Service Manual - Dana Corporation
Contents
1. Pressure Engagement ici isir bida asa Fl di a eei reached ete dea wel dec eh dees 13 Manual Engagement m dis sisi a rd Aantal aed mani nanan 13 AM a A ii 14 Drive Pinlon Oil Sealed i Vea TA bt ee oe 15 Removal A A SAA 15 Installation 0 A A A AA a A AA AA tA a a 15 Wheel HUB iii i A A AA eve aie ee ee 16 into le comicios ld e ts A A ia 16 Wheel Hub Components Disassembly ooooooccconccconoccconnccccconcco naco nonn cnn annonces 18 Sun Gear and Axe alivian tl dd ti a A eas ae ae dete 18 Planetary Carrier AA ee a A A 18 Ring Gear and Motion a a eee 19 ME A O 19 Wheel Hub Components Assembly 2 EA MA AAE AHHAR REAAAAEEME INA ANKAMMZZEMMENEEEEMET nati 20 Wheel Hub i A A A ae ea en ea eee 20 Ring Gear and Mount site just ip p a a eek Neves ra geld Tama 20 Planetary Cartier i ia ii bir b a cai a eee ee hain el ee Ae th aed a g 21 oun Gear and Axle Shall taco lts denne aera Aad aaa a tdt SS 22 Wheel Hub Installation 2 b at Ma kata iu ts tates tats tai eat int Seidel te hala ata dada fin 22 Head ModelGross Reference Chart cet f isibu baka kind pagni bia bi nada bata Bid isa rd bba kai i B d g a p 24 e Wheel Reduction Axle Service and Maintenance Instructions Axle and Carrier Assembly Model Identification Differential carrier identification is either stamped on the carrier itself or on a metal tag affixed to the carrier Location on the carrier is the same TOP VIEW Eaton Axie E TN MODEL HEAD RATIO SPEC2. of RTV sealant to the shift cylinder flange to serve as a seal between the shift unit and the carrier Install the shift cylinder assembly over the pushrod orienting the cylinder so that the breather port is facing up as the axle will be installed in the vehicle Compress the assembly to keep the pushrod piloted in the carrier The spring force is higher for the hydraulic shift than the air shift version so expect higher forces to compress the assembly Tighten the two shift cylinder mounting screws longer than those used on the air shift unit to 28 35 ft Ibs Adjust the shift fork position using the following procedure Fit a dummy shaft through the sliding clutch into the differential side gears e Place a 0 120 in feeler gauge between the tips of the curvic clutch teeth and slide the shiff fork along the push rod to set clutch clearance at 0 120 in as shown in the illustration e Tighten shift fork capscrew to 26 30 ft Ibs CLUTCH CLEARANCE 0 120 SLIDING CLUTCH FIXED CLUTCH DIFFERENTIAL CASE Assembling Continued Drive Pinion Oil Seal e Check operation of differential lock by connecting high pressure air or hydraulic line of 140 psi supply to shift cylinder If this is not possible use a 0 75 16 UNF bolt but do not over torque to manually engage the clutches When the fork is adjusted correctly curvic teeth should be fully engaged with the fork free to float The shift ass
3. pin Remove thrust washers from planetary Carrier Remove planetary gear from carrier ROLLERS wann Remove bearing rollers and spacer from inside planetary gear NOTE The WR10 and 12 models have two locking balls 18 Ring Gear and Mount Disengage ring gear retaining ring Slide ring gear off ring gear mont Pull outer bearing cone off ring gear mount sleeve e Adrift can be used to drive dearing off of mount through holes in mount Wheel Hub 1 Pullouter bearing cup out of hub 2 Pulloil seal and seal band out of hub 3 Disengage inner bearing retaining ring OUTER BEARING CUP RING BEARING KNOCKOUTS GEAR RING GEAR MOUNT INNER BEARING BEARING CONE BEARING CONE RETAINING RING 4 Remove inner bearing cone out of hub 5 Drive inner bearing cup out of hub BEARING RETAINING RING 19 Wheel Hub Components Assemblv Wheel Hub Press inner bearing cup into hub Press outer bearing cup into hub RETAINING Install bearing cone and retaining ring RING l INNER Install oil seal and seal band into hub BEARING INNER OUTER BEARING BEARING CONE CUP Ring Gear and Mount 1 Slide ring gear onto ring gear mount 2 Install ring gear retaining ring 3 Press outer bearing cone onto ring RETAINING gear mount RING outer BEARING CUP BEARING RING GEAR CONE MOUNT 20 Planetarv Carrier ig Slide bearing spacer into planetry gear In
4. 800 621 8084 OE Dealers 1 877 777 5360 www spicerparts com AXSM 0050 Printed in U S A Copyright Dana Limited 2012 All rights reserved Dana Limited
5. SERIAL NO CUST PART NO Axle Specification Number The complete axle is identified bv the specification number stamped on the side of the axle housing or metal tag affixed to axle housing This number identifies all component parts of the axle as built bv Spicer including special OEM requirements such as voke or flange COMPLETE AXLE SPECIFICATION NO e Wheel Reduction Drive Axles Description and Operation Spicer wheel reduction drive axles described in this publication have a base single reduction axle combined with wheel reduction hubs These units are designed for off highway construction agriculture and timber applications This type of axle provides a vehicle with superior traction and towing capabilities This is accomplished through a planetary gear systems contained in the wheel hubs reducing wheel rpm and increasing torque Power Flow and Torque Distribution Torque power flow from the vehicle driveline is transmitted to the differential through the primary drive pinion ring gear and differential The gearing and differential design depends on the particular axle model The primary gearing design can be spiral bevel or hypoid The differential design can be open automatic locking or manual locking The differential transmits torque to the axle shafts which drive a planetary gear system within the wheel hub The planetary carrier rotates against a fixed gear and drives the wheel hub Differential ge
6. Spicer Drive Axles SPICER Service Manual Spicer Drive Axles AXSM 0050 September 2007 e Wheel Reduction Axle Service and Maintenance Instructions Introduction Dana Corporation Axle amp Brake Division presents this publication to aid in maintenance and overhaul of Spicer WheelReduction drive axles Model No This manual covers the nine axle models listed WR3 to the right Their design is generally common with differences in load capacity Capacity WR3N variations are achieved by combining basic WR3D differential carrier assemblies in different axle housings axle shafts and hub reduction equipment WR5 The majority of the instructions in this manual relate WRSD oniv to the wheel hub For instructions concerning WR7 non hub components it mav be necessarv to reference additional service manuals WR7D For driveline information or axle mounting refer WR10 to vehicle manufacturer s literature WR10D WR12 WR12D Contents Spicer Wheel Reduction Axle Service and Maintenance Instructions 22ss e en 2 Axle and Carrier Assembly Model Identification nn cana nn nr rnn nanna nt 2 Axle Specification NUMDE 2 is ottan Loans sa kena vended efa a da ta sk esta fa Meant ida 2 Spicer Wheel Reduction Drive Axles nanna nt An tan nnAnnnnnnnAnnt ene 3 Description and Operatioti i ntesiet A L a fel ee 3 Power Flow and Torque Distribution L an nn mnn nn nn EAEAN EESE EEEE EEE 3 Wheel Redu
7. aft assembly out of axle housing e Asteel rod with a 1 2 thread can be installed into the axle shaft to aid in pulling the axle shaft Pull wheel hub capscrews Remove planetary carrier assembly from wheel hub e Capscrews can be installed in unused planetary carrier holes to jack carrier out of hub Remove set screw spindle nut and washer WARNING THE SPINDLE NUT SECURES THE RING GEAR MOUNT ASSEMBLY AND WHEEL HUB TO THE AXLE HOUSING MAKE SURE THESE ITEMS ARE PROPERLY SUPPORTED BEFORE REMOVING SPINDLE NUT Pull ring gear mount assembly off of spindle Remove wheel hub assembly from axle housing Remove oil seal and seal band from end of axle housing Removal SUN GEAR AND AXLE SHAFT RING GEAR ASSEMBLY MOUNT ASSEMBLY LOCKING WASHER ABUTMENT CAP PLANETARY CARRIER SPINDLE OIL SEAL SEAL BAND HUB Wheel Hub Components Disassemblv Sun Gear and Axle Shaft 1 Disengage snap ring at wheel end of axle shaft 2 Pull sun gear off axle shaft spine AXLE SHAFT Planetary Carrier 1 Drive idler pinion pin out of planetary carrier using a brass hammer or drift Drive pin from back of planetary carrier out through the front locking ball end of pin LOCKING should emerge from carrier first PLANETARY CAUTION THE IDLER PINION PIN IS HARDERNED STEEL AND SHOULD NOT ABE STRUCK BY A STEEL HAMMER Remove pinion locking ball from idler pinion
8. ar ratios range from 3 08 1 to 7 17 1 Hub assembly ratio is either 4 2 1 or 4 5 1 depending on the axle model Wheel Reduction Hub Assembly Part Nomenclature WASHER WR 10 12 AXLE HOUSING SPINDLE STUD AXLE SHAFT SEAL BANDS OIL SEAL RETAINING RING INNER BEARING CONE INNER BEARING CUP SILICONE SEALANT OUTER a BEARING CUP OUTER BEARING LOCKING WASHER PLANETARY CARRIER SPINDLE NUT THRUST IF mse PLANETARY GEAR A BEARING SET LOCKING PINION PIN BALL Torque Specifications 385 375 FT LBS WR 3 5 amp 7 450 540 FT LBS l UE U Q Y WR 108 12 U S a NN NAS AS 250 FT LBS WR 3 5 amp 7 350 FT LBS WR 10 amp 12 80 95 FT LBS WR 3 5 amp 7 127 149 FT LBS WR 10 amp 12 35 42 FT LBS WR 3 5 amp 7 i 45 54 FT LBS WR 10 amp 12 Lubrication The abilitv of a drive axle to deliver quiet trouble free operation over a period of years is largely dependent upon the use of good quality gear lubricants in correct quantities The most satisfactory results can be obtained by Approved Lubricants General Gear lubricants acceptable under military specification MILSPEC MIL L 2105D Lubricating Oils Gear Multipurpose are approved for use in Spicer Drive Axles The MIL L 2105D specification defines performance and viscosity requirements for multigrade oils It supersedes bo
9. ction Hub Assembly 2 Le AM rn rr mant 4 Part Nomen lattire ii iene ace ae A A ee aia 4 Torque Specifications sis ek iii ett a b a ee a eaten a 5 LUBriC ations oc sei aes Be eed ee ee eed ed ees ee ee Ta 6 Approved Cubricants ii tis A a a e ma Ta Coase a Selanne tate ele eed 6 General ii A l 6 Syntheti Based sa ii iii ie evened ee dias 6 Lube Sampling and Condition Monitoring 0 0 0 0 nanna an KEEA An A HEEERAAAAEEEMAnENEEEEEEEEEtT 6 Makeup ube 22 2 ia ta We an a ta a ia a cca aa tdt 6 Viscositv Ambient Temperature Recommendations 0 0 en eennnnnnnnnn cnica non nnncnnn non cn nc nn ana ncccnnnns 6 Lube Change intervals Axle Housing ccioocoocioniniciciir ias aida 7 General seta da ate Seed nt aged na iad dn el Maa aie ent 7 Drive PINION tii Ana A A Ba kl avin a Lit uae neat eee 7 Changing Difterential Lubrication eee kan AAAAAAAAEKEEMA aaia a aea iini 8 Draining A a fa a a ai Ela 8 EJIDO sce a A Ai A a en A 8 Changing Wheel Hub Lubri ation otiia dd da lite 9 Draining iii ld ee A a ed ee dia 9 FINA da i a Pr ar a Pt c a 9 Cleaning Inspection Replacement nanna nannti n nn mant eee 10 8 l 12 1 S 10 OS PEO A 10 Repair nd Replacement rt A teehee 11 Adjustments ici a a a a eee levee oad Melee 12 Whieel Bearing Adjustment oia dd a ARAGOA EAEE AR EAA NEER A 12 Wheel Differential Lock Optional Equipment nn cee 13 Removal ct cit dia altered nada Be bea 13 Air
10. embly should disengage freely Recheck the 120 in gap with the shift cylinder fully disengaged If not proper readjust using the above procedure e Install the pipe plug Install the indicator switch making sure that the plastic sealing washer is under the switch Tighten to 10 12 ft Ibs torque Removal 1 3 Remove input yoke according to the in structions in the appropriate head service manual Pry out oil seal assembly by inserting screw drivers into notches between seal assembly and bearing cage Remove three seals Installation Install three seals Position oil seal assembly in bearing cage with notches at top and bottom positions and grease fitting at the 9 00 o clock position Drive oil seal assembly into bearing cage Install input yoke per head service manual instructions 10 To more easily drop the head into the housing the differential lock clutches should be engaged with a 0 75 16 UNF bolt CAUTION TURN THE BOLT INTO THE PORT ONLY ENOUGH TO ENGAGE THE CLUTCHES OVER TORQUING MAY CAUSE DAMAGE TO THE SHIFT UNIT This bolt may be left in until axle shipment to make axle shaft installation easier Upon shipment of the axle remove the bolt and replace with the plug that came with the shift unit 15 Wheel Hub Removal 16 1 Drain wheel hub lube by following the procedure in this manual Remove abutment cap by removing capscrews Pull sun gear and axle sh
11. g reused coat with Loctite 277 or equivalent before installing The set screw is advanced completely when one internal thread of set screw hole is showing e If set screw does not align with washer hole tighten the spindle nut until the next hole aligns Do not exceed 350 ft Ibs 450 ft lbs on WR10 12 12 13 14 15 Stake set screw in place with a center punch at four 4 places around set screw hole thread Install sun gear and axle shaft assembly Install planetary carrier with RTV on flange Apply Loctite 277 or equivalent to bolts Torque bolts to 75 85 ft Ibs 149 179 ft Ibs on WR10 and 12 models Install Apply abutment cap with RTV on flange Loctite 277 to bolts Torque bolts to 35 40 ft lbs 45 54 on WR10 12 STAKING PATTERN SPINDLE LOCK NUT LOCKING WASHER SPINDLE THREADS ABUTMENT CAP PLANETARY CARRIER Wheel Differential Lock Optional Equipment Removal Axle models indentified with a D suffix are equipped with a manual locking differential Special methods are required to remove the differential carrier from the axle housing IMPORTANT When removing axle shafts identifv left and right shaft location for reference during reassembiv 1 Drain axle lubricant and disconnect driveline following instructions for vour specific axle 2 Disconnect lead wires at optional selector switch if installed and hvdraulic line at shift cvlinder 3 To faci
12. haft Wheel Hub Installation 1 Slide sun gear onto splines at wheel end of axle shaft The part number side of gear should be away from shaft On D model axles ensure that the double or long spline shaft end is installed in the differential lock cylinder side Install snap ring onto end of axle shaft Install oil seal and seal band onto spindle Install wheel hub assembly on spindle Install ring gear mount assembly into hub Install washer on sindle against ring gear support Install nut on spindle with stepped diameter against washer Torque nut to 250 ft lbs 350 ft Ibs on WR10 and 12 models Rotate hub 360 in both directions while hitting hub or ring gear support with a soft mallet Re torque to 250 ft Ibs 350 ft Ibs on WR10 and 12 models and repeat steps 5 and 6 until 250 ft Ibs 350 ft Ibs WR10 12 does not advance the nut Install one 1 126900 set screw 207357 on WR10 and 12 models in nut with dog point engaging washer hole If set screw is being reused coat with Loctite 277 or equivalent The set screw is advanced completely when one intrnal nut thread is showing e If set screw does not align with washer hole tighten sindle nut until next hole aligns Do not exceed 350 ft Ibs 450 ft lbs WR10 12 Stake set screw in place with a center punch at four 4 places around internal nut thread Install sun gear and axle shaft assembly e A steel rod
13. litate removal of the differential carrier assembly the Differential Lock should be engaged and held in the engaged position This can be accomplished by one of two methods Air Pressure Engagement Using an auxiliary air line apply 80 120 psi air pressure to shift cylinder air port to engage clutch Manual Engagement Install an 3 4 16 UNF bolt over 1 5 38mm long in the cylinder hydraulic port to manually engage the clutches NOTE Hand tighten the bolt over torquing may cause damage to the shift unit To facilitate hand tightening coat bolt threads with axle lube NOTE With either method the axle shaft may have to be rotated to permit the clutch to become engaged 4 Continue removing differential carrier as sembly following instructions for your specific axle N AIR OR HYDRAULIC TO CYLINDER PORT 13 Wheel Differential Lock Optional Equipment Assembling 1 14 Assemble head without differential lock components exactly as the standard S model Adjust pattern on the head tester using standard procedures Install the fixed clutch on the flanged differential case splined hub and fit the retaining snap ring Install the snap ring on the pushrod Assemble shift fork spring pin sliding clutch and capscrew Assemble the pushrod through the carrier shift fork assembly actuator and return spring in proper order and orientation per the assembly drawing Apply a small amount
14. of conventional gaskets The compound will provide a more effective seal against lube seepage and is easier to remove from mating surfaces when replacing parts Mating surfaces must be clean and free of oil for maximum sealing effectiveness 11 Adjustments Wheel Bearing Adjustment Wheel bearings should be adjusted at regular intervals using the following procedure 1 10 11 12 Drain wheel hub lube per instructions in this manual Remove the planetarv carrier assembiv Remove the sun gear and axle shaft assembiv Remove set screw spindle lock nut and washer Clean spindle threads carrier abutment threads and hub threads of Loctite Clean all sealing surfaces Visually inspect spindle for damage or wear Inspect the nut and spindle threads for damage Apply a light coat of oil to the spindle threads Inspect doweled washer and replace if damaged Install washer on spindle against ring gear support Install nut on spindle with stepped diameter against washer Torque nut to 250 ft Ibs 350 ft Ibs on WR10 and 12 models Rotate hub 360 in both directions while hitting hub or ring gear support with a soft mallet Re torque to 250 ft Ibs 350 ft Ibs on WR10 and 12 models and repeat Step 9 until 250 ft Ibs 350 ft Ibs WR10 12 does not advance the nut Install one 1 new 126900 set screw 207357 on WR10 and 12 models in nut with dog point engaging washer hole If the set screw is bein
15. ombination of the intervals stated in the following chart and user judgment based heavilv on the application and operating environment NOTE At both the initial and all subseguent lubricant changes Spicer recommends cleaning the magnetic filler plug and drain plugs and cleaning the breather Guidelines Lube Change Intervals for Drive Axles Maximum Lubricant Hours of Change Tvpe Service Interval P a e Ger Spicer Drive Pinion Seal The drive pinion requires DAILY greasing through the grease fitting on the drive pinion oil seal Lubrication Changing Differential Lubrication Draining Drain when the lube is at normal operating temperature It will run freely and minimize the time necessary to fully drain the axle 1 Unscrew the magnetic drain plug on the underside of the axle housing and allow the lube to drain into a suitable container 2 Inspect drain plug for large quantities of metal particles After initial oil change this condition is a sign of damage or extreme wear in the axle Inspection of the entire unit may be warranted 3 Clean the drain plug and replace it along with an O Ring WR10 12 or sealant WR3 5 and 7 after the lube has drained completely IMPORTANT Used lubricants are dangerous environmental pollutants Dispose of all lubricants properly Filling 1 Remove the filler hole plug from right side of housing 2 Fill the axle with approved lubricant until le
16. ost of the part Steel Parts Gear sets input and output shaft differential parts pinion pins and bearings are not repairable Worn or damaged parts should be discarded without hesitation Also discard mating parts in some cases Gear sets for example must be replaced in sets The ring and pinion gearing must be changed in matched sets Spur and differential gearing can be serviced separately Miscellaneous Parts Seals and washers are routinely replaced None of these parts can be reused if damaged Fasteners using self locking nylon patches may be reused if not damaged But they should be secured by placing a few drops of Loctite 277 on the threaded surface of the hole and then carefully torqued during installation Axle Housing Repairs are limited to removal of nicks or burrs on machined surfaces and the replacement of loose or broken studs CAUTION ANY DAMAGE THAT AFFECTS THE ALIGNMENT OR STRUCTURAL INTEGRITY OF THE HOUSING REQUIRES HOUSING REPLACEMENT REPAIR BY WELDING OR STRAIGHTENING SHOULD NOT BE ATTEMPTED THIS PROCESS CAN AFFECT THE HOUSING HEAT TREATMENT AND CAUSE IT TO FAIL COMPLETELY WHEN UNDER LOAD Silicone Rubber Gasket Compound For more effective sealing Spicer uses silicone rubber gasket compound to seal most metal to metal mating surfaces Spicer includes gasket compound and application instructions in many repair kits It is recommended that this compound be used in place
17. pection Careful inspection will help determine whether Cleaning The differential carrier assembly may be steam cleaned while mounted in the housing as long as all openings are tightly plugged Once removed from its housing do not steam clean differential carrier or any components Steam cleaning at this time could allow water to be trapped in cored passages leading to rust lubricant contamination and premature component wear The only proper way to clean the assembly is to disassemble it completely Other methods will not be effective except as preparatory steps in the process Wash steel parts with ground or polished surfaces in solvent There are many suitable commercial solvents available WARNING GASOLINE IS NOT AN ACCEPTABLE SOLVENT BECAUSE OF ITS EXTREME COMBUSTIBILITY IT IS UNSAFE IN THE WORKSHOP ENVIRONMENT Inspection Inspect steel parts for notches visible steps or grooves created by wear Look for pitting or cracking along gear contact lines Scuffing deformation or discoloration are signs of excessive heat in the axle usually related to low lubricant levels or improper lubrication practices Before reusing a gear set inspect teeth for signs of excessive wear Check tooth contact pattern for evidence of incorrect adjustment see Adjustment Section for correct pattern parts should be reused Often the causes of premature wear or drive axle failure also can be discovered Wash castings or other ro
18. stall 48 bearing rollers 24 on each side IDLER of spacer into planetary gear Pack gear PINION PIN LOCKING with grease to hold rollers in place THRUST WASHER e WR3 has caged roller assemly without spacer Position the planetary carrier on a sturdy flat surface with filler hole side up ROLLERS Place 2 thrust washers one on each side lanet in planet of gear and planetary gear in planetary eve carrier The curved ends of the thrust washers must face the outside edge of carrier ROLLERS PLANETARY Position idler pinion pin in planetary carrier GEAR PLANETARY hole above gear bearing and thrust washer G CARRIER assembly The pin end with lock ball E detente should be away from the carrier The lock ball denente should also be aligned with the notch in the carrier Use a brass hammer or drift to drive idler pinion pin into planetary carrier and through thrust washers planetary gear and bearing Only drive 3 4 of pin length into carrier CAUTION THE IDLER PINION PIN IS HARDERNED STEEL AND SHOULD NOT BE STRUCK BY A STEEL HAMMER Install pinion locking ball two per pin on WR10 12 in detente on pinion pin Drive pinion pin completely into planetary housing and flush with abutment cap surface Make sure locking ball and bottom thrust washer are properly aligned before driving in pin Repeat this procedure for each planetary grear 21 Wheel Hub Components Assemblv 22 Sun Gear and Axle S
19. th MIL L 2105B MIL L 2105C and cold weather specification MIL L 10324A This specification applies to both petroleum based and synthetic based gear lubricants if they appear on the most current Qualified Products List QPL 2105 for MIL L 2105D NOTE The use of separate oil additives and or friction modifiers are not approved for use in Spicer Drive Axles Synthetic Based Synthetic based gear lubricants exhibit superior thermal and oxidation stability and generally degrade at a lower rate when compared to petroleum based lubricants The performance characteristics of these lubricants include extended change intervals improved fuel economy better extreme temperature operation reduced wear and cleaner component appearance The family of Spicer gear lubricants represent apremium quality synthetic lube that fully meets or exceeds the requirements of MIL L 2105D These products available in both 75W 90 and80W 140 have demonstrated superior performance in comparison to others qualified under the MILSPEC as proven by extensive laboratory and field testing following the directions contained in this manual The following lubrication instructions represent the most current recommendations from the Dana Corporation Axle amp Brake Division Lube Sampling and Condition Monitoring For information contact your local Spicer representation at phone numbers listed on the back cover of this manual Make up Lube Maximum amo
20. ugh parts in solvent or clean in hot solution tanks using mild alkali solutions If a hot solution tank is used make sure parts are heated thoroughly before rinsing Rinse thoroughly to remove all traces of the cleaning solution Dry parts immediately with clean rags Lightly oil parts if they are to be reused immediately Otherwise coat parts with oil and wrap in corrosion resistant paper Store parts in a clean dry place Inspect machined surfaces of cast or malleable parts They must be free of cracks scoring and wear Look for elongation of drilled holes wear on surfaces machined for bearing fits and nicks or burrs in mating surfaces Inspect fasteners for rounded heads bends cracks or damaged threads The axle housing should be examined for cracks or leaks Also look for loose studs or cross thread holes Inspect machined surfaces for nicks or burrs Repair and Replacement IMPORTANT To get maximum value from an axle rebuild replace lower cost parts such as thrust washers seals etc These items protect the axle from premature wear or loss of lubricants Replacing these parts will not increase rebuild cost significantiv It is also important to replace anv part that displav signs heavv wear even ifit is not cracked or broken A significant portion of a worn part s useful life has been expended If it were to fail later the cost of repairing the resulting damage to the axle would be far greater than the c
21. unt of non synthetic make up lube is 10 Viscosity Ambient Temperature Recommendations The following chart lists the various SAE Grades covered by MIL 2105D and the associated ambient temperature range for each Those SAE Grades shown with an asterisk are available in the Spicer family of synthetic gear lubricants The lowest ambient temperatures covered by this chart are 40 F and 40 C Lubrication recommendations for those applications that consistently operate below this temperature range must be obtained through the Dana Corporation Axle amp Brake Division Grade Ambient Temperature Range 75W 40 F to 15 F 40 C to 26 C 75W 80 40 F to 80 F 40 C to 27 C 75W 90 40 F and above 40 C and above 80W 90 15 F to 100 F 26 C to 38 C 80W 140 15 F and above 26 C and above 85W 140 10 F and above 12 C and above Lube Change Intervals Axle housing General The initial lubricant change is one of the most important factors in axle component life and durabilitv because of the elimination of break in contaminants These contaminants are primarilv metal from initial break in wear of rotating components and silicon from the sand used in manufacture of cast components For either a new or rebuilt drive axle the lubricant should be changed from both the axle and wheel end assemblies within the first 50 hours of operation Subsequent lubricant changes should be based on a c
22. vel with the bottom of the filler hole NOTE Lube fill capacities in the following chart are good guidelines but the actual capacity will vary somewhat Always use the filler hole as the final reference If lube is level with the bottom of the hole the axle is properly filled Lube Capacities ja WR3 WR5 WR7 WR10 12 Gallons 6 65 8 10 23 25 30 38 Changing Differential Lubrication Draining Drain when the lube is at normal operating temperature It will run freely and minimize the time necessary to fully drain the axle 1 Make sure the drain plug is at the bottom most position on the axle being serviced 2 Unscrew the magnetic drain plug and allow the lube to drain into a suitable container 3 Clean the drain plug Install drain plug and O Ring WR10 and 12 or sealant WR3 5 and 7 IMPORTANT Used lubricants are dangerous environmental pollutants Dispose of all lubricants properly Filling 1 Remove the filler hole plug from the front of the planetary gear housing Make sure that the filler hole is in a horizontal line with the center of the wheel hub Fill the wheel hub with approved lubricant until level with the bottom of the filler hole Install fill plug and O Ring WR10 and 12 or sealant WR3 5 and 7 PROPER FILL LEVEL PROPER DRAIN HOLE POSITION Cleaning Inspection Replacement 10 As the drive axle is disassembled set all parts aside for thorough cleaning and ins
23. with a 1 2 thread can be inserted into the end of the axle shaft and used to aid shaft installation Install planetary carrier with RTV on flange Apply Loctite 277 to bolts Torque bolts to 80 95 ft Ibs 127 149 ft Ibs pm WR10 and12 molels Install abutment cap with RTV on flange Apply Loctite 277 to bolts Torque bolts to 35 42 ft lbs 45 54 on WR10 12 Wheel Hub Installation Continued SUN GEAR AND AXLE SHAFT ASSEMBLY RING GEAR MOUNT ASSEMBLY Y LOCKING WASHER SET SCREW ABUTMENT CUP PLANETARV CARRIER SPINDLE OIL SEAL SEAL BAND 23 Wheel Hub Components Assemblv 24 Head Model Cross Reference Chart Axle Head Model Model 20 WRD 3 Head Service Manual EA 43 EA 43 a 15100 EA 1504D EA 9 so eas PL 16144 EA 90 EA 43 21065S EA 93 EA 48 we 200 p E WR10 RS402 EA 89 EA 41 WR3D WR7 21065S EA 93 EA 48 wR 210860 gt WRRD 23075D EA 94 sup Pinion Shaft Spline sa INV 34 10 34 10 2 00 i 41 Notes lt Dana gt SPICER Drivetrain Products Axles Driveshafts Off Highway Transmissions LONG Thermal Products Transmission Oil Coolers Engine Oil Coolers VICTOR REINZ Sealing Products Gaskets and Seals Cylinder Head Cover Modules Thermal Acoustic Protective Shielding Dana Aftermarket Group PO Box 321 Toledo Ohio 43697 0321 Warehouse Distributor 1
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