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
131
Theory of Operation
Theory of Operation
Torque Distribution with Lockout Engaged
(Inter-axle Differential is Not Operating)
A lockout mechanism is incorporated in the power divider to
enable the vehicle driver to lock out the inter-axle differential
and provide maximum traction under adverse road conditions.
In operation, an air cylinder (controlled by a cab-mounted
valve) shifts a sliding clutch on the input shaft. To lock out in-
ter-axle differential action, the clutch engages the helical-side
gear and causes this gear, the input shaft and differential to ro-
tate as one assembly. This action provides a positive drive to
both axles. The clutch should only be engaged when both axles
are rotating at the same speed. Operation should be limited to
low traction situations and should be disengaged when normal
traction returns. Failure to do so will result in poor handling
and damage to the axle components.
With the lockout engaged, torque is distributed to both axles
without differential action. The forward axle pinion and ring
gear are driven by the helical side gear. The rear axle gearing
is driven from the output shaft side gear and inter-axle drive-
line.
Note: Varied road surface conditions can result in unequal
torque distribution between the two axle assemblies.
Prolonged operation with the lockout engaged can damage
axle and driveline components.
CAUTION
1 - Input torque
2 - Drive is from input shaft through helical gears to forward gearing
3 - Drive is from output shaft side gear to rear gearing
4 - Inter-axle differential not operating
5 - Lockout engaged
1
5
2
3
4
Torque is transmitted to both axles without inter-axle differential action