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
104
Lubrication
Change Lube
Drain
Drain when the lube is at normal operating temperature (150°–
200°F). It will run freely and minimize the time necessary to
fully drain the axle, this insures the axle is flushed.
Unscrew the magnetic drain plug on the underside of the axle
housing and allow the lube to drain into a suitable container.
Note: Dispose of all used lubricants properly by following dis-
posal methods approved for mineral or synthetic based
oils.
After initial oil change, inspect drain plug for large quantities of
metal particles. These are signs of damage or extreme wear in
the axle. Clean the drain plug and replace it after the lube has
drained completely. Inspect breather for clogging or corrosion.
Clean or replace as necessary.
Fill
Front Axle
a. With vehicle on level ground, remove the filler hole
plug from the axle housing cover and fill the axle with
approved lubricant until level with the bottom of the
hole.
Rear Axle
a. Remove the filler hole plug from the axle housing
cover and fill the axle with the approved lubricant un-
til level with the bottom of the hole.
b. If wheel ends were removed, follow instructions in
wheel end servicing page 100.
Always use the filler hole as the final reference. If lube is level
with the bottom of the hole, the axle is properly filled.
Note: Lube fill capacities (see chart) are basic guidelines and
will vary based on the angle the axle is installed in a par-
ticular chassis. Torque fill plug to 40–60 lbs. ft. (54–82
N•m).
TIP: The axle can be filled through the axle housing breather
hole. Fill until lube level is even with the bottom of filler hole in
axle housing rear cover.
Correct lube level at bottom of filler hole.
1 - With axle on level surface, fill housing with oil to bottom
of plug.
2 - Temperature sensor mounting hole.
Tandem Axle Model Number Pints Liters
461 DD(P), DS(P) 43 20.3
461 DP(P), DT(P) 46 21.8
461 RC, RP, RT 39 18.5
461 RD, RS 40 18.9
462 DD(P), DS(P) 40 18.9
462 RD, RS 37 17.5
463 DD(P), DP(P), DS(P), DT(P) 40 18.9
463 RD, RP, RS 37 17.5
521 DD(P), DP(P), DS(P), DT(P) 42 19.9
521 RC, RD, RP, RS, RT 39 18.5
581 DD(P), DP(P), DS(P) 42 19.9
581 RD, RP, RS 39 18.5
601 DC(P), DD(P), DP(P) 42 19.9
601 RP 39 18.5
651 DP(P) 41 19.4
651 RP 37 17.5
652 DP(P) 41 19.4
652 RP 37 17.5