Illustrated Parts List
Contents
1. Hem Description Qty DS344 DS405 P DD405 P Notes BASIC OVERHAUL KIT 504030 504030 504031 Contents Identified with e 1 Forward Carrier Cap Sub Assy includes items 1 3 and 33 Standard Mdls 132038 NSS 1 132466 132466 Diff Lock Mdls 132043 NSS 1 132467 2 Flat Washer 4 210288 210288 210288 2A Plug O Ring 1 131809 131809 131809 3 Capscrew 4 210095 210095 210095 4 Cotter Pin 2 090873 090873 090873 5 Dowel Pin 2 007641 007641 007641 6 Diff Brg Adjuster Plain Half 1 129130 129130 128616 7 Brg Cup Plain Half 1 129566 129566 15092 8 Brg Cone Plain Half 1 1295650 129565 128604 9 Diff Brg Adjuster Flange Half 1 129128 129128 129128 10 Brg Cup Flange Half 1 1295640 1295640 1295640 11 Brg Cone Flange Half 1 129563 129563 129563 WHEEL DIFF CASE KITS Includes items 12 14 12 Diff Case RH Flg Half 133737 note 12 1 508653 508653 508724 Ratios 2 64 to 3 25 133738 note 12 508654 508654 508725 Ratios 3 36 to 3 90 133739 note 12 508655 508655 508726 Ratios 4 11 to 4 88 133740 note 12 508656 508656 508727 Ratios 5 29 to 7 17 13 Diff Case LH Plain Half 1 132437 132437 128607 see note 12 below 14 Capscrew 12 127465 127465 127465 WHEEL DIFF SIDE GEAR KIT 39 Inv Spline 217461 Includes items 15 19 41 Inv Spline 216229 216229 Includes items 15 19 WHEEL DIFF KIT w o SIDE GEARS 216228 216228 216228 Includes it2. RA344 RS344 RA404 RS404 RA405 RS454 RD404 Item Description Qty RS405 RA454 RD405 RD454 Notes BASIC OVERHAUL KIT 216221 216221 217464 217464 Contents Identified with e BEARING KIT 216248 216248 512805 512805 Contents Identified with 1 Diff Carr amp Brg Caps Kit See Chart Below includes items 1 3 32 amp 33 Model Type Part No Casting No Notes RS344 404 405 454 510018 129541C replaces 216223 131812 RA344 404 405 454 NLA 510020 NLA 129541C replaced 510019 RD404 405 454 510017 128600C replaces 217362 131828 2 Flat Washer 4 210288 210288 210288 210288 2a Plug amp O Ring Assembly 1 131809 131809 131809 131809 3 Capscrew 4 210095 210095 210095 210095 4 Cotter Pin 2 090873 090873 090873 090873 Replaces 126156 5 Diff Brg Adjuster Plain Half 1 129130 129130 128616 128616 RA models see page 28 6 Bearing Cup Plain Half 1 129566 129566 129566e 129566 Replaces 9803 7 Bearing Cone Plain Half 1 129565 e 129565 e 129565e 129565 Replaces 27813 8 Diff Brg Adjuster Flange Half 1 129128 129128 129128 129128 Replaces 127410 RA models see page 28 9 Bearing Cup Flange Half 1 129564e 129564e 129564e 129564 Replaces 90943 10 Bearing Cone Flange Half 1 129563e 129563e 129563e 129563 Replaces 6802 WHEEL DIFF CASE KITS Includes items 11 13 11 Diff Case LH Flg Half 1 133737 was 129464 note 11 1 508653 508653 5087
3. Old Part Number Part Number Notes 006082 129563 009803 129566 014217 129561 027813 129565 085439 129560 090943 129564 121753 508652 See bulletin ABIB 9701 126156 090873 126841 See bulletin ABIB 9609 for replacement kits 127369 129305 127410 129128 127412 129130 127487 217519 See bulletin ABIB 9709 127494 130907 127495 130907 127506 129783 127506 cannot be used in axle designs built after 11 2 99 127601 129767 127648 127628 128146 129044 See bulletin ABIB 9609 128445 129046 See bulletin ABIB 9609 128401 129047 See bulletin ABIB 9609 128612 508290 See bulletin ABIB 9609 128806 508652 See bulletin ABIB 9701 128926 126840 129037 217519 See bulletin ABIB 9709 129056 NONE Never released 129489 217519 See bulletin ABIB 9709 129490 217519 See bulletin ABIB 9709 129859 129584 210280 See bulletin ABIB 9609 for replacement kits 210299 129433 216222 510021 DS344 404 405 216230 508653 See bulletin ABIB 9701 216231 508654 See bulletin ABIB 9701 216232 508655 See bulletin ABIB 9701 216233 508656 See bulletin ABIB 9701 217166 508724 See bulletin ABIB 9701 217168 508726 See bulletin ABIB 9701 217169 508727 See bulletin ABIB 9701 217360 510022 DS404P 405P 217361 510025 404 405 217536 510029 DA344 404 405 217537 510026 404P 405P 50 Ouick Part Number Replacement Listing Ouick Part Number Replacement Listing Current Replacement Old Part Number
4. Spicer Drive Axles SPICER Illustrated Parts List AXIP0200 April 2011 344 404 405 454 Models Table of Contents General Information 2 How To Use Illustrated Parts List 2 Model Identification 3 Single Reduction Front Axles After June 2008 6 B anng u u uuu eee 11 Single Reduction Front Axles Before June 2008 12 Wheel Differential Lock Assembly 17 Piston Cover Upgrade Kits 19 Wiring Harness Usage by OEM 19 Air Lockout Parts After 11 2 98 20 Air Lockout Parts Before 11 2 98 22 Single Reduction Rear Axles 24 In Axle Speed 27 Output Shaft and Axle Housing Components 29 Carrier Mounting Flange Design Change ol Axle Shafa YO CN 34 Axle Shafts Single Reduction Models 34 Axle Shafts Diff Lock Models 34 Axle Shafts Models having IASS 35 Axle Shafts Wide Track Models 35 AXIO HOUSIMOS Sonata aae Taa esaat aze 36 Gear amp Pinion 39 Service Carrier Assemblie
5. 4 1 513380 127388 37 130125 9 211470 127388 37 127447 9 4 33 513379 130201 39 130126 9 211471 127389 39 127448 9 4 63 513378 130196 37 129733 8 211472 127390 37 127449 8 4 88 513377 130197 39 129735 8 211473 127391 39 127450 8 5 29 513376 130196 37 129816 7 211474 127390 37 127451 7 5 57 513375 130197 39 129820 7 211475 127391 39 127452 7 6 17 513374 127390 37 129843 6 211476 127390 37 127453 6 6 50 511571 129736 39 127454 6 211477 127391 39 127454 6 7 17 511572 130178 43 130177 6 NA NA NA NSS Not Sold Separately Note In mid 2004 the original design gearing kits were replaced by new gearing that contain design enhancements In some cases when changing certain ratios ratios affected or using new design gearing kits to replace original gearing a differential flange half case change may be required All flange half differential cases are now available thru Spicer as individual components 39 Gear amp Pinion Kits Gear amp Pinion Kits R Rear Axle Standard Applications R344 404 405 454 17060 19060 21060 22060S D L 15 4 15 7 Hypoid Spline 39 1 95 Involute Pinion Nut Part No 127589 Spicer Current Current Original Original Original Ratios Kit Gear NSS Pinion NSS Kit Gear NSS Pinion NSS 2 64 211478 127380 37 127420 14 NA NA NA 2 85 211479 127381 37 127421 10 NA NA NA 2 93 509424 1
6. Notes define unique characteristics or replacement notes Kits Assy s Where Used indicates Kits or Assemblies that contain a particular part e Other pertinent information is listed in tables or parts listings as required Indicates information important to ordering or use DS404 DD404 Notes 123456 789101 See Axle Shaft Chart 246810 121416 2 Flat Washer 4 Item Description Qty 1 Axle Shaft 2 Summary of Kits and Assemblies Oil Seal amp Shim Kit 216225 Basic Overhaul Kit 216221 Includes 29 30 36 Model Identification Model Identification Locating Model Designation Information e Axle Model Identification Part Number and Serial Number are located on a tag at the axle centerline This information will help to locate information in this book and to identify the correct parts for servicing Drive Axles CUST PART NO SPEC SERIAL NO O O MODEL PARTNO RATIO MADE IN Model Number Part Number and Serial Number are located on the data plate on the axle centerline Drive Axle Assembly Tag 1 Country or origin NOTE When inquiring about specific information on your axle write 2 Axle model identification down all of the above information from your tag and call your local OEM 3 Specification number assigned to the axle built by Spicer Identifies dealer or your Dana representative component parts of the axle including special OEM requirements such as yoke
7. 454 510031 NLA 130809 Replaces 129539 129540 DA404P 405P 454P 510032 NLA 130819 Replaces 129551 2 Flat Washer 4 210288 210288 210288 210288 2A Plug O Ring 1 131809 131809 131809 131809 Not Illustrated 3 Capscrew 4 210095 210095 210095 210095 4 Cotter Pin 2 090873 090873 090873 090873 Replaces 126156 5 Dowel Pin 2 007641 007641 007641 007641 5A Output Shaft O Ring 2 127545 127545 127545 127545 6 Diff Brg Adjuster Plain Half 1 129130 129130 128616 128616 DA models see page 22 1 7 Brg Cup Plain Half 1 129566 129566 015092 015092 129566 Replaces 9803 8 Brg Cone Plain Half 1 129565 129565 128604e 128604 129565 Replaces 27813 9 Diff Brg Adjuster Flange Half 1 129128 129128 129128 129128 DA models see page 22 10 Brg Cup Flange Half 1 129564e 129564e 129564e 129564 129564 Replaces 90943 11 Brg Cone Flange Half 1 129563 129563e 129563e 129563e 129563 Replaces 6082 WHEEL DIFF CASE KITS Includes items 12 14 12 Diff Case RH Flg Half 133737 was 129464 note 12 1 508653 508653 508724 508724 Ratios 2 64 to 3 25 133738 was 129465 note 12 508654 508654 508725 508725 Ratios 3 36 to 3 90 133739 was 129466 note 12 508655 508655 508726 508726 Ratios 4 11 to 4 88 133740 was 129467 note 12 508656 508656 508727 508727 Ratios 5 29 to 7 17 13 Diff Case LH Plain Half 1 132437 132437 Was 127498 see note 12 below Diff Case LH Plain Half 128607 128607 14 Capscrew 12 1
8. 5 8 635 STR 5 126684 1 41 1 87 46 156 4 8 5 8 635 STR 5 DD454 128910 1 41 1 87 42 460 4 8 5 8 635 STR 6 RD454 128504 1 41 1 87 46 156 11 8 5 8 635 STR 6 1 Ford 6 Kenworth 2 GMC 7 Volvo White 3 Freightliner 8 Marmon 4 Mack 9 Western Star 5 Peterbilt 10 Navistar 35 Axle Housing Axle Housing In the 4th guarter of 1998 a design change was made to the FORWARD axle housings in the 404 family axles The axle housing rear cover is no longer a bolt on cover but is a welded assembly shown and is not serviceable Shown below is an axle housing part number cross reference listing for some common D R housings used in production If the part number on your tag is not listed below consult your OEM local OEM dealer or your Dana representative 1 877 777 5360 Axle Tag I D Old Service Current Service Series Number Part Number Part Number OEM Notes DS404 305828 216123 319421 321501 Peterbilt Bare Hsg 05404 305828 319157 319903 Peterbilt Has Torgue Rod Bkt amp Spring Seats For Air Leaf Suspension DS404 305828 319161 319905 Peterbilt Has Torgue Rod Bkt amp Spring Seats For Air Trac Suspension DS404 305828 320175 Peterbilt Has Torque Rod Bkt amp Spring Seats For Low Air Suspension DS404 305920 217641 319623 Navistar Has Torque Rod Bkt amp Hanger Bkts DS404 305924 216019 319413 Navistar Has Torque Rod Bracket
9. 6 4 9041X 1710 30 Y 5 25 1 94 6 09 127624 6 4 9001X 1710 45 Y 6 12 1 94 6 09 127638 5 4 9271 1610 45 Y 6 00 1 88 5 31 128722 6 4 9001 1X 1710 39 5 X 6 12 1 94 6 19 128737 6 4 9041 1X 1710 30 X 5 25 1 94 6 19 210835 170 4 221 1X SPL170 25 X 5 27 2 16 5 51 210837 170 4 241 1X SPL170 45 X 6 50 2 16 5 51 Call for availability 46 Yokes and Flanges Yokes and Flanges Rear Axle Input 39 1 95 Involute Spline Production Service Yoke amp Slinger Part Joint Dimensions in inches Assy Number Series Angle Style A B G 127415 6 4 9031X 1710 30 Y 5 25 1 94 6 09 127637 6 4 8991X 1710 45 Y 6 12 1 94 6 09 128720 5 4 8261 1610 45 Y 6 00 1 88 5 31 128721 128721 1610 22 Y 4 72 1 88 5 31 128745 6 4 9031 1X 1710 30 X 5 25 1 94 6 19 128746 6 4 8991 1X 1710 39 5 X 6 12 1 94 6 19 129019 5 4 9241 1X 1610 45 X 6 00 1 88 5 31 129043 5 4 9231 1X 1610 23 X 4 88 1 88 5 31 129164 3 4 13081 1X 1480 19 X 4 34 1 38 3 69 129166 4 4 7571 1X 1550 24 5 X 4 30 1 38 4 47 210839 170 4 261 1X SPL170 25 X 5 16 2 16 5 51 210841 170 4 281 1X SPL170 45 X 6 24 2 16 5 51 210875 210875 RPL20 30 4 85 N A 5 30 210877 210877 RPL20 429 X 5 69 N A 5 30 210923 90 4 251 1X SPL90 15 4 75 1 61 4 53 Call for availability 47 Kits and Assemblies Kits and Assemblies Oil Seal Installation Tools This Kit contains installation tools used for installing driveline
10. 9 Compression Spring 1 127474 10 Capscrew 2 128744 11A Piston Housing Standard 1 129005 11B Piston Housing GM Only 1 129004 12 Gasket 1 128643 13 O Ring 1 210180 14 Piston 1 129290 15 Push Rod 1 129583 NLA Replaced by 510840 16 Shift Fork Assy 1 129783 Replaces 127506 17 Compression Spring 1 129584 18 Capscrew 1 128744 19 Piston Housing 1 128733 20 Ring 1 128734 21 O Ring 1 210180 22 Piston 1 128724 23 Snap Ring 2 128725 24 O Ring 1 120728 25 O Ring 1 128729 26 Pilot Plate 1 128726 27 _ O Ring 1 128727 28 _ O Ring 1 128331 29 Rod 1 128730 30 Compression Spring 1 128731 31 Shift Fork Assy 1 129783 Replaces 127506 32 PDU Cover Original Design 1 127605 NLA 129572 NLA 127605 NLA Summary of Kits and Assemblies Air L O Kit w o Shift Fork 507494 Includes 10 11A 12 14 Air L O Kit Complete 508121 Includes 10 11A 12 17 Repair Kit 507709 Includes 12 14 Air 1 0 Kit w o Shift Fork 216048 Includes 18 30 Air L O Kit Complete NLA 128735 NLA Includes 18 31 23 Single Reduction Rear Axles Single Reduction Rear Axles See Ring Gear amp Pinion page 39 11 Flange Half LH Parts for Diff Lock Assy 1 with Dif Lockup Ta 28 25 See Ring Gear amp Pinion bM 39 p 24 Dos 26 32 lt 1 Pad 33 i 30 ex Q ex a A 7 9 231 CARR CAP for See iss JP R454 model not page illustrated 24 Single Reduction Rear Axles
11. DS405 306296 219144 319447 Peterbilt Has Brackets For Hendrickson Suspension DS405 306296 319157 319903 NLA Peterbilt Has Torque Rod Bkt amp Spring Seats For Air Leaf Suspension DS405 306296 216604 319421 321501 Peterbilt Bare Hsg DS404 306358 507322 319659 Peterbilt KW Bare Hsg DD404 306436 319423 321501 Peterbilt KW Volvo Bare Hsg DD405 306460 319427 321501 Peterbilt KW Bare Hsg DS404 306492 218639 NONE Peterbilt KW Housing w Brackets NLA use Bare Service Hsg DS404 306758 217672 321501 Peterbilt KW Bare Hsg DS404 307190 307191 319449 Volvo GM Housing w Brackets DD404 307346 307347 NONE Ford Housing w Brackets NLA use Bare Service Hsg DD404 318646 318647 NONE Ford Housing w Brackets NLA use Bare Service Hsg DD404 318660 318661 NONE Ford Housing w Brackets NLA use Bare Service Hsg DD404 318664 318665 NONE Ford Housing w Brackets NLA use Bare Service Hsg DD405 319430 319431 NONE Volvo Has Torgue Rod Bracket DD404 319440 319441 321501 Western Star Bare Hsg DD405 319494 319495 Mack Has Tracking Rod Bracket DS405 319622 319623 NONE Navistar Had Unigue Brake Flange DD405 319684 319419 Navistar Has Brackets DD404 319710 319711 321501 N A Bare Hsg DD404 319728 319729 319447 Freightliner Has Torque Rod and Hanger Brackets DD454 320112 320113 Terex Has Torque Rod and Hanger Brackets Wide Trac Design DD405 320254 319649 Volvo Has Brackets DDH44 320300 319449 Volvo GM Has Brackets DD405 321066 321067 Peterbilt
12. DSH40P 682758 4 63 675715 DDH40 682768 4 88 675652 DSH40P 682759 4 88 675716 DDH40 682769 5 29 675653 DSP40P 682009 5 29 675717 DDP40 682961 5 57 675654 DSP40P 682010 5 57 675718 DDP40 682962 6 17 675655 DSP40P 682011 6 17 675719 DDP40 682963 6 50 675656 DSP40P 682012 6 50 675720 DDP40 682964 7 17 DSP40P 682013 7 17 DDP40 682016 43 Service Carrier Assemblies Supersession of D R454 Models to New Generation Models In 2003 the D R454 models were discontinued and replaced by the DSH40 RSH40 family of carriers In 2009 additional replacements were made and are reflected below Reference Spicer bulletin abib 0902 for specific details of those changes DD454P Replaced By Current Part RD454 Replaced By Current Part Ratio NLA Model Number Ratio NLA Model Number 2 64 675689 NLA none 2 64 675721 NLA none 2 85 675690 NLA none 2 85 675722 NLA none 3 08 675691 DDH40P 682770 3 08 675723 RDH40 675790 3 25 675692 DDH40P 682771 3 25 679724 RDH40 675791 3 36 675693 DDH40P 682772 3 36 675725 RDH40 675792 3 55 675694 DDH40P 682773 3 55 675726 RDH40 675793 3 70 675695 DDH40P 682774 3 70 675727 RDH40 675794 3 90 675696 DDH40P 682775 3 90 675728 RDH40 675795 411 675697 DDH40P 682776 441 675729 RDH40 675796 4 33 675698 DDH40P 682777 4 33 675730 RDH40 675797 4 63 675699 DDH40P 682778 4 63 675731 RDH40 675798 4 88 675700 DDH40P 682779 4 88 675732 RDH40 675
13. GMC 7 Volvo White 3 Freightliner 8 Marmon 4 Mack 9 Western Star 5 Peterbilt 10 Navistar 34 Axle Shafts Models having IASS In Axle Speed Sensors for ABS Body Shaft Spline Flange Flange Model PartNo Qty Spline 0 D Length Length 0 D Holes OEM RA344 129052 NLA 1 39 1 81 38 500 11 6 125 12 748 TPR 2 129053 1 39 1 87 42 750 11 6 223 12 781 TPR 2 128434 NLA 1 41 1 87 38 976 11 8 5 8 635 STR 6 5 3 DA404 128435 1 41 1 87 43 307 11 8 5 8 635 STR 6 5 3 RA404 128558 1 41 1 87 38 130 11 8 5 8 773 STR 7 10 DA454 128559 1 41 1 87 42 460 11 8 5 8 773 STR 7 10 RA454 128560 1 41 1 87 38 976 11 8 5 8 948 TPR 2 4 7 9 128561 1 41 1 87 43 307 11 8 5 8 948 TPR 2 4 7 9 128562 NLA 1 41 1 87 38 130 11 8 5 8 948 TPR 1 128563 1 41 1 87 42 460 11 8 5 8 948 TPR 1 1 Ford 6 Kenworth 2 GMC 7 Volvo White 3 Freightliner 8 Marmon 4 Mack 9 Western Star 5 Peterbilt 10 Navistar Axle Shafts Wide Track Models Body Shaft Spline Flange Flange Model PartNo Qty Spline 0 D Length Length 0 D Holes OEM 129388 1 41 1 87 43 887 4 8 5 8 773 STR 7 05404 129434 1 41 1 87 38 976 4 8 5 8 773 STR 7 RS404 129306 1 41 1 87 45 500 4 8 5 8 635 STR 9 DS454 128243 1 41 1 87 40 630 4 8 5 8 635 STR 9 5454 128914 1 41 1 87 45 500 4 8 5 8 773 STR 7 128912 1 41 1 87 41 313 4 8 5 8 773 STR 7 128910 1 41 1 87 42 460 4 8
14. Has Brackets 36 Housing Tag I D Old Service Current Service Series Number Part Number Part Number OEM Notes DD405 321220 321221 GM Has Brackets DD405 321248 321249 NONE Sutphen Has Torque Rod Bracket and Hanger Brackets DD405 321262 321263 Freightliner Has Hanger Brackets DD405 321276 321277 Peterbilt Has Torque Rod Bracket DD405 321286 319447 Freightliner Has Torque Rod and Hanger Brackets DD405 321350 321351 Western Star Has Brackets DD405 321356 319475 Crane Mack GM Has Brackets DD405 321360 321361 Kenworth Has Torque Rod Bracket and Hanger Brackets DD405 321422 321501 Western Star Bare Hsg DD405 321500 321501 Peterbilt Bare Hsg w Diff Lock Cutout DSH40 321548 321549 Sterling FL Paccar Bare Hsg DD405 321552 321553 Paccar Has Tracking Rod Bracket DD454 321556 319659 Paccar Terex Bare Hsg Wide Track Design DD405 321634 319903 Paccar Has Torque Rod and Hanger Brackets DD405 321680 321681 Freightliner Bare Hsg w Unique Brake Flange DS404 322460 319419 Navistar Bare Hsg w ABS Blocks DD405 322578 320597 Navistar Has Tracking Rod Bracket DD405 322652 319847 Freightliner Has Brackets DD405 322730 322731 Service Has Hanger Brackets DD405 322734 322735 NONE Service Has Hanger Brackets DD404 32
15. Part Number Notes 218167 508725 See bulletin ABIB 9701 219704 508652 See bulletin ABIB 9701 820643 129558 216223 510018 217362 510017 510019 510020 51 For spec ing or service assistance call 1 877 777 5360 or visit our website at www dana com Dana Commercial Vehicle Products Group 3939 Technology Drive d Maumee Ohio USA 43537 DANA SPICER www dana com All applications must be approved by the Application Engineering Department Specifications and or design are subject to change without notice or obligation Drivetrain Products Printed in USA AXIP 0200 04 11
16. the new variable pinion bearing spacers listed below Spacer washer 127565 is no longer available and has been removed from all service kits The current variable pinion bearing spacers listed above are sold separately or available in listed pinion bearing spacer Kit D344 404 P 405 P 454 P R344 404 405 454 17 19 21 22060 PINION BRG SPACER KIT 504043 includes items w PINION BRG SPACER KIT 504016 includes items w New Spacers Spacer Thickness Bearing Spacers Part Number Spacer Thickness 129079 0 797 91552 0 623 129080 0 798 91553 0 624 129081 0 800 91554 0 625 129082 0 801 91555 0 626 129083 0 802 91556 0 627 129084 0 803 91557 0 628 129085 0 804 91558 0 629 129086 0 806 91559 0 630 129087 0 807 91560 0 631 129088 0 808 91561 0 632 129089 0 809 91562 0 633 129090 0 810 91564 0 634 129091 0 811 91566 0 635 129093 0 812 91568 0 636 129097 0 814 91572 0 637 129099 0 815 91576 0 638 129101 0 816 91580 0 639 129103 0 817 91584 0 640 129105 0 818 91588 0 641 129107 0 819 91592 0 642 129109 0 820 91596 0 643 129111 0 821 91600 0 644 129113 0 822 91602 0 645 129115 0 823 91604 0 646 129117 0 824 91606 0 647 129119 0 825 91608 0 648 129120 0 826 91610 0 649 129121 0 828 91611 0 650 129122 0 829 91612 0 651 129123 0 830 91613 0 652 12
17. 0823 Note 1 13 Capscrew After 11 2 98 9 210091 Note 1 After 2 2 00 11 210091 Note 1 14 Washer Capscrew 11 128415 NSS Not Sold Separately NOTE 1 On June 3 2002 the design of the power divider cover changed The original PDU cover P N 129572 had 9 holes and required 9 fasteners The current design PDU cover P N 130823 has 11 holes and requires the use of 11 long fasteners The original 129572 covers are no longer available thru Dana Summary of Kits and Assemblies Air L O Kit Complete 510052 Includes 53 59 Repair Kit 510053 Includes 55 58 Shift Fork amp Compression Spring Kit 510870 Includes 53 54 21 Air Lockout Parts Before 11 2 1998 Air Lockout Parts Before 11 2 1998 Lockout design before 11 2 98 b 6 e n 2E j 0 0 50 a j TORTE y a 27 26 25 24 23 22 34 202 49 22 Air Lockout Parts Before 11 2 1998 Air Lockout Parts Before 11 2 1998 Straight Air Straight Air Before 11 2 96 to 11 2 1996 11 2 1998 Navistar ltem _ Description Qty Cylindrical Cast Iron Rev Air Notes 1 Capscrew 2 210381 2 Mounting Bracket 1 NLA Order 507494 3 Piston Housing 1 NLA Order 507494 4 O Ring 1 210180 5 Piston 1 NLA Order 507494 6 Shoulder Washer 1 NLA Order 507494 7 Push Rod 1 127477 8 Shift Fork Assy 1 129783 Replaces 127506
18. 127598e 127598e 127598e Shim 030 127599e 127599e 127599e 127599e 52 Oil Seal V Ring 1 128703e 128703e 128703e 128703e 53 Input Brg Cover Assy 129575 129575 129575 129575 After 11 2 98 Includes Item 50 129574C 54 Input Brg Cover Assy 1 127602 127602 127602 127602 Before 11 2 98 Includes 50 127490C 55 O Ring Refer to Note 55 129576 NLA 129576 129576 129576 NLA Used on mdls made after 11 2 98 NLA refer to Note 55 56 Bearing Cover Cap Screw 6 210115 210115 210115 210115 57 Oil Seal 1 127591e 127591e 127591e 127591 58 Locknut 1 128049 128049 128049 128049 In 216226 Kit M42 1 5 59 Plug 1 090325 090325 090325 090325 See bulletin AXIB 9510 60 Lube Trough 1 129577 129577 129577 129577 61 Lube Pump Assembly 1 127534 127534 127534 127534 Pump Models Only 62 Capscrew 3 127551 127551 127551 127551 Pump Models Only 63 Drive Coupling Service 1 128628 128628 128628 128628 Pump Models Only 64 Poppet Valve Plug 1 019411 019411 019411 019411 Pump Models Only Hole size changed 2 97 Same as 90897 65 Pipe Plug 4 090897 090897 090897 090897 Pump Models Only 66 Filter Screen Assy 1 127649 127649 127649 127649 Pump Models Only 67 Thrust Screw 1 126193 126193 68 Jam Nut 1 210184 210184 69 RTV Sealant 1 107276Se 107276Se 107276Se 107276Se Illustrated NSS Not Sold Separately NOTE 55 This o ring is no longer used in these models and is also no longer required when rebuilding
19. 24 508724 Ratios 2 64 to 3 25 133738 was 129465 note 11 508654 508654 508725 508725 Ratios 3 36 to 3 90 133739 was 129466 note 11 508655 508655 508726 508726 Ratios 4 11 to 4 88 133740 was 129467 note 11 508656 508656 508727 508727 Ratios 5 29 to 7 17 12 Diff Case RH Plain Half 1 132437 132437 was 127498 see note 11 below Diff Case RH Plain Half 128607 128607 13 Capscrew 12 127465 127465 128619 128619 WHEEL DIFF SIDE GEAR KIT Includes items 14 18 39 Inv Spline 217461 41 Inv Spline 216229 216229 216229 216229 WHEEL DIFF KIT w o SIDE GEARS 216228 216228 216228 216228 Includes items 15 18 14 Side Gear 39 Inv spline 2 127367 41 Inv spline 2 127368 127368 127368 127368 15 Side Gear Thrust Washer 2 127386 127386 127386 127386 16 Side Pinion Thrust Washer 4 129305 129305 129305 129305 Replaces 127369 17 Side Pinion 4 133761 133761 133761 133761 Replaces 127364 18 Diff Spider 1 127359 127359 127359 127359 NOTE 11 All differential case halves are now available separately Design enhancements in the diff cases were released in 2007 refer to bulletin ABIB 0704 25 Single Reduction Rear Axles RA344 RS344 RA404 RS404 RA405 RS454 RD404 Item Description Qty RS405 RA454 RD405 RD454 Notes RING GEAR NUT amp BOLT KIT 508652 508652 508652 508652 Includes items 19 20 19
20. 27465 127465 127465 127465 WHEEL DIFF SIDE GEAR KIT Includes items 15 19 All 344 models 39 Inv 217461 All other models 41 Inv 216229 216229 216229 216229 WHEEL DIFF KIT w o SIDE GEARS 216228 216228 216228 216228 Includes items 16 19 15 Side Gear 39 Inv spline 2 127367 41 Inv spline 2 127368 127368 127368 127368 16 Side Gear Thrust Washer 2 127386 127386 127386 127386 17 Side Pinion Thrust Washer 4 129305 129305 129305 129305 18 Side Pinion 4 133761 133761 133761 133761 133761 replaces 127364 19 Diff Spider 1 127359 127359 127359 127359 NOTE 12 All differential case halves are now available separately Design enhancements in the diff cases were released in 2007 refer to bulletin ABIB 0704 14 Before June 2008 DS344 DA404 P DS404 P DA405 P DA454 P DD404 P Item Description Qty DS405 P DS454 P DD405 P DD454 P Notes RING GEAR NUT amp BOLT KIT 508652 508652 508652 508652 Includes items 20 21 20 Nut 16 126216 126216 126216 126216 21 Bolt 16 129686 129686 129686 129686 129686 Replaces 128806 See bulletin ABIB 9701 22 Pilot Brg 1 127484 127484 127404e 127484 23 Pinion Brg Cone Inner 1 129560e 129560e 129560e 129560 129560 Replaces 85439 24 Pinion Brg Spacer Svc Kit AR 504043 504043 504043 504043 Individual Pinion Bearing Spacers Listed on page 11 25 Pinion Brg Cage amp Cup A
21. 29534 41 129533 14 NA NA NA 3 08 513373 127381 37 139737 12 211480 127381 37 127422 12 3 25 513372 127382 39 130127 12 211481 127382 39 127423 12 3 36 513371 127381 37 130128 11 211482 127381 37 127424 11 3 42 504055 134325 41 134326 12 NA NA NA 3 55 513370 127382 39 130129 11 211483 127382 39 127425 11 3 70 513369 127381 37 130130 10 211484 127381 37 127426 10 3 90 513368 127382 39 130131 10 211485 127382 39 127427 10 4 1 513367 127381 37 130132 9 211486 127381 37 127428 9 4 33 513366 130200 39 130133 9 211487 127382 39 127429 9 4 63 513365 130194 37 129748 8 211488 127383 37 127430 8 4 88 513364 130195 39 129750 8 211489 127384 39 127431 8 5 29 513363 130194 37 129818 7 211490 127383 37 127432 7 5 57 513362 130195 39 129822 7 211491 127384 39 127433 7 6 17 513361 127383 37 129844 6 211492 127383 37 127434 6 6 50 211493 127384 39 127435 6 NA NA NA 7 17 211494 127385 43 127436 6 NA NA NA NSS Not Sold Separately Note In mid 2004 the original design gearing kits were replaced by new gearing that contain design enhancements In some cases when changing certain ratios ratios affected or using new design gearing kits to replace original gearing a differential flange half case change may be required All flange half differential cases are now available thru Spicer as individual components Spicer offers new highly developed
22. 3398 502005 GM Has Brackets DD405 323529 502041 Peterbilt Has Torque Rod Bracket and ABS Blocks DD405 323619 502060 Navistar Has Hanger Brackets DD405 323797 502073 Volvo Has Tracking Rod Bracket DD405 323798 502072 Volvo Has Tracking Rod Bracket RS344 305482 214132 GM Bare Hsg RS454 305700 214987 Peterbilt Bare Hsg Short Trac Length RS404 305830 322557 Peterbilt Bare Hsg RS404 305896 216128 322557 PB Int FL KW Bare Hsg RS404 306084 216126 Volvo Has Torque Rod Bkt amp Hanger Bkt RS405 306298 322557 PB Int FL KW Bare Hsg RD454 306494 218640 NONE N A Has Torque Rod and Hanger Brackets RS404 306816 217663 NONE Freightliner Bare Hsg w Unique Brake Flange RS405 307030 218041 Mack Has Torque Rod and Hanger Brackets RS405 307044 219145 321429 Peterbilt GM Has Torgue Rod and Hanger Brackets RS405 307142 219387 NONE Ford Has Torgue Rod and Hanger Brackets RS344 307178 307179 GM Has Torgue Rod and Hanger Brackets small spindle RD405 307182 307183 321429 GM Has Torgue Rod and Hanger Brackets RS404 307280 219800 NONE Volvo Bare Hsg w Unigue Brake Flange RD404 307348 307349 NONE Ford Has Torgue Rod and Hanger Brackets RD405 307842 307843 Crane Carrier Has Torque Rod and Hanger Brackets RD405 307872 307873 319207 GM Has Torque Rod and Hanger Brackets RD454 318674 318675 NONE Ford Has Torque Rod and Hanger Brackets RD405 319206 319207 GM Has Torque Rod and Hanger Brackets RD454 320156 320157 NON
23. 43 For Items 46 through 49 See page 20 50 Bearing Cup 1 1008912e 1008912e 1008912e 1008912e use 129559 NOTE 39 Helical Gear part numbers 127495 amp 130907 are totally interchangeable The 130907 is an enhanced design and 127495 is no longer being produced No other associated parts are affected by this change These parts are used in ALL D404 family axles NOTE 43 Kit 510593 replaces kit 216226 in all situations But kit 216226 cannot replace kit 510593 in the following specific models DSH40 P DDH40 P DSH44 P and DDH44 P unless it contains shaft number 129770 Kit 510593 contains input shaft p n 129770 which is Induction Hardened for those model applications Input shaft p n 128704 which is NOT Induction Hardened was originally included in kit 216226 up to April 22 2003 Beginning April 22 2003 Dana began using induction hardened input shaft 129770 in place of 128704 Before June 2008 DS344 DA404 P DS404 P DA405 P DA454 P DD404 P Item Description Qty DS405 P DS454 P DD405 P DD454 P Notes OIL SEAL amp SHIM KIT 1 216224 216224 216224 216224 Includes items 51 57 amp 127592 Oil Seal PINION CAGE SHIM KIT 1 504032 504032 504032 504032 Includes 5 each of shims below 51 Shim 003 AR 1275950 1275950 1275950 1275950 Shim 005 1275960 127596 127596 127596 Shim 010 127597e 127597 127597 127597 Shim 020 127598e
24. 5566 3 70 675623 3 90 675564 4 11 675414 4 33 675415 4 63 675416 4 88 675417 5 29 675418 5 57 675419 6 17 675420 6 50 675421 7 17 675422 45 Yokes and Flanges Yokes and Flanges The following yoke reference information can be used for ordering replacement yoke assemblies for new service carriers Shown below are original production part numbers and shown next to them are how those Yoke amp Slinger Assy s are serviced thru the Spicer aftermarket Always double check part supersession and options before ordering product STYLE X STYLE Y STYLE Z Half Round Full Round Half Round Tapped Holes Bearing Forward Axle Input 44 2 250 Involute Spline Production Service Yoke amp Slinger Part Joint Dimensions in inches Assytt Number Series Angle Style A B G 127550 6 4 8981 1X 1710 23 Y 5 19 1 94 6 09 127617 6 4 8981 1X 1710 30 X 5 19 1 94 6 19 127618 6 3 4 5221X 1760 30 Y 5 25 1 94 7 00 127619 6 5 4 4571X 1810 30 Y 5 25 1 94 7 55 127620 5 4 9261 1X 1610 35 X 5 00 1 88 5 31 127621 6 5 4 4571 1X 1810 30 X 5 25 1 94 7 64 127622 6 3 4 5221 1X 1760 30 X 5 25 1 94 7 09 210831 170 4 201 1X SPL170 25 X 5 27 2 16 5 51 210833 250 4 81 1X SPL250 25 X 5 49 2 36 5 31 Call for availability Forward Axle Output 39 1 950 Involute Spline Production Service Yoke amp Slinger Part Joint Dimensions in inches Assy Number Series Angle Style A B G 127558
25. 799 5 29 675701 DDP40P 682993 5 29 675733 RDP40 676025 5 57 675702 DDP40P 682994 5 57 675734 RDP40 676026 6 17 675703 DDP40P 682995 6 17 675735 RDP40 676027 6 50 675704 DDP40P 682996 6 50 675736 RDP40 676028 7 17 DDP40P 682015 7 17 RDP40 681444 Service carriers for Reverse Air DA RA models and models with In Axle Speed Sensors IASS are no longer offered by Dana Contact your Dana representative at 1 877 777 5360 for additional assistance 44 Service Carrier Assemblies Service Carrier Assemblies DS344 DL344 Single Reduction Single Reduction w Differential Lock 39 Inv Spline 39 Inv Spline Side Gear p n 127367 Limited Slip p n 130141 Service Old Part Service Old Part Ratio Carrier Number Ratio Carrier Number 2 64 682883 675883 4 33 call Dana N A 2 85 682884 675884 4 63 call Dana N A 2 93 682885 675885 4 88 call Dana N A 3 08 682886 675886 5 29 call Dana N A 3 25 682887 675887 6 17 682163 676163 3 36 682888 675888 6 50 682164 676164 3 55 682889 675889 3 70 682890 675890 3 90 682891 675891 4 11 682892 675892 4 33 682893 675893 4 63 682894 675894 4 88 682895 675895 5 29 682896 675896 5 57 682897 675897 6 17 682898 675898 6 50 682899 675899 RS344 Single Reduction 39 Inv Spline Side Gear p n 127367 Service Ratio Carrier 2 64 N A 2 85 N A 2 93 N A 3 08 675914 3 25 N A 3 36 675565 3 55 67
26. 81 TPR 2 130911 1 39 1 81 42 875 4 6 625 8 635 STR 10 130912 1 39 1 81 38 688 4 6 625 8 635 STR 10 127437 1 41 1 87 38 976 4 8 500 8 635 STR 6 5 3 DS404 127438 1 41 1 87 43 307 4 8 500 8 635 STR 6 5 3 RS404 128514 1 41 1 87 38 130 4 8 500 8 773 STR 70 DS454 128515 1 41 1 87 42 460 4 8 500 8 773 STR 7 10 RS454 128516 1 41 1 87 38 976 4 8 500 8 948 TPR 247 9 128517 1 41 1 87 43 307 4 8 500 8 948 24 79 128521 1 41 1 87 38 130 4 8 500 8 948 TPR 1 128522 1 41 1 87 42 460 4 8 500 8 948 TPR 1 1 Ford 6 Kenworth 2 GMC 7 Volvo White 3 Freightliner 8 Marmon 4 Mack 9 Western Star 5 Peterbilt 10 Navistar Axle Shafts Diff Lock Models Body Shaft Spline Flange Flange Model PartNo Qty Spline 0 D Length Length 0 D Holes OEM 17060D 19060D RD344 132872 1 39 1 81 38 500 4 6 625 8 635 STR 10 132878 1 39 1 87 42 750 11 6 625 8 635 STR 10 129439 1 39 1 81 38 500 4 6 223 12 566 STR 6 133659 1 39 1 87 42 750 11 6 223 12 566 5 6 127437 1 41 1 87 38 976 4 8 5 8 635 STR 3 5 6 128435 1 41 1 87 43 307 11 8 5 8 635 STR 3 5 6 DD404 128514 1 41 1 87 38 130 4 8 5 8 773 STR 7 10 RD404 128559 1 41 1 87 42 460 11 8 5 8 773 STR 7 10 DD454 128516 1 41 1 87 38 976 4 8 5 8 948 TPR 2 4 7 9 RD454 128561 1 41 1 87 43 307 11 8 5 8 948 TPR 2 4 7 9 128521 1 41 1 87 38 130 4 8 5 8 948 TPR 1 3 128563 1 41 1 87 42 460 11 8 5 8 948 TPR 1 3 1 Ford 6 Kenworth 2
27. 9124 0 831 91614 0 653 129125 0 832 91615 0 654 129126 0 833 Single Reduction Forward Axles Before June 2008 Single Reduction Forward Axles Before June 2008 Parts for the Differential Lock Assembly see page 17 454 Series See Ring Gear amp Pinion Without Pump page 39 Single Reduction Forward Axles Before June 2008 Single Reduction Forward Axles Before June 2008 Hole In Cover IL Removed February 1 1996 A j 58 9 AU See Yokes and Flanges on page 46 See Air Lockout Parts on page 20 Single Reduction Forward Axles Before June 2008 DA344 DS344 DA404 P DS404 P DA405 P DA454 P DD404 P Item Description Qty DS405 P DS454 P DD405 P DD454 P Notes BASIC OVERHAUL KIT 216220 216220 217463 217463 Contents Identified with e BEARING KIT 216234 216234 512800 512800 Contents Identified with 1 Diff Carr amp Brg Caps Kit Kits NLA See Chart and Notes Below Includes 1 3 5 Model Type Part No Casting No Notes D454 P Models also DS344 404 405 454 510023 NLA 130809 Replaces 129539 129540 include items 67 68 DS404P 405P 454P 510024 NLA 130819 Replaces 129551 NOTE All Original Carr Caps NLA DD404 405 454 510027 NLA 130814 Replaces 129550 Must Purchase Complete Carrier DD404P 405P 454P 510028 NLA 130814 Replaces 129550 Refer to bulletin abib 0805 DA344 404 405
28. E Peterbilt Has Torque Rod and Hanger Brackets RS404 320258 216126 Volvo Bare Hsg 37 Housing Tag I D Old Service Current Service Series Number Part Number Part Number OEM Notes RD405 320264 307713 Volvo Has Torque Rod Bracket RS454 320444 320445 NONE Linkbelt Has Torgue Rod and Hanger Brackets Wide Trac Design RD405 320452 320453 Mack Has Torque Rod and Hanger Brackets RS454 320462 320463 Linkbelt Has Torgue Rod and Hanger Brackets Wide Trac Design RS344 320572 320573 Navistar Has Torgue Rod and Hanger Brackets ABS Blocks RS344 320590 320591 Navistar Has Torgue Rod and ABS Blocks RS404 320628 320629 Navistar Has Brackets RD405 321078 321079 Peterbilt Has Brackets RD405 321082 321083 Peterbilt Has Tracking Rod Bracket RS404 321091 321091 Peterbilt Has Brackets RD405 321264 507422 Freightliner Has Hanger Brackets RS404 321316 502052 321317 Peterbilt Has Brackets RD405 321362 321363 NONE Kenworth Has Torgue Rod and Hanger Brackets RD454 321550 321551 Freightliner Bare Hsg w Cut out for Diff Lock 12 5mm Wall RD405 321636 319159 NONE Peterbilt Has Torque Rod Bkt and Spring Seats For Air Leaf Suspension RD405 321650 321651 Sutphen Has Torque Rod Bkts and Hanger Brackets RD405 321682 321683 Freightliner Bare Hsg w Unique Brake Flange RD405 321826 321429 Peterbilt Volvo Has Torque Rod
29. Gen Tech quiet gearing for single axle applications that require low noise resolution while maintaining the same high strength quality that Spicer genuine gearing is known for This gearing like all Spicer gearing is developed and machined in sets and specified by many customers in medium duty applications Never mix gears and pinions from different sets within an axle Shortened gearing life noise and failure may occur When replacing gearing check the drive pinion and ring gear numbers to the charts below to get the correct replacement service Kit 40 Gear amp Pinion Kits Gear amp Pinion Kits Rear Single Axle Gen Tech Quiet Gearing Applications 17060 19060 21060 22060S D L BC 15 4 Hypoid 39 1 95 Inv Spline Pinion Nut Part No 127589 Spicer Current Current Ratios Kit Gear NSS Pinion NSS 4 30 508401 129449 43 129450 10 4 33 508366 129740 39 132455 9 4 63 504012 132132 37 132314 8 4 78 508402 129449 43 129451 9 4 88 508368 132135 39 132100 8 5 29 508367 132137 37 132103 7 5 57 511576 132139 39 132106 7 6 17 504013 132141 37 132311 6 6 50 504010 127384 39 132997 6 7 17 514337 127385 43 132998 6 NSS Not Sold Separately Note Spicer Gen Tech gearing is uniquely designed for single axle applications that specify quiet gearing The use of replacement standard gearing in these applications or the use of any gearing in Spicer carriers not m
30. Not Sold Separately NOTE 2 All 404 405 454 models except 344 Use p n 19186 30714 for D R344 series NOTE 13 In the 4th qtr of 1998 a design change was made to the FORWARD axle housings in the 404 family axles The axle housing rear cover is no longer a bolt on cover but is a welded assembly The bolt up cover are no longer manufactured or offered by Dana e included in basic overhaul kit included in bearing kit 30 Carrier Mounting Flange Design Change Carrier Mounting Flange Design Ghange Beginning June 3rd 2002 the nominal thickness of the carrier to housing flange was increased in the D R404 family models This change reguired the use of new fastener parts A new 45mm capscrew P N 130836 was released as it replaced both 210173 and 130158 old design capscrews Additionally a much thicker boss was added to the flange at the 12 00 amp 6 00 o clock positions These new thicker flange bosses reguire an even longer 70mm capscrew P N 130837 A thicker and larger diameter flat washer P N 130877 was also released as part of this upgrade The new washer replaces existing washer 29804 The existing stud P N 127641 and nut P N 127567 are not affected by these changes and will continue to be used SERVICE CARRIER NOTE Both thin flange and thick flange design carriers are still used by various OEM s If you have a vehicle that was originally equipped with a Spicer carrier built with the Thin Flange carrier desig
31. Nut 16 126216 126216 126216 126216 20 Bolt 16 129686 129686 129686 129686 Replaces 128806 See bulletin ABIB 9701 21 Pinion Pilot Brg 1 127485 127485 127485e 127485 22 Brg Inner 1 129562 129562 129562e 129562 Replaces 14218 23 BRG SPACER KIT AR 504016 504016 504016 504016 Individual Pinion Bearing Spacers Listed on page 11 24 Pinion Brg Cage amp Cup Assy 1 127600 127600 127600 127600 standard design includes items 24 26 129996 parking brake option Cage 127481C NSS 25 Pinion Brg Cup Inner 1 129561 e 129561 e 129561e 129561 Replaces 14217 26 Pinion Brg Cup Outer 1 012495e 012495e 012495e 012495e 27 Brg Cone Outer 1 012496e 012496e 012496e 012496 28 Capscrew 6 210115 210115 210115 210115 OIL SEAL amp SHIM KIT 216225 216225 216225 216225 Includes items 29 30 34 PINION CAGE SHIM KIT 504032 504032 504032 504032 Includes 5 each of shims below 29 Shim 003 AR 127595 127595 127595 127595 Shim 005 127596 127596 127596 127596 010 127597 127597 127597 127597 Shim 020 127598e 127598e 127598e 127598e Shim 030 127599e 127599e 127599e 127599e 30 Oil Seal 1 127591e 127591e 127591e 127591 31 Pinion Nut 1 127589 127589 127589 127589 M36 x 1 5 32 Thrust Screw 1 126193 126193 126193 126193 33 Jam Nut 1 210184 210184 210184 210184 34 RIV Sealant 1 107276Se 107276Se 107276Se 107276Se No
32. SPRING KIT 1 510870 510870 510870 Includes Items 53 amp 54 53 Shift Fork Assy NSS 1 129856 129856 129856 Order kit 510870 54 Compression Spring 1 129859 129859 129859 55 Piston Cover Assy 1 129573 129573 129573 Includes Cover 129578 and item 56 56 O Ring 1 129579 129579 129579 57 Piston 1 129580 129580 129580 58 O Ring 1 210180 210180 210180 59 Shipping Plug 1 599792 599792 599792 60 Thrust Screw 1 126193 126193 61 Jam Nut 1 210184 210184 62 RTV Sealant 1 107276Se 1072765 1072765 Illustrated 55 Not Sold Separately Summary of Kits and Assemblies Air L O Kit Complete 510052 Includes 53 59 Repair Kit 510053 Includes 55 58 Shift Fork amp Compression Spring Kit 510870 Includes 53 54 Pinion Bearing Spacers Pinion Bearing Spacers Note March 1 1995 Spicer D344 404 405 454 series axles were built with a thicker variable pinion spacer different from the original design axles built before this date used a two washer setup This two washer setup is comprised of a spacer washer 127565 and a variable pinion bearing spacer part number by thickness When servicing the above models select a variable pinion bearing spacer from the list below to attain the correct pinion bearing preload All procedures on Pinion Bearing Preload remain the same and the proper steps should be followed according to your Spicer Service Manual If you have an existing 127565 spacer washer do not use it with
33. and Hanger Brackets and ABS Blocks RD405 322270 307875 322271 GM Has Torque Rod Brackets and Hanger Brackets RD405 322556 322557 Volvo PB Int FL KW Bare Hsg w Cut out for Diff Lock 11mm Wall and ABS Blocks RD405 322732 322733 Service Has Torque Rod Brackets RD405 322736 322737 NONE Service Has Hanger Brackets RS344 323395 502043 GM Has Torque Rod Bracket RD404 323399 502006 GM Has Torque Rod Brackets and ABS Blocks RD405 323555 502039 Kenworth Bare Hsg w Unique Brake Flange and ABS Blocks RD405 323587 502016 GM Has Torque Rod Bracket and ABS Blocks 38 Gear amp Pinion Kits Gear amp Pinion Kits D Forward Axles D344 404 405 454 15 4 15 7 Hypoid Pinion Nut Part No 126182 Spicer Current Current Original Original Original Ratios Kit Gear NSS Pinion NSS Kit Gear NSS Pinion NSS 2 64 211462 127387 37 127439 14 NA NA NA 2 85 211463 127388 37 127440 13 NA NA NA 2 93 509423 129532 41 129531 14 NA NA NA 3 08 513386 127388 37 129716 12 211464 127388 37 127441 12 3 25 513385 127389 39 130120 12 211465 127389 39 127442 12 3 36 513384 127388 37 130121 11 211466 127388 37 127443 11 3 42 504056 134327 41 134328 12 NA NA NA 3 55 513383 127389 39 130122 11 211467 127389 39 127444 11 3 70 513382 127388 37 130123 10 211468 127388 37 127445 10 3 90 513381 127389 39 130124 10 211469 127389 39 127446 10
34. anufactured by Spicer could lead to noise complaints or failures and are not warranted by Dana 41 Service Carrier Assemblies DS404 P RS404 Single Reduction Single Reduction 41 Inv Spline 41 Inv Spline Side Gear p n 127368 Side Gear p n 127368 Non Pump Pump Old Part Old Part Service Service Service Number Number Ratio Carrier Notes Ratio Carrier Carrier Non Pump Pump 2 64 674877 2 64 682861 682200 674861 675200 2 85 674878 2 85 682862 682201 674862 675201 3 08 674879 3 08 682863 682202 674863 675202 3 25 674880 3 25 682864 682203 674864 675203 3 36 674881 3 36 682865 682204 674865 675204 3 55 674882 3 55 682866 682205 674866 675205 3 70 674883 3 70 682867 682206 674867 675206 3 90 674884 3 90 682868 682207 674868 675207 411 674885 4 11 682869 682208 674869 675208 4 33 674886 4 33 682870 682209 674870 675209 4 63 674887 4 63 682871 682210 674871 675210 4 88 674888 4 88 682872 682211 674872 675211 5 29 674889 529 682873 682212 674873 675212 5 57 674890 5 57 682874 682213 674874 675213 6 17 674891 6 17 682875 682214 674875 675214 6 50 674892 6 50 682876 682012 674876 N A 7 17 674893 DD404 P RD404 Single Reduction w Differential Lock Single Reduction w Differential Lock 41 Inv Spline 41 Inv Spline Side Gear p n 127368 Side Gear p n 127368 No
35. els 134192 Lube Pump Assembly All Models BEFORE June 2008 127534 Lube Pump Parts Kit All Models AFTER June 2008 504029 Manifold Parts Kit Pump Mdls AFTER June 2008 504029 Oil Seal Driver Installation Kit All Models 217414 Oil Seal amp Shim Kit All D series 216224 Oil Seal amp Shim Kit All series 216225 Output Shaft Kit All D Models 216227 Pinion Brg Spacer Kit All D Models 504043 Pinion Brg Spacer Kit All Models 504016 Pinion Brg Cage Shim Kit 504032 Kits and Assemblies Service Kits and Assemblies Ring Gear Nut amp Bolt Kit 508652 Shift Fork amp Spring Kit 510870 Wheel Diff Case Kit 2 64 to 3 25 All DS RS Models 508653 Wheel Diff Case Kit 3 36 to 3 90 All DS RS Models 508654 Wheel Diff Case Kit 4 11 to 4 88 All DS RS Models 508655 Wheel Diff Case Kit 5 29 to 7 17 All DS RS Models 508656 Wheel Diff Case Kit 2 64 to 3 25 All DD RD Models 508653 Wheel Diff Case Kit 3 36 to 3 90 All DD RD Models 508654 Wheel Diff Case Kit 4 11 to 4 88 All DD RD Models 508655 Wheel Diff Case Kit 5 29 to 7 17 All DD RD Models 508656 Wheel Diff Side Gear Kit 41 Inv 216229 Wheel Diff Side Gear Kit 39 Inv 217461 Wheel Diff Kit w o side gears All Models 216228 49 Ouick Part Number Replacement Listing Ouick Part Number Replacement Listing Current Replacement
36. ems 16 19 15 Side Gear 39 Inv Spline 2 127367 Side Gear 41 Inv Spline 2 127368 127368 16 Side Gear Thrust Washer 2 127386 127386 127386 17 Side Pinion Thrust Washer 4 129305 129305 129305 18 Side Pinion 4 133761 133761 133761 19 Diff Spider 1 127359 127359 127359 RING GEAR NUT amp BOLT KIT 1 508652 508652 508652 Includes items 20 21 20 Nut Ring Gear 16 126216 126216 126216 21 Bolt Ring Gear 16 129686 129686 129686 22 Pinion Pilot Brg 1 127484 127484 127484 23 Brg Cone Inner 1 129560e 129560 129560 55 Not Sold Separately NOTE 12 All differential case halves are now available separately Design enhancements in the diff cases were released in 2007 refer to bulletin ABIB 0704 Single Reduction Forward Axles After June 2008 DS404 P DD404 P Item Description Qty DS344 DS405 P DD405 P Notes 24 PINION BRG SPACER KIT AR 504043 504043 504043 Individual Pinion Bearing Spacers Listed on pg 11 25 Pinion Brg Cage amp Cup Assy 1 129767 129767 129767 Cage 127488C Includes item 25 27 26 Pinion Brg Cup Inner 1 129561 129561 129561 27 1 012495e 012495e 012495e 28 Pinion Brg Cone Outer 1 127535 127535 127535 29 Capscrew 6 210115 210115 210115 30 Pinion Helical Gear 1 127523 127523 127523 31 Roll Pin 1 118807 118807 118807 32 Slotted Pinion Nut 1 126182 126182 126182 Manifold Parts Ki
37. ential Lock Forward Axle DD404 P DD405 P DD454 P Rear Axle RS344 RS404 RS405 RS454 Rear Axle RD404 RD405 RD454 Axle Capacity 34 000 Lbs 40 000 Lbs 40 000 Lbs 45 000 Lbs Axle Capacity 40 000 Lbs 40 000 Lbs 45 000 Lbs Gear Size 15 40 15 70 Hypoid Gear Nom 15 40 15 70 Hypoid Gear Nom 15 40 15 70 Hypoid Gear Nom 15 40 15 70 Hypoid Gear Nom Gear Size 15 40 15 70 Hypoid Gear Nom 15 40 15 70 Hypoid Gear Nom 15 40 15 70 Hypoid Gear Nom Single Reduction Models With IASS In Axle Speed Sensors NLA Forward Axle DA344 NLA DA404 P NLA DA405 P NLA DA454 P NLA Rear Axle RA344 NLA RA404 NLA RA405 NLA RA454 NLA Axle Capacity 34 000 Lbs 40 000 Lbs 40 000 Lbs 45 000 Lbs Gear Size 15 40 15 70 Hypoid Gear Nom 15 40 15 70 Hypoid Gear Nom 15 40 15 70 Hypoid Gear Nom 15 40 15 70 Hypoid Gear Nom Note The D R454 and the DA RA344 404 models no longer produced after 2001 Single Reduction Forward Axles After June 2008 Single Reduction Forward Axles After June 2008 Parts for the Differential Lock Assembly see page 17 ap Half WA See Ring Gear amp Pinion page 39 22 a 7 23 Single Reduction Forward Axles After June 2008 Single Reduction Forward Axles After June 2008 See Yokes and Flanges Page 46 Single Reduction Forward Axles After June 2008 DS404 P DD404 P
38. ial Lock Assembly 6 N ZOX y 2 1 cg Cover Gasket Current Design 129035 Old Design 210280 x 2 D Wheel Differential Lock Assembly Wheel Differential Lock Assembly After July 1 1996 Bulletin ABIB 9609 the diff lock selector switch is located on a piston cover that has a 14 mm threaded hole to accommodate the 129035 switch The original piston covers are replaced by PISTON COVER UPGRADE KITS and the 129035 selector switch is now included with any Carrier Unit built after July 1 1996 date code H96183 When ordering a piston cover upgrade Kit it is important to select a kit that includes the proper wiring harness for the vehicle being repaired reference charts below Parts Used Parts Used Item before 7 1 1996 after 7 1 1996 Description Notes Order Upgrade Kit 1 210280 Note 1 129035 Selector Switch Note 2 2 126618 129034 Nylon Washer Black 3 128146 Note 1 129044 Wiring Harness Metri Pack 150 Series 508396 4 128445 Note 1 129046 Wiring Harness Metri Pack 280 Series 508291 5 128481 Note 1 129047 Wiring Harness Weather Pack 508289 6 128641 129425 Piston Cover Inch Thread Airline Hole See Below 6 128612 129424 Piston Cover Metric Thread Airline Hole 508290 NOTE 1 Part is no longer available you must order upgrade kits NOTE 2 Service carrier units built after 7 1 96 are built with 129425 Piston Covers and include a new selector swi
39. individually new Thick Flange carrier design as fully detailed in Spicer bulletin AXIP 0210r1 Shown below are the axle housing hardware kits and fastener locations for both variations View fastener locations as if 512087 Hardware Kit Thick Flange installing differential into the axle housing Part No Qty Description 107276S 1 RTV Sealant 3 oz Tube 127567 4 Nut P 130836 8 Capscrew 45 mm Short Head to Housing 130837 4 Capscrew 70 mm Long 130877 12 Washer 129293 1 Loctite 271 0 5 ml Tube Forward Rear A shais136 1 Instruction Sheet Thick Flange Carriers Carriers 511600 Hardware Kit Thin Flange Part No Qty Description 127567 4 Nut 127641 4 Stud 130836 10 Capscrew was 130158 Head to Housing 129293 1 Loctite 271 0 5 ml Tube 107276S 1 RTV Sealant 3 oz Tube shais131 1 Instruction Sheet Forward Rear Carriers Carriers A 127641 Studs amp 127567 Nuts B 130836 Capscrews Short 45 mm C 130837 Capscrews Long 70 mm D 130877 Flat Washers All Locations 32 Carrier Mounting Flange Design Change Casting amp Service Parts Cross Reference Listing Below are two helpful cross reference charts Chart A shows casting numbers that can guickly identify the old design parts versus the new design parts Chart B is a service parts cross reference listing The part numbers in this chart are sorted by part type refer
40. l Number Ratio NLA Model Number 2 64 675657 NLA none 2 64 675673 NLA none 2 85 675658 NLA none 2 85 675674 NLA none 3 08 675659 DSH40 682740 3 08 675675 RSH40 675780 3 25 675660 DSH40 682741 3 25 675676 RSH40 675781 3 36 675661 DSH40 682742 3 36 675677 RSH40 675782 3 55 675662 DSH40 682743 3 55 675678 RSH40 675783 3 70 675663 DSH40 682744 3 70 675679 RSH40 675784 3 90 675664 DSH40 682745 3 90 675680 RSH40 675785 4 11 675665 DSH40 682746 4 11 675601 RSH40 675786 4 33 675666 DSH40 682747 4 33 675682 RSH40 675787 4 63 675667 DSH40 682748 4 63 675683 RSH40 675788 4 88 675668 DSH40 682749 4 88 675684 RSH40 675789 5 29 675669 DSP40 682977 5 29 675685 RSP40 676041 5 57 675670 DSP40 682978 5 57 675686 RSP40 676042 6 17 675671 DSP40 682979 6 17 675687 RSP40 676043 6 50 675672 DSP40 682980 6 50 675688 RSP40 676044 7 17 DSP40 682014 TAT RSP40 681443 DS454P Replaced By Current Part DD454 Replaced By Current Part Ratio NLA Model Number Ratio NLA Model Number 0264 675641 NA none 2 64 675705 NLA none 2 95 675642 NLA none 2 85 675706 NLA none 3 08 675643 DSH40P 682750 3 08 675707 DDH40 682760 3 25 675644 DSH40P 682751 3 25 675708 DDH40 682761 3 36 675645 DSH40P 682752 3 36 675709 DDH40 682762 3 55 675646 DSH40P 682753 3 55 675710 DDH40 682763 3 70 675647 DSH40P 682754 3 70 675711 DDH40 682764 3 90 675648 DSH40P 682755 3 90 675712 DDH40 682765 4 11 675649 DSH40P 682756 4 11 675713 DDH40 682766 4 33 675650 DSH40P 682757 4 33 675714 DDH40 682767 4 63 675651
41. mple shims Assy Assembly Brg Bearing Diff Differential Hsg Housing IASS In Axle Speed Sensor Inv Involute N A Not Applicable NSS Not Serviced Separately Items which can only be purchased in sets kit form or service assemblies Example brake shoes Effectively using a Parts Listing Example Follow the example below to locate and order exactly what is required for servicing Match to items on illustration Use to identify Part Order this quantity for servicing Order part number by model indicated e RH LH Right Hand Left Hand Determined as viewed from behind the vehicle looking forward e RTV Gasket Compound Formed in place gasket sealer It is recommended for use on all surfaces requiring a gasket Str Straight Illustrations e Illustrations show parts in assembly groups e Item numbers on illustrations correspond with parts listings on pages that accompany the drawings e Notes are included on illustrations where needed Parts Listings e Parts listings are defined by parts groupings and are broken down by service assemblies e Parts Listings identify a part for servicing with the following categories e Item corresponds with numbers on illustrations for part identification e Part Name specifies part name or description Quantity Qty quantity required for assembly e Current Part service part numbers are broken down by model type or other applicable information
42. n it can be universally serviced with an current Thick Flange Carrier Assembly The repairing dealer must simply make sure to use the correct axle housing fasteners hardware parts when re installation of the replacement carrier is done e Differential Carriers with THICK FLANGE carrier use axle housing hardware kit P N 512087 e Differential Carriers with THIN FLANGE carrier use axle housing hardware kit P N 511600 GM Vehicles use a double ended capscrews at the housing fastener location The hardware kits above can be used but the unique capscrew must be purchased individually New Axle Housing Fasteners Old Flat Washer New Wider and Thicker Flat Washer P N 130877 Old Capscrew New Longer 45 mm Capscrew P N 130836 New Longer 70 mm Capscrew P N 130837 IMPORTANT Spicer does not recommend the mixing of various designs carrier to housing capscrews on the same assembly Whether mixing or not torgues must be measured using a calibrated torgue wrench Failure to re torgue bolts and nuts to proper specifications may lead to carrier to housing leaks and possible component damage 31 Carrier Mounting Flange Design Change Axle Housing Fasteners NOTE GM Vehicles use a double ended capscrews at the housing fastener location The hardware kits above can be used but the unigue On June 3 2002 the D R404 family models were upgraded to the capscrew must be purchased
43. n Pump Pump Old Part Old Part Service Service Service Number Number Ratio Carrier Notes Ratio Carrier Carrier Non Pump Pump 2 64 676013 replaces 675280 2 64 682510 682303 675510 675303 2 85 675281 2 85 682251 682304 675251 675304 3 08 675282 3 08 682252 682305 675252 675305 3 25 675283 3 25 682253 682306 675253 675306 3 36 675284 3 36 682254 682307 675254 675307 3 55 675285 3 55 682255 682308 675255 675308 370 675286 3 70 682256 682309 675256 675309 390 675287 3 90 682257 682310 675257 675310 411 675288 4 11 682258 682311 675258 675311 4 33 675289 4 33 682259 682312 675259 675312 4 63 675290 4 63 682260 682313 675260 675313 4 88 675291 4 88 682261 682314 675261 675314 5 29 675292 5 29 602262 682315 675262 675315 5 57 675293 5 57 682263 682316 675263 675316 617 675294 6 17 682264 682317 675264 675317 6 50 675295 6 50 682265 682318 675265 675318 747 675296 42 Service Carrier Assemblies Supersession of D R454 Models to New Generation Models In 2003 the D R454 models were discontinued and replaced by the DSH40 RSH40 family of carriers In 2009 additional replacements were made and are reflected below Reference Spicer bulletin abib 0902 for specific details of those changes DS454 Replaced By Current Part RS454 Replaced By Current Part Ratio NLA Mode
44. oil seals Using these tools ensures proper installation of the seal Failure to use these tools may result in an improperly installed or damaged seal Oil Seal Driver Installation Kit 217414 126917 128706 D nput 726977 A Pinion 48 Service Kits and Assemblies Axle Housing Hardware Kit Thick Flange Carriers 512087 Axle Housing Hardware Kit Thin Flange Carriers 511600 Basic Overhaul Kit DD Models BEFORE June 2008 217463 Basic Overhaul Kit RD Models BEFORE June 2008 217464 Basic Overhaul Kit DS Models BEFORE June 2008 216220 Basic Overhaul Kit RS Models BEFORE June 2008 216221 Basic Overhaul Kit D40K Standard mdls AFTER June 2008 504030 Basic Overhaul Kit D40K Diff Lock mdls AFTER June 2008 504031 Bearing Kit DS Models BEFORE June 2008 216234 Bearing Kit RS Models BEFORE June 2008 216248 Bearing Kit DD Models BEFORE June 2008 512800 Bearing Kit RD Models BEFORE June 2008 512805 Cage amp Cup Assy All D series 129767 Cage amp Cup Assy All R series 127600 Cage amp Cup Assy All series Parking Brake Option 129996 Input Brg Cover Assy After 11 2 98 129575 Input Brg Cover Assy Before 11 2 98 127602 Input Shaft Kit All D Models BEFORE June 2008 510593 Input Shaft Kit D4OK PUMP Models AFTER June 2008 504027 Input Shaft Kit D40K NON PUMP Models AFTER June 2008 504026 Inter Axle Diff Assy All D Mod
45. rews 129572 NLA PDU Cover 9 hole Replaced in production by 130823 PDU Cover 510023 NLA Carrier amp Cap Kit DS344 404 405 454 See note below 510024 NLA Carrier amp Cap Kit DS404P 405P 454P See note below 510027 NLA Carrier amp Cap Kit DD404 405 454 See note below 510028 NLA Carrier amp Cap Kit DD404P 405P 454P See note below 510017 Carrier amp Cap Kit RD404 405 454 510018 Carrier amp Cap Kit RS344 404 405 454 NOTEAII Original design Forward Carrier amp Cap kits made BEFORE JUNE 2008 are no longer available thru Dana Only New design carrier cap kits are available and they are not interchangeable Reference Spicer Bulletin ABIB 0801 for more detailed information 33 Axle Shafts Spicer 404 series axle shafts are used in sets have unegual shaft Iengths and may be location specific or Wheel Equipment specific When replacing 404 axle shafts locate the axle shaft part number see Model Identification page 4 or select the correct axle shaft from the chart below before placing your order DO NOT MISPLACE AXLE SHAFTS FROM THEIR INTENDED LOCATION NOTE STR Straight TPR Tapered Axle Shafts Single Reduction Models Body Shaft Spline Flange Flange Model PartNo Qty Spline 0 D Length Length 0 D Holes OEM 170605 190605 RS344 129010 1 39 1 81 38 500 4 6 223 12 781 TPR 2 129479 1 39 1 81 42 750 4 6 223 12 7
46. s 42 Supersession of D R454 Models to New Generation Models 43 Yokes and Flanges 46 Kits and Assemblies 48 Oil Seal Installation Tools 48 Service Kits and Assemblies 48 Quick Part Number Replacement Listing 50 General Information General Information How To Use lllustrated Parts List Ordering Parts This parts book is organized in sections according to parts servicing reguirements Use the Contents or page headings and colored tabs to find information Use this book to order parts for your Spicer Axle For convenience part numbers have been included for all pieces of the carrier assembly Some of these parts such as the carrier and caps are serviced only in kits or assemblies Part numbers are for your reference only Those parts not serviced separately are identified with NSS Kits and Assemblies Kits and Assemblies contain groups of individual or assembled parts developed for optimal replacement or repair of a service problem Kits and Assemblies are shown with applicable parts groupings in the parts listing See the Appendix for detailed information concerning kits applicable to this model Abbreviations ABS Antilock Brake System AR As Reguired Parts that vary in guantity with each axle Exa
47. s or flanges OEM part number assigned to the axle build Carrier assembly serial number assigned by the manufacturing plant Axle gear ratio Carrier assembly production or service part number The axles illustrated in this book are specified with a variety of different axle shafts according to OEM specifications When ordering replacement axle shafts note the part number stamped into the flange o Axle Shaft Part Number 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 DS 404 P Gearing Te D Forward Tandem Axle Standard R RearTandem Axle P Optional S SingleReduction DesignLevel D Single Reduction with WheelDifferentialLock Capacity x10001bs A SingleReductionwith Example 40 40 000 Ibs In Axle Speed Sensors IASS Example DS ForwardTandem SingleReduction or RS RearTandem SingleReduction Models The following models are included in this publication Single Reduction Models Forward Axle DS344 DS404 P DS405 P DS454 P Single Reduction Models with Wheel Differ
48. see note below 7 O ring 2 14033 14033 See Note below 8 Bushing Sleeve 2 129059 NLA 129059 NLA See Note below 9 Snap Ring 2 129057 NLA 129057 NLA See Note below NOTE Some IASS model parts are no longer manufactured or available and stock availability of individual items are limited If Key components for these models are not available retrofitting the vehicle and ABS systems to more conventional system set up will be required Consult your OEM for engineering help 28 Output Shaft and Axle Housings Output Shaft and Axle Housings See Yokes page 46 CA Oe WU Qe See page 32 for axle housing hardware kits and fastener location Head to Housing Fasteners Viewed from rear of axle with drain plug down 29 Output Shaft and Axle Housings Output Shaft and Axle Housings Item Description Qty Part No Notes 1 Axle Shaft 2 Axle Shaft Chart page 34 2 Outer Bearing Adjuster Nut 2 119881 See Note 2 3 Lockwasher w Tab 2 129132 4 Dowel Type Lockwasher 2 119883 5 Inner Bearing Adjuster Nut 2 119882 6 Axle Housing Assy 1 Note See page 36 See your OEM Catalog n U Tube Breather Kit 1 507162 Contains items 129340 amp 302706 8 Magnetic Drain Plug 3 4 1 054254 All D R models 9 Stud Carrier to Hsg 4 127641 All D R models M16 X 1 5 10 Wa
49. sher Carrier to Hsg 12 029804 All D models 10A Washer Carrier to Hsg 4 029804 All R models 11 Nut Carrier to Hsg 4 127567 All R models 12 Capscrew Carrier to Hsg 10 130836 All D R models was 210173 and 130158 M16 X 2 0 13 Axle Hsg Cover Kit 1 217519 NLA Includes 13 15 16 23 29 Cover casting 127486C NSS Replaces 129490 127487 129489 129037 Refer to note 13 below Ref Bulletin ABIB 9709 14 Capscrew Hsg Cover to Hsg 8 210135 M12x1 75 15 Magnetic Plug 1 1 075130 See Bulletin ABIB 9709 15 Non Magnetic Plug 3 4 129492 See Bulletin ABIB 9709 15 Magnetic Plug 3 4 129491 See Bulletin ABIB 9709 16 Temperature Sensor Plug 1 2 090898 17 Lube Tag for 3 4 Plug 1 129486 See Bulletin ABIB 9709 Part Not Illustrated 17 Lube Tag for 1 Plug 1 128288 See Bulletin ABIB 9709 Part Not Illustrated 18 Nut Hsg Cover to Hsg 4 127569 All Forward Axles 19 Lockwasher Hsg Cover to Hsg 4 210140 All Forward Axles 20 Stud Hsg Cover 4 127568 All Forward Axles 21 Dowel Pin Hsg Cover 1 007641 All Forward Axles OUTPUT SHAFT KIT 216227 Includes Items 22 23 22 Output Shaft 127646 NSS 23 Locknut Hex 1 127588 M39 x 1 5 24 Oil Seal 1 127592 25 Snap Ring 103 1 129594e Replaces 127538 127537 26 Bearing Cup 2 127539e 27 Bearing Cone 2 127540 28 Seal Driver 1 126917 In Kit 217414 29 Adapter 1 128706 In Kit 217414 30 Loctite Adhesive 1 129293 Not Illustrated 5 ml Tube 31 RTV Sealant 1 107276S Not Illustrated 3 oz Tube NSS
50. ssy 1 129767 129767 129767 129767 Includes item 25 27 Cage 127488C NSS 129767 Replaces 127601 26 Pinion Brg Cup Inner 1 129561 e 129561 e 129561e 129561 129561 Replaces 14217 27 Pinion Brg Cup Outer 1 012495e 012495e 012495e 012495e 28 Brg Cone Outer 1 127535 e 127535 e 127535e 127535 29 Capscrew 6 210115 210115 210115 210115 30 Pinion Helical Gear 1 127523 127523 127523 127523 31 Roll Pin 1 118807 118807 118807 118807 32 Slotted Pinion Nut 1 126182 126182 126182 126182 34 Output Shaft Brg Cup 1 127536 127536 127536e 127536 35 Output Shaft Brg Cone 1 110812e 110812e 110812e 110812e 36 Output Shaft Side Gear 1 127645 127645 127645 127645 37 Snap Ring 1 085997 085997 085997 085997 38 Inter Axle Diff Assy 1 134192 134192 134192 134192 134192 replaces 128634 129771 39 Helical Side Gear amp Bushing 1 130907 130907 130907 130907 Was 127495 and 127494 See Assy Gear 130906 NSS Note 39 Includes Item 40 40 Bushing Helical Gear 2 129371 129371 129371 129371 129371 Replaces 127543 41 Thrust Washer Helical Gear 1 132439e 132439e 132439e 132439e 132439 replaces 128702 42 Lockout Sliding Clutch 1 127510 127510 127510 127510 43 Input Shaft Kit 1 510593 510593 510593 510593 Includes Items 41 43 58 shaft 129770 NSS was 128704 Was 216226 See Note 43 44 Retainer 1 128700 128700 128700 128700 45 Input Shaft Bearing Cone 1 129558e 129558e 129558e 129558 129558 Replaces 8206
51. sy Gear Stamp 130906 NSS 37 Bushing Helical Gear 2 129371 129371 129371 38 Thrust Washer Helical Gear 1 132439e 132439e 132439e 39 Lockout Sliding Clutch 1 127510 127510 127510 Single Reduction Forward Axles After June 2008 DS404 P DD404 P Hem Description Qty DS344 DS405 P DD405 P Notes 40 Oil Retainer 1 128700 128700 128700 41 Input Shaft Bearing Cone 1 129558e 129558e 129558e 42 Bearing Cup 1 10089120 10089120 1008912e can use 129559 For PDU Cover amp Lockout Details See page 20 OIL SEAL amp SHIM KIT 1 216224 216224 216224 Includes shims amp oil seals 127591 127592 PINION CAGE SHIM KIT 1 504032 504032 504032 Includes 5 each of shim listed below 43 Shim 003 AR 127595 127595 127595 Shim 005 127596 127596 127596 010 127597 127597 127597 Shim 020 127598e 127598e 127598e Shim 030 127599e 127599e 127599e 44 Oil Seal V Ring 1 128703e 128703e 128703e 45 Input Brg Cover Assy 1 129575 129575 129575 Castit129574C Includes item 42 46 Bearing Cover Cap Screw 6 210115 210115 210115 47 Oil Seal 1 127591e 127591 127591 48 Locknut 1 128049 128049 128049 In 510593 Kit M42 1 5 49 Lube Trough 1 129577 129577 129577 50 Power Divider Cover 1 130823 130823 130823 11 hole design 51 Washer Capscrew 11 128415 128415 128415 52 Capscrew Long 11 210091 210091 210091 SHIFT FORK amp COMPRESSION
52. t Non Pump 1 513880 513880 513880 NON PUMP Includes 132435 Seal Manifold Assy Non Pump 1 NON PUMP Must order kit 132435 NSS Output Side Gear Non Pump 132443 132443 132443 NON PUMP Input Shaft Kit Non Pump 504026 504026 504026 NON PUMP Includes 132447 128049 132439 Input Shaft Non Pump 132447 NSS NON PUMP Must order kit Manifold Parts Kit Pump Model 504029 504029 PUMP MODELS Includes 133964 134010 129338 134011 131366 Seal Manifold Assy Pump PUMP MODELS Must order kit 131366 NSS Filter Screen Assy 133964 133964 PUMP MODELS Collar Lock 134010 134010 PUMP MODELS Clamp 129338 129338 PUMP MODELS Lube Hose 134011 134011 PUMP MODELS Lube Pump Kit 904028 504028 504028 PUMP MODELS Includes 132060 131541 132061 131368 Output Side Gear Pump Model 504028 504028 PUMP MODELS 132061 NSS Lube Pump 131368 NSS 504028 504028 PUMP MODELS Pump Locking Pin 131541 131541 PUMP MODELS Input Shaft Kit Pump Model 904027 904027 904027 PUMP MODELS Includes 132446 128049 132439 Input Shaft Pump Model PUMP MODELS Must order kit 132446 NSS 33 Bearing Race 34 Bearing Cone 110811 110811 110811 132060 132060 132060 l 35 Inter Axle Diff Assy 134192 134192 134192 134192 replaces 128634 129771 36 Helical Side Gear amp Bushing 130907 130907 130907 Includes item 37 As
53. t Illustrated NSS Not Sold Separately 26 In Axle Speed Sensor In Axle Speed Sensor In Axle Speed Sensor Before 11 2 98 In Axle Speed Sensor After 11 2 98 F NOTE Sensor connector installed up through carrier hole reference bulletin ABIB 9901 2f In Axle Speed Sensor In Axle Speed Sensor DA344 RA344 DA344 RA344 DA404 P RA404 DA404 P 404 DA405 P RA405 RA405 P RA405 DA454 P RA454 DA454 P RA454 Item Description Qty Before 11 2 98 Before 11 2 98 After 11 2 98 After 11 2 98 Notes 1 Sensor Connector 2 128713 128713 See Note below 2 Diff Bearing Adjusters Plain Half 344 series 1 129056 NLA 129056 NLA 129056 NLA 129056 NLA See Note below Flange Half 344 series 1 129055 NLA 129055 NLA 129055 NLA 129055 NLA See Note below Plain Half 404 405 454 1 128429 NLA 128429 NLA 128429 NLA 128429 NLA See Note below Flange Half 404 405 454 1 128428 NLA 128428 NLA 128428 NLA 128428 NLA See Note below 3 Rotor Assembly 41 spline 2 128081 NLA 128081 NLA 128081 NLA 128081 NLA All models except D R344 39 spline 2 128993 NLA 128993 NLA 128993 NLA 128993 NLA D R344 models only 4 Sensor Assembly 2 128082 NLA 128082 NLA 128082 NLA 128082 NLA See Note below 5 Fasteners 4 128074 NLA 128074 128074 NLA 128074 NLA See Note below 6 Sensor Connector Assy 2 129061 NLA 129061 NLA Includes Item 7
54. tch Piston Cover Upgrade Kits Kit Contents Description b08289 508290 508291 508396 Selector Switch 14 MM 129035 129035 129035 129035 Nylon Washer 129034 129034 129034 129034 Piston Cover 129425 129424 129425 129425 Wiring Harness 129047 129047 129046 129044 Cover Gasket 128643 128643 128643 128643 Cover 129424 and 128612 have metric threaded airline hole for GMC applications Wiring Harness Usage by OEM Wiring Harness Part Numbers OEM Before 7 1 96 After 7 1 96 Notes Volvo GMC Navistar 128491 129047 Item 5 Pg 18 Kenworth Peterbilt Western Star Freightliner 128146 129044 Item 3 Pg 18 Ford Mack 128445 129046 Item 4 Pg 18 Air Lockout Parts After 11 2 1998 Air Lockout Parts After 11 2 1998 Lockout design after 2 2 00 11 hole cover Lockout design after 11 2 98 9 hole cover 1 w 5 4 3 2 20 Air Lockout Parts After 11 2 1998 Integral Shift Item Description Qty Cylinder Models Notes 1 Plastic Shipping Plug 1 599792 2 Piston Cover Assy 1 129573 Cover 129578 Includes 3 3 O Ring 1 129579 4 Piston 1 129580 5 O Ring 1 210180 6 Push Rod Assy 1 N A Order Kit 510870 7 Shift Fork Assy 1 129856 Order Kit 510870 8 Compression Spring 1 129859 9 Shift Fork Assy Welded 1 129856 Order Kit 510870 10 Compression Spring 1 129859 included in 510870 Kit 11 PDU Cover 9 hole 1 129572 NLA Note 1 12 PDU Cover 11 hole 1 13
55. the carrier RTV can be used as replacement for this o ring The o ring is no longer available through Dana Wheel Differential Lock Assembly Rear carrier illustrated above Parts for forward carrier are e Cys 1 10 identical to rear carrier 15 PH 12 16 17 14 13 All D R404 Item Description Qty Diff Lock Mdls Notes 1 Fixed Curvic Clutch Gear 1 128627 2 Snap Ring 1 129433 Replaces 210299 3 SL Curvic Clutch Gear 41 Inv spline 1 126840 4 Compression Spring 1 128614 SHIFT FORK ASSY 217465 Includes items 5 6 5 Shift Fork 128611C NSS 1 128609 Fork NSS 6 Spring Pin 1 210020 7 Push Rod 1 128617 8 Piston Driver 1 128640 9 Set Screw 1 128618 10 Piston 1 128624 11 O Ring 1 210180 12 Piston Cover 1 See page 18 amp 19 13 Gasket 1 128643 14 Capscrew Flg Head 2 128744 15 Capscrew 1 128274 M12x1 5 16 Washer 1 129034 See page 18 amp 19 17 Switch 1 129035 See page 18 amp 19 18 Fitting Assy 1 128178 Note 18 Not Illustrated 19 Wiring Harness 1 See page 18 amp 19 Not Illustrated 20 Washer 1 210288 Note 20 Not lllustrated NOTE 18 Used in clearance sensitive applications fitting also converts Metric threads to English threads NOTE 20 A washer was used in some diff lock carriers for a limited time 3 90 ratios only part is longer used or required Wheel Differential Lock Assembly Wheel Different
56. to the New Part Description column Chart A Part Number Cross Reference Casting Numbers New Casting Old Casting Part No Part No Description Model 130809 129539 129540 Diff Carrier Casting DA344 404 405 454 DS344 404 405 454 130814 129550 Diff Carrier Casting DD404 DD404P DD454 DD454P 130819 129551 Diff Carrier Casting DA404P 405P 454P DS404P 405P 454P 130822 129571 PDU Cover Casting D Forward Carriers 11 hole 130824 129351C 129541 Diff Carrier Casting RA344 404 405 454 RS344 404 405 454 130827 128600 Diff Carrier Casting RD404 RD454 Chart B Part Number Cross Reference Service Parts Service Replaces Service Part No Part No Description Notes 511600 None Axle Hsg hardware Kit Thin Flange Models Use only in Models with Thin Flange Carrier Design 512087 None Axle Hsg hardware Kit Thick Flange Models Use only in Models with Thick Flange Carrier Design 130836 130158 210173 Capscrew 45 mm Use in All Models New amp Old Design 130837 None Capscrew 70 mm Use only in Models with Thick Flange Carrier Design 130158 NLA Capscrew 40 mm Replaced by 130836 Capscrew 210173 NLA Capscrew 40 mm Replaced by 130836 Capscrew 130877 29804 Flat Washer Use in All Models New amp Old Design 029804 None Flat Washer Was used in various brake assemblies 130823 PDU Cover 11 hole All D Forward Carriers new cover uses 11 capsc
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