DANA Spicer Single Drive Axles Service Manual

Spicer ® Single Drive Axles Service Manual Single Reduction & Single Reduction with Differential Lock AXSM-0060 May 2016 17060S 17060D 19060S 19060D 21060S 21060D 22060S 22060D P19060S P21060S P22060S

Important Notice 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 WARNING: Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician. CAUTION CAUTION: Failure to follow indicated procedures may cause component damage or malfunction. IMPORTANT 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. Always use genuine Spicer replacement parts.

AXSM-0060 May 2016 II Table of Contents Table of Contents General Information Introduction .................................................................. 1 Model Listing ................................................................ 1 Model Identification ...................................................... 2 Parts Identification ....................................................... 2 Ring Gear and Pinion .................................................... 3 Inspection Failure Analysis ........................................................... 4 Inspect Assembly ........................................................ 6 Inspect Axle Housing .................................................. 6 Inspect Primary Gearing ..............................................6 DIfferential Carrier Exploded View ............................................................. 7 Remove Differential Carrier ......................................... 8 Install Differential Carrier ........................................... 9 Carrier Assembly - Exploded View ............................ 10 Disassemble Carrier Assembly ................................... 10 Remove Wheel Differential - With Differential Lock .. 10 Remove Wheel Differential .......................................... 12 Remove Pinion Assembly ............................................ 13 Pinion Assembly Exploded View ........................................................... 14 Disassembly & Overhaul Drive Pinion ......................... 15 Replace Pinion Bearing Cage Cups ............................ 16 Adjust Pinion Bearing Preload (Trial Buildup) ............. 17 Adjust Pinion Bearing Preload (Final Buildup) ............ 18 Install Drive Pinion Assembly ..................................... 21 Wheel Differential Exploded View ........................................................... 22 Disassemble, Overhaul, & Assemble ......................... 23 Measure and Adjust Carrier Assembly ....................... 26 Adjust Ring and Pinion Tooth Contact Pattern ........... 28 Wheel Differential Lock Exploded View ........................................................... 30 Install and Adjust Wheel Differential Lock ................ 31 Install and Adjust Ring Gear Thrust Bolt ................... 32 Replace Seal ............................................................. 33 Housing Breather Install New Housing Breather (Metal and Plastic) .... 34 Wheel End Seal Exploded View ........................................................... 35 Remove and Overhaul Wheel End Seal ..................... 36 Install Wheel End Seal .............................................. 36 Wheel Adjustment Systems Adjust Wheel Bearing ................................................ 37 Wheel End Verify Wheel End-Play Procedure .............................. 39 Adjust End-Play with Tire & Wheel Assembly ............ 39 Adjust End-play with Wheel Hub ................................ 39 Lubricate Wheel End.................................................... 40 Lubrication Approved Lubricants ................................................... 41 Recommendations for Viscosity / Ambient Temp ........ 41 Lube Change Intervals ................................................. 42 Change Lube ................................................................ 43 Towing Proper Vehicle Towing ................................................. 44 Theory of Operation Wheel Differential Assembly Operation ....................... 45 Wheel Differential Lock Operation ............................... 46 Parts Identification Rear Drive Axle Parts - Exploded View ......................... 48 Axle Housing - Exploded View ...................................... 49 Torque Chart Fastener Torque Specifications...................................... 50

1 AXSM-0060 May 2016 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 anytime 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. Introduction Dana presents this publication to aid in maintenance and overhaul of Spicer single reduction drive axles. Instructions contained cover the models listed below. 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. The suffix letter “P” in the model number indicates a lube pump is standard. Pump models are equipped with a gerotor pump, designed to provide additional lubrication to the inter-axle differential and related parts. Model Listing The following models are included in this publication. Rear Axle Load Capacity 17060S 17,600 19060S P19060S 19,000 21060S P21060S 21,000 22060S P22060S 22,000 19 06 0 S GAWR x 1000 lbs. Series (family) Gearing: D - Single Reduction with Wheel Differential Lock I - Integral Brake L - Limited-Slip N - No-Spin O - Rolled Over P - Lube Pump R - Retarder/Parking Brake Ready S - Single Reduction T - Duel Reduction W - Wide-track Design level

AXSM-0060 May 2016 2 General Information Model Identification Parts Identification Axle Housing Axle Shaft Data plate is located on the axle centerline 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 1 - Country of origin 2 - Axle modle identification 3 - Specification number assigned to the axle built by Spicer. Identifies all component parts of the axle including special OEM requirements such as yoke 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 Axle Shaft Part Number PT. NO . HSG. CAP. LBS. HSG. I.D. NO. HO USING MADE IN Spicer ® Identification Tag General Information

3 AXSM-0060 May 2016 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 5 2 3 1 7 8 L 7 0 3 8 1 4 L7038 4 7 G 3 127 0H 6 8 6

AXSM-0060 May 2016 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, including questions to ask: • Talk to the operator of the truck. • Look at the service records. • Find out when the truck was last serviced. • Ask: In what type of service is the truck being used? • Ask: Has this particular failure occurred before? • Ask: 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: Was the vehicle operating at normal temperatures? • Ask: Were the gauges showing normal ranges of operation? • Ask: 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. 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 working 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. Inspection

5 AXSM-0060 May 2016 Inspection Prepare the Parts for Inspection After the preliminary investigation, locate the failure and prepare 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 recommended 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 viscosity? 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 failure 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 here 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 in correcting 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.

AXSM-0060 May 2016 6 Inspection Inspect Assembly 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. WARNING 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 solutions. 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. CAUTION Any damage which affects the alignment or structural integrity 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. 1 - Axle housing 2 - Machined surface 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 lubrication 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 surfaces 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. 1 2 Inspection

7 AXSM-0060 May 2016 Differential Carrier Differential Carrier Assembly - Exploded View 3 2 1 1 - Carrier Fasteners 2 - Carrier Assembly 3 - Single Axle Assembly

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DANA Spicer Single Drive Axles Service Manual

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