Description

Dana Spicer ES42-5 1990 Parts Catalog – What You Actually Need on the Bench

I’ve been turning wrenches since before some of you were born, and if there’s one thing that burns my tailgate, it’s watching a guy hold up a rebuild because he ordered the wrong input shaft. You pull a transmission apart, find a chipped gear, and then spend two days cross-referencing aftermarket catalogs that don’t match what’s in your hand. That’s lost billable time and a pissed-off customer. The Dana Spicer ES42-5 1990 Parts Catalog stops that nonsense cold. This is the factory-issued parts list for the ES42-5 Series transmission, published April 1, 1990, by Spicer (Dana Corporation). It’s 27 pages of exactly what you need to identify, order, and verify every component in that gearbox.

Ratio Tables and Gear Identification

First thing you’ll hit is the ratio table on page 1. This catalog covers two models: ES42-5A and ES42-5D. Both share 1st (7.22), 2nd (3.88), 3rd (2.21), and reverse (7.22). The difference shows up in 4th gear: 1.48 on the 5A, 1.40 on the 5D. 5th is 1.00 on both. If you’re swapping a mainshaft or countershaft and don’t verify those ratios, you’ll end up with a transmission that whines in every gear. The catalog also includes the drive gear table and clutch housing dimensions (pages 6-7), so you can match bellhousing bolt patterns and pilot bearing depths before you bolt anything together.

Gears and Related Parts – Exploded Views with Part Numbers

Pages 2-5 break down the drive gear group, mainshaft group, countershaft group, and rear drive/idler shaft group. Each group has a clear exploded diagram with reference numbers tied to the parts list. The drive gear group (page 2-2) shows the input shaft, bearing, and retaining nut. The mainshaft group (page 2-3) includes the mainshaft itself, sliding clutches, and synchronizer assemblies. Countershaft group on pages 4-5 lists every gear, spacer, and bearing. If you’ve got a worn countershaft gear and need the correct replacement, this catalog gives you the Spicer part number. Not an aftermarket cross-reference. The original number.

Clutch Housing Dimensions and Bearing Cap Charts

Clutch housing dimensions (pages 6-7) include SAE bellhousing patterns and depth measurements. You need to know if your clutch housing matches the flywheel housing on the engine? It’s right there – in inches. The drive gear bearing cap group (pages 8-9) comes with a chart that lists clutch applications. Same for the rear bearing cap chart (page 12) with brake applications. If you’re retrofitting a transmission into a truck that came with a different brake setup, that chart saves you from ordering the wrong rear cap.

Shift Levers, Remote Controls, and Yokes

Shift lever and fork assembly (page 14) and shift lever and dome assembly (page 15) cover the internal shift rails and interlock parts. The remote control assembly (pages 16-17) is for installations where the shift lever isn’t directly on top of the transmission – think cab-over trucks or low-profile chassis. Pages 18 covers companion flanges and yoke part numbers. If you’re mating a driveshaft to the output, you need the yoke spline count and pilot diameter. This catalog lists both. The clutch release code table on page 15 gives you the release bearing and fork combo for each clutch size.

Overhaul Kits – Major and Minor (Pages 20-21)

Spicer designed these transmissions with overhaul kits: major and minor. The major kit includes all bearings, gaskets, seals, and o-rings for a full rebuild. The minor kit covers seals and gaskets for a quick reseal. Part numbers are listed. No guesswork. You order the kit, open the box, and all the right parts are there. The tabulated bills of materials (pages 22-25) cross-reference every part number to the exploded view reference numbers. If you need an input shaft bearing, you find the reference number on the diagram, then look up the OEM part number in the B/M list.

Who Needs This Catalog and Why

If you’re a shop owner with an old dump truck, a school bus fleet, or a backhoe that still runs a Spicer ES42-5, this catalog belongs on your bench. It’s also for the DIY guy who bought a surplus military truck and wants to rebuild the transmission himself. The ES42-5 was used in medium-duty trucks, off-road equipment, and industrial applications throughout the late 80s and 90s. I’ve seen guys try to use generic bearing catalogs and guess at snap ring thicknesses – that ends with a transmission that leaks or breaks a tooth within a thousand miles. The factory catalog eliminates that risk.

OEM vs. Aftermarket – Why Factory Specs Matter

I won’t waste your time with the usual rant, but I’ll say this: I’ve had aftermarket part suppliers hand me a bearing that was 0.003” undersized on the OD. Would it fit? Sure. Would it spin in the bore after 50 hours of heavy load? Yeah. Then you’re splitting the case again, and the customer pays for your second attempt. The Dana Spicer ES42-5 1990 Parts Catalog is the original document printed by Dana Corporation. It uses the same part numbers and specs the factory used on the assembly line. No cross-references, no “replace with” notes. Just the right data. For more context on how these transmissions fit into the broader drivetrain landscape, check the Automotive Industry Overview and Internal Combustion Engine resources.

Related Manuals You Might Need

If you’re rebuilding the whole drivetrain, consider pairing this parts catalog with a service manual that covers disassembly and assembly procedures. The Spicer ES42-5, ES52-5, CM49 Series Service Manual gives you the torque specs and clearances. For a broader view of heavy-duty transmissions, the Spicer T20000 Series Transmission Parts Overview covers larger models. And if you’re working on a CM55 transmission, the SPICER T210-CM55 Main Transmission Parts List complements this catalog.

Frequently Asked Questions

Does this catalog include torque specs for reassembly?

This is a parts list, not a service manual. It gives part numbers and exploded views, but not torque values. Pair it with the service manual for assembly specs.

How do I identify which model ES42-5 I have – the A or D variant?

Look at the nameplate affixed to the right side of the transmission housing. It will have the model designation, B/M number, and serial number. The ratio table on page 1 of this catalog lists the differences: 4th gear ratio is 1.48 for 5A and 1.40 for 5D. You can also check the B/M number in the tabulated bills of materials on pages 22-25 to confirm which parts apply. If the nameplate is missing or illegible, you’ll have to count teeth on the mainshaft and countershaft gears and divide to confirm ratios. That’s a pain, but it works.

Stop wasting time chasing aftermarket cross-references and incorrect part numbers. Access the Factory Manual and get the original Spicer parts data for your ES42-5 transmission. You’ll order the right parts the first time, and your transmission will thank you.