Spicer Tandem Drive Axles Pro-40 Single Reduction and Sin User Manual

Spicer® Tandem Drive AxlesServicPRO-40 Single Reduction & Single Reduction withWheel Differential Locke ManualAXSM0058September 2013D40-145DR40-14

79InspectionInspectionInspect Axle HousingAxle housing inspection and repairs are limited to the follow -ing checks or repairs:• Visually inspect axle

97105Torque ChartRear CarrierLocation Thread Size Class/Grade Torque SpecificationPinion End Nut M36 x 1.5 10.9 625-1040 lbs. ft. (848-1410 N•m)

98

All applications must be approved by the Application Engineering Department. Specifications and/or design are subject to change without notice or obli

810Inspect Primary Gearing Before reusing a primary gear set, inspect teeth for signs of excessive wear. Check tooth contact pattern for evidence of i

911Tandem AxleTandem Axle Assemblies 1 - Carrier fasteners 2 - Carrier assembly3 - Front axle assembly4 - Rear axle assembly5 - Inter-axle differentia

1013Forward AssemblyDifferential Carrier Assembly - ForwardDisassemble Carrier - ForwardNote: The removal of the forward carrier does not require dis-

1114Forward AssemblyInstall Differential Carrier - ForwardNote: Before installing carrier assembly, inspect and thor-oughly clean interior of axle hou

1215Forward AssemblyInter-Axle Lockout Types - ForwardParts Exploded ViewAir-operated to engage the lockout and spring-released to disengage the locko

1316Forward AssemblyDisassemble LockoutExternal Type Lockout8. With axle installed in vehicle, place differential lock selector valve in the disengage

141 417Forward AssemblyPower Divider - ForwardParts Exploded View1 —Output shaft nut2 —Output yoke3 —Output seal4 —Output shaft bearing snap ring5 —Ou

1518Forward AssemblyDisassemble, Assemble and Overhaul Power Divider - In VehicleThe power divider cover comes off as a unit followed by the input sha

1619Forward Assembly17. Remove helical side gear and snap ring.18. Remove thrust washer.19. Remove lockout sliding clutch from the input shaft.20. Rem

Introduction Model Listing ...1 Model Information ...

1720Forward Assembly25. Press input bearing cone on input shaft.26. If input shaft bearing cup needs replacement, use either of the following recommen

1821Forward AssemblyInstall Power Divider to Carrier Assembly - In VehicleNote: See page 20 for out of vehicle.Note: Parts inspection and cleaning pro

1922Forward Assembly8. Install helical side gear and snap ring.9. Install input shaft drive assembly into the carrier.10. Install shift fork, compre

2023Forward AssemblyDisassemble, Assemble and Overhaul Power Divider - Out of VehicleThe power divider cover comes off as a unit followed by the input

2124Forward Assembly11. Remove the IAD assembly from the output side gear.12. Remove the output side gear.Note: Remove lube pump if you have one.13. I

2225Forward Assembly18. If input shaft bearing cup needs replacement, use either of the following recommended practices:• Weld a bead around the cup,

2326Forward AssemblyInstall Power Divider to Carrier Assembly - Out of VehicleNote: Parts inspection and cleaning procedures are important and should

2427Forward AssemblyNote: The input shaft snap ring is not used in this buildup.9. Install plastic oil trough in power divider cover.10. Install power

2528Forward AssemblyLube Pump DisassemblyFor output side gear and/or pump replacement, follow the procedure below.1. Remove the output side gear beari

2629Forward AssemblyLube Manifold Disassembly1. Disconnect the hose from the lube manifold.2. Remove the manifold assembly by prying it out around the

Table of ContentsDifferential Carrier - Rear ...59 Parts Exploded View ...

2730Forward AssemblyNote: For non-pump manifold installation, it is important to line up the oil inlet path hole in the manifold with the oil path ope

2831Forward AssemblyMeasure and Adjust Input Shaft End-PlayNote: After power divider overhaul and installation on carrier, check and adjust input shaf

2932Forward Assembly8. To add or remove shims, remove input shaft nut and yoke. Remove cap screws, lock washers and bearing cover. Add or remove shims

3033Forward AssemblyCarrier Assembly - ForwardParts Exploded View1 — Piston engagement bolt2 — Cap screw3 — Switch4 — Washer5 — O-ring6 — Piston7 — Se

3134Forward AssemblyDisassemble Carrier AssemblyNote: For models having the wheel differential lock option or a carrier thrust bolt follow the steps b

3235Forward AssemblyDisassemble Wheel Differential (All Standard Models)Note: Omit this step if the gear set is to be replaced. If gear set is to be r

3336Forward AssemblyDisassemble Pinion Assembly1. Remove pinion bearing cage cap screws. Remove pinion and cage assembly from carrier. Remove shim pac

3437Forward AssemblyFront Axle Pinion Assembly - ForwardParts Exploded View1—Pinion pilot bearing2—Pinion3—Pinion bearing cone - inner4—Pinion bearing

3538Forward AssemblyDisassemble and Overhaul Drive PinionThe following procedures cover both forward and rear differ-ential drive carrier disassembly.

3639Forward Assembly10. Remove inner bearing cone from pinion using a split-type puller. Use two procedure steps to remove each bearing.a. Mount pulle

11IntroductionIntroductionIntroductionDana Spicer Corporation, Commercial Vehicle Division, presents this publication to aid in maintenance and overha

3740Forward Assembly4. Seat cups securely to shoulder. Check clearance between cup and bearing cage. Must be less than 0.001".Adjust Pinion Beari

3841Forward Assembly3. Rotate pinion cage while applying press load (see chart below) to the assembly and check rolling torque. Wrap soft wire around

3942Forward Assembly3. Install bearing cage on drive pinion.4. Press outer bearing cone on pinion.To prevent bearing damage, spin cage while pressing

4043Forward AssemblyPress Methoda. If a press is used, position a sleeve or spacer so that load is applied directly to the back face of the outer bear

4144Forward AssemblyInstall Drive Pinion Assembly1. Place shim pack on carrier making sure holes are properly aligned. Make sure shims are flat with n

4245Forward AssemblyWheel Differential - ForwardParts Exploded View1 - Ring gear2 - Cap screw3 - Flat washer4 - Diff. carrier bearing caps5 - Cotter p

4346Forward AssemblyDisassemble, Overhaul, and Assemble Wheel Differential - ForwardDisassemble Wheel Differential During following procedure, place d

4447Forward AssemblyOverhaul and Assemble Wheel DifferentialTo prevent bearing damage, use suitable sleeve that only contacts the inner race of the co

4548Forward Assemblyside gear hub.8. Install ring gear. Secure with bolts and nuts.Note: Flange half differential cases were redesigned starting with

4649Forward AssemblyMeasure and Adjust Carrier AssemblyAdjust Backlash and Preload1. Turn the flange half bearing adjuster in until the ring gear cont

22IntroductionModel IdentificationPart IdentificationDrive Axle1 - Country of origin2 - Axle model identification3 - Specification number assigned to

4750Forward AssemblyChange Backlash SettingIf you have too much backlash the ring gear needs to move closer to the pinion. Back off the plain half adj

4851Forward AssemblyAdjust Ring and Pinion Tooth Contact PatternNote: Rear axle gearing is shown in the following instructions. Correct tooth contact

4952Forward AssemblyAdjust Pinion PositionIf the gear pattern shows incorrect tooth depth contact, change drive pinion position by altering the shim p

5053Forward AssemblyWheel Differential Lock - ForwardParts Exploded View1—Piston engagement bolt2—Cap screw3 —Switch4—Washer5 —O-ring6 —Piston7—Setscr

5154Forward AssemblyInstall and Adjust Wheel Differential LockNote: With differential carrier completely assembled and adjusted, install differential

5255Forward AssemblyInstall and Adjust Ring Gear Thrust Bolt1. Thread thrust screw into the carrier until firm contact with the back face of the ring

5356Forward AssemblyHousing and Output Shaft Assembly - ForwardParts Exploded View1— Output shaft nut2— Output yoke3— Output seal4— Snap ring5— Outer

5457Forward AssemblyDisassemble Output Shaft AssemblyNote: For forward axle rear covers that are removable the out-put shaft may be removed when the c

5558Forward AssemblyOverhaul and Assemble Output Shaft AssemblyNote: Lubricate the parts with gear lube during assembly.1. The output shaft bearings a

5659Forward Assembly11. Install yoke nut using one of the following options:g. Install a new nut with the pre-applied thread adhesive compound. Tighte

33IntroductionIntroductionRing Gear and PinionNote: Ring gear and drive pinion are matched parts and must be replaced in sets.1 - Part number2 - Numbe

5760Forward AssemblyMeasure and AdjustNote: Use bearing cup driver to insure seating of snap ring after installation with snap ring pliers.See illustr

5861Forward AssemblyDue to the resiliency of the plastic driver, hammer rebound may occur when the seal is seated. Keep clear of the ham-mer rebound p

5963Rear AssemblyRear AssemblyDifferential Carrier Assembly - Rear1 - Carrier fastener 2 - Carrier assembly Rear Assembly12

6064Rear AssemblyDifferential Carrier - RearParts Exploded View19876543211121314151631302928271718213219102425222320B20A26 1 - Pi nion N u t 2 - End

6165Rear AssemblyRear AssemblyInstall Differential Carrier - RearIMPORTANT: Before installing carrier assembly, inspect and thoroughly clean interior

6266Rear AssemblyDrive PinionRear Axle Pinion Assembly Parts Exploded View1 - Pinion Nut2 - End Yoke3 - Slinger4 - Oil Seal5 - Outer Pinion Bearing Co

6367Rear AssemblyRear AssemblyPinion Disassembly1. Remove yoke nut. 2. Remove yoke using a yoke puller service tool.1 - Yoke puller3. Remove oil seal.

6468Rear AssemblyPinion InstallationFinal BuildupNote: Do not install oil seal in carrier until bearing preload is correctly adjusted.1. Press inner b

6569Rear AssemblyRear Assembly7. Measure torque to rotate the pinion with an inch-pound torque wrench. Torque measurements should be taken every fourt

6670Wheel DifferentialWheel Differential AssemblyParts Exploded View1 - Diff. Case Bearing Adjuster2 - Diff. Bearing Cup3 - Diff. Case Bearing Cone4 -

45General InformationGeneral InformationThe description and specifications contained in this servicepublication are current at the time of printing.Da

6771Wheel DifferentialDisassemble, Overhaul, and Assemble Wheel Differential Disassemble Wheel DifferentialIMPORTANT: Do not press on the wheel differ

68725. The locking pins are slip fit and should fall from the case easily.6. Remove the half shafts first and then remove their side pinions and thrus

6973Assemble Wheel Differential10. Press new bearing cone on the differential case.11. Place thrust washer on the side gear. Lubricate both sides of t

707416. Install a side pinion and thrust washer on the half shaft side.17. Install the half shaft so that the pin is facing upward and push it in unti

717522. Install and hand-tighten all new ring gear cap screws23. The interface of the ring gear to differential case is a press fit. Put the assembly

727626. Install differential case assembly into carrier. Be careful not to damage the differential bearings lower-ing the assembly.27. Lubricate the d

7377Measure and Adjust Carrier AssemblyAdjust Backlash and Preload1. Turn the flange half-bearing adjuster in until the ring gear contacts the pinion

7478Change Backlash SettingIf you have too much backlash, the ring gear needs to move closer to the pinion. Back off the plain half-adjuster, counting

7579Adjust Ring and Pinion Tooth Contact Pattern1 - Face width2 - Tooth depth3 - Heel4 - Top land5 - Root6 - Toe3. Identify if new or used gearing.4.

7680ring gear away from the pinion to increase backlash.1. Loosen the bearing adjuster on the teeth side of the ring gear several notches.2. Loosen th

57InspectionInspectionInspectionFailure AnalysisFailure analysis is the process of determining the original cause of a component failure in order to k

7781SealsSealsService Kit 217414New Welded D-Housing CoverLube Quantity Difference0 (zero)Standout of Output Shaft YokeLength increased by 6mm (.25&qu

7883LubricationGeneral Lubrication InformationThe ability of a drive axle to deliver quiet, trouble-free operationover a period of years is largely de

7984LubricationLube Change IntervalsThis product combines the latest manufacturing and partwashing technology. When filled with a Spicer approvedsynth

8085LubricationChange Lube DrainDrain when the lube is at normal operating temperature (150°–200°F). It will run freely and minimize the time neces-sa

8187Wheel End SealWheel End Seal - Parts Exploded View1 - Installation tool2 - Seal3 - Rear hub123Wheel End Seal

8288Wheel End SealDisassemble and Overhaul Wheel End Seal Never work under a vehicle supported by only a jack. Always support vehicle with stands. Blo

8389Wheel End SealWheel End SealVerify Wheel End-play ProcedureVerify that end-play meets specification using a dial indicator. An indicator with 0.00

8490Wheel End SealLubricate Wheel End Before operating the axle, the wheel hub cavities and bear-ings must be lubricated to prevent failure.When wheel

8591Proper Vehicle TowingProper Vehicle TowingProper Vehicle TowingWithout Wheel Differential LockLift the drive wheels completely off of the ground o

8693Theory of OperationPower Divider Operation (Power Flow and Torque Distribution)In operation, the power divider accepts torque from the vehicle dri

68InspectionPrepare the Parts for Inspection After the preliminary investigation, locate the failure and pre -pare the part for examination. In carrie

8794Theory of OperationWith Lockout Engaged (Inter-Axle Differential is Not Operating) Lockout should only be engaged when both axles are rotat-ing at

8895Theory of OperationOperate Wheel Differential AssemblyThe Dana wheel differential lock is driver-controlled and oper-ated by a carrier mounted air

8996Theory of OperationWheel Differential LockThe Dana Wheel Differential Lock is an optional feature for Dana Axles. In operation, it positively lock

9097Theory of OperationDifferential Lock EngagedAir pressure applied to the shift cylinder moves the piston, push rod, shift fork and the sliding curv

911 499Parts IdentificationParts IdentificationPower Divider - ForwardParts Exploded View1 —Output shaft nut2 —Output yoke3 —Output seal4 —Output shaf

92100Front Drive AxleParts Exploded View1— Flange half bearing adjuster2— Flange half bearing cup3— Flange half bearing cone4— Flange half carrier cap

93101Wheel Differential Lock AssemblyParts Exploded View1— Fixed curvic clutch gear2— Snap ring3— Curvic clutch gear4— Spring pin5— Shift fork6— Compr

94102Parts Exploded View 19876543211121314151631302928271718213219102425222320B20A261 - Pinion Nut2 - End Yoke and Slinger3 - Oil Seal4 - Outer Pinio

95103Housing and Output Shaft AssemblyParts Exploded View1— Output shaft nut2— Output yoke3— Output seal4— Snap ring5— Outer bearing cup6— Outer beari

96104Parts IdentificationFastener Torque SpecificationsForward CarrierNote: Fasteners using self-locking thread “patches” may be reused if not damaged