Service Manual

1 Spicer Steer AxlesServi ce ManualAXSM0038 September 2013 Warnings and CautionsWarnings and CautionsThe description and specifications contained in this Service publication are current at the time of reserves the right to discontinue or to modify its models and/or procedures and to change specifications at any time without use genuine Spicer replacement or machining on any axle component is prohibitedunless noted otherwise in this document or other Spicerservice effort has been made to ensure the accuracy of all information in this guide. However, Dana makes noexpressed or implied warranty or representation based on the enclosed reference to brand names in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents, if available, may be NoticeThis symbol is used throughout thismanual to call attention to procedureswhere carelessness or failure to followspecific instructions may result inpersonal injury and/or from the instructions, choiceof tools, materials and recommendedparts mentioned in this publicationmay jeopardize the personal safetyof the Service technician or : Failure to follow indicatedprocedures creates a high risk of personalinjury to the servicing : Failure to follow indicatedprocedures may cause componentdamage or : Highly recommendedprocedures for proper Service of this : Additional Service information notcovered in the Service : Helpful removal and installationprocedures to aid in the Service of this and CautionsWarnings and CautionsiiGeneral InformationWarnings and Cautions.

2 I Important Notice ..iGeneral Information ..1-3 Axle Identification ..1 Axle Assembly Model Information ..2 Model Coverage ..3 Inspection ..4-8 Procedures and Intervals ..4 E Family Exploded View ..4 EFA Family Exploded View ..5 I and D Family Exploded View ..6 General Inspection ..7 Component Inspection ..7 Knuckle Vertical Play Inspection ..7 Bushing Inspection (End-play) ..8 Tie Rod Inspection ..9 -10 Tie Rod End Replacement ..11 Straight Socket Tie Rod Ends ..11 Drop Socket Tie Rod Ends ..11 Alignment / Adjustment ..12 Wheel Camber ..12-15 Caster Adjustment ..16 Toe Setting ..17 Steering Stop Adjustment ..18 Disassembly, Overhaul, and Assembly ..19-30 Steering Knuckle Disassembly ..19-20 Kingpin Bushing and Seal Replacement ..20-22 Steering Knuckle Assembly ..23-24 Bushing End-play Verification ..25-26 Replacing Staked Draw Keys with Threaded ..27-28 Installing Dual Draw Keys ..28 Steer Axle Grease Procedure ..29-30 Kingpin Joint Greasing Procedure.

3 29 Tie Rod End Greasing Procedure ..30 General Specifications ..31-33 Wheel Bearing Adjustment ..31 Wheel Kingpin Clearance New ..31 Kingpin Clearance In Service ..31 E Family Fastener Torque Specifications ..32 EFA Family Fastener Torque Specifications ..32 I and D Family Fastener Torque Specifications ..32 Wheel Bearing Adjustment ..34-38 Wheel Bearing Adjustment ..34 Stamped Locking Nut System ..35 Single Nut (Castle Nut) Locking System ..36 Pro-Torq spindle Nut Service ..37 Additional Service Information ..39 Appendix ..40-43 Special Service Tools ..40 Lubrication ..41-42 Verify Wheel End-play Procedure ..43 Readjust Wheel End-play Procedure ..431 General InformationGeneral InformationAxle IdentificationThe Spicer front non-drive steering axles are identified witha tag located between the spring pads on the front side ofthe center beam axle tag contains the serial number, the model number,and the assembly Assembly TagE Famil yEF A FamilyI Fa milyJulian Date Code1 - Tag1 - Dana Part Numbe r11 - Dana P art Number2 - Serial Number3 - Model Number4 - Cus tomer Part Number5 - Line Set Number6 - Julian Date 9 8170 Model YearDay of Year2 General InformationModel InformationE FamilyEFA FamilyI FamilyDesign Level0 - Standard1 - Heavy Duty Beam2 - Maximum Contact Kingpin Joint3 - Maximum Contact Kingpin Joint and Heavy-Duty BeamE -120 2 IBeam TypeI - I-Beam Standard Overall WidthW - Over 96" Overall WidthT - Tubular BeamC - Center (Top) Mount Air Disk BrakeSeriesGAWR x 100.

4 120 x 100 = 12,000 FamilyDesign Level0 - Standard AxleD -85 0 FBeam TypeF - Standard WidthW - Over 96" Overall WidthN - Narrow WidthSeriesGAWR x 1,000 lbs.(450 Kg)Nominal LoadCapacity12 - 12,000 - 18,000 - 22,000 - 24,000 TypeF = I-Beam Standard Overall WidthT = Tubular BeamBeam Drop1 - in. to Tube Centerline4 - in. to Spring Pad5 - in. to Tube CenterlineEFA 12 F 4I120 SGNominal LoadCarrying Capacity 60 = 6,000 lbs. 80 = 8,000 = 10,000 = 12,000 = 14,000 = 16,000 = 18,000 = 20,000 lbs. Beam Type /Series SG = SB = W = I-Beam StandardOverall WidthCoach BeamOver 96"Overall Width3 General InformationGeneral InformationModel CoverageE Famil yEF A FamilyI and D Famil yNote: These nominal ratings are general guidelines. Actual load rating varies with application and duty cycle. Applicationsrequire Spicer engineering Load Ratings lbs. [kg]E-1000I E-1000W E-1002I E-1002W10,000 [4,536]E-1200I E-1200W E-1201W E-1202I E-1202WE-1203I12,000 [5,443]E-1320I E-1320W E-1322I E-1322W13,200 [5,987] E-1460I E-1460W E-1462I E-1462W14,600 [6,622]ModelNominal Load Rating lbs.

5 [kg]EFA- 12F3 Superseded by EFA-12F4 EFA- 13F3 Superseded by EFA-12F4EF A-12F4 EF A-13F512,000-13,200[5,443-5,987]EFA- 18F3 Superseded by EFA-20F4EF A-20F420,000 [9,072]EF A-22T2 EF A-22T522,000 [9,979]EF A-24T2 EF A-24T524,000 [10,886]ModelNominal Load Rating lbs. [kg]I- 60S GD-600N6,000 [2,722]D-700ND-700F 7,000 [3,175]D-800F D-800WI- 80S G8,000 [3,629]D-850F D-850W8,500 [3,856]I- 100 S, SG I-100W10,000 [4,536]I- 120S, SG, SGL I-120W12,000 [5,443]I-130SG I-130W13,000 [5,896]I-132SG13,200 [5,987]I- 140S, SG I-140W14,600 [6,622]I- 160S, SG I-160W I-160SB16,000 [7,257]I- 180S, SG I-180W18,000 [8,165]D-2000F20,000 [9,072]I- 200S, SG I-200W20,000 [9,072]D-2200F22,800 [10,342]I-220W22,800 [10,342]4 InspectionInspectionProcedures and IntervalsThe following inspection procedures are consistent with industry practice and are recommended as Inspection guide-lines for periodic Service .

6 Use manufacturer s instructions as a primary Family Exploded ViewIntervals of inspection or Service are recommended for gen-eral or average vehicle use. It may be appropriate to increase frequency of in tervals depending on the type of vehicle - Nut, Draw Key2 - Seal, Grease3 - Shim4 - Axle Beam5 - Key, Draw6 - Bearing, Thrust7 - Screw, Stop8 - Nut, Jam9 - Nut, Slotted10 - Pin, Cotter11 - Bolt, Clamp12 - Tube, Cross13 - Clamp14 - Nut15 - Tie Rod End16 - Lube Fitting17 - Cap, Knuckle18 - Foam Insert19 - Gasket20 - Bushing21 - Kingpin22 - Nut, outer spindle *23 - Washer, Retainer*24 - Washer, spindle *25 - Nut, Inner spindle *26 - Steering Knuckle27 - Dual Draw Key Beam* Nut, Pro-Torq (optional alternative for items 22-25)6234261916211781619172017202252422 15141312910115231818275 InspectionInspectionEF A Family Exploded View127241112211413252624171819151316202 162310789352229281 - Lubrication Fitting2 - Hex Bolt3 - Washer4 - Knuckle Cap5 - Bushing6 - Knuckle Pin7 - Washer, Spindle8 - Hex Nut, Spindle9 - Cotter Pin10 - Steering Knuckle11 - Cotter Pin12 - Hex Nut, Steer Arm13 - Seal Knuckle14 - Shim15 - Thrust Bearing16 - Draw Key17 - Nut, Draw Key18 - Stop Screw19 - Nut, Jam20 - Cotter Pin21 - Woodruff Key22 - Cross Tube Assembly23 - Tie Rod Arm24 - Steer Arm Ball Stud25 - Ball Stud Nut26 - Ball Stud Cotter Pin27 - Steer Arm28 - I-Beam29 - Tubular Beam6 InspectionI and D Family Exploded View151630911133210121417751682325262427 282221291920191810333231435341 - I-Beam2 - Seal, Kingpin3 - Shim4 - Draw Key, Outer5 - Draw Key, Inner6 - Nut, Draw Key7 - Washer, Belleville8 - Bearing Assembly, Thrust9 - Bolt, Kingpin Cap10 - Grease Fitting11 - Cap.

7 Kingpin12 - O-Ring13 - Bushing, Kingpin14 - Kingpin15 - Pin, Cotter16 - Nut, Slotted17 - Knuckle, Steering18 - Bolt, Stop19 - Key, Woodruff20 - Arm, Steering21 - Nut, Tie Rod22 - Pin, Cotter Tie Rod23 - Tube, Cross24 - Bolt, Tie Rod Clamp25 - Nut, Tie Rod Clamp26 - Clamp, Tie Rod27 - Tie Rod End28 - Grease Fitting29 - Arm, Tie Rod30 - Pin, spindle Cotter31 - spindle Nut, Inner32 - Nut, spindle Lock Washer33 - spindle Nut, Outer34 - Washer, Bearing Retainer35 - Nut, Slotted Spindle7 InspectionInspectionGeneral InspectionInspect the axle to ensure proper assembly and to identify broken parts and loose fasteners each time the vehicle is lubricated. Make sure spring to axle beam mounting nuts and steering connection fasteners are Alignment - Follow vehicle manufacturer s instructions for wheel alignment inspection intervals. If excessive steering effort, vehicle wander, or uneven and/or excessive tire wear is evident, check wheel alignment.

8 Refer to Wheel eering Axle Stops - Inspect for missing, loose or bent steer stops. Damaged or missing steering axle stops may indicate other problems with the steering system. This can result in damage to steering system components. Replace missing or damaged stops and reset steering system geometry. Refer to vehicle manufacturer s instructions for proper steering sys-tem Rod Ends - Inspect each time axle is lubricated. Check for seal damage, worn ball socket or loose fasteners. Knuckle Thru st Bearin gs - When disassembled, visually inspect for any damage and check for smooth operation. For maximum Service life, replace the thrust bearing whenever the knuckle assembly is ngpins - For maximum Service life replace kingpins when servicing knuckle InspectionPrepare for axle inspection as parking brake and block drive wheels to prevent vehicle th e vehicle un til steering axle wheels are off the ground. Support raised vehicle with safety work under a vehicle supported only by a jack.

9 Al ways use safety Vertical Play dial indicator on axle beam. Reference the dial indicator pr obe on the knuckle a lever, pry steering knuckle the dial a lever, pry the steering knuckle upward. Note indic ator reading. If reading exceeds " ( mm), refer to Removal and Disassembly for overhaul : Perform above inspection procedure with axle assem-bled and installed on vehicle with tires and wheels attached. To check knuckle vertical play during axle assembly. Refer to Steering Knuckle Famil yEF A, I Fa milyWARNING1 - Reference on top of knuckle2 - Dial indicator3 - Pr y bar4 - Pry knuckle downward1 - Reference on top of knuckle2 - Dial indicator3 - Pr y bar4 - Pry knuckle downward213412348 InspectionBushing Inspection (End-Play)Following regular and th orough greasing practices wil l maxi-mize bushing Bushing Lateral In spectionThis procedure measures upper bushing wear due to side and vertical loading.

10 Dial indicator on the axle. Reference the upper part of the steering Famil yEF A, I and D Famil the tire and wheel assembly in and out with a push/pull motion and have an assistant record the dial indicator the upper bushing if readings are in excess of .015" (0 .3 8 mm).Lo wer Bushing Lateral InspectionThis procedure measures lower bushing wear due to side and vertical dial indicator on the axle. Reference the base of the lower arm on the steering Famil yEF A, I and D Fa bottom of tire and wheel assembly in and out with a push/pull motion and have an assistant record dial indicator the lower bushing if dial indicator readings are in excess of .015" ( mm).Note: To avoid inaccurate measurements, be careful not to let the knuckle turn while moving assembly in and out. Applying brakes will help lock wheel : Locate indicator on a smooth, flat surface for best - Dial indicator2 - Reference on top lip of steering knuckle3 - Attach to axle beam1 - Dial indicator2 - Reference on top lip of steering knuckle3 - Attach to axle beam01020304050403020102132131 - Attach to axle beam2 - Reference on lower steering knuckle3 - Dial indicator1 - Attach to axle beam2 - Reference on lower steering knuckle3 - Dial indicator00120300450403020103213219 InspectionInspectionTie Rod sure the boot completely covers the ball joint of the tie rod end with no cracks or tears.