Spicer Tandem Drive Axles Service Manual D__R440, 460, 48 User Manual

Spicer® Tandem Drive Axles Sevice ManualAXSM-0042September 2007Models:D/R440 D/R460D/R480 D/R485D/R461 D/R462D/R463 D/R521D/R581 D/R601D/R651 D/R652D/

6General InformationRing Gear and Pinion Note: Ring gear and drive pinion are matched parts and mustbe replaced in sets.1 - Part number2 - Number of r

96Wheel End SealRemove and Overhaul Wheel End SealNever work under a vehicle supported by only a jack. Alwayssupport vehicle with stands. Block the wh

97Wheel Adjustment SystemsWheel Adjustment SystemsWheel Adjustment SystemsAdjust Wheel BearingDo not mix spindle nuts and lock washers from different

98Wheel Adjustment SystemsThree-piece Tang-type Lock Washer Systema. Install the Tang-type lock washer on the spindle. Never tighten the inner nut for

99Wheel EndWheel EndVerify Wheel End-play ProcedureVerify that end-play meets specification using a dial indicator.An indicator with 0.001" (0.03

100Wheel EndLubricate Wheel EndBefore operating the axle, the wheel hub cavities and bear-ings must be lubricated to prevent failure. When wheel ends

101Wheel EndWheel EndWheel Ends Without Oil Fill Hole 1. With axle level and wheel ends assembled, add lubri-cant through filler hole in axle housing

102LubricationLubricationThe ability of a drive axle to deliver quiet, trouble-free operationover a period of years is largely dependent upon the use

103LubricationLubricationLube Change IntervalsThis product combines the latest manufacturing and partwashing technology. When filled with a Dana appro

104LubricationChange LubeDrainDrain when the lube is at normal operating temperature (150°–200°F). It will run freely and minimize the time necessary

105LubricationLubricationStandpipesDrive axles are lubricated with oil drawn from a large sump in-tegral to the assembly. Most axle designs attempt to

7Failure AnalysisFailure AnalysisFailure Analysis Failure analysis is the process of determining the originalcause of a component failure in order to

106LubricationHorizontal Mounting12° Installation12° Installation with StandpipeNote: Grades must be continuous or lengthy in nature. Moni-tor oil tem

107Torque ChartTorque ChartTorque ChartFastener Axle Model Class Size Tool Size Lbs.-ft. N-mCarrier & Cap-Misc. Parts Bearing Cap Capscrew-All Mod

108Torque ChartCast Iron Cover Style Cover Capscrew 5 7/16 - 14 5/8 48-56 65-76Push Rod Nut --- 3/8 - 24 5/8 13-17 18-23Wheel End-Misc. Parts Axle Sha

109Wheel Differential LockWheel Differential LockWheel Differential LockComparison Information on Dana Wheel Differential Locking AxlesThis section co

110Wheel Differential LockDifferential Lock Theory of OperationThe Dana Wheel Differential Lock is an optional feature forDana axles. In operation, it

111Control SystemsControl SystemsControl SystemsTwo types of systems may be used to control the DifferentialLock operation:• Transmission low-range in

112Control SystemsDirect Driver-Controlled SystemThe driver manually locks and unlocks the wheel differential,using a cab-mounted air valve. The follo

113Dual Range Axle Shift SystemsDual Range Axle Shift SystemsDual Range Axle Shift SystemsThere are two shift system designs predominantly used to se-

114Dual Range Axle Shift SystemsStandard System for Axle Range Selection and Inter-Axle Differential Lockout (straight air type)DescriptionThe standar

115Dual Range Axle Shift SystemsDual Range Axle Shift SystemsFor vehicles equipped with transmission-drive speedometers,the system includes a speedome

8Failure AnalysisMake a Preliminary Investigation These steps consist of external inspections and observationsthat will be valuable when combined with

116Dual Range Axle Shift Systems“Standard” Lockout (straight-air type)Description:The “standard” lockout unit is of the straight-airtype and is air-op

117Dual Range Axle Shift SystemsDual Range Axle Shift SystemsAxle Range Selection and Inter-Axle Differential Lockout SystemDescription and OperationT

118Dual Range Axle Shift SystemsAxle Range Interlock OperationEngage Lockout (Lock Differential) (Axle in High or LowRange)1 - Reservoir air pressure2

119Dual Range Axle Shift SystemsDual Range Axle Shift SystemsDisengage Lockout (Unlock Differential) (Axle in High or Low Range)1 - Reservoir air pres

120TroubleshootingTroubleshootingCheck for Air Pressure and Air LeaksA simple method for quickly locating troubles in a shift systemcan be accomplishe

121TroubleshootingTroubleshootingCheck Electrical SystemCheck Solenoid Valve1. When ignition switch is “ON,” solenoid valve is ener-gized and air pres

122Proper Vehicle TowingProper Vehicle TowingWithout Wheel Differential LockLift the drive wheels completely off of the ground or damagewill occur.Do

123Proper Vehicle TowingProper Vehicle Towing7. Install temporary cover on hub to prevent contamina-tion from entering and also to prevent the loss of

124Air Shift System ComponentsAxle Shift System ComponentsAir Shifter Valves (Standard System)Note: For air shifter valve repair instruction, refer to

125Air Shift System ComponentsAir Shift System ComponentsAxle Range Shifter Valve Interlock PinAssemblyNote: Before reassembly, lubricate o-rings with

9InspectionInspectionInspectionClean1. Wash steel parts with ground or polished surfaces insolvent. There are many suitable commercial sol-vents avail

126Inter-Axle Differential LockoutInter-Axle Differential Lockout With Interlock Control Valve (straight-air type) Lockout CylinderDisassemble cylinde

127Inter-Axle Differential LockoutInter-Axle Differential LockoutSpeedometer AdapterThe speedometer adapters are lubricated and sealed for life ofthe

128Inter-Axle Differential LockoutQuick Release ValveIf quick release valve fails to operate properly, it may be re-paired as follows:1. Disassemble v

129Theory of OperationTheory of OperationTheory of OperationSpicer tandem drive axles described in this publication are sin-gle reduction units design

130Theory of OperationPower Flow and Torque DistributionTorque Distribution with Lockout Disen-gaged (Inter-axle Differential is Operating)Torque (pow

131Theory of OperationTheory of OperationTorque Distribution with Lockout Engaged (Inter-axle Differential is Not Operating)A lockout mechanism is inc

132InspectionLubricationThe ability of a drive axle to deliver quiet, trouble-free operationover a period of years is largely dependent upon the use o

133InspectionInspectionLube Change IntervalsThis product combines the latest manufacturing and partwashing technology.Note: When filled with an Spicer

134InspectionChanging LubeDrainingDrain when the lube is at normal operating temperature (150°-200°F). It will run freely and minimize the time necess

135InspectionInspectionStandpipesDrive axles are lubricated with oil drawn from a large sump in-tegral to the assembly. Most axle designs attempt to p

10InspectionInspect Primary Gearing Before reusing a primary gear set, inspect teeth for signs of ex-cessive wear. Check tooth contact pattern for evi

136Theory of OperationTorque Distribution in Low RangeTorque is transmitted to both axles through inter-axle differential action.1 - Input torque2 - D

137Theory of OperationTheory of OperationDual Range Tandem Shift SystemRange selection is accomplished by an air shift system and is driver-controlled

138Theory of OperationDual Range GearingThe gearing for each axle is a combination of a spiral bevel ring gear and pinion and a planetary unit.First r

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For spec‘ing or service assistance, call 1.800.621.8084 or visit our website at www.spicerparts.com Dana Commercial Vehicle Products Group3939 Techno

11Differential Carrier AssemblyDifferential Carrier AssemblyDifferential Carrier Assembly - Parts1 - Carrier fasteners2 - Carrier assembly3 - Forward

12Differential Carrier AssemblyForward Axle Differential Carrier Removal and InstallationRemoval of Forward Differential CarrierNote: The removal of t

13InspectionInspectionInstallation of Forward Differential Carrier Before installing carrier assembly, inspect and thoroughlyclean interior of axle ho

14Differential Carrier AssemblyInstallation of Forward Axle Housing Cover and Output Shaft Bearing PartsNote: Forward axle should be assembled to the

15Differential Carrier AssemblyDifferential Carrier AssemblyRear Axle Differential Carrier Removal and InstallationRemoval of Rear Differential Carrie

iWarningWarnings and CautionThe description and specifications contained in this service publication are current and the time of printing.Dana Corpora

16Differential Carrier AssemblyRear Differential Carrier “Installation”Before installing carrier assembly, inspect and thoroughlyclean interior of axl

17Differential LockoutDifferential LockoutDifferential LockoutInter-Axle Lockout TypesAll are air-operated to engage the lockout and spring-releasedto

18Differential LockoutOriginal Design Lockout - 1948 to Present(*Optional design for use with all dualrange tandem axles)• Die cast body• Square Top•

19Differential LockoutDifferential LockoutCylindrical Design Lockout - October 1989to February 1996• External type lockout• Stamped steel piston cover

20Differential LockoutDifferential Lockout OverhaulInstructions for the three different designs are on the followingpages: Cast Iron Cover Lockout -

21Differential LockoutDifferential LockoutOriginal Design Lockout OverhaulNote: Find instructions for:Cast Iron Cover Lockout - Overhaul on page 20Cyl

22Differential LockoutCylindrical Design Lockout - OverhaulNote: Find instructions for:Cast Iron Cover Lockout - Overhaul on page 20Original Design Lo

23InspectionInspectionPower Divider - Parts Exploded View1 - Output shaft2 - Bushings*3 - O-rings4 - Bearing cup5 - Bearing cone6 - Side gear7 - Snap

24Power DividerRemove Power DividerThe power divider can be replaced with the axle assembly bothin or out of the chassis and with the differential car

25Power DividerPower DividerRemove Power Divider from Differential Carrier (with carrier removed from axle housing)Note: It is assumed that the differ

iiTable of ContentsTable of ContentsTable of Contents - VisualWheel DifferentialAssemblyPage 68-82Carrier AssemblyPage 45-56Wheel EndPage 99-101Power

26Power Divider7. Tilt carrier and remove the output shaft assembly.8. If removal of the output shaft side gear bearing cup isnecessary, use puller to

27Power DividerPower DividerDisassemble, Assemble and Overhaul the Power DividerThe power divider may be serviced with the carrier assemblyin or out o

28Power Divider7. At this point in disassembly, it is desirable to removelube pump drive gear nut. Hold input shaft yoke to se-cure drive gear, then l

29Power DividerPower DividerDisassemble Power Divider Cover (For Axles with Input Shaft Tapered Roller Bearing) Note: The drive on early pump models i

30Power Divider1. With drive gear locknut previously removed andworking through input shaft bore, gently pry oil pumpdrive gear from its shaft. See st

31Power DividerPower DividerAssemble Power Divider Cover (For Axles with Input Shaft Tapered Roller Bearing)1. Install pinion outer bearing race in po

32Power Divider6. Press input bearing cone on input shaft.7. Press bearing cup in input bearing cover.8. If bushing removal is needed, the bushings mu

33Power DividerPower Divider10. Check expansion plug in power divider cover to makesure it is in place and firmly seated. If loose, seat bytapping wit

34Power DividerInter-axle Differential1 - Case half2 - Spider3 - Bushing (use on models built before November 1, 1991)4 - Side pinion5 - Thrust washer

35Power DividerPower DividerDisassemble Inter-axle Differential1. Punch mark differential case halves for correct posi-tion during reassembly.2. Remov

iiiTable of ContentsIntroduction ...1Failure Analysis ...

36Power DividerOutput Shaft Assembly*Bushing removed from production axles in September 1994.Output shafts with P/N 129016 do not use bushings.1 - Out

37Power DividerPower DividerDisassemble Output ShaftSnap ring is spring steel and may pop off. Wear safety glass-es when removing.1. Mount shaft assem

38Power DividerInstall Power Divider on Differential Carrier (with carrier assembled to axle housing) Note: Lubricate all parts before installation.1.

39Power DividerPower Divider6. Make certain dowel pins are installed in carrier, theninstall power divider assembly.TIP: During installation, rotate

40Power DividerInstall Power Divider on Differential Carrier (with carrier removed from axle housing)The following instructions pertain to installatio

41Power DividerPower DividerNote: Lifting mechanism may create nicks and burrs on inputyoke. Remove if present.7. If removed, install dowel pins in ca

42Power DividerMeasure and Adjust Input Shaft End-PlayNote: After power divider overhaul and installation on carrier,check and adjust input shaft end-

43Power DividerPower DividerWith Input Shaft Axial Spring Thrust ButtonIn September 1988, Spicer added an axial spring and thrustbutton between the in

44Power Divider5. Position a dial indicator on the end of the input shaft.6. Lift up on pry bar to compress input shaft.7. Insert a pry bar through th

45Carrier AssemblyCarrier AssemblyForward Axle Carrier Assembly (Single Speed) with Diff. Lock - Parts Exploded View52 53 54 56 57 58 55 6 1 559742319

1General InformationGeneral InformationIntroductionDana Corporation, Axle & Brake Division, presents this publi-cation to aid in maintenance and o

46Carrier Assembly6061626364 6566INTER-AXLEDIFFERENTIALASSEMBLY6768697170747375727076 777879 80 81 82 8391939284 85 86 88 89908710510639 31 40414243 4

47Carrier AssemblyCarrier Assembly1 - Differential carrier & bearing caps2 - Bearing capscrew3 - Flat washer4 - Lockwire5 - Dowel bushing6 - Beari

48Carrier AssemblyRear Axle (Single Speed) - Parts Exploded View6 5 1 1 22 23 24 29 31 32243 658 9272628 25 26 23 30 3316 17 19 14 1410 11 12 15 18 20

49Carrier AssemblyCarrier Assembly1 - Differential carrier & bearing caps2 - Bearing capscrew3 - Flat washer4 - Lockwire5 - Bearing cap adjuster l

50Carrier AssemblyForward Axle (Two Speed) - Parts Exploded View1234567891011121314151617181920212223242526272829303132333435Dual Range AxlesPlanetary

51Carrier AssemblyCarrier Assembly1 - Nut2 - Washer (used on DT461-P, DT652P,DP461-P, DP652-P)3 - Yoke4 - Bearing retainer washer (used onDT440-P, DT4

52Carrier AssemblyRear Axle (Two Speed) - Parts Exploded View23456891011121314151617181921222324252627293031323334353637383940414243444546475556575859

53Carrier AssemblyCarrier Assembly1 - Cotter pin2 - Adjusting lock3 - Bearing cap4 - Capscrew5 - Flat washer6 - Dowel bushing7 - Lockwire8 - Bearing c

54Carrier AssemblyDisassemble Differential Carrier (with power divider removed) Dual range axles only1. Remove shift fork seal and spring. 2. Remove e

55Carrier AssemblyCarrier AssemblyRemove Wheel Differential (All StandardModels)Note: If gear set is to be reused, check tooth contact patternand ring

2General InformationModel ListingThe following models are included in this publication:The suffix letter "P" in the model number indicates t

56Carrier AssemblyRemove Pinion Assembly1. Forward Axle: Remove pinion nut. Remove helicaldrive gear using puller. Remove helical gear spacer(D440-P a

57Drive PinionDrive PinionDrive Pinion - Parts Exploded ViewFront Axle Pinion AssemblyRear Axle Pinion Assembly1 - Pinion pilot bearing2 - Pinion3 - P

58Drive PinionDisassemble and Overhaul Drive PinionThe following procedures cover both forward and rear differ-ential drive carrier assembly.Note: Dan

59Drive PinionDrive Pinion8. Remove inner bearing cone from pinion using a split-type puller. Use two procedure steps to remove eachbearing.a. Mount p

60Drive Pinion3. Install inner and outer pinion bearing cups. Use apress and an appropriate drive sleeve. Make certainbearing cup is evenly and firmly

61Drive PinionDrive Pinion2. With the bearings well lubricated, place the assemblyin the press. Position sleeve so that load is applied di-rectly to t

62Drive PinionFinal BuildupNote: On rear axles, do not install oil seal in cage until bearingpreload is correctly adjusted.After bearing cups are inst

63Drive PinionDrive PinionSpecifications for Pinion Bearing Final Buildup Preload TestTorque to Rotate Bearing Cage (w/o pinion seal) 15-35 lbs. in.(1

64Drive Pinion9. Stake pilot bearing using staking tool. This is essen-tial to retain the bearing.10. Rear Axle Only: With pinion installed and bearin

65Drive PinionDrive PinionInstall Drive Pinion Assembly1. Forward Axle Only: Place shim pack on carrier mak-ing sure holes are properly aligned. Make

3General InformationGeneral InformationModel InformationGearingCapacity (x 1000 lbs.)Design LevelLube PumpD - Forward Tandem AxleR - Rear Tandem AxleS

66Drive PinionInstall Helical Gear and Pinion Outer Support Bearing - Forward Axle OnlyNote: After differential adjustment is complete or if dummyyoke

67Drive PinionDrive Pinion4. If removed, install bearing race in power divider cov-er, using driver and hammer.5. Install snap ring to secure bearing

68Wheel Differential AssemblyWheel Differential Assembly - Parts Exploded ViewSingle Reduction Differential1 - Sliding clutch2 - Diff. lock differenti

69Wheel Differential AssemblyWheel Differential AssemblyPlanetary and 2 - Speed Differential1 - Sliding clutch (dual range only)2 - Differential beari

70Wheel Differential AssemblyDisassemble, Overhaul and Assemble Wheel Differential (Forward and Rear Axles)For Single Reduction Differential Case Disa

71Wheel Differential AssemblyWheel Differential AssemblyOverhaul and Assemble Wheel DifferentialTo prevent bearing damage, use suitable sleeve that on

72Wheel Differential AssemblyPlanetary and 2-Speed Models (Forward and Rear Axles) 1 - Differential case capscrew2 - Differential case (plain)3 - Side

73Wheel Differential AssemblyWheel Differential AssemblyDisassemble Dual Reduction Differential CaseNote: For Single Reduction Differential Case see p

74Wheel Differential Assembly10. Remove inner side gear and thrust washer.11. First, try to lift off high-speed clutch plate by hand. Ifit cannot be r

75Wheel Differential AssemblyWheel Differential AssemblyAssemble Dual Reduction Differential CaseNote: Lubricate internal parts with gear lube during

4General InformationModel IdentificationDrive AxleNote: Tags that do not include all the information shown hereare older models (before May 1987).1 -

76Wheel Differential Assembly3. Place thrust washer and side gear in differential case.4. Assemble side pinions and thrust washers on spider.Place thi

77Wheel Differential AssemblyWheel Differential Assembly8. Place thrust washer in support case.9. During installation of ring gear, temporarily use tw

78Wheel Differential AssemblyInstall Differential–Forward and Rear AxlesNote: Lubricate bearings during the following assembly proce-dures.1. Place ri

79Wheel Differential AssemblyWheel Differential AssemblyMeasure and Adjust Carrier AssemblyAdjust Backlash and Preload1. Turn the flange half bearing

80Wheel Differential AssemblyChange Backlash SettingIf you have too much backlash the ring gear needs to movecloser to the pinion. Back off the plain

81Wheel Differential AssemblyWheel Differential AssemblyAdjust Tooth Contact PatternAdjust Ring and Pinion Tooth Contact PatternNote: Rear axle gearin

82Wheel Differential AssemblyAdjust Pinion PositionIf the gear pattern shows incorrect tooth depth contact, changedrive pinion position by altering th

83Wheel Differential LockWheel Differential LockWheel Differential Lock - Parts Exploded View1 - Shift fork seal and spring assembly2 - Shift fork and

84Wheel Differential LockInstall and Adjust Wheel Differential Lock, Dual Range Shifters1. For planetary double reduction axles (on backfaceside of ri

85Wheel Differential LockWheel Differential LockPiston Air Shift Unit 1 - Cover assembly2 - Cover bearing3 - Screw and washer assembly4 - Cover gasket

5General InformationGeneral InformationPart IdentificationAxle Housing Axle Shaft1 - ID Tag 2 - Axle shaft part number1PT. NO.HSG. CAP.

86Wheel Differential LockAir Shift Unit ReplacementRemoval of Shift Unit1. Disconnect air lines at shift unit cover.2. Disconnect the wiring harness a

87Wheel Differential LockWheel Differential LockAir Shift Unit OverhaulDisassemble Unit1. Remove capscrews, lock washers, cover and gasketfrom housing

88Wheel Differential LockParts InspectionShift Fork Seal: Inspect shift fork seal for defects and tight fiton shift fork. A spring is used to assure a

89Wheel Differential LockWheel Differential LockAssemble UnitNote: Prior to assembly, the piston felt oilers should be soakedin SAE 10 oil for one hou

90Wheel Differential LockLubricationLubricant: Use SAE 10 motor oil* for temperature above 0°F (–18°C). For temperatures below 0°F (–18°C), mix three

91Housing and Rear Cover AssemblyHousing and Rear Cover AssemblyHousing and Rear Cover Assembly - Parts Exploded View1 - Rear cover2 - Rear cover caps

92SealsSealsReplace SealDana strongly recommends using seal drivers when installingnew seals. Use the proper driver to make sure that the seal issquar

93SealsSealsNew Welded D-Housing CoverLube Quantity Difference0 (zero)Standout of Output Shaft YokeLength increased by 6 mm (.25"), this should n

94Housing BreatherHousing BreatherInstall New Axle Housing Breather (Metaland Plastic)Dana uses an axle housing breather that consists of a fitting,ho

95Wheel End SealWheel End SealWheel End Seal - Parts Exploded View1 - Installation tool2 - Seal3 - Rear hub123