Spicer Single Drive Axles

Service Manual
Spicer® Drive Axles
AXSM-8941
June 2016
 General Information

General Information
The description and specifications contained in this service publication are current at the time of printing. Dana Corporation
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

This symbol is used throughout this WARNING:Failure to follow indicated

manual to call attention to procedures procedures creates a high risk of personal
where carelessness or failure to follow injury to the servicing technician.
specific instructions may result in personal
injury and/or component damage.
CAUTION:Failure to follow indicated procedures
may cause component damage or malfunction.
Departure from the instructions, choice of
tools, materials and recommended parts
IMPORTANT:Highly recommended procedures
mentioned in this publication may
for proper service of this unit.
jeopardize the personal safety of the
service technician or vehicle operator.
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 Dana replacement parts.

 Table of Contents

Table of Contents - Visual

Table of Contents
Carrier
Wheel Assembly
Differential page 8
Assembly Drive
page 17 Pinion
page 12

Pinion
Housing Seals
Breather page 12
page 26
Lubrication
page 33

Wheel
End Seal
page 28
 Table of Contents

Table of Contents
General Information Housing Breather
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Install New Axle Housing Breather -
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 2 (Metal and Plastic) . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . 3 Axle Housing
Ring Gear and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . 4 Axle Housing - Exploded View . . . . . . . . . . . . . . . . . .27
Inspection Wheel End Seal
Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wheel End Seal Parts - Exploded View . . . . . . . . . . .28
Prepare the Parts for Inspection . . . . . . . . . . . . . . . . 6 Remove and Overhaul Wheel End Seal . . . . . . . . . . .29
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install Wheel End Seal . . . . . . . . . . . . . . . . . . . . 29
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Wheel Adjustment Systems
Inspect Axle Housing . . . . . . . . . . . . . . . . . . . . . . 7 Adjust Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . .30
Inspect Primary Gearing . . . . . . . . . . . . . . . . . . . 7
Wheel Ends
Differential Carrier Assembly Verify Wheel End-Play Procedure . . . . . . . . . . . . . . .32
Differential Carrier Assembly - Exploded View . . . . . . 8
Lubrication
Removal of Differential Carrier From Axle Housing . . 9
Lubricate Wheel End . . . . . . . . . . . . . . . . . . . . . . . . .33
Install Differential Carrier . . . . . . . . . . . . . . . . . . . . . 10
General Lubrication Information . . . . . . . . . . . . . . . .35
Remove Wheel Differential . . . . . . . . . . . . . . . . . . . . 11
Approved Lubricants . . . . . . . . . . . . . . . . . . . . . .35
Pinion Assembly Recommendations for Viscosity/
Rear Axle Pinion Assembly - Exploded View . . . . . . 12 Ambient Temperature . . . . . . . . . . . . . . . . . . . . 35
Remove Pinion Assembly . . . . . . . . . . . . . . . . . . . . 13 Lube Change Intervals . . . . . . . . . . . . . . . . . . . . . . . .36
Install Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . 15 Change Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Wheel Differential Assembly Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Wheel Differential Assembly - Exploded View . . . . . 17 Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassemble, Overhaul and Proper Vehicle Towing
Assemble Wheel Differential . . . . . . . . . . . . . . . . . . 18 With Truetrac Limited Slip Differential. . . . . . . . 38
Disassemble Wheel Differential . . . . . . . . . . . . . 18 Torque Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Overhaul and Assemble Wheel Differential. . . . . 20
Parts Identification
Wheel Differential Adjustments Rear Drive Axle Parts - Exploded View . . . . . . . . . . .40
Measure and Adjust Carrier Assembly
Torque Specifications
(Adjust Backlash and Preload) . . . . . . . . . . . . . . . . . 22
Fastener Torque Specifications . . . . . . . . . . . . . . . . .41
Change Backlash Setting . . . . . . . . . . . . . . . . . . . . . 23
Service Tools
Adjust Tooth Contact Pattern
Recommended Service Tools . . . . . . . . . . . . . . . . . .42
Adjust Ring and Pinion Tooth Contact Pattern . . . . . 24
Adjust Ring Gear Position (Backlash) . . . . . . . . . . . 25
 General Information

General Information
Introduction
Dana Corporation presents this publication to aid in mainte-
nance and overhaul of Dana single reduction drive axles.
Instructions contained cover the models listed below. Their
design is common, with differences in load capacity. Capacity
S 135 S
variations are achieved by combining basic differential carrier Spicer Gearing Type
assemblies with different axle housings, axle shafts, and S = Single Reduction
wheel equipment. L = True Trac Differential
N = No Spin
Model Listing
The following models are included in this publication: Nominal Load
Carrying Capacity
Dana Single Reduction Axles 135 = 13,500 lbs.
With Standard Wheel Differential 150 = 15,500 lbs.

S135L S135N S135S

S150L S150N S150S

1
 General Information

Model Identification

2
1

(P) CARRIER # 360CR100 6X

SER # SPICER 94070

620112 RATIO 3.91 R1 4242

4
5

CUST. PART NO. Spicer®

Data plate is
SPEC.

MODEL

MADE IN:
SERIAL NO.

PART NO. RATIO

located on the
axle centerline
1 - Customer part number (optional)
2 - Dana part number
3 - Julian date code
4 - Line set number (optional)
5 - Last six digits of vehicle serial number Rear Axle
(optional) (Top View)

2
 General Information

Parts Identification
Axle Housing Julian Date Code

94 070
Model Year Day of Year

1 2

3
360RF100-6 MODEL
S135-S
4
4
SER # RATIO 94070
620112 3.91 R1 4242

General Information
5
6

1 - Dana part number

2 - Customer part number (optional)
3 - Model
4 - Julian date code
5 - Line set number (optional)
6 - Last six digits of vehicle serial number (optional)

Axle Shaft

1 - Axle shaft part number

3
 General Information

Ring Gear and Pinion

Manufacturer’s Date - Date gear set was made.

Spicer Trademark - Company logo and location of manufac-

Matched Set Number - Spicer ring and pinions are manufac-
turing facility.
tured as matched sets. Both ring and pinion are marked with a
corresponding number (i.e. 260), which identifies them as a
360GP104 - Part number of pinion gear. (TYPICAL)
matched set.
Tooth Combination (i.e. 41-11) - Indicates the pinion has 11
A gear set that does not have the same match set numbers
teeth and the ring gear has 41 teeth which results in a 3.73:1
should not be mated together. If either ring gear or pinion
ratio.
require replacement, a new matched set must be used.

41-11

260
41-11

2 3 4 6 7
5

260

1 - Spicer trademark 5 - Spicer trademark

2 - Tooth combination 6 - Manufacturer’s date
3 - Part number 7 - Matched set number
4 - Heat code

4
 Inspection

Failure Analysis
Failure analysis is the process of determining the original You need to be a good listener. Sometimes, insignificant or
cause of a component failure in order to keep it from happen- unrelated symptoms can point to the cause of the failure.
ing again. Too often, when a failed component is replaced
• Ask: Was the vehicle operating at normal tempera-
without determining its cause, there will be a recurring failure.
tures?
If a carrier housing is opened, revealing a ring gear with a bro-
ken tooth, it is not enough to settle on the broken tooth as the • Ask: Were the gauges showing normal ranges of
cause of the carrier failure. Other parts of the carrier must be operation?
examined. For a thorough understanding of the failure and
• Ask: Was there any unusual noise or vibration?
possible insight into related problems, the technician needs to
observe the overall condition of the vehicle.
After listening, review the previous repair and maintenance
records. If there is more than one driver, talk to all of them
No one benefits when a failed component goes on the junk

Inspection
and compare their observations for consistency with the ser-
pile with the cause unknown. Nothing is more disturbing to a
vice and maintenance records. Verify the chassis Vehicle
customer than a repeat failure. Systematically analyzing a fail-
Identification Number (VIN) number from the vehicle identifi-
ure to prevent a repeat occurrence assures quality service by
cation plate, as well as the mileage and hours on the vehicle.
avoiding unnecessary downtime and further expense to the
customer. Make a Preliminary Investigation
These steps consist of external inspections and observations
The true cause of a failure can be better determined by know- that will be valuable when combined with the results of the
ing what to look for, determining how a piece of the equip- parts examination.
ment was running and learning about previous problems. In
the case of a rebuilt rear axle, mismatched gears may have • Look for leaks, cracks, or other damage that can
been installed. point to the cause of the failure.
• Make note of obvious leaks around plugs and seals.
The more successful shops prevent repeat equipment failures A missing fill or drain plug would be an obvious
by developing good failure analysis practices. Knowing how cause for concern.
to diagnose the cause of a premature failure is one of the pre-
requisites of a good heavy-equipment technician. • Look for cracks in the carrier housing (harder to see,
but sometimes visible).
How to Diagnose a Failure
• Does the general mechanical condition of the vehicle
The following five steps are an effective approach to good fail-
indicate proper maintenance or are there signs of
ure diagnostics:
neglect?
1. Document the problem.
• Are the tires in good condition and do the sizes
2. Make a preliminary investigation. match?
3. Prepare the parts for inspection. • If equipped with a torque-limiting device, is it work-
ing properly?
4. Find the cause of the failure
5. Correct the cause of the problem. During the preliminary investigation, write down anything out
of the ordinary for later reference. Items that appear insignifi-
Document the Problem
cant now may take on more importance when the subassem-
Here are some guidelines for starting to learn about a failure,
blies are torn down.
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?

5
 Inspection

Prepare the Parts for Inspection

After the preliminary investigation, locate the failure and pre- Find the Cause of the Failure
pare the part for examination. In carrier failure analysis, it may Here begins the real challenge to determine the exact cause of
be necessary to disassemble the unit. the failure. Keep in mind that there is no benefit to replacing a
failed part without determining the cause of the failure. For
• When disassembling subassemblies and parts, do
example, after examining a failed part and finding that the fail-
not clean the parts immediately since cleaning may
ure is caused by a lack of lubrication, you must determine if
destroy some of the evidence.
there was an external leak. Obviously, if there is an external
• When tearing down the drive axle, do it in the recom- leak, just replacing the failed gear is not going to correct the
mended manner. Minimize any further damage to the situation.
unit.
Another important consideration here is to determine the spe-
• Ask more questions when examining the interior of
cific type of failure which can be a valuable indicator for the
the carrier. Does the lubricant meet the manufacturer
cause of failure. The following pages show different types of
specifications regarding quality, quantity, and vis-
failures and possible causes. Use this as a guide in determin-
cosity? As soon as you have located the failed part,
ing types of failures and in correcting problems.
take time to analyze the data.
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 Note: Replace conventional gaskets with silicone rubber gas-

ket compound (included in many repair kits). The com-
1. Wash steel parts with ground or polished surfaces in pound provides a more effective seal against lube
solvent. There are many suitable commercial sol- seepage and is easier to remove from mating surfaces
vents available. Kerosene and diesel fuel are accept- when replacing parts.
able.
1
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

Inspection
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.
2
3. Rinse thoroughly to remove all traces of the cleaning
solution. 1 - Axle Housing
2 - Machined Surface
4. Dry parts immediately with clean rags.
5. Oil parts. Inspect all steel parts for:

• If parts are to be reused immediately: Lightly oil. • Notches, visible steps or grooves created by wear.

• If parts are to be stored: Coat with oil, wrap in corro- • Pitting or cracking along gear contact lines.
sion resistant paper and store in a clean, dry place. • Scuffing, deformation, or discolorations. These are
signs of excessive heat in the axle and are usually
related to low lubrication levels or improper lubrica-
Inspect Axle Housing tion practices.

Axle housing inspection and repairs are limited to the follow- In addition, inspect the following for damage:
ing checks or repairs: • Differential gearing.
• Visually inspect axle housing for cracks, nicks and • Bearings for loose fit on drive pinion, pilot bearing,
burrs on machined surfaces. and differential bearings.
• Check carrier bolt holes and studs for foreign mate- • All fasteners for rounded heads, bends, cracks or
rial. damaged threads.
• Replace damaged fasteners. Look for loose studs or • Inspect machined surfaces of cast or malleable
cross threaded holes. parts. They must be free of nicks, burrs, cracks,
scoring, and wear.
CAUTION: Any damage which affects the alignment or
structural integrity of the housing requires housing • Look for elongation of drilled holes, wear on sur-
replacement. Do not repair by bending or straightening. faces machined for bearing fits and nicks or burrs in
This process can affect the material’s properties and mating surfaces.
cause it to fail completely under load.
• Check all seals and gaskets. 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.

7
 Differential Carrier

Differential Carrier Assembly - Exploded View

1 - Carrier fasteners
2 - Carrier assembly
3 - Single axle assembly

8
 Differential Carrier

Removal of Differential Carrier From Axle Housing

1. Block wheels. 8. Loosen all but the top two carrier-to-housing mount-
ing bolts. Remove all bolts except the top two. These
2. Remove axle housing drain plug and drain lubricant.
two bolts will prevent the carrier assembly from fall-
3. Disconnect drive shafts at the rear U-joint. ing.
Note: If end yoke and/or seal is to be replaced, loosen yoke 9. Separate the differential carrier from the housing
nut at this time. using the removal slots. Make sure the carrier is bal-
anced properly on jack. Remove the top two carrier
4. Remove axle shaft flange nuts. mounting bolts. Remove the differential carrier
5. Hold a large brass drift or a brass hammer against assembly from the axle housing.
the center of the axle shaft flange. Strike the drift
with a large hammer or sledge until the axle shaft
separates from the hub.

CAUTION: Do not strike the flange directly with a steel

hammer or sledge. This may crack and splinter mate- 1
rial, possibly causing serious or fatal injury. Do not pry
or chisel axle flange away from hub; damage to sealing 1
surfaces could occur.
6. Remove axle shafts.
1 - Removal slots
7. Support the differential carrier assembly on a roller
jack. Secure as necessary to prevent it from falling 10. Mount carrier assembly in a suitable rebuild stand.

Differential Carrier
off the jack when removed from the housing.

9
 Differential Carrier

Install Differential Carrier

IMPORTANT: Before installing the carrier assembly, inspect TIP: To assist in installing complete differential car-
and thoroughly clean interior of axle housing using an appro- rier use two pieces of threaded rod threaded into
priate solvent and clean rag. carrier cap screw holes. Rod should be approxi-
mately 6" long. Use these to pilot the carrier into the
1. Apply Dana approved RTV compound on axle hous-
housing.
ing mating surface as shown in the illustration. Com-
pletely remove all old gasket material prior to 2. Install carrier to housing, washers, cap screws, and
applying new material. Compound will set in 20 min- nuts. Torque to proper specifications. See torque
utes. Install carrier before compound sets or reapply. chart of page 41.
3. Install axle shafts and axle stud nuts (if used, also
install lock washers and tapered dowels).
4. Add axle lubricant. Fill to the bottom of the fill hole.
5. Connect inter-axle driveline, making sure all yokes
are in phase. Lubricate U-joints.

1 - Apply silicone gasket in this pattern

10
 Differential Carrier

Remove Wheel Differential - All Standard Models

1. Mount differential carrier in repair stand. 3. Remove cap screws, flat washers, and bearing caps.
Loosen bearing adjusters and remove adjusters and
Note: Omit this step if the gear set is to be replaced. If gear
bearing cups.
set is to be reused, check tooth contact pattern and ring
gear backlash before disassembling differential carrier.
When checking backlash, a yoke or helical gear must be
installed and torqued to get an accurate reading. Best
results are obtained when established wear patterns are
maintained in used gearing.

4. Using a chain hoist, lift ring gear and differential

assembly out of carrier.

Differential Carrier
2. If reusing gear set, also punch mark bearing adjust-
ers for reference during assembly.

11
 Pinion Assembly

Rear Axle Pinion Assembly - Exploded View

1 2 4
3

5
6
7
8
9

10

1 - Pinion 6 - Outer pinion bearing cup

2 - Inner pinion bearing cone 7 - Outer pinion bearing cone
3 - Inner pinion bearing cup 8 - Pinion seal
4 - Carrier housing 9 - End yoke assembly
5 - Pinion preload spacer (Selective) 10 - Pinion hex nut

12
 Pinion Assembly

Remove Pinion Assembly

Pinion Assembly
1. Remove yoke nut. 4. Place carrier in a press with threaded end of pinion
face up.
Note: Use of a torque multiplier is recommended as torque
specification on input nut is 700-900 lbs. ft. 2
(950-1,220 N•m).
2. Remove yoke using a yoke puller service tool.
1
3
4

1 - Carrier assembly
2 - Press
3 - Bearing preload spacer
1 - Yoke puller 4 - Pinion
5 - Wood block
3. Remove oil seal.
5. Place a wood block under pinion to avoid damage to
gear teeth.
6. Press pinion through outer bearing and out of carrier
casting.
7. Remove bearing preload spacer and save for use in
reassembly.
8. If the gearset is to be reused, remove inner bearing
at this time with a suitable puller. If the gearset is to
be replaced, new bearings must be installed.

13
 Pinion Assembly

9. If bearings are to be replaced, remove bearing cups

from carrier casting at this time.
a. Mount puller vertically to separate the bearing.
This action will force puller halves under bearing
and start moving bearing off pinion.

b. Mount puller horizontally to press pinion out of

bearing.
1

1 - Press

14
 Pinion Assembly

Install Pinion Assembly

Pinion Assembly
1. Press inner bearing cone onto pinion. 6. Inspect end yoke or flange for grooves in seal sur-
face caused by contaminants. If grooves can be
detected with fingernail, then end yoke must be
repaired with a CR approved repair sleeve or
replaced.
7. Use yoke installer service tool and install yoke with-
out seal.

2. Press inner and outer bearing cups into the carrier

until seated. Use a feeler gage (approximately
0.0015") to make sure bearing cups are fully seated
in bearing bores. Apply lubricant to both cup and
cone.
3. Place carrier housing in press with the pinion sup-
ported by wood block (6" X 6" X 6"), so the inner pin-
ion bearing is mated to the cone. 8. Use torque multiplier and torque pinion nut to
700-900 lbs. ft. (950-1,220 N•m).
2
9. Measure torque to rotate with an inch-pound torque
wrench. Torque measurements should be taken
every fourth revolution and should read between 10-
1
40 lbs. in. of bearing preload.
3
4

1 - Carrier assembly
2 - Press
3 - Bearing preload spacer Note: If bearing preload does not fall within allowed limits,
4 - Pinion preload can be increased by using a thinner spacer and
5 - Wood block decreased by using a thicker spacer.

4. Insert original preload spacer and outer bearing onto 0.001" change in preload spacer thickness will change
pinion. torque to rotate approximately 30 lbs. in.

5. Press outer bearing onto pinion until completely Note: Individual carriers may vary slightly.
seated.

15
 Pinion Assembly

Pinion bearing preload spacers are available in the Note: Dana strongly recommends using seal drivers when
following thicknesses 0.286"-0.315" (7.26-8.00 installing new seals. Use the proper driver to ensure the
mm). Refer to S135/S150 service parts booklet for seal is square and installed to the proper depth.
kits of commonly used preload spacers.
CAUTION: Oil seals can be easily damaged prior to
Always measure each spacer before assembly to
installation. Use care when handling the new seal to pre-
ensure correct thickness.
vent damage or contamination. Leave the seal in its
Note: Closer adjustment can be made by sanding the next package until installation. On new yokes, leave the pro-
thicker spacer to desired thickness using emery cloth on tector on the yoke until it is installed on the shaft to pre-
a flat surface. vent damage or contamination.
12. Install end yoke using yoke installer service tool
CAUTION: Wash spacer thoroughly of emery cuttings
DST1009.
before installing on pinion.
10. Repeat process until torque to rotate is between
10-40 lbs. in. After proper preload is achieved,
remove yoke and install new seal with proper service
tool.
11. Install pinion oil seal with proper service tool.
(Acceptable torque to rotate is 15-45 lbs. in. when
pinion seal is installed.)

Note: Spicer recommends that new torque prevailing nuts be

2 used.
13. Apply Loctite 680 (green) to threads.
14. Use torque multiplier and torque pinion nut to
700-900 lbs. ft. (950-1,220 N•m).

1 - Tool
2 - Seal
3 - Pinion bearing cage

16
 Wheel Differential

Wheel Differential Assembly - Exploded View

16
15
13 14

12

Wheel Differential
10
9
8
11

7
6 6
4 5 7

3
2
1

17
18

1 - Differential bearing adjusting ring 7 - Differential side gear 13 - Differential case half
2 - Differential bearing cup 8 - Differential cross shaft 14 - Differential bearing cone
3 - Differential bearing cone 9 - Differential pinion mate 15 - Differential bearing cup
4 - Differential case bolt 10 - Thrust washer 16 - Differential bearing adjusting ring
5 - Differential case half 11 - Ring gear rivet 17 - No-Spin (optional)
6 - Thrust washer 12 - Ring gear 18 - Truetrac (optional)

17
 Wheel Differential

Disassemble, Overhaul and Assemble Wheel Differential

Disassemble Wheel Differential Incorrect Procedure

CAUTION: During following procedure, place differen-

tial assembly on malleable surface to prevent damage
when ring gear falls off its mounting position. 1 2

Note: Inspect all parts, including the machined surfaces of the

case half.

If any gears are to be replaced, they must be replaced in sets.

Inspect thrust washers for scoring and excessive wear.
Replace all worn or damaged parts.
1 - Ring gear
1. When it is necessary to remove ring gear from the 2 - Case
differential case, carefully center punch each rivet
head. Using a 9/16" drill bit, drill through rivet heads 2. Punch mark differential cases for correct location
to depth shown. Next, use a rounded type punch to during reassembly. Remove cap screws and lift off
drive out remaining portion of the rivet. plain differential case half.
Correct Procedure

1 2 1

1 - Case
2 - Ring gear 1 - Punch marks

CAUTION: Always use a soft hammer or H.D. plastic 3. Lift out side gear and thrust washer.
head hammer to strike punch.

Note: Do not use a chisel to remove rivet heads, damage to

differential case may result.

18
 Wheel Differential

4. Lift out spider, side pinions, and thrust washers. 7. Remove bearing cone from plain case half in two
steps:
a. Mount puller vertically to split bearing. This
action will start moving the bearing off the case.

5. Remove remaining side gear and thrust washer.

Wheel Differential
6. Remove bearing cones from case halves using suit-
able puller.

b. Mount the puller horizontally to remove the

cone.

8. Remove the bearing cone from the flanged case half

using a suitable puller.

19
 Wheel Differential

Overhaul and Assemble Wheel Differential 4. Lubricate all differential parts.

5. Assemble side pinion and thrust washers on spider.
CAUTION: To prevent bearing damage, use suitable Place this assembly in flanged differential case.
sleeve that only contacts the inner race of the cone. A Rotate gears and check for proper mesh.
used bearing race would be a suitable tool. This tool
should have a slit cut if the ID is the same as the flange
OD.
1. Press new flange half bearing cones on differential
case halves.

6. Place side gear and thrust washer on side pinions.

7. Align punch marks and install plain case half. Install

2. Press new plain half bearing cones on differential cap screws and tighten to proper specifications as
case halves. outlined in the back of this publication. Check differ-
ential for free rotation by turning side gear hub.

3. Place thrust washer and side gear in flanged differ-

ential case.

1 - Punch marks

8. Install ring gear. Secure with bolts and nuts.

20
 Wheel Differential

Note: Use the bolt kit 360KY100-X 0.625"-180NF bolt. Torque 10. Install the bearing cup and bearing adjuster to the
bolt to 180-220 lbs. ft. (244-298 N•m). flange half side first.

9. Lower assembled differential assembly into the car-

Wheel Differential
rier using a hoist and a strap. Be careful not to dam-
age the differential bearings lowering the assembly.
11. Install the bearing cup and bearing adjuster to the
plain half side. Use a long screwdriver or bar to lift
the differential up while installing the cup and bear-
ing adjuster.

21
 Wheel Differential Adjustments

Measure and Adjust Carrier Assembly (Adjust Backlash and Preload)

1. Turn the flange half bearing adjuster in until the ring 3. Tighten the plain half adjuster two lug notches. Start
gear contacts the pinion (zero backlash) than back with the notch at the top, count two notches coun-
the adjuster out two notches of the adjuster lugs. terclockwise on the adjuster, and turn the adjuster so
the notch is facing straight up. You now have a two
notch preload.

2
2
1
1

1 - Lugs
2 - One notch
1 - Flange half
2 - Plain half 4. Use a rubber mallet to make certain both bearing
adjusters are fully seated.
2. Tighten the plain half adjuster until the bearing cup 5. Measure backlash. Make sure it is within specifica-
just starts to turn, this is a zero bearing preload. tion of 0.008"–0.018".
TIP: To give yourself room to adjust contact pattern,
set it between 0.010"– 0.012".

22
 Wheel Differential Adjustments

Change Backlash Setting

If you have too much backlash the ring gear needs to move Measure Ring Gear Runout
closer to the pinion. Back off the plain half adjuster, and count
1. Measure ring gear total radial run out. (Indicator
the number of notches you backed it off. Each notch equals
reading should not exceed 0.010").
about 0.003" of backlash.

IMPORTANT: In order to maintain the differential bearing pre-

load you will need to turn the flange half bearing adjuster the
same amount in the same direction. If you need more back-
lash reverse this procedure.
Recheck Backlash
1. Install carrier bearing caps and torque carrier cap
bolts to specifications outlined in the back of this
publication.
2. If the bearing adjusters were not in straight or fully
seated the backlash will change.
a. Used Gearing: Reset to backlash recorded 2. Measure ring gear total backface runout. (Indicator
before disassembly. reading should not exceed 0.010").

b. New Gearing: Backlash should be between

0.008" and 0.018".

Wheel Differential
Adjustments
3. Check ring gear tooth contact pattern. Paint ring gear
teeth and check tooth contact pattern. Correct tooth
patterns. Check adjusting procedures outlined in this
section.
4. Install bearing adjuster cotter pins.

23
 Adjust Tooth Contact Pattern

Adjust Ring and Pinion Tooth Contact Pattern

Note: Rear axle gearing is shown in the following instructions. Used Gearing - Correct Pattern
Correct tooth contact patterns and adjustments are the Used gearing will not usually display the square, even contact
same for forward and rear axles. pattern found in new gear sets. The gear will normally have a
“pocket” at the heal end of the gear tooth. The more use a
2 gear has had, the more the line becomes the dominant char-
acteristic of the pattern.

Adjust used gear sets to display the same contact pattern

1 observed before disassembly. A correct pattern is up off the
3 toe and centers evenly along the face width between the top
4 land and root. Otherwise, the length and shape of the pattern
5 are highly variable and is considered acceptable as long as it
6 does not run off the tooth at any point.

1 - Face width
2 - Tooth depth
3 - Heel
4 - Top land
5 - Root
6 - Toe

1. Identify if new or used gearing. 1 - Pattern along the face width could be longer
2. Check tooth contact pattern (new or used gearing). Adjust Contact Pattern
New Gearing - Correct Pattern If necessary, adjust the contact pattern by moving the ring
Paint six ring gear teeth 180° apart with marking compound gear and drive pinion.
and roll the gear to obtain a contact pattern. The correct pat- • Ring gear position controls the backlash. This
tern is slightly below center on the ring gear tooth with length- adjustment moves the contact pattern along the face
wise contact up off the toe. The length of the pattern in an width of the gear tooth.
unloaded condition is approximately one-half to two-thirds of
the ring gear tooth in most models and ratios. • Pinion position is determined by the size of the pin-
ion bearing cage shim pack. It controls contact on
The pattern could vary in length and should cover 1/2 tooth or the tooth depth of the gear tooth.
more (face width). The pattern should be evenly centered
between tooth top land and root and should be up off the These adjustments are interrelated. As a result, they must be
tooth toe. considered together even though the pattern is altered by two
distinct operations. When making adjustments, first adjust the
pinion, then the backlash. Continue this sequence until the
pattern is satisfactory.

24
 Adjust Tooth Contact Pattern

Adjust Ring Gear Position (Backlash)

Note: Tooth contact pattern can be moved only by adjusting 3. Return to adjuster on teeth side of ring gear and
backlash. The tooth contact pattern can be moved in the tighten adjuster until it contacts the bearing cup.
direction of heel-to-toe, and toe-to-heel; depth of the
4. Continue tightening the same adjuster 2 or 3 notches
pattern cannot be adjusted. If an acceptable tooth con-
and recheck backlash.
tact pattern cannot be established within limits of back-
lash, contact Spicer Service at 1-800-826-HELP (4357). If the pattern is concentrated at the heel (too far up
the tooth), move the ring gear toward the pinion to
If the gear pattern shows incorrect face width contact, change decrease backlash.
backlash by adjusting the ring gear.

If the pattern is too close to the edge of the tooth toe, move
the ring gear away from the pinion to increase backlash.

5. Loosen the bearing adjuster on the teeth side of the

ring gear several notches.
6. Tighten the opposite adjuster one notch.
1. Loosen the bearing adjuster on the teeth side of the 7. Return to adjuster on teeth side of ring gear and

Adjust Tooth Contact

ring gear several notches. tighten adjuster until it contacts the bearing cup.
2. Loosen the opposite adjuster one notch. 8. Continue tightening the same adjuster 2 or 3 notches
and recheck backlash.

Pattern

25
 Housing Breather

Install New Axle Housing Breather - (Metal and Plastic)

Dana uses an axle housing breather that consists of a fitting, Plastic only: Tighten until one thread is showing.
hose, and clamp assembly. This breather design has
improved resistance to water ingestion, and clogging caused
by dirt, ice, or snow buildup around the base of the breather.
See installation instructions below (all views from rear).
1. Install fitting in breather hole.

4. Insert hose onto fitting, long end down.

2. Tighten fitting finger tight.

5. Push hose firmly against fitting. Rotate hose to point

3. Using a 3/4" wrench: down.

Metal only: Rotate the fitting at least 1/2 turn until

nipple points to rear.

26
 Axle Housing

Axle Housing - Exploded View

3 4

1 2

1 - Axle shaft
2 - Fill plug
3 - Breather

Axle Housing
4 - Housing

27
 Wheel End Seal

Wheel End Seal Parts - Exploded View

1 - Installation tool
2 - Seal
3 - Rear hub

28
 Wheel End Seal

Remove and Overhaul Wheel End Seal

WARNING: Never work under a vehicle supported by Install Wheel End Seal
only a jack. Always support vehicle with stands. Block
the wheels and make sure the vehicle will not roll before 1. Before installation, lubricate the following with the
releasing the brakes. same lubricant used in the axle sump:
• Inner bearing
CAUTION: Wheel end seals can be easily damaged dur-
ing handling. Leave the seal in its package until installa- • Wheel seal (follow the directions provided by
tion to prevent damage or contamination. the seal supplier)
1. Remove outer bearing and wheel. 2. Place the seal on the installation tool.
2. Remove oil seal. 3. Drive the seal with the installation tool onto the hub.
3. Remove inner bearing.
4. Remove old wear sleeve (2-piece design only) with a
ball peen hammer and discard.

CAUTION: Do not cut through the old wear sleeve.

Damage to the housing may result.
Note: Deep gouges can be repaired by filling gouge with hard-
ening gasket cement and smoothing with emery cloth.
5. Inspect spindle journal and hub bore for scratches or
burrs. Recondition with an emery cloth as required.

Wheel End Seal

6. Clean hub cavity and bearing bores before reassem-
bly. Be sure to remove contaminants from all
recesses and corners.
7. Clean bearings thoroughly with solvent and examine
for damage. Replace damaged or worn bearings.

CAUTION: Always use the seal installation tool specified

by the seal manufacturer. Using an improper tool can
distort or damage the seal and cause premature seal
failure.

29
 Wheel Adjustment Systems

Adjust Wheel Bearing

WARNING: Do not mix spindle nuts and lock washers 8. Back off the inner nut one full turn. Rotate the wheel
from different systems. Mixing spindle nuts and lock hub.
washers can cause wheel separation.
9. Retighten the inner nut to 50 lbs. ft. (68 N•m) while
Note: The lock washer for a four-piece tang/dowel-type wheel rotating the wheel hub.
nut system is thinner than the lock washer for a three-
10. Back off the inner nut exactly 1/4 turn.
piece tang-type wheel nut system and is not designed to
bear against the inner nut. Note: This adjustment procedure allows the wheel to rotate
freely with 0.001" -0.005" (0.025 mm–0.127 mm) end-
1. Inspect the spindle and nut threads for corrosion
play.
and clean thoroughly or replace as required.
11. Install the correct lock washer for the wheel nut sys-
Note: Proper assembly and adjustment is not possible if the
tem being used.
spindle or nut threads are corroded.
Three-piece Dowel-type Lock Washer System
2. Inspect the tang-type washer (if used). Replace the
washer if the tangs are broken, cracked, or damaged.
3. Install the hub and drum on the spindle with care to
prevent damage or distortion to the wheel seal.

CAUTION: A wheel dolly is recommended during instal-

lation to make sure the wheel seal is not damaged by the
weight of the hub and drum. Never support the hub on
the spindle with just the inner bearing and seal. This can 1
damage the seal and cause premature failure. 2
3
4. Completely fill the hub cavity between the inner and 4
outer bearing races with the same lubricant used in
the axle sump.
5. Before installation, lubricate the outer bearing with 1 - Inner nut
the same lubricant used in the axle sump. 2 - Dowl pin
3 - Dowel-type lock washer
Note: Lubricate only with clean axle lubricant of the same type 4 - Outer nut
used in the axle sump. Do not pack the bearings with
grease before installation. Grease will prevent the proper a. Install the dowel-type lock washer on the spin-
circulation of axle lubricant and may cause wheel seal dle.
failure.
Note: If the dowel pin and washer are not aligned, remove
6. Install the outer bearing on the spindle. washer, turn it over, and reinstall. If required, loosen the
inner nut just enough for alignment.
7. Install the inner nut on the spindle. Tighten the inner
nut to 200 lbs. ft. (271 N•m) while rotating the wheel Note: Never tighten the inner nut for alignment. This can pre-
hub. load the bearing and cause premature failure.

CAUTION: Never use an impact wrench to adjust wheel b. Install the outer nut on the spindle and tighten
bearings. A torque wrench is required to assure the nuts to 350 lbs. ft. (475 N•m).
are properly tightened. c. Verify end-play, see “Verify Wheel End Play Pro-
cedure”.

30
 Wheel Adjustment Systems

Three-piece Tang-type Lock Washer System Four-piece Tang/Dowel-type Lock Washer System

3
4
5
1
2 21
3

1 - Inner nut
2 - Tang-type lock washer 0.123" (3.124 mm) thick 1 - Inner nut
3 - Outer nut 2 - Dowel pin
3 - Dowel-type lock washer
a. Install the tang-type lock washer on the spindle. 4 - Tang-type lock washer 0.0478" (1.2065 mm) thick
5 - Outer nut
Note: Never tighten the inner nut for alignment. This can pre-
load the bearing and cause premature failure.
a. Install the dowel-type lock washer on the spin-
b. Install the outer nut on the spindle and tighten dle.
to 250 lbs. ft. (339 N•m). Note: If the dowel pin and washer are not aligned, remove

Wheel Adjustment
c. Verify end-play, see “Verify Wheel End Play Pro- washer, turn it over and reinstall. If required, loosen the
cedure”. inner nut just enough for alignment.

Systems
d. After verifying end-play, secure wheel nuts by Note: Never tighten the inner nut for alignment. This can pre-
bending one of the locking washer tangs over load the bearing and cause premature failure.
the outer wheel nut and another tang over the
inner wheel nut. b. Install the tang-type lock washer on the spindle.

e. Go to step 12. c. Install the outer nut on the spindle and tighten
to 250 lbs. ft. (339 N•m).
d. Verify end-play, see “Verify Wheel End Play Pro-
cedure”.
e. After verifying end-play, secure the outer nut by
bending two opposing tangs (180° apart) of the
locking washer over the outer nut.
12. Install the following:
• New gasket at axle shaft flange.
• Axle shaft.
• Axle flange nuts and tighten to specified torque.
13. Lubricate axle wheel ends.

31
 Wheel Ends

Verify Wheel End-Play Procedure

Verify end-play meets specification using a dial indicator. An Adjust End-play with Wheel Hub
indicator with 0.001" (0.03 mm) resolution is required. Wheel
Insufficient End-play - If end-play is not present, remove the
end play is the free movement of the tire and wheel assembly
outer nut and pull the lock washer away from the inner nut,
along the spindle axis.
but not off the spindle. Loosen the inner nut to the next
adjustment hole of the dowel-type washer (if used). Reassem-
Correct end-play is 0.001" - 0.005" (0.025 - 0.125 mm).
ble the washer and re-torque the outer nut. Verify end-play
Adjust End-Play with Tire and Wheel Assembly with a dial indicator.
1. Attach a dial indicator with its magnetic base to the
Excessive End-play - If end-play is greater than 0.005" (0.127
hub or brake drum.
mm), remove the outer nut and pull the lock washer away
2. Adjust the dial indicator so its plunger or pointer is from the inner nut, but not off the spindle. Tighten the inner
against the end of the spindle with its line of action nut to the next alignment hole of the dowel-type washer (if
approximately parallel to the axis of the spindle. used). Reassemble the washer and re-torque the outer nut.
Verify end-play with a dial indicator.
3. Grasp the wheel assembly at the 3 o’clock and 9
o’clock positions. Push the wheel assembly in and
Fine Tuning the End-play - If, after performing the readjust-
out while oscillating it to seat the bearings. Read
ment procedures, end-play is still not within the 0.001" -
bearing end-play as the total indicator movement.
0.005" (0.025 - 0.127 mm) range, disassemble and inspect
the components. If parts are found to be defective, replace the
CAUTION: If end-play is not within specification, read-
defective parts, reassemble and repeat wheel bearing adjust-
justment is required.
ment procedure. Verify end-play with a dial indicator.

32
 Lubrication

Lubricate Wheel End

CAUTION: Before operating the axle, the wheel hub Wheel End with Oil Fill Hole
cavities and bearings must be lubricated to prevent
failure. 1

When wheel ends are serviced, follow Dana’s wheel end lubri-
cation procedure before operating the axle.

Dana axles may be equipped with either of two wheel end

designs:
• Wheel ends with an oil fill hole.
• Wheel ends without an oil fill hole.
Wheel Ends With Oil Fill Hole 2

1. Rotate the wheel end hub until the oil fill hole is up.
2. Remove the oil fill plug.
3. Pour 1/2 pint of axle sump lubricant into each hub
through the wheel end fill hole.
4. Install oil fill plug and tighten to specified torque.
3

Lubrication
1 - Wheel end oil fill hole
2 - Proper lubricant level
3 - Lubricant flow from sump

33
 Lubrication

Wheel Ends Without Oil Fill Hole

1. With axle level and wheel ends assembled, add lubri- 5. Lower the left side.
cant through filler hole in axle housing cover until
6. With axle on a level surface, add lubricant through
fluid is level with the bottom of filler hole.
housing cover oil filler hole until fluid is level with the
2. Raise the right side of the axle 6" or more. Hold axle bottom of the hole.
in this position for one minute.
Note: Axles without wheel end fill holes will require approxi-
3. Lower the right side. mately 2.5 additional pints of lubricant to bring the lube
4. Raise the left side of the axle 6" or more. Hold axle in level even with the bottom of fill hole.
this position for one minute.

3 4
1

1 - Lubricant filler hole

2 - Temperature sensor mounting hole
3 - Oil will run into wheel end
4 - Oil will run into wheel end

34
 Lubrication

General Lubrication Information

The ability of a drive axle to deliver quiet, trouble-free opera- Recommendations for Viscosity/Ambient
tion over a period of years is largely dependent upon the use
of good quality gear lubrication in the correct quantity. The Temperature
most satisfactory results can be obtained by following the
directions contained in this manual. The following chart lists the various SAE Grades covered by
MIL-L-2105D and the associated ambient temperature range
The following lubrication instructions represent the most cur- from each. Those SAE grades shown with an asterisk (*) are
rent recommendations from the Commercial Vehicle Division available in the Spicer family of synthetic gear lubri-
of Dana Corporation. cants.

The lowest ambient temperatures covered by this chart are

Approved Lubricants -40°F and -40°C. Lubrication recommendations for those
applications which consistently operate below this tempera-
General - Gear lubrications acceptable under military specifi- ture range, must be obtained through Dana Corporation by
cation (MILSPEC) MIL-L-2105D (Lubricating Oils, Gear, Mul- contacting your local Dana representative.
tipurpose) are approved for use in Dana Drive Axles. The MIL-
L-2105D specification defines performance and viscosity
requirements for multigrade oils. It supersedes both MIL-L- GRADE AMBIENT TEMPERATURE RANGE
2105B, MIL-L-2105C and cold weather specification MIL-L- 75W -40°F to -15°F (-40°C to -26°C)
10324A. This specification applies to both petroleum-based
and synthetic based gear lubricants if they appear on the most 75W-80 -40° to 80° (-40°C to 21°C)
current “Qualified Products List” (QPL-2105) for MIL-L- 75W-90* -40°F to 100°F (-40°C to 38°C)
2105D.
75W-140 -40°F and above (-40°C and above)

Lubrication
Note: The use of separate oil additives and/or friction modifi-
ers are not approved in Dana Drive Axles. 80W-90 -15°F to 100°F (-26°C to 38°C)
80W-140* -15°F and above (-26°C and above)
Synthetic based - Synthetic-based gear lubricants exhibit
superior thermal and oxidation stability, and generally 85W-140 10°F and above (-12°C and above)
degrade at a lower rate when compared to petroleum-based
lubricants. The performance characteristics of these lubri- * Available in the Spicer family of synthetic gear lubri-
cants include extended change intervals, improved fuel econ- cants.
omy, better extreme temperature operation, reduced wear and
cleaner component appearance. The family of Dana
Spicer™ gear lubricants represents a premium quality
synthetic lube which fully meets or exceeds the requirements
of MIL-L-2105D. These products, available in both 75W-90
and 80W-140, have demonstrated superior performance in
comparison to others qualified under the MILSPEC, as dem-
onstrated by extensive laboratory and field testing. For a com-
plete list of Spicer® approved synthetic lubricants
contact your local Dana representative. See back cover of this
manual for appropriate phone number.

Makeup Lube - Maximum amount of non-synthetic makeup

lube is 10%.

35
 Lubrication

Lube Change Intervals

This product combines the latest manufacturing and part Severe Service Lubrication Change Intervals - Severe ser-
washing technology. When filled with -«ˆViÀ vice applications are those where the vehicle consistently
approved synthetic lubricant at the factory, the initial drain operates at or near its maximum GCW or GVW ratings, dusty
is not required. or wet environments, or consistent operation on grades
greater than 8%. For these applications, the ON/OFF HIGH-
Change the lubricant within the first 5,000 miles of opera- WAY portion of the chart should be used. Typical applications
tion when not using a -«ˆVer approved synthetic lubri- are construction, logging, mining and refuse removal.
cant in either a new axle or after a carrier head
replacement. Base subsequent lubricant changes on a com- Note: Clean metallic particles from the magnetic filler plug
bination of the following chart and user assessment of the and drain plugs. Clean or replace the breather yearly to
application and operating environment. avoid lube contamination due to water ingestion.

Guidelines - Lube Change Intervals for Drive Axles

LUBRICANT TYPE ON-HIGHWAY MILES MAXIMUM CHANGE ON/OFF HIGHWAY MAXIMUM CHANGE
INTERVAL SERVERE SERVICE MILES INTERVAL
Mineral Based 100,000 Yearly 40,000 Yearly
Spicer Approved 250,000 3 Years 100,000 Yearly
Synthetic

For additional lubrication information, see TCMT-0021.

36
 Lubrication

Change Lube

Drain Note: Lube fill capacities (see chart) are basic guidelines and
will vary based on the angle the axle is installed in a par-
1. Drain when the lube is at normal operating tempera- ticular chassis. Torque fill plug to 40–60 lbs. ft. (54–82
ture. It will run freely and minimize the time neces- N•m).
sary to fully drain the axle, this insures the axle is
flushed. Drain into suitable container with lube at TIP: The axle can be filled through the axle housing breather
normal operating temperature. Inspect drain plug for hole. Fill until lube level is even with the bottom of filler hole in
excessive metal particle accumulation symptomatic axle housing rear cover.
of extreme wear. Clean and replace plug after drain-
ing 1
2. Unscrew the magnetic drain plug on the underside of
the axle housing and allow the lube to drain into a
suitable container.
Note: Dispose of all used lubricants properly by following dis-
posal methods approved for mineral or synthetic based 2
oils.
1 - Lubricant filler hole
3. After initial oil change, inspect drain plug for large 2 - Temperature sensor mounting hole
quantities of metal particles. These are signs of dam-
age or extreme wear in the axle. Clean the drain plug
and replace it after the lube has drained completely.
Inspect breather for clogging or corrosion. Clean or Lube Capacities (Approximate*) - DO NOT OVERFILL AXLES
replace as necessary.

Lubrication
MODEL PINTS LITERS
Note: After initial lube change, the entire unit should be S135S / S150S 24.5 11.6
inspected if excessive particle accumulation is observed.
* Lube capacity will vary depending upon the housing angle
in each vehicle. Capacities given above are for an angle of
Fill 4°. Fill to the lower edge of the fill hole in the axle housing
as shown above.
1. With vehicle on level ground, remove the filler hole
plug from the axle housing cover and fill the axle
with approved lubricant until level with the bottom of Axles installed at angles exceeding 6° or operated regularly on
the hole. grades exceeding 12% may require stand-pipes to allow
proper fill levels. For specific information, contact Axle &
2. If wheel ends were removed, follow instructions in Brake Engineering Department.
wheel end servicing section.

Always use the filler hole as the final reference. If lube is level
with the bottom of the hole, the axle is properly filled.

37
 Proper Vehicle Towing

Proper Vehicle Towing

Lift the drive wheels completely off of the ground or damage When the vehicle experiences unequal side to side traction
will occur. (for instance on wet, muddy, icy or sand/gravel terrain), the
pinions resist rotation in the case and transfer torque from
WARNING: Do not lift the front wheels (non-drive one side gear to the other. All mating pinions tend to separate
wheels). This alters the oil’s position in the drive axle, from each other and from the side gears and they wedge into
draining it away from the drive pinion and its bearings. their case pockets. This provides a friction force that retards
If the pinion is rotated under these conditions for any or prevents the wheel with lesser traction from rotating and
period of time, bearings will overheat resulting in axle spinning out.
damage or failure.

If it is impossible to lift the drive wheels, remove all axle

shafts to prevent gear rotation and cap the wheel hubs to pre-
vent loss of lubricant and a possible road hazard. See the fol-
lowing section Proper Vehicle Towing with Wheel Differential
Lock for removal procedure.

With Truetrac Limited Slip Differential

These differentials perform like conventional (open) differen-
tials under normal driving conditions - until traction control is
needed. Then the imbalanced gear forces automatically apply
resistance to the wheel (or axle) with the lesser traction.

Planetary pinion gears are supported in pockets of the case.

Each pinion meshes with its side ear and with a mating pinion
of the opposite planetary gear set.

38
 Proper Vehicle Towing

Torque Flow
While driving with equal load on and equal traction under both With unequal load and/or traction on each drive wheel, a
drive wheels, the Truetrac differential provides equal torque to major portion of the torque will be transferred from one side
each wheel. to the other to reduce the chance of a one wheel spin-out.

1 1

Proper Vehicle Towing

1 - Torque flow distribution while operating with equal 1 - Torque flow distribution with less load over or ground
loading and ground coefficient coefficient under left wheel

39
 Parts Identification

Rear Drive Axle Parts - Exploded View

17
18
16
21 15
13 14

12

10
9
8
11
21

20 7 6 No- Spin Differential

6
19 4 5 7

3
2
1

27
28
29
30
31

32
22 26
23
24

25

1 - Differential bearing adjusting ring 12 - Ring gear 23 - Inner pinion bearing cone
2 - Differential bearing cup 13 - Differential case half 24 - Inner pinion bearing cup
3 - Differential bearing cone 14 - Differential bearing cone 25 - Carrier mounting bolt
4 - Differential case bolt 15 - Differential bearing cup 26 - Carrier housing
5 - Differential case half 16 - Differential bearing adjusting ring 27 - Pinion preload spacer (selective)
6 - Thrust washer 17 - Differential bearing cap bolt 28 - Outer pinion bearing cup
7 - Differential side gear 18 - Washer 29 - Outer pinion bearing cone
8 - Differential cross shaft 19 - Adjusting ring lock bolt 30 - Pinon seal
9 - Differential pinion mate 20 - Adjusting ring lock 31 - End yoke assembly
10 - Thrust washer 21 - Differential bearing cap 32 - Pinion hex nut
11 - Ring gear rivet 22 - Pinion

40
 Torque Specifications

Fastener Torque Specifications

S135 / S150 Fasteners

Position Thread Size Grade lbs. ft. N•m

Pinion Nut 1 1/4" - 12 8 700 - 900 950 - 1,220
Adjusting Ring Lock 3/8" - 16 8 20 - 30 27 - 41
Bolts
Carrier Mounting Bolts 1/2" - 13 8 100 - 120 136 - 163
Differential Bearing Cap 9/16" - 18 8 115 - 135 160 - 183
Bolts
Differential Cases Bolts 1/2" - 13 8 100 - 120 136 - 163
Fill Plug 3/4" - 14 --- 35 - 45 47 - 61
Drain Plug 3/4" - 14 --- 35 - 45 47 - 61
Axle Shaft to Wheel 1/2" - 20 --- 55 - 71 75 - 96
Hub Nuts
5/8" - 18 --- 170 - 190 230 - 258
3/4" - 16 --- 285 - 345 386 - 468

Note: Refer to vehicle manufacturer specifications for axle Flange-Wheel Nut Fastener torque.

Torque Specifications
S135 / S150 Specifications

Position U.S. Metric

Pinion
Pinion Bearing Preload* 10 - 40 lbs. in. 1.13 - 4.50 N•m
Differential
Ring Gear to Pinion Backlash 0.006" - 0.012" 0.15 - 0.33 mm
Ring Gear Rivet Pressure 45 - 50 tons 41 - 45 tonnes
Lubrication**
Lube capacity (Approx.***) 24.5 pints 11.6 liters
* Pinion bearing preload is established prior to installation of pinion seal.
** For additional lubrication information, see TCMT-0021.
*** Capacity will vary depending on the housing angle in each vehicle.

41
 Service Tools

Recommended Service Tools

Order Number Illustration Description
DST1001 Carrier Stand

Torque Multipliers
DST1002 Maximum 1,000 lbs. ft.
DST1003 Maximum 2,000 lbs. ft.
DST1004 Maximum 4,000 lbs. ft.
DST1005 Maximum 12,000 lbs. ft.

DST1006 Yoke Remover, Bar Type

DST1009 Installer, Differential Yoke (1 1/4" - 12)

DST1000-1 Seal Installation Tube Handle

42
 Service Tools

Order Number Illustration Description

DST1000-2 Pinion Seal Installer

No Part Number Wooden Block (Approx. 6" x 6" x 6")

All service tools available from OTC Division:

Service Tools
655 Eisenhower Drive
Owatonna, MN 55060
Telephone: 1-800-533-0492

Service Tools
Fax Number: 507-455-7011

43
ForDana Aftermarket
spec‘ing Group
or service assistance, call 1.800.621.8084 or visit our website at www.spicerparts.com
PO Box 321
Toledo, Ohio 43697-0321

Warehouse
Dana Distributor:
Commercial Vehicle1.800.621.8084
Products Group
OE Dealers: 1.877.777.5360
3939 Technology Drive
Maumee, Ohio, USA 43537
www.spicerparts.com
www.dana.com

AXSM-8941 Printed in U.S.A.

Copyright Dana Limited, 2012.
All rights reserved. Dana Limited.