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

98
Wheel Adjustment Systems
Three-piece Tang-type Lock Washer System
a. Install the Tang-type lock washer on the spindle.
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 250
lbs. ft. (339 N•m)
c. Verify end-play. See Verify Wheel End-play Procedure
on page 99.
d. After verifying end-play, secure wheel nuts by bend-
ing one of the locking washer tangs over the outer
wheel nut and another tang over the inner wheel nut.
e. Go to step 12.
Four-piece Tang/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 Tang-type lock washer on the spindle.
c. Install the outer nut on the spindle and tighten to 250
lbs. ft. (339 N•m).
d. Verify end-play. See Verify Wheel End-play Procedure
on page 99.
e. After verifying end-play, secure the outer nut by
bending (180° apart) two opposing tangs of the lock-
ing washer over the outer nut.
12. Install the following:
• New gasket at axle shaft flange.
• Axle shaft.
• Axle flange nuts and tighten to specified torque.
13. Lubricate axle wheel ends.
1 - Inner nut (P/N 11249)
2 - Tang-type lock washer (P/N 11245) .123” thick
3 - Outer nut (P/N 11249)
1
2
3
IMPORTANT
1 - Inner nut (P/N 119882)
2- Dowel pin
3 - Dowel-type lock washer (P/N 119883)
4 - Tang-type lock washer (P/N 129132) .0478” thick
5 - Outer nut (P/N 119881)
1
2
3
4
5
IMPORTANT