HN® Rear Suspension

VariRate® Spring System

LIT NO: SP-212
DATE: September 2015 REVISION: F

CONTENTS

DESCRIPTION Page
Parts Lists
■■ HN 402/462/522 - 11/00 - Current. . . . . . . . . . . . . . . . . 2
■■ HN 402/462/522 - 9/98-11/00 . . . . . . . . . . . . . . . . . . . 4
HN 402/462/522 - 4/96-8/98. . . . . . . . . . . . . . . . . . . . 6
HN 402/462/522 - 11/00–Current
■■

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

HN 402/462/522 - 9/98–11/00

HN 402/462/522 - 4/96–8/98
HN® 402/462/522

Vehicles built after 11/00

41
36
39
35 38
37 41
34
40 36

4 8 34 41
5 38 36

4 41 37
5

1
35 40
39
38

16
17 15

6 14
13
9 9
10 10

2 5 12
3
11 23 25 24
5 12
3
19
20 22 22
18
54 19
20

26a,b
13,14
33 27b,c
32
26c 20
21

20
21 28b,c
29 32 31
30 27a

30
33 32
28a 32
31

2 SP-212
 HN® 402/462/522
KEY NO. PART NO. DESCRIPTION QTY. KEY NO. PART NO. DESCRIPTION QTY.
1 HN 402/462/522 Saddle Assembly, See 2 27 Bar Pin End Bushing Service Kit, One Wheel End,
Figure 1 below, Dimension “A” Saddle Height, a 34013-087L Non-Shim Type, 28a, 30
Includes Key Nos. 2-18 b 34013-088L Shim Type, Includes Key No. 28b, 29a-30
60686-0XX 16½",17½", or 18½" c 34013-188L Rotating, Shim Type, 28c, 29a-30
58650-0XX 20¼" or 22½" 28 *Bar Pin End Bushing 4
60879-000L Bolster Spring Service Kit, One Set, (2 pc) a Non-Shim Type
Includes Key No. 2 b Shim Type
2 *Bolster Spring 4 c Rotating, Shim Type
3 25114-011 7/16"-20 UNF x 1¼" Bolt 32 29 Bar Pin Shim 8
4 48949-000 7/16"-20 UNF-2B Locknut 32 a 50131-000 0.25" / 0.12" Standard
5 22962-027 7/16" Washer 64 b 50130-000 0.19" / 0.19" Optional
6 60314-000 Auxiliary Load Spring 2 c 57026-000 0.375" Optional flat shim
7 58960-003 Auxiliary Load Spring Shim 6 30 34013-104 Bar Pin End Bushing Fastener Kit, One
8 58196-006 ½"-13 UNC x 2¾" Round Head Square Neck Bolt 6 Wheel End, Includes Key Nos. 31-33
Replaces 58196-005 31 48941-000 1"-8 UNC x 6" Hex Bolt 4
9 22962-011 ½" Washer 6 32 22962-008 1" Hardened Washer 8
10 49846-000 ½"-13 UNC-2A Locknut 6 33 48942-000 1"-8 UNC Locknut 4
11 57878-003 Rebound Strap 2 34 **One-piece Longitudinal Torque Rod Assembly,
60639-000 Anchor Plate Assembly, Includes Key Nos. 12-14 4 Straddle/Straddle, Specify Length in mm
12 *Anchor Plate 4 ULTRA ROD®, Includes Key No. 36a
13 *½" Washer 8 62000-XXX Front 1
14 *½"-13 UNC-2A Locknut 8 62001-XXX Rear 1
15 58948-001 Auxiliary Load Spring Mounting Plate 2 ULTRA ROD® PLUS™, Includes Key No. 36b
16 58949-000 Auxiliary Load Spring Mounting Plate Shim 2 72000-XXX Front 1
(Inboard - ¼" thick) 72001-XXX Rear 1
17 22962-020 Outboard Spacer (¼" thick) 2 35 ***One-piece Transverse Torque Rod Assembly, 2
18 58343-001 Saddle Vee Bracket 2 Straddle/Taper, Specify Length in mm
58440-001 Vee Bracket Fastener Service Kit, One Side, 62350-XXX ULTRA ROD, Includes Key Nos. 36a-37a
Includes Key Nos. 19-21 72350-XXX ULTRA ROD PLUS, Includes Key Nos. 36b-37b
19 50764-006 ¾"-10 UNC-2A x 2" Hex Head Bolt 8 92350-XXX XTRB, Includes Key Nos. 36c-37c
20 22962-001 ¾" Washer 16 36 Straddle Bushing 4
21 49842-000 ¾"-10 UNC-2B Locknut 8 a 47691-000L ULTRA ROD
22 60680-003L Shock Absorber 4 b 64400-002L ULTRA ROD PLUS
23 22962-001 ¾" Washer 4 c 66649-002L XTRB
24 30585-000 5/8" Upper Shock Locknut 4 37 Taper Bushing 2
25 22962-004 5/8" Upper Shock Washer 4 a 64697-000H ULTRA ROD
26 Equalizing Beam Assembly 2 b 64400-004L ULTRA ROD PLUS
a 58494-001 HN 462, 54" Non-Shim Type c 66649-004L XTRB
58494-002 HN 462, 54" Shim Type Optional Two-Piece Torque Rod Assembly with
58494-005 HN 402/462, 60" Non-Shim Type Bushings Service Kit
58494-006 HN 402/462, 60" Shim Type 60218-000 ULTRA ROD Straddle/Straddle
58494-009 HN 402/462, 72½" Non-Shim Type 60215-000 ULTRA ROD Straddle/Taper
58494-010 HN 402/462, 72½" Shim Type 65781-000 ULTRA ROD PLUS Straddle/Taper
b 59973-003 HN 522, 54" Shim Type 65781-001 XTRB Straddle/Straddle
c 57889-004 HN 402, 52" Non-Shim Type 65781-002 XTRB Straddle/Taper
57889-005 HN 402, 52" Shim Type 38 22186-000 Torque Rod Frame Bracket 2
57889-001 HN 402, 54" Non-Shim Type 39 45045-003 Back-up Plate (for Torque Rod) 2
57889-002 HN 402, 54" Shim Type 40 ****Transverse Rod Axle Bracket 2
41 49689-000 Torque Rod Shim As Req.
70867-001 P-80 Lubricant - 10 ml (Not Shown) Per Bushing 1

Locate the part number (see sideview) on the saddle assembly, if the saddle assembly number is not legible or available, contact the
vehicle manufacturer (be prepared with the vehicle VIN number and saddle height) to request the appropriate part number equipped
on the vehicle.

SIDE VIEW
Bottom
of Frame
Location of
Saddle Assembly Dim. "A"
Part Number Loaded Ride Height
(Saddle Height)

CL of End Hub

SP-212 3 For all (*) see Notes on Page 8

HN® 402/462/522

Vehicles built between 9/98 and 11/00 42

37
40
36 39
38 42
35
41 37

35 42
39 37
9 8
10
42 38

4 5 36 41
40
39
1

17

16

18 15 14 10 13
10 11
12
11
2 5 13
3
26 25
24
5
3
20 23
21 23
19
54

20
21
27a,b 14,15

34 28b,c
33
22 21

27c 21
22
29b,c
30 33 32
31 28a

31
34 33
29a 33
32

4 SP-212
 HN® 402/462/522
KEY NO. PART NO. DESCRIPTION QTY. KEY NO. PART NO. DESCRIPTION QTY.
1 HN 402/462/522 Saddle Assembly, See 2 28 Bar Pin End Bushing Service Kit, One Wheel End,
Figure 1 on page 3, Includes Key Nos. 2-19 a 34013-087L Non-Shim Type, 29a, 31
60686-0XX 16½", 17½", or 18½" b 34013-088L Shim Type Includes Key No. 29b, 30-31
58650-0XX 20¼" or 22½" c 34013-188L Rotating, Shim Type, 29c, 30-31
60879-000L Bolster Spring Service Kit, One Set, (2 pc) 29 *Bar Pin End Bushing 4
Includes Key No. 2 a Non-Shim Type
2 *Bolster Spring 4 b Shim Type
3 25114-011 7/16"-20 UNF x 1¼" Bolt 32 c Rotating, Shim Type
4 48949-000 7/16"-20 UNF-2B Locknut 32 30 Bar Pin Shim 8
5 22962-027 7/16" Washer 64 a 50131-000 0.25" / 0.12" Standard
6 58947-000 Auxiliary Load Spring 2 b 50130-000 0.19" / 0.19" Optional
7 58960-001 Auxiliary Load Spring Shim 6 c 57026-000 0.375" Optional flat shim
8 58196-004 ½"-13 UNC x 2¼" Round Head Bolt 4 31 34013-104 Bar Pin End Bushing Fastener Kit, One Wheel
9 24531-016 ½"-13 UNC x 3½" Bolt 4 End, Includes Key Nos. 32-34
10 22962-011 ½" Washer 12 32 48941-000 1"-8 UNC x 6" Hex Bolt 4
11 49846-000 ½"-13 UNC-2A Locknut 8 33 22962-008 1" Hardened Washer 8
12 57878-003 Rebound Strap 2 34 48942-000 1"-8 UNC Locknut 4
13 60639-000 Anchor Plate Assembly, Includes Key Nos. 14-15 4 35 **One-piece Longitudinal Torque Rod Assembly,
Replaces 59779-000 Straddle/Straddle, Specify Length in mm
14 *½" Washer 8 ULTRA ROD, Includes Key No. 37a
15 *½"-13 UNC-2A Locknut 8 62000-XXX Front 1
16 58948-001 Auxiliary Load Spring Mounting Plate 2 62001-XXX Rear 1
Replaces 58948-000 ULTRA ROD PLUS, Includes Key No. 37b
17 58949-000 ¼" Auxiliary Load Spring Mounting Plate Shim 4 72000-XXX Front 1
18 58524-000 7/8" Rebound Strap Mounting Plate 2 72001-XXX Rear 1
19 58343-001 Saddle Vee Bracket 2 36 ***One-piece Transverse Torque Rod Assembly, 2
Replaces 58343-000 Straddle/Taper, Specify Length in mm
58440-001 Vee Bracket Fastener Service Kit, One Side, 62350-XXX ULTRA ROD, Includes Key Nos. 37a-38a
Includes Key Nos. 20-22 72350-XXX ULTRA ROD PLUS, Includes Key Nos. 37b-38b
20 50764-006 ¾"-10 UNC-2A x 2" Hex Head Bolt 8 92350-XXX XTRB, Includes Key Nos. 37c-38c
21 22962-001 ¾" Washer 16 37 Straddle Bushing 4
22 49842-000 ¾"-10 UNC-2B Locknut 8 a 47691-000L ULTRA ROD
23 60680-003L Shock Absorber 4 b 64400-002L ULTRA ROD PLUS
24 22962-001 ¾" Washer 4 c 66649-002L XTRB
25 30585-000 5/8" Upper Shock Locknut 4 38 Taper Bushing 2
26 22962-004 5/8" Upper Shock Washer 4 a 64697-000H ULTRA ROD
27 Equalizing Beam Assembly 2 b 64400-004L ULTRA ROD PLUS
a 58494-001 HN 462, 54" Non-Shim Type c 66649-004L XTRB
58494-002 HN 462, 54" Shim Type Optional Two-Piece Torque Rod Assembly with
58494-005 HN 402/462, 60" Non-Shim Type Bushings Service Kit
58494-006 HN 402/462, 60" Shim Type 60218-000 ULTRA ROD Straddle/Straddle
58494-009 HN 402/462, 72½" Non-Shim Type 60215-000 ULTRA ROD Straddle/Taper
58494-010 HN 402/462, 72½" Shim Type 65781-000 ULTRA ROD PLUS Straddle/Taper
b 59973-003 HN 522, 54" Shim Type 65781-001 XTRB Straddle/Straddle
c 57889-004 HN 402, 52" Non-Shim Type 65781-002 XTRB Straddle/Taper
57889-005 HN 402, 52" Shim Type 39 22186-000 Torque Rod Frame Bracket 2
57889-001 HN 402/462, 54" Non-Shim Type 40 45045-003 Back-up Plate (for Torque Rod) 2
57889-002 HN 402/462, 54" Shim Type 41 ****Transverse Rod Axle Bracket 2
42 49689-000 Torque Rod Shim As Req.
70867-001 P-80 Lubricant - 10 ml (Not Shown) Per Bushing 1

SP-212 5 For all (*) see Notes on Page 8

HN® 402/462/522

Vehicles built between 4/96 and 8/98

38
33
36
32 35
34 38
31
8 37 33
9
10 31 38
35 33
4
5
38 34

1 32
36 37
35

6
13
10
10 12 11
3 11 14
2 23 22
21

16

17
20 20
15
5 4

16
16 17
19a,b 17
10,11

17 30 24b,c
18 29

17
18 25b,c
19c 26 29 28

27 24a

27
30 29
25a 29
28

6 SP-212
 HN® 402/462/522
KEY NO. PART NO. DESCRIPTION QTY. KEY NO. PART NO. DESCRIPTION QTY.
1 HN 402/462/522 Saddle Assembly, See 2 25 *Bar Pin End Bushing 4
Figure 1 on Page 3, Includes Key Nos. 2-15 a Non-Shim Type
60686-0XX 16½",17½", or 18½" b Shim Type
58650-0XX 20¼" or 22½" c Rotating, Shim Type
60879-000L Bolster Spring Service Kit, One Set, (2 pc) 26 Bar Pin Shim 8
Includes Key No. 2 a 50131-000 0.25" / 0.12" Standard
2 *Bolster Spring 4 b 50130-000 0.19" / 0.19" Optional
3 25114-011 7/16"-20 UNF x 1¼" Bolt 32 c 57026-000 0.375" Optional flat shim
4 48949-000 7/16"-20 UNF-2B Locknut 32 27 34013-104 Bar Pin End Bushing Fastener Kit, One Wheel
5 22962-027 7/16" Washer 64 End, Includes Key Nos. 28-30
6 Auxiliary Load Spring (58189-000 no longer 2 28 48941-000 1"-8 UNC x 6" Hex Bolt 4
available, see conversion kit 57974-011 below) 29 22962-008 1" Hardened Washer 8
7 57993-002 Auxiliary Load Spring Shim 6 30 48942-000 1"-8 UNC Locknut 4
8 58196-002 ½"-13 UNC-2A x 3½" Round Head Bolt 4 31 **One-piece Longitudinal Torque Rod Assembly,
9 24531-017 ½"-13 UNC-2A x 2¼" Hex Head Bolt 4 Straddle/Straddle, Specify Length in mm
10 22962-011 ½" Washer 16 ULTRA ROD, Includes Key No. 33a
11 49846-000 ½"-13 UNC-2A Locknut 12 62000-XXX Front 1
12 57878-003 Rebound Strap 2 62001-XXX Rear 1
13 58524-000 Rebound Strap Mounting Plate 2 ULTRA ROD PLUS, Includes Key No. 33b
14 60639-000 Anchor Plate Assembly, Includes Fasteners 2 72000-XXX Front 1
Replaces 59779-000 72001-XXX Rear 1
15 58343-001 Saddle Vee Bracket 2 32 ***One-piece Transverse Torque Rod Assembly, 2
58440-001 Vee Bracket Fastener Service Kit, One Side, Straddle/Taper, Specify Length in mm
Includes Key Nos. 16-18 62350-XXX ULTRA ROD, Includes Key Nos. 33a-34a
16 50764-006 ¾"-10 UNC-2A x 2" Hex Head Bolt 8 72350-XXX ULTRA ROD PLUS, Includes Key Nos. 33b-34b
17 22962-001 ¾" Washer 16 92350-XXX XTRB, Includes Key Nos. 33c-34c
18 49842-000 ¾"-10 UNC-2B Locknut 8 33 Straddle Bushing 4
19 Equalizing Beam Assembly 2 a 47691-000L ULTRA ROD
a 58494-001 HN 462, 54" Non-Shim Type b 64400-002L ULTRA ROD PLUS
58494-002 HN 462, 54" Shim Type c 66649-002L XTRB
58494-005 HN 402/462, 60" Non-Shim Type 34 Taper Bushing 2
58494-006 HN 402/462, 60" Shim Type a 64697-000H ULTRA ROD
58494-009 HN 402/462, 72½" Non-Shim Type b 64400-004L ULTRA ROD PLUS
58494-010 HN 402/462, 72½" Shim Type c 66649-004L XTRB
b 59973-003 HN 522, 54" Shim Type Optional Two-Piece Torque Rod Assembly with
c 57889-004 HN 402, 52" Non-Shim Type Bushings Service Kit
57889-005 HN 402, 52" Shim Type 60218-000 ULTRA ROD Straddle/Straddle
57889-001 HN 402/462, 54" Non-Shim Type 60215-000 ULTRA ROD Straddle/Taper
57889-002 HN 402/462, 54" Shim Type 65781-000 ULTRA ROD PLUS Straddle/Taper
20 60680-003L Shock Absorber 4 65781-001 XTRB Straddle/Straddle
21 22962-001 ¾" Washer 4 65781-002 XTRB Straddle/Taper
22 30585-000 5/8" Locknut 4 35 22186-000 Torque Rod Frame Bracket 2
23 22962-004 5/8" Washer 4 36 45045-003 Back-up Plate (for Torque Rod) 2
24 Bar Pin End Bushing Service Kit, One Wheel End, 37 ****Transverse Rod Axle Bracket 2
a 34013-087L Non-Shim Type, 25a, 27 38 49689-000 Torque Rod Shim As Req.
b 34013-088L Shim Type, Includes Key No. 25b, 26a-27 70867-001 P-80 Lubricant - 10 ml (Not Shown) Per Bushing 1
c 34013-188L Rotating, Shim Type, 25c, 26a-27

Key No. 6 Auxiliary Spring Conversion Kit No. 57974-011

Axle Set – Includes Key Nos. 1-11 QTY.
1 60314-000 Auxiliary Spring 2
2 58960-003 Auxiliary Spring Shim 6
3 58196-006 ½"-13 UNC x 2¾" Round Head Bolt 4
4 24531-016 ½"-13 UNC x 3½" Bolt 4
5 22962-011 ½" Hardened Washer 14
6 49846-000 ½"-13 UNC Locknut 14
7 57878-003 Rebound Strap 2
8 64700-000 Anchor Plate Assembly 4
9 58948-001 Auxiliary Spring Mounting Plate 2
10 58949-000 ¼" Auxiliary Spring Mounting Plate Shim 4
11 58524-000 7
⁄8" Rebound Strap Mounting Plate 4

SP-212 7 For all (*) see Notes on Page 8

 HN® Rear Suspension

■■ Special Tools

Bar Pin Style End Bushing tools

Installation tool Removal tools
Hendrickson Part No. 66086-103 Hendrickson Part No. 66086-104
OTC Part No. 1757 OTC Part No. 206457
Visit otctools.com Visit otctools.com

Use with the equalizing beam removed from the truck, and in conjunction
with OTC No. 51100 press plate and a 100 ton hydraulic shop press.

Hendrickson Part No. 66086-105

OTC Part No. 302030
Visit otctools.com

Torque rod Bushing funnel tools

Hendrickson Part No. 66086-001

ULTRA ROD
Hendrickson Part No. 66086-000
ULTRA ROD PLUS

NOTES: Equalizing beam axle brackets for drive axles are supplied by the axle manufacturer.
* Item included in assembly/kit only, part not sold separately.
** Hendrickson’s part number is stamped on the torque rod for identification. Be sure to include the suffix number when ordering, this number indicates torque
rod length. The Hendrickson 2-piece torque rods can be used to create the desired length, see Torque Rod Selection Guide Literature No. 45745-148.
*** Transverse torque rods are mandatory for HN Suspension regardless of axle spacing, see Literature No. 59310-004 for more information.
**** Not supplied by Hendrickson, used for reference only, refer to the vehicle manufacturer for more information. Hendrickson is not responsible for
components supplied by the vehicle manufacturer.

Hendrickson HAULMAAX / HN Bolster Gauge, Literature No. 48422-546 can be obtained on-line at www.hendrickson-intl.com/litform.

This is a general parts list to provide directional information. Components may vary by model. Questions in regards to parts, contact Hendrickson Truck Parts at
1.866.755.5968 (Toll-free U.S. and Canada), 630.910.2800 (Outside U.S. and Canada) or e-mail: [email protected].

www.hendrickson-intl.com

Truck Commercial Vehicle Systems 1.866.755.5968 (Toll-free U.S. and Canada)

800 South Frontage Road 1.630.910.2800 (Outside U.S. and Canada)
Woodridge, IL 60517-4904 USA Fax 1.630.910.2899

Information contained in this literature was accurate at the time of publication. Product changes may have been made after the copyright date that are not reflected.
SP-212 Rev F 09-15 © 1997 – 2015 Hendrickson USA, L.L.C. All Rights Reserved Printed in United States of America