Spicer® Drive Axles
Illustrated Parts List
Spicer® DSS40, DDS40, RSS40, and RDS40
AXIP-0342
July 2004
Table of Contents
Introduction
Model Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
How to Use Illustrated Parts List . . . . . . . . . . . . 3
Model Identification . . . . . . . . . . . . . . . . . . . . . . 4
Single Reduction
Forward Axle - DSS40(P), DDS40(P). . . . . . . . . 5
Rear Axle - RSS40, RDS40 . . . . . . . . . . . . . . . 13
Piston Air Shift Unit
Piston Air Shift Unit . . . . . . . . . . . . . . . . . . . . . 16
Axle Housings & Shafts
Axle Shaft Configurations . . . . . . . . . . . . . . . . 18
Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DSS40(P) / RSS40 . . . . . . . . . . . . . . . . . . . . . 19
Yokes
All DSS40, DDS40. . . . . . . . . . . . . . . . . . . . . . 20
All RDS40, RDD40 . . . . . . . . . . . . . . . . . . . . . 21
Appendix
Ring Gear and Pinion Identification . . . . . . . . . 22
Pinion Bearing Spacers - DSS40(P), RSS40,
DDS40(P), RDS40. . . . . . . . . . . . . . . . . . . . . . 22
Drive Pinion and Gear Set . . . . . . . . . . . . . . . . 23
New Carrier Assemblies . . . . . . . . . . . . . . . . . 24
1
Introduction
Introduction
Model Listing
The following models are represented in this publication.
Single Reduction Models
Forward Axle Rear Axle Axle Capacity Gear Size
DSS40(P) RSS40 40,000 lbs 18” Gear
DDS40(P) RDS40 40,000 lbs 18” Gear
2
Introduction
How to Use Illustrated Parts List
Ordering 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.
• 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
• A/R-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: brake
shoes.
• 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
• IASS - In Axle Speed Sensor
• ABS - Antilock Brake System
• N/A - Not Applicable
• 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 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
• Current Part - service part numbers are broken down by
model, type or other applicable information
• Notes - define unique characteristics or replacement notes
• Kits and Assemblies - indicated Kits or Assemblies that contain a particular part
• Other pertinent information is listed in tables or parts listings as
required.
Effectively using a parts listing - Example
• Follow the example below to locate and order exactly what is required for servicing.
Order Part
Match to items
on illustration Use to identify Part
Item Description Qty Part No. Notes
84 Lock washer 10 90417 See Axle Shaft Chart
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
Number by Model
indicated
Indicated information important
to ordering or use
3
Model Identification
Introduction
D S S 40 - (P)
D - Tandem Forward Axle
with Interaxle Differential
R - Tandem Rear Axle
(P) - Optional Lube Pump
GAW Rating x 1000 lb.
Super-40
TM
Gearing:
S - Single Reduction
D - Driver Controlled Differential Lock
Locating Model Designation Information
• 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.
MODEL
MADE IN:
PART NO. RATIO
Spicer
™
• Model Number, Part Number and Serial Number are located on the data plate on the axle centerline
• 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
4
Single Reduction
Forward Axle - DSS40(P), DDS40(P)
Forward Axle
4
2
3
6
1
9
7
8
42 43 44 45 47 48 49 46
50
RH
5
1
DIFFERENTIAL
& RING GEAR
12
13
10
11
1
21
14 15 16 19 20
DIFFERENTIAL
LOCK
102
14
17 18 23 22 26 24 25 22 23 20 16 15LH14
20
RH
103
99
101
100
104
105
10
1
106
107
11
108
5
Forward Axle
66 67
51
68
69 70 71 72
96
52
53
54 55
73
56
82
INTER-AXLE
DIFFERENTIAL
ASSEMBLY
58
57
84
59
83
74 75 76 78 79 80 81
61
95
60
63
64
77
THESE PARTS
ARE MOUNTED
IN POWER
DIVIDER COVER –
NOTE 1
65
60
62
27 17 28
NOTE 1: See page
11 for design change
information.
29
30
31 33
LUBE PUMP
90 89 86
323534
31
39
36
28
85 97 91 88
82
87
37
40
38 37
41
94 93
92
6
Forward Axle
Item Description Qty DSS40(P) DDS40(P) Notes
BASIC OVERHAUL KIT 509302 509305 Contents identified by *
1 Diff. Carrier & Bearing Caps
Carrier Casting No. 128282C (NSS)
1 509303 – Includes items 2-5, 6-14
Diff. Carrier & Brg. Cap Kit
Carrier Casting No. 110500 (NSS)
2 Bearing Cap Screw 4 127180 32732
3 Flat Washer 4 32912 32912
4 Lockwire 4 12563 12563
5 Dowel Bushing 2 32730 32730
6 Bearing Cap Adjuster Lock (LH & RH) 2 14275 –
Bearing Cap Adjuster Lock (RH) 1 – 14275
7 Bearing Cap Adjuster Lock (LH) 1 – 45448
8 Adjuster Lock Cap Screw 2 210601 210601
9 Cotter Pin (LH & RH) 2 90876 90876
10 Filler Plug 1 90325 90325
11 Carrier Cover Dowel Pin 2 7641 7641
12 Thrust Screw Jam Nut 1 210184 210184
13 Ring Gear Thrust Screw 1 126193 126193
14 Diff. Bearing Adjuster (RH) 1 39448 –
Diff. Bearing Adjuster (LH) 1 21637 21637
15 Diff. Bearing Cup (RH) 1 19529* 21632*
Diff. Bearing Cup (LH) 1 15092* 15092*
16 Diff. Bearing Cone (RH) 1 27666* 102660*
Diff. Bearing Cone (LH) 1 27876* 27876*
17 Ring Gear & Drive Pinion Set 1 See Chart See Chart Page 22
18 Bolt 16 67586 67586 In Kit 70745
19 Nut 16 60600 60600 In Kit 70745
WHEEL DIFF CASE KITS Includes items 20-21
3.55-4.11 98610 217619
4.33-6.67 121845 217620
20 Diff. Cases – –
Plain Half (LH) NSS 86777 86777
Flange Half (RH) NSS – –
3.55-4.11 88501 128980
4.33-6.67 126234 128981
21 Diff. Case Cap Screw 12 88503 88503
WHEEL DIFF. SIDE GEAR KIT 120739 123292 Includes items 22-26
WHEEL DIFF. KIT w/o SIDE GEAR KIT 118749 118749 Includes items 23-26
22 Diff. Side Gear 2 120052 – 41 Involute
23 Side Gear Thrust Washer 2 27274* 27274*
24 Side Pinion 4 86780 86780
25 Side Pinion Thrust Washer 4 86781* 86781*
26 Spider 1 86778 86778
27 Pinion Pilot Bearing 1 126187* 126187*
Note 1: New design parts beginning February 2000. See Page 11 for more detail and reference Dana Bulletin ABIB-0102.
1 – 508472
– 82451
– 93401 36 Involute
7
Forward Axle
Item Description Qty DSS40(P) DDS40(P) Notes
28 Pinion Bearing Cone 2 129562* 129562* Inner & Outer, Was 14218
29 Pinion Bearing Spacer Washer 1 78904* 78904*
30 Pinion Bearing Spacer AR See Chart See Chart Page 22
31 Pinion Bearing Cup 2 129561* 129561* Was 14217
32 Pinion Bearing Cage & Cup Assy 1 78914 78914 Cage #78932, Includes Item 31
33 Pinion Bearing Cage Shim AR
.003" 45461* 45461*
.005" 62829* 62829*
.010" 45462* 45462*
.020" 62830* 62830*
.030" 113131* 113131*
34 Pinion Bearing Cage Capscrew 6 62158 62158
35 Lockwasher 6 37207 37207
36 Pinion Helical Gear 1 119995 119995
37 Outer Pinion Bearing & Race -
Before 2/2000
38 Outer Pinion Bearing Snap Ring -
Before 2/2000
39 Pinion Support Bearing - After 2/2000 1 120080 120080
40 Pinion Shaft End Nut 1 126182 126182
41 Pinion Nut Spring Pin 1 118807 118807
42 Output Shaft Nut 1 210508 210508
43 Output Shaft Washer 1 210509 210509
44 Output Shaft Yoke 1 See Chart See Chart
45 Rear Bearing Retaining Washer 1 78922* 78922*
46 Axle Housing Cover Assy Includes Items 47-50
(Cover 78923R) NSS 1 217647 217647 Replaces 216642, 107863
47 Output Shaft Oil Seal 1 210737* 210737*
48 Bearing Snap Ring 1 78937* 78937*
49 Output Shaft Bearing Race – Inner 1 118787* 118787* Order #78936 Brg Assy
Output Shaft Bearing Race – Outer 1 118788* 118788* Order #78936 Brg Assy
50 Magnetic Filler Plug 1 75130 75130 7/8"
Cover Plug 1 90898 90898 1/2"
51 Output Shaft Kit
(Shaft 129016, 41 Splines 2.100" dia) NSS
52 Output Shaft "O" ring 2 78931* 78931*
53 Output Shaft Bearing Cup (Inner) 1 24328* 24328*
54 Output Shaft Bearing Cone (Inner) 1 24330* 24330*
55 Output Shaft Side Gear 1 78911 78911
56 Side Gear Snap Ring 1 85994* 85994*
57 Output Shaft Compression Spring 1 127095 127095
58 Output Shaft Thrust Bearing 1 51228 51228
INTER-AXLE DIFF. CASE KIT 1 211252 211252 Includes Items 60-62
59 INTER-AXLE DIFF. ASSY - COMPLETE 1 512845 512845 Includes Items 60-65
60 Inter-axle Diff. Case Half (NSS) 2 126151 126151
61 Case Bolt 8 57636 57636
Note 1: New design parts beginning February 2000. See Page 11 for more detail and reference Dana Bulletin ABIB-0102.
1 78916* 78916* Note 1
1 78937* 78937* Note 1
1 122419 122419 Includes Items 42, 43, 52, 56
Replaces 119991
Replaces 121681
8
Forward Axle
Item Description Qty DSS40(P) DDS40(P) Notes
62 Case Nut 8 57637 57637
63 Side Pinion 4 95218 95218
64 Side Pinion Thrust Washer 4 126180* 126180*
65 Spider 1 130904 130904 Replaces 126152
66 Helical Side Gear Snap Ring 1 78909* 78909*
67 Helical Side Gear & Bushing Assy
(Side Gear 113328) NSS
68 Helical Side Gear Bushing 2 75063 75063
69 Helical Side Gear Thrust Washer 1 79034* 79034*
70 Helical Side Gear "D" Washer 1 56360* 56360*
71 Lockout Sliding Clutch 1 119948 119948
72 Input Shaft Kit
(Shaft 129017, 46 Splines 2.350" dia.) NSS
73 Input Shaft Bearing Cone 1 98387* 98387*
74 Input Shaft Bearing Cup 1 98388* 98388*
75 Input Bearing Cover Shim AR
.003" 78918* 78918*
.005" 78919* 78919*
.010" 78920* 78920*
.020" 113130 113130 Not in overhaul kits
.030" 113131 113131 Not in overhaul kits
76 Input Bearing Cover, Cup & Oil Seal Assy
(Cover 111690) NSS
77 Bearing Cover Cap Screw 5 126243 126243
78 Input Shaft Oil Seal 1 210736* 210736*
79 Input Yoke & Slinger 1 See Yokes, Page 20
80 Input Shaft Nut Washer 1 126242* 126242*
81 Input Shaft Nut 1 126155 126155
82 PDU Cover Assy
Non-Pump Models
Diff. Carrier Cover Assy
Pump Models
83 Carrier Cover Cap Screw 8 90069 90069 (short)
84 Lockwasher 10 90417 90417
85 Pipe Plug 1 90325 90325
86 Expansion Plug 1 9797 9797
87 Magnetic Filter Screen 1 102611* 102611*
LUBE PUMP REPLACEMENT KIT 121302 Includes items 88-94, 97
88 Lube Pump Cover 1 102607 102607
89 Pump Drive Gear 1 119946 119946
90 Drive Gear Locknut 1 111451 111451
91 Cover "O" Ring 1 102620* 102620*
92 Cover Dowel Pin 2 102617 102617
93 Cover Cap Screw 4 102618 102618
94 Lockwasher 4 90419 90419
Note 1: New design parts beginning February 2000. See Page 11 for more detail and reference Dana Bulletin ABIB-0102.
1 113331 113331 Includes Item 68
1 122418 122418 Replaces 119990
Includes Item 81
1 509643 509643 Includes Items 74, 78
1 510792 510792 Note 1
1 510793 510793 Note 1
1 9309 9309 (long)
1 81855 81855 (socket head)
9
Forward Axle
Item Description Qty DSS40(P) DDS40(P) Notes
95 AIR OPERATED LOCKOUT ASSY -
COMPLETE
96 Shift Fork & Push Rod Assy 1 103529 103529
97 Pump Gear & Shaft Assy
2.188" Shaft 1 102625 102625 Order Complete Lube Pump
2.438" Shaft 1 111779 111779 Order Complete Lube Pump
98 Gasket Compound AR 107276S* 107276S* Not Illustrated
99 Expansion Plug (Upper) 1 30703 30703
100 Shift Fork Shaft 1 113801 113801 Includes 113140 O-ring
101 Expansion Plug (Lower) 1 9797* 9797*
102 Sliding Clutch 1 E935088 E935088
103 Shift Fork & Roller Assy 1 84508 84508
104 Shift Unit Mounting Stud 2 119863 119863
105 Shift Fork Seal & Spring Assy 1 119855 119855
106 Shift Unit Assy 1 See Piston Air Shift Unit Page 16
107 Flat Washer 2 119857 119857
108 Stud Nut 2 63028 63028
Note 1: New design parts beginning February 2000. See Page 11 for more detail and reference Dana Bulletin ABIB-0102.
1 217794 217794 Reference Page 11
Kits and Assemblies DSS40(P) DDS40(P)
Basic Overhaul Kit 509302 509305 Contents Identified with *
Oil Seal & Shim Kit 118111 118111 Includes 31, 45, 73, 76 & 97
Lube Pump Replacement Kit 121302 121302 Includes 86-92, 95, 96
Wheel Diff. Case Kit 98610 98610 Ratios 3.55-4.11
Wheel Diff. Case Kit 121845 121845 Ratios 4.33-6.67
Wheel Diff. Side Gear Pinion Kit 120739 123292 Includes Items 22-26
Wheel Diff. Kit Less Side Gears 118749 118749 Includes Items 23-26
IAD Diff. Case Kit 211252 211252 Includes 58-60
IAD Complete 512845 512845 Includes 58-63
Includes Items 18-19
Includes Items 18-19
10
Forward Axle
In February 2000, a product upgrade was made to the power divider section of the DSS/DDS40(P) models. The outer pinion support bearing
was upgraded from a three-piece bearing assembly & snap ring design to a one-piece roller bearing design. The new bearing part-no. 120080
has a higher load capacity and the assembly procedure is now simplified.
As part of the change, new production power divider covers 129965 (pump models) and 129969 (non-pump models) were released. The
120080 bearing can only be used with these new covers. The older power divider covers that are machined with a snap ring groove are no
longer available and are replaced in service by Power Divider Cover kits. The new kits will also include the new 120080 support bearing. The
older design bearing parts (78916 and 78937) will remain available for service as shown on the chart below.
New Service
Part Number Description
103526, 103536, 117311 PDU Cover - Pump Models 510792 Includes new 129965 cover & 120080 brg
129459, 508497 PDU Cover - Non - Pump Models 510793 Includes new 129969 cover & 120080 brg
129965 New PDU Cover order kit above Pump models
129969 New PDU Cover order kit above Non-Pump models
78916 Outer Pinion Brg & Race Assy still available Use only with OLD style PDU covers
78937 Outer Pinion Brg Snap Ring still available Use only with OLD style PDU covers
120080 New Outer Pinion Brg current Use only with NEW style PDU covers
High Entry 4x4, 6x6 and Military applications not affected by this change
Replacement
Part-No.
Notes
Shown below is a quick reference chart for power divider cover castings for both “pump” models and “non-pump” models.
Reference
Power Divider Stamped Part Number Model Type
103526, 103536, 117311, 129965, 510792 pump models 103526C
129459, 508497, 129969, 510793 non pump models 129459C
Casting Number
11
Forward Axle
Differential Lockout
Cast Iron Cover Lockout - February 1996 to Present (Single Reduction Models)
1
Item Description Qty Order Part No. Notes
COMPLETE LOCKOUT KIT W/SHIFT FORK 1 217794 Includes items 1-8
COMPLETE LOCKOUT KIT W/O SHIFT FORK 1 508457 Includes items 3-8
1 Shift Fork Assembly 1 103529
2 Compression Spring 1 031038
3 Piston Stop 1 129153
4 O-Ring 1 210180
5 Piston 1 129150
6 Lock Nut 1 128160
7 Cast Iron Piston Housing 1 129149
8 Cap Screw 2 090031
2
3 4
5
6 7
Early Models: Cylindrical Design Lockout
8
7
6
10
Item Description Qty Order Part No. Notes
1 Cap Screw 2 210381
2 Lock Washer 2 90415
3 Mounting Bracket 1 NLA
4 Piston Housing 1 NLA
5 Lock Nut 1 128160
6Piston 1 NLA
7 Piston O-Ring 1 210180
8 Shoulder Washer 1 NLA
9 Compression Spring 1 31038
10 Shift Fork & Push Rod Assy 1 103529
*NLA - No Longer Available
8
9
5
4
3 2
1
12
Rear Axle
Rear Axle - RSS40, RDS40
11 12 13 16 19 21 22 18 19 14 16 13 12 11
17 18 20 15 15
10
243
8
9
3428 27 29 26 27 24 31
1 23
14
24 25
30
32 33651
35
38
43
42
41
16
11
36
40
1
37
39
LH
13
Rear Axle
Item Description Qty RSS40 RDS40 Notes
BASIC OVERHAUL KIT
122434 217622 Contents identified by *
DIFF. CARRIER & BEARING CAP KIT
1 Carrier Casting No 127220-C 1 98593 – Includes items 2-4, 7
Carrier Casting No 127218R 1 – 98590 Includes items 2-4, 40-44
2 Bearing Cap Screw 4 127180 –
2 – 127180
2 – 32732
3 Flat Washer 4 32912 –
2 – 32912
4 Lockwire 4 12563 12563
5 Bearing Cap Adjuster Lock 2 14275 –
Bearing Cap Adjuster Lock (RH) 1 – 14275
6 Cotter Pin 2 90876 90876
7 Dowel Bushing 2 32730 32730
8 Bearing Cap Adjuster Lock (LH) 1 – 45448
9 Dowel Bushing Adjuster Lock 2 37746 37746
10 Capscrew 2 210601 210601
11 Diff. Bearing Adjuster (RH) 1 21637 21637
Diff. Bearing Adjuster (LH) 1 39448 82451
12 Diff. Bearing Cup (RH) 1 15092* 15092*
Diff. Bearing Cup (LH) 1 19529* 21632*
13 Diff. Bearing Cone (RH) 1 27876* 27876*
Diff. Bearing Cone (LH) 1 27666* 102660*
14 Ring Gear & Drive Pinion Set 1 See Appendix: Gear & Pinion
Information
15 Bolt 16 67586 67586 In Kit 70745
Nut 16 60600 60600 In Kit 70745
WHEEL DIFF. CASE KITS
3.55-4.11 98610 217619
4.33-6.67 121845 217620
WHEEL DIFF. SIDE GEAR KIT
120739 114472 Includes items 21-25
WHEEL DIFF. KIT w/o SIDE GEAR KIT 118749 118749 Includes items 22-25
16 Diff. Case (Flanged Half) NSS
3.55-4.11 1 88501 128980
4.33-6.67 1 126234 128981
Diff. Case (Plain Half) NSS 1 86777 86777
17 Diff. Case Cap Screw 12 88503 88503
18 Diff. Side Gear 2 120052 – 41 Involute
2 – 93401 36 Involute
19 Side Gear Thrust Washer 2 27274* 27274*
20 Side Pinion 4 86780 86780
21 Side Pinion Thrust Washer 4 86781* 86781*
22 Spider 1 86778 86778
23 Pinion Pilot Bearing 1 126187* 126187*
24 Pinion Bearing Cone (Inner) 1 27239* 27239*
Pinion Bearing Cone (Outer) 1 14218* 14218*
25 Pinion Bearing Spacer* AR See Appendix: Gear & Pinion
Information
* Note: Pinion Bearing Spacer information is included in the Appendix: Gear & Pinion Information
14
Rear Axle
Item Description Qty RSS40 RDS40 Notes
26 Pinion Bearing Cage & Cup Assy
(Production # 128976)
27 Pinion Bearing Cup (Inner) 1 27238* 27238*
Pinion Bearing Cup (Outer) 1 14217* 14217*
28 Pinion Bearing Spacer Washer 1 078904 31366
29 Pinion Bearing Cage Shim AR
0.003 67920* 67920*
0.005 67921* 67921*
0.010 67922* 67922*
0.020 67923* 67923*
0.030 67924* 67924*
30 Bearing Cage Cap Screw 6 130187 130187 Replaces: 113327 & 128532
31 Oil Seal 1 210724* 210724*
32 Input Yoke 1 See Yokes, Page 20
33 Flat Washer 1 210509 210509
34 Pinion Nut 1 210508 210508
Differential Lock
35 Expansion Plug (Lower) 1 9797 9797
Expansion Plug (Upper) 1 30703* 30703*
36 Sliding Clutch 1 E935088 E935088
37 Shift Fork & Pin Assy 1 84508 84508
38 Shift Fork Shaft Assy
Shaft #41103 NSS
39 Shift Fork Mounting Stud 2 119863 119863
40 Shift Fork Seal & Spring Assy 1 119855* 119855*
41 Stud Nut 2 63028 63028
42 Flat Washer 2 119857 119857
43 Shift Unit Assy 1 See Piston Air Shift Unit, Page 16
44 Gasket Compound AR 107276S* 107276S* Not Illustrated
* Note: Pinion Bearing Spacer information is included in the Appendix: Gear & Pinion Information
1 210592 210592 Cage # 079245 Includes Item 27
1 113801 113801 Includes 113140 O-ring
Kits and Assemblies RSS40 RDS40
Basic Overhaul Kit 122434 217622 Contents identified with *
Wheel Diff. Case Kit 98610 217619 Ratios 3.55-4.11 / Includes Items 16-17
Wheel Diff. Case Kit 121845 217620 Ratios 4.33-6.67 / Includes Items 16-17
Wheel Diff Side Gear & Pinion Kit 120739 114472 Includes Items 18-22
Wheel Diff Kit Less Side Gears 118749 118749 Includes Items 19-22
Oil Seal & Shim Kit 122436 122436 Includes Items 29, 31, & RTV
15
Piston Air Shift Unit
Piston Air Shift Unit
12
10
13
14
15
17
Piston Air Shift Unit
18
19
9
20
16
35 1 4 2 6 823
24 25
7
21
11
22
16
26
61804-6-94
Piston Air Shift Unit
Item Description Qty Part No. Notes
1 COVER ASSY 1
DD Models - cover# 73484 -NSS 129032 Includes Item 2
RD Models - cover# 73485 -NSS 129033
2 Cover Bearing 1 73481
3 Screw & Washer Assy 7 88053 Self-Tapping
4 Cover Gasket 1 73488
5 Cover Plug 1 28325
6 Actuating Lever Pin 1 73456
7 Clevis Pin 1 73498
8 ACTUATING LEVER, PIN & BLOCK ASSY 1
DD Models 129025
RD Models 129029
9 Shift Hsg Cover 1 73490
10 Seal Ring 1 73492
11 Cover Bolt 4 73491
12 Lock Nut 4 47641
13 Lock Nut 1 73496
14 Washer 1 111406
15 Piston 1 73493
16 Felt Piston Oiler (strip) 2 96916
17 Piston O-Ring 1 32832
18 Grommet 1 32826
19 Push Rod 1 73497
20 Compression Spring 1 73494
21 Piston Stop 1 73495
22 HOUSING ASSY 1 Includes Items 3 & 23 and 84805 Bushing
(part not shown)
DD Models 82428
RD Models 82429
23 Housing Bearing 1 73481
24 Switch 1 129035
25 Nylon Washer 1 129034
26 Wiring Harness 1 129044 Metri-pack 150 series
129046 Metri-pack 280 series (Mack Only)
129047 Weather Pack
Kits and Assemblies
DD Models
Air Shift Unit 129006
Piston Air Shift Unit & Wiring Harness 129068 Incls Items 1-25 & Wiring Harness 129044
Piston Air Shift Unit & Wiring Harness 129069 Incls Items 1-25 & Wiring Harness 129046
Piston Air Shift Unit & Wiring Harness 129070 Incls Items 1-25 & Wiring Harness 129047
RD Models
Air Shift Unit 129038
Piston Air Shift Unit & Wiring Harness 129065 Incls Items 1-25 & Wiring Harness 129044
Piston Air Shift Unit & Wiring Harness 129066 Incls Items 1-25 & Wiring Harness 129046
Piston Air Shift Unit & Wiring Harness 129067 Incls Items 1-25 & Wiring Harness 129047
17
Axle Housings & Shafts
Axle Housings & Shafts
Axle Shaft Configurations
Axles are built with a number of different axle shafts, on the basis of OEM specification.
When ordering replacement axle shafts, note the part number stamped into the flange.
Axle Shafts
Model Part No. Qty Spline
DDS40
RDS40
DDS40
RDS40
* = Diff Lock Shaft w/11” Splines, and are used in sets.
1 = Freightliner
2 = Kenworth
3 = Peterbilt
4 = Volvo White
5 = Mack
6 = Western Star
110888 2 41 1.87 41.313 8.50 .635 STR 1, 2, 3, 4
129330 2 41 1.87 41.500 8.50 .948 TPR 5, 6
129332 2 41 1.87 40.690 8.50 .773 STR 4
129141* 1 36 2.06 40.600 11" 8.50 .948 TPR 1
126880 1 36 2.06 40.600 4" 8.50 .948 TPR 1
129140* 1 36 2.06 40.600 11" 8.50 .773 STR 4
128055 1 36 2.06 40.600 4" 8.50 .773 STR 4
129139* 1 36 2.06 41.375 11" 8.50 .635 STR 1, 2, 3, 4
129508 1 36 2.06 41.375 4" 8.50 .635 STR 1, 2, 3, 4
Body
O.D.
Shaft
Length
Spline
Length
Flange
O.D.
Flange
Holes
OEM
18
DSS40(P) / RSS40
Axle Housings & Shafts
17
19
15
12
11
13
10
14
14
7
6
Axle Housing
ID Tag
2
3
4
5
8161821
2020
1
Item Description Qty Part No. Notes
1 Axle Shaft 2 See Chart Page 18
2 Adjuster Nut - Inner 2 119881
3 Bearing Adjuster Lockwasher 2 119883
4 Tanged Lockwasher 2 129132
5 Adjuster Nut - Outer 2 119882
6 Axle Housing 1 N/A See OEM - Housings Vary
7 Axle Housing Cover Assy 1 216642 Casting # 78923
8 Magnetic Drain Plug 1 54254
9 Magnetic Filler Plug 1 75130
10 Cover Locating Dowel 1 7641 Forward Axle Only
11 Cover Cap Screw 1 79558 Forward Axle Only
7 128533 Forward Axle Only
12 Cover Stud 4 49982 Forward Axle Only
13 Nut 4 42364 Forward Axle Only
14 Lockwasher 4 90415 Forward Axle Only
15 Stud 4 36435 Forward Axle Only
16 Stud 8 36435 (short) Rear Axle Only
4 51212 (long) Rear Axle Only
17 Nut 4 90208 Forward Axle Only
18 Nut 12 90208 Rear Axle Only
19 Lockwasher 4 90422 Forward Axle Only
20 Lockwasher 12 90422 Rear Axle Only
21 Cap Screw 2 99708 (12 pt.) Forward Axle Only
6 128532 Forward Axle Only
22 U-Tube Breather Kit 507162 Not Illustrated
19
Yokes
Yokes
STYLE X
Half Round
A
C
B
STYLE Y
Full Round
A
C
STYLE Z
Half Round
Tapped Holes
Bearing Strap
B
A
C
All DSS40, DDS40
Forward Axle - Input / 46 - 2.350 Involute Spline, Hub Dia. 3.19"
Dimensions (in inches): Replaces Old Straight Spline Yokes
Yoke &
Seal Kit
210843* SPL 170 25° X 6.53 2.16 5.51
210845* SPL 250 25° X 6.76 2.36 5.31
216471 1710 30° Y 6.01 1.94 6.09 82468 6-4-4581 17NYS39-3
216473 1760 30° Y 6.20 1.94 7.00 109639 6-3-4-131
216476 1810 22.5° X 6.01 1.94 7.55 84886 6.5-4-1991 18NYS39-3
216477 82N/8C 30° X 4.75 N/A 6.88 119420
* Yoke and slinger only. Purchase oil seal separately.
Series
Joint
Angle
StyleABC
Dana/
Eaton
Spicer Rockwell
Forward Axle - Output / 41 - 2.100 Involute Spline, Hub Dia. 3.00"
Dimensions (in inches): Replaces Old Straight Spline Yokes
Yoke &
Seal Kit
216479 1610 45° Y 6.50 1.88 5.31 99714 5-4-5031 16NYS34-7
216480 1710 38° Y 6.62 1.94 6.09 83800 6-4-4591 7NYS34-8
216481 1760 38° Y 5.81 1.94 7.55
216482 1810 30° Y 5.81 1.94 7.55 87512 6.5-4-2291 8NYS34-1
* Yoke and slinger only. Purchase oil seal separately.
Series
20
Joint
Angle
StyleABC
Dana/
Eaton
Spicer Rockwell
Yokes
All RDS40, RDD40
Rear Axle - 41 - 2.100 Involute Spline, Hub Dia. 2.50"
Yoke &
Slinger
Assy**
128882 1610 26° Y 5.19 1.88 5.31 99715 5-4-5031 16NYS34-7
128883 1610 37° Y 6.00 1.88 5.31
128884 1710 28° Y 5.19 1.94 6.09
128885 1710 42° Y 6.12 1.94 6.09 83801 6-4-4591 7NYS34-8
128886 1760 30.5° Y 5.25 1.94 7.00
128887 1810 30° Y 5.25 1.94 7.55 87513 6.5-4-2291 8NYS34-1
128888 72N/7C N/A Z 4.25 N/A 4.62 106459*
210853 SPL 170 25° X 5.32 2.16 5.51
210855 SPL 170 45° X 6.68 2.16 5.51
* Mechanics part number 272715.
** Yoke and slinger only. Purchase oil seal separately.
Series
Joint
Angle
StyleABC
Dimensions (in inches): Replaces Old Straight Spline Yokes
Dana/
Eaton
Spicer Rockwell
21
Appendix
Appendix
Ring Gear and Pinion Identification
• Ring Gear and Drive Pinion are matched parts and must be replaced in sets.
• Complete identification is stamped on both parts shown in the adjacent drawing.
• Order by Dana "Set No." which includes drive pinion nut.
Single Reduction
Ring Gear
L
7
0
3
Matched Gear Set Number
Self Locking Nut
Ring Gear Teeth
L7038
Side
8
8
8
6
7
8
Part Number
3
6
-
9
Pinion
3
9
-
A
E
Manufacturing Numbers
Pinion Teeth
Part Number
9
1
-
F
J
Pinion Teeth
Ring Gear Teeth
6-39
JD77
93
85405
Front
Manufacturing Numbers
EATON
Pinion Bearing Spacers - DSS40(P), RSS40, DDS40(P), RDS40
Pinion Bearing Spacer size is equal to thickness in inches. The most commonly used spacers are indicated with an asterisk*.
Size " Part # Size " Part # Size " Part # Size " Part #
0.167 91679 0.176 91688 0.185 91702* 0.194 91719
0.168 91680 0.177 91689* 0.186 91704* 0.195 91720*
0.169 91681 0.178 91690* 0.187 91706* 0.196 91721
0.170 91682 0.179 91691* 0.188 91708* 0.197 91722
0.171 91683 0.180 91692* 0.189 91710* 0.198 91723*
0.172 91684 0.181 91694* 0.190 91712 0.199 91724
0.173 91685 0.182 91696* 0.191 91714 0.200 91725
0.174 91686 0.183 91698* 0.192 91716 0.201 91726
0.175 91687 0.184 91700* 0.193 91718* 0.202 91727
22
Drive Pinion and Gear Set
Appendix
Single Reduction - 18" Gearing
Forward Axle Models: DSS40(P), DDS40(P)
Ratios Kit # Gear (NSS)
3.55 122667 126678 (39) 126679 (11)
3.70 122334 98160 (37) 126161 (10)
3.90 123333 99900 (39) 127047 (10)
4.11 122335 94381 (37) 126162 (9)
4.33 122336 78856 (39) 126163 (9)
4.56 122337 78858 (41) 126164 (9)
4.88 122338 78860 (39) 126165 (8)
5.29 211333 127339 (37) 127327 (7)
5.43 122339 78862 (38) 126166 (7)
6.17 122340 78864 (37) 126167 (6)
6.50 212890 128028 (39) 128029 (6)
6.67 213287 107888 (40) 128052 (6)
Pinion (NSS)
41, 2.100" Dia.
Single Reduction - 18" Gearing
Rear Axle Models: RSS40, RDS40
Ratios Kit # Gear (NSS)
3.55 122668 111349 (39) 126677 (11)
3.70 121887 88500 (37) 126120 (10)
3.90 123334 99896 (39) 127048 (10)
4.11 121888 88502 (37) 126121 (9)
4.33 121889 52999 (39) 126118 (9)
4.56 121890 73312 (41) 126125 (9)
4.88 121891 53001 (39) 126119 (8)
5.29 211335 127338 (37) 127328 (7)
5.43 121892 53003 (38) 126122 (7)
6.17 121893 53005 (37) 126123 (6)
6.50 212891 128030 (39) 128031 (6)
6.67 213288 53007 (40) 128054 (6)
Pinion (NSS)
41, 2.100" Dia.
23
Appendix
New Carrier Assemblies
These assemblies are complete, less input yoke and diff. lock shift units.
P = Pump
Single Reduction Models
41 Involute Splines
Gear Ratio
DSS40 DSS40-P RSS40
3.55 675638 675583 675575
3.70 675571 675600 675576
3.90 675572 675584 675577
4.11 675876 675585 675578
4.33 675573 675586 675579
4.56 675574 675587 675580
4.88 N/A N/A N/A
5.29 676113 675632 675633
Forward Assy Rear Assy
Single Reduction w/Diff Lock
36 Involute Splines
Gear Ratio
DDS40 DDS40-P RDS40
3.55 675602 675588 675928
3.70 675603 675589 675594
3.90 675604 675590 675595
4.11 675605 675601 675596
4.33 675606 675591 675597
4.56 675607 675592 675598
4.88 N/A N/A N/A
5.29 675608 675593 675599
Forward Assy Rear Assy
24
Service Kit: 217590
Seal
Part Number
Appendix
D-Input D-Output R-Pinion
210736 210737 210724
D-Input D-Output R-Pinion
Location
Tool Number
Used
210749
210750
210751 210749
25
Dana Aftermarket Group
For spec‘ing or service assistance, call 1.800.621.8084 or visit our website at www.spicerparts.com
PO Box 321
Toledo, Ohio 43697-0321
Warehouse Distributor: 1.800.621.8084
Dana Commercial Vehicle Products Group
OE Dealers: 1.877.777.5360
3939 Technology Drive
Maumee, Ohio, USA 43537
www.spicerparts.com
www.dana.com
AXIP-0342 Printed in U.S.A.
Copyright Dana Limited, 2012.
All rights reserved. Dana Limited.
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