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
109
Wheel Differential Lock
Wheel Differential Lock
Wheel Differential Lock
Comparison Information on Dana Wheel
Differential Locking Axles
This section covers Dana wheel differential locking axles. The
basic concept of Dana Wheel Differential Locking axles are the
same, but the designs vary model to model. When servicing
your differential lock axle, pay close attention to all NOTES,
TIPS and WARNING signs that will assist you while you work
on your axle. The differential lock axles listed below are
grouped together by design type.
Note: Information for Type 1 and 2 differential lock axles are
not covered in this manual, refer to AXSM-0048 and
AXSM-0046 for information pertaining to those axles.
Parts unique to type 3 differential lock axles.
Type 1 Style Differential Lock Axles Feature:
• A sliding curvic clutch
• A fixed curvic clutch
• The flange half differential case is externally splined
• Uses double spline or extended spline axle shaft (11"
spline length) on flange half side of axle
• Uses standard spline axle shaft (4" spline length) on
plain half side of axle
• The differential lock selector switch is located on the
carrier/cap assembly
Type 2 Style Differential Lock Axles Feature:
• A sliding curvic clutch
• A fixed curvic clutch
• The plain half differential case is externally splined
• Uses extended spline axle shaft (11" spline length) on
plain half side of axle
• Uses extended spline axle shaft (11" spline length) on
plain half side of axle
• Uses standard spline axle shaft (4" spline length) on
flange half side of axle
• The differential lock selector switch is located on the
differential lock shift cylinder
Type 3 Style Differential Lock Axles Feature:
• A two-speed carrier/cap assembly
• A splined clutch splined internally
• The differential lock is shifted by air shift units
• The differential lock selector switch is located on the
air shift unit
• The flange half of the case is splined internally
• Uses extended spline axle shaft (11" spline length) on
flange half side of axle
• Uses standard spline axle shaft (4" spline length) on
plain half side of axle
Type 1* Type 2* Type 3
19055D 21080D 19060D DD/RD461
21065D 23080D 21060D DD/RD521
22065D 26080D 22060D DD/RD581
23070D 23105D DD/RD404
23085D 26105D DD/RD454
26085D 30105D
* See AXSM-0048 and AXSM-0046 Service Manual for tech-
nical information