NEW REDESIGNED 40K TANDEM CARRIERS SERVICE/TECHNICAL DATE: 24/2/2010

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1 DA NEW REDESIGNED 40K TANDEM CARRIERS SERVICE/TECHNICAL DATE: 24/2/2010 TO: All Service & Parts Departments Affected Models: All D344, 404, 405, DST40, 41, DSP40, 41, DSH40, DSH44 (Includes Diff Lock and Pump option models) Dana has engineered in a significant product upgrade to the current 40K tandem axles. At the core of these product enhancements is the incorporation of Dana s patented and proven On Demand lube pump. This innovative lubrication system operates primarily during spinout situations. The remaining 99+% of the time, the pump is idle and ready to be activated instantaneously, in forward or reverse. When compared to competitive axles that continuously operate a lube pump, this efficiency upgrade saves up to 2HP and also decreases oil sump temperature by as much as 20 F. The wasted HP incurred by the other axles relates directly to reduced fuel economy, higher temperatures in the lube sump, and reduced lubricant life. The new design carriers have been optimally designed such that there is now a 12lbs weight savings on pump carrier models. This same system is currently used in the D170 and D190 family of heavy duty tandems. SERVICE PARTS IMPACT: Use of the new design units in Australian Locally built axle assembly s begins February 2010.These design upgrades will impact customers who stock parts or service carriers for the models listed above. Service Carriers are completely interchangeable as units. Individual internal parts and kits are not interchangeable! It is important for customers to beware of the part number changes and in time begin making stocking adjustments accordingly

2 NEW SERVICE PART NUMBERS: Outlined below are the newly released service parts. Dealers should begin to maintain an initial level of these parts going forward as the individual parts between the old and new are not compatible. All parts for the older design carriers will continue to be offered thru service. BASIC OVERHAUL KITS Dana has reduced the complexity of the repaired kits offered on the new carriers by only releasing Basic Overhaul Kits. Two new kits have been released that come complete with all the necessary bearings, shims, washers and RTV sealant required when doing an overhaul. NEW OVERHAUL KIT PART NUMBERS: Basic Overhaul Kit D40K Standard Models [Models: DS344, DS404, DS405, DSP40, DSP41, DST40, DST41, DSH40, DSH44] Basic Overhaul Kit D40K Diff-Lock Models [Models: DD404, DDP40, DDP41, DDH40, DDH44] INPUT SHAFT KITS The new design carriers now utilize a Pump version and a Non Pump version input shaft. The part number of the shaft is stamped on the part for easy identification. Each shaft is sold thru service in a kit form that includes the nut, thrust washer and torque information sheet. NEW INPUT SHAFT KIT PART NUMBERS: Input Shaft Kit - Non Pump (shaft p/n ) Input Shaft Kit - Pump Models (shaft p/n ) LUBE PUMP, OUTPUT SHAFT SIDE GEARS AND LOOSE PARTS Listed below are the balance of the new individual service parts located in the power divider section of the forward carrier. These parts are related directly to the new design lube pump system. Detailed parts and illustrations are shown on pages 4 & 5 of this bulletin. IMPORTANT NOTE: The output shaft side gears are designed for use with specific input shafts, i.e. pump design vs. non pump design. Do not to mix these parts. Use pump model output shafts with pump model input shafts as well as non-pump output shaft side gear with non-pump input shafts! Mixed parts will assemble together, but they are not designed to run together and failure will occur if any parts are mixed.

3 NEW KITS AND LOOSE PART NUMBERS: Lube Pump Parts Kit Pump Models Manifold Parts Kit Pump Models Output Side Gear Pump Models (only sold as kit# ) Filter Screen Assembly Pump Models Collar Lock Pump Models Lube Hose Pump Models Bearing Cone Pump and Non Pump Models Output Side Gear Non Pump Models SERVICE CARRIERS The service carriers are completely interchangeable as a unit but the components inside are not. Knowing the design level being serviced is very important when ordering replacement parts for any repairs or overhauls. New Service Carrier part numbers have been released so customers can take advantage of the new design. The old design service carriers will be phased out. Refer to page 6 of this bulletin for a complete crossover listing of carrier part numbers. Original design service carriers are completely interchangeable with new design carriers! NEW DESIGN FORWARD CARRIER POWER DIVIDER: SERVICE KITS & LOOSE PARTS LISTING: Input Shaft Kit - Non Pump (includes items 11a, plus nut, washer - not shown below) Input Shaft Kit - Pump Models (includes items 11b, plus nut, washer - not shown below) Lube Pump Kit D40P (includes items 7-8, 9b-10) Manifold Parts Kit D40K Pump Models (includes items 2-4, 5b) Manifold Parts Kit D40K Non-Pump Models (includes item 5a) Basic Overhaul Kit D40K Standard Models Basic Overhaul Kit D40K Diff-Lock Models

4 1a Forward Carrier/Cap Standard Models NSS (not offered thru service)*note1 1b Forward Carrier/Cap Diff-Lock Models NSS (not offered thru service)*note Filter Screen Assembly 3a Collar Lock (located on filter end of hose) 3b Clamp (located on manifold end of hose) Lube Hose 5a Seal Manifold Assembly Non Pump Models (sold only in kit# ) 5b Seal Manifold Assembly Pump Models (sold only in kit# ) Bearing Race Bearing Cone Pin 9a Output Side Gear Non Pump Models 9b Output Side Gear Pump Models (only sold in kit# ) Lube Pump (sold as part of kit# ) 11a Input Shaft Non Pump Models (sold only as kit# ) 11b Input Shaft Pump Models (sold only as kit# ) Refer to FIG 1 on page 5 Note 1: The new base Carrier/Cap (item#1) is designed to use NEW style parts only. It is not possible to retrofit or interchange OLD and NEW design parts. Item#1 is not offered as a service part a complete new carrier should be ordered.

5 NEW DESIGN FORWARD CARRIER POWER DIVIDER: FIG 1 Spicer Service Parts Dana Holding Corporation

6 ORIGINAL: design carriers and NEW design carriers are completely interchangeable as a unit! Shown below are replacement reference charts sorted by model family. Print and use as a quick reference guide! DSH = SINGLE SPEED DDH = DIFF LOCK. Current literature can be downloaded from Click on the Literature button or The EXPERT icon, and navigate to the literature needed. Should you have any queries on the above or require further information, please contact Dana Australia on DANA Shane Carey Sales & Service Representative Spicer Driveline Products Encl: DA012010

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