Eaton Axle and Brake Service Manual. 2-Speed and Double ...

Spicer ® Drive AxlesService Manual2-SpeedDouble ReductionAXSM0040July 1995

The description, testing procedures, andspecifications contained in this servicepublication were current at the time of printing.Dana reserves the right to discontinue ormodify its models and/or procedures and tochange specifications at any time withoutnotice and without incurring obligation.The recommendations of the vehiclemanufacturer should be considered as theprimary source of service information regardingthis Spicer product. This manual is intended tobe used as a supplement to such information.Any reference to brand names in thispublication is made simply as an example ofthe types of tools and materials recommendedfor use and, as such, should not be consideredas an endorsement. Equivalents, if available,may be used.Always use genuine Spicer replacement parts.2Price $3.50

PARTS IDENTIFICATION/NOMENCLATUREGeneralInformationThe service procedures and specifications in this publication cover the Spicer Axleslisted in the charts below.For Spicer Brake service information, refer to BRSM-O033 Service Manual.For shift system service information refer to Spicer Shift System Manual AXSM-0029For Parts identification, refer to your appropriate Spicer parts manual, referenceSpicer product literature order form TCFM-0018 for listings.Early Axle SeriesAxleAxle Model Nos.Series 2-Speed Double Reduction15 15201 1530116 16244 1634417 17201, 17221 17301, 1732118 18201, 18221 18301, 1832121 21221 2132122 22221, 22223 2232123 23221 2332126 26221 2632130 30227 3032735 -35327NOTE: Throughout the manual, axle series identificationis used to indicate variances between axles.2-Speed15040T19050T19055T19060T21060T21065T22060T22065T23070T23080T23085T26080T26085TLate Axle ModelsAxle Model Nos.Double Reduction15040P19050P19055P19060P21060P21065P22060P22065P23070P23080P23085P26080P26085P30055P35055PAxle IdentificationAxle and differential carrier identification iseither stamped on the carrier itself or on ametal tag affixed to the carrier. Location onthe carrier is the same.OLD STYLE TAGAxle Specification NumberThe complete axle is identified by thespecification number stamped on the rearright-hand side of the axle housing. Thisnumber identifies all component parts of theaxle as built by Spicer, including specialOEM requirements such as yoke or flange.In addition, some axles may include a metalidentification tag (see illustration).This tag only identifies the housing. It does notidentify the differential carrier assembly components.METALIDENTIFICATIONTAG4

GeneralInformationPARTS lDENTIFICATION/NOMENCLATURERing Gear and Pinion IdentificationRing Gear and Drive Pinion are matchedparts and must be replaced in sets.Check the appropriate Spicer Axle partsbook for part numbers and orderinginstructions.To aid in identifying gear sets, both partsare stamped with such information asnumber of pinion and ring gear teeth,individual part number and matched setnumber (refer to drawing).SpicerINDICATES GENUINESPICER PARTS5

MAINTENANCE / ADJUSTMENTPeriodicServiceLubricationThe ability of a drive axle to deliverquiet, trouble-free operation over aperiod of years is largely dependentupon the use of good quality gearlubricant in correct quantity. TheApproved Lubricantsmost satisfactory results can beobtained by following the dirrecommendationsfromections contained in this book.The following lubrication instructionsrepresent the most currentDana.Section 2Approved Lubricants - General:Gear lubricants acceptable undermilitary specification (MILSPEC)MIL-L-2105D (Lubricating Oils,Gear, Multipurpose) are approvedfor use in Spicer Drive Axles.The MIL-L-2105D specificationdefines performance and viscosityrequirements for multigrade oils.It supersedes both MIL-L-2105B,MIL-L-2105C and cold weatherspecification MIL-L-10324A. Thisspecification applies to bothpetroleum-based and syntheticbasedgear lubricants if theyappear on the most current"Qualified Products List "(QPL-2105) for MIL-L-2105D.NOTE: The use of separate oiladditives and/or friction modifiersare not approved for use in SpicerDrive Axles.Approved Lubricants - Syntheticbased: Synthetic-based gearlubricants exhibit superior thermaland oxidation stability, andgenerally degrade at a lower ratewhen compared to petroleumbasedlubricants. The performancecharacteristics of these lubricantsinclude extended change intervals,improved fuel economy, betterextreme temperature operation,reduced wear and cleanercomponent appearance. The familyof Spicer gear lubricants representsa premium quality synthetic lubewhich fully meets or exceeds therequirements of MIL-L-2105D. Theseproducts, available in both 75W-90and 80W-140, have demonstratedsuperior performance in comparisonto others qualified underthe MILSPEC, as demonstrated byextensive laboratory and fieldtesting.Lube Sampling and ConditionMonitoring: For information,contact your local Dana representationat phone numbers listed onthe back cover of this manual.Makeup Lube: Maximum amount ofnon-synthetic makeup lube is 100%.Viscosity/Ambient TemperatureRecommendations: The followingchart lists the various SAE Gradescovered by MIL-2105D and theassociated ambient temperaturerange for each. Those SAE Gradesshown with an asterisk (*) areavailable in the Spicer family ofsynthetic gear lubricants.The lowest ambient temperaturescovered by this chart are -40 o F and-40 o C. Lubrication recommendationsfor those applications whichconsistently operate below thistemperature range, must beobtained through the Dana.GradeAmbient Temperature Range75W -40 o F to -15 o F (-40 o C to -26 o C)75W-80 -40 o F to 80 o F (-40 o C to 21 o C)75 W-90* -40 o F to 100 o F (-40 o C to 38 o C)75 W-140 -40 o F and above (-40 o C and above)80W-90 -15 o F to 100 o F (-26 o C to 38 o C)80W-140*-15 o F and above (-26 o C and above)85 W-140 10 o F and above (-12 o C and above)6

PeriodicServiceMAINTENANCE / ADJUSTMENTLube Change IntervalsLubrication Change Internals -General: The initial lubricantchange is one of the mostimportant factors in axle componentlife and durability, becauseof the elimination of break-incontaminants. These contaminantsare primarily iron from the initialbreak-in wear of rotatingcomponents, and silicon from thesand used in manufacture of castcomponents.For either a new or rebuilt driveaxle, the lubricant should bechanged within the first 3000 to5000 miles of operation. Subsequentlubricant changes should bebased on a combination of theintervals stated in the followingchart and user judgment basedheavily on the application andoperating environment.Changing LubeDRAINING: Drain into suitable containerwith lube at normal operating temperature.Inspect drain plug for excessive metalparticle accumulation symptomatic ofextreme wear. Clean and replace plug afterdraining.Lubrication Change Intervals - NOTE: At both the initial and allSevere Service: Severe service subsequent lubricant changes,applications are those whichSpicer recommends that therequire the axle to be consistently magnetic filler and drain plugs,operated near it•s maximum GCW and the breather be cleaned.or GVW ratings, dusty or wetenvironments, or consistent operationon grades greater than 8%.For these applications, the ON/OFFHIGHWAY portion of the chartshould be used.Guidelines - Lube Change Intervals for Drive AxlesMaximum On/Off Highway MaximumLubricant On Highway Change Severe Service ChangeType Miles Interval Miles Interval, r 1 1 IMineral100,000 Yearly 40,000 YearlyBasedSpicerApproved 250,000 3 Year 100 ,000 YearlySynthetlcNOTE: After initial lube change, the entireunit should be inspected if excessiveparticle accumulation is observed.FILLING: Remove filler hole plug and fillhousing- - -with approved lubricant until levelwith bottom of filler hole.ISection 2Late Axle Model15040T/P . . . . . . . . . . . . . . .19050T/P . . . . . . . . . . . . . . .19055T/P, 19060T/P . . . . . .21060T/P, 21065T/P,22060T/P, 22065 T/P . . .23070T/P . . . . . . . . . . . . . . .23080T/P . . . . . . . . . . . . . . .Lube Capacities DO NOT OVERFILL AXLESPints24.033353539.041(Liters)(17.3)(15.6)(16.6)(16.6)(18.4)(19.0)41 (19.0)41 (19.0)36 (17.0)36 (17.0)NOTE: Capacities do not apply to housings not designed by SpicerEarly Spicer Housing Vendor HousingAxle(Round Arm)Series Pints (liter)23 (11) 19 ( 9)33 24 (11)37 (18) 29 (14)37 (18) - -41 (19) 34 (16)41 (19)- -Axles installed at angles exceeding 6 o or operated regularly on grades exceeding may require stand-pipes to allowproper fill levels. For specific information, contact your Dana representative at phone numbers listed on back cover ofthis manual.7

MAINTENANCE / ADJUSTMENTPeriodicServiceWheel End LubricationIMPORTANT: In cases where wheelequipment is being installed, either new orafter maintenance activity, the lube cavitiesare empty. Bearings and seals must bemanually supplied with adequate lubricantor they will be severely damaged before thenormal motion of the vehicle can supplylube to the hub ends of the housing.To avoid the risk of premature damage towheel bearings and seals, they must be"prelubed" any time the wheel equipment isbeing installed. There are two methods ofdoing this. The correct method will dependon the type of wheel equipment being used.Section 2Lubrication When Hubs Have No Filler Holes (Preferred Method*)(Follow procedure in numerical sequence.)3. Jack up right side ofaxle. Maintain this position1. Fill axle with lube through axle housing cover filler hole. for one minute to allow2. Jack up left side of axle.Maintain this position for \one miflow inright silube to flow into wheelends at left side.4. With vehicle level a~ain, add lubethrough axle housing cover filler hole. Theaxle should require two additional pints oflube to bring level up to bottom of filler hole.*The above procedure is the preferred method since it optimizes the lube supply to thewheel end components and axle sump.Hubs Equipped with Lube Filler HolesPour a pint of standard axle lubricant intothe hub through the cavity filler holeprovided.8

PeriodicServiceMAINTENANCE / ADJUSTMENTWheel Bearing AdjustmentWheel bearings should be adjusted atregular intervals using the followingprocedure:PREPARATION: Provide means to capturelubricant that will escape when axle shaftsare removed. Remove axle shafts. Jack thewheel to be adjusted clear of the ground.After securely blocking the vehicle to preventrolling, release the parking brake, allowingthe wheel to rotate freely.1. Remove outer adjusting nut and doweled(or tanged) washer.2. Visually inspect spindle for damage orwear. Inspect the nut and spindle threads fordamage. Make certain that the nut turnswithout binding by cleaning the threads andapplying a light coat of oil prior to adjustingthe wheel bearings. Inspect tanged washer(if used). Replace washer if tangs are brokenor badly misshaped.3. Torque inner nut to 200 lbs.-ft.(272 N.m)while rotating the wheel. Loosen the nutone full turn. - Re-torque to 50 Ibs.-ft.(68 N.m). Back off nut 1/4 of a full turn.4. Install doweled (or tanged) washer. If thedowel pin and washer (or washer tang andnut flat) are not aligned, remove washer, turnit over and reinstall. For further alignment,loosen the inner nut slightly.5. install outer nut and torque as follows:l Doweled washer type lock - 300 Ibs.-ft.(408 N.m)l Tanged washer type lock - 250 Ibs.-ft.(339 N.m)WARNING: Never work under avehicle supported only by a jack.Insure that the vehicle will not rollbefore releasing brakes.TANGED WASHER TYPEThis adjustment procedure should allowwheel to turn freely within .001" to .005" 6. If using the tanged washer type lock,(0.025 to 0.125 mm) end-play. secure adjusting nuts by bending one wheelNOTE: The end-play should be measured nut washer tang over each nut. Bend tangsusing a dial indicator. If the tires and wheels over the closest flat perpendicular to the tangare on the hub, prying the wheel end before (see illustration).making the end-play measurement will 7. Reinstall axle shaft. Refill axle to properproduce a more accurate reading.lube level.Section 29

MAINTENANCE / ADJUSTMENTPeriodicServiceCleaningProper cleaning requires completedisassembly.The differential carrier assembly may besteam cleaned only while mounted inhousing provided all openings are plugged.Wash steel parts with machined surfaces ina commercial solvent.Wash castings or other rough parts insolvent or clean in hot solution tanks usingmild alkali solutions, heating partsthoroughly before rinsing.WARNING: Gasoline is not anacceptable cleaning solvent becauseof its extreme combustibility. It isunsafe in the workshop environment.Rinse all parts thoroughly. Dry immediatelywith clean rags. Lightly oil parts and wrapin corrosion-resistant paper if not reusedimmediately. Store parts in a clean,dry place.Section 2InspectionAll axle components should be closelyinspected after cleaning to determinewhich require replacement. For moredetailed inspection guidelines and failureanalysis, see Spicer Failure AnalysisService Manual AXSM-0020In General:Inspect steel parts for notches, visible stepsor grooves. Look for scuffing, deformationor discoloration related to improperlubrication.Inspect gear teeth for signs of excessivewear, pitting or cracking along contactlines before reusing. Check tooth contactpattern.Inspect machined surfaces of cast ormalleable parts for cracks, scoring, andwear. Look for elongation of drilled holes,wear on machined surfaces and nicks orburrs in mating surfaces.Inspect fasteners for rounded heads, bends,cracks or damaged threads.The axle housing should be inspected forcracks or leaks, loose studs or crossthreadedholes.A CAUTION: Any damage which affectsthe alignment or structural integrity of thehousing requires housing replacement.Repair by welding or straightening shouldnot be attempted. This process can affectthe housing metallurgy and cause it to failcompletely when under load.Repair and ReplacementReplace lower-cost parts, such as thrustwashers, seals, etc., that protect the axlefrom premature wear and do not addgreatly to the cost of your rebuild.Replace heavily worn but unbroken parts,since the damage done, should they fail,would greatly exceed their replacement cost.Steel parts such as shafts or gears are notrepairable. If worn or damaged, they shouldbe replaced, along with mating parts asnecessary.Seals and washers should be routinelyreplaced. Fasteners with self-lockingpatches may be reused if secured withseveral drops of Loctite #277.Axle housing repairs are limited to removalof nicks or burrs on machined surfaces orreplacement of damaged studs.10

Drive AxleOverhaulREMOVAL / DISASSEMBLYDifferential Carrier Assembly Removal(Follow procedure in numerical sequence.)5. 2-Speed Axle Only - Disconnect shiftunit air lines or electrical wires.Remove shift units.NOTE: When shift unit or axle shaft isremoved, provide container to catch4. Remove axle shafts, stud nuts, lockwashers \ oil that escapes from reservoir.and taper dowels (if used). If necessary, \loosen dowels by holding a brass drift in6. Remove nuts, cap screws and washersthe center of the shaft head and striking itfastening carrier to axle housing. Removea sharp blow with a hammer.differential carrier assembly.WARNING: Do not strike the axleshaft flange with a hammer. Do notuse chisels or wedges to loosenshaft or dowels.WARNING: Do not lie under carrierwhile removing fasteners or afterfasteners are removed. Use transmissionjack to support and removedifferential carrier assembly.NOTE: If replacing carrier assembly as a unit, turn to Assembly Section 3, page 31, for instructions.Disassemble Differential CarrierNOTE: If gear set is to be reused, checktooth contact pattern and ring gearbacklash before disassembling differentialcarrier. Best results are obtained whenestablished wear patterns are maintained inused gearing. Omit this step if the gear setis to be replaced.1. Mount differential carrier assembly inrepair stand. Loosen but do not removepinion nut..Section 311

REMOVAL / DISASSEMBLYDrive AxleOverhaulDisassemble Differential Carrier (cont'd)2. Remove shift fork seal and spring.Remove expansion plugs, then working atthe lower (or small) plug hole, drive out theshift fork shaft.WARNING: When using a drift, punchor similar tool, wear safety glasses.3. 2-Speed Axles Only: Remove slidinggear. To remove sun gear, remove theretainer which holds gear in position, thenremove sun gear.Section 3NOTE: When reusing gear set, punchmark bearing adjusters and bearing capsfor location and easier adjustment duringreassembly.4. On teeth-side of ring gear, cut lockwireand remove bearing cap screws. Removecap, adjuster and lock.On back-side of ring gear, cut lockwire andremove bearing cap screws. If the gear set isto be reused, remove bearing cap, adjusterand lock as an assembly. This will facilitatecorrect positioning of ring gear duringreassembly.12

Drive AxleREMOVAL / DISASSEMBLYDisassemble Differential Carrier (cont'd)5. Remove bearing cups. Using a chainhoist lift ring gear and differential assemblyout of carrier.CAUTION: During removal of drivepinion assembly, do not allow pinion todrop on hard surface.6. Invert carrier in stand for drive pinionremoval.~7. Remove pinion bearing cage cap screws,invert carrier in stand, then drive pinioncage assembly out of carrier. If the gear setis to be reused, keep the shim pack intactfor use during reassembly. If the originalshims cannot be reused, record the numberof shims in the pack and the size of each.Disassemble Drive PinionCAUTION: During the following yokeremoval procedure, do not allow pinion todrop on hard surface.1. If pinion nut was not loosened duringearlier disassembly, clamp yoke in visejaws. Use brass pads to prevent damage.Loosen and remove pinion nut. To removeyoke, use suitable puller or press pinionout of yoke.Section 3Overhaul13

REMOVAL / DISASSEMBLYDrive AxleOverhaulDisassemble Drive Pinion (cont'd)2. Support cage and press pinion out ofbearing cage.Press„IIIOUTERBEARINGCUPREMOVALIllÍ3. Press oil seal and outer bearing cup outof cage. Discard oil seal.4. On Early Axle Series 23 thru 35 and23070 T/P, 26085 T/P, 35055 P, remove andretain bearing spacer washer from pinion. Onall axles, remove and retain bearing spacer.5. Using a bearing cup remover, removeinner bearing cup.NOTE: Bearing cup remove~ part numberJ-3940 (Kent Moore Co.) or equivalent canbe used to remove inner bearing cup.6. Remove pilot bearing and inner bearingcone from pinion, using a split-type puller.Use two procedure steps to remove eachbearing (see illustrations below).PILOT BEARING REMOVALSection 3FIRST, mount splitter vertically to splitbearing.SECOND, mount splitter horizontally toremove bearing.14

Drive AxleREMOVAL / DISASSEMBLYDisassemble Wheel Differential1. Remove nuts and bolts fastening ringgear and support cases.2. Remove small support case and thrustwasher.3. Remove ring gear..NOTE: A soft-faced hammer or mallet maybe required to dislodge gear from itsmounting.4. To remove differential assembly, placesupport case assembly on a bench or onthe floor. Position case on its side, thenslowly roll the case and slide differentialassembly out of the case.Section 3Overhaul15

REMOVAL / DISASSEMBLYDrive AxleOverhaulDisassemble Wheel Differential (cont'd)5. Remove thrust washer from largesupport case.\L6. Invert differential assembly to removeidler pins, then remove idler pinions.IdlerIDLER PIN7. Punch mark differential cases for correctlocation in reassembly. Remove cap screwsand separate case halves.Section 38. Lift off thrust washer and side gear.9. Lift out spider, side pinions and thrustwashers. Remove side gear and thrustwasher.16

Drive AxleREMOVAL / DISASSEMBLYDisassemble Wheel Differential (CO~tJ~)10. First, try to lift off high-speed clutchplate by hand. If it cannot be removedeasily, press off plate as follows: (Refer toillustration).A. Insert properly sized adapters (roundmetal stock) into two idler pin holes andinvert the case assembly in a press. Theclutch plate should be down. The adapterlength should provide space for removal ofthe plate.B. Use bar stock to block the center hole inthe clutch plate and press against it withthe press ram.C. Continue to press until the plate breaksloose from the plate dowel pins.11. Remove bearing cones from supportcases using suitable puller (see illustration).NOTE: Holes are provided in case to enableremoval of bearing cone with a pilot punch(see illustration). Tap alternately througheach hole until cone is removed.WARNING: When using a drift,punch or similar tool, wear safetyglasses.Section 3Overhaul17

REMOVAL / DISASSEMBLYDrive AxleOverhaulAssemble Wheel DifferentialNOTE: Lubricate internal parts with gearlube during reassembly.1. Press bearing cones on support cases(see illustration).CAUTION: To prevent bearing conedamage, use suitable sleeve that onlycontacts the inner race of the cone.2. Position high-speed clutch plate withchamfered end of the clutch teeth towardidler pinions. Press clutch plate on case(see illustrations below).CLUTCH PLATEINSTALLATIONr 1I I Clutch.:. .:. . . . . . . . . . . . . . . . . .Section 3CAUTION: It is important that the ends of the dowel pins are recessed 1/8" below surface ofthe clutch plate. If pins extend beyond plate surface, press pins to proper depth. Don't pressthem in too far.18

Drive AxleOverhaulINSTALLATION / ASSEMBLYAssemble Wheel Differential (contJd)3. Place thrust washer and side gear indifferential case (with pins).4. Assemble side pinions and thrustwashers on spider. Place this assembly indifferential case.5. Place side gear and thrust washer inposition on side pinions.6. Align punch marks and place plain caseon case (with pins). Install cap screws andtorque (see chart back page).IDLER PIN AND PINIONINSTALLATIONNOTE: Turn side gear hub to check for freedifferential rotation. Rotation may requireup to 50 ft.-lbs. (65 N-m) torque.7. Install idler pins and pinions.8. Place thrust washer in large support case.Section 319

Section 3INSTALLATION / ASSEMBLYDrive AxleOverhaulAssemble Wheel Differential (cent'd)9. During installation of ring gear,temporarily use two bolts in mountingholes to assure bolt hole alignment. Placering gear on large support case (seeillustration), then remove the two bolts.10. Place support case and ring gearassembly upright on a bench or the floor.Carefully lower differential assembly intocase. Engage idler pinions with ring gearteeth to complete the installation.NOTE: During differential installation, besure thrust washer stays in its propermounting position.11. install thrust washer and small supportcase over differential assembly.12. Carefully install ring gear bolts, makingcertain flat on bolt head is seated againstthe outside diameter of the large supportcase. Install and torque nuts (see chart,back page).NOTE: Temporarily install sliding clutch(or sun gear) and check planetary for freerotation.20

Drive AxleOverhaulREMOVAL / DISASSEMBLYAssemble Drive PinionNOTE: Lubricate parts with gear lubeduring reassembly. When installing bearingcones and pilot bearing, use properly-sizedsleeves that only contact the innerbearing race.1. Before installing cups, check for burrs onbearing surfaces and remove. Press bearingcups in cage.2. Press pilot bearing on pinion. Stakebearing using staking tool. See illustrationfor stake pattern.3. Perform Trial Build-Up Pinion PreloadTest following procedures on next page.Section 321

Section 3ASSEMBLY / ADJUSTMENTDrive AxleOverhaulPinion Bearing Preload Adjustment(Trial Build-Up Test).The pinion bearing spacer thickness controlsbearing preload. The spacer size forcorrect preload can be predetermined byusing a "Initial Build-Up" procedure asdescribed below:1. Assemble pinion bearing cage, cups andbearing spacer... (without pinion or oil seal).See illustration for pacerwasher application.Use nominal size spacer (see chart).NOTE: During assembly procedure, centerbearing spacer between the two bearingcones.2. Lubricate bearings and place the assemblyin the press. Position sleeve or spacer sothat load is applied directly to the backfaceof the outer bearing cone.3. Apply press load to the assembly (seechart). Wrap soft wire or strong string aroundthe bearing cage, attach spring scale andpull steadily. Preload is correct when torquerequired to rotate the pinion bearing cage isfrom 10-20 LBS. -IN. (1.1-2.3 N.m). Thisspecification is translated into spring scalereadings in the chart below.4. If necessary, adjust pinion bearingpreload by changing the pinion bearingspacer. A thicker spacer will decreasepreload. A thinner spacer will increasepreload.22

REMOVAL / DISASSEMBLYDrive AxleOverhaulTria/ Buiki-Up Test (cont'd)CAUTION: Use the correctly sizedspacer. Do not use shim stock or grindspacers. These practices can lead to loss ofbearing preload and gear or bearing failure.5. Once correct bearing preload has beenestablished, note the spacer size used.Select a spacer 0.001" larger for use in thefinal pinion bearing cage assembly. Thelarger spacer compensates for slight"growth" in the bearings which occurs whenthey are pressed on the pinion shank.NOTE: With the first stage of bearing preloadadjustment ("Trial Build-Up") completed,continue reassembly of bearing cage andpinion.6. Press inner bearing cone on pinion usinga properly sized sleeve.I9. At this stage of pinion reassembly,recheck bearing preload adjustment byperforming "Final Bearing Preload Test" (seefollowing procedures).7. Install bearing spacer washer whereused. See illustration on preceding pagefor applications.8. Install bearing cage and cup assembly onpinion. Insert outer bearing cone in cage,then press bearing cone and cage assemblyon pinion.Final Pinion Bearing Preload Test1. With pinion and bearing cage assembled PRESS METHOD: Press should be equippedas previously described, measure bearing with a calibrated load cell to insure properpreload using either of the two following clamp load. Position a sleeve so that load ismethods:applied directly to backface of the outerbearing cone. Apply clamp load (see chartVISE METHOD: Install yoke and nut,next page). Check bearing cage rollingtightening nut to correct torque (see chart). torque (see Step 2).Mount the pinion assembly in a vise,clamping yoke firmly. Apply clamp load(see chart next page). Check bearing cagerolling torque (see Step 2).Section 323

ASSEMBLY / ADJUSTMENTDrive AxleFinal Pinion Bearing Preload Test(cont'd)2. Measure Pinion Bearing Preload - Use aspring scale to test the assembly rollingtorque. To use the spring scale, wrap softwire around the bearing cage, attach thescale and pull. Preload is correct whentorque required to rotate the pinion bearingcage is from 15 to 35 LBS.-IN. (1.7-4.0 N.m).This specification is translated into springscale readings in the chart below.3. Adjust Pinion Bearing Preload - Ifnecessary, adjust pinion bearing preload.Disassemble the pinion bearing cage asrecommended in this manual and changethe pinion bearing spacer. A thicker spacerwill decrease preload. A thinner spacer willincrease preload.IMPORTANT: Use the correctly sizedspacer. Do not use shim stock or grindspacers. These practices can lead to loss ofbearing preload and gear or bearing failure.Install Pinion Oil Seal and Yoke1. With pinion bearing preload adjustmentcomplete, install oil seal. Use a press andproperly sized sleeve to prevent distortionor contact with seal lips during installation(see illustration).Section 32. Make sure yoke is clean and dry. Installyoke and nut (or nut and washer on somemodels). Tighten nut to correct torque (see .chart above~.NOTE: After tightening nut, recheck pinionbearing rolling torque, then proceed withpinion installation in carrier.Overhaul24

Drive AxleASSEMBLY / ADJUSTMENTInstall Drive Pinion1. Place shim pack on carrier.NOTE: If gear is to be reused, install samequantity and size of shims removed duringdisassembly. When installing a new gearset, use nominal shim pack (see chart).PINIONIN STALLAT IONAlign oilholes inshims \2. Install pinion assembly. Install bearingcage cap screws. Torque cap screws(see chart, back page).NOTE: After tightening pinion nut, recheckpinion bearing rolling torque.Install Differential andRing Gear AssemblyNOTE: Lubricate bearings during thefollowing assembly procedures.1. Place ring gear and differential assemblyin carrier. Insure that ring gear and drivepinion mesh properly.NOTE: During installation, tilt carrier toallow support case pilot to rest in carrierbore, then install bearing cup as shown inillustration. Also install bearing cup onopposite side of differential.CAUTION: When installing bearingcaps and adjusters, exercise care not tocross threads.2. Install bearing adjusters and caps.3. Install and tighten bearing cap screwsfinger-tight. If this is difficult, use handwrench.NOTE: The assembly is now ready foradjustment of differential bearing preload,ring gear backlash and gear tooth contact(see next page).Section 3Overhaul25

ADJUSTMENTDrive AxleOverhaulAdjust Differential Bearing PreloadCorrect differential bearing preload insuresproper location of these bearings underload and helps position the ring gear forproper gear tooth contact.1. Lubricate differential bearings2. Loosen the bearing adjuster on the sameside as the ring gear teeth until its firstthread is visible.3. Tighten the bearing adjuster on the backfaceside of the ring gear until there is nobacklash. This can be tested by facing thering gear teeth and pushing the gear awayfrom the body while gently rocking the gearfrom side to side. There should be no freemovement.Rotate the ring gear and check for anypoint where the gear may bind. If such apoint exists, loosen and retighten the backside adjuster. Make all further adjustmentsfrom the point of tightest mesh.Section 34. At teeth side of ring gea~ tighten adjusteruntil it contacts the bearing cup. Continuetightening adjuster two or three notchesand this will preload bearings and provideapproximate backlash. Measure backlashand adjust if necessary (see following page).26

Drive AxleOverhaulADJUSTMENTAdjust Ring Gear BacklashIMPORTANT: Check backlash asbelow and adjust if necessary.described1. Measure backlash with a dial indicator.The indicator should be positioned on aring gear tooth, at the extreme heel end,perpendicular to the tooth surface.BACKLASH SPECIFICATIONS (Normal)New Gearing:Early Axle Series 15 through 18Late Axle Models 15040T/P through 19055T/P . . . . . . . . . . . . . . . 0.006"-0.016" (0.15-0.41mm)Early Axle Series 21 through 35Late Axle Models 21065T/P through 35055T/P . . . . . . . . . . . . . . 0.008"-0.018" (0.20-0.46mm)NOTE: For new gearing, check ring gear backlash after each shim changeand adjust if necessary.Used Gearing: Reset to normal backlash recorded before disassembly.To REMOVE backlash: Loosen the adjusteron the teeth side of the ring gear severalnotches. Tighten the opposite adjuster onenotch.Return to adjuster on teeth side of ring gearand tighten adjuster until it contacts thebearing cup. Continue tightening the sameadjuster 2 or 3 notches. Recheck backlash.To ADD backlash: Loosen the adjuster onthe teeth side of the ring gear severalnotches. Loosen the opposite adjusterone notch.Return to adjuster on teeth side of ring gearand tighten adjuster until it contacts thebearing cup. Continue tightening the sameadjuster 2 or 3 notches. Recheck backlash.Section 327

ADJUSTMENTDrive AxleOverhaulAdjust Ring Gear Tooth ContactAfter differential bearing preload and gearbacklash adjustment is complete, checkgear tooth contact pattern and adjust ifnecessary.CORRECT TOOTH CONTACT PATTERN(NEW GEARING)Paint ring gear teeth with markingcompound and roll the gear to obtain acontact pattern as shown in the drawings.The length of the pattern in an unloadedcondition is approximately one-half to twothirdsof the ring gear tooth in most modelsand ratios.CORRECT TOOTH CONTACT PATTERN(USED GEARING)Used gearing may not display the square,even contact pattern found in new gearsets. The gear may have a "pocket" at heelend of contact pattern. The more use a gearhas had, the more the pocket becomes thedominant characteristic of the pattern.Section 3Adjust used gear sets to display the samecontact pattern observed before disassembly.A correct pattern is up slightly offthe toe and centers evenly along the facewidth between the top land and root.Otherwise, the length and shape of thepattern are highly variable and are consideredacceptable as long as there is somepattern on toe end of the tooth.NOTE: Tooth contact patterns are a function of the relative positions of the ring gearand pinion. An improper pattern will require relocation of either or both. Always adjustpinion position first, if necessary, then ring gear position. Recheck backlash when done.28

Drive AxleOverhaulADJUSTMENTAdjust Ring Gear Tooth Contact (cont)d)Adjust Pinion PositionIf the contact pattern shows incorrect tooth depth contact, change drive pinion position byaltering the shim pack under the cage and cup assembly. Used gears should achieve propercontact with the same shims removed from the axle at disassembly../If the pattern is too close to the root of thegear tooth, add pinion shims.If the pattern is too close to the top land ofthe gear tooth, remove pinion shimsNOTE: Check ring gear backlash after each shim change and adjust if necessary to maintaincorrect backlash (see backlash specs, page 27). Always recheck tooth contact pattern aftermaking shim pack changes.Adjust BacklashIf the contact pattern shows incorrect face width contact, change backlash and recheck the„contact pattern.With the pattern concentrated at the toe(too far down the tooth), ADD BACKLASHby loosening the bearing adjuster on theteeth side of ring gear several notches.Loosen the opposite adjuster one notch.Return to adjuster on teeth side of ring gearand tighten adjuster until it contacts thebearing cup. Continue tightening the sameadjuster 2 or 3 notches. Recheck backlash.If the pattern is concentrated at the heel (toofar up-the tooth), REMOVE BACKLASHby loosening the bearing adjuster on theteeth side of ring gear several notches.Tighten the opposite adjuster one notch.Return to adjuster on teeth side of ring gearand tighten adjuster until it contacts thebearing cup. Continue tightening the sameadjuster 2 or 3 notches. Recheck backlash.Section 329

ASSEMBLY / ADJUSTMENTDrive AxleOverhaulAdjust Ring Gear Tooth Contact (cont'd)When preload, backlash, and tooth contactare correct, align differential bearing adjustersand locks, then tighten differentialbearing cap screws to correcttorque (see chart, back page)Differential Carrier Final Assembly1. Install adjuster lock and cap screw on ringgear teeth side.2. 2-Speed Axles (on backface side of ringqear): Install adjuster lock, dowel bushingsand cap screws: Torque cap screws (seechart, back page). Lockwire differentialbearing cap, and adjuster lock cap screws.3. 2-Speed Axles: Position shift fork incarrier opening, then install sliding clutch.With clutch installed, engage shift fork yokewith clutch collar. Then install shift forkshaft. Install expansion plugs to sealopenings. Install shift unit seal and spring.rSection 3tSUN GEAR COMPONENTSNOTE: Lockwire used on all Early AxleModels and Late Axle Model 35055P.IMPORTANT (2-SPEED AXLES) Electricshift unit replacement. Before installing arebuilt or new shift unit, check fit of shiftfork to slider block pivot using a "Fit-Up"Card or Template (P/N 128039.)These cards are furnished with new shiftunits, retrofit and slider block kits.Instructions are contained on the card orrefer to Spicer Service Manual EA-29.4. Planetary Double Reduction Axles (onbackface side of ring gear): Install sun gearand retainer, then install cap screws thatfasten both retainer and adjuster lock.Tighten screws to correct torque (seechart, back page) and lockwire.Lockwire cap screws when used. Seeillustration for application.30

Drive AxleOverhaulINSTALLATION / ASSEMBLYInstall Differential Carrier AssemblyNOTE: Before installing carrier assembly,inspect and thoroughly clean interior ofaxle housing.NOTE: Use silicone rubber gasketcompound on axle housing mating surfaceas shown in the illustration. Gasketcompound will set in 20 minutes. Installcarrier before compound sets or reapply.1. Install differential carrier assembly inaxle housing. Install cap screws, nuts andlockwashers. Tighten to correct torque(see chart, back page).2. Install axle shafts and stud nuts. Connectdriveline.3. Fill axle with correct lube (seeLubrication Section 2, page 6 and 7).NOTE: Before installing electric shift unit,see IMPORTANT NOTE on page 30.4. For electric shift units, connect electricalwires. Install shift unit, nuts and washers.Tighten nuts to correct torque (see chart,back page).For air shift units, connect airline. Installshift unit, nuts and washers. Tighten nutsto correct torque (see chart, back page).NOTE: When axle has been disassembledor housing, gears, axle shafts or wheelequipment replaced, check axle assemblyfor proper differential action beforeoperating vehicle. Wheels must rotate freelyand independently.Section 331

Fastener Torque SpecificationsEarly Late ThreadFastener Axle Series Axle Models Size Grade Ibs.-ft. N.mDifferential Case 15-16 15040T/P-19050T/P 7/16-14 8 60-70 81-94Cap Screw 17-3!5 19055T/P-35055P 1/2-13 8 90-110 122-149Ring Gear 15 15040T/P 7/16-20 9 70-90 94-122Bolt Nut 16 19050T/P 1/2-20 8 95-115 129-15617-35 19055T/P-35055P 9/16-18 8 110-130 149-176Pinion Bearing 15-22 15040T/P-22065T/P 9/16-12 5 110-125 149-170Cage Cap Screw 23-35 23070T/P-35055P 5/8-11 5 160-176 216-238Bearing Cap 15 15040T/P 5/8-11 8 170-190 230-257Cap Screw 16 19050T/P 11/16-11 8 240-280 325-37917-35 19055T/P-35055P 13/16-10 8 370-430 501-58315 15040T/P 7/16-14 5 48-56 65-75Cap Screw 16 19050T/P 1/2-13 8 95-115 129-15617-35 19055T/P-26085T/P 5/8-11 5 160-176 216-23823070T/P 5/8-11 8 220-240 298-32517-35 35055P NUT 5/8-18 8 220-240 298-32535 Series Housing 3 5 35055P 7/16-14 5 35-51 47-69Cover 1/2-13 5 75-85 101-115NUT 1/2-20 8 110-130 149-176Pinion Nut 15 1-20 360-440 488-59616 1-1/8-18 360-440 488-59617-18 1-1/4-12 480-600 650-81317-22 1-1,/2-18 560-700 759-94923-35 1 -3/4-12 840-1020 1139-1383Pinion Nut 15040T/P *M30x1.5 376-461 510-625*Metric 19050T/P *M30x1.5 376-461 510-62519055T/P-22065T/P *M36x I . 5 542-664 735-90023070T/P-35055P *M42x I . 5 789-966 1070-1310Bearing Adjuster 15-16 15040T/P-19050T/P 9/1 6-12 5 115-125 155-169Lock 17-35 19055T/P-35055P 5/8-1 1 5 160-176 216-238Electric Shift UnitShift Unit All 2-Speed Models 7/1 6-20 8 35-45 47-61Stud/NutAirShift Unit7/1 6-20 8 55-61 74-82Shift Fork Opening All Double Reduction Models 7/1 6-14 5 35-45 47-61Cover ScrewCorrect tightening extremely important to assure long Spicer Axle life Bolt head markingsand dependable performance Under-tightening of attaching parts is just as harmful asfor grade identificationover-tightening.Exacttorque values WIII assure the best results.The data Includes fastener size, grade and torque tightening values. Axle models areIncluded to pinpoint identification of fasteners for your particular axle.determine or for designation stamped on bolt head (see Ô+ÕÓIllustration). Grade 5 Grade 832

For spec‘ing or service assistance, call 1-877-777-5360 or visit our website at www.dana.comDana Commercial Vehicle Products Group3939 Technology DriveMaumee, Ohio, USA 43537www.dana.comAll applications must be approved by the Application Engineering Department. Specifications and/or design are subject to change without notice or obligation. Printed in USA AXSM-0040 07/95