Dana Spicer tandem drive axle service manual

Spicer ® Tandem Drive Axles Service Manual Single Reduction & Single Reduction with Wheel Differential Lock AXSM-0046 July 2016 DDH/RDH40 DSH/RSH40 DSP/RSP40 DST40(P) DDT41(P) DSP/RSP41 DST41(P) DDH/RDH44 DSH/RSH44 DA/RA344 DS/RS344 DA/RA404(P) DD/RD404 DS/RS404(P) DA/EA405(P) DD/RD405 DS/RS405(P) DD/RD454 DS/RS454(P)

This symbol is used throughout this manual to call attention to procedures where care- lessness 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 mayjeopardize 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. Always use genuine Spicer replacement parts. 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. General Information Important Notice

General Information General Information ......................................................... i Introduction .................................................................... 1 Model Listing ................................................................. 1 Model Information........................................................... 1 Model Identification ........................................................ 2 Part Identification............................................................ 2 Ring Gear and Pinion ...................................................... 3 Inspection Failure Analysis ............................................................... 4 Prepare the Parts for Inspection ..................................... 5 Inspection .... .................................................................. 6 Check Input Shaft End-play (Forward Axle) .................. 7 Check Output Shaft End-play (Forward Axle)...................7 Remove Differential Carrier Differential Carrier Assembly - Parts................................ 8 Remove Differential Carrier (Forward and Rear).............. 9 Install Differential Carrier Install Differential Carrier (Forward and Rear) ............... 10 Differential Lockout Inter-Axle Lockout Types ............................................... 11 Remove Lockout ........................................................... 14 Install Lockout .............................................................. 14 Power Divider Power Divider - Parts Exploded View ............................ 15 UNITS BUILT BEFORE 11/2/1998 ................................. 16 Remove Power Divider .................................................. 16 Disassemble, Assemble, and Overhaul Power Divider .......................................................... 17 Remove Lube Pump ..................................................... 21 Install Lube Pump ........................................................ 21 Install Power Divider to Carrier Assembly .................... 22 UNITS BUILT AFTER 11/2/1998 ................................... 24 Disassemble, Assemble, and Overhaul Power Divider (In Vehicle) ........................................ 24 Lube Pump Removal: Assemblies Built Before June 15, 2008 ................. 27 Lube Pump Installation: Assemblies Before June 15, 2008 ........................... 27 Lube Pump Removal: Assemblies Built After June 15, 2008 .................. 28 Lube Pump Installation: Assemblies After June 15, 2008 .............................29 Lube Manifold Removal ................................................. 31 Manifold Installation ...................................................... 31 Hose/ Filter Assembly ................................................... 32 Install Power Divider to Carrier Assembly (In Vehicle) ........................................................ 33 Disassemble, Assemble, and Overhaul Power Divider (Out of Vehicle) ......................... 36 Lube Pump Removal: Assemblies Built Before June 15, 2008 .............. 40 Lube Pump Installation: Assemblies Built Before June 15, 2008 ............. 40 Lube Pump Removal: Assemblies Built After June 15, 2008 .............. 41 Lube Pump Installation: Assemblies Built After June 15, 2008 ................ 42 Lube Manifold Removal ...............................................43 Manifold Installation .....................................................43 Hose/ Filter Assembly ...................................................44 Install Power Divider to Carrier Assembly (Out of Vehicle) .................................................... 45 Measure and Adjust Input Shaft End-Play.....................47 Carrier Assembly Carrier Assembly - Parts Exploded View ......................49 Disassemble Carrier Assembly ....................................49 Drive Pinion Front Axle Pinion Assembly-Parts Exploded View........ 53 Rear Axle Pinion Assembly-Parts Exploded View......... 53 Disassemble and Overhaul Drive Pinion ..................... 54 Replace Pinion Bearing Cage Cups ........................... 56 Adjust Pinion Bearing Preload .................................... 57 Final Buildup ............................................................... 58 Install Drive Pinion Assembly ...................................... 61 Wheel Differential Assembly Wheel Differential - Parts Exploded View .....................63 Disassemble, Overhaul and Assemble Wheel Differential (Forward and Rear Axles) .....................64 Overhaul and Assemble Wheel Differential ..................65 Measure and Adjust Carrier Assembly .........................67 Change Backlash Setting .............................................68 Measure Ring Gear Runout ..........................................68 Adjust Tooth Contact Pattern Adjust Ring and Pinion Tooth Contact Pattern .............69 Adjust Pinion Position ...................................................70 Adjust Ring Gear Position (Backlash) ............................70 Wheel Differential Lock Wheel Differential Lock - Parts Exploded View ............71 Install and Adjust Wheel Differential Lock ....................72 Install and Adjust Ring Gear Thrust Bolt .......................73 Table of Contents Table of Contents

Housing and Output Shaft Assembly Remove Output Shaft Assembly ...................................74 Housing and Output Shaft Assembly - Parts Exploded View ................................................75 Overhaul and Assemble Output Shaft Assembly .........76 Measure and Adjust .....................................................78 Seals Replace Seal .................................................................79 Guidelines for Reusing Yoke .........................................79 Service Kit 217414 ........................................................80 New Welded D-Housing Cover .....................................80 IASS Inter-Axle Speed Sensor - Parts Exploded View ..........81 Disassemble Inter-Axle Speed Sensor .........................82 Overhaul Inter-Axle Speed Sensor ...............................82 Install Inter-Axle Speed Sensor ....................................83 Housing Breather Install New Axle Housing Breather (Metal and Plastic) ................................................. 84 Wheel End Seal Wheel End Seal - Parts Exploded View ........................ 85 Remove and Overhaul Wheel End Seal .........................86 Install Wheel End Seal .................................................86 Wheel Adjustment Systems Adjust Wheel Bearing .................................................. 87 Wheel End Verify Wheel End-play Procedure ................................ 89 Readjust Wheel End-play Procedure ............................ 89 Lubricate Wheel End .................................................... 90 Wheel Ends Without Oil Fill Hole .................................. 91 Lubrication General Lubrication Information ................................... 92 Approved Lubricants ................................................... 92 Recommendations for Viscosity / Ambient Temp. ....... 92 Lube Change Intervals ................................................. 93 Change Lube ................................................................ 94 Standpipes ................................................................... 95 Final Check .................................................................. 96 Towing Proper Vehicle Towing ................................................... 97 Theory of Operation Power Divider Operation (Power Flow and Torque Distribution) .................... 98 Operate Wheel Differential Assembly ......................... 100 Control Systems for Differential Lock ......................... 100 Wheel Differential Lock ............................................... 101 Parts Identification Power Divider - Parts Exploded View ......................... 103 Front Drive Axle - Parts Exploded View ...................... 104 Rear Drive Axle - Parts Exploded View ....................... 105 Inter-Axle Speed Sensor - Parts Exploded View............ 106 Wheel Differential Lock Assy - Parts Exploded View...... 106 Housing and Output Shaft Assembly - Parts Exploded View ............................................ 107 Torque Chart Fastener Torque Specifications .................................. 108 Table of Contents

1 General Information General Information 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. Model Information FORWARD AXLE REAR AXLE FORWARD AXLE REAR AXLE LOAD CAPACITY . s b l 0 0 0 , 4 3 4 4 3 S R 4 4 3 S D DA344 RA344 DS404(P) RS404 DSP41 RSP41 40,000 lbs. DA404(P) RA404 DSH40 RSH40 DD404(P) RD404 DDH40 RDH40 DS405(P) RS405 DSH44 RSH44 DS405(P) RA405 DDH44 RDH44 DD405(P) RD405 DST40(P) RST40 DSP40 RSP40 DST41(P) RSDT41 DDT41(P) DS454(P) RS454 DD454(P) RD454 45,000 lbs. DA454(P) RA454(P) Gearing Capacity (x 1000 lbs.) Design Level Lube Pump D - Forward Tandem Axle R - Rear Tandem Axle S - Single Reduction T - Dual Range P - Planetary Double Reduction D - Single Reduction with Wheel Differential Lock A - Single Reduction with In-Axle Speed Sensors (IASS) Example: DS = Forward Tandem Axle/Single Reduction or RS = Rear Tandem Axle/Single Reduction Example: 40 = 40,000 lbs. P = Standard (P) = Optional D - Tandem Forward Axle with Inter-Axle Differential R - Tandem Rear Axle Gearing S - Single Reduction D - Driver Controlled Differential Lock (P) = Optional Lube Pump H= High Performance-40ª T= Torsionally Tuned P= Premium Capacity (x 1000 lbs.) Example: 40 = 40,000 lbs.

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 Data plate is located on the axle centerline Forward Axle (Side View) 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 Spicer 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 5 2 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 happen- ing 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 pre- requisites 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 tempera- tures? • 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 combine 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.

5 Inspection 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 determine, 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 sol- vents available. Kerosene and diesel fuel are acceptable. Gasoline is not an acceptable solvent because of its extreme combustibility. It is unsafe in the workshop envi- ronment. 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 gas- ket 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 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. WARNING CAUTION 1 - Axle Housing 2 - Machined surface 1 2

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Dana Spicer tandem drive axle service manual

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