Instruction Manual

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HX500-QR

SEPTEMBER 2005

Supersedes

HX500-QR

Dated April 2005

HEAVY AXLE COMPONENTS

Summary of content (46 pages)

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HEAVY AXLE COMPONENTS HX500-QR SEPTEMBER 2005 Supersedes HX500-QR Dated April 2005
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TABLE OF CONTENTS TABLE OF CONTENTS MODEL IDENTIFICATION............................................................................................3 Steer Axle Identification ......................................................................................................................................................3 Spicer Steer Axle Nomenclature..........................................................................................................................................
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TABLE OF CONTENTS Spicer Legacy Models .......................................................................................................................................................38 F Series .............................................................................................................................................................................39 G Series..............................................................................................................................
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MODEL IDENTIFICATION MODEL IDENTIFICATION Steer Axle Identification The Spicer front non drive steering axles are identified with a tag located between the spring pads, on the front side of the center beam section. CUST PART NO. SPEC. XXXXXX MODEL XXXXX PART NO. SPICER XXXX SERIAL NO. XXXXXXXX RATIO XXXXX MADE IN: Axle Assembly Number Spicer Steer Axle Nomenclature The Spicer model numbering system provides pertinent information about the axle for easy identification.
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SPICER HEAVY AXLE PRODUCTION KEY SPICER HEAVY AXLE PRODUCTION KEY Non Drive Front Axles Spicer Model Tandem Drive Axles G.A.W.R. Production Dates I50 5,000 Pre 1989 I60 6,000 I75 G.A.W.
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SPICER STEER AXLE SERVICE PARTS SPICER STEER AXLE SERVICE PARTS King Pin Kits - All Models FEATURES: • Spicer king pin kits include the latest genuine original design parts. Parts are designed to prevent contamination and significantly improve durability and reduce maintenance • Kits include sealed thrust bearings that improve life and ensure durability.
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SPICER STEER AXLE SERVICE PARTS King Pin Kits Model Kit Part # Size* Bushing Type** Pin Type*** Pin Length Pin Diameter 811525 Standard G S 9.965 1.873 FA10 62905R93 Standard B S 5.44 0.861 FA48 - No Longer Available 134455R91 .015/0S B S 6.25 1.123 69971R91 Standard B S 6.25 1.109 134456R91 .015/0S B S 6.75 1.248 70594R91 Standard B S 6.75 1.234 134457R91 .015/0S B S 7.65 1.248 61556R91 Standard B S 7.66 1.234 493092C92 .002/OS B S 8.85 1.
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SPICER STEER AXLE SERVICE PARTS Tie Rod Assemblies/Kits (I Family) “A” “A” “B” “B” * Drop-Center Application I-80, I-100 Tie Rod Assemblies TIE ROD END ASSY - COMPLETE CROSS TUBES TIE ROD ENDS Cross Tube Width Cross Tube Assy. (includes clamp) Tube Length “B” LH Side Type RH Side I-80 I-100 Assy. Length “A” N/A 120TR100-1X 64.72 1.50 120TR106 59.38 120TR109 S 120TR110 N/A 100TR105-3X 64.72 1.44 N/A 59.38 140TR111 S 140TR112 N/A N/A 64.72 2.25 140TR116-1 42.
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SPICER STEER AXLE SERVICE PARTS “A” “A” “B” “B” * Drop-Center Application I-120, I-130, I-132, I-140 Tie Rod Assemblies TIE ROD END ASSY - COMPLETE CROSS TUBES I-140 ASSY LENGTH "A” CROSS TUBE WIDTH CROSS TUBE ASSY (includes clamp) TUBE LENGTH "B” LH Side Type RH Side N/A N/A 64.72 1.50 120TR106 59.38 120TR109 S 120TR110 N/A N/A 64.72 1.44 N/A 59.38 140TR111 S 140TR112 N/A 140TR129-1* 64.72 2.25 140TR116-1 42.92 140TR130 D 140TR131 N/A 140TR105-2 65.28 1.
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SPICER STEER AXLE SERVICE PARTS I-100W, I-120W, I-140W Tie Rod Assemblies TIE ROD END ASSEMBLY - COMPLETE I-100W I-120W I-140W CROSS TUBES TIE ROD ENDS ASSY LENGTH: "A” CROSS TUBE WIDTH CROSS TUBE ASSY (includes clamp) TUBE LENGTH "B” LH Side Type RH Side 68.50 1.90 971093 61.
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SPICER STEER AXLE SERVICE PARTS “A” “A” “B” “B” * Drop-Center Application E-1000I, E-1002I, E-1200I, E-1202I, E-1320I, E-1322I, E-1460I, E-1462I Tie Rod Assemblies TIE ROD END ASSEMBLY - COMPLETE CROSS TUBES E-1000I, E-1002I, E-1200I,E-1202I, E-1320I, E-1322I, E-1460I, E-1462I ASSY LENGTH "A” TUBE WIDTH CROSS TUBE ASSY (includes clamp) CROSS TUBE LENGTH “B” LH Side Type RH Side End Length 818462 65.90 1.53 N/A 60.00 817018 S 817019 6.00 970578 65.90 1.75 N/A 53.
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SPICER STEER AXLE SERVICE PARTS EFA 10F4, 12F4, 13F5 Tie Rod Assemblies TIE ROD END ASSEMBLY - COMPLETE CROSS TUBES TIE ROD ENDS EFA10F4, 12F4, 13F5 ASSY LENGTH "A” TUBE WIDTH "B” CROSS TUBE ASSY (includes clamp) CROSS TUBE LENGTH LH Side Type RH Side End Length 1005692 64.69 1.75 N/A 59.43 140TR109 S 140TR110 5.44 1005693 65.75 1.75 N/A 60.50 140TR109 S 140TR110 5.44 970578 65.90 1.75 N/A 53.50 970579 D 970580 9.26 1008060 66.77 2.00 1006732 60.
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SPICER STEER AXLE SERVICE PARTS Shown below are several part numbers that have been, or should be serviced by the most optimal part Spicer offers thru Service. Use this when receiving part number inquiries from customers.
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DRIVE AXLE SERVICE PARTS DRIVE AXLE SERVICE PARTS Bearing Kits FEATURES: • Each bearing kit comes complete with exactly the right combination of parts you need to get your axle back in shape and on the road • Highest quality mix of bearings, cups, and cones for performance you can count on. • Premium oil seals to keep lube in, and dust and road grime out • Handy RTV compound to seal the repair NOTE: Kits are listed by the “base” model designation in numeric sequence.
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DRIVE AXLE SERVICE PARTS Bearing Kits Model Part # Model Part # Model Part # 38 DS 99044 110S, 130S 511859 380 RP/RT 99051 38 RP/RT/R3 99051 170D 514011 380 RS built after 5/1/78 99041 38 RS 99041 170R - Ratios 2.69-3.91 514013 380 RS built before 5/1/78 99051 40 DSH 512812 170R - Ratios 4.10-7.17 514014 381(P) DP/DT 115125 40 RSH 512806 170S - Ratios 2.69-3.91 514013 381(P) DS 114394 40 RST - Ratios 2.64-5.57 Built after 4/1/05 514059 170S - Ratios 4.10-7.
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DRIVE AXLE SERVICE PARTS Bearing Kits Model Part # Model Part # Model Part # 403(P) DS built before 4/6/89 114394 460(P) DS 118122 G155T, G175T GGAKA101 X 403 RS built after 1/1/95 509689 460(P) DS w/CTD sub.
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SPICER DRIVE AXLE SERVICE PARTS Basic Overhaul Kits FEATURES: • Our most comprehensive kit comes complete with everything you need for a thorough and lasting repair. • Highest quality mix of bearings, cups, and cones, each precisely selected for maximum performance in every position and application • Premium oil seals for your best protection against nagging leaks and damaging contamination • Production upgrades that keep Genuine Spicer parts better than the OE parts they replace.
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SPICER DRIVE AXLE SERVICE PARTS Basic Overhaul Kits Model Overhaul Kit Part Number Model Overhaul Kit Part Number 340 DP/DT 110584 40 RDH 510400 340 DS - Built after 4/30/78 110593 40 RDS 217622 340 RP/RT 110585 40 RSH 510398 340 RS - Built after 4/30/78 110555 40 RSS 122434 340 RS - Built before 4/30/78 110579 40 RST - Ratios 2.64-5.57, Built after 4/1/05 514061 341 DS - Built after 1/1/95 509691 40 RST - Ratios 2.64-5.
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SPICER DRIVE AXLE SERVICE PARTS Basic Overhaul Kits Model Overhaul Kit Part Number Model Overhaul Kit Part Number 402(P) DC 213422 451P DS - Built after 1/1/95 509691 402(P) DP/DT 115124 451P DS - Built after 4/6/89 124487 402(P) DS - Built after 1/1/95 509691 451P DS - Built before 4/6/89 114399 402(P) DS - Built after 4/6/89 124487 451 RP/RT 110585 402(P) DS - Built before 4/6/89 114399 451 RS - Built after 1/1/95 509690 402 RA - Built after 1/1/95 509690 451 RS - Built after 4/
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SPICER DRIVE AXLE SERVICE PARTS Basic Overhaul Kits Model Overhaul Kit Part Number Model Overhaul Kit Part Number 50 DP/DT 110584 601P DD 217621 50 RP/RT 110585 601P DP/DT 122421 521P DC 122657 601P DS 122437 521P DD 217621 601 RC 122448 521P DP/DT 122421 601 RD 217622 521P DS 122437 601 RP/RT 122424 521 RC 122448 601 RS 122434 521 RD 217622 650P DP - w/case #103530 110605 521 RP/RT 122424 650 RP 110604 521 RS 122434 651P DD 217621 580P DP - w/ case # 103530 110
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SPICER DRIVE AXLE SERVICE PARTS Ring Gear & Pinion Sets FEATURES: • All ring gear and pinion sets designed and tested to meet original equipment specifications • Built to the latest designs that include premium heat treat processes and the most optimum tooth profiles for applications like off-road high horsepower trucks or noise sensative bus and motor home applications • High grade steel used to achieve maximum durability • Priced competitively against non-genuine gearing and backed 100% by Spicer’
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SPICER DRIVE AXLE SERVICE KITS Axle Model Ring & Pinion Kit Part # Ratio Ring Gear Bolt Kits Notes 17100/18100 (continued) 096623 4.88 87955 16” gearing; 5/8” bolt hole 096624 5.29 87955 16” gearing; 5/8” bolt hole 096625 5.57 87955 16” gearing; 5/8” bolt hole 096833 3.70 / 5.05 70745 16” gearing; 5/8” bolt hole 096837 4.88 / 6.65 70745 16” gearing; 5/8” bolt hole 096838 5.29 / 7.21 70745 16” gearing; 5/8” bolt hole 096839 5.57 / 7.
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SPICER DRIVE AXLE SERVICE PARTS Axle Model Ring & Pinion Kit Part # Ratio Ring Gear Bolt Kits Notes 34DTB 095547 3.70 / 5.05 87955 16” gearing; 5/8” bolt hole D135 69021R93 5.29 Not Applicable 10 STR Spline 578793C91 5.38 Not Applicable 10 STR Spline 69022R93 6.17 Not Applicable 10 STR Spline 69015R93 7.17 Not Applicable 10 STR Spline 095557 3.70 70745 16” gearing; 5/8” bolt hole 095559 4.33 70745 16.5” gearing; 5/8 bolt holes 095560 4.56 70745 16.
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SPICER DRIVE AXLE SERVICE KITS Ring & Pinion Kit Part # Ratio Ring Gear Bolt Kits Notes 597236C91 3.54 390KY101-X 16” Hypoid Gearing 597237C91 3.73 390KY101-X 597238C91 3.91 390KY101-X J-Series 597239C91 4.10 390KY101-X 175, 190, 210, 220, 340, 380, 400 597240C91 4.44 390KY101-X 597241C91 4.78 390KY101-X 047KG100 X 5.11 390KY101-X 597242C91 5.38 390KY101-X 047KG101 X 5.63 390KY101-X 597243C91 6.14 390KY101-X 597244C91 6.57 390KY101-X 597245C91 7.
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SPICER DRIVE AXLE SERVICE PARTS 24 Axle Model Ring & Pinion Kit Part # Ratio Ring Gear Bolt Kits S230, S260 (continued) 300KG108 X 3.91 300KY100 X 300KG109 X 4.10 300KY100 X 300KG105 X 4.44 300KY100 X 300KG106 X 4.78 300KY100 X S400 390KG100 X 2.81 390KY100 X Front Rear 390KG101 X 2.93 390KY100 X 390KG102 X 3.07 390KY100 X 390KG203 X 3.21 390KY100 X 390KG204 X 3.42 390KY100 X 390KG120 X 3.54 390KY100 X 390KG105 X 3.73 390KY100 X 390KG106 X 3.
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SPICER DRIVE AXLE SERVICE KITS Axle Model Ring & Pinion Kit Part # Ratio Ring Gear Bolt Kits W440, W460 (continued) 597255C91 6.57 057KY101 X 597256C91 7.
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SPICER DRIVE AXLE SERVICE KITS Seals - Drive, Steer & Wheel Ends Spicer Seal Drivers are listed on page 29 FEATURES: • Same OEM engineered quality seals used in today’s production units which includes the Micro-Lip XL designs • Seals made of high-performance Viton which prolongs seal life at extreme heat temperatures unlike conventional seals • Seals are resistant to degradation by a wide spectrum of fluids, including lubricants and their additives Seals - Rear Pinion Location Spicer Model Spicer
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SPICER DRIVE AXLE SERVICE KITS Seals - Rear Pinion Location Spicer Model Spicer Part # N175, N190, N210, J175S, J190S, J210S, J220S, J230SB, W230S, G340S (RR), G380S (RR), S400 (RR) 401HH102 Used from July 1991 to Jan 1999. Triple Lip design (brown) *note1 HH105 New Unitized Seal introduced in Jan, 1999. Replaces both 401HH102 and GGAHH103 for these models only.
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SPICER DRIVE AXLE SERVICE KITS Seals - Forward Output Location Spicer Part Number Spicer Model Notes D344, 404, 405, 454, DSH40, 44, DST40, 41 127592 Microlip XL design 44DS, DS340, 380, 400, DS341, 381, 401, 402, 403, DT341, 381, 402 119431 Triple Lip Viton design - used until 1990, replaced by triple lip design #127720 in tandem models only! 127720 Microlip XL design - replaced the 119431 triple lip seal in these models and this location in 1990 N340S, N400i, S400S 401HH103 Used after July 1
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SPICER DRIVE AXLE SERVICE KITS Dana Oil Seal Installation Tools Listed below are oil seal driver kits for some popular Dana Tandem Drive Axle models. These kits are available from your local parts dealer.
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SPICER DRIVE AXLE SERVICE PARTS KITS Wheel Differential Case Kits FEATURES: • All Spicer Differential Case Kits are made with genuine original production parts • Differential Cases made from high strength, heat-treated iron • All kits include specific capscrews designed with a thread adhesive that helps maintain the necessary retention in the wheel differential section Differential Case Kits Model Part Number Ratio D135S 493202C91 5.29/7.17 F155, F170S 592224C91 4.44/5.38 493203C91 5.57/7.
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SPICER DRIVE AXLE SERVICE PARTS KITS Differential Case Kits Model Part Number Ratio 300KQ101X 3.73/4.44 For diff-lock models only 300KQ102X 4.78/5.63 For diff-lock models only 16120, 16130 211570 All ratios 16220,16320,16244*, 16344*, 16247, 16802, 19050T/P, 30DT/RT, 30DP/RP 51559 All ratios 13802, 15200, 15300, 15040T/P 52112 All ratios 19055S, 21065S, 22065S 211407 3.08/3.55 Standard diff models 121770 3.70/4.33 Standard diff models 121771 4.63/7.
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SPICER DRIVE AXLE SERVICE PARTS KITS Wheel Differential Side Gear Kits FEATURES: • Precision forged side gears and pinion mates • Latest designs include premium heat treat processes and the most optimum tooth profiles and tooth angles.
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SPICER DRIVE AXLE SERVICE PARTS KITS Wheel Differential Kits (less Side Gears) Spicer Model Spicer Part Number 15040S/T/P 118746 19050S/T/P 121749 19055S/D/T/P, 21065S/D/T/P, 22065S/D/T/P 118748 Miscellaneous Axle Kits Spicer Model Spicer Part Number Description G155T, G175T GGAKD103X Parts kit for converting 2-Speeds to Single Speed M190T, M210T, M220T MJAKD104X Parts kit for converting 2-Speeds to Single Speed J340, J380, J400 472KS102X IAD assy S400S 512865 Helical gear retrofit ki
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SPICER DRIVE AXLE SERVICE PARTS Axle Shafts FEATURES: • All Spicer axle shafts are made to the same genuine original production specifications • All shafts made from high grade steel that includes Dana’s exclusive inductalloy hardening process • More flexible, reliable, and more shock resistant than non-genuine shafts: 16 & 19 Spline BODY SPLINE FLANGE Part # Length Diameter Length O.D O.D. BoltCircles # of Holes Hole Type Notes 58975 38.44 1.69 16 STR / 4" spline 1.88 6.22 5.
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SPICER DRIVE AXLE SERVICE PARTS 33 Spline BODY SPLINE FLANGE Part # Length Diameter Length O.D. O.D. Bolt Circles # of Holes Hole Type 91133 41.38 2.06 4 2.125 8.50 7 8 .635 STR 113334 40.75 2.06 4 2.125 8.50 7 8 .773 STR 99407 41.22 2.06 4 2.125 8.50 7 8 .635 STR 113615 46.156 2.06 4 2.125 8.50 7 8 .948 TPR 126160 41.38 2.06 4 2.125 8.50 7 8 .948 TPR Notes 34 Spline BODY SPLINE FLANGE Part # Length Diameter Length O.D. O.D.
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SPICER DRIVE AXLE SERVICE PARTS 36 Spline BODY SPLINE FLANGE Part # Length Diamater Length O.D. O.D. Bolt Circles # of Holes Hole Type Notes 128055 40.60 2.06 4 2.31 8.50 7 8 .773 STR 128375 40.91 1.75 4 1.85 6.12 5.25 12 .748 TPR 128438 39.76 2.25 4 2.31 8.50 7 8 .773 STR 128440 40.56 2.25 4 2.31 8.50 7 8 .948 TPR 128549 40.56 2.25 11.5 2.31 8.50 7 8 .635 STR 128553 40.00 2.25 4 2.31 8.50 7 8 .635 STR 129138 41.38 2.06 11 2.31 8.
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SPICER DRIVE AXLE SERVICE PARTS 41 Spline BODY SPLINE FLANGE Part # Length Diameter Length O.D. O.D. Bolt Circles # of Holes Hole Type Notes 110888 41.31 1.87 4 2.10 8.50 7 8 .635 STR 126877 40.63 1.87 4 2.10 8.50 7 8 .948 TPR 127437 38.98 1.87 4 2.10 8.50 7 8 .635 STR replaced 129752 127438 43.31 1.87 4 2.10 8.50 7 8 .635 STR replaced 129753 128435 43.31 1.87 11 2.10 8.50 7 8 .635 STR 128514 38.13 1.87 4 2.10 8.50 7 8 .
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SPICER DRIVE AXLE SERVICE PARTS Service Carriers FEATURES: • 100% genuine Spicer parts used in every assembly, including premium gearing, bearings, and seals • Latest engineered product upgrades used in every assembly • Cost competitive with reman pricing • No core return charges Spicer Legacy Models Model Spicer Part # Axle Spline Ratio Side Gear Part # 19055D Single Carrier w/ Differential Lock 675624 39 Involute 7.17 110525 21065S/22065S 675516 41 Involute 3.
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SPICER DRIVE AXLE SERVICE PARTS F Series Model F155S/F170S F170SN Spicer Part # Axle Spline Ratio Side Gear Part # 029CA104 5X 36 Involute 4.33 029GD104 029CA104 7X 36 Involute 4.56 029GD104 029CA104 1X 36 Involute 4.78 029GD104 029CA104 2X 36 Involute 5.57 029GD104 029CA104 3X 36 Involute 6.50 029GD104 029CA104 4X 36 Involute 7.17 029GD104 029CA105 1X 36 Involute 4.78 No Spin Differential 029CA105 5X 36 Involute 4.
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SPICER DRIVE AXLE SERVICE PARTS J Series Model Spicer Part # Axle Spline Ratio Side Gear Part # J190S/J210S (continued) R44CA103 9X 39 Involute 7.17 R44GD103 R44CA103 10X 39 Involute 8.17 R44GD103 047CA107 1X 41 Involute 3.54 047GD105 047CA107 2X 41 Involute 3.73 047GD105 047CA107 3X 41 Involute 3.91 047GD105 047CA107 4X 41 Involute 4.10 047GD105 047CA107 5X 41 Involute 4.44 047GD105 047CA107 6X 41 Involute 4.78 047GD105 047CA107 12X 41 Involute 5.
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SPICER DRIVE AXLE SERVICE PARTS J Series Model J400S Forward Carrier (cont) - (Note 1) Spicer Part # Axle Spline Ratio Side Gear Part # 472CA112 9X 41 Involute 6.57 047GD105 472CA112 10X 41 Involute 7.17 047GD105 Note 1: J400S Forward Carrier part numbers “472CA115” are replaced by the 472CA112 carriers. M Series Model Spicer Part # Axle Spline Ratio Side Gear Part # MJACA122 54X 39 Involute 3.70 MJAGD115 MJACA122 71X 39 Involute 3.90 MJAGD115 MJACA122 53X 39 Involute 4.
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SPICER DRIVE AXLE SERVICE PARTS M Series Model M220T NS (continued) M230T Spicer Part # Axle Spline Ratio Side Gear Part # MJACA126 9X 41 Involute 5.29 No Spin Differential MJACA126 1X 41 Involute 5.57 No Spin Differential MJACA126 3X 41 Involute 6.14 No Spin Differential MJACA126 2X 41 Involute 6.50 No Spin Differential MJACA126 4X 41 Involute 7.17 No Spin Differential MJACA134 8X 41 Involute 3.70 MJAGD112 MJACA134 9X 41 Involute 3.
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SPICER DRIVE AXLE SERVICE PARTS S Series Single Axles Model Spicer Part # Axle Spline Ratio Side GearPart # S230SL Single Axle w/ Differential lock (continued) 300CA100 9X 46 Involute 4.10 300CA100 5X 46 Involute 4.44 300CA100 6X 46 Involute 4.78 Spicer Part # Axle Spline Ratio Side Gear Part # 390CA111 1X 41 Involute 2.81 047GD100 390CA111 2X 41 Involute 2.93 047GD100 390CA111 3X 41 Involute 3.07 047GD100 390CA111 4X 41 Involute 3.21 047GD100 390CA111 5X 41 Involute 3.
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SPICER DRIVE AXLE SERVICE PARTS W Series Model W230S Rear-Rear Carrier (continued) W230S Rear-Rear Carrier - Pinion-Up W230SN Rear-Rear Carrier W460S Forward Carrier w/o the Lockout Cylinder Cover 44 Spicer Part # Axle Spline Ratio Side Gear Part # 057CA108 5X 46 Involute 4.44 057GD102 057CA108 6X 46 Involute 4.78 057GD102 057CA108 7X 46 Involute 5.38 057GD102 057CA108 8X 46 Involute 6.14 057GD102 057CA108 9X 46 Involute 6.57 057GD102 057CA108 10X 46 Involute 7.
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Dana Corporation Heavy Vehicle Technologies and Systems Service PO Box 321 Toledo, Ohio 43697-0321 1-800-SAY-DANA (729-3262) www.dana.com www2.dana.com/expert HX500-QR 9/05 Printed in U.S.A Dana Corporation Heavy Vehicle Technologies and Systems Service - Canada 5095 South Service Road Beamsville, Ontario LOR 1BO Tech Service: (905) 563-4991 Copyright Dana Corporation, 2005. All rights reserved.