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
103
Lubrication
Lubrication
Lube Change Intervals
This product combines the latest manufacturing and part
washing technology. When filled with a Dana approved syn-
thetic lubricant at the factory, the initial drain is not re-
quired.
Change the lubricant within the first 5,000 miles of operation
when not using a Spicer approved synthetic lubricant in
either a new axle or after a carrier head replacement. Base
subsequent lubricant changes on a combination of the follow-
ing chart and user assessment of the application and operating
environment.
Severe Service Lubrication Change Intervals - Severe service
applications are those where the vehicle consistently operates
at or near its maximum GCW or GVW ratings, dusty or wet en-
vironments, or consistent operation on grades greater than
8%. For these applications, the ON/OFF HIGHWAY portion of
the chart should be used. Typical applications are construc-
tion, logging, mining and refuse removal.
Note: Clean metallic particles from the magnetic filler plug and
drain plugs. Clean or replace the breather yearly to avoid
lube contamination due to water ingestion.
* Axles using LMS wheel end system
** Axles using adjustable wheel bearing system
Synthetic
or Mineral
Lubricant SAE Change Interval for Line Haul Change Interval for Voca-
tional
Synthetic* SHAES-256 SAE 75W-90 500,000 miles [800,000 Km] or
5 years
120,000 miles (193,000 Km)
or 1year
Synthetic** SHAES-256 SAE 75W-90,
75W-140
250,000 miles (400,000 Km) or
3 years
60,000 miles [96,500 Km] or 1
year
Mineral
Base
MIL-L-2105E/J02360,
API GL-5 Gear Oil,
MIL-PRF-2105E
75W, 75W-90,
75W-140, 80W-
90, 85W-140
120,000 miles [193,000 Km] or
1 year
60,000 miles [96,500 Km] or
1 year