Description

Dana Spicer PS95-9A, PS125-9A, PS140-9A, PSO125-9A, PSO140-9A 2007 Service Manual

If you’re tearing into a Dana Spicer 9- or 10-speed transmission and you don’t have the factory specs in front of you, you’re gambling with someone’s expensive hardware. I’ve seen guys use aftermarket torque charts that were off by 15 ft-lbs and then wonder why the output shaft seal started leaking after 200 miles. This isn’t a guess. This is the 2007 Service Manual from Transmission Technologies Corporation (TTC), straight off the press from Dana Spicer. It covers the PS95-9A, PS125-9A, PS140-9A, PSO125-9A, and PSO140-9A models – all 9-speed variants – plus a few 10-speed models like the PSO100-10S. At 47 pages, it’s not a novel. It’s a workbench reference. And it expects you to read the safety warnings before you start.

Torque Specs and Fluid Capacities – Fixed Numbers, Not Suggestions

Page 5 of this manual gives you the torque values for every critical fastener on these transmissions. I’m talking main case bolts, range case bolts, shift tower bolts, and the clutch housing. These aren’t “tighten until snug” numbers. They’re in foot-pounds, with a tolerance window. If you’re rebuilding a PS125-9A and you don’t have those #4B specs for the 10-speed variations, you’re blind. The manual also lists oil capacities in quarts and tells you which gear lube to use for the OptimLube system (Section II, page 10). Skip that step, and you’ll be pulling the range case apart again in six months.

Disassembly Sequence – From Shift Tower to Countershaft

The manual walks you through the tear-down in the order a professional would do it. Section III covers general disassembly (pages 11-12), then Section IV takes apart the shift tower. Section V handles the remote control assembly. Section VI goes into the range case disassembly – with exploded drawings on pages 15-16. I’ve used aftermarket manuals that skip the step where you have to remove the snap ring before the rear bearing comes off. This one doesn’t. It shows you the snap ring location and the tool you’ll need. Section VII dives into the main case disassembly, including the shift forks, clutch housing, and the Optilube system. The exploded drawings on pages 22-25 are worth the price alone. You can see exactly which washer goes where, because stacking them wrong changes your end-play.

7 Major Systems Covered – What You’ll Find Inside

• General Information (Section I): 9-speed and 10-speed specifications, torque table, driver instructions.
• Maintenance (Section II): Air line piping diagram, filter regulator, lubrication schedule.
• Disassembly (Sections III-VIII): Full breakdown of shift tower, remote control, range case, main case, and countershaft.
• Cleaning & Inspection (Section IX): What to look for on gears, bearings, and synchronizers.
• Reassembly (Sections X-XIII): Main case, range case, remote control, shift tower – in that order.
• Troubleshooting (Section XIV): 4 pages of symptoms and causes – covers everything from hard shifting to gear jump-out.

Why OEM Documentation Beats Generic Reprints

I’ve had a customer bring in a Spicer transmission that another shop had supposedly rebuilt. The shop used a third-party PDF that listed the wrong preload for the countershaft bearings. The transmission sounded like a coffee grinder. This manual was printed by TTC (Transmission Technologies Corporation) for Dana Spicer in August 2007. It’s the same binder that a dealer technician would have used. The torque values, the shim thicknesses, the air line routing – they all come from the engineering department, not from some guy with a scanner. If you’re serious about not pulling this transmission twice, use the Service Manual that has the OEM part number on page 2. Aftermarket reprints? I’ve seen them miss the “use only one gasket under the shift tower” warning on page 3. That’s how you get shift fork binding. This manual has that warning in bold.

For related factory manuals, check the Dana Spicer 1372-A Service Manual – Factory Specs & Rebuild Guide”>, the Dana Spicer ES60-5, CM59, ES60-5A, ES60-5C, ES60-5D Service Manual”>, and the Dana Spicer ES46-5 ES56-5 2002 Service Manual – 40 Pages of Factory Specs”>.

If you need a refresher on how Manual Transmission”> basics work, Wikipedia has a solid overview. The same article also covers the evolution of Manual Transmission”> designs – helpful context if you’re new to heavy-duty gearboxes.

Who Should Use This Manual

Home garage enthusiasts who are rebuilding their own truck transmission will get the most out of it. You need basic mechanical skills – reading a torque wrench, understanding snap ring pliers, having a press for bearing replacement. The manual assumes you can interpret an exploded drawing and follow a sequence. It does not hold your hand. But it does tell you exactly what to torque on page 5 and how to reinstall the range case fork alignment on pages 34-38. If you’re a shop owner, this belongs in your tech’s toolbox. One rebuild using the wrong specs costs more than the price of this PDF.

Does This Manual Cover the 10-Speed Models Too?

Yes, it includes the 10-speed variants PSO100-10S, PSO125-10S, PSO140-10S, and PSO150-10S.

The 10-speed specs are on page 4B, with a separate torque table. The disassembly procedures are nearly identical to the 9-speed, but the shift pattern and some internal parts differ. The manual has separate exploded drawings for the 10-speed main case.

What’s the difference between this OEM manual and a generic aftermarket one?

Aftermarket manuals often omit the safety symbols and the specific warnings about gasket thickness and sealant use. This manual tells you on page 2 that using more than one gasket under the shift tower will cause binding. Aftermarket reprints skip that line. Also, this manual has the OEM part number (SPTS0130807) and the TTC copyright – meaning it’s the exact document that Dana Spicer authorized. Aftermarket copies frequently have blurry exploded drawings or missing page numbers. You’re paying for accuracy.

I’ve been wrenching since before most of you were born. When a transmission leaves my shop, I want it to stay sealed. That means using the right specs from the right source. Access the Factory Manual and keep it on your tablet or print it out. Your transmission – and your wallet – will thank you.