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
13
Inspection
Inspection
Installation of Forward Differential Carrier
Before installing carrier assembly, inspect and thoroughly
clean interior of axle housing using an appropriate solvent
and clean rag.
1. Use silicone rubber gasket compound on axle hous-
ing mating surface as shown in the illustration. Com-
pletely remove all old gasket material prior to
applying new material. Compound will set in 20 min-
utes. Install carrier before compound sets or reapply.
TIP: To assist in installing complete differential carri-
er, use two pieces of threaded rod (5/8"- 11 UNS)
threaded into carrier capscrew holes. Rod should be
approximately 6" long. Use these to pilot the carrier
into the housing.
2. Install differential carrier assembly to axle housing
using lockwashers, capscrews and nuts. Torque to
proper specification (see Torque Chart on page 107).
3. With the forward axle now assembled to the housing,
proceed with Installation of Forward Axle Housing
Cover and Output Shaft Bearing Parts, on next page.
4. Install output yoke and self-locking nut. Tighten to
specified torque (see Torque Chart on page 107).
Reference Yoke Installation Section page 92.
5. Install axle shafts and axle stud nuts (If used, also in-
stall lock washers and taper dowels).
The differential lock 461/521/581 models use axle shafts
with different spline length (4" or 11"). Axle shafts may also
be location specific with various wheel equipment. Do not
misplace axle shafts from their intended location.
6. Connect main and inter-axle driveline. Ensure drive-
lines are properly phased. Lubricate U-joints.
7. Add axle lubricant. See Lube Fill Capacities on page
104 for correct amount.
Note: Oil fill plug removed from D461/462/463 Differential
Carriers. The oil fill plug hole located in the differential
carrier was removed. Lube capacity is not affected, cus-
tomers to fill axle with lube through rear cover fill hole or
through the breather hole in housing. February 1, 2000.
8. Connect air lines to differential.
When axle has been disassembled
or housing, axle shafts or wheel equipment re
placed, check axle assembly for proper differen-
tial action before operating vehicle. Wheels must
rotate freely and independently.
Road test vehicle to bring axle lubricant up to temperature. Re-
check joints, drain and fill plugs for leakage. Re-tighten as nec-
essary.
IMPORTANT
WARNING
1 - Apply silicone gasket in this pattern
2 - Typical stud locations
IMPORTANT
1
2
Differential Carrier Side of Axle Housing
Axle Housing Silicone Gasket Compound Pattern