Service Manual D__R440, 460, 480, D_R461, 462, 463, 521, 581, 601, 651, 652, 653 Owner manual
Table Of Contents
- Warnings and Caution
- Table of Contents - Visual
- Introduction
- Failure Analysis
- Inspection
- Differential Carrier Assembly - Parts
- Forward Axle Differential Carrier Removal and Installation
- Installation of Forward Differential Carrier
- Installation of Forward Axle Housing Cover and Output Shaft Bearing Parts
- Rear Axle Differential Carrier Removal and Installation
- Rear Differential Carrier “Installation”
- Differential Lockout
- Differential Lockout Overhaul
- Original Design Lockout Overhaul
- Cylindrical Design Lockout - Overhaul
- Power Divider - Parts Exploded View
- Remove Power Divider
- Remove Power Divider from Differential Carrier (with carrier removed from axle housing)
- Disassemble, Assemble and Overhaul the Power Divider
- Disassemble Power Divider Cover (For Axles with Input Shaft Tapered Roller Bearing)
- Assemble Power Divider Cover (For Axles with Input Shaft Tapered Roller Bearing)
- Inter-axle Differential
- Output Shaft Assembly
- Install Power Divider on Differential Carrier (with carrier assembled to axle housing)
- Install Power Divider on Differential Carrier (with carrier removed from axle housing)
- Measure and Adjust Input Shaft End-Play
- Forward Axle Carrier Assembly (Single Speed) with Diff. Lock - Parts Exploded View
- Rear Axle (Single Speed) - Parts Exploded View
- Forward Axle (Two Speed) - Parts Exploded View
- Rear Axle (Two Speed) - Parts Exploded View
- Disassemble Differential Carrier (with power divider removed)
- Drive Pinion - Parts Exploded View
- Disassemble and Overhaul Drive Pinion
- Install Drive Pinion Assembly
- Install Helical Gear and Pinion Outer Support Bearing - Forward Axle Only
- Wheel Differential Assembly - Parts Exploded View
- Disassemble, Overhaul and Assemble Wheel Differential (Forward and Rear Axles)
- Planetary and 2-Speed Models (Forward and Rear Axles)
- Disassemble Dual Reduction Differential Case
- Assemble Dual Reduction Differential Case
- Install Differential-Forward and Rear Axles
- Measure and Adjust Carrier Assembly
- Wheel Differential Lock - Parts Exploded View
- Install and Adjust Wheel Differential Lock, Dual Range Shifters
- Piston Air Shift Unit
- Air Shift Unit Replacement
- Air Shift Unit Overhaul
- Housing and Rear Cover Assembly - Parts Exploded View
- Seals
- Housing Breather
- Wheel End Seal - Parts Exploded View
- Remove and Overhaul Wheel End Seal
- Wheel Adjustment Systems
- Verify Wheel End-play Procedure
- Lubricate Wheel End
- Lubrication
- Lube Change Intervals
- Change Lube
- Standpipes
- Torque Chart
- Wheel Differential Lock
- Differential Lock Theory of Operation
- Control Systems
- Dual Range Axle Shift Systems
- Troubleshooting
- Proper Vehicle Towing
- Axle Shift System Components
- Inter-Axle Differential Lockout With Interlock Control Valve (straight-air type)
- Theory of Operation
- Power Flow and Torque Distribution
- Lubrication
- Torque Distribution in Low Range
97
Wheel Adjustment Systems
Wheel Adjustment
S
y
stems
Wheel Adjustment Systems
Adjust Wheel Bearing
Do not mix spindle nuts and lock washers from different sys-
tems. Mixing spindle nuts and lock washers can cause
wheel separation.
Note: The lock washer for a four-piece tang/dowel-type wheel
nut system is thinner than the lock washer for a three-
piece tang-type wheel nut system and is not designed to
bear against the inner nut.
1. Inspect the spindle and nut threads for corrosion and
clean thoroughly or replace as required.
Note: Proper assembly and adjustment is not possible if the
spindle or nut threads are corroded.
2. Inspect the tang-type washer (if used). Replace the
washer if the tangs are broken, cracked, or damaged.
3. Install the hub and drum on the spindle with care to
prevent damage or distortion to the wheel seal.
A wheel dolly is recommended during installation to make
sure that the wheel seal is not damaged by the weight of the
hub and drum. Never support the hub on the spindle with just
the inner bearing and seal. This can damage the seal and
cause premature failure.
4. Completely fill the hub cavity between the inner and
outer bearing races with the same lubricant used in
the axle sump.
5. Before installation, lubricate the outer bearing with
the same lubricant used in the axle sump.
Note: Lubricate only with clean axle lubricant of the same type
used in the axle sump. Do not pack the bearings with
grease before installation. Grease will prevent the proper
circulation of axle lubricant and may cause wheel seal
failure.
6. Install the outer bearing on the spindle.
7. Install the inner nut on the spindle. Tighten the inner
nut to 200 lbs. ft. (271 N•m) while rotating the wheel
hub.
Never use an impact wrench to adjust wheel bearings. A
torque wrench is required to assure that the nuts are proper-
ly tightened.
8. Back off the inner nut one full turn. Rotate the wheel
hub.
9. Retighten the inner nut to 50 lbs. ft. (68 N•m) while
rotating the wheel hub.
10. Back off the inner nut exactly 1/4 turn.
Note: This adjustment procedure allows the wheel to rotate
freely with 0.001"–0.005" (0.025 mm–0.127 mm) end-
play.
11. Install the correct lock washer for the wheel nut sys-
tem being used.
Three-piece Dowel-type Lock Washer System
a. Install the Dowel-type lock washer on the spindle.
Note: If the dowel pin and washer are not aligned, remove
washer, turn it over and reinstall. If required, loosen the
inner nut just enough for alignment.
Never tighten the inner nut for alignment. This can preload
the bearing and cause premature failure.
b. Install the outer nut on the spindle and tighten to 350
lbs. ft. (475 N•m).
c. Verify end-play. See Verify Wheel End-play Procedure
on page 99.
WARNING
CAUTION
CAUTION
1 - Inner nut (P/N 119882)
2 - Dowel pin
3 - Dowel-type lock washer (P/N 119883)
4 - Outer nut (P/N 119881)
1
2
3
4
IMPORTANT