DANA Spicer AXSM0056 User manual

Spicer®Single Drive Axles
Service Manual
AXSM0056
September 2013
S170 Series
S190 Series
S590Series

General Information
General Information
The description and specifications contained in this service publication are current at the time of printing.
Dana reserves the right to discontinue or to modify its models and/or procedures and to change specifications at any
time without notice.
Any reference to brand names in this publication is made simply as an example of the types of tools and materials recommended
for use and should not be considered an endorsement. Equivalents, if available, may be used.
Important Notice
Always use genuine Spicer replacement parts.
This symbol is used throughout this
manual to call attention to procedures
where carelessness or failure to follow
specific instructions may result in
personal injury and/or component
damage.
Departure from the instructions, choice
of tools, materials and recommended
parts mentioned in this publication
may jeopardize the personal safety
of the service technician or vehicle
operator.
WARNING: Failure to follow indicated
procedures creates a high risk of personal
injury to the servicing technician.
CAUTION: Failure to follow indicated
procedures may cause component
damage or malfunction.
IMPORTANT: Highly recommended
procedures for proper service of this unit.
Note: Additional service information not
covered in the service procedures.
Tip: Helpful removal and installation
procedures to aid in the service of this unit.

Table of Contents
Table of Contents
Table of Contents
Wheel
Differential
Assembly
page 23
Carrier
Assembly
page 7
Drive
Pinion
page 12
Seals
page 47
Housing
Breather
page 46
Lubrication
page 54
Wheel
Differential
Lock
page 40
Wheel
End Seal
page 47

General Information
Introduction .....................................................................1
Model Identification ..................................................... 2-3
Failure Analysis ...........................................................4-5
Inspection........................................................................6
Differential Carrier Assembly - Parts................................7
Remove Differential Carrier..........................................8-9
Install Differential Carrier...............................................10
Remove Wheel Differential (All Standard Models) ..........11
Pinion Removal .........................................................12-13
Pinion Assembly - Parts Exploded View .........................14
Drive Pinion Overhaul and Assembly.........................15-19
Wheel Differential - Parts Exploded View...................... 20
Wheel Differential Disassembly - Before July 2013
Forward Carrier Assembly .................................. 21-22
Wheel Differential Assembly -
Forward Carrier Assembly .................................. 23-24
Install Wheel Differential Assembly -
Forward Carrier Assembly .................................. 25-29
Wheel Differential Disassembly - After July 2013
Forward Carrier Assembly .................................. 30-31
Wheel Differential Assembly -
Forward Carrier Assembly .................................. 32-34
Install Wheel Differential Assembly -
Forward Carrier Assembly .................................. 35-37
Adjust Tooth Contact Position ..................................38-39
Wheel Differential Lock - Parts Exploded View.............. 40
Install and Adjust Wheel Differential Lock ......................41
Housing and Output Shaft Assembly -
Parts Exploded View.................................................42
Replace Seal............................................................43-44
Service Kit.................................................................... 45
Housing Breather.......................................................... 46
Wheel End Seal - Parts Exploded View ..........................47
Remove and Overhaul Wheel End Seal.......................... 48
Adjust Wheel Bearing...............................................49-50
Verify Wheel Endplay Procedure ....................................51
Lubricate Wheel End................................................ 52-53
General Lubrication Information.................................... 54
Lube Change Intervals .................................................. 55
Change Lube ................................................................ 56
Standpipes .............................................................. 57-58
Proper Vehicle Towing....................................................59
Power Divider Operation
(Power Flow and Torque Distribution) .................60-61
Operate Wheel Differential Assembly.............................62
Direct Driver-Controlled System.................................... 63
Wheel Differential Lock............................................64-65
Pinion Assembly - Parts Exploded View ........................ 66
Wheel Differential -
Parts Exploded Views ...............................................67
Wheel Differential Lock Assembly -
Parts Exploded Views .............................................. 68
Housing and Output Shaft Assembly -
Parts Exploded View................................................ 69
Fastener Torque Specifications ......................................70

1
General Information
General Information
Introduction
Dana Commercial Vehicle Systems Division, presents this
publication to aid in maintenance and overhaul of Spicer
tandem drive axles.
Instructions contained cover the models listed. Their design is
common, with differences in load capacity. Capacity variations
are achieved by combining basic differential carrier assemblies
with different axle housings, axle shafts and wheel
equipment.
Model Listing
Model Information
The following models are included in this publication:
Heavy Singles
S21-170 S26-190
S21-170D S26-190D
S23-170 S30-590
S23-170D S30-190
S23-190 S30-190D
S23-190D S30-190E
S25-170 S35-590
S26-170 - - -
S 23-1 7 0 D
D - Dual Drive Forward Axle
with Inter-Axle Differential
G - Single Rear Axle (Global)
R - Dual Drive Rear Axle
S - Single Rear Axle (N.A.)
Gear Type
1 - Standard Single Reduction
2 - Dual Range
3 - Planetary Double Reduction
4 - Open
5 - Helical Reduction
Options
C - Controlled Traction
D - Differential Lock
E - High Entry Single
H - Heavy Wall
I - Integral Brake
L - Limited-Slip
P - Lube Pump
R - Retarder Ready
W - Wide-Track
Design Level
Head Assembly Series
GAW Rating
x 1000 lbs. (N. America) "-"
x 1 Tn. (Europe) "."

2
General Information
Model Identification
Drive Axle
Parts Identification
Axle Housing
Axle Shaft
1 - Country or origin
2 - Axle model identification
3 - Specification number assigned to the axle built by Spicer.
Identifies all component parts of the axle including
special OEM requirements such as yokes or flanges.
4 - OEM part number assigned to the axle build
5 - Carrier assembly serial number assigned by the
manufacturing plant
6 - Axle gear ratio
7 - Carrier assembly production or service part number
Rear Axle (Top View)
4
6
5
1
3
2
7
Spicer®
MODEL PART NO. RATIO
MADE IN:
SPEC. SERIAL NO.
CUST. PART NO.
Spicer
®
MODEL PARTNO. RATIO
MADEIN:
SPEC. SERIALNO.
CUST.PART NO.
1 - ID Tag
1
PT. NO.
HSG. CAP. LBS.
HSG. I.D. NO.
HOUSING MADE IN
Spicer®
2 - Axle shaft part number
2

3
General Information
General Information
Ring Gear and Pinion
Note: Ring gear and drive pinion are matched parts and
must be replaced in sets.
1 - Part number
2 - Number of ring gear teeth
3 - Manufacturing numbers
4 - Matching gear set number
5 - Number of pinion teeth
6 - Date code
7 - Indicates genuine Spicer parts
8 - Heat code
41-8
SPICER
127381
OF
NL2
17
127
8-41
127428
SPICER
17
G
6-39
JD77
85405
DANA
86
52
3
1
7
8
L
7
0
3
8
1
4
L7038
4
7
G
3
127
0H
6
8
6

4
Inspection
Failure Analysis
Failure analysis is the process of determining the original
cause of a component failure in order to keep it from
happening again. Too often, when a failed component is
replaced without determining its cause, there will be a recurring
failure. If a carrier housing is opened, revealing a ring
gear with a broken tooth, it is not enough to settle on the broken
tooth as the cause of the carrier failure. Other parts of the
carrier must be examined. For a thorough understanding of
the failure and possible insight into related problems, the
technician needs to observe the overall condition of the vehicle.
No one benefits when a failed component goes on the junk
pile with the cause unknown. Nothing is more disturbing to a
customer than a repeat failure. Systematically analyzing a failure
to prevent a repeat occurrence assures quality service by
avoiding unnecessary downtime and further expense to the
customer.
The true cause of a failure can be better determined by
knowing what to look for, determining how a piece of the
equipment was running, and learning about previous problems.
In the case of a rebuilt rear axle, mismatched gears may
have been installed.
The more successful shops prevent repeat equipment failures
by developing good failure analysis practices. Knowing how
to diagnose the cause of a premature failure is one of the
prerequisites of a good heavy-equipment technician.
How to Diagnose a Failure
The following five steps are an effective approach to good
failure diagnostics.
1. Document the problem.
2. Make a preliminary investigation.
3. Prepare the parts for inspection.
4. Find the cause of the failure.
5. Correct the cause of the problem.
Document the Problem
Here are some guidelines for starting to learn about a failure.
• Talk to the operator of the truck.
• Look at the service records.
• Find out when the truck was last serviced.
Ask the following questions:
• In what type of service is the truck being used?
• Has this particular failure occurred before?
• How was the truck working prior to the failure?
You need to be a good listener. Sometimes insignificant or
unrelated symptoms can point to the cause of the failure.
Ask the following questions:
• Was the vehicle operating at normal temperatures?
• Were the gauges showing normal ranges of operation?
• Was there any unusual noise or vibration?
After listening, review the previous repair and maintenance
records. If there is more than one driver, talk to all of them
and compare their observations for consistency with the
service and maintenance records. Verify the chassis Vehicle
Identification Number (VIN) number from the vehicle identification
plate, as well as the mileage and hours on the vehicle.

5
Inspection
Inspection
Make a Preliminary Investigation
These steps consist of external inspections and observations
that will be valuable when combined with the results of the
parts examination.
•Look for leaks, cracks or other damage that can
point to the cause of the failure.
•Make note of obvious leaks around plugs and seals.
A missing fill or drain plug would be an obvious
cause for concern.
•Look for cracks in the carrier housing (harder to see,
but sometimes visible).
•Does the general mechanical condition of the vehicle
indicate proper maintenance or are there signs of
neglect?
•Are the tires in good condition and do the sizes
match?
•If equipped with a torque-limiting device, is it work-
ing properly?
During the preliminary investigation, write down anything
out of the ordinary for later reference. Items that appear
insignificant now may take on more importance when the
subassemblies are torn down.
Prepare the Parts for Inspection
After the preliminary investigation, locate the failure and pre-
pare the part for examination. In carrier failure analysis, it may
be necessary to disassemble the unit.
•When disassembling subassemblies and parts, do
not clean the parts immediately since cleaning may
destroy some of the evidence.
•When tearing down the drive axle, do it in the recom-
mended manner. Minimize any further damage to the
unit.
•Ask more questions when examining the interior of
the carrier. Does the lubricant meet the manufacturer
specifications regarding quality, quantity and viscos-
ity? As soon as you have located the failed part, take
time to analyze the data.
Find the Cause of the Failure
Here begins the real challenge to determine the exact cause of
the failure. Keep in mind that there is no benefit to replacing a
failed part without determining the cause of the failure. For
example, after examining a failed part and finding that the fail-
ure is caused by a lack of lubrication, you must determine if
there was an external leak. Obviously, if there is an external
leak, just replacing the failed gear is not going to correct the
situation.
Another important consideration is to determine the specific
type of failure which can be a valuable indicator for the cause
of failure. The following pages show different types of failures
and possible causes. Use this as a guide in determining types
of failures and to correct problems.
Correct the Cause of the Problem
Once the cause of the problem has been determined, refer to
the appropriate service manual to perform the repairs.

6
Inspection
Inspection
Clean
1. Wash steel parts with ground or polished surfaces
in solvent. There are many suitable commercial
solvents available. Kerosene and diesel fuel are
acceptable.
Gasoline is not an acceptable solvent because of its
extreme combustibility. It is unsafe in the workshop
environment.
2. Wash castings or other rough parts in solvent or
clean in hot solution tanks using mild alkali solu-
tions.
Note: If a hot solution tank is used, make sure parts are
heated thoroughly before rinsing.
3. Rinse thoroughly to remove all traces of the cleaning
solution.
4. Dry parts immediately with clean rags.
5. Oil parts.
•If parts are to be reused immediately: Lightly oil.
•If parts are to be stored: Coat with oil, wrap in
corrosion resistant paper and store in a clean,
dry place.
Inspect Axle Housing
Axle housing inspection and repairs are limited to the
following checks or repairs.
•Visually inspect axle housing for cracks, nicks, and
burrs on machined surfaces.
•Check carrier bolt holes and studs for foreign
material.
•Replace damaged fasteners. Look for loose studs or
cross threaded holes.
Any damage which affects the alignment or structural integ-
rity of the housing requires housing replacement. Do not
repair by bending or straightening. This process can affect
the material's properties and cause it to fail completely
under load.
•Check all seals and gaskets.
Note: Replace conventional gaskets with silicone rubber
gasket compound (included in many repair kits). The
compound provides a more effective seal against lube
seepage and is easier to remove from mating surfaces
when replacing parts.
Inspect Components
Inspect all steel parts for:
•Notches, visible steps or grooves created by wear
•Pitting or cracking along gear contact lines
•Scuffing, deformation, or discolorations. These are
signs of excessive heat in the axle and are usually
related to low lubrication levels or improper lubrica-
tion practices.
In addition, inspect the following for damage:
•Differential gearing.
•Bearings for loose fit on drive pinion, pilot bearing,
and differential bearings.
•All fasteners for rounded heads, bends, cracks, or
damaged threads.
•Inspect machined surfaces of cast or malleable
parts. They must be free of nicks, burrs, cracks,
scoring, and wear.
•Look for elongation of drilled holes, wear on sur-
faces machined for bearing fits and nicks or burrs in
mating surfaces.
Inspect Primary Gearing
Before reusing a primary gear set, inspect teeth for signs of
excessive wear. Check tooth contact pattern for evidence of
incorrect adjustment.
WARNING
CAUTION
1
2
1 - Axle housing
2 - Machined surface