Spicer Dodge 1999-2001 Light Duty Axle Applications User Manual
Dodge 1999-2001
Light Duty Axle Applications
X510-5
September, 2001
Supersedes X510-5DSD
dated January 1999
SAFETY INFORMATION
WARNING - Failure to follow these instructions could affect vehicle performance and/or
safety and result in personal injury or death.
• Do not convert or alter Spicer axles except in accordance with vehicle manufacturer's
instructions.
Spicer axles are designed to meet OEM vehicle manufacturer's design and performance
specifications. Improper conversion or alteration of these axles can damage the axles and/or
other vehicle systems. Contact the OEM manufacturer for specific directions and guidelines.
• Do not change axle gear ratios on vehicles with anti-lock braking systems except in
accordance with the vehicle manufacturer's instructions.
Vehicles with anti-lock braking systems may utilize sensors and tone rings within the axle
housings to ensure the functioning of the anti-lock brakes. Improperly changing the axle
ratios may defeat the anti-lock braking system. If changing axle ratios will require changing
the location of the tone ring on the ring gear flange relative to the location of the sensor in
the axle housing, contact the OEM manufacturer for specific directions and guidelines.
• Do not reuse or substitute ring gear bolts.
If you reuse a ring gear bolt or substitute an inferior quality bolt, the bolt may loosen or back
out of its threaded hole, causing severe damage to the axle gears and other components and
possibly resulting in a sudden "locking up" of the axle and loss of control of the vehicle.
Always use new bolts specifically recommended for the application and install bolts using
proper tools and torquing to the proper specifications.
CAUTION - Do not substitute parts not of Spicer quality.
Spicer axles are designed for each model vehicle, and manufactured and tested for safety and best
performance. Replacement parts from other manufacturers may not be made to Spicer's rigid quality
standards. To be sure you're getting Spicer quality, always use genuine Spicer parts.
This symbol warns of possible personal injury.
X510-5
Contents
How to Use This Catalog ........................................ 2
General Information ................................................. 4
Axle Kits ................................................................... 6
Model 35/194 Front
Dakota
Exploded View & Parts Listing ..................................... 8
Bill of Material Table ...................................................... 9
Model 44/216 Front Disconnect
W1500 & W2500 Ram
Exploded View & Parts Listing ................................... 12
Bill of Material Table .................................................... 14
Variable Parts Table ................................................... 15
Model 60/248 Front Disconnect
W2500HD, W3500 & Non-ABS Air Force Tow
Exploded View & Parts Listing ................................... 18
Bill of Material Table .................................................... 20
Variable Parts Table ................................................... 22
Model 44/216 ICA Rear
Viper
Exploded View & Parts Listing ................................... 26
Bill of Material Table .................................................... 27
Model 60/248 Rear
B-300 Maxivan HD
Exploded View & Parts Listing ................................... 30
Bill of Material Table .................................................... 32
Variable Parts Table ................................................... 32
Model 60/248 Rear
D2500 & W2500 Ram
Exploded View & Parts Listing ................................... 34
Variable Parts Table ................................................... 35
Bill of Material Table .................................................... 36
Model 70/267 Rear
D2500 & W2500 Ram
Exploded View & Parts Listing ................................... 40
Bill of Material Table .................................................... 42
Variable Parts Table ................................................... 44
Model 80/286 Rear
D2500, D3500, W2500 & Sweptline
Exploded View & Parts Listing ................................... 46
Bill of Material Table .................................................... 48
Variable Parts Table ................................................... 52
Shim Table ............................................................. 54
1
X510-5
How to Use This Catalog
This catalog contains applications and part listings for front and rear axles which fit Chrysler/Dodge
vehicles from model years 1999-2001. For information on model years between 1967-1978, please refer
to catalog X510-8DSD; Ford model years 1979-1999 refer to X510-9. For miscellaneous models from
years 1979-1984, please refer to X510-7DSD.
The data in this publication is arranged by make, then in numerical order by model for front axles and then
for rear axles. Each model contains the following three sections as appropriate:
• Parts Listing and Exploded View
This section contains an exploded view of the axle and lists all the part numbers for those parts illustrated.
The parts that do not have a common part number have a footnote reference indicating where to find the
correct part number for each Bill of Material.
• Bill of Material Table
This section contains vehicle applications listed in order by year. Included in the table are the major kits
and assemblies for each Bill of Material number.
2
X510-5
• Variable Parts Table
This section contains the individual part numbers that vary by Bill of Material number for a given model.
Note: Additional information on Spicer axles can be found in our General Information catalog number
XGI. It contains the following sections:
• Bill of Material Numerical Listing
• Ring and Pinion Kits
• Differential Case Assembly Kits
• Axle Shaft Dimension and Components
3
X510-5
General Information
How To Identify A Spicer Axle
All Spicer Carrier Type axles are identified with a manufacturing date (1) and Bill of Material number (2)
stamped on the right or left hand tube on driving axles. The Bill of Material number may also be found on the
carrier in some models as shown in illustration (2A). For independent front suspension (IFS) axles, the B/M
number may be located at one of three locations: 1). A vertically positioned tag near the center of the right
hand side support arm, 2) stamped into the left hand side support arm (opposite end of the camber adjuster), or 3) stamped into the "nose end" of the axle carrier. The location of the information will depend on
the manufacturing date of the axle.
The axle model number will be cast into one of the webs as shown (3), or it can be on the nose.
Each axle contains a gear ratio tag (4), and if the axle is equipped with a limited slip differential, it will have a
tag specifying the type of limited slip lubricant to be used (5).
Refer to the appropriate model number section for parts identification and a breakdown of the Bill of Material.
How To Change Gear Ratios
To increase or decrease a gear ratio, there are certain steps that must be taken. The differential case depends upon the ratio
desired. For each axle model, there is a high-ratio and a low-ratio case as illustrated below:
Axle Model Low Ratio Case High Ratio Case Axle Model Low Ratio CaseHigh Ratio Case
Model 27 3.73 and Down 3.92 and Up Model 50 4.10 and Down ............. —
Model 28 3.45 and Down 3.73 and Up Model 60 4.10 and Down .... 4.56 and Up
Model 28 IFS Aerostar 2.27, 3.73 — Model 61
Model 30 3.55 and Down 3.73 and Up Semi Float 3.00 and 3.07 only
Model 35 2.35 only — Model 61
Model 35 2.73 - 3.31 3.54 and Up Full Float 3.31 and Down .... 3.54 and Up
Model 36 ICA 2.73 and Down 3.07 and Up Model 70 4.10 and Down .... 4.56 and Up
Model 44 3.73 and Down 3.92 and Up Model 70-3HD 3.42 and Down .... 3.73 and Up
Model 44 ICA Model 70-2UA 3.07 only ....................... —
1984 & earlier 3.73 and Down 3.92 and Up Model 80 3.73 and Down .... 4.10 and Up
Model 44 ICA
1985 & later 2.87 and Down 3.07 and Up
Example - If you have a model 44 Rear Axle with a 3.54 ratio and wish to change to a 3.73 ratio, you change only the ring gear
and pinion assembly. If you change the ratio to a 4.09, you must change to a high-ratio case in addition to changing the ring
gear and pinion. The application section will show you what case to use. When the vehicle is equipped with both front and
rear driving axles, the gear ratios must be the same in both axles. The drive gear screws are self-locking and must be
replaced with new screws each time that they are removed.
4
X510-5
How Limited Slip Differentials Operate
A conventional differential transmits all the ring gear torque through the differential gears to the axle shafts.
Torque is at all times equal on the axle shafts, and if one wheel slips, the other wheel can only put out as much
torque as the slipping wheel.
The Spicer Limited Slip differential has the same power flow as a conventional differential, plus a more direct flow
which automatically takes effect as driving conditions demand. This more direct power flow is from the differential case to each axle shaft through a clutch plate and disc arrangement.
Arrangement of these plates and discs is at the option of the vehicle manufacturer, so care should be taken
during disassembly to note the arrangement of these components.
The Limited Slip construction permits differential action when required for turning corners and transmits equal
torque to both wheels when driving straight ahead. However, when one wheel tries to spin due to leaving the
ground, a patch of ice, etc., the clutch packs automatically provide more torque to the wheel which is not trying
to spin.
The Limited Slip differential resists wheel spin on bumpy roads and provides more pulling power when one wheel
tries to slip. In many cases of differences in traction, pulling power will be automatically provided until both
wheels start to slip.
In diagnosis of vehicle operators' complaints, it is important to recognize two things.
1. If, with unequal traction, both wheels slip, the Limited Slip Differential has done all it can pssibly do.
2. In extreme cases of differences in traction, the wheel with the least traction may spin after the Limited . Slip
has transferred as much torque as possible to the non-slipping wheel.
How To Distinguish a Powr-Lok™ from a Trac-Lok™
All Models except Model 80 /286: The Powr-Lok
design is identified by its 2-piece case. The Trac-Lok
design is identified by its 1-piece case.
Model 80 /286 only: Both the Powr-Lok and the TracLok use 2-piece cases in the model 80 (286) axle. The
difference between the two is in the shape of the holes
for the cross shaft. The Powr-Lok case will have cross
POWR-LOK™
2-Piece Case
4 Pinion Mate Gears
shaft holes that are "U" shaped in one case half and "V"
shaped in the other case half. The Trac-Lok case will
have cross shaft holes that are semicircles in both case
halves.
It is also possible to replace an existing Powr-Lok unit
with a complete Trac-Lok unit. For this purpose, the
differential case assembly must be replaced.
How To Obtain Special Service Tools
Special service tools (see service manuals) can be obtained from the following company:
Kent-Moore
OE Tool and Equipment Group
SPX Corporation
28635 Mound Road
Warren MI 48092-3499
(800) 345-2233
TRAC-LOK™
1 or 2-Piece Case
2 Pinion Mate Gears
5
Light Axle Kits
X510-5
DIFFERENTIAL CASE KIT
DIFFERENTIAL CASE ASSEMBLY KIT
SHAFT ASSEMBLY KIT
DRIVE PINION & GEAR ASSEMBLY KIT
CARRIER COVER KIT
6
DIFFERENTIAL INNER PARTS KIT
X510-5
Model 35 /194
Front Axles for
Dakota and Durango
7
Chrysler/Dodge 35/194 Front
Exploded View
X510-5
8
X510-5
Chrysler/Dodge 35/194 Front
Parts Listing
ITEM PART
NO. NUMBER
DESCRIPTION
1 -(3) Housing - Axle Service
2 -(1) Drive Pinion & Gear Assembly
3 701130X PKG - Inner Pinion Shim
4 707162X KIT - Inner Pinion Bearing
5 42102 Collapsible Spacer
6 706894X KIT - Outer Pinion Bearing
7 42778 Slinger - Outer Pinion Bearing
8 48009 Seal - Pinion Oil
9 48008 Seal - End Yoke
10 2-4-8131-1 End Yoke
11 44189 Pinion Nut
707438X KIT - Carrier Cover
12 -(4) Carrier Cover
13 41356 Plug - Carrier Cover
14 40286-5 Bolt - Carrier Cover (qty 10)
15 38615 RTV Silicone Sealant
16 -(3) Differential Bearing Cap
ITEM PART
NO. NUMBER
DESCRIPTION
17 40284-1 Bolt - Differential Bearing Cap
18 706016X Differential Bearing Kit
19 701004X PKG - Differential Bearing Shim
20 -(1) Case - Differential (std)
21 41221 Bolt - Drive Gear (qty 10)
22 42570 Snap Ring
23 46504 Pinion - Differential
24 47559 Gear - Differential
25 34096 Thrustwasher - Differential Pinion
26 34095 Thrustwasher - Differential Gear
27 41648 Shaft - Differential Pinion
28 13449 Roll Pin - Differential Shaft
29 565977 Bearing
30 46485 Oil Seal
31 47067 Axle Shaft (LH)
32 47065 Axle Shaft (RH)
33 41962 Vent - Axle Shaft (RH)
(1) See "Bill of Material Table" below
(2) See "Variable Parts Table" within this section
(3) Contact Vehicle Manufacturer
(4) Not Sold Separately
N.I. = Not Illustrated
Bill of Material Table
Axle Axle Kits Shaft & Joint Assy.
Bill of
Material
Diff.
Type
Ratio
Ring Gear &
Pinion Kit
(7)
Case Assy.
(8)
Kit
1997-99 Dakota & Durango
610576-1 Standard 3.21 75812-5X 75935X 47071 707436X
610576-2 Standard 3.55 74346-5X 75934X 47069 707436X
610576-3 Standard 3.92 75813-5X 75934X 47069 707436X
610576-4 Standard 3.21 75812-5X 75935X 47071 707436X
610576-5 Standard 3.55 74346-5X 75934X 47069 707436X
610576-6 Standard 3.92 75813-5X 75934X 47069 707436X
Differential
Case Kit
Inner Parts
Kit
Right Hand
Shaft Assy.
Left Hand
Shaft Assy.
NOTE: All Ring & Pinion Kits with base number 706930 are reverse spiral bevel
(7) See Ring Gear & Pinion Kits in XGI Catalog for ratio & tooth combinations.
(8) See Differential Case Assy Kits in XGI Catalog for spline data & ratios.
9
Notes
X510-5
10
X510-5
Model 44 /216
Front Disconnect Axles for
W1500 & W2500 Ram
11
Chrysler/Dodge 44/216 Disconnect Front
Exploded View
X510-5
12
X510-5
Chrysler/Dodge 44/216 Disconnect Front
Parts Listing
ITEM PART
NO. NUMBER
1 -(3) Housing - Axle Service
2 -(1) Drive Pinion & Gear Assembly
3 701112X PKG - Inner Pinion Bearing Shim
4 706015X KIT - Inner Pinion Bearing
5 44896 Collapsible Spacer
6 706030X KIT - Outer Pinion Bearing
7 13575 Slinger - Outer Pinion Bearing
8 -(2) Seal - Pinion Oil
9 -(2) Seal - End Yoke
10 -(2) End Yoke Assembly (inc 9)
11 30186 Washer - Pinion Nut
12 30185 Pinion Nut
707192X KIT - Carrier Cover (inc 13,14,15)
13 -(4) Carrier Cover
14 36472 Plug - Carrier
15 34279 Bolt - Carrier Cover (qty 10)
16 38615 RTV Silicone Sealant
17 -(3) Differential Bearing Cap
18 48632-1 Bolt - Diff Bearing Cap
19 706032X KIT - Differential Bearing
20 706086X PKG - Differential Bearing Shim
21 -(1) Case - Differential
22 41221 Bolt - Drive Gear (qty 10)
23 45872 Pinion - Differential
24 45870 Gear - Differential
25 13338-3 Thrustwasher - Differential Pinion
26 32121 Thrustwasher - Differential Gear
27 39194 Shaft - Differential
28 13449 Lock - Differential Shaft
29 48489 Seal - Tube (left side)
-(2) KIT - Socket Assembly
30 500024-6 Cotter Pin
31 40584 Slotted Nut
32 40916 Upper Socket
33 -(2) Lock Nut
34 -(2) Lower Socket
DESCRIPTION
(inc items 30, 31, 32, 33, 34)
ITEM PART
NO. NUMBER
35 -(2) Stop Screw
36 -(2) Jam Nut
37 -(3) Knuckle (RH)
-(3) Knuckle (LH)
38 44993-1 Bolt - Knuckle (if required)
39 -(1) Shaft & Joint Assembly
40 45942 Slinger
41 -(2) Shaft & Slinger/Tone Ring Assy.
42 -(3) Hub Assembly
43 -(2) Spacer - Flat
44 45523 Washer - Flat
45 46085 Slotted Nut
46 500025-10 Cotter Pin
47 50429(6) Bushing - Synthetic
48 45770 Output Shaft
75265X KIT - Front Axle Shaft (inc 48, 65)
49 500396-10 Bolt - Disconnect Assembly
50 500357-9 Lock Washer
51 -(3) Brake Line Clip
52 43424 Protection Shield
-(3) Cover & Motor Assembly
53 -(4) Motor Assembly
54 -(4) O-Ring
55 -(4) Cover - Housing
56 -(4) O-Ring
57 -(4) Switch Assembly
58 -(4) Snap Ring
59 -(4) Snap Ring
60 -(4) Shift Fork
61 -(4) Clip
62 46401 Clutch Collar
63 41494 Gasket
64 48488 Seal - Tube (right side)
65 43337 Bushing
66 50382 Oil Seal
DESCRIPTION
(inc 53,54,55,56,57,58,59,60,61)
(1) See "Bill of Material Table" on next page
(2) See "Variable Parts Table" within this section
(3) Contact Vehicle Manufacturer
(4) Not Sold Separately
(5) Bearing Assembly 566008 was used in older models and is still available for service.
13
Chrysler/Dodge 44/216 Disconnect Front
X510-5
Bill of Material Table
Axle Axle Kits Shaft & Joint Assy.
Bill of
Material
Diff.
Type
Ratio
Ring Gear &
Pinion Kit
(7)
Case Assy.
(8)
Kit
1999 W1500
610786-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 76812-1X 76813-1X
610786-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 76812-1X 76813-1X
610787-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 76812-1X 76813-1X
610787-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 76812-1X 76813-1X
610826-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 76812-1X 76813-1X
610826-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 76812-1X 76813-1X
610827-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 76812-1X 76813-1X
610827-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 76812-1X 76813-1X
610834-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 708060 708061
610834-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 708060 708061
610835-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 708060 708061
610835-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 708060 708061
2000 W1500
610800-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 76812-1X 76813-1X
610800-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 76812-1X 76813-1X
Differential
Case Kit
Inner Parts
Kit
Right Hand
Shaft Assy.
Left Hand
Shaft Assy.
610801-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 76812-1X 76813-1X
610801-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 76812-1X 76813-1X
610847-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 708060 708061
610847-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 708060 708061
610847-3 Standard 4.10 707338-5X 707021-1X 706024X 707025-1X 708060 708061
610848-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 708060 708061
610848-2 Standard 3.92 707338-2X 707021-1X 706024X 707025-1X 708060 708061
610938-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 708060 708061
610938-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 708060 708061
610939-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 708060 708061
610939-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 708060 708061
2000 W1500 Off Road Axle
610911-1 Standard 4.10 707338-5X 707021-1X 706024X 707025-1X 708060 708061
610940-1 Standard 4.10 707338-5X 707021-1X 706024X 707025-1X 708060 708061
2000-01 W1500
611048-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 708060 708061
611048-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 708060 708061
611049-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 708060 708061
611049-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 708060 708061
611050-1 Standard 4.10 707338-5X 707021-1X 706024X 707025-1X 708060 708061
2001 W1500
611149-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 708060 708061
611149-2 Standard 3.92 707338-2X 707022-1X 706024X 707025-1X 708060 708061
611150-1 Standard 3.54 707338-1X 707021-1X 706024X 707025-1X 708060 708061
611150-2 Standard 3.92 707338-2X 707022-1X 706025X 707025-1X 708060 708061
611151-1 Standard 4.10 707338-5X 707021-1X 706024X 707025-1X 708060 708061
14
(7) See Ring Gear & Pinion Kits in XGI Catalog for ratio & tooth combinations.
(8) See Differential Case Assy Kits in XGI Catalog for spline data & ratios.
X510-5
Chrysler/Dodge 44/216 Disconnect Front
Variable Parts Listing
Kits & Parts - Use With All Applications
Description & Item Number (Refer to the
"Exploded View" at the front of this section)
1 Seal - Pinion Oil 8 44895 44895 47761 44895 44895
2 Seal - End Yoke 9 232549 232549 47762 232549 232549
3 End Yoke Assembly (inc 9) 10 2-4-7651-1X 2-4-7651-1X - (10) 2-4-7651-1X 2-4-7651-1X
4 KIT - Socket Assembly - 707315X 707315X 707315X 707315X 707315X
5 Lock Nut 33 35566 35566 35566 35566 35566
6 Lower Socket 34 40113 40113 40113 40113 40113
7 Stop Screw 35 31026-3 31026-3 - 31026-3 31026-3
8 Jam Nut 36 49270 49270 - 49270 49270
9 Shaft & Tone Ring/Slinger Assembly 41 74917X (11) 74917X (11) 74917X (11) 74917X (11) 74917X (11)
10 Spacer - Flat 43 44997 48352 - 44997 48352
1 Seal - Pinion Oil 8 44895 44895 50092 50092 50092
2 Seal - End Yoke 9 232549 232549 47762 47762 47762
3 End Yoke Assembly (inc 9) 10 2-4-7651-1X 2-4-7651-1X 2-4-8431-1 2-4-8431-1 2-4-8431-1
4 KIT - Socket Assembly - 707315X 707315X 708072 708072 708072
5 Lock Nut 33 35566 35566 50153 50153 50153
6 Lower Socket 34 40113 40113 50154 50154 50154
7 Stop Screw 35 31026-3 31026-3 - 49501 8 Jam Nut 36 49270 49270 - - 9 Shaft & Slinger Assembly 41 80566 80566 80566 80566 80566
10 Spacer - Flat 43 44997 48352 - - -
610786 610787 610800 610826 610827
610834 610835 610847 610911 610939
Bills of Material
610801
610848 610938
610940 611149
611048 611150
611049 611151
611050
1 Seal - Pinion Oil 8 50092 50092
2 Seal - End Yoke 9 47762 47762
3 End Yoke Assembly (inc 9) 10 2-4-8431-1 2-4-8431-1
4 KIT - Socket Assembly - 708072 708072
5 Lock Nut 33 50153 50153
6 Lower Socket 34 50154 50154
7 Stop Screw 35 49501 50752
8 Jam Nut 36 - 9 Shaft & Slinger Assembly 41 80566 80566
10 Spacer - Flat 43 - -
(10) 7290 Series used in vehicle. Service 1330 Series using 2-4-8431-1, 5-637X and 2-70-18X
(11) 74917X is used in some non-ABS applications; check tone ring for interference fit.
15
Notes
X510-5
16
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