 

t o turn turn is is is felt 

felt 

befor before befor before 

e full full engagement engagement of of lock, lock, st st stop st op turning turning bolt. 

bolt. 

REMOV REMOVAL REMOV AL OF OF DIFF-LOCK DIFF-LOCK DIFF-LOCK ASSEMBL ASSEMBLY 

ASSEMBL 


e 1 115 

1 

NO NO NOTE: NO NO TE: The The The carrier carrier should should alr alread alr ead eady eady 

y be be be r rremo 

rr 

emo emoved emo ed fr from fr from 

om 

the the vv 

vehicle vv 

ehicle befor befor before befor before 

e pr pr proceeding pr pr oceeding with with the the disa disassembl disa ssembl ssembly ssembl y of 

of 

the the diff-lock diff-lock component component components. component s. See See FF 

Figur FF 

igur igure igur e 1 115. 

1 5. 

28 

CARRIER CARRIER REMOV REMOVAL REMOV AL 

Ov Over Ov er er-t er -t -tor -t or orquing or quing ma ma may ma may 

y cause cause damage damage t tto 

tt 

o the the shift shift unit. 

unit. 

4. To ensure lock is fully engaged, rotate the drive 

pinion or the right-side wheel. 

5. Remove axle shafts by normal removal procedures. 

6. Remove carrier assembly from axle housing. 

Carrier Carrier Carrier Carrier Carrier RR 

Remo RR 

emo emo emovvvvval emo al al al al Complet Complet Completeeeee Complet Complet 

1. 1. 1. Remove the electric switch unit from the carrier. 

2. 2. Remove the bolts and washers from the air 

shift cylinder. 

3. 3. Remove air shift cylinder. 

4. 4. Remove the shift shaft and shift fork by unthreading 

the shaft. 

5. 5. Remove compression spring. 

6. 6. Remove the shift fork and clutch collar from the 

carrier. 

Diff Diff Diff-Lock Diff Diff-Lock 

-Lock -Lock -Lock RR 

Remo RR 

emo emo emovvvvval emo al al al al Complet Complet Completeeeee Complet Complet

INST INSTALLA INST ALLA ALLATION ALLATION 

TION OF OF DIFF-LOCK DIFF-LOCK ASSEMBL ASSEMBLY ASSEMBL 

1. 1. Place the arms of the shift fork over the clutch collar 

so that the threaded end of the fork faces the 

direction shown in Figur igur igur igure igur e 1 115. 

1 

2. 2. Position the shift fork collar assembly into the 

carrier so the collar fits over the splined differential 

case. 

3. 3. While holding the collar in place insert the spring 

into the shift shaft and thread the shaft into the 

shift fork. Torque the shift shaft 20-30 Lb-Ft 

(27-41 N-m). 

4. 4. Lubricate the O-ring of the shift piston and install 

into the shift cylinder. (Install the piston so that the 

metal spacer is visible. This area will fit over the 

shift shaft.) 

5. 5. Clean the mating surfaces of the carrier shift 

cylinder and apply a .125 in. (3.175 mm) continuous 

bead of Loctite 518 to the carrier surface. See 

See 

Figur igur igur igure igure 

e 1 116. 

1 6. 

6. 6. Install the shift cylinder into the carrier. Do not 

allow the cylinder to rotate once it has been seated. 

29 

7. Install the two shift cylinder washers and bolts and 

torque 30-40 Lb-Ft (41-54 N-m). 

8. 8. Install the threaded plug into the center of the shift 

cylinder an torque 20-30 Lb-Ft (27-41 N-m). 

9. 9. Thread the electric switch unit into the top of the 

carrier and torque 20-30 Lb-Ft (27-41 N-m). 

10. 0. Install the air coupler into the air port. 

Loctit Loctite Loctit e 5 5518 

5 

Ga Gask Ga sk sket sk et Eliminat Eliminator Eliminat or 

Diff Diff Diff-Lock Diff Diff-Lock 

-Lock -Lock -Lock Inst Inst Installation Inst Installation 

allation allation allation Complet Complet Completeeeee Complet Complet 


1

AIR PRESSURE METHOD 

1. Install the right-side axle shaft through the 

clutch collar and into the differential side gear of 

the carrier assembly. The axle shaft is used to 

align splines of the the differential case half and 

clutch collar. 

2. Rotate right-side axle shaft until splines of clutch 

collar and the differential case half are aligned. 

CA CAUTION: CA UTION: Do Do no not no t use use hands hands t tto 

tt 

o position position shift 

shift 

collar collar while while air air pr pressur pr ssur ssure ssur e is is being being applied applied applied t tto 

t o shift shift 

shift 

cylinder cylinder, cylinder , injury injury could could r rresult. 

r sult. 

3. Connect auxiliary air supply to shift cylinder. 

4. Apply and hold air pressure to the shift cylinder. 

Applying air will move the shift collar inward 

and engage the splines with the differential case 

splines locking the assembly. 

5. To ensure the clutch collar and differential case 

splines have engaged completely, rotate right-side axle 

shaft. When fully engaged remove shaft from the 

carrier assembly. 


IMPOR ANT ANT: ANT: 

: Hold Hold air air pr pressur pr ssur ssure ssur e on on lock locked lock locked 

ed carrier carrier 

carrier 

assembl ssembl ssembly ssembl y until until until it it ha has ha s been been comple completel comple comple el ely el y inst installed inst alled int into int 

axle axle housing. housing. 

housing. 

6. Install carrier assembly into axle housing and fasten 

using normal installation procedures. 

7. Remove auxiliary air supply from shift assembly and 

connect the vehicle air line to shift cylinder. 

8. Install axle shafts into housing. Use procedures 2 and 

3 from the "Inst "Install "Inst all Axle Axle Shaft Shafts Shaft s Aft After Aft After 

er T TTowing" 

T wing" 

section. 

9. Remove jack stands from vehicle and lower to shop 

floor. 

MANUAL ENGAGING METHOD 

1. Align the splines of the clutch collar and the 

differential case by hand. 

30 

CARRIER CARRIER INST INSTALLA INST ALLA ALLATION ALLA TION 

2. Install a M12 X 1.50 bolt into the shift cylinder 

air-port to manually engage the lock. 


IMPOR ANT ANT: ANT : Hand Hand tight tighten tight en M1 M12 M1 M12 

2 X X X 1.5 1.50 1.5 0 bolt bolt bolt with with a 

a 

sock socket. sock t. See See F FFigur 

FF 

igur igure igur e 11 

17. 11 

HAND TIGHTEN M12 X 1.50 BOLT 

USING SOCKET 


1 

CA CAUTION: CA UTION: If If a a a high high rr 

resist rr 

sist sistance sistance 

ance t tto 

t o turn turn is is is felt 

felt 

befor before befor e full full engagement engagement of of of lock, lock, st stop st op turning turning the the bolt. 

bolt. 

Ov Over Ov er er-t er -t -tor -t or orquing orquing 

quing ma may ma y cause cause damage damage t tto 

t o the the the shift shift unit. 

unit. 

Realign ealign spline splines spline s and and and contin contin continue contin contin ue t tto 

t o tight tighten. tight en. 

3. To ensure lock is fully engaged, rotate the drive 

pinion. 

4. Install carrier assembly into axle housing and fasten 

using normal procedures. 

5. Remove manual engaging bolt from shift cylinder, 

replace with air shift cylinder plug and torque 

20-30 Lb-Ft (27-41 N-m). 

6. Connect the vehicle air line to the shift cylinder 

assembly. 

7. Install axle shafts into the axle housing. Use 

procedures 2 and 3 from the "Inst Inst Inst Install Inst all Axle Axle Shaft Shafts Shaft 

Aft After Aft er T TTowing 

T wing wing" wing section, page 26. 

8. Remove jack stands from under vehicle and 

lower to shop floor. 

Carrier Carrier inst installation inst allation complet complete complet

CHECKING CHECKING DIFFERENTIAL DIFFERENTIAL LOCK LOCK OPERA OPERATION 

OPERA TION 


IMPOR ANT ANT: ANT: 

: Befor Before Befor Befor e tt 

testing tt 

sting differ differential differ ential lock 

lock 

oper operation, oper tion, v vvehicle 

v ehicle m mmust 

m ust be be lo lower lo er er ered er ed comple completel comple comple el el ely el 

to o floor floor and and clear clear of of all all obst obstacle obst acle acles acle s (jack (jack st stands, st ands, 

hoist, hoist, t ttools, 

t ools, e eetc.). 

e tc.). 

1. Start engine and allow air pressure system to build 

up to normal operating level. 

2. Place cab differential lock switch in the unlocked 

(disengaged) position. 

3. Drive vehicle at very slow speed, (MAX 10 M.P.H.) 

and check differential lock cab light. The indicator 

light should be OFF when lock is in the disengaged 

(unlocked) position. 

4. Continue to drive vehicle at low speed (MAX 10 

M.P.H.) and flip differential lock cab switch to the 

engaged (locked) position. The indicator light 

should now come ON. 

31 


IMPOR ANT ANT: ANT : If If indica indicator indica or light light rr 

remains rr 

emains on on when 

when 

switch switch is is is in in the the unlock unlocked unlock ed position, position, position, check check t tto 

t o see see if if the 

the 

man manual man ual engaging engaging bolt bolt w wwas 

w s rr 

remo r remo 

emo emoved emo ed fr from fr from 

om the the the shift 

shift 

cylinder cylinder cylinder a aassembl 

a ssembl ssembly. ssembl . If If engaging engaging bolt bolt r rremains, 

r remains, 

emains, r rremo 

r emo emove emo 

it it and and r rreplace 

r eplace with with shift shift shift cylinder cylinder plug. plug. R RRetest 

RR 

st for 

for 

corr correct corr ect differ differential differ ential lock lock oper oper operation. oper tion. 

NO NOTE: NO TE: If If differ differential differ ential lock lock lock still still doe does doe s no not no t oper oper operate oper e in 

in 

accor accordance accor dance with with abo abo above abo e t ttest 

t st sts, st s, check check all all air air and 

and 

electrical electrical connections. connections. La Lastl La stl stly, stl , , if if needed, needed, r rremo 

r emo emove emo 

carrier carrier b bby 

b y pr procedur pr ocedur ocedures ocedur s outlined outlined in in the the the "Carrier "Carrier R RRe 

R e 

mo moval mo al " " section section and and follo follow follo w all all aa 

assembl aa 

ssembl ssembly ssembl y st steps st eps for 

for 

inst installa inst alla allation allation 

tion of of the the carrier carrier carrier int into int o the the housing. 

housing. 

Differ Differential Differ ential Lock Lock Check Check Complet Complete 

Complet

ORDER ORDER ORDER NUMBER 

NUMBER 

ILLUSTRA ILLUSTRATION 

ILLUSTRA TION 

DS DST1 DS T1 T100 T100 

00 001 00 

CARRIER CARRIER S SSTAND 

S AND 

32 

RECOMMENDED RECOMMENDED SER SERVICE SER VICE TOOLS 

TOOLS 

DESCRIPTION 

DESCRIPTION 

DESCRIPTION 

DS DST1 DS T1 T100 T1 00 002 00 

Maxim Maximum Maxim um 1,000 1,000 Lb-Ft 

Lb-Ft 

DS DST1 DS T1 T100 T1 00 003 00 

DS DST1 DS T1 T100 T1 00 004 00 

DS DST1 DS DST1 

T1 T100 T100 

00 005 00 

DS DST1 DS T1 T100 T1 00 006 00 

DS DST1 DS T1 T100 T1 00 007 00 

TOR OR ORQUE OR UE MUL MULTIPLIER MUL MULTIPLIER 

TIPLIER TIPLIERS TIPLIER 


Lb-Ft 


Lb-Ft 

Maxim Maximum Maxim um 1 112,000 

1 2,000 Lb-Ft 

Lb-Ft 

YOKE OKE OKE REMO REMOVER, REMO REMOVER, 

VER, BB 

BAR BB 

AR TYPE 

TYPE 

INS INSTALLER, INS ALLER, DIFFERENTIAL DIFFERENTIAL DIFFERENTIAL Y YYOKE 

Y OKE 

(1-3/4"-1 (1-3/4"-1 (1-3/4"-12) 

(1-3/4"-1 (1-3/4"-1 2) 

DS DST1 DS T1 T1000-1 T1 000-1 SEAL SEAL INS INSTALLA INS ALLA ALLATION ALLA TION TUBE TUBE HANDLE HANDLE 

HANDLE 

DS DST1 DS T1 T1000-3 T1 000-3 PINION PINION PINION SEAL SEAL INS INSTALLER INS ALLER

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

PO Box 321 

Toledo, Ohio 43697-0321 

Dana Warehouse Commercial Distributor: Vehicle 1.800.621.8084 

Products Group 

3939 OE Technology Dealers: 1.877.777.5360 

Drive 

Maumee, Ohio, USA 43537 

www.spicerparts.com 

www.dana.com 

AXSM-8942 Printed in U.S.A. 

Copyright Dana Limited, 2012. 

All rights reserved. Dana Limited.

Spicer Drive Axles Service Manual

Create successful ePaper yourself

Delete template?

Save as template?