Dana Spicer ® ®

D22/P22 Series
Trailer Axles
Service Manual STPD-1010 August 1997

Visit our web site at http://roadranger.com.

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SPICER D22 AX (STRAIGHT)

SPICER D22 AU (BENT OR DROP)

INTRODUCTION

Spicer Trailer Products are engineered to meet the WARNING THIS SYMBOL IS USED TO INDICATE
demanding requirements of the trucking industry. This POTENTIALLY HAZARDOUS SITUATIONSWHICH , IF NOT AVOIDED,
manual is provided to help maintain the safety, depend- COULD RESULT IN SERIOUS INJURY OR DEATH.
ability and performance designed into Spicer Trailer
CAUTION THIS SYMBOL IS USED TO INDICATE
Products. Study this manual carefully before you perform POTENTIALLY HAZARDOUS SITUATIONS WHICH, IF NOT AVOIDED,
installation or maintenance procedures. MAY RESULT IN PROPERTY OR EQUIPMENT DAMAGE.

You will find DANGER, WARNING, CAUTION, and NOTE THIS SYMBOL IS USED TO INDICATE THAT
NOTE symbols and statements throughout this manual. YOU MUST DO SOMETHING IN ORDER FOR THE AXLE OR BRAKE
TO FUNCTION PROPERLY.

DANGER THIS SYMBOL IS USED TO INDICATE If you have any questions about this manual or its
IMMINENTLY HAZARDOUS SITUATIONS WHICH, IF NOT AVOIDED, instructions, contact Spicer Trailer Products at
WILL RESULT IN SERIOUS INJURY OR DEATH. (334) 286-7000.
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TABLE OF CONTENTS
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Axle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
General Welding Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Recommended Brake Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . .9
Brake Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Welding ABS Wheel Speed Sensor Blocks . . . . . . . . . . . . . . . . . . . . . . .11
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Suggested Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .12
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

SAFETY PRECAUTIONS

WARNING BEFORE PERFORMING ANY MAINTENANCE OR IF YOU ASSEMBLE AXLE COMPONENTS IMPROPERLY
REPAIR WORK REQUIRING RAISING OF VEHICLE, ENSURE VEHICLE IS IF YOU USE INCOMPATIBLE AXLE COMPONENTS
PROPERLY SUPPORTED WITH LIFT STANDS OF SUFFICIENT RATED IF YOU USE AXLES OR AXLE COMPONENTS IN A
CAPACITY. DO NOT RELY ON JACKS ALONE FOR SUPPORT NON-APPROVED APPLICATION
OF VEHICLE.
WARNING THIS MANUAL CONTAINS DETAILED SAFETY
WARNING SAFETY GLASSES SHOULD BE WORN AT ALL INSTRUCTIONS. READ, UNDERSTAND AND FOLLOW THIS MANUAL.
TIMES WHEN ASSEMBLING OR DISASSEMBLING AXLES AND THEIR GET PROPER TRAINING
COMPONENTS. LEARN AND FOLLOW SAFE OPERATING PROCEDURES
WARNING A SERIOUS OR FATAL INJURY CAN OCCUR... USE PROPER TOOLS AND SAFETY EQUIPMENT
IF YOU LACK PROPER TRAINING
USE PROPER COMPONENTS THAT ARE IN GOOD CONDITION
IF YOU FAIL TO FOLLOW PROPER PROCEDURES
IF YOU DO NOT USE PROPER TOOLS AND SAFETY EQUIPMENT

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AXLE IDENTIFICATION

TRAILER AXLE PART NUMBER NOMENCLATURE:

Application Specific
Spindle Type:

D=Friction Welded
P=Propar D22AX503AXX
A, K=Press In
Axle Type: Wall Thickness

AX=Straight Wheel End Configuration

AU=Drop
AS=Square

AXLE MODEL: AXLE TYPE:

(/NOMINALCAPACITY/BEARING COMBINATION/SPINDLE TYPE) AX Straight Tube Axle Assembly
A10 / 10000# / 28995 25580 / Pressed-In Spindle (Replaced by D10 Model) AU Bent Tube Axle Assembly
D10 / 10000# / 28995 25580 / Friction Welded Spindle AS Square Tube Axle Assembly
A13 / 13000# / 567 528 / Pressed-In Spindle (Replaced by D14 Model)
WALL THICKNESS:
K14 / 15000# / 567 528 / Pressed-In Spindle (Replaced by D14 Model)
5 = 7/16” Nominal Wall Thickness
D14 / 15000# / 567 528 / Friction Welded Spindle
6 = 5/8” Nominal Wall Thickness
K21 / 20000# / 663 HM-212049 / Pressed-In Spindle
7 = 3/4” Nominal Wall Thickness
D21 / 20000# / 663 HM-212049 / Friction Welded Spindle
K22 / 22500# / HM-218248 HM-212049 / Pressed-In Spindle WHEEL END CONFIGURATION:
D22 / 22500# / HM-218248 HM-212049 / Friction Welded Spindle 00= W/ Spiders or Flanges, No Brakes, Hubs or Drums
P22 / 22500# / HM-518445 HM-518445 / Friction Welded Spindle 01=W/ Brakes, Hubs and Drums
K25 / 25000# / 749 643 / Pressed-In Spindle (Obsolete) 02= W/ Spiders or Flanges and Hubs & Drums No Brakes
K30 / 30000# / 769 740 / Pressed-In Spindle 03= W/ Brakes, No Hubs and Drums
A45 / 45000# / 787 6580 / Integral Spindle 04= W/ Hubs, No Spiders, Flanges or Brakes
A65 / 65000# / 896 6580 / Integral Spindle 05= No Spiders or Flanges, No Brakes, Hubs or Drums

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AXLE INSTALLATION

To assure safe operation and maximum durability on parts TOP-CENTERHOLE

such as brake linings and tires, it is necessary to position

and install the axle properly. It is recommended that the 20° 20°
axle assembly be installed so the cams rotate in the same
direction as the wheels.

WHEEL ROTATION AXLE

TOP-CENTER
HOLE

CAM ROTATION
CENTERLINE

AXLE REPAIR

CAMAND WHEELS ROTAT EI NT H E SAME DIRECTION

WARNING ANY AXLE FOUND WITH CRACKS SHOULD
Installation in which the camshaft rotation is opposite that NOT BE REPAIRED, BUT REPLACED IMMEDIATELY. REPAIR WELDING
of wheel rotation could cause noisy brakes, chatter, and CAN BE DETRIMENTAL TO THE STRUCTURAL INTEGRITY OF THE AXLE

wheel “hop.” With this in mind, the axle should be BEAM, WHERE THE BENEFIT OF THE ORIGINAL TUBE HEAT TREAT-
MENT MAY BE NULLIFIED BY THE WELDING. AN AXLE SHAFT WEAK-
ordered with the placement of air chamber and slack
ENED BY WELDING COULD FAIL AND CAUSE AN ACCIDENT WHICH
adjuster assemblies that will ensure the correct directional
COULD RESULT IN SERIOUS INJURY OR DEATH.
rotation of the cams when the axle is installed.
NOTE CAMBERED AXLES MUST BE INSTALLED WITH THE
Unless otherwise specified by the customer, Spicer Trailer
DIE MARKS IN THE TOPPOSITION .
Axles are manufactured without camber. If the axle is cam-
bered, the top dead center of the axle will have a small die It is the responsibility of the axle installer to adjust the
mark on each end of the axle close to the inboard side of brakes properly. See the recommended adjustment proce-
the brake spider. dure covered in this manual.

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TRAILER AXLE ALIGNMENT or mm/M. Each format can produce equivalent results.
Proper preparation is a must for effective axle alignment. Spicer Trailer Axles are built to less than +/- 2.5 MOA
The vehicle, tools and equipment, and work site must all run out at each spindle.
be appropriate for axle alignment. The process also requires
TOE-IN TOE-OUT:
a trained technician who knows the specifications.
Installed axles should measure no more than 8 MOA toe-
I. VEHICLE PREPARATION in and 4 MOA toe-out.
TMC RP 708, TRAILER AXLE ALIGNMENT, addresses
ALIGNMENT: Axles should be adjusted to an alignment of
all the steps needed to make the trailer ready for alignment.
no more than 5 MOA scrub with the true center of the
To review these: 1) Inspect the suspension and the axles trailer frame if it is a single axle. If the trailer has multiple
for any obvious damage; 2) Tighten, repair or replace - as axles, each axle should be adjusted to not more than 2.5
needed - any parts that do not meet suspension or axle MOA scrub relative to the front (or reference) axle. (This
manufacturer criteria for serviceability; 3) Check tires adjustment was previously stated as a difference of not
for proper inflation and matching diameters; 4) Park the more than 1/16” between the right and left centers of adja-
trailer on a smooth and level pad with the parking brakes cent axles.)
released. Note: After backing the trailer in, pull it forward
CAMBER: Typical trailer axles exhibit 23-29 MOA of
10 feet to gentle stop. This will allow suspension parts to
TOTAL camber change from an off-ground free state to a
settle in a “forward running” position. Use wheel chocks to
fully loaded condition. Cambered axles are engineered to
prevent injury due to accidental movement of the trailer;
flex to a straight beam under load. New Spicer Trailer
5) With the brakes still released, adjust the height control
Axles may be cambered - by special order - with 33 MOA
valve for the proper setting and the upper coupler to the
of positive camber. This allows the vertical axis through
proper height by raising or lowering the landing gear legs;
the tire to return to near “plumb” condition when loaded.
6) DO NOT proceed unless the wheel bearing end play is
known to be in adjustment per TMC, the bearing manufac- III. ADJUSTMENTS
turer and/or this manual. All fasteners should be loosened prior to measurements
and adjustments. This reduces disturbances to the measur-
ing equipment. All adjustments to axle alignment should
be made by first moving the axle toward the rear of the
trailer — past the intended point. The axle should then
be adjusted forward to intended mark. This step assures
that any free motion in the system is placed in a “draft”
condition.

A repeated difficulty in adjusting the axle to the desired

reading is most often due to a loose wheel bearing, badly
worn suspension component, or a combination.

WARNING NEVER BEND THE AXLE - BY ANY MEANS -

II. SPECIFICATIONS IN ORDER TO CORRECT ANY ALIGNMENT CONDITION! THIS
Axle alignment specifications may be stated in inches, COULD WEAKEN THE AXLE AND CAUSE AXLE FAILURE WHICH COULD
degrees, minutes of angle (MOA or 1/60th of a degree), RESULT IN SERIOUS INJURY OR DEATH.

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GENERAL WELDING RECOMMENDATIONS

In welding suspension component parts to the Spicer The arc should not be broken at the end of each pass and
Trailer Axle, extreme care must be exercised to obtain their the corners should be wrapped. The electrode should be
correct location and to ensure the spring seated load bear- backed up to fill in the fillet crater at the end of each pass.
ing surfaces are parallel to each other. Any welding of Thoroughly clean the weld between each pass.
additional attachments to the axle should be approved
by the Spicer Trailer Product Engineering Department CAUTION DO NOT BRING AXLES IN FROM
to maintain warranty coverage. NONHEATED STORAGE AND WELD WHILE COLD.

It is necessary when welding to avoid the high stress areas CAUTION TO PROVIDE OPTIMUM SUSPENSION-TO-TUBE
on the tube top (compression zone) and tube bottom WELDS, PREHEATING IS RECOMMENDED. PREHEATING WILL MINIMIZE
(tension zone). All welds should be made as close to the LOSS OF THE DUCTILE PROPERTIES IN THE WELD AREA BY SLOWING

horizontal centerline as possible. When the axle tube is THE RATE OF COOLING, THUS REDUCING THE FORMATION OF AN

subjected to the heat from welding and then rapid cooling, UNTEMPERED MARTENSITIC GRAIN STRUCTURE ADJACENT TO THE
WELD. MARTENSITE, A BRITTLE GRAIN STRUCTURE, IS FORMED BY
the material adjacent to the weld loses its desirable ductile
THE RAPID COOLING OF THE METAL SURROUNDING THE WELD AREA.
properties and becomes brittle. If this condition exists in
PREHEAT THE SUSPENSION SEAT WELD AREA TO 500-600 DEG. F
the high stress areas under maximum load conditions,
WITH A ROSEBUD PRIOR TO WELDING. PREHEAT TEMPERATURE
the life of the axle will be greatly reduced and premature
SHOULD BE VERIFIED WITH A TEMPERATURE SENSITIVE CRAYON
fatigue failure can occur. Recommended locations for the
OR OTHER APPROPRIATE MEANS.
welds are shown below.
CAUTION DO NOT “TEST THE ARC” ON THE
WELD PLACEMENT RECOMMENDATIONS
FOR SUSPENSION BRACKETRY AXLE BEAM.
NO WELD
ZONE HARDWARE FIT
3.00
Avoid excessive welding. Fit the seat/hardware as close as
possible to the axle. The gap should not exceed 1/8-inch,
see Figure 2.

2.00" MAX.
1/8" MAX.

1.50"

CORRECT INCORRECT
4.00
NO WELD ZONE
FIG. 2
FIG. 1

The welding rods should conform to AWS (American

Welding Society), grade E-7018 (Oven-Dried) or compara-
ble. Recommended rod size is 5/32” at voltage and amper-
age recommended by the electrode manufacturer. For
maximum strength, a three-pass weld should be used.

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WELDING METHODS
Table 1 lists four methods which may be used to weld
NO TACK (1) TACK WELD
hardware to trailer axles. The weld tensile strength must WELDS AT EACH SIDE
THE ENDS
be 70,000 psi per AWS specifications.

TABLE 1

METHOD FOR WELDING

CARBON AND LOW AWS ELECTRODE AWS
ALLOY STEELS CLASSIFICATION SPEC
Shielded Metal Arc E70XX A5.1
(stick electrodes) A5.5
Gas Metal Arc ER70S-X A5.18 FIG. 3
(MIG, solid wire feed)
Gas Tungsten Arc ER70-X A5.18 NOTE FOR MAXIMUM STRENGTH, A THREE-PASS WELD
(TIG) has a non-consumable SHOULD BE USED. ALL FINAL WELDS SHOULD BE MADE IN ONE
electrode, use stick electrodes
CONTINUOUS PASS. THE ARC SHOULD NOT BE BROKEN AT THE
Flux Cored Arc E70T-X A5.20
(self shielded wire) END OF EACH PASS AND THE CORNERS SHOULD BE WRAPPED.

NOTE TO PREVENT AXLE DISTORTION:

WELDING HARDWARE TO AXLE
• ALTERNATE WELDS BETWEEN THE FRONT AND REAR OF
THE BRACKET.
CAUTION • ALTERNATE WELDS BETWEEN THE ROADSIDE BRACKET
• THEAXLE INSTALLERSHOULDOBTAINANDREAD A COPY OF THE AND CURBSIDE BRACKET.
SUSPENSIONMANUFACTURER’S INSTALLATIONINSTRUCTIONS.
• ONLY USE OPERATORS CERTIFIED BY AWS (THE AMERICAN WELDING This welding recommendation pertains to all Spicer
SOCIETY). tubular axles. Unapproved variation from the procedures
• THE AXLE ANDITSMATING BRACKETSMUST BE AT 60°F MINIMUMAND
FREE OFMOISTURE , DIRT, SCALE, PAINTANDGREASE . DO NOT BRING
listed will void the Axle Warranty and could result in an
IN AXLES FROMNON-HEATED STORAGE ANDWELD WHILECOLD. unsafe weld. In the case of an uncertain circumstance, the
• PREVENTBEARING DAMAGE. WHENGROUNDINGWELDINGEQUIPMENT Spicer Trailer Products Engineering Department should
TO THE AXLE, PREVENT CURRENT FROM PASSINGTHROUGH THEWHEEL
be contacted.
BEARINGS.

TACK WELDING BRACKET TO AXLE:

NOTE DO NOT PLACE TACK WELDS AT WHAT WILL BE THE

ENDS OF THE FINAL WELD.

NOTE TACK WELD ALL BRACKETS ONTO AXLE BEFORE

FUSING THESE TACK WELDS INTO FINAL WELDS.

NOTE THOROUGHLY CLEAN THE SLAG FROM THE TACK

WELDS BEFORE APPLYING THE FINAL WELDS.

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WHEEL BEARINGS

OIL LUBRICATED WHEEL ENDS*: GREASE LUBRICATED WHEEL ENDS:

*Note: For unitized wheel ends, please refer to
the Spicer RM™ Service Manual Grease should be replaced if contaminated or if the hub
Oil should be changed at least every 100,000 miles or once is removed from the spindle. For normal service, grease
a year, and whenever the seals or brakes are replaced. Oil should be replaced annually or at 100,000 mile intervals.
level should be inspected every 1,000 miles. Always allow For severe or off-highway service, grease should be
a few minutes, after adding oil or after vehicle operation, replaced semi-annually or at 30,000 mile intervals.
for the oil to settle when establishing the required oil level. Bearings should be packed by machine or by hand meth-
ods to ensure grease is forced into the cavities between
SUGGESTED OIL PROPERTIES the rollers, cone and cage of the bearings. The wheel and
Petroleum based or synthetic oils that meet or exceed
hub cap should be filled with grease when reassembling.
military specification MIL-L-2105D and API (American
Petroleum Institute) service classification GL-1 through SUGGESTED GREASE PROPERTIES
GL-5 are the minimum requirements for use in Spicer The table below indicates the NLGI† Grade of grease rec-
Trailer Axles. ommended under normal loading and operating speeds of
100-1000 rpm. For heavy loads and low speeds, the advice
The table below indicates which SAE viscosities are recom-
of a lubrication engineer should be obtained.
mended for various temperature ranges the vehicle will
encounter.
GREASE GUIDE
SAE 140
SOAP BASED NLGI
SAE 85W-140 GREASE GREASE
TYPE GRADE NOTE
SAE 90
Calcium Complex #1 Use in extreme cold
SAE 80W-140 Lithium Complex #2 Normally Preferred
SAE 80W
SEMI FLUID NLGI
SAE 75W-140
SYNTHETIC GREASE
SAE 75W-90 GREASE TYPE GRADE NOTE
Mobilith 007 #00 Normally Preferred
SAE 75W or equivalent
†
C -40 -26 -12 0 +4 +15 +27 +38 C National Lubricating Grease Institute

F -40 -15 -10 +32 +40 +60 +80 +100 F

WARNING DO NOT MIX LITHIUM, CALCIUM, SODIUM
AMBIENT AIR TEMPERATURE
OR BARIUM COMPLEX GREASES DUE TO POSSIBLE COMPATIBILITY
PROBLEMS. WHEN CHANGING FROM ONE TYPE OF GREASE TO
WARNING DO NOT MIX MOTOR OIL WITH EP GEAR OIL, ANOTHER, IT IS NECESSARY TO ENSURETHAT ALL THE OLD GREASE
DUE TO POSSIBLE COMPATIBILITY PROBLEMS. HAS BEEN REMOVED.

WARNING FAILURE TO CORRECTLY LUBRICATE BEARINGS - AND TO MAINTAIN PROPER LUBRICATION - COULD CAUSE BEARING
AND AXLE SPINDLE DAMAGE, WHICH COULD RESULT IN THE WHEEL LOCKING UP OR COMING OFF DURING VEHICLE OPERATION.

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WHEEL BEARING ADJUSTMENT PROCEDURE WARNING FAILURE TO TORQUE THE OUTER LOCK NUT
DOUBLE NUT ARRANGEMENT PROPERLY COULD CAUSE THE WHEEL TO COME OFF DURING VEHI-
1. Prior to installing any wheel-end fasteners, make sure CLE OPERATION, WHICH COULD RESULT INPROPERTY DAMAGE,
the spindle area is free of dirt and debris. As well, make SERIOUS INJURY OR DEATH.

sure all nuts and washers are free of dirt. Clean mating WARNING IF AN EXTERNAL TANG OR SETSCREW TYPE
surfaces are important for proper wheel end assembly. LOCK WASHER IS USED, IT IS IMPORTANT TO REMEMBER TO BEND
THE TABS OVER THE OUTER LOCK NUT, OR TO INSTALL THE SET
2. After properly installing the bearing cones and wheel
SCREWS IN THE LOCK WASHER, AFTER THE OUTER NUT HAS BEEN
end seal onto the spindle, and sliding the wheel end onto
TORQUED. FAILURE TO FOLLOW THIS PROCEDURE COULD RESULT
the spindle, tighten the inner spindle nut with a torque
IN PROPERTY DAMAGE, SERIOUS INJURY OR DEATH.
wrench to 150-200 ft. lbs. to set the bearings and wheel
end. Caution: Do not use an air impact wrench to tighten Periodic inspection and regular replacement of lubricant
this nut! is important to obtaining maximum bearing life. Always
inspect bearing for damage prior to installation. When
3. Loosen this inner nut to allow the brake drum to rotate
installing wheel bearings it is important to ensure both
freely. Backing off one (1) full turn is recommended.
the inside of the wheel hub and bearings are clean. Spicer
4. Retighten the inner spindle nut to 50 ft. lbs. by hand recommends that seals be replaced when wheels are
using a torque wrench to position the bearings for final removed. Extreme care should be taken when reinstalling
adjustment. Caution: Do not use an air impact wrench wheels to prevent damage to the seals.
to tighten this nut!

5. Back the inner spindle nut off 1/4 turn.

6. Install the retaining fastener or fasteners onto the spin-

dle according to the fastener used. If washers are used, be
sure they are facing in the right direction and are clean.
Make sure any washers with dowels fit properly into the
mating holes.

7. Install the outer spindle nut. Using a torque wrench,

tighten this nut to 300-400 ft.-lbs. Resulting end play
should be .001" to .005".

Note: If end play is not .001" to .005", disassemble and repeat this
procedure.

SPECIFICATIONS

AXLE LOCATION SPICER BEARING SPICER BEARING INDUSTRY STD. INDUSTRY STD. WIDTH OUTSIDE INSIDE
MODEL CUP NUMBER CONE NUMBER CUP NUMBER CUP NUMBER DIAMETER BORE
D22 Inner M10HA102 M10HB100 HM218210 HM218248 1.575” 5.787” 3.542”
D22 Outer M10HA103 M10HB101 HM212011 HM212049 1.500” 4.813” 2.625”
P22 Inner/Outer M10HA116 M10HB119 HM518410 HM518445 1.563” 6.000” 3.501”

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RECOMMENDED BRAKE ADJUSTMENT PROCEDURE

CAUTION WHEN AUTOMATIC BRAKE ADJUSTERS ARE

CAUTION FAILURE TO PROPERLY ADJUST BRAKES COULD USED, IT IS NECESSARY TO FOLLOW THE INSTALLATION AND
CAUSE REDUCED BRAKING PERFORMANCE.
ADJUSTMENT PROCEDURERECOMMENDED BY THE AUTOMATIC
A. Grease cam bracket and spider fittings prior to brake BRAKE ADJUSTER MANUFACTURER. FAILURE TO FOLLOW THE REC-
shoe installation. OMMENDED PROCEDURE COULD RESULT IN IMPROPER OPERATION
OF THE AUTOMATIC SLACK ADJUSTER, RESULTING IN REDUCED
WARNING CARE MUST BE EXERCISED TO PREVENT BRAKE PERFORMANCE OR PREMATURE LINING WEAR.
GREASE FROM COMING IN CONTACT WITH BRAKE LININGS WHICH
3. For burnished brakes, apply pressure to brakes and
COULD CAUSE A REDUCTION IN BRAKING PERFORMANCE.
REDUCED BRAKING PERFORMANCE COULD CAUSE AN ACCIDENT check for lining to drum contact. Using a .010" feeler
RESULTING IN SERIOUS INJURY OR DEATH. gauge, the lining to drum contact should range from 60
to 100% during brake application.
B. Adjust the slack adjuster until the brake lining comes
into contact with the brake drum. 4. Check to ensure the lining is inside the drum during
application. More than .060" protruding out of the
1. For green brakes* there should be a slight amount of
drum is not recommended.
wheel drag at initial adjustment to compensate for any
lining irregularities (high spots, etc.). D. Rapidly release air pressure from the brakes and
*A “green brake” is an unground, unburnished brake. There is a confirm that all brakes quickly release to the normal
break-in period where the lining will seat into a normal conact
pattern with the drum. relaxed position.
2. For burnished or broken-in brakes, back off the
slack adjuster to achieve .010" clearance between WARNING
drum and shoe. • BRAKELININGSCONTAINNON -ASBESTOSFIBERS
• BREATHINGBRAKEDUS T MAY BEHAZARDOUS TO YOUR HEALTHAND MAY
C. Apply brakes using normal truck operating pressure. CAUSE SERIOUSRESPIRATORY OR OTHERBODILY HARM.
• AVOIDCREATINGDUS T.
(Average line pressure should be 90 psi.) • DON’T REMOVEBRAKEDRUM WITHOUTPROPER PROTECTIVE EQUIPMENT.
• DO NOT WORKON LININGSWITHOUTPROPERPR OTECTIVEEQUIPMENT.
• DO NOT REPLACELININGSWITHOUTPROPERPR OTECTIVE EQUIPMENT.
WARNING USE OF AIR PRESSURE IN EXCESS OF 130 PSI • DON’T ATTEMPT TO SAND, GRIND, CHISEL, FILE, HAMMERORALTERBRAKE
COULD RESULT IN FAILURE OF THE AIR CHAMBER OR SPRING BRAKE LININGSINANY MANNER WITHOUTPROPERPR OTECTIVE EQUIPMENT.
• FOLLOW O.S.H.A. STANDARDS FOR PROPER PROTECTIVE DEVICES TO BE
CHAMBER, WHICH COULD RESULT IN SERIOUS INJURY OR DEATH.
USED WHEN WORKING WITHBRAKEMATERIALS .

1. Check the amount of push rod travel. Maximum

should not exceed 2.5" for Type 30 Long Stroke WARNING IT IS CRITICAL THAT ANY BRAKE DRUM
chambers, 2" for Type 30 chambers and 1 3/4" for REACHING MAXIMUM WEAR DIAMETER, AS CAST ON DRUM, BY
Type 24 chambers. TURNING, GRINDING, AND/OR WEARING BE CONSIDERED UNSAFE
AND IMMEDIATELY REPLACED. IN ORDER TO AVOID SERIOUS INJURY
a. Optimum pushrod travel on a green brake* OR DEATH, ANY BRAKE DRUM EXCEEDING THIS DIMENSION IS
should be under 2". CONSIDERED A SAFETY HAZARD. IF IN DOUBT, CONTACT THE
BRAKE DRUM MANUFACTURER.
b. Optimum pushrod travel on a burnished or
broken-in brake should be under 1 3/4".

2. Check the angle between the slack adjuster and push

rod. With the brakes applied, the angle should be 90
degrees +/- 5 degrees.

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BRAKE DISASSEMBLY/ASSEMBLY

BRAKE DISASSEMBLY: 6" BRAKE

1. Release brakes and back off slack adjuster. ADJUSTER
(A-A HOLES)

2. Remove slack adjuster lock ring and slack adjuster. 5 1/2"

5" BRAKE BRAKE ADJUSTER
3. Remove brake drum. ADJUSTER (A-B HOLES)
(B-B HOLES)

4. Remove anchor pins and brake shoes.

CAUTION EXCESSIVE POUNDING ON ANCHOR PINS

OR CAM ROLLER PINS TO REMOVE OR INSTALL THEM CAN DAMAGE
THE PINSAND CAUSE MISALIGNMENT OF THE BRAKE SPIDERS AND
FIG. 4
BRAKE SHOES. THE USE OF A SOFT HAMMER OR BRASS DRIFT
IS RECOMMENDED TO REMOVE OR INSTALL THE ANCHOR PINS WARNING WHEN REASSEMBLING BRAKES, SPICER
IF NECESSARY. TRAILER PRODUCTS RECOMMENDS THAT THE BRAKE RETURN
SPRINGS BE REPLACED WITH NEW SPRINGS TO ASSURE PROPER
5. Remove brake return springs.
OPERATION OF THE BRAKE.

6. Remove camshaft lock ring, spacer washer, and cam

4. Install the brake return springs on the brake shoes.
shaft.
5. Position brake shoes on the spider and insert the
7. Remove cam roller and shaft (in the case of the cast
anchor pins.
shoe, remove roller shaft set screw and roller assembly)
and anchor pin bushing from shoes. 6. If air brake chambers are replaced, the correct mounting
holes must be used to correspond to brake adjuster length
8. Remove anchor pin bushings, camshaft bushing and
(See Fig.4).
seals from spider.
7. Connect slack adjuster to brake chamber push rod.
BRAKE ASSEMBLY
1. Install new anchor pin bushings, camshaft bushing 8. Adjust brakes as outlined in brake adjustment
and camshaft seals into the spider. procedures.

NOTE TO ENSURE BRAKES MEET F.M.V.S.S. 121 PER-

WARNING WHEN INSTALLING CAMSHAFT SEALS,
FORMANCE REQUIREMENTS, SPICER TRAILER PRODUCTS RECOM-
THE SEAL ON THE SLACK ADJUSTER SIDE SHOULD BE INSTALLED
MENDS THAT ONLY ORIGINAL EQUIPMENT BRAKE COMPONENTS BE
WITH SEAL FACING INTO SPIDER. THIS ALLOWS GREASE TO PURGE
USED.
OUTSIDE THE BRAKE ASSEMBLY WHEN GREASING THE CAMSHAFT
BUSHING. FAILURE TO FOLLOW THISPROCEDURE COULD CAUSE Any questions or comments on the above procedure should
GREASE TO COME INTO CONTACT WITH BRAKE LININGS, CAUSING be directed to the Spicer Trailer Engineering Department.
BRAKE FAILURE.

2. Install cam roller assemblies onto the brake shoes.

3. Install the camshaft into the spider. Install spacer wash-

er and lock ring on cam before sliding the cam through
the camshaft support bracket. Install the slack adjuster
and the lock ring.

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D22/P22 Manual pdf 9/23/97 2:51 PM Page 13

WELDING ABS WHEEL SPEED SENSOR BLOCKS

12 TONEOR
11 1 EXCITER RING

WHEEL HUB
10 2 SPEED SENSOR
MOUNTING BLOCK
MOUNT SENSOR
BLOCK IN THIS
RANGE BLOCK BORE
9 3

SENSOR BLOCK AXLE

WELD BEAD
(ALONGBOTHSIDES )

FIG. 5 FIG. 6

SENSOR BLOCK

SPRING CLIP
.125” TO .187”
SPRING CLIP TAB MOUNTING BLOCK
EXCITER RING

SPEED SENSOR WELD BEAD HUB

FIG. 7 FIG. 8

Correct installation of the speed sensor blocks is extremely 3. Remove the hub and bearing assembly and brake
important for proper operation of the AntiLock system. assembly from the axle spindle. Clean all oil or grease
Use electric welding equipment only to install the blocks. from the axle spindle.

1. Properly support the trailer axle using jack stands. Be 4. Install the sensor block on the fixture tool and attach
sure to provide proper clearance to be able to weld the the fixture tool to the axle spindle.
sensor block on the axle near the tone (exciter) ring.
5. Adjust the position of the fixture tool as necessary to
2. With the hub in place, locate the sensor mounting align the sensor block to the scribed position in Step 2 and
block at the 9 or 3 o’clock position on the axle spindle to tighten in place.
lessen the effect from axle flexure due to loading. See
6. Weld the sensor block to the spindle axle. Weld along
Figure 5. Manually hold the sensor block in place and
both sides of the block. See Fig. 6.
scribe its location on the axle spindle. See Fig. 6 & 8.
7. Remove the fixture tool and let the sensor block cool.
Important: the distance of the sensor block from the face
After cool down, install the sensor spring clip and sensor
of the tone ring “teeth” must be between .125” to .187”.
as illustrated in Fig. 7.
See Fig. 8.

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D22/P22 Manual pdf 9/23/97 2:51 PM Page 14

TORQUE SPECIFICATIONS

FASTENER SPECIFICATIONS

PART NAME SIZE & THREAD TORQUE

Spindle Outer Nut 2 5/8 - 16 UN 250-400 ft.-lbs.
Cam Brackets 5/16 - 18 Self-tapping 175-225 in.-lbs.
Air Chamber 5/8 - 11 UNC 100-115 ft.-lbs.
Mounting Bolts
Dust Shield Self-tapping 180-200 in.-lbs.
Mounting
Brake Lining Brass Screw 100-150 in.-lbs.
To Table 3/8 - 24 UNF
Hub Cap to Hub 1/14 - 20 UNC 96-144 in.-lbs.
5/16 - 18 UNC 144-216 in.-lbs.
Wheel Stud 3/4 - 16 UNF 175-200 ft.-lbs.
Backnut 7/8 - 14 UNF 180-250 ft.-lbs.
1 - 14 UNF 200-300 ft.-lbs.
Haldex ABA 7/16 - 14 UN 40-50 ft.-lbs.
Control Arm Nut

SUGGESTED PREVENTATIVE MAINTENANCE

EVERY 1,000 MILES: 100,000 MILES, ONCE A YEAR, OR AT BRAKE RELINE:

Check oil level in wheel hub and inspect wheel Replace wheel bearing lubricating oil (if applicable).
for leaks. Check brake air chambers and slack adjusters.
Inspect brake rollers, roller shafts, anchor pins and
15,000 MILES OR MINIMUM OF TWICE A YEAR:
bushings and replace if necessary.
Check brake adjustment.
Lubricate brake adjusters.
Repack wheel bearings (grease application).
Check shoes for bent shoe ribs, cracks in shoe table
25,000 TO 30,000 MILES welds or ribs, and elongated rivet holes. Replace shoes
Check lining wear and estimate replacement time. if any of these conditions exist.
Replace with new shoes or reline when thickness of
lining is 1/4" at thinnest point, or 1/16" above rivet or
bolt head. Replace any cracked, broken or oil-soaked
linings immediately.
Inspect camshaft, camshaft spider bushing, and
camshaft support bracket bushing for any signs of wear.
Lubricate camshaft bushings.
Inspect brake drums for heat checks, grooves, hot
spots, glazing, cracks, and out of round.

12
D22/P22 Manual pdf 9/23/97 2:51 PM Page 15

NOTES

13
The Roadranger® System is an unbeatable combination of the
best products from Eaton and Dana, partnering to provide you
the most advanced, most trouble-free drivetrain in the industry.
And it's backed by the Roadrangers -- the most experienced,
most expert, most accessible drivetrain consultants in the
business.

For spec'ing or service assistance,call 1-800-826-HELP (4357),

24 hours a day, 7 days a week, (Mexico: 8-332-1515) for more
time on the road. Or visit our web site at http://roadranger.com.

National Institute for

STPD-1010
08/97 POD
Printed in U.S.A.

Copyright Dana Corporation, 2001. DANA CORPORATION hereby

grants its customers, vendors, or distributors permission to freely
copy, reproduce and/or distribute this document in printed format.
THIS INFORMATION IS NOT INTENDED FOR SALE OR RE-SALE,
AND THIS NOTICE MUST REMAIN ON ALL COPIES.