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
107
Torque Chart
Torque Chart
Torque Chart
Fastener Axle Model Class Size Tool Size Lbs.-ft. N-m
Carrier & Cap-Misc. Parts Bearing Cap Capscrew-All Models 8 13/16 - 10 1-1/8 370-430 501-583
Bearing Adjuster Lock Capscrew 5 5/8 - 11 1-1/8 160-176 217-239
Pinion Bearing Sleeve Capscrew 5 5/16 - 18 --- 16-20 21-27
Thrust Screw Jam Nut 4 M24 36mm 150-190 203-258
Shift Fork Cover Capscrew 5 7/16 - 14 --- 35-45 47-61
Ring Gear Nut/Bolt Forward & Rear Single Speed 8 5/8 - 18 15/16 180-220 242-298
Forward & Rear Two Speed 8 9/16 - 18 --- 110-130 149-176
Pinion Bearing Cage
Capscrew
All Forward Models 8 9/16 - 12 --- 155-175 210-237
All Rear Models 5 5/8 - 11 --- 160-176 217-239
Differential Case Capscrew 440/460/461/521 8 9/16 - 12 --- 116-130 157-176
480/581 Models 8 5/8 - 11 --- 165-195 224-264
Input Shaft Nut All Forward Models --- 1 7/8 - 12 --- 840-1020 1139-1383
--- M48 X 1.5 70mm 840-1020 1139-1383
Input Shaft Brg. Cover
Capscrew
All Forward Models 5 1/2 - 13 --- 75-85 101-115
Axle Housing
Misc. Related Parts
Carrier to Hsg-Capscrew
All Models
8 5/8 - 18 --- 220-240 271-312
Carrier to Hsg-Stud Nut at Dowels 8 5/8 - 18 --- 150-170 203-230
Carrier to Hsg Capscrew-Forward
Axles
8 5/8 - 11 --- 220-240 271-312
Axle Hsg Cover-Capscrew 5 7/16 - 14 --- 65-78 88-106
Axle Hsg Cover-Stud Nut at Dowels --- 7/16 - 20 --- 65-78 88-106
Oil Drain Plug --- --- 1/2 drive 40-60 54-81
Magnetic Fill Plug --- 13/16 7/8 wrench 40-60 54-81
Output Shaft (Thru Shaft)
Nut
D440/460/480 --- 1 3/4 - 12 --- 840-1020 1139-1383
D461/521/581 --- M42 X 1.5 55mm 789-996 1070-1310
Pinion Nut D440/460/480 --- 1 3/4 - 12 --- 980* 1329*
- Slotted nut torque to 980
lbs. ft.
D461/521/581 --- M42 X 1.5 65mm 840-1020 1139-1383
- Continue tightening nut to R440/460/480 --- 1 3/4 - 12 --- 840-1020 1139- 1383
align slot with the nearest
hole in pinion shank
R461/521/581 --- M42 X 1.5 55mm 789-966 1070-1310
Power Divider Misc. Parts Inter-Axle Differential-Nuts/Bolts 8 5/16 - 24 --- 17-23 23-31
PDU Cover Capscrew-Standard 6 9/16 - 13 --- 110-126 149-170
PDU Cover Capscrew-Socket Head 8 9/16 - 12 --- 115-125 155-169
Lube Pump Misc. Parts Cover Capscrew 5 1/4 - 20 7/16 85-105 lbs. in. 10-12
Drive Gear Locknut --- 7/16 - 20 5/8 35-45 47-61
Filter Screen/Pipe Plug --- 3/4 - 14 1 1/16 40-60 54-81
Misc. IAD Lockout Parts Body Capscrew 5 7/16 - 14 5/8 48-56 65-76
Original Style Body Cover Capscrew 5 1/4 - 20 7/16 96-108 lbs.in. 10-12
Push Rod Nut --- 3/8 - 24 --- 20-26 27-35
Aluminum Canister Style Hsg Bracket Capscrew 5 7/16 - 14 --- 48-56 65-76
Push Rod Nut --- 3/8 - 24 5/8 13-17 18-23