Illustrated Parts List

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1 Spicer Tandem Axles Illustrated Parts List AXIP0085a January 1994 Single Reduction, Dual Range, & Double Reduction Addendum 461, 462, 463, 521, ,000-65,000 lbs

2

3 Introduction Single Reduction w/wheel Differential Lock - Forward Axle Contents DD461-P DD521-P DD581-P Differential Lockout Assembly Pinion Bearing Spacers Single Reduction w/wheel Differential Lock - Rear Axle Shift System Appendix RD461 RD521 RD Piston Air Shift Unit Carrier Exchange Assemblies Drive Pinion and Gear Set Axle Shaft Chart The following models are represented in this publication Single Reduction Models w/wheel Differential Lock Forward Axle Rear Axle Axle Capacity Gear Size DD-461-P RD ,000 lbs 18" Gear DD-521-P RD ,000 lbs 18" Gear DD-581-P RD ,000 lbs 18" Gear Model Identification Using Model Designation to Identify Axle Components The Axle Model Identification number contains information that is important to understand when purchasing service parts or new components. The Model identification number provides important vehicle, capacity and application information and model features. Use this guideline to understand your Axle Model Identification. If you need assistance, contact your Dana representative. DD -461-P Gearing D - Forward Tandem Axle R - Rear Tandem Axle S - Single Reduction T - Dual Range P - Double Reduction C - Controlled Traction D - Single Reduction with Wheel Differential Lock A - Single Reduction with In-Axle Speed Sensors (IASS) Lube Pump P = Standard (P) = Optional Design Level Capacity (x 1000) Example: 46 = 46,000 Example: DS = Forward Tandem/Single Reduction or RS = Rear Tandem/Single Reduction 1

4 Single Reduction w/wheel Differential Lock Forward Axle DIFFERENTIAL & RING GEAR RH LH

5 Single Reduction w/wheel Differential Lock Forward Axle INTER-AXLE DIFFERENTIAL ASSEMBLY DD461-P DD521-P DD581-P THESE PARTS ARE MOUNTED IN POWER DIVIDER COVER LUBE PUMP

6 Single Reduction w/wheel Differential Lock Forward Axle Item Description Qty Order Part No. Notes BASIC OVERHAUL KIT Contents Identified with * 1 DIFF CARRIER & BRG CAP KIT Includes Items: 2-5, Carrier Casting No NSS cover plate & RTV 2 Bearing Cap Screw Flat Washer Lockwire Dowel Bushing Brg Cap Adjuster Lock (RH) Capscrew Brg Cap Ajuster Lock (LH) Cotter Pin (LH) Expansion Plug (Upper) * 11 Expansion Plug (Lower) * 12 Filler Plug /4" 13 SHIFT FORK SHAFT ASSY Includes O-Ring Shaft# NSS 14 Carrier Cover Dowel Pin Shift Unit Mounting Stud Shift Fork Seal & Spring Assy Flat Washer Stud Nut Shift Fork & Roller Assy Shift Unit Assy 1 See: Piston Air Shift Unit, Pg Sliding Clutch Diff Brg Adjuster (RH) Diff Brg Cup (RH) * 24 Diff Brg Cone (RH) * 25 Diff Brg Adjuster (LH) Diff Brg Cup (LH) * 27 Diff Brg Cone (LH) * WHEEL DIFF CASE KITS 1 Ratios Includes Items Ratios Diff Case (Plain Half) NSS NSS 29 Diff Case (Flanged Half) NSS NSS Ratios NSS Ratios Diff Case Capscrew Ring Gear & Drive Pinion Set 1 See: Gear & Pinion Listing, Pg Bolt In kit Nut In kit WHEEL DIFF SIDE GEAR KIT Includes Items WHEEL DIFF KIT w/o SIDE GEARS Includes Items Diff Side Gear - 36 Involute Side Gear Thrust Washer * 36 Side Pinion Side Pinion Thrust Washer * 38 Spider

7 Single Reduction w/wheel Differential Lock Forward Axle Item Description Qty Order Part No. Notes 39 Pinion Pilot Brg * 40 Pinion Brg Cone * 41 Pinion Brg Spacer Washer * 42 Pinion Brg Spacer AR See: Pinion Brg Spacer Chart, Pg 7 43 Pinion Brg Cup * 44 PINION BRG CAGE & CUP ASSY Includes Item 43 Cage # NSS 45 Pinion Brg Cage Shim AR.003" 45461*.005" 62829*.010" 45462*.020" 62830*.030" 45463* 46 Lockwasher Bearing Cage Capscrew Pinion Helical Gear Outer Pinion Support Brg & Race Assy * 50 Pinion Shaft End Nut Pinion Nut Spring Pin Outer Pinion Brg Snap Ring * 53 Output Shaft Nut Output Shaft Washer Rear Brg Retaining Washer AXLE HSG COVER ASSY Includes Items Cover# NSS 57 Output Shaft Oil Seal * Microlip Design 58 Bearing Snap Ring * 59 Output Shaft Brg Assy * Inner Race NSS Outer Race NSS 60 Magnetic Filler Plug " Filler Plug /2" 61 OUTPUT SHAFT KIT Includes Items 53-54, 62-63, 67 Shaft# NSS 41 SPL, 2.100" dia. 62 Output Shaft Bushing * 63 Output Shaft O-Ring * 64 Output Shaft Brg Cup * 65 Output Shaft Brg Cone * 66 Output Shaft Side Gear Side Gear Snap Ring * 68 Output Shaft Compression Spring Output Shaft Thrust Bearing INTER-AXLE DIFF ASSY Includes Items INTER-AXLE DIFF CASE KIT Includes Items Case Half NSS 72 Case Bolt Case Nut Side Pinion Side Pinion Thrust Washer * DD461-P DD521-P DD581-P 5

8 Single Reduction w/wheel Differential Lock Forward Axle Item Description Qty Order Part No. Notes 77 Helical Side Gear Snap Ring * 78 Helical Side Gear & Bushing Assy Includes Item 79 Gear# NSS 79 Helical Side Gear Bushing * 80 Helical Side Gear Thrust Washer * 81 Helical Side Gear D Washer * 82 Lockout Sliding Clutch INPUT SHAFT KIT Includes Item 91 Shaft# NSS, 46 SPL, 2.350" dia. 84 Input Shaft Brg Cone * 85 Input Shaft Brg Cup * 86 Input Bearing Cover Shim AR.003" 78918*.005" 78919*.010" 78920*.020" * 87 INPUT BRG COVER ASSY Includes Items 85 & 89 Cover# NSS 88 Bearing Cover Capscrew Input Shaft Oil Seal * Microlip Design 90 Input Shaft Nut Washer * 91 Input Shaft Nut PDU CARRIER COVER ASSY Includes Items Cover# NSS 93 Carrier Cover Capscrew Short Long Socket Head 94 Lockwasher Pipe Plug Expansion Plug Magnetic Filter Screen * LUBE PUMP REPLACEMENT KIT Includes Items Pump Gear & Shaft Assy Cover O-Ring * 100 Lube Pump Cover Lockwasher Cover Capscrew Cover Dowel Pin Pump Drive Gear Drive Gear Locknut AIR-OPER. LOCKOUT ASSY See: Differential Lockout Assy, Pg SHIFT FORK & PUSH ROD ASSY RTV - Sealant AR * 6

9 Single Reduction w/wheel Differential Lock Differential Lockout Assembly DD461-P DD521-P DD581-P Item Part Name Qty Order Part No. Remarks 1 Capscrew Lockwasher Mounting Bracket Piston Housing Locknut Piston Piston O-Ring Shoulder Washer Compression Spring Shift Fork & Push Rod Assy RTV Sealant AR Kits And Assemblies Air-Operated Lockout Assy Includes Items 1-10 Air Lockout Repair Kit Includes Items 5-9 Piston Kit Includes Items 3-8 Pinion Bearing Spacers Pinion Bearing Spacer size is equal to thickness in inches. The most commonly used spacers are indicated with an asterix*. Size" Part# Size" Part# Size" Part# Size" Part# * * * * * * * * * * * * * * * * Lockout Assembly Pinion Bearing Spacers

10 Single Reduction w/wheel Differential Lock Rear Axle RH LH Item Description Qty Order Part No. Notes BASIC OVERHAUL KIT Contents Identified with * 1 DIFF CARRIER & BRG CAP KIT Includes Items: 2-5, Carrier Casting No R -NSS cover plate & RTV 2 Bearing Cap Screw Flat Washer Lockwire Dowel Bushing Brg Cap Adjuster Lock (RH) Cotter Pin (RH) Brg Cap Ajuster Lock (LH) Adjuster Lock Capscrew Dowel Bushing -Adjuster Lock Expansion Plug (Upper) * 12 Expansion Plug (Lower) * 13 SHIFT FORK SHAFT ASSY Includes O-Ring Shaft# NSS 14 Stud Nut Flat Washer

11 Single Reduction w/wheel Differential Lock Rear Axle Item Description Qty Order Part No. Notes 16 Shift Fork Seal & Spring Assy * 17 Shift Fork Mounting Stud Shift Fork & Roller Assy Shift Unit Assy 1 See: Piston Air Shift Unit, Pg Diff Brg Adjuster (RH) Diff Brg Cup (RH) * 22 Diff Brg Cone (RH) * 23 Sliding Clutch Diff Brg Adjuster (LH) Diff Brg Cup (LH) * 26 Diff Brg Cone (LH) * 27 Ring Gear & Drive Pinion Set 1 See: Gear & Pinion Listing, Pg 12 WHEEL DIFF CASE KITS 1 Includes Items Ratios Ratios Diff Case (Plain Half) NSS NSS 29 Diff Case (Flanged Half) NSS NSS Ratios NSS Ratios Diff Case Capscrew Bolt In kit Nut In kit WHEEL DIFF SIDE GEAR KIT Includes Items WHEEL DIFF KIT w/o SIDE GEARS Includes Items Diff Side Gear - 36 Involute Side Gear Thrust Washer * 35 Side Pinion Side Pinion Thrust Washer * 37 Spider Pinion Pilot Brg * 39 Pinion Brg Cone (Inner) * 40 Pinion Brg Spacer Washer * 41 Pinion Brg Spacer AR See: Pinion Brg Spacer Chart, Pg 7 42 Pinion Brg Cup (Inner) * 43 PINION BRG CAGE & CUP ASSY Includes Items 42 & 45 Cage# NSS 44 Pinion Brg Cage Shim AR.003" 67920*.005" 67921*.010" 67922*.020" 67923*.030" 67924* 45 Pinion Brg Cup (Outer) * 46 Brg Cage Capscrew Pinion Brg Cone (Outer) * 48 Pinion Oil Seal * Microlip Design 49 Flat Washer Pinion Nut RTV Sealant AR * 9 RD461 RD521 RD581

12 Shift System Piston Air Shift Unit

13 Shift System Piston Air Shift Unit Item Description Qty Order Part No. Notes 1 COVER ASSY 1 DD Models - cover# NSS Includes Item 2 RD Models - cover# NSS Cover Bearing Screw & Washer Assy Self-Tapping 4 Cover Gasket Cover Plug Actuating Lever Pin Clevis Pin ACTUATING LEVER, PIN & BLOCK ASSY 1 DD Models RD Models Shift Hsg Cover Seal Ring Cover Bolt Lock Nut Lock Nut Washer Piston Felt Piston Oiler (strip) Piston O-Ring Grommet Push Rod Compression Spring Piston Stop HOUSING ASSY 1 Includes Items 3 & 23 DD Models RD Models Housing Bearing Switch Nylon Washer Wiring Harness Metri-pack 150 series Metri-pack 280 series (Mack Only) Weather Pack Kits And Assemblies Piston Air Shift Unit DD Models Piston Air Shift Unit & Wiring Harness Incls Items 1-25 & Wiring Harness Piston Air Shift Unit & Wiring Harness Incls Items 1-25 & Wiring Harness Piston Air Shift Unit & Wiring Harness Incls Items 1-25 & Wiring Harness RD Models Piston Air Shift Unit & Wiring Harness Incls Items 1-25 & Wiring Harness Piston Air Shift Unit & Wiring Harness Incls Items 1-25 & Wiring Harness Piston Air Shift Unit & Wiring Harness Incls Items 1-25 & Wiring Harness

14 Appendix Drive Pinion and Gear Set Single Reduction - 18" Gearing Forward Axle Models: DD461-P, DD521-P, DD581-P Rear Axle Models: RD461, RD521, RD581 Ratios Gear Set Gear (NSS) Pinion (NSS) Gear Set Gear (NSS) Pinion (NSS) 41,2.100" Dia. 41,2.100" Dia (39) (11) (39) (11) (37) (10) (37) (10) (39) (10) (39) (10) (37) (9) (37) (9) (39) (9) (39) (9) (41) (9) (41) (9) (39) (8) (39) (8) (37) (7) (37) (7) (38) (7) (38) (7) (37) (6) (37) (6) (39) (6) (39) (6) (40) (6) (40) (6) Carrier Exchange Assemblies These assemblies are complete, less input yoke and shift units. Single Reduction w/differential Lock Gear Ratio DD461-P RD461 DD521-P RD Involute DD581-P RD

15 Appendix Axle Shaft Chart Body Shaft Spline Flange Flange Part No. Qty Spline O.D. Length Length O.D. Holes OEM " (.948) TPR 4,6,7,9,11 1 = Ford " (.948) TPR 4,6,7,9,11 2 = GMC " (.948) TPR 6 3 = Freightliner " (.948) TPR 6 4 = Mack " (.948) TPR 5,6,7,9 5 = Peterbilt " (.948) TPR 5,6,7,9 6 = Kenworth " (.948) TPR 7,9 7 = Volvo White " (.948) TPR 7,9 8 = Marmon " (.635) STR 5,6 9 = Western Star " (.635) STR 5,6 10 = Navistar " (.948) TPR 1 11 = Crane Carrier " (.948) TPR " (.773) STR " (.773) STR " (.773) STR " (.773) STR " (.948) TPR 4,5,7,8,9, " (.948) TPR 4,5,7,8,9, " (.635) STR 3, " (.635) STR 3,5 Axle Shaft Chart Gear & Pinion Set 13 Differential Carrier Assemblies

16 For spec ing or service assistance, call or visit our website at Dana Commercial Vehicle Products Group 3939 Technology Drive Maumee, Ohio, USA All applications must be approved by the Application Engineering Department. Specifications and/or design are subject to change without notice or obligation. Printed in USA AXIP-0085a 01/94

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