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
135
Inspection
Inspection
Standpipes
Drive axles are lubricated with oil drawn from a large sump in-
tegral to the assembly. Most axle designs attempt to position
vital components such as pinion bearings in close proximity to
this sump, keeping them bathed in a generous supply of oil at
all times.
When drive axles are installed at severe angles in vehicle chas-
sis, the position of these components is changed relative to the
oil sump. The same effect is present when the vehicle travels
up a steep grade. Oil in the sump remains level while the axle
itself tilts up or down. This makes it possible for bearings and
gears located well forward in the assembly to “starve” for lu-
brication even though the axle is filled to the base of the fill
plug hole as recommended by the manufacturer.
Axles should be modified with standpipes to raise lube levels
whenever chassis installation angles exceed 10° and when the
vehicle must negotiate continuous or lengthy grades on a rou-
tine basis.
The chart below gives standpipe recommendations for vehi-
cles operating in consistently mountainous areas.
Note: Grades must be continuous or lengthy in nature. Moni-
tor oil temperatures before installing standpipes. Axles
should operate at approximately 100°F (38°C) over am-
bient temperature and not exceed 240°F (116°C).
Final Check
Prior to putting vehicle back into service, run the vehicle to
bring axle lube up to temperature.
Check filler and drain plugs and axle joints for leakage. Re-
tighten to specifications as necessary.
Tandem Forward Axles
Installation
Angle*
5-10%
Grade
10-15%
Grade
15-20%
Grade
0°---
3° - - 2.00”
5° - 1.00” 2.25”
7° - 1.25” 2.50”
10° 1.50” 1.75” 2.75”
13° 1.75” 2.00” 3.00”
15° 2.50” 2.50” 3.25”
Tandem Rear Axles
Installation
Angle*
5-10%
Grade
10-15%
Grade
15-20%
Grade
0° - - -
3° - - 1.00”
5° - 1.00” 1.75”
7° - 1.75” 2.00”
10° - 2.00” 2.25”
13° 1.00” 2.25” 2.75”
15° 2.00” 2.50” 3.25”
*Pinion Pointing Upward
1 - Oil filler hole
2 - Lost oil capacity
3 - Additional oil capacity
1
1
1
2
3
Horizontal
mounting
12˚ Installation
12˚ Installation
with standpipe