Spicer Drive Axles Failure Analysis Service Manual Bedienungsanleitung

Spicer® Drive AxlesService ManualFailure AnalysisAXSM0020June 2009

Glossary and Nomenclature9Stress OverviewMost failures involve some form of mechanical stress. Even when the initial or basic cause of the failure res

Glossary and Nomenclature10Glossary and NomenclatureGear Tooth NomenclatureTooth Identification:Drive side ofPinionTop landToeRootHeelCoast sideflankD

Glossary and Nomenclature11Primary Gearing NomenclatureRing and Pinion Identification - To aid in identifying gear sets, both parts are stamped with i

Glossary and Nomenclature12Glossary and NomenclatureFront Drive Axle NomenclatureWheel diffspiderSide GearSide gearthrust washerFlange halfdiff caseRi

Glossary and Nomenclature13Lockoutsliding clutchInputshaftOutputside gearbearing cupOutputside gearOutputside gearbearing coneHelicalside gearbushings

Glossary and Nomenclature14Glossary and NomenclatureRear Drive Axle NomenclatureR-head carrieror rear carrierInner pinionbearing conePinioncage shimIn

Glossary and Nomenclature15Parts IdentificationCUST. PART NO. - OEM Part NumberSERIAL NO. - Assembly NumberRATIO - Axle RatioSPEC. - Dana’s Build Shee

Gearing and Torque Distribution16Gearing and Torque DistributionPower FlowFor technical reference, this section describes and illustrates the way powe

Gearing and Torque Distribution17Spin-out CombinationsSpin-out is a term used to describe excessive differential action. Wheel differential spinout oc

Failure Analysis18Failure AnalysisHow to Diagnose a FailureFailure analysis is the process of determining the original cause of a component failure in

Table of ContentsIntroductionOverview ... 2Failure PreventionCorrect Specifications

Failure Analysis19Make a Preliminary InvestigationThese steps consist of external inspections and observations that will be valuable when combined wit

Ring Gear and Pinion20Ring Gear and PinionShock (Impact) FailureRing Gear - Catastrophic Failure Ring Gear - Coast Side Shock FailureDrive Pinion - To

Ring Gear and Pinion21Fatigue FailureRing Gear - Catastrophic Fatigue Failure Ring Gear - Start of a Fatigue FailureDrive Pinion - Torsional Fatigue F

Ring Gear and Pinion22Ring Gear and PinionPitting and Spalling FailuresRing Gear - PittingDrive Pinion - PittingDrive Pinion - Case Crush Drive Pinion

Ring Gear and Pinion23Lubrication FailuresRing Gear - Incorrect Lube Drive Pinion - Incorrect LubeRing Gear - Low Lube - Crows Foot Drive Pinion - Low

Wheel Differential24Wheel DifferentialShock (Impact) FailureWheel Differential - Catastrophic Failure Wheel Diff. Spider - Shock LoadSide Gear - Catas

Wheel Differential25Spinout - Over Heat FailuresSide Pinion Thrust Washers - Scoring Side Pinion - GallingWheel Differential - Catastrophic Wheel Diff

Power Divider26Power DividerShock (Impact) FailureIAD Spider - Shock Failure Spider - Smooth Even Surface - Shock FailureSliding Clutch - Shock Failur

Power Divider27Helical Side Gear - Shock Failure Output Side Gear - Shock FailureInput Shaft - Torsional Shock Failure Output Shaft - Torsional Shock

Power Divider28Power DividerFatigue FailuresInput Shaft - Torsional Fatigue Failure at Splines Input Shaft - Fatigue FailureOutput Shaft - Torsional F

Introduction2IntroductionOverviewThis document is a general reference guide to mechanical failures of heavy truck axles. We approach the subject of ax

Power Divider29Pitting and Spalling FailuresHelical Side Gear - Pitting Side Gear - PittingOutput Side Gear - Spalling Side Pinion - PittingGeneral De

Power Divider30Power DividerSpinout FailuresIAD Spider Arm - Galling IAD Spider Arm - ScoringIAD Spider Arm - Bore Galling Thrust Washer to Input Shaf

Power Divider31Helical Side Gear Bearing Damage Output Side Gear - Stub-End Bore GallingGeneral Description: Spinout is excessive wheel spinning that

Power Divider32Power DividerLubrication FailuresInput Shaft Bearing - Low Lube Output Side Gear Bearing - Low LubeHelical Side Gear Bushing - Lubrican

Power Divider33Input Shaft Stub End - Water Contamination Output Side Gear - Water ContaminationUsual Causes: • Incorrect lube (wrong viscosity or wro

Bearings34BearingsNormal and Contamination WearNormal Uneven Wear Pattern - Low Mileage Normal Even Wear Pattern - High MileageContamination - Scratch

Bearings35Pitting and Spalling DamageBearing Cup - Pitting Bearing Cone - PittingBearing Cup - Spalling Bearing Cone - Spalling - Water ContaminationB

Bearings36Power DividerGeneral Description: This failure may start as bruising or denting then progress to frosting, pitting, and finally spalling. As

Seals and Yokes37Yoke Wear and Seal Lip WearYoke to Seal Interface - Normal Wear Yoke to Seal Interface - Extreme WearraeW emertxE - piL laeSraeW lamr

Seals and Yokes38Seals and YokesInstallation ProblemsBent Outer Shell - Do Not Reuse Dirt Between Seal and Bearing CageDamaged Seal Lip ContaminationB

Failure Prevention3Correct SpecificationsThis section considers three general areas of truck procurement, operation and maintenance that will help pre

Seals and Yokes39Note: Reference Seal Maintenance Guide TCSM-0912.General Description: A seal has two critical functions: to retain lube and to exclud

Axle Shafts40Axle ShaftsShock and Fatigue FailureAxle Shaft - Twisted Splines Torsional ShockTorsional Shock Failure - Close upAxle Shaft - Torsional

Axle Shafts41General Description: Shock damage occurs from overstressing the shaft beyond the strength of the material. The failure canbe immediate (a

Two Speed Planetary42Two Speed PlanetaryPitting and Spalling FailuresSliding Clutch - Pitting Planetary Gear - SpallingSliding Clutch - Shock Failure

Two Speed Planetary43Wear and ScoringClutch Plate - Improper Shift Sliding Clutch - Improper ShiftBronze Idler Pins - Normal/Excessive Wear Bronze Idl

Drive Axle Housing44Drive Axle HousingSpindle Damage and Fatigue CracksSpindle Water Contamination Fatigue CracksHousing Arm Fatigue Hanger Bracket Fa

Drive Axle Housing 45Loose or Over-Torqued HardwareLoose Clamping Hardware Over-torqued Clamping HardwareGeneral Description: Sufficient clamp load at

Steer Axle46Steer Axle Bushing Damage - InstallationImproper Kingpin Installation Improper ReamingGeneral Description: Damaged bushing material, areas

Steer Axle47Bushing and Kingpin Wear - ContaminationGeneral Description:Rust, grooving, and scoring to the bushing area of the kingpin, bushings exces

Steer Axle48Steer AxleBushing and Kingpin Wear - NormalGeneral Description:Normal wear to a bushing will show an even wear pattern at one location onl

Failure Prevention4Failure PreventionDriving PracticesDriving practices have a large influence on the service life of a truck axle. Good driving pract

All applications must be approved by the Application Engineering Department. Specifications and/or design are subject to change without notice or obli

Failure Prevention5Controlled Traction DifferentialA controlled traction differential is a biasing unit designed into the axle wheel differential. It

Failure Prevention6Failure PreventionMaintenance, Rebuilding, and AdjustmentProper maintenance is essential to achieve the maximum life designed and b

Glossary and Nomenclature7GlossaryAbrasion - The process of rubbing, grinding, or wearing awayof material from a surface by friction.Backface Runout -

Glossary and Nomenclature8Glossary and NomenclatureRadial Runout - Refers to the total amount of movement of theoutside diameter of the ring gear duri