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
126
Inter-Axle Differential Lockout
Inter-Axle Differential Lockout
With Interlock Control Valve (straight-air type)
Lockout Cylinder
Disassemble cylinder by performing the following steps:
1. Remove capscrews, Iock washers, cover assembly
and o-ring.
2. Remove hex-nut piston and o-rings.
3. Remove body capscrews and lock washers, then re-
move body and piston as an assembly.
Assemble cylinder by performing the following steps:
1. Apply gasket compound to mounting surface on
power divider cover.
2. Install lockout body. Secure with capscrews and lock
washers. Torque capscrews to 48-56 lbs. ft. (65-76
N•m).
Note: Before installation, soak piston felt oilers in SAE 30 en-
gine oil and lubricate o-rings with a high-viscosity sili-
cone oil or barium grease o-ring lubricant.
3. Install felt oilers and o-ring on piston.
4. Install compression spring over shift fork push rod.
Install piston in body. Install o-ring over push rod and
in piston. Install hex-nut piston and tighten to 20-26
lbs. ft. (27-35 N•m). Install o-ring on piston.
5. Install o-ring in lockout body cover. Install cover as-
sembly and secure with capscrews and lock washers.
Torque capscrews to 6-108 lbs. in. (10-12 N•m).
6. Adjust interlock control valve.
Interlock Control Valve
Repair and Replacement
Replace faulty valve as an assembly.
Remove Valve
1. Loosen lock nut and unscrew valve body from cylin-
der cover.
Install and Adjust Valve
Note: If button is not assembled to valve stem, install as fol-
lows:
• Insert valve stem to full depth of the button. Lock
in place with set screw. Torque set screw to 6.
lbs. in. (0.7 N•m).
1. With button assembled to valve, install lock nut and
lock washer on valve body. With lockout cylinder ex-
hausted, screw the valve assembly into the lockout
cylinder cover until the valve is seated on hex-nut pis-
ton.
2. To adjust, unscrew control valve until the valve air-
delivery port is aligned with the lockout cylinder air-
inlet port.
Note: Do not unscrew valve more than 360°.
Lock the valve in place with lock nut. (3.9 N•m)