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
20
Differential Lockout
Differential Lockout Overhaul
Instructions for the three different designs are on the following
pages:
Cast Iron Cover Lockout - Overhaul on page 20
Original Design Lockout - Overhaul on page 21
Cylindrical Design Lockout - Overhaul on page 22
Cast Iron Cover Lockout - Overhaul
Disassemble and Remove Lockout
Note: With axle installed in vehicle, place differential lock se-
lector valve in the disengaged (or unlocked) position.
Disconnect the air line at the lockout piston cover.
1. Remove capscrews and lock washers fastening pis-
ton housing to power divider cover. Remove the cast
iron piston housing.
2. Remove lock nut, piston with o-ring, piston driver
and compression spring from push rod.
Note: The shift fork and push rod cannot be removed with
power divider cover installed (see Remove Power Divider on
page 24).
Lockout Interchangeability
The cast iron design lockout assembly is interchangeable with
previously designed lockouts, only as a complete assembly.
The original shift fork and push rod can be used for all three
design type lockouts and need not be replaced.
Retrofit kits are available to convert the non-current design
lockouts to the current cast iron cover design lockout. For ad-
ditional information, refer to Dana Parts Books AXIP-0085.
Retrofit as follows:
1. Disassemble and remove the old design lockout.
2. Assemble and install the cast iron cover lock-out.
Mounting screws are not interchangeable between the vari-
ous design style lockouts. They are a different length and
size.
Assemble and Install Lockout - Cast Iron
Cover Design
1. With shift fork and sliding clutch installed, install
compression spring on push rod.
2. Place piston driver on push rod against compression
spring. The large diameter end of piston driver must
face power divider cover.
3. Lubricate o-ring with silicone-based lubricant and in-
stall o-ring on piston.
4. Place piston assembly on push rod against piston
driver.
5. Install lock nut on push rod and tighten to 13-17 lbs.
ft. (18-23 N•m).
6. Apply silicone gasket compound to mounting surface
on power divider cover.
7. Install piston housing cover.
8. Install capscrews and tighten to 48-56 lbs. ft.
(65-76 N•m).
9. If axle is installed in vehicle, apply sealant to air line
fitting and connect air line.
CAUTION
1 - Lockout silicone gasket pattern
1