Bulletin DA012010 New Redesigned 40K Carriers - …

1 Spicer Service Parts Dana Holding Corporation DRIVE AXLE INFO DA012010 NEW Redesigned 40K TANDEM Carriers SERVICE/TECHNICAL DATE: 24/2/2010 TO: All Service & Parts Departments Affected Models: All D344, 404, 405, DST40, 41, DSP40, 41, DSH40, DSH44 (Includes Diff Lock and Pump option models) Dana has engineered in a significant product upgrade to the current 40K tandem axles. At the core of these product enhancements is the incorporation of Dana s patented and proven On Demand lube pump. This innovative lubrication system operates primarily during spinout situations. The remaining 99+% of the time, the pump is idle and ready to be activated instantaneously, in forward or reverse. When compared to competitive axles that continuously operate a lube pump, this efficiency upgrade saves up to 2HP and also decreases oil sump temperature by as much as 20 F. The wasted HP incurred by the other axles relates directly to reduced fuel economy, higher temperatures in the lube sump, and reduced lubricant life.

2 The new design Carriers have been optimally designed such that there is now a 12lbs weight savings on pump carrier models. This same system is currently used in the D170 and D190 family of heavy duty tandems. SERVICE PARTS IMPACT: Use of the new design units in Australian Locally built axle assembly s begins February design upgrades will impact customers who stock parts or service Carriers for the models listed above. Service Carriers are completely interchangeable as units. Individual internal parts and kits are not interchangeable! It is important for customers to beware of the part number changes and in time begin making stocking adjustments accordingly Spicer Service Parts Dana Holding Corporation DRIVE AXLE INFO NEW SERVICE part NUMBERS: Outlined below are the newly released service parts. Dealers should begin to maintain an initial level of these parts going forward as the individual parts between the old and new are not compatible.

3 All parts for the older design Carriers will continue to be offered thru service. BASIC OVERHAUL KITS Dana has reduced the complexity of the repaired kits offered on the new Carriers by only releasing Basic Overhaul Kits. Two new kits have been released that come complete with all the necessary bearings, shims, washers and RTV sealant required when doing an overhaul. NEW OVERHAUL KIT part NUMBERS: 504030 Basic Overhaul Kit D40K Standard Models [Models: DS344, DS404, DS405, DSP40, DSP41, DST40, DST41, DSH40, DSH44] 504031 Basic Overhaul Kit D40K Diff-Lock Models [Models: DD404, DDP40, DDP41, DDH40, DDH44] INPUT SHAFT KITS The new design Carriers now utilize a Pump version and a Non Pump version input shaft. The part number of the shaft is stamped on the part for easy identification. Each shaft is sold thru service in a kit form that includes the nut, thrust washer and torque information sheet. NEW INPUT SHAFT KIT part NUMBERS: 504026 Input Shaft Kit - Non Pump (shaft p/n 132447) 504027 Input Shaft Kit - Pump Models (shaft p/n 132446) LUBE PUMP, OUTPUT SHAFT SIDE GEARS AND LOOSE PARTS Listed below are the balance of the new individual service parts located in the power divider section of the forward carrier .

4 These parts are related directly to the new design lube pump system. Detailed parts and illustrations are shown on pages 4 & 5 of this Bulletin . IMPORTANT NOTE: The output shaft side gears are designed for use with specific input shafts, pump design vs. non pump design. Do not to mix these parts. Use pump model output shafts with pump model input shafts as well as non-pump output shaft side gear with non-pump input shafts! Mixed parts will assemble together, but they are not designed to run together and failure will occur if any parts are mixed. Spicer Service Parts Dana Holding Corporation DRIVE AXLE INFO NEW KITS AND LOOSE part NUMBERS: 504028 Lube Pump Parts Kit Pump Models 504029 Manifold Parts Kit Pump Models 132061 Output Side Gear Pump Models (only sold as kit# 504028) 133964 Filter Screen Assembly Pump Models 134010 Collar Lock Pump Models 134011 Lube Hose Pump Models 132060 Bearing Cone Pump and Non Pump Models 132443 Output Side Gear Non Pump Models SERVICE Carriers The service Carriers are completely interchangeable as a unit but the components inside are not.

5 Knowing the design level being serviced is very important when ordering replacement parts for any repairs or overhauls. New Service carrier part numbers have been released so customers can take advantage of the new design. The old design service Carriers will be phased out. Refer to page 6 of this Bulletin for a complete crossover listing of carrier part numbers. Original design service Carriers are completely interchangeable with new design Carriers ! NEW DESIGN FORWARD carrier POWER DIVIDER: SERVICE KITS & LOOSE PARTS LISTING: 504026 Input Shaft Kit - Non Pump (includes items 11a, plus 128049 nut, 132439 washer - not shown below) 504027 Input Shaft Kit - Pump Models (includes items 11b, plus 128049 nut, 132439 washer - not shown below) 504028 Lube Pump Kit D40P (includes items 7-8, 9b-10) 504029 Manifold Parts Kit D40K Pump Models (includes items 2-4, 5b) 513880 Manifold Parts Kit D40K Non-Pump Models (includes item 5a) 504030 Basic Overhaul Kit D40K Standard Models 504031 Basic Overhaul Kit D40K Diff-Lock Models Spicer Service Parts Dana Holding Corporation DRIVE AXLE INFO 1a.

6 132038 Forward carrier /Cap Standard Models NSS (not offered thru service)*Note1 1b. 132043 Forward carrier /Cap Diff-Lock Models NSS (not offered thru service)*Note1 2. 133964 Filter Screen Assembly 3a. 134010 Collar Lock (located on filter end of hose) 3b. 129338 Clamp (located on manifold end of hose) 4. 134011 Lube Hose 5a. 132435 Seal Manifold Assembly Non Pump Models (sold only in kit# 513880) 5b. 131366 Seal Manifold Assembly Pump Models (sold only in kit# 504029) 6. 110811 Bearing Race 7. 132060 Bearing Cone 8. 131541 Pin 9a. 132443 Output Side Gear Non Pump Models 9b. 132061 Output Side Gear Pump Models (only sold in kit# 504028) 10 131368 Lube Pump (sold as part of kit# 504028) 11a 132447 Input Shaft Non Pump Models (sold only as kit# 504026) 11b 132446 Input Shaft Pump Models (sold only as kit# 504027) Refer to FIG 1 on page 5 Note 1: The new base carrier /Cap (item#1) is designed to use NEW style parts only.

7 It is not possible to retrofit or interchange OLD and NEW design parts. Item#1 is not offered as a service part a complete new carrier should be ordered. Spicer Service Parts Dana Holding Corporation DRIVE AXLE INFO NEW DESIGN FORWARD carrier POWER DIVIDER: FIG 1 Spicer Service Parts Dana Holding Corporation DRIVE AXLE INFO ORIGINAL: design Carriers and NEW design Carriers are completely interchangeable as a unit! Shown below are replacement reference charts sorted by model family. Print and use as a quick reference guide! DSH = SINGLE SPEED DDH = DIFF LOCK. Current literature can be downloaded from Click on the Literature button or The EXPERT icon, and navigate to the literature needed. Should you have any queries on the above or require further information, please contact Dana Australia on 1300 00 DANA Shane Carey Sales & Service Representative Spicer Driveline Products Encl: DA012010