SERVICE MANUAL

SERVICE MANUAL SECTION

2 SPEED REAR AXLES: SPICER

Vendor: SPICER
Model: 1000
Model: 2000
Model: 3000
Model: 4000
Model: 7000
Unit Code: 14CDA
Unit Code: 14CDB
Unit Code: 14130
Unit Code: 14131
Unit Code: 14132
Unit Code: 14133
Vendor Code: G155T, G175T, M190T, M210T, M220T, M230T

S14015, Formerly CTS-5193

03/31/1996

S14015
Copyright © 03/31/1996 Navistar, Inc.
 TABLE OF CONTENTS

TABLE OF CONTENTS
1. SERVICE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1. REBUILD FACILITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2. END YOKES AND FLANGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3. CLEANLINESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.4. BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.2. HIGH RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.3. LOW RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3. IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1. AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.2. GEAR SET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

4. REMOVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.1. DIFFERENTIAL CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.2. DIFFERENTIAL FROM CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

5. DISASSEMBLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.1. RING GEAR AND SUPPORT CASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.2. DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.3. PINION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

6. CLEAN AND INSPECT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

6.1. CLEAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6.2. DRY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6.3. INSPECT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Thrust Washers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Splines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

7. ASSEMBLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.1. DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.2. RING GEAR AND SUPPORT CASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
7.3. PINION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Pinion Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Pinion Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

8. INSTALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
8.1. RING GEAR SUPPORT CASE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
8.2. SUN GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.3. RING AND PINION GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Contact Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
8.4. CARRIER ASSEMBLY INTO AXLE HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
8.5. WHEEL BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

2 SPEED REAR AXLES: SPICER (S14015) i

TABLE OF CONTENTS

TABLE OF CONTENTS (CONT.)

9. LUBRICATION AND SEALANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

9.1. MAXIMUM OIL SUMP TEMPERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2. RECOMMENDED LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.3. CHANGE INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.4. AFTER OVERHAUL OR CHANGE INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.5. SUBMERSION OR DEEP WATER FORDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.6. LUBRICANT ANALYSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.7. RECOMMENDED SEALING MATERIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

10. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

10.1. TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

11. SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

11.1. SPECIFICATIONS TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
11.2. SPACERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
11.3. TORQUE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
11.4. SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

ii 2 SPEED REAR AXLES: SPICER (S14015)

 SERVICE PROCEDURES

1. SERVICE PROCEDURES
WARNING

MATERIAL DUST DURING BRAKE SERVICING

1. Studies have indicated that exposure to excessive amounts of brake material dust
(whether asbestos or non-asbestos, fiberglass, mineral wool, aramid, ceramic
or carbon) may be a potential cancer-causing health hazard. Even though the
Occupational Safety and Health Administration (OSHA) has not set any limits on
non-asbestos dust exposure, there is some medical opinion that such non-asbestos
fibers can cause cancer as well. Since most automotive friction materials normally
contain a sizeable amount of this material, it is important that people who handle
brake linings be aware of the problem and know the precautions to be taken.
2. Areas where brake work is done should be set aside, if possible, and should be posted
with a material dust exposure sign as follows:

BRAKE LINING FIBER DUST HAZARD

AVOID BREATHING DUST

WEAR ASSIGNED PROTECTIVE EQUIPMENT

DO NOT REMAIN IN AREA UNLESS YOUR WORK REQUIRES IT

BREATHING BRAKE LINING FIBERS MAY BE HAZARDOUS TO YOUR HEALTH

3. OSHA standards should be consulted with respect to mandatory requirements as well
as for suggested procedures to minimize exposure. (Reference: Title 29, Code of
Federal Regulations, Section 1910.1001.)
4. Whenever possible, work on brakes in a separate area away from other operations.
5. Always wear a respirator approved by NIOSH or MSHA during all brake service
procedures. Wear the respirator from removal of the wheels through assembly.
6. NEVER use compressed air or dry brushing to clean brake parts or assemblies. OSHA
recommends that you use cylinders that enclose the brake. These cylinders have
vacuums with high efficiency (HEPA) filters and worker’s arm sleeves. But, if such
equipment is not available, carefully clean parts and assemblies in the open air.
7. Clean brake parts and assemblies in the open air. During disassembly, carefully place
all parts on the floor to avoid getting dust into the air. Use an industrial vacuum
cleaner with a HEPA filter system to clean dust from the brake drums, backing plates
and other brake parts. After using the vacuum, remove any remaining dust with a rag
soaked in water and wrung until nearly dry.
8. Grinding or machining brake linings. If you must grind or machine brake linings,
take additional precautions because contact with fiber dust is higher during these
operations. In addition to wearing an approved respirator, do such work in an area
with exhaust ventilation.

2 SPEED REAR AXLES: SPICER (S14015) 1

DESCRIPTION REBUILD FACILITIES

9. Cleaning the work area. NEVER use compressed air or dry sweeping to clean the work
area. Use an industrial vacuum with a HEPA filter and rags soaked in water and wrung
until nearly dry. Dispose of used rags with care to avoid getting dust into the air. Use
an approved respirator when emptying vacuum cleaners and handling used rags.
10. Worker clean-up. Wash your hands before eating, drinking or smoking. Do not wear
your work clothes home. Vacuum your work clothes after use and then launder them
separately, without shaking, to prevent fiber dust from getting into the air.

1.1. REBUILD FACILITIES

A suitable holding fixture or carrier overhaul stand is desirable (refer to SPECIAL TOOLS), but not necessary
to rebuild these units. Alternately, a sturdy shop table of approximately 30 inches in height can be used with
suitable means to hold the carrier securely for rebuild operations. A light chain hoist should be used to relocate
the carrier housing and to install or remove the ring gear and support case assembly.

1.2. END YOKES AND FLANGES

CAUTION

Hammering on end yokes or flanges to remove or install them is not only destructive to
the yoke or flange itself, but can also cause serious internal damage. Hammering on end
yokes can close in the bearing bores or misalign yoke lugs and result in early failures
of journal needle bearings or other driveline components. Serious damage can also be
done internally to the ring and pinion set or pinion bearings by hammering on external
parts. End yokes or flanges should be removed or installed using a recommended
method such as that described herein.

WARNING

Wear safe eye protection. Do not hit steel parts with a steel hammer. Parts can break
and cause injury.

1.3. CLEANLINESS
Axle carrier subassemblies should be steam cleaned prior to removal from the vehicle.

Dirt is abrasive and will cause premature wear of otherwise serviceable parts. Service personnel should use a
wash tank for thorough cleaning of parts just prior to reassembly.

1.4. BEARINGS
When axle carrier is disassembled, all bearings should be removed with pullers designed for this purpose.
Loose bearings should be wrapped to keep out dirt. Clean, inspect and lubricate all bearings just prior to
reassembly.

2. DESCRIPTION
Refer to Figure 1 .

2 2 SPEED REAR AXLES: SPICER (S14015)

 DESCRIPTION

1. PINION NUT 5. OUTER PINION BEARING

2. PINION NUT WASHER 6. PINION BEARING SPACER SET
3. END YOKE 7. BOLT
4. OUTER PINION OIL SEAL

2 SPEED REAR AXLES: SPICER (S14015) 3

DESCRIPTION GENERAL

8. DIFFERENTIAL CARRIER WITH 28. DIFFERENTIAL BEARING

CAPS
9. ADJUSTMENT LOCK
10. WASHER
11. BEARING CAP BOLT
12. REAR PINION BEARING
RETAINER
13. REAR PINION BEARING
14. PINION GEAR
15. PINION GEAR SHIM SET
16. INNER PINION OIL SEAL
17. INNER PINION BEARING
18. SHIFT FORK
19. SHIFT FORK SET SCREW
20. SHIFT MOTOR SHAFT
21. SHIFT MOTOR STUD
22. SHIFT MOTOR SEAL
23. SHIFT MOTOR WASHER
24. SHIFT MOTOR LOCKNUT
25. CLUTCH PLATE
26. LEFT DIFFERENTIAL CASE
HALF
27. DIFFERENTIAL SIDE GEAR
AND PINION GEAR SET
Figure 1
29. DIFFERENTIAL BEARING
ADJUSTER
30. DIFFERENTIAL SUPPORT
CASE
31. THRUST WASHER
32. RIGHT DIFFERENTIAL CASE
HALF
33. PINION IDLER GEAR
34. PINION IDLER PIN
35. SUN GEAR
36. SUN GEAR RETAINER
37. LEFT DIFFERENTIAL SUPPORT
CASE
38. THRUST WASHER PLATE
39. RING GEAR
40. AXLE SHAFT
41. VENT
42. AXLE HOUSING
43. FILLER PLUG
44. TEMPERATURE SENDER PLUG
45. DRAIN PLUG
Spicer Two Speed Rear Axle - Exploded View

2.1. GENERAL
Spicer assembly consists of a full float, cold formed and welded, banjo-type housing member to which the
differential carrier assembly is bolted. The banjo housing is the vehicle load carrying member, and the
differential carrier assembly is the torque transmitting portion of the axle. It consists of a primary hypoid gear
set for high range operation that is combined with a secondary spur gear planetary for low range operation.
Range changes are easily made by means of a hand control button mounted on the gear shift lever. The
control button causes the planetary sun gear to act as a sliding clutch member and moves it in and out of
engagement with two clutching plates to complete range changes.

2.2. HIGH RANGE

In high range, the sun gear locks the planet gears with the planet plate and the ring gear. The unit then
functions as a single reduction axle. Power flows in the pinion to the ring gear through the differential case to
the differential cross shaft. The cross shaft transfers it through the differential pinion gears to the left and right
differential side gears, and finally to the axle shafts.

2.3. LOW RANGE

In low range, engine power is transmitted to the hypoid ring gear as before. It then flows to the ring gear
internal spur teeth, which transfer it to the planet gears that are attached to the differential case. Because
the sun gear is clutched to a stationary retainer plate, it cannot rotate and acts as a reaction member for the
planet gears. This causes the planet gears to rotate around the sun gear, driving the differential case at a
speed slower than the ring gear, creating the additional low range reduction ratio and further multiplying engine
torque. From this point, power flows in the same sequences as when the axle is in high range.

4 2 SPEED REAR AXLES: SPICER (S14015)

 IDENTIFICATION

3. IDENTIFICATION
3.1. AXLE
All Spicer axle assemblies are identified with two tags. One is located on the differential carrier, and the other
on the right front leg of the banjo housing (Figure 2 ).

Figure 2 Axle Identification Tags

2 SPEED REAR AXLES: SPICER (S14015) 5

IDENTIFICATION GEAR SET

Table 1 Table 1 - Axle Code/Model Identification

Nav. Code Spicer Model Load Capacity

14CDA G155-T 15,500 Lbs.
14CDB M230-T 23,000 Lbs.
14130 G175-T 17,500 Lbs.
14131 M190-T 19,000 Lbs.
14132 M220-T 22,000 Lbs.
14133 M210-T 21,000 Lbs.

3.2. GEAR SET

Refer to Figure 3.

6 2 SPEED REAR AXLES: SPICER (S14015)

GEAR SET IDENTIFICATION

Figure 3 Gear Set Identification

Manufacturer’s date - date gear set was made.

Dana - D-Dana name-and location of manufacturing

GGAGR104 - part number of ring gear (typical).

Tooth Combination (i.e., 39-6) - indicates the ring gear has 39 teeth and the pinion 6 teeth which results
in a 6.50:1 ratio.

Matched set number - Spicer ring and pinions are manufactured as a matched set. Both pieces are marked
with a corresponding number (i.e., 268) which identifies them as a matched set.

2 SPEED REAR AXLES: SPICER (S14015) 7

REMOVE

A gear set that does not have the same matching numbers should not be run together. If either a ring gear or
pinion requires replacement, they must be replaced as a matched set.

4. REMOVE
4.1. DIFFERENTIAL CARRIER
NOTE – Steam clean axle assembly before removing carrier.

Wheel ends may have one bolt replacing a stud. This is thru-drilled into the cavity and can be used to
drain and fill the wheel end.

1. Block wheels.

2. Shift the axle into low range.

3. Drain lubricant from axle housing.

4. Remove axle shift unit from carrier assembly.

NOTE – Shift unit contains lubricant. Provide container to catch lubricant.

For servicing the shift unit, refer to GROUP 14 - REAR AXLE in the CTS-5000 Master Service Manual.

5. Disconnect drive shaft at rear U-joint. Refer to GROUP 06 - PROPELLER SHAFTS in the CTS-5000
Master Service Manual for the correct procedure to remove the shafts.

NOTE – If ring or pinion bearings are to be removed, break loose pinion nut at this time.

6. Remove the axle shaft flange nuts.

7. Hold a large brass drift or brass hammer against the center of the axle shaft flange. Strike the drift with
sharp blows from a large hammer or sledge until axle shaft separates from hub.

WARNING

Do not strike the axle flange directly with a steel hammer or sledge. This may crack and
splinter material, possibly causing serious or fatal injury. Do not pry or chisel axle flange
away from hub or damage to sealing surfaces could occur.

8. Remove axle shafts.

9. Support carrier assembly on roller jack. Secure as necessary to prevent carrier from falling from jack
when removed from housing.

10. Remove differential carrier-to-axle housing bolts.

11. Break carrier loose from housing with the use of pry bars behind carrier flange mounting face (Figure 4 ).

8 2 SPEED REAR AXLES: SPICER (S14015)

DIFFERENTIAL CARRIER REMOVE

Figure 4 Carrier Housing Removal

12. Remove carrier from housing.

13. Mount carrier assembly in suitable rebuild stand (Figure 5 ). Refer to SPECIAL TOOLS (See SPECIAL
TOOLS, page 45).

Figure 5 Carrier Mounted in Rebuild Stand

2 SPEED REAR AXLES: SPICER (S14015) 9

REMOVE DIFFERENTIAL FROM CARRIER

4.2. DIFFERENTIAL FROM CARRIER

Refer to Figure 6 .

Figure 6 Differential - Exploded View

1. Place the carrier in a suitable holding fixture such as a carrier repair stand. If ring gear and pinion are to be
reused, measure gear backlash prior to disassembly.

IMPORTANT – If the ring and pinion is to be re-used, ring gear backlash should be checked and recorded
before disassembly. Backlash should be reset to this specification after completion of repairs. For backlash
specifications refer to SPECIFICATIONS (See SPECIFICATIONS, page 42).

2. Remove the shift fork spring and seal from the carrier housing.

3. New Style: Remove set screw and shift fork shaft. Remove shift fork. Proceed to step 6.

Old Style: Remove shift fork shaft snap ring, using suitable snap ring pliers. Be sure to retrieve the
retaining ring so that it cannot be lost in the differential carrier.

4. Remove sealer from shift fork shaft holes.

5. Remove shift fork shaft by using a drift and hammer. Pull shift fork from housing.

NOTE – Shaft will only drive out in one direction.

6. Remove sun gear.

10 2 SPEED REAR AXLES: SPICER (S14015)

 DISASSEMBLE

7. Remove four (4) sun gear retainer bolts and sun gear retainer plate.

NOTE – For ease of disassembly, the ring gear bolts can be loosened at this time.

8. Remove adjusting ring retainers.

9. Remove four (4) differential bearing cap bolts.

10. Back out either adjusting ring to relieve preload.

11. Remove bearing caps.

12. Remove adjusting rings.

13. Lift the ring gear and differential subassembly out of carrier. The ring gear side of the subassembly
must be tipped up for the ring gear to clear the pinion roller bearing retainer.

NOTE – Use care to avoid damage to ring and pinion gears.

5. DISASSEMBLE
5.1. RING GEAR AND SUPPORT CASE
Refer to Figure 7.

Figure 7 Ring Gear and Support Case - Exploded View

2 SPEED REAR AXLES: SPICER (S14015) 11

DISASSEMBLE RING GEAR AND SUPPORT CASE

1. Prior to disassembly, mark the right and left support case halves and ring gear for reassembly in the
same position (Figure 8 ).

Figure 8 Ring Gear

2. Remove ring gear bolts. Remove differential support case (L.H. half) using pry bars.

NOTE – It is recommended that whenever the ring gear bolts are removed, they be replaced.

3. Remove aluminum thrust washer plate.

NOTE – Thrust washer plate may be retained in support case, due to oil retention. It should be
removed and cleaned before reassembly.

4. Remove planet gear mounting plate from assembly. Use care to avoid damage to surfaces of plate
and planet gear shafts.

5. Remove planet gears and planet shafts.

6. Turn assembly over and support on differential case dowel pins.

CAUTION

Care must be taken to keep differential subassembly properly positioned in support case
to prevent damage when removing ring gear.

7. Rotate ring gear to make sure support case is seated squarely on differential subassembly. Using a soft
hammer, tap each side of ring gear alternately to remove from support case half.

8. Lift support case from differential subassembly. Remove thrust washer from differential subassembly.

9. If the right differential support case bearing is to be replaced, it may be removed as shown in Figure 9 .

12 2 SPEED REAR AXLES: SPICER (S14015)

DIFFERENTIAL DISASSEMBLE

Figure 9 Support Case Bearing Removal

10. If the left differential support case bearing is to be replaced, it may be removed as shown in Figure 9 .

5.2. DIFFERENTIAL
Refer to Figure 10.

Figure 10 Differential - Exploded View

2 SPEED REAR AXLES: SPICER (S14015) 13

DISASSEMBLE DIFFERENTIAL

NOTE – Differential case halves are matched and marked during manufacture. No further marking is
necessary (Figure 11).

Figure 11 Differential Case

1. Remove differential case bolts and lift off right hand case half.

2. Remove thrust washer and side gear.

3. Lift out cross shaft, differential pinion gears and thrust washers.

NOTE – Inspect all parts, including the matched surfaces of the case itself. Where necessary, replace
all worn parts. If excessive wear is noticed on all parts, it is suggested that the complete differential
assembly be replaced.

If any gears are to be replaced, they must be replaced in sets. Inspect thrust washers for scoring and
excessive wear; replace if necessary.

4. Lift out side gear and thrust washer.

14 2 SPEED REAR AXLES: SPICER (S14015)

PINION DISASSEMBLE

5.3. PINION

Figure 12 Pinion - Exploded View

1. Turn the carrier to a vertical position and remove the four (4) roller bearing retainer bolts. Lift the bearing
retainer from the roller bearing and carrier housing, tapping with soft hammer from underneath side if
necessary.

2. Turn the nose of the carrier to a horizontal position to remove the pinion nut. Hold the end yoke stationary,
and remove the pinion nut and washer.

3. Remove the end yoke, using a suitable puller (Figure 13 ).

4. Replace pinion nut finger tight. Tap pinion free of bearing with soft hammer.

Figure 13 End Yoke Removal

5. Support pinion from inside carrier, and remove pinion nut.

2 SPEED REAR AXLES: SPICER (S14015) 15

CLEAN AND INSPECT

6. Remove pinion.

7. Near the spline end of the pinion and between the pinion bearings is a (selective) pinion bearing spacer
used for pinion bearing preload. Retain this spacer for possible use in reassembly.

8. Remove pinion roller bearing from end of pinion.

9. Remove inner bearing cone from pinion.

10. Remove the pinion oil seal. Discard the seal and replace it with a new one at time of reassembly. Remove
the outer pinion bearing cone.

11. Rotate carrier to pinion nose down position. Remove the pinion oil slinger seal from the carrier and
discard. Install a new seal at time of reassembly.

12. With nose of the carrier down, remove the outer pinion bearing cup.

CAUTION

Do not nick the carrier bearing bore.

13. Turn the carrier over and remove the inner bearing cup.

CAUTION

Do not nick the carrier bearing bore.

6. CLEAN AND INSPECT

6.1. CLEAN
1. Parts should be cleaned with emulsion cleaners or petroleum base cleaning solvent.

CAUTION

Alkaline type solutions may cause damage to machined surfaces and should be avoided.

2. Make sure interior of axle housing is clean prior to re-assembly.

3. Clean old gasket material off all gasket surfaces.

6.2. DRY
Use soft, clean, lintless towels or rags to dry components after cleaning. Bearings should NOT be dried by
spinning with compressed air. This can damage mating surfaces due to lack of lubrication.

After drying, parts should be coated with a light coat of lubricant or rust inhibitor to prevent damage from
corrosion. If parts are to be stored for a prolonged period, they should be wrapped in wax paper.

6.3. INSPECT
Prior to reassembly, inspect parts for signs of excessive wear or damage. Replacement of these parts can
prevent premature failure and costly downtime.

16 2 SPEED REAR AXLES: SPICER (S14015)

INSPECT CLEAN AND INSPECT

Bearings

Bearing surfaces should be inspected for pitting, excessive wear, or overheating (Figure 14 ).

Figure 14 Check Bearing Surfaces

Thrust Washers

Inspect thrust washers for scoring and cracking (Figure 15 ).

Figure 15 Inspect Thrust Washers

Gears

Inspect gears for wear or damage. Replace gears that are pitted, scored, or worn (Figure 16 ).

Figure 16 Inspect Gears

2 SPEED REAR AXLES: SPICER (S14015) 17

CLEAN AND INSPECT INSPECT

Shafts

Inspect shafts for nicks or scores (Figure 17 ).

Figure 17 Inspect Shafts

Splines

Inspect all splines for wear, distortion from twisting, and cracking (Figure 18 ).

Figure 18 Inspect Splines

Housings

Inspect housing for stripped threads and bending fatigue (Figure 19 ).

18 2 SPEED REAR AXLES: SPICER (S14015)

 ASSEMBLE

Figure 19 Inspect Housing

7. ASSEMBLE
7.1. DIFFERENTIAL
Refer to Figure 20.

Figure 20 Differential Reassembly

1. Apply a small amount of lubricant to all mating surfaces. This will keep thrust washer in place during
assembly, and provide for initial lubrication.

2. Place thrust washer and side gear in left hand differential case.

3. Assemble differential pinions and thrust washers on cross shaft. Place assembly in left side of differential
case.

4. Place side gear and thrust washer in position on differential pinions.

2 SPEED REAR AXLES: SPICER (S14015) 19

ASSEMBLE RING GEAR AND SUPPORT CASE

5. Assemble case halves, making sure match marks are lined up.

6. Install case bolts. Tighten alternately and evenly. Tighten bolts to:

14CDA and 14130, 70 to 80 ft-lbs. (95 to 108 N•m).

14131, 14132, 14133 and 14CDB, 110 to 125 ft-lbs. (149 to 169 N•m).

7.2. RING GEAR AND SUPPORT CASE

Refer to Figure 21.

Figure 21 Ring Gear and Support Case Reassembly

1. Install differential bearing cone onto hub of right hand half of differential support case.

2. Install differential bearing cone onto hub of left hand half of differential support case.

NOTE – To protect bearings during the following steps, install bearing cups on bearing cones.

3. Apply lubricant to thrust washer surfaces and install in differential support case.

4. Install differential assembly in differential support case. Rotate differential assembly to assure proper
installation.

5. Install ring gear on differential support case, aligning bolt holes. Make sure ring gear is seated.

NOTE – If old gear is used, make sure match marks are aligned.

6. Lubricate and install the four (4) planet gear shafts in the holes of the differential case. Place the planet
gears in position on the planet gear shafts.

20 2 SPEED REAR AXLES: SPICER (S14015)

PINION ASSEMBLE

NOTE – Remove any burrs from planet gear mounting plate.

7. Position the planetary gear mounting plate on the planet gear shafts and dowels with the chamfered
teeth facing the planet gears. Tap the plate with a soft hammer, if necessary, to seat the plate against
the differential case.

NOTE – Be sure that the planet gear shafts and dowel pins are flush or below flush prior to installing
thrust plate.

8. Apply lubricant to each side of the differential support case thrust plate and position the thrust plate on the
planet gear mounting plate.

9. Place the left differential support case on the ring gear and line up the bolt holes. If old ring gear is used,
make sure match marks are aligned.

10. Install and tighten the ring gear bolts alternately and evenly. Tighten bolts to:

14CDA, 14130 — 110 to 125 ft-lbs. (149 to 169 N•m)

14131, 14132, 14133, 14CDB — 160 to 180 ft-lbs. (217 to 244 N•m).

7.3. PINION
General

1. Assemble the proper slinger and inner bearing cone onto pinion (Figure 22 ).

Figure 22 Pinion Gear Assembly

2. Press roller bearing on the drive pinion (Figure 23 ).

2 SPEED REAR AXLES: SPICER (S14015) 21

ASSEMBLE PINION

Figure 23 Roller Bearing Reassembly

3. Stake roller bearing in six places, using staking tool (Figure 23 ). Refer to SPECIAL TOOLS, for staking
tool information.

NOTE – Make sure all carrier bores are free from all nicks, dirt, or any other contamination.

4. Install the outer pinion bearing cup into the carrier.

5. Install the inner pinion bearing cup into the carrier.

6. Use a feeler gauge or shim stock to ensure bearing cups are completely seated in bearing bores (.0015
approx.) (Figure 24 ). This is necessary for proper pinion position.

Figure 24 Feeler Gauge To Ensure Bearing Cups Are Seated

7. Install inner pinion oil seal into the carrier with the tabs locking into the oil channel. Make sure the flat side
of the seal is seated against the bottom of the bearing cup bore so that the lip side will be against the
pinion oil slinger.

8. Install pinion into carrier. The pinion should be restrained from end movement by using a retaining strap
(Figure 25 ).

22 2 SPEED REAR AXLES: SPICER (S14015)

PINION ASSEMBLE

Figure 25 Retaining Strap on Pinion

9. Rotate carrier to a vertical position. Place selective preload spacer on pinion. Install outer bearing cone
onto pinion.

NOTE – The reason for not assembling a new pinion oil seal at this time is due to the possibility
of having to adjust pinion preload or pinion position. It would be necessary to again remove the
seal and, as mentioned, whenever seals are removed, they are to be discarded because of possible
damage.

10. Inspect end yoke seal surface for grooves caused by seal lip. If grooves can be detected with a fingernail,
yoke should be replaced.

11. Assemble end yoke, washer, and old pinion nut onto pinion. Tighten nut to: 700 to 900 ft-lbs. (949 to
1220 N•m). The old nut can be used during this adjustment phase of the assembly, saving the new
one for final assembly.

12. Remove pinion retainer strap. Using an in-lb. torque wrench, rotate pinion, noting rolling torque. Rolling
torque of pinion should read between 20 to 50 in-lbs. (2.3 to 5.7 N•m).

NOTE – To increase preload, decrease thickness of preload spacer; to decrease preload, increase
thickness of preload spacer. Every .001‟ (.025 mm) change in thickness of preload spacer changes
torque to rotate by approximately 30 in-lbs.

NOTE – A selective pinion bearing spacer is used to develop pinion bearing preload. The spacer is
available in the following thicknesses (Spacer Thickness Chart below). Measure the spacer with a
micrometer before assembly to assure correct thickness.

Table 2 Spacer Thickness Chart

In. mm In. mm
.696 17.68 .712 18.09
.697 17.70 .713 18.11
.698 17.73 .714 18.14
.699 17.76 .715 18.16
.700 17.78 .716 18.19
.701 17.81 .717 18.21

2 SPEED REAR AXLES: SPICER (S14015) 23

ASSEMBLE PINION

Table 2 Spacer Thickness Chart (cont.)

In. mm In. mm
.702 17.83 .718 18.24
.703 17.86 .719 18.26
.704 17.88 .720 18.29
.705 17.91 .721 18.31
.706 17.93 .722 18.34
.707 17.96 .723 18.36
.708 17.98 .724 18.39
.709 18.01 .725 18.42
.710 18.03 .726 18.44
.711 18.06 .727 18.47

13. Remove pinion nut, washer and end yoke. Apply a light coat of lubricant to the lip of the seal and
assemble Into housing.

14. Assemble end yoke, washer, and new pinion nut. Tighten to:

700 to 900 ft-lbs. (949 to 1220 N•m).

Recheck torque to rotate.

15. Rotate carrier to vertical position with yoke down. Install pinion roller bearing retainer, using soft hammer if
necessary.

16. Install four retainer bolts. Tighten bolts to:

14CDA, 14130 - 70 to 80 ft-lbs. (95 to 108 N•m).

14131, 14132, 14133, 14CDB - 110 to 125 ft-lbs. (149 to 169 N•m).

Pinion Position

Beginning with carriers GGA-1007032 and MJA-1007160, a new method of setting pinion position has been
adopted. A number is etched on the machined surface under the roller bearing retainer plate on each carrier.
This number is used in conjunction with the number etched on each pinion to determine the proper pinion
bearing spacer (selective) for proper assembly. It eliminates the need for measuring with special gauge tools.

Ring gears and pinions are supplied in matched sets only. Matching numbers on both the pinion and ring
gear are etched for verification (Figure 26 ). If a new gear set is being used, verify the numbers of each
pinion and ring gear before proceeding with assembly.

24 2 SPEED REAR AXLES: SPICER (S14015)

PINION ASSEMBLE

Figure 26 Matching Numbers on Pinion and Ring Gear

Pinion position is based on the mounting distance measured from the centerline of the ring gear to the back
of the pinion head (Figure 27 ). This dimension is controlled by shimming between the inner bearing cone
and pinion head with a selective pinion oil singer.

Figure 27 Centerline of Ring Gear

0n the button end of each pinion there is etched either a plus (+) number, a minus (—) number, or a zero (0).
This number indicates the best running position for each particular gear set. This number represents the
number of thousandths to be added to or subtracted from the nominal mounting distance.

2 SPEED REAR AXLES: SPICER (S14015) 25

ASSEMBLE PINION

A plus (+) number etched on the pinion would mean that number must be added to the nominal mounting
distance to get the required mounting distance.

For example: If a pinion is etched + 3, this would mean the required mounting distance is more than nominal
by .003 in. (.076 mm). In other words, the pinion would require .003 in. (.076 mm) thinner shim than a
pinion etched "0" to allow for this difference. To achieve proper pinion position, decrease the pinion position
spacer thickness by .003 in. (.076 mm).

Similarly, if a pinion is etched -3, this means the required mounting distance is less than normal by .003 in.
(.076 mm). In other words, this pinion would require .003 in. (.076 mm) thicker shim than a pinion etched "0"
to allow for this difference. To achieve proper pinion position, increase the pinion position spacer thickness
by .003 in. (.076 mm).

The number etched on the carrier (Figure 28 ) also refers to the mounting distance, based on a "0" etched
pinion. This number represents thickness in thousandths of the selective pinion position spacer required
for a "0" etched pinion.

Figure 28 Carrier Number

The table below contains two examples which illustrate how the carrier etch and the pinion etch interact:

Table 3 Carrier Etch & Pinion Etch Table

EXAMPLE A EXAMPLE B
Number etched on button end of pinion +3 -2
Number etched on carrier 63 61
Add or subtract pinion etch to get correct pinion 063 .061
position spacer
-.003 +.002
.060 .063

Select a pinion position spacer that is closest to the calculated value from table.

26 2 SPEED REAR AXLES: SPICER (S14015)

PINION ASSEMBLE

NOTE – The pinion position spacer functions as a selective shim to determine the position of the pinion
(mounting distance).

The pinion position spacer is available in the following thicknesses (Pinion Position Thicknesses below).
Measure the pinion position spacer with a micrometer before assembly to assure correct thickness.

Table 4 Pinion Position Thicknesses

In. mm In. mm
.052 1.321 .070 1.778
.055 1.397 .073 1.854
.058 1.473 .076 1.930
.061 1.549 .079 2.007
.064 1.626 .082 2.083
.067 1.702

Pinion Setting

Using a micrometer, measure thickness of old pinion position spacer.

NOTE – If old pinion position spacer is bent or mutilated, it should be replaced.

0n the new gear set, notice the "+", "—" or "0" etching on both the old and new pinions, and adjust the thickness
of the pinion position spacer to compensate for the difference of these two figures. Refer to Figure 26 .

Refer to Pinion Setting Chart, Figure 29 .

For example, if the pinion reads +2 and the new pinion is -2, add .004 in. to the original pinion position spacer
thickness to determine thickness of new pinion position spacer required.

2 SPEED REAR AXLES: SPICER (S14015) 27

ASSEMBLE PINION

28 2 SPEED REAR AXLES: SPICER (S14015)

 INSTALL

8. INSTALL
8.1. RING GEAR SUPPORT CASE ASSEMBLY
Refer to Figure 30 .

Figure 30 Ring Gear Support Case Assembly - Exploded View

1. Install ring gear and support case assembly into the carrier housing. The ring gear side of the support
case assembly must be tipped up to clear pinion roller bearing retainer during assembly. Care should
be taken to avoid nicking of gear and pinion teeth. Check differential bearing cups to be sure they are in
proper position with respect to the bearing cones.

2. Be sure support case is piloted into differential counter bore.

3. Assemble differential bearing caps. Install bearing cap bolts (finger tight only).

4. Install adjusting rings (Figure 31 ).

2 SPEED REAR AXLES: SPICER (S14015) 29

INSTALL RING GEAR SUPPORT CASE ASSEMBLY

Figure 31 Adjusting Ring Installation

5. Tighten adjusting ring on back side of ring gear (left) until there is zero (0) backlash between the ring
gear and pinion.

6. Tighten adjusting ring (on the tooth side of ring gear) until bearing cup is seated. Continue to tighten
adjusting ring until ring gear is within specified backlash (.008 to .016 in. or .20 to .40 mm).

This adjustment will also preload differential bearings.

7. Check ring gear and pinion backlash in four equally spaced positions around the ring gear with a dial
indicator (Figure 32 ).

Figure 32 Ring Gear & Pinion Backlash Check

If the average backlash tolerance is within .008 to .016 in. (.20 to .40 mm), the setting is acceptable.

If a gear set is to be reused, reset the backlash recorded prior to disassembly.

30 2 SPEED REAR AXLES: SPICER (S14015)

SUN GEAR INSTALL

8. Once the proper backlash has been set, tighten the differential bearing cap bolts to:

Table 5 Differential Bearing Cap Bolt Torque

Code Torque
14CDA, 14130 220 to 250 ft-lbs. (298 to 339 N•m)
14131, 14132, 14133, 14CDB 290 to 350 ft-lbs. (393 to 475 N•m)

For checking proper ring and pinion tooth contact pattern, refer to RING AND PINION GEAR.

9. Install the adjusting ring retainers, washers and bolts. Tighten the retainer bolts to:

30 to 40 ft-lbs. (41 to 54 N•m).

CAUTION

During repair of carrier, special attention should be given to proper assembly of the left
and right differential bearing adjusting rings. The inside of each bearing adjusting ring
is relieved to provide clearance for the differential bearing cage. If either adjuster is
installed backwards (inside out), it may interfere with the adjacent bearing cage, which
could cause premature failure of the bearing assembly.

NOTE – Assemble adjusting rings so that the side with two shoulders is facing out to ensure
clearance for the bearing cage. (Inside face has only one shoulder.)

8.2. SUN GEAR

1. Install sun gear retainer plate with chamfered teeth facing out and four bolts. Tighten bolts to:

220 to 250 ft-lbs. (298 to 339 N•m).

2. Install the sun gear.

3. Slide shift fork into carrier housing and position on sun gear. Install shift fork shaft through hole in carrier
housing and shift fork.

4. New Style:

Insert and tighten set screw to 50 to 70 ft-lbs. (68 to 95 N•m).

Old Style: Install shift fork shaft retainer clip. Fill the shift fork shaft holes with RTV sealant.

5. Install the shift fork seal and spring to the dimension shown in Figure 33 .

2 SPEED REAR AXLES: SPICER (S14015) 31

INSTALL RING AND PINION GEAR

Figure 33 Shift Fork Seal & Spring Installation

8.3. RING AND PINION GEAR

Contact Pattern

Refer to Figure 34 .

Figure 34 Gear Tooth Nomenclature

The toe of the gear tooth is the portion of the tooth surface at the end towards the center.

The heel of the gear tooth is the portion of the tooth surface at the outer end.

The top land of a gear tooth is the surface of the top of the tooth.

1. To obtain correct contact pattern, paint ring gear teeth with marking compound and apply load while
rotating pinion.

2. The tooth contact patterns should have the same general shape and position as the ring gear teeth
shown in Figure 35 .

32 2 SPEED REAR AXLES: SPICER (S14015)

RING AND PINION GEAR INSTALL

Figure 35 Correct Tooth Contact

3. If the pattern is concentrated more toward the heel (Figure 36 ), backlash must be reduced. Recheck
backlash as described in RING GEAR SUPPORT CASE ASSEMBLY. To reduce backlash, loosen the
differential case side adjusting ring until the measured backlash is within specification. The tooth contact
pattern should now have the same general shape and location as shown in Figure 36 . If the contact
pattern still does not conform, less backlash than normal is required. To avoid reducing differential bearing
preload excessively, further loosening of the right hand adjusting ring should be accompanied by equal
tightening of the flange side adjusting ring. Decreasing backlash moves the ring gear toward the pinion.

Figure 36 Ring Gear Out Too Far

4. If the pattern is concentrated at the toe (Figure 37 ), more backlash is required. Recheck backlash. To
increase backlash, tighten the differential case side adjusting ring further until the measured backlash
is within specification. The tooth contact pattern should now spread more across the ring gear tooth as
in step 2. If the contact pattern still does not conform, more backlash than normal is required. To avoid
increasing differential bearing preload excessively, further tightening of the differential case side adjusting
ring should be accompanied by equal loosening of the flange side adjusting ring. Increasing backlash
moves the ring gear away from the pinion.

2 SPEED REAR AXLES: SPICER (S14015) 33

INSTALL RING AND PINION GEAR

Figure 37 Ring Gear In Too Far

5. If a pattern is concentrated at the ring gear tooth root (Figure 38 ), the pinion is too close to the ring gear. It
must be moved out and away to establish its proper mounting distance and contact pattern as shown in
step 2. This is accomplished by choosing a thicker pinion position cage shim. Readjust pinion-to-ring gear
backlash, as required, once proper pinion mounting distance has been established.

Figure 38 Pinion In Too Far

6. If pattern is concentrated at the tooth top land (Figure 39 ), the pinion is too far away from the ring gear
and must be moved closer to the ring gear to establish its proper mounting distance and tooth contact
pattern. This is accomplished by selecting a thinner pinion position cage shim. Readjust pinion-to-ring
gear backlash as required once proper pinion mounting distance has been established.

34 2 SPEED REAR AXLES: SPICER (S14015)

CARRIER ASSEMBLY INTO AXLE HOUSING INSTALL

Figure 39 Pinion Out Too Far

8.4. CARRIER ASSEMBLY INTO AXLE HOUSING

1. Thoroughly clean the inside of the carrier housing and inspect the housing mounting surface for nicks and
general cleanliness. Stone the surface if necessary to remove burrs or nicks.

2. Apply Loctite 518 gasket eliminator material to the housing carrier mounting flange. A 1/8 inch bead on the
outside of all carrier mounting holes, and an additional bead around holes is required (Figure 40 ).

Figure 40 Carrier Housing Lubrication

3. Thread two studs into housing so that they will extend at least one inch above the housing mounting face
to serve as carrier assembly alignment guides. This procedure is necessary to avoid having to rotate the
carrier once it is against the Loctite 518 coated mounting surface to align bolt holes. Such realignment can
cause the Loctite seal to be broken, leading to in-service oil leakage.

4. Assemble the carrier to the housing and install the carrier-to-housing bolts, replacing the two guide studs
with mounting bolts. Tighten bolts to:

Table 6 Carrier-to-Housing Bolt Torque

Code Torque
14CDA, 14130 100 to 120 ft-lbs. (136 to 163 N•m)
14CDB, 14131, 14132,, 14133 240 to 260 ft-lbs. (325 to 352 N•m)

2 SPEED REAR AXLES: SPICER (S14015) 35

LUBRICATION AND SEALANT WHEEL BEARINGS

Refer to the TORQUE CHART.

5. Allow one hour cure time for gasket material before adding hypoid lubricant.

6. Remove old axle flange gasket and clean mating surfaces of hub and axle flange.

7. Insert both axle shafts, using new shaft-to-hub gaskets and install the axle nuts and/or bolts.

8. Re-install the shift unit.

NOTE – For servicing the shift unit, refer to Group 14 - REAR AXLE in the CTS-5000 Master Service
Manual.

9. Replace the drain plug after cleaning the magnet, the plug threads, and the area around the drain hole.
Refill the axle housing to the proper level with proper hypoid lubricant, as recommended earlier. Replace
the filler hole plug after cleaning the magnet, the plug thread, and the area around the fill hole.

8.5. WHEEL BEARINGS

For proper wheel bearing installation and adjustment, refer to GROUP 14 - REAR AXLE in the CTS-5000
Master Service Manual.

9. LUBRICATION AND SEALANT

To ensure proper lubrication and operating temperature, correct lubricants and lubricant levels must be
maintained.

9.1. MAXIMUM OIL SUMP TEMPERATURE

Table 7 Maximum Oil Sump Temperature

Operating Condition Maximum Temp.

Continuous service 250°F
Short duration-15 minutes 300°F
max.
Mountain grades or other severe service

9.2. RECOMMENDED LUBRICANTS

Hypoid gear lubricants that meet or exceed military specification MlL-L-2105D, and API service classification
GL-5 are the minimum requirements. Refer to GROUP 10 - LUBRICATION in the CTS-5000 Master Service
Manual or the vehicle Operators Manual for proper lubricant.

9.3. CHANGE INTERVALS

Recommended lubricant change intervals are dependent on the application and operating environment.
Refer to GROUP 10 - LUBRICATION in the CTS-5000 Master Service Manual or the vehicle Operators
Manual for recommended change intervals.

36 2 SPEED REAR AXLES: SPICER (S14015)

AFTER OVERHAUL OR CHANGE INTERVALS LUBRICATION AND SEALANT

9.4. AFTER OVERHAUL OR CHANGE INTERVALS

Fill the axle assembly with specified lubricant to the proper operating level (Figure 41 ). Following an overhaul,
the lubricant level must be checked and refilled after 24 hours of operation. This procedure is necessary to
replenish the small amount of lubricant that is retained in the internal cavities and wheel ends during initial
operation of the axle assembly. Refer to GROUP 10 - LUBRICATION in the CTS-5000 Master Service
Manual or the vehicle Operators Manual for correct fill capacity.

Figure 41 Operating Level of Lubricant

NOTE – Capacity will vary depending on the housing angle in each vehicle. Lubricant must be level with
opening (Figure 41 ).

9.5. SUBMERSION OR DEEP WATER FORDING

In the event the axle assembly should become submerged in water over the housing vent, it is recommended
that the lubricant be checked for contamination. If water is detected, wheel bearings, hub cavities, and internal
components must be inspected. Replace any damaged parts prior to reassembly.

9.6. LUBRICANT ANALYSIS

The use of lubricant analysis for the monitoring of physical properties and contamination levels of gear oil is
recommended. The recommended sampling intervals are 50,000 miles or annually for on-highway, and 25,000
miles or twice per year for on/off highway and severe service applications.

The most accurate samples are obtained shortly after the axle has been operated, while the oil is still warm
and mixed. Care should be taken to draw the sample from the center of the sump and to avoid areas close to
magnetic plugs.

9.7. RECOMMENDED SEALING MATERIAL

The new material used is Loctite 518 gasket eliminator. Although the sealant is more expensive than most
RTV’s, less material is used and the seal is far superior.

2 SPEED REAR AXLES: SPICER (S14015) 37

TROUBLESHOOTING

Requirements

1. The mating surfaces must be clean and free of oil film prior to applying sealant.

To assure clean surfaces:

Solvent is to be applied to the mating surfaces and wiped dry with a clean, lint-free towel.

The solvent used should not leave any film or residue. Approved solvent: TRI-CLEAN or
equivalent.

The towels used should not leave any dust, film, lint or residue on the jointing surfaces.
2. A uniform and continuous bead of sealant is to be applied to one of the surfaces.
3. The use of studs as guide pins is recommended when assembling, for proper alignment. Once the
surfaces are touching, the parts should NOT be rotated.
4. The bead is to be 1/16 inch to 1/8 inch diameter depending upon width of the joint; see model
illustrations for bead size.

For additional information on sealing material, refer to GROUP 10 - LUBRICATION AND SEALERS in the
CTS-5000 Master Service Manual.

10. TROUBLESHOOTING
10.1. TROUBLESHOOTING CHART
Table 8 Troubleshooting Chart

Condition Possible Cause Remedy

Noise on Drive 1. Excessive pinion to ring gear backlash. 1. Adjust.

2. Worn pinion and ring gear. 2. Replace.

3. Worn pinion bearings. 3. Replace.

4. Loose pinion bearings. 4. Adjust.

5. Excessive pinion end play. 5. Adjust.

6. Worn differential bearings. 6. Replace.

7. Loose differential bearings. 7. Adjust.

8. Excessive ring gear run-out. 8. Replace.

9. Low lubricant level. 9. Replenish.

10. Wrong or poor grade lubricant. 10. Replace.

11. Bent axle housing. 11. Replace.

38 2 SPEED REAR AXLES: SPICER (S14015)

TROUBLESHOOTING CHART TROUBLESHOOTING

Table 8 Troubleshooting Chart (cont.)

Condition Possible Cause Remedy
Noise on Coast 1. Axle noises heard on drive will usually be heard 1. Adjust or replace. (See
on coast, although not as loud. above.)

2. Pinion and ring gear too tight (audible when 2. Adjust.

decelerating and disappears when driving).
Intermittent Noise 1. Warped ring gear. 1. Replace.

2. Loose differential case bolts. 2. Tighten.

Constant Noise 1. Flat spot on pinion or ring gear teeth. 1. Replace.

2. Flat spot on bearings. 2. Replace.

3. Worn pinion splines. 3. Replace.

4. Worn axle shaft dowel holes. 4. Replace.

5. Worn hub studs. 5. Replace.

6. Bent axle shaft. 6. Replace.

Noisy on Turns 1. Worn differential side gears and pinions. 1. Replace.

2. Worn differential spider. 2. Replace.

3. Worn differential thrust washers. 3. Replace.

4. Worn axle shaft splines. 4. Replace.

Two-Speed Fails to 1. Defective electrical circuit. 1. Correct.
Shift
2. Defective shift unit. 2. Replace.

3. Lack of air pressure. 3. Correct.

4. Worn or broken sun gear or clutch plate. 4. Replace.

Fracture of Ring 1. Excessive loading of the gear beyond design Replace ring gear and pinion
Gear Teeth at the intent. as matched set.
Tooth Heel
2. Incorrect gear adjustment (excessive backlash). Carefully follow the
recommended procedures for
adjusting ring gear and pinion
backlash tooth pattern.
Fracture of Ring 1. Shock impact loading. Replace ring gear and pinion
Gear Teeth at the as matched set.
Tooth Toe 2. Incorrect gear adjustment (insufficient backlash).
Carefully follow the
recommended procedures for
adjusting ring gear and pinion
backlash tooth pattern.

2 SPEED REAR AXLES: SPICER (S14015) 39

TROUBLESHOOTING TROUBLESHOOTING CHART

Table 8 Troubleshooting Chart (cont.)

Condition Possible Cause Remedy
Scored and/or 1. Insufficient lubrication. Replace ring gear and pinion
Scuffed Ring and as matched set.
Pinion Gear Teeth 2. Contaminated lubricant.
Replace pinion bearings,
3. Wrong lubricant or lubricant with depleted taking care to set ring and
additives. pinion position and bearing
preloads properly.
4. Worn pinion bearings which result in pinion end
play and incorrect ring and pinion tooth contact. Use correct lubricant, fill to
proper level and change at
recommended intervals.
Overheated Ring 1. Prolonged operation at excessive temperatures. Replace ring gear and pinion
and Pinion Gear as matched set.
Teeth. Look for 2. Incorrect lubricant.
Discoloration of the Use correct lubricant, fill to
Gear Teeth 3. Low oil level. proper level and change at
recommended intervals.
4. Contaminated lubricant.

NOTE: All of the above can result in inadequate

lubricant film between tooth surfaces which causes
surfaces to overheat due to excessive friction.
Pitted Drive Pinion 1. Extremely severe service. Replace ring gear and pinion
Teeth as matched set.
2. Insufficient lubrication.
Use correct lubricant, fill to
proper level and change at
recommended intervals.
Bent Axle Housing 1. Vehicle overloading. Replace axle housing.

2. Vehicle accident.

3. Shock loading.
Worn or Pitted 1. Insufficient lubrication. Replace bearing cups and
Bearing cones in matched sets. Check
2. Contaminated lubricant. roller ends for excessive wear
by comparing used rollers with
3. Very severe service. a new bearing.

4. Normal wear. Use correct lubricant, fill to

proper level and change at
recommended intervals.

40 2 SPEED REAR AXLES: SPICER (S14015)

TROUBLESHOOTING CHART TROUBLESHOOTING

Table 8 Troubleshooting Chart (cont.)

Condition Possible Cause Remedy
Leaking Oil Seal 1. Prolonged operation at excessive oil Replace the oil seal and
temperatures. mating surface if damaged.

2. Scored or dented yoke wear surface. Use correct lubricant, fill to

proper level and change at
3. Improperly installed oil seal. recommended intervals.

4. Nicked or cut seal lip.

5. Contaminated lubricant.
Excessive End Yoke 1. Severe service. Replace the end yoke.
Spline Looseness
2. Loose pinion nut. Check the pinion spline for
excessive wear.
3. Pinion endplay.
Replace the ring gear and
pinion as a matched set if
necessary.
Fatigue Fracture 1. Severe service. Replace the ring gear and
of the Pinion Gear pinion as a matched set.
Teeth. Look for
Clear-cut, Wavy
Fracture Lines
(Beachmarks)
Fracture of 1. Shock loading of differential components. Replace differential side
Differential Side gears, pinion mates, and
Gears and Pinion cross shaft as a set.
Mates
Scoring and/or 1. Excessive wheel spinning. Replace differential side
Seizure of Cross gears, pinion mates, cross
Shaft Arms and 2. Inadequate lubrication. shaft and thrust washers as a
Pinion Mate Gears set.
3. Extremely severe service.
Use correct lubricant, fill to
4. Unequal tire pressures. proper level and change at
recommended intervals.
Worn Side Gear 1. Severe service. Replace differential side gears
Splines (Excessive and pinion mates as a set.
Backlash) Replace worn axle shafts.
Scored or Worn 1. Insufficient lubrication. Replace any scored washer
Thrust Washer and any worn washer that is
Surfaces 2. Improper lubrication. .005 inch thinner than a new
one.
3. Contaminated lubricant.
Use correct lubricant, fill to
proper level and change at
recommended intervals.

2 SPEED REAR AXLES: SPICER (S14015) 41

SPECIFICATIONS

Table 8 Troubleshooting Chart (cont.)

Condition Possible Cause Remedy
Excessively Worn 1. Improper axle range shift. Replace clutching plates or
or Chipped Clutch sun gear as required.
Teeth on Sun Gear 2. Malfunctioning shift motor system.
or Retaining Plates Check for proper shift motor
system action.
Scored or Worn 1. Insufficient lubrication. Replace shafts that are
Bronze Planet Gear excessively or non-uniformly
Shafts 2. Contaminated lubricant. worn.

Use correct lubricant, fill to

proper level and change at
recommended intervals.
Worn Pinion Roller 1. Severe service. Replace pinion roller bearing
Bearing Retainer and retainer.
Bore 2. Excessive pinion end play.
Check pinion for excessive
3. Inadequate lubrication. end play.

4. Contaminated lubricant. Use correct lubricant, fill to

proper level and change at
recommended intervals.
Twisted or Broken 1. Severe vehicle operation. Replace the shaft.
Axle Shaft
Fractured Axle Shaft 1. Loose wheel bearing. Replace the shaft.
at the Flange
2. Bent axle housing. Check housing distortion.
Make certain that wheel
3. Loose shaft to wheel hub bolts. bearings are not worn or
misadjusted.

11. SPECIFICATIONS
11.1. SPECIFICATIONS TABLE
Table 9 Specifications Table

Component U.S. Metric

Pinion Bearing Preload* 20 - 50 In-Lbs. 2.3 - 5.6 N•m
Ring Gear to Pinion Backlash .008 - .016 In. .20 - .40 mm
*Pinion Bearing Preload is to be established prior to installation of pinion seal.

11.2. SPACERS
Available pinion bearing preload spacer thicknesses:

.696 inch (17.68 mm) to .727 inch (18.46 mm) in .001 inch (.025 mm) increments.

42 2 SPEED REAR AXLES: SPICER (S14015)

TORQUE CHART SPECIFICATIONS

11.3. TORQUE CHART

Table 10 Common Fasteners

Item Model Torque

No.* Position ** Thread Grade Ft-Lbs. N•m
1 Pinion Nut G,M 1 1/4-12 700-900 949-1,220
2 Carrier to Housing G 1/2-13 8 100-120 136-163
Bolt M 5/8-11 8 240-260 325-352
3 Adjuster Lock Bolt G,M 3/8-16 8 30-40 41-54
4 Cap Bolt G 5/8-18 8 220-250 298-339
M 3/4-16 8 290-350 393-475
5 Pinion Bearing G 7/16-14 8 70-80 95-108
Retainer Bolt M 1/2-13 8 110-125 149-169
6 Differential Case G 7/16-14 8 70-80 95-108
Bolt M 1/2-13 8 110-125 149-169
7 Shift Fork Set Screw G,M 3/4-16 50-70 68-95
8 Shift Motor Lock Nut G,M 7/16-14 55-65 75-88
9 Support Case and G 1/2-13 8 110-125 149-169
Ring Gear Bolt M 9/16-12 8 160-180 217-244
10 Sun Gear Retainer Bolt G,M 5/8-18 8 255-275 298-339
11 Axle Shaft Mount- G 9/16-18 8 88-122 119-165
ing Nut (Nylok) M 3/4-16 8 217-240 294-325
* Refer to Figure 42 for torque items
** G = 14CDA, 14130
M = 14CDB, 14131, 14132, 14133

2 SPEED REAR AXLES: SPICER (S14015) 43

SPECIFICATIONS TORQUE CHART

Figure 42 Rear Axle Torque Locations

44 2 SPEED REAR AXLES: SPICER (S14015)

SPECIAL TOOLS SPECIFICATIONS

11.4. SPECIAL TOOLS

ZTOEM 6600 STAKING TOOL

Figure 43 ZTOEM 6600 STAKING TOOL

ZTOEM 4193 CARRIER OVERHAUL STAND

Figure 44 ZTOEM 4193 CARRIER OVERHAUL STAND

ZTSE2847 Yoke Remover, Bar Type – A yoke remover tool for extracting shaft end yokes on rear axles having
an interference fit between the yoke and the axle input or output splined shaft.

2 SPEED REAR AXLES: SPICER (S14015) 45

SPECIFICATIONS SPECIAL TOOLS

Figure 45 ZTSE2847 Yoke Remover, Bar Type

ZTSE4335 Installer, Differential Yoke – 1 1/2" – 12 and 1 1/4" – 12. Used for the installation of the end
yoke onto the splines of the pinion, input, output or through shaft. This tool presses the yoke in place with
forcing screw action, eliminating costly part damage.

Figure 46 ZTSE4335 Installer, Differential Yoke

Torque Multipliers

These powerful Torque Multipliers are designed as general all – purpose utility tools. They provide the
necessary power to tighten threaded fasteners such as nuts, bolts, cap screws, etc.

46 2 SPEED REAR AXLES: SPICER (S14015)

SPECIAL TOOLS SPECIFICATIONS

Figure 47 Torque Multipliers

Ordering Information
No. ZTOEM6106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Torque Multiplier. 1000 ft-lbs. Wt., 7 lbs.
No. ZTOEM6107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Torque Multiplier. 2000 ft-lbs. Wt., 14 lbs.
No. ZTOEM6108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Torque Multiplier. 4000 ft-lbs. Wt., 30 lbs.
No. ZTOEM6109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Torque Multiplier. 12,000 ft-lbs. Wt., 80 lbs.
No. ZTOEM6110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Drive Adapter. 3/4" Female x 1/2" Male
No. ZTOEM6111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Drive Adapter. 3/4" Female x 1" Male
No. ZTOEM6112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Drive Adapter. 1/2" Female x 3/4" Male
No. ZTOEM6113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . Drive Adapter. 1" Female x 3/4" Male

Table 11 Tool Information Table

Part No. Cap. Ft-Lbs. Input Drive Output Ratio

Drive
ZTOEM6106 1000 1/2” 3/4” 4 to 1
ZTOEM6107 2000 3/4” 1” 4 to 1
ZTOEM6108 4000 1” 1 1/2” 4.33 to 1
ZTOEM6109 12,000 1” 2 1/2” 6 to 1

2 SPEED REAR AXLES: SPICER (S14015) 47