Information ulletin ulletin Type: Service Information Topic: Carrier Design Modifications to Dana 34-44K Tandem Drive xles Spicer xles & rakes I-0210r1 Revised Edition ffected Models: 34,000-44,000 Lb. Family of Tandem Drive xles Effective June 3rd, 2002 the DSP40 (P) Tandem Drive xles, currently used by Peterbilt and Kenworth, will have significant design improvements made to the power divider cover to carrier and carrier to housing flanges. These design improvements will have an impact on service parts as outlined throughout this bulletin. Over the next several months, these design changes will be phased into all other 34-44,000 lb tandem axle models for other customers as well as axles with Lube Pump and Differential-Lock options. ase Models ffected* DSP/RSP40 DSP/RSP41 DS/RS344 DS/RS404 DS/RS405 DS/RS454 DSH/RSH40 DSH/RSH44 DST40** DST41** *These design changes will impact base models with Lube Pump, Differential-Lock and In xle Speed Sensors. *These changes WILL T affect the DSS/RSS40 models. **These design changes WILL T affect RST40, RST41 Dana DSP40 xle with New Design Carrier Mounting Flange and Power Divider Cover. Information pertaining to the specific changes described above can be found in the following sections. Carrier Mounting Flange Design Change Page 2 ffects on Carrier Exchange ssemblies Page 2 Carrier Fastener Change Page 2-3 Power Divider Cover Design Change Page 3 Casting & Service Parts Cross Reference Charts Page 4 Capscrew/Stud Faster Location Chart Page 5
Carrier Mounting Flange Design Change DESIGN CHNGE: The nominal thickness of the carrier to housing flange has been increased on both the forward and rear-rear axles. This change will require the use of new fastener parts. new (45mm) capscrew (P/N 130836) has been released. dditionally, a much thicker boss has been added to the flange at the 12:00 & 6:00 o clock positions. These new thicker flange bosses will require an even longer capscrew (P/N 130837). thicker and larger diameter flat washer (P/N 130877) has also been released as part of this upgrade. The existing stud (P/N 127641) and nut (P/N 127567) will continue to be used. Refer to page 5 for specific washer, capscrew and stud details and locations. New Dana Thick Flange Carriers Require New Longer Style Capscrews at the 12:00 & 6:00 o clock Positions. CRRIER EXCHNGE SSEMLIES ny new Carrier Exchange ssembly produced with the new thick flange carrier will include a carrier-to-housing fastener hardware kit (P/N 512087). The carrier exchange part numbers will not change, as the new design carriers will be implemented for service as they are released in production. TE: ecause of the popularity of the Dana Carrier Exchange program, stock levels of the older design carriers outlined in this bulletin at OEM PDC s and DELERSHIP S are numerous. If you have a vehicle that is originally built with a new style thick flange carrier, it can be serviced with an older style Carrier Exchange ssembly. The repairing dealer must simply make sure to use the correct axle housing hardware parts when installation is done. In this case it will be necessary to use an Old Style housing fastener hardware kit (P/N 511600). Carrier Fastener Change DESIGN CHNGE: New fasteners were released for the thick flange carriers as described above. Shown below are the new fastener parts along with a fastener replacement chart for reference. new xle Housing Hardware kit (P/N: 512087) has been released for use with all thick flange design carriers. New Longer Capscrews DN P/N s 130836-(70mm), 130837-(45mm) New Wider & Thicker Flat Washer DN P/N 130877 IMPORTNT! Dana does not recommend the mixing of various designs carrier-to-housing capscrews on the same assembly. Whether mixing or not, torques must be measured using a calibrated torque wrench. Failure to re-torque bolts and nuts to proper specifications may lead to carrier to housing leaks and possible component damage. 2
Carrier Fastener Change Continued NEW XLE HOUSING HRDWRE KIT P/N 512087 This new hardware kit can only be used with the axles assembled with the new thick flange carriers. The new long capscrews in this kit will not work with the old thin flange carriers. CURRENT XLE HOUSING HRDWRE KIT P/N 511600 This hardware kit can only be used with axles assembled with the old thin flange carriers. (TE) TE: The need for Dana kit (P/N 511600) will still remain important if doing repairs to axles manufactured before 6/3/02. The total build population of thin flange carriers ranges from early 1993 through 2002. FSTENER REPLCEMENT CHRT DN PRT-. PRT TYPE DESCRIPTION USE w/ OLD CRRIER USE w/ NEW CRRIER 130836 NEW CPSCREW-LONG (70mm) YES 130837 NEW CPSCREW-STNDRD (45mm) YES YES 130158, 210173 OLD CPSCREW-STNDRD (40mm) YES 127641 SME STUD (PRT DID T CHNGE) YES YES 127567 SME NUT (PRT DID T CHNGE) YES YES 130877 NEW FLT WSHER YES YES 29804 OLD FLT WSHER YES Power Divider Cover Design Change DESIGN CHNGE: The power divider cover on the forward carrier has been redesigned to include two additional bosses, which requires two more fasteners. The previous design PDU cover assembled to the carrier with a total of nine fasteners where the new PDU cover now uses 11. The fastener part number did not change; it remains (P/N 210091). NEW PDU COVER P/N: 130823 - The new power divider cover (P/N 130823) with 11 fastener holes will adapt to all older model carriers designed with only nine fastener hole locations (TE). This new cover will become the standard PDU covered offered for service replacing (P/N 129572). TE: When used with an old carrier the new PDU cover with two additional bolt holes will seal as well as the original design. OLD PDU COVER P/N: 129572 - The old PDU cover CNT adapt to new carriers that have 11 fastener holes. The cover will not seal to the carrier and leakage will occur. The original nine-hole PDU cover is obsolete and replaced by the new 11-hole (P/N 130823) covers. POWER DIVIDER REPLCEMENT CHRT DN PRT-. DESCRIPTION USE w/ OLD CRRIER USE w/ NEW CRRIER 129572 OLD PDU COVER OK 130823 NEW PDU COVER OK OK 3
Casting & Service Parts Cross-Reference Listing elow you will find cross-reference charts for the changes describe in this bulletin. Chart- shows casting numbers that can quickly identify the old design parts versus the new design parts. Chart- is a service parts cross-reference listing. Sorted by New Part Description refer to this list when making decisions when using existing stock or ordering new service parts for various models. CHRT : PRT NUMER CROSS-REFERENCE - CSTING NUMERS NEW CSTING PRT-. OLD CSTING PRT-. DESCRIPTION MODEL 130809 129539, 129540 Diff Carrier Casting D344, 404, 405, 454, DS344,404,405, 454, DSH40, DSH44, DSP40, DSP41, DST40, DST41 130814 129550 Diff Carrier Casting DD404, DD404P, DD454, DD454P, DDH40, DDH40P, DDH44, DDH44P, DDP40, DDP40P, DDP41, DDP41P, DDT40, DDT41 130819 129551 Diff Carrier Casting D404P, 405P, 454P, DS404P, DS405P, DS454P, DSH40P, DSH44P, DSP40P, DSP41P, DDT40P, DDT41P 130822 129571 PDU Cover Casting ll "D" Forward Carriers - 11 hole 130824 129351C, 129541 Diff Carrier Casting R344, 404, 405, 454, RS344, RS404, 405, 454, RSH40, RSH44, RSP40, RSP41 130827 128600 Diff Carrier Casting RD404, RD454, RDH40, RDH44, RDP40, RDP41 CHRT : PRT NUMER CROSS-REFERENCE - SERVICE PRTS CURRENT SERVICE PRT-. REPLCES OLD SERVICE PRT-. NEW PRT DESCRIPTION TES 511600 none xle Hsg Hardware Kit - Thin Flange Models Use only in Models w/ Thin Flange Carrier Design 512087 none xle Hsg Hardware Kit - Thick Flange Models Use Only in Models w/ Thick Flange Carrier Design 130836 130158, 210173 Capscrew - 45mm Use in ll Models (New & Old Design) 130837 none Capscrew - 70mm Used Only in Models w/ Thick Flange Carrier Design 130158 NL Capscrew - 40mm Replaced by 130836 Capscrew 210173 NL Capscrew - 40mm Replaced by 130836 Capscrew 510017 217362 Carrier & Cap Kit Replaced by Carrier/Cap Kit having Thrust olt & Jam Nut Option 510018 216223 Carrier & Cap Kit Replaced by Carrier/Cap Kit having Thrust olt & Jam Nut Option 510019 510020 Carrier & Cap Kit Replaced by Carrier/Cap Kit having Thrust olt & Jam Nut Option 510023 510021 Carrier & Cap Kit Replaced by Carrier/Cap Kit having Thrust olt & Jam Nut Option 510024 510022 Carrier & Cap Kit Replaced by Carrier/Cap Kit having Thrust olt & Jam Nut Option 510027 510025 Carrier & Cap Kit Replaced by Carrier/Cap Kit having Thrust olt & Jam Nut Option 510028 510026 Carrier & Cap Kit Replaced by Carrier/Cap Kit having Thrust olt & Jam Nut Option 510031 510029 Carrier & Cap Kit Replaced by Carrier/Cap Kit having Thrust olt & Jam Nut Option 510032 510030 Carrier & Cap Kit Replaced by Carrier/Cap Kit having Thrust olt & Jam Nut Option 130877 29804* Flat Washer Use in ll Models (New & Old Design) - *Old Part Not Obsolete 29804* none Flat Washer Used only in rake ssemblies - *Part Not Obsolete 130823 129572 PDU Cover - 11 hole ll "D" Forward Carriers (new cover uses 11 capscrews) 129572 NL PDU Cover - 9 hole Replaced by 130823 PDU Cover 510023 Carrier & Cap Kit DS344, 404, 405, 454, DSP40, DSP41, DSH40, DSH44, DST40, DST41 510024 Carrier & Cap Kit DS404P, 405P, 454P, DSP40P, DSP41P, DSH40P, DSH44P, DST40P, DST41P 510027 Carrier & Cap Kit DD404, 405, 454, DDP40, DDP41, DDH40, DDH44, DDT40, DDT41 510028 Carrier & Cap Kit DD404P, 405P, 454P, DDP40P, DDP41P, DDH40P, DDH44P, DDT40P, DDT41P 510031 Refer to Note 1 Carrier & Cap Kit D344, 404, 405, 454 510032 Carrier & Cap Kit D404P, 405P, 454P Note 1: The Carrier & Cap kits have been optimized for service. New design carriers and hardware will be provided in kits when various model options are released through production. THIS SECTION OF ULLETIN REVISED FROM ORIGINL PULICTION. 510017 Carrier & Cap Kit RD404, 405, 454, RDP40, RDP41, RDH40, RDH44 510018 Carrier & Cap Kit RS344, 404, 405, 454, RSP40, RSP41, RSH40, RSH44 510019 Carrier & Cap Kit R344, 404, 405, 454 4
Capscrew & Stud Fastener Locations for Dana 34-44,000 lbs Tandem xle Models fter 6/3/02* *These are the fastener configurations when all changes are completely implemented. Changes to the new design carriers are being done as a running change. GM models require special double-ended capscrews. D344, 404, 405, DS344, 404, 405, 454, DD404, 405, 454, DSP40, 41, DDP40, 41 DST40, DST41 R344, 404, 405, RS344, 404, 405, 454, RD404, 405, 454, RSP40, 41, RDP40, 41 DSH40, DDH40 DSH44, DDH44 C HED TO HOUSING HED TO HOUSING C HED TO HOUSING 127641 Studs & 127567 Nuts 130836 Capscrews Short (45mm) C 130837 Capscrews Long (70mm) D 130877 Flat Washers ll Locations - Studs to Extend 1-11/16 (43mm) from Face of housing. RSH40, RDH40 RSH44, RDH44 HED TO HOUSING VIEW LOCTION OF FSTENERS RE VIEWED S IF INSTLLING DIFFERENTIL INTO THE XLE HOUSING. For spec ing or service assistance, call 1-800- 24 hours a day, 7 days a week, (Mexico: 8-332-1515). Or visit our web site at: www.com Dana Corporation I-0210r1 Copyright Dana Corporation, 2002 Commercial Vehicle xle Division ugust 2002 ll Rights Reserved. P.O. ox Printed in U.S.. www.dana.com 5