Service Manual D__R440, 460, 480, D_R461, 462, 463, 521, 581, 601, 651, 652, 653 Owner manual

21
Differential Lockout
Differential Lockout
Original Design Lockout Overhaul
Note: Find instructions for:
Cast Iron Cover Lockout - Overhaul on page 20
Cylindrical Design Lockout - Overhaul on page 22
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 cov-
er to the body. Remove cover and o-ring.
2. Remove nut, flat washer and o-ring from push rod.
3. Remove body capscrews and lock washers, then re-
move body and piston as an assembly. Remove o-
ring and felt oilers from the piston.
Note: The shift fork and push rod cannot be removed with
power divider cover installed (see Remove Power Divider on
page 24).
Retrofit Original Design to Cast Iron Cover
Design Lockout
The cast iron cover design lockout assembly is interchange-
able with the original design lockout, only as a complete as-
sembly. The original shift fork and push rod can be used for
either model lockout 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 original design lockout.
2. Assemble and install the cast iron cover lockout.
Mounting screws are not interchangeable between the vari-
ous design style lockouts. They are a different length and
size.
Assemble and Install Original Design Lock-
out
With shift fork and sliding clutch installed in power divider cov-
er, assemble and install lockout as follows:
1. Apply silicone gasket compound to mounting surface
on power divider cover.
2. Install lockout body. Secure with capscrews and lock
washers. Torque capscrews to 48-56 lbs. ft.
(65-76 N•m).
Note: Before installation, soak piston felt oilers in SAE 30 en-
gine oil and lubricate o-rings with a high-viscosity sili-
cone oil or barium grease o-ring lubricant.
3. Install felt oilers and large o-ring on piston.
4. Install compression spring over shift fork push rod.
Install piston over end of shift fork into lockout body.
Secure with lock washers and lock nut. Torque lock-
nut (see Torque Chart on page 107).
5. Install o-ring in lockout body cover. Install cover and
secure with capscrews and lock washers. Torque
capscrews to 96-108 lbs. in. (10-13 N•m).
CAUTION
1 - Lockout silicone gasket pattern
1