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
134
Inspection
Changing Lube
Draining
Drain when the lube is at normal operating temperature (150°-
200°F). It will run freely and minimize the time necessary to
fully drain the axle, insuring the axle is flushed.
Unscrew the magnetic drain plug on the underside of the axle
housing and allow the lube to drain into a suitable container.
Note: Dispose of all used lubricants properly by following dis-
posal methods approved for mineral or synthetic based
oils.
After initial oil change, inspect drain plug for large quantities of
metal particles. These are signs of damage or extreme wear in
the axle. Clean the drain plug and replace it after the lube has
drained completely. Inspect breather for clogging or corrosion.
Clean or replace as necessary.
Filling
Front Axle
• With vehicle on level ground, remove the filler hole
plug from the center of the axle housing cover and fill
the axle with approved lubricant until level with the
bottom of the hole.
Rear Axle
• Remove the filler hole plug from the center of the axle
housing cover and fill the axle with the approved lu-
bricant until level with the bottom of the hole.
• If wheel ends were removed.
Always use the filler hole as the final reference. If lube is level
with the bottom of the hole, the axle is properly filled.
Note: Lube fill capacities are basic guidelines and will vary
based on the angle the axle is installed in a particular
chassis. Torque fill plug to 40-60 lbs. ft. (54–81 N•m).
Lube Fill Capacities
TIP: The axle can be filled through the axle housing breather
hole. Fill until lube level is even with the bottom of filler hole in
axle housing rear cover.
1 - With axle on level surface, fill housing with oil to bottom
of plug
1
2
Single Reduction Tandem
Drive Axles
Pints Liters
RS/RD/RA461 42 20
RS/RD/RA521 41 19.5
DS/DD/DA461-P 49 23
DS/DD/DA521-P 48 22.5
DS/DD/DA581-P 48 22.5
RS/RD/RA581 41 19.5