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
122
Proper Vehicle Towing
Proper Vehicle Towing
Without Wheel Differential Lock
Lift the drive wheels completely off of the ground or damage
will occur.
Do not lift the front wheels (non-drive wheels). This alters
the oil’s position in the drive axle, draining it away from the
drive pinion and its bearings. If the pinion is rotated under
these conditions for any period of time, bearings will over-
heat resulting in axle damage or failure.
If this is impossible to lift the drive wheels, remove all axle
shafts to prevent gear rotation and cap the wheel hubs to pre-
vent loss of lubricant and a possible road hazard. See the fol-
lowing section Proper Vehicle Towing with Wheel Differential
Lock for removal procedure.
With Wheel Differential Lock
Follow this procedure to remove all axle shafts preventing gear
rotation with the drive wheels and possible lubrication dam-
age.
1. Engage the wheel differential lock, indicator light is
on (move vehicle to verify engagement).
2. Shift transmission into neutral.
3. With vehicle stationary, release the air pressure on
the wheel differential lock shift system and apply the
parking brake.
4. Disconnect the air supply and fitting at the shift cylin-
der.
5. Install the shipping capscrew 128642 (.250 X 18 X
1.5") NPSM screw. GM models require part number
128274 (M12 X 1.5 X 38mm) screw. Tighten cap-
screw to manually engage the wheel differential lock
until the indicator light is on and the differential lock
is completely engaged.
6. Remove the axle shafts.
7. Install temporary cover on hub to prevent contamina-
tion entering and also to prevent the loss of lubricant.
With Wheel Differential Lock (Type 3 Only)
Follow these listed procedures for vehicle towing when the
drive axles are equipped with Type 3 wheel differential lock.
Note: To eliminate the need for disconnecting drivelines and
axle shafts, trucks/tractors should be towed from the
REAR whenever possible.
The following procedure should be followed for vehicle towing
when the drive axle wheel ends are running on pavement (ve-
hicle being towed from the front). Removing the axle shafts
prevents gear rotation with the drive wheels and possibly lubri-
cation damage.
Towing Vehicles from the Front
1. For Type 3 differential lock axles. As a common prac-
tice put the axles in the unlocked position.
2. Shift transmission into neutral.
3. Block wheels.
4. Connect air lines from the tow truck’s air reservoir
system to charge the primary air system of the dis-
abled truck/tractor–preferably to the inlet fitting of the
unit’s air dryer.
5. Release the emergency/spring brakes of the disabled
truck/tractor. Then, manually cage the spring brakes.
Do not back off the slack adjusters.
6. Remove the axle shafts, note the specific location of
the axle shafts.
Note: Spicer Type 3 (461
/521/581) differential lock axle shafts
are location spe
cific. The axle shaft with the 11” spline
length belongs on the flange half side of axle (same side
as the shift unit). Failure to put the correct axle shaft in its
intended location will lead to an inoperable differential
locking axle.
WARNING