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

7
Differential Carrier
Assembl
y
Differential Carrier Assembly
Differential Carrier Assembly - Parts
1 - Carrier fasteners
2 - Carrier assembly
3 - Single axle assembly
1
2
3

8
Differential Carrier Assembly
Remove Differential Carrier
Note: The removal of the forwardcarrier does not require dis -
connecting of the inter-axledrivelineandremoval of the
output shaftyoke assembly as most other Spicer tan-
dems require.
Standard Differentials
1. Block the vehicle.
2. Drainaxlelubricant.
3. Disconnectdriveline.
4. Disconnectleadwires to the selectorswitch and air
line at shiftcylinder.
5. Removeaxle shafts.
Do not lie under carrier after fasteners are removed. Use
transmission jack to support differential carrier assembly
prior to lo osening fasteners.
6. To removeaxle shaft, remove axle stud nuts.
(If used,remove lock washers and taper dowels.)
7. Removeaxle shafts.
Note: All models in this publicationuseaxle shafts with
unequal lengths. Axle shafts may also be location spe-
cific with various wheelequipment. Do not misplace axle
shafts from their intended location. Identify left and right
shafts for reference duringreassembly.
TIP: If necessary, loosen dowels by holding a brass
drift in the center of the shaft headandstriking drift
with a sharpblow witha hammer.
Do not strike the shaft head with a steel hammer. Do not
use chisels or wedges to loosen shaft or dowels.
8. Removecarriercapscrews, nuts,andlockwashers.
9. Removedifferentialcarrierassembly.
WARNING
CAUTION

9
Carrier Assembly
Carrier Assembly
6. Mount the differential carrier in a head stand with
the wheel differential facing upward.
Note:For easier disassembly, loosen but do not remove the
pinion nut.
7. Remove the carrier differential bearing cap
capscrews, flat washers and bearing caps.
8A. Use Spicer’s wheel diff. bearing adjustment tool
(part number 513061) to back off the threaded
cups and remove.
Before July 2013
8B. Using a long flat blade screwdriver on a pry bar,
back off one of the wheel diff. bearing adjusters
and remove.
After July 2013
9. Using a chain hoist and the proper strap, lift the
ring gear and wheel differential assembly from
the carrier.
1 - Threaded bearing cup
2 - Adjustment plate
1
2

10
Differential Carrier Assembly
Install Differential Carrier
Before installing carrier assembly, inspect and thoroughly
clean interior of axle housing using an appropriate solvent
and clean rag.
1. Apply Spicer approved RTV compound on axle
housing mating surface as shown in the illustration.
Completely remove all old gasket material prior to
applying new material. Compound will set in 5 minutes.
Install carrier before compound sets or reapply.
TIP: To assist in installing complete differential carrier
use two pieces of threaded rod (M16 X 1.5)
threaded into carrier capscrew holes. Rod should be
approximately 6" long. Use these to pilot the carrier
into the housing.
2. Install carrier to housing, lock washers, capscrews
and nuts. Torque to proper specification. Torque to
250–290 lbs. ft. (339–393 N•m).
3. Install axle shafts and axle stud nuts. (If used, also
install lock washers and tapered dowels.)
4. Add axle lubricant. Fill to bottom of filler hole.
5. Connect driveline, making sure all yokes are in
phase. Lubricate u-joints.
IMPORTANT
1 - Apply silicone gasket in this pattern
1

11
Carrier Assembly
Remove Wheel Differential (All Standard Models)
Carrier Disassembly
For models having the wheel differential lock option or a
carrier thrust bolt, refer to the following procedure. These
parts must be removed first before further disassembly of
the wheel differential can take place.
1. For ease of service, mount differential carrier in
head stand with differential locked with the differ-
ential lock facing up.
2. Remove the threaded cylinder cap.
3. Remove the piston push rod from the shift fork.
4. Remove the shift fork and sliding clutch assembly.
Note: Do not disassemble the shift fork from the sliding
clutch unless parts are to be replaced. To disassem-
ble, use a pin punch to remove spring pin from the
fork leg. The sliding clutch can now be removed from
the fork.
5. Remove the shift fork spring.
Note: Omit this step if the ring gear is to be replaced. If the
ring gear is to be reused, check the tooth contact pat-
tern and ring gear backlash before disassembling the
carrier assembly. When checking the backlash, a yoke
or helical gear must be installed and torqued to the
proper specification to get an accurate reading. Best
results are obtained when tooth contact patterns are
maintained in used gearing.
Carrier Assembly

12
Drive Pinion
Pinion Removal
1. If a pilot web is used, remove the web capscrews.
a. For S190 disassembly, install a M10 x 1.50
bolt in the threaded jack holes found in-
between the pilot web capscrews.
b. For S190 disassembly, use the pry slots pro-
vided at each end of the pilot web.
2. Before the pinion nut can be loosened, you must
de-stake the nut from the slot of the pinion.
3. To de-stake the nut, use a chisel or drift with a
round tip. The flange of the nut must be pushed far
enough outward so that the staked area will not
interfere with the pinion threads when the nut is
removed. See diagram below.
Failure to de-stake the pinion nut will result in damage to
the drive pinion threads when removed. The pinion nut
should never be reused, always replace with new.
4. Remove the pinion nut.
1
1
1 - Threaded Jack Holes
1
1
1 - Slots
CAUTION
1 - Round Tipped Chisel
2 - Machined Slot In Pinion
3 - Nuts Staking Flange
1
2
3

13
Drive Pinion
Drive Pinion
5. Place carrier assembly into a press, place a 2" x 6"
x 6" wood block under the pinion. This will ensure
that when the pinion is pressed free from the bear-
ings the pinion will not be damaged.
6. Use the proper pressing tool to press the end of
the pinion until free from the pinion bearings.
The bearing spacer will be reused or used as a starting
point when resetting the pinion bearing preload. Do not
discard this part.
1 - Carrier Assembly
2 - Press
3 - Pinion
4 - Wood Block
2
1
3
4
1 - Press
1
IMPORTANT

14
Drive Pinion
Pinion Assembly - Parts Exploded View
1 - Pinion pilot bearing
2 - Pinion
3 - Pinion bearing cone - inner
4 - Pinion bearing cup - inner
5 - Pinion bearing spacer
6 - Pinion bearing cup - outer
7 - Pinion bearing cone - outer
8 - Oil seal
9 - Yoke
10 - Pinion nut
1
2
3
4
5
6
7
8
9
10

15
Drive Pinion
Drive Pinion
Drive Pinion Overhaul and Assembly
The preload of the bearings on the drive pinion is adjusted by
a spacer between the inner and outer bearing cones and the
helical gear. The preload is adjusted by changing the thickness
of the spacer. A thicker spacer will decrease the preload, a
thinner spacer will increase the bearing preload.
The following procedure covers both the forward and rear axle
carrier overhaul and assembly.
Note: See carrier disassembly for instructions on pinion and
yoke removal.
1. If the model of axle uses a pilot bearing, remove the
bearing using a split-type puller. Use two procedure
steps to remove each bearing.
a. Mount the puller vertically to separate the bear-
ing from the pinion. This action will force the
puller halves behind the bearing race and start
moving the bearing from the pinion.
b. Mount the puller horizontally to press the bear-
ing from the pinion.
2. Remove the inner pinion bearing cone from the pin-
ion using a split-type puller. Use two procedure
steps to remove each bearing.
a. Mount the puller vertically to separate the bear-
ing from the pinion. This action will force the
puller halves behind the bearing race and start
moving the bearing from the pinion.
b. Mount the puller horizontally to press the bear-
ing from the pinion.
1
1 - Press

16
Drive Pinion
Use the correctly sized spacer. Do not use shim stock or
grind spacers. These practices can lead to loss of bearing
preload and gear or bearing failure.
To prevent bearing damage, use suitable sleeve that only
contacts the inner race of bearing cone.
3. Use a press sleeve to install the inner bearing cone
and pilot bearing, if used, onto the pinion. Apply
pressure until the bottom of the cone touches the
shoulder of the pinion. Apply lubricant to the cone of
the bearing .
4. If removed, install the inner and outer bearing cups
into the carrier.
a. To install the inner bearing cup, place the carrier
in a press with the bottom of the carrier facing
up.
b. Place the cup in the bore, usea sleeve or bear-
ing driver tool to press the cup until it is fully
seated. Use a feeler gage to make sure the cup
is fully seated.
c. If replacement of the output shaft side gear
bearing cup is necessa ry, use either of the fol-
lowing methods:
Weld: Place a weld bead around the inside of
the cup, when the weld cools the cup will fall
out.
Hamme r: Use a rolling head prybar to get under
the cup and then, with a hammer and drift from
the back side of carrier, tap out bearing cup.
d. To install the outer bearing cup, place the carrier
in a press with the top of the carrier facing up.
e. Place the cup in the bore, use a sleeve or bear -
ing driver tool to press the cup until it is fully
seated. Use a feeler gage to make sure the cup
is fully seated.
Note: If a press is not available, use a sleeve or bearing driver
and a hammer to install the cups .
5. Place the pinion on a 6” x 6” x 6” block of wood and
lower the carrier over the pinion .
6. Install the pinion spacer.
IMPORTANT
6-39
JD77
85405
DANA
86
L
7
0
3
8