Spicer DS-RS461, DS-RS462, DS-RS463, DS-RS521, DS-RS581 User Manual

Spicer

Tandem Axles

Illustrated Parts List

AXIP0085

January 1994

Single Reduction, Dual Range, & Double Reduction 461, 462, 463, 601, 652, 653 46,000–65,000 lbs

Introduction

Models Listing ------------------------------------------------------------------------------- 2 How to Use The Illustrated Parts List ---------------------------------------------------- 3 Model Identification ------------------------------------------------------------------------ 4-5

Single Reduction

DS461-P • DS521-P • DS581-P ---------------------------------------------------------- 6-11 RS461 • RS521 • RS581 ------------------------------------------------------------------ 12-13

Dual Range & Planetary Double Reduction

DT/DP461-P • DT/DP521-P • DT/DP601-P• DT/DP651-P ----------------------------- 14-19 RT/RP461 • RT/RP521 • RT/RP601 • RT/RP651 --------------------------------------- 20-23

Introduction

Contents

Planetary Double Reduction

TP/SP461 • TP/SP521• TP/SP601 • TP/SP651 ----------------------------------------- 24-29

Shift System

Differential Lockout Assembly - Current Production ----------------------------------- 30 Air Operated Lockout Assembly - Non-Current Production --------------------------- 31 Axle Range Selection & Differential Lockout System ---------------------------------- 32 -33 Axle Shift System -------------------------------------------------------------------------- 34 Air Shifter Valve ----------------------------------------------------------------------------- 35 Piston Air Shift System -------------------------------------------------------------------- 36-37

Axle Housings & Shafts

461,521,581,601 Forward/Rear Housings ---------------------------------------------- 38 651 Housings -------------------------------------------------------------------------------- 38 Axle Shaft Configurations ----------------------------------------------------------------- 39 Axle Hsg/Shafts Models: D521/D581/D601/T521/T601/S521/S601------------------ 40 Axle Hsg/Shafts Models: D651/T651/S651---------------------------------------------- 41

Appendix

Gear and Pinion Information *------------------------------------------------------------ 42-43

* Pinion Bearing Spacer information included

Differential Carrier Assemblies------------------------------------------------------------ 44-45 Input/Output Yoke Information ----------------------------------------------------------- 46-48

Models Listing

The following models are represented in this publication.

Model Listing

Single Reduction Models

Forward Axle Rear Axle Axle Capacity Gear Size

DS-461-P RS-461 46,000 lbs 18” Gear DS-521-P RS-521 52,000 lbs 18” Gear DS-581-P RS-581 58,000 lbs 18” Gear

Dual Range Models

Forward Axle Rear Axle Axle Capacity Gear Size

DT-461-P RT-461 46,000 lbs 18” Gear DT-521-P RT-521 52,000 lbs 18” Gear DT-601-P RT-601 60,000 lbs 18” Gear DT-651-P RT-651 65,000 lbs 18” Gear

Planetary Double Reduction Models

Forward Axle Rear Axle Axle Capacity Gear Size

DP-461(P) RP-461 46,000 lbs 18” Gear TP-461 SP-461 46,000 lbs 18” Gear DP-521(P) RP-521 52,000 lbs 18” Gear TP-521 SP-521 52,000 lbs 18” Gear DP-601(P) RP-601 60,000 lbs 18” Gear TP-601 SP-601 60,000 lbs 18” Gear DP-651(P) RP-651 65,000 lbs 18” Gear TP-651 SP-651 65,000 lbs 18” Gear

Introduction

Dual Planetary & Double Rduction Model Configurations

These configuations will accomodate a variety of applications and chasis types. Other combinations of Forward and Rear axles are also utilized. Common configurations are illustrated.

Forward Axles:

DP - Inter-axle differential w/ pressure lube pump TP - Straight drive through shaft / no inter-axle differential

Rear Axles:

RP - Standard entry SP - High entry

Standard Tandems

Forward

DP Model

High-entry forward, standard rear w/ inter-axle differential & special lube system

TP Model

Rear

RP Model

High-entry Tandems

Forward

DP Model

Both high-entry w/ inter-axle differential & special lube system

Rear

SP Model

TP Model SP Model

SP Model

TP Model

Both high-entry w/out inter-axle differential

TP Model

*TP Model

High-entry forward, standard rear w/o inter-axle differential

Both high-entry w/out inter-axle differential. *Using Forward Axle model in Rear Axle application.

Introduction

How To Use The Illustrated Parts List

Ordering Spicer® Parts

• This parts book is organized in sections according to parts servicing requirements. 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.

• See the Appendix for detailed information concerning kits applicable to this model.

Abbreviations

• AR - As Required - Parts that vary in quantity with each axle. Example: shims

• NSS - Not Serviced Separately - Items which can only be purchased in sets, kit form or service assemblies. Example: ring gear

• RH/LH - Right Hand/Left Hand - Determined as viewed from behind the vehicle looking forward.

• RTV - Gasket Compound - Formed-in-place gasket sealer. It is recommended for use on all surfaces requiring a gasket.

• Assy - Assembly

• Brg - Bearing

• Diff - Differential

• Hsg - Housing

• Inv - Involute

• Str - Straight

Illustrations

• Illustrations show parts in assembly groups.

• Item numbers on illustrations correspond with parts listings on pages that accompany the drawings

• Notes are included on illustrations where additional is needed.

Parts Listings

• Parts listings are defined by parts groupings and are broken down by service assemblies.

• Parts Listings identify a part for servicing with the following categories:

• Item - corresponds with numbers on illustrations for part identification

• Description - specifies part name or description

• Quantity (Qty) - quantity required for assembly

• Order Part No. - service part numbers are broken down by model, type or other applicable information

• Notes - define unique characteristics or requirements

• Kits And Assemblies - order the part numbers indicated

* Other pertinent information is listed in tables or parts listings as required.

Using the IPL

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

Item Description Qty Order Part No. Notes

84 Lockwasher 10 90417 85 Pipe Plug 1 90325

Kits And Assemblies

Basic Overhaul Kit 1 122437 Contents Identified with * Oil Seal & Shim Kit 1 118111 Includes 33,46,75,78 &RTV

Order this quantity for servicing

Order this number

Indicates information important to ordering or use

Introduction

Model Identification

Locating Model Designation Information

• Axle Model Identification, Part Number and / or Serial Number are located on the axle centerline. This information will help to locate information in this book and to identify the correct parts for servicing.

• Axle Housings are identified by the specification number stamped on the rear right-hand side of the axle housing. This number identifies all components of the axle as built by Spicer, including OEM special requirements such as yoke or flange. Some axles may also include an identification tag as shown.

Axle Specification Number

• The axles illustrated in this book are found on a number of different axle shafts, according to OEM specifications.

When ordering replacement axle shafts, note the part number stamped into the flange.

Axle Shaft Part Number

Identification Tag

PT NO. HSG MODEL HSG CAP.

SERIAL NO..

LBS.

Introduction

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.

Model Indentification

D S - 3 41- P

G earin g

D - Forward T a nde m Axl e R - Rear T a nde m Axl e S - S i ngl e Reductio n T - Dual Rang e P - Double Reducti o n C - Controll e d T ractio n

E xample : D S = Forward T andem/S in gle Reductio n o r R S = Rear T andem/S ingle Reduction

Older Model Serial Numbers

• Units built before May 1987 were identified with a date coding system. Carrier assemblies produced after this date are assigned unique serial numbers. Serial numbers are stamped into the carrier casting or contained on a metal tag attached to the carrier.

L u b e P u m p

P = Standar d (P) = Opti ona l

D e sign L e v e l

Capac ity (x 1000)

Example: 3 4 = 34,00 0

H 8 6 1 7 9 673 3

Producing Plant

Year produced

Day of year produced (1-365)

Unique number assigned to each axle produced

Forward Axle

Single Reduction

41 42 43 44 46 47 48 45 6 1 5

DIFFERENTIAL

& RING GEAR

14 15 16 19 20 17 18 23 22 26 24 25 22 23 20 16 15 14

Single Reduction

54 55

INTER-AXLE DIFFERENTIAL ASSEMBLY

Forward Axle

DS581-P

DS461-P DS521-P

66 67

27 17 28

69 70 71 72 73

31 33

323534

74 75 76 78 79 80 81

THESE PARTS ARE MOUNTED IN POWER DIVIDER COVER

38 37

LUBE PUMP

90 89 86

85 97 91 88

94 93

Single Reduction

Forward Axle

Item Description Qty Order Part No. Notes

1 Diff. Carrier & Bearing Caps 1 122474 Includes items 2-5, 8-14

Carrier Casting no. 128282C NSS 2 Bearing Cap Screw 4 127180 3 Flat Washer 4 32912 4 Lockwire 4 12563 5 Dowel Bushing 2 32730 6 Bearing Cap Adjuster Lock (RH) 45448 See Note 1 7 Cap Screw (RH) 210601 See Note 1 8 Bearing Cap Adjuster Lock 2 14275 LH & RH 9 Cotter Pin 2 90876 LH & RH

10 Filler Plug 1 90325 11 Carrier Cover Dowel Pin 2 7641 12 Ring Gear Thrust Screw 1 126193 13 Thrust Screw Jam Nut 1 210184 14 Diff. Bearing Adjuster (RH) 1 39448 Replaced old #79898 14 Diff. Bearing Adjuster (LH) 1 21637 15 Diff. Bearing Cup (RH) 1 19529* 15 Diff. Bearing Cone (LH) 1 15092* 16 Diff. Bearing Cone (RH) 1 27666* 16 Diff. Bearing Cone (LH) 1 27876* 17 Ring Gear & Drive Pinion Set 1 See Appendix: Gear & Pinion Information 18 Bolt 16 67856 In Kit 70745 19 Nut 16 60600 In Kit 70745 20 Diff Case (Flanged Half) NSS 1 88501 Ratios 3.55-4.11 - order 98610

126234 Ratios 4.33-6.67 - order 121845

Diff. Case (Plain Half) NSS 1 86777

21 Diff. Case Cap Screw 12 88503 22 Diff Side Gear (36 Involute) 2 93401 23 Side Gear Thrust Washer 2 27274* 24 Side Pinion 4 86780 25 Side Pinion Thrust Washer 4 86781* 26 Spider 1 86778 27 Pinion Pilot Bearing 1 126187* 28 Pinion Bearing Cone 2 14218* 29 Pinion Bearing Spacer Washer 1 78904* 30 Pinion Bearing Spacer AR See Appendix: Gear & Pinion Information 31 Pinion Bearing Cup 2 14217* 32 Pinion Bearing Cage & Cup Assy 1 78914 Cage #78932, Includes Item 31

Note 1: Current Production uses (2) 14275 Adjuster Locks (Item #8) & (2) 90876 Cotter Pins (Item #9). Old Style Adjuster Lock #45448 & Capscrews # 210601 remain available for service.

Single Reduction

Forward Axle

Item Description Qty Order Part No. Notes

33 Pinion Bearing Cage Shim AR

.003" 45461* .005" 62829* .010" 45462*

.020" 62830* 34 Bearing Cage Cap Screw 6 62158 35 Lockwasher 6 37207 36 Pinion Helical Gear 1 119995 37 Outer Pinion Bearing & Race 1 78916* 38 Outer Pinion Bearing Snap Ring 1 78937* 39 Pinion Shaft End Nut 1 126182 40 Pinion Nut Spring Pin 1 118807 41 Output Shaft Nut 1 210508 42 Output Shaft Washer 1 210509 43 Output Shaft Yoke 1 See Appendix:Input/Output Yoke Information 44 Rear Bearing Retaining Washer 1 78922* 45 Axle Housing Cover Assy 1 107863 Includes Items 46-49

(Cover 84546) NSS 46 Output Shaft Oil Seal 1 119429* or 210737* See Appendix:Input/Output Yoke Information 47 Bearing Snap Ring 1 78937* 48 Output Shaft Bearing Race – Inner 1 118787* Order #78936 Brg Assy 48 Output Shaft Bearing Race – Outer 1 118788* Order #78936 Brg Assy 49 Magnetic Filler Plug 1 75130 49 Retainer Plug 1 90898 50 Output Shaft Kit 1 122419 Includes Items 41,42, 51,52,56

(Shaft 119991, 41 Splines 2.100" dia) NSS 51 Output Shaft Bushing 1 48922* 52 Output Shaft "O" ring 2 78931* 53 Output Shaft Bearing Cup (Inner) 1 24328* 54 Output Shaft Bearing Cone (Inner) 1 24330* 55 Output Shaft Side Gear 1 78911 56 Side Gear Snap Ring 1 85994* 57 Output Shaft Compression Spring 1 127095 58 Output Shaft Thrust Bearing 1 51228 59 Inter-axle Diff. Assy 1 121681 Includes Items 60-65 60 Inter-axle Diff Case Kit 1 211252 Includes Items 60-62 60 Case Half NSS 2 126151 Order 211252 61 Case Bolt 8 57636

/8"

/2"

DS581-P

DS461-P DS521-P

Note: Item 46 Output Shaft Oil Seal — See Appendix:Input/Output Yoke Information before ordering.

Single Reduction

Forward Axle

Item Description Qty Order Part No. Notes

62 Case Nut 8 57637 63 Side Pinion 4 95218 64 Side Pinion Thrust Washer 4 126180* 65 Spider 1 126152 66 Helical Side Gear Snap Ring 1 78909* 67 Helical Side Gear & Bushing Assy 1 113331 Includes Item 68

(Side Gear 113328) NSS 68 Helical Side Gear Bushing 2 75063* 69 Helical Side Gear Thrust Washer 1 79034* 70 Helical Side Gear "D" Washer 1 56360* 71 Lockout Sliding Clutch 1 119948 72 Input Shaft Kit

(Shaft 119990, 46 Splines

2.350" dia.) NSS 1 122418 Includes Item 81 73 Input Shaft Bearing Cone 1 98387* 74 Input Shaft Bearing Cup 1 98388* 75 Input Bearing Cover Shim AR

.003" 78918* .005" 78919* .010" 78920* .020" 113130

76 Input Bearing Cover, Cup &

Oil Seal Assy (Cover 111690) NSS 1 111691 Includes Items 74, 78 77 Bearing Cover Cap Screw 5 126243 78 Input Shaft Oil Seal 1 119430* or 210736* See Appendix:Input/Output Yoke Information 79 Input Yoke & Slinger 1 See Appendix:Input/Output Yoke Information 80 Input Shaft Nut Washer 1 126242* 81 Input Shaft Nut 1 126155 82 Diff. Carrier Cover Assy 1 117311 Includes Items 85-86, 37 & 47

(Cover 103526) NSS

83 Carrier Cover Cap Screw 8 90069 (short)

1 9309 (long) 1 81855 (socket head)

Note: Item 78 Input Shaft Oil Seal — See Appendix:Input/Output Yoke Information before ordering.

Single Reduction

Forward Axle

Item Description Qty Order Part No. Notes

84 Lockwasher 10 90417 85 Pipe Plug 1 90325 86 Expansion Plug 1 9797 87 Magnetic Filter Screen 1 102611* 88 Lube Pump Cover 1 102607 89 Pump Drive Gear 1 119946 90 Drive Gear Locknut 1 111451 91 Cover "O" Ring 1 102620* 92 Cover Dowel Pin 2 102617 93 Cover Cap Screw 4 102618 94 Lockwasher 4 90419 95 Air Operated Lockout Assy

Complete 1 123218 See Shift System: Lockout Assembly 96 Shift Fork & Push Rod Assy 1 103529 See Shift System: Lockout Assembly 97 Pump Gear & Shaft Assy 1 102625 Order Complete Lube Pump

Replacement Kit

Gasket Compound AR 107276*

DS581-P

DS461-P DS521-P

Kits And Assemblies

Basic Overhaul Kit 122437 Contents Identified with * Oil Seal & Shim Kit 118111 Includes 33,46,75,78 &RTV Lube Pump Replacement Kit 121302 Includes 88-94, 97 Wheel Diff Case Kit 98610 Ratios 3.55-4.11 / Includes Items 20-21 Wheel Diff Case Kit 121845 Ratios 4.33-6.67 / Includes Items 20-21 Wheel Diff Side Gear Pinion Kit 114472 Includes Items 22-26 Wheel Diff Kit Less Side Gears 118749 Includes Items 23-26

Single Reduction

Rear Axle

10 11 12 15 18 20 21 17 18 13 15 12 11 10

16 17 19 14 14

243 6

8 9 27 26 28 25 26 23 30 33

6 5 1 1 22 23 24 29 31 32

Item Description Qty Order Part No. Notes

1 Diff. Carrier & Bearing Caps 1 122432 Includes Items 2-4, 7-9

Carrier Casting No 127220R 2 Bearing Cap Screw 4 127180 3 Flat Washer 4 32912 4 Lockwire 4 12563 5 Bearing Cap Adjuster Lock 2 14275 6 Cotter Pin 2 90876 7 Dowel Bushing 2 32730 8 Ring Gear Thrust Screw 1 126193 9 Thrust Screw Jam Nut 1 210184

10 Diff. Bearing Adjuster (RH) 1 21637

Diff. Bearing Adjuster (LH) 1 39448

Single Reduction

Rear Axle

Item Description Qty Order Part No. Notes

11 Diff. Bearing Cup (RH) 1 15092*

Diff. Bearing Cup (LH) 1 19529*

12 Diff. Bearing Cone (RH) 1 27876*

Diff. Bearing Cone (LH) 1 27666* 13 Ring Gear & Drive Pinion Set 1 See Appendix: Gear & Pinion Information 14 Bolt 16 67586 In Kit 70745

Nut 16 60600 In Kit 70745 15 Diff. Case (Flanged Half) NSS 1 88501 Ratios 3.55-4.11 - order 98610

126234 Ratios 4.33-6.67 - order 121845

Diff. Case (Plain Half) NSS 1 86777 16 Diff. Case Cap Screw 12 88503 17 Diff. Side Gear 2 93401 36 Involute 18 Side Gear Thrust Washer 2 27274* 19 Side Pinion 4 86780 20 Side Pinion Thrust Washer 4 86781* 21 Spider 1 86778 22 Pinion Pilot Bearing 1 126187* 23 Pinion Bearing Cone (Inner) 1 27239*

Pinion Bearing Cone (Outer) 1 14218* 24 Pinion Bearing Spacer* AR See Appendix: Gear & Pinion Information 25 Pinion Bearing Cage & Cup Assy 1 210592 Cage # 210591 Includes Item 26 26 Pinion Bearing Cup (Inner) 1 27238*

Pinion Bearing Cup (Outer) 1 14217* 27 Pinion Bearing Spacer Washer 1 31366* 28 Pinion Bearing Cage Shim AR

.003" 67920*

.005" 67921*

.010" 67922*

.020" 67923*

.030" 67924* 29 Bearing Cage Cap Screw 6 113327 30 Oil Seal & Retainer 1 113866* or 210724* See Appendix:Input/Output Yoke Information 31 Input Yoke 1 See Appendix:Input/Output Yoke Information 32 Flat Washer 1 210509 33 Pinion Nut 1 210508

Gasket Compound AR 107276*

RS581

RS461 RS521

Kits And Assemblies

Basic Overhaul Kit 122434* Contents identified with * Wheel Diff. Case Kit 98610 Ratios 3.55-4.11 / Includes Items 15-16 Wheel Diff. Case Kit 121845 Ratios 4.33-6.67 / Includes Items 15-16 Wheel Diff Side Gear & Pinion Kit 114472 Includes Items 17-21 Wheel Diff Kit Less Side Gears 118749 Includes Items 18-21 Oil Seal & Shim Kit 122436 Includes Items 28, 30, & RTV

* Note: Pinion Bearing Spacer information is included in the Appendix: Gear & Pinion Information

Note: Item 30 Oil Seal & Retainer — See Appendix:Input/Output Yoke Information before ordering.

Forward Axle

SEE INPUT & OUTPUT YOKES

63 64 65

Dual Range & Planetary

Double Reduction

DIFFERENTIAL & RING GEAR

15 16

DUAL RANGE AXLES

PLANETARY DOUBLE REDUCTION AXLES

21 22 23

30 31 34 37 35 36 41 30 23 22 21

43 41

38 39

+ 36 hidden pages