Illustrated Parts List - Canada Wide Parts Distributors Ltd

5 Forward Axle Item Description Qty Order Part No. Notes DD521-P DD581-P 39 Pinion Pilot Brg 1 126187* 40 Pinion Brg Cone 2 14218* 41 Pinion Brg Space...

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Illustrated Parts List AXIP0085a January 1994 Single Reduction, Dual Range, & Double Reduction Addendum 461, 462, 463, 521, 581 46,000 - 65,000 lbs

Introduction

Contents

Single Reduction w/Wheel Differential Lock - Forward Axle DD461-P•DD521-P•DD581-P ------------------------------------------------- 2-6 Differential Lockout Assembly -------------------------------------------------- 7 Pinion Bearing Spacers ---------------------------------------------------------- 7

Single Reduction w/Wheel Differential Lock - Rear Axle RD461•RD521•RD581 --------------------------------------------------------- 8-9

Shift System Piston Air Shift Unit --------------------------------------------------------- 10-11

Appendix Carrier Exchange Assemblies -------------------------------------------------- 12 Drive Pinion and Gear Set ------------------------------------------------------ 12 Axle Shaft Chart ----------------------------------------------------------------- 13

The following models are represented in this publication Single Reduction Models w/Wheel Differential Lock Forward Axle

Rear Axle

Axle Capacity

Gear Size

DD-461-P DD-521-P

RD-461 RD-521

46,000 lbs 52,000 lbs

18" Gear 18" Gear

DD-581-P

RD-581

58,000 lbs

18" Gear

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.

D D - 4 6 1 - P Gearing

Lube Pump

D - Forward Tandem Axle R - Rear Tandem Axle

P = Standard (P) = Optional

S - Single Reduction T - Dual Range P - Double Reduction C - Controlled Traction D - Single Reduction with Wheel Differential Lock A - Single Reduction with In-Axle Speed Sensors (IASS)

Design Level

Example: DS = Forward Tandem/Single Reduction or RS = Rear Tandem/Single Reduction

Capacity (x 1000)

Example: 46 = 46,000

1

Single Reduction w/Wheel Differential Lock Forward Axle 4

53 54

55

57 58 59

56

6

1

2 3 1

9 8

10

13

12

1

14

5

60

11 7 19 15 16

17 18

DIFFERENTIAL & RING GEAR 20

30

LH

RH 21

2

22

23

24 33

29

31

32 35 34

38 36 37 34 35

28

27

26

25

Single Reduction w/Wheel Differential Lock Forward Axle

62

64

65

66

67

72

70 76

75 74

77

78

79

92 80 81 82

83

94

71

73

93

84

85 86 87 89

90 91

88 THESE PARTS ARE MOUNTED IN POWER DIVIDER COVER

107 106

39

31

40

41 42

43

45

46 44

43 47

40

48

50 49

52 49

51

LUBE PUMP 95

105 104 96

92

98

97

101 100 102

99

103

3

DD521-P

68 69

71

DD461-P DD581-P

61

63

INTER-AXLE DIFFERENTIAL ASSEMBLY

Single Reduction w/Wheel Differential Lock Forward Axle Item

Description

Qty

Order Part No.

Notes

BASIC OVERHAUL KIT

1

217621

Contents Identified with *

1

DIFF CARRIER & BRG CAP KIT Carrier Casting No. 110500 -NSS

1

106710

Includes Items: 2-5, 10-18 45521 cover plate & 107276 RTV

2 3

Bearing Cap Screw Flat Washer

4 4

32732 32912

4 5

Lockwire Dowel Bushing

4 2

12563 32730

6 7

Brg Cap Adjuster Lock (RH) Capscrew

1 2

45448 210601

8 9

Brg Cap Ajuster Lock (LH) Cotter Pin (LH)

1 1

14275 90876

10 11

Expansion Plug (Upper) Expansion Plug (Lower)

1 1

30703* 9797*

12 13

Filler Plug SHIFT FORK SHAFT ASSY

1 1

90325 113801

14

Shaft# 41103 -NSS Carrier Cover Dowel Pin

2

7641

15 16

Shift Unit Mounting Stud Shift Fork Seal & Spring Assy

2 1

119863 119855

17 18

Flat Washer Stud Nut

2 2

119857 63028

19 20 21

Shift Fork & Roller Assy Shift Unit Assy Sliding Clutch

1 1 1

84508

22 23

Diff Brg Adjuster (RH) Diff Brg Cup (RH)

1 1

82451 21632*

24 25

Diff Brg Cone (RH) Diff Brg Adjuster (LH)

1 1

102660* 21637

26 27

Diff Brg Cup (LH) Diff Brg Cone (LH)

1 1

15092* 27876*

WHEEL DIFF CASE KITS Ratios 3.55-4.11

1

See: Piston Air Shift Unit, Pg 10-11 935088

217619

28

Ratios 4.33-6.67 Diff Case (Plain Half) NSS

1

29

Diff Case (Flanged Half) NSS

1

30 31

Diff Case Capscrew Ring Gear & Drive Pinion Set

12 1

88503

32 33

Bolt Nut

16 16

67586 60600

WHEEL DIFF SIDE GEAR KIT WHEEL DIFF KIT w/o SIDE GEARS

Includes Items 28-30

217620 86777-NSS 128980-NSS 128981-NSS

Ratios 3.55-4.11 Ratios 4.33-6.67 See: Gear & Pinion Listing, Pg 12

114472 118749

34 35

Diff Side Gear - 36 Involute Side Gear Thrust Washer

2 2

93401 27274*

36 37

Side Pinion Side Pinion Thrust Washer

4 4

86780 86781*

38

Spider

1

86778

4

3/4" Includes 113140 O-Ring

In kit 70745 In kit 70745 Includes Items 34-38 Includes Items 35-38

Single Reduction w/Wheel Differential Lock Forward Axle Item

Qty

Order Part No.

39

Pinion Pilot Brg

1

126187*

40 41

Pinion Brg Cone Pinion Brg Spacer Washer

2 1

14218* 78904*

42 43

Pinion Brg Spacer Pinion Brg Cup

44

PINION BRG CAGE & CUP ASSY Cage # 78932 -NSS

45

Pinion Brg Cage Shim .003"

AR 2 1

Notes

DD461-P DD581-P

Description

See: Pinion Brg Spacer Chart, Pg 7 14217* 78914

Includes Item 43

DD521-P

AR 45461*

.005" .010"

62829* 45462*

.020" .030"

62830* 45463*

46 47

Lockwasher Bearing Cage Capscrew

6 6

37207 62158

48 49

Pinion Helical Gear Outer Pinion Support Brg & Race Assy

1 1

119995 78916*

50 51

Pinion Shaft End Nut Pinion Nut Spring Pin

1 1

126182 118807

52 53

Outer Pinion Brg Snap Ring Output Shaft Nut

1 1

78937* 210508

54 55 56

Output Shaft Washer Rear Brg Retaining Washer AXLE HSG COVER ASSY

1 1 1

210509 78922 107863

Includes Items 57-59

57

Cover# 84546 -NSS Output Shaft Oil Seal

1

210737*

Microlip Design

58 59

Bearing Snap Ring Output Shaft Brg Assy

1 1

78937* 78936*

Inner Race 118787-NSS

60

Magnetic Filler Plug

1

75130

Outer Race 118788-NSS 1"

61

Filler Plug OUTPUT SHAFT KIT

1 1

90898 122419

62

Shaft# 119991-NSS 41 SPL, 2.100" dia. Output Shaft Bushing

1

48922*

63 64

Output Shaft O-Ring Output Shaft Brg Cup

2 1

78931* 24328*

65 66

Output Shaft Brg Cone Output Shaft Side Gear

1 1

24330* 78911

67 68

Side Gear Snap Ring Output Shaft Compression Spring

1 1

85994* 127095

69 70

Output Shaft Thrust Bearing INTER-AXLE DIFF ASSY

1 1

51228 121681

Includes Items 71-76

71

INTER-AXLE DIFF CASE KIT Case Half 126151-NSS

1

211252

Includes Items 72-73

72 73

Case Bolt Case Nut

8 8

57636 57637

74 75

Side Pinion Side Pinion Thrust Washer

4 4

95218 126180*

1/2" Includes Items 53-54, 62-63, 67

5

Single Reduction w/Wheel Differential Lock Forward Axle Item

Description

Qty

Order Part No.

77

Helical Side Gear Snap Ring

1

78

Helical Side Gear & Bushing Assy Gear# 113328-NSS

1

79 80

Helical Side Gear Bushing Helical Side Gear Thrust Washer

2 1

75063* 79034*

81 82

Helical Side Gear ”D” Washer Lockout Sliding Clutch

1 1

56360* 119948

83

INPUT SHAFT KIT Shaft# 119990-NSS, 46 SPL, 2.350" dia.

1

122418

84 85

Input Shaft Brg Cone Input Shaft Brg Cup

1 1

86

Input Bearing Cover Shim .003"

Notes

78909* 113331

Includes Item 79

Includes Item 91

98387* 98388*

AR 78918*

.005" .010"

78919* 78920*

87

.020" INPUT BRG COVER ASSY

1

113130* 111691

88

Cover# 111690-NSS Bearing Cover Capscrew

5

126243

89 90

Input Shaft Oil Seal Input Shaft Nut Washer

1 1

210736* 126242*

91 92

Input Shaft Nut PDU CARRIER COVER ASSY Cover# 103526-NSS

1 1

126155 103536

93

Carrier Cover Capscrew

8 1

90069 9309

Short Long

1 10

81855 90417

Socket Head

94

Lockwasher

95 96

Pipe Plug Expansion Plug

1 1

90325 9797

97

Magnetic Filter Screen LUBE PUMP REPLACEMENT KIT

1

102611* 121302

98 99

Pump Gear & Shaft Assy Cover O-Ring

1 1

102625 102620*

100 101

Lube Pump Cover Lockwasher

1 4

102607 90419

102 103

Cover Capscrew Cover Dowel Pin

4 2

102618 102617

104 105

Pump Drive Gear Drive Gear Locknut

1 1

119946 111451

106 107

AIR-OPER. LOCKOUT ASSY SHIFT FORK & PUSH ROD ASSY

1 1

123218 103529

108

RTV - Sealant

6

AR

107276*

Includes Items 85 & 89

Microlip Design

Includes Items 95-96

Includes Items 98-105

See: Differential Lockout Assy, Pg 7

Single Reduction w/Wheel Differential Lock

Differential Lockout Assembly

10

8

9

6

7

5

4

3

2

1

DD461-P DD581-P DD521-P

Part Name

Qty

Order Part No.

1

Capscrew

2

210381

2 3

Lockwasher Mounting Bracket

2 1

90415 127675

4 5

Piston Housing Locknut

1 1

119923 128160

6 7

Piston Piston O-Ring

1 1

119912 210180

8 9

Shoulder Washer Compression Spring

1 1

210452 31038

1 AR

103529 107276

10 11

Shift Fork & Push Rod Assy RTV Sealant

Remarks

Lockout Assembly

Item

Kits And Assemblies Air-Operated Lockout Assy.

123218

Includes Items 1-10

Air Lockout Repair Kit

211198

Includes Items 5-9

Piston Kit

121333

Includes Items 3-8

Pinion Bearing Spacers

Pinion Bearing Spacers Pinion Bearing Spacer size is equal to thickness in inches. The most commonly used spacers are indicated with an asterix*. Size"

Part#

Size"

Part#

Size"

Part#

Size"

Part#

.167 .168

91679 91680

.177 .178

91689* 91690*

.187 .188

91706* 91708*

.197 .198

91722 91723*

.169 .170

91681 91682

.179 .180

91691* 91692*

.189 .190

91710* 91712

.199 .200

91724 91725

.171 .172

91683 91684

.181 .182

91694* 91696*

.191 .192

91714 91716

.201 .202

91726 91727

.173 .174

91685 91686

.183 .184

91698* 91700*

.193 .194

91718* 91719

.175 .176

91687 91688

.185 .186

91702* 91704*

.195 .196

91720* 91721 7

Single Reduction w/Wheel Differential Lock Rear Axle 20

21 22

28

34

36

37

33

34

27

29

26

25

24

RH LH 30

33

35

31

16

19 15 14

32

11 13

9 8 1

2

18 17

4

43

10

45

38 7 6 1 3 Item

5

1

Description

12

27

39 40 41 42 44

Qty

Order Part No.

BASIC OVERHAUL KIT

1

217622

1

DIFF CARRIER & BRG CAP KIT Carrier Casting No. 127218R -NSS

1

98590

2

Bearing Cap Screw

2 2

32732 127180

3 4

Flat Washer Lockwire

4 4

32912 12563

5 6

Dowel Bushing Brg Cap Adjuster Lock (RH)

2 1

32730 14275

7 8

Cotter Pin (RH) Brg Cap Ajuster Lock (LH)

1 1

90876 45448

9 10

Adjuster Lock Capscrew Dowel Bushing -Adjuster Lock

2 2

210601 37746

11 12

Expansion Plug (Upper) Expansion Plug (Lower)

1 1

13

SHIFT FORK SHAFT ASSY Shaft# 41103 -NSS

1

113801

14 15

Stud Nut Flat Washer

2 2

63028 119857

8

46

47 48

49 50

Notes Contents Identified with * Includes Items: 2-5, 10-17 45521 cover plate & 107276 RTV

30703* 9797* Includes 113140 O-Ring

23

Single Reduction w/Wheel Differential Lock Rear Axle Description

Qty

16

Shift Fork Seal & Spring Assy

1

119855*

17 18

Shift Fork Mounting Stud Shift Fork & Roller Assy

2 1

119863 84508

19 20

Shift Unit Assy Diff Brg Adjuster (RH)

1 1

21637

21 22

Diff Brg Cup (RH) Diff Brg Cone (RH)

1 1

15092* 27876*

23 24

Sliding Clutch Diff Brg Adjuster (LH)

1 1

935088 82451

25 26

Diff Brg Cup (LH) Diff Brg Cone (LH)

1 1

21632* 102660*

27

Ring Gear & Drive Pinion Set WHEEL DIFF CASE KITS

1 1

28 29

Diff Case (Plain Half) NSS Diff Case (Flanged Half) NSS

Notes

See: Piston Air Shift Unit, Pg 10-11

RD521

Ratios 3.55-4.11 Ratios 4.33-6.67

Order Part No.

RD461 RD581

Item

See: Gear & Pinion Listing, Pg 12 Includes Items 28-30 217619 217620

1 1

86777-NSS 128980-NSS 128981-NSS 88503

30

Diff Case Capscrew

12

31 32

Bolt Nut

16 16

WHEEL DIFF SIDE GEAR KIT WHEEL DIFF KIT w/o SIDE GEARS

67586 60600 114472 118749

33 34

Diff Side Gear - 36 Involute Side Gear Thrust Washer

2 2

93401 27274*

35 36

Side Pinion Side Pinion Thrust Washer

4 4

86780 86781*

37 38

Spider Pinion Pilot Brg

1 1

86778 126187*

39 40

Pinion Brg Cone (Inner) Pinion Brg Spacer Washer

1 1

27239* 31366*

41 42

Pinion Brg Spacer Pinion Brg Cup (Inner)

AR 1

27238*

43

PINION BRG CAGE & CUP ASSY Cage# 210591-NSS

44

Pinion Brg Cage Shim .003"

1

Ratios 3.55-4.11 Ratios 4.33-6.67 In kit 70745 In kit 70745 Includes Items 33-37 Includes Items 34-37

See: Pinion Brg Spacer Chart, Pg 7 210592

Includes Items 42 & 45

AR 67920*

.005" .010"

67921* 67922*

.020" .030"

67923* 67924*

45 46

Pinion Brg Cup (Outer) Brg Cage Capscrew

1 6

14217* 113327

47 48

Pinion Brg Cone (Outer) Pinion Oil Seal

1 1

14218* 210724*

49 50

Flat Washer Pinion Nut

1 1

210509 210508

51

RTV Sealant

AR

Microlip Design

107276* 9

Shift System

Piston Air Shift Unit

18 19 12 9 10 13 14 15

20

17 16

21

11 22

3 5 24 25 1

4

2

6

7

8 23

26

61804-6-94

10

Shift System

Piston Air Shift Unit Item

Description

Qty

1

COVER ASSY

1

DD Models - cover# 73484 -NSS RD Models - cover# 73485 -NSS

Order Part No.

Notes

129032 129033

Includes Item 2

Cover Bearing Screw & Washer Assy

1 7

73481 88053

4 5

Cover Gasket Cover Plug

1 1

73488 28325

6 7

Actuating Lever Pin Clevis Pin

1 1

73456 73498

8

ACTUATING LEVER, PIN & BLOCK ASSY 1 DD Models

129025

RD Models Shift Hsg Cover

1

129029 73490

10 11

Seal Ring Cover Bolt

1 4

73492 73491

12 13

Lock Nut Lock Nut

4 1

47641 73496

14 15

Washer Piston

1 1

111406 73493

16 17 18

Felt Piston Oiler (strip) Piston O-Ring Grommet

2 1 1

96916 32832 32826

19 20

Push Rod Compression Spring

1 1

73497 73494

21 22

Piston Stop HOUSING ASSY

1 1

73495

9

DD Models RD Models

Self-Tapping

Piston Air Shift Unit

2 3

Includes Items 3 & 23 82428 82429

23 24

Housing Bearing Switch

1 1

73481 129035

25 26

Nylon Washer Wiring Harness

1 1

129034 129044

Metri-pack 150 series

129046 129047

Metri-pack 280 series (Mack Only) Weather Pack

Piston Air Shift Unit & Wiring Harness Piston Air Shift Unit & Wiring Harness

129068 129069

Incls Items 1-25 & Wiring Harness129044 Incls Items 1-25 & Wiring Harness 129046

Piston Air Shift Unit & Wiring Harness

129070

Incls Items 1-25 & Wiring Harness 129047

Piston Air Shift Unit & Wiring Harness Piston Air Shift Unit & Wiring Harness

129065 129066

Incls Items 1-25 & Wiring Harness 129044 Incls Items 1-25 & Wiring Harness 129046

Piston Air Shift Unit & Wiring Harness

129067

Incls Items 1-25 & Wiring Harness 129047

Kits And Assemblies DD Models

RD Models

11

Appendix

Drive Pinion and Gear Set Single Reduction - 18" Gearing

Ratios

Forward Axle Models: DD461-P, DD521-P, DD581-P

Rear Axle Models: RD461, RD521, RD581

Gear Set

Gear Set

Gear (NSS)

Pinion (NSS)

Gear (NSS)

41,2.100" Dia.

Pinion (NSS) 41,2.100" Dia.

3.55 3.70

122667 122334

126678(39) 98160(37)

126679(11) 126161(10)

122668 121887

111349(39) 88500(37)

126677(11) 126120(10)

3.90 4.11

123333 122335

99900(39) 94381(37)

127047(10) 126162(9)

123334 121888

99896(39) 88502(37)

127048(10) 126121(9)

4.33 4.56

122336 122337

78856(39) 78858(41)

126163(9) 126164(9)

121889 121890

52999(39) 73312(41)

126118(9) 126125(9)

4.88 5.29

122338 211333

78860(39) 127339(37)

126165(8) 127327(7)

121891 211335

53001(39) 127338(37)

126119(8) 127328(7)

5.43 6.17

122339 122340

78862(38) 78864(37)

126166(7) 126167(6)

121892 121893

53003(38) 53005(37)

126122(7) 126123(6)

6.50 6.67

212890 213287

128028(39) 107888(40)

128029(6) 128052(6)

212891 213288

128030(39) 53007(40)

128031(6) 126124(6)

Carrier Exchange Assemblies These assemblies are complete, less input yoke and shift units. Single Reduction w/Differential Lock

Gear Ratio

DD461-P

RD461

DD521-P

RD521

DD581-P

RD581

3.55 3.70

675326 675327

675338 675339

3.90 4.11

675328 675329

675340 675341

4.33 4.56

675330 675331

675342 675343

4.88 5.29

675332 675333

675344 675345

5.43 6.17

675334 675335

675346 675347

6.50 6.67

675336 675337

675348 675349

36 Involute

12

Appendix

Axle Shaft Chart

Body O.D.

Shaft Length

Spline Flange Length O.D.

36 36

2.25 2.25

41.25 41.312

3.750" 10.236"

8.375 8.375

8 (.948) TPR 8 (.948) TPR

4,6,7,9,11 4,6,7,9,11

1 = Ford 2 = GMC

1 1

36 36

2.25 2.25

45.25 45.25

3.750" 10.236"

8.375 8.375

8 (.948) TPR 8 (.948) TPR

6 6

3 = Freightliner 4 = Mack

126195 128547

1 1

36 36

2.25 2.25

42.25 42.216

3.750" 10.236"

8.375 8.375

8 (.948) TPR 8 (.948) TPR

5,6,7,9 5,6,7,9

5 = Peterbilt 6 = Kenworth

126196 129002

1 1

36 36

2.25 2.25

44.25 44.25

3.750" 10.236"

8.375 8.375

8 (.948) TPR 8 (.948) TPR

7,9 7,9

7 = Volvo White 8 = Marmon

128553 128549

1 1

36 36

2.25 2.25

40.563 40.563

4.000" 10.236"

8.375 8.375

8 (.635) STR 8 (.635) STR

5,6 5,6

9 = Western Star 10 = Navistar

126881 128318

1 1

36 36

2.25 2.25

40 40.563

3.750" 10.236"

8.375 8.375

8 (.948) TPR 8 (.948) TPR

1 1

11 = Crane Carrier

128400 128550

1 1

36 36

2.25 2.25

41.312 41.312

4.000" 10.236"

8.375 8.375

8 (.773) STR 8 (.773) STR

10 10

126973 128317 126965

1 1 1

36 36 36

2.25 2.25 2.25

40.563 40.563 41.312

4.000" 10.236" 4.000"

8.375 8.375 8.5

8 (.773) STR 8 (.773) STR 8 (.948) TPR

10 10 4,5,7,8,9,11

128315 126967

1 1

36 36

2.25 2.25

41.312 41.312

10.236" 4.000"

8.5 8.5

8 (.948) TPR 8 (.635) STR

4,5,7,8,9,11 3,5”

128316

1

36

2.25

41.312

10.236"

8.5

8 (.635) STR

3,5”

Part No.

Qty

119903 128315

1 1

119904 129000

Spline

Flange Holes

OEM

Axle Shaft Chart Gear & Pinion Set Differential Carrier Assemblies

13

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 Maumee, Ohio, USA 43537 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.

Printed in USA

AXIP-0085a 01/94