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
22
Differential Lockout
Cylindrical Design Lockout - Overhaul
Note: Find instructions for:
Cast Iron Cover Lockout - Overhaul on page 20
Original Design Lockout - Overhaul on page 21
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
mounting bracket to power divider cover. Remove
bracket and piston housing.
2. Remove lock nut, piston with o-ring, compression
spring and shoulder washer 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).
Retrofit Cylindrical Design to Cast Iron
Cover Design Lockout
The cast iron cover design lockout assembly is interchange-
able with the cylindrical design lockout, only as a complete as-
sembly. The original shift fork and push rod can be used for
either type 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 cylindrical design lock-
out.
2. Assemble and install the cast iron cover lockout.
Mounting screws are not interchangeable between various
design style lockouts. They are a different length and size.
Assemble and Install Lockout-Cylindrical
Design
1. With shift fork and sliding clutch installed, place the
shoulder washer (white plastic) over push rod. The
large diameter side of the washer must face the pow-
er divider cover.
2. Install compression spring on push rod.
3. Lubricate o-ring with silicone-based lubricant and in-
stall o-ring on piston.
4. Place piston assembly on push rod. The large diame-
ter end of piston must face power divider cover.
5. Install lock nut on push rod and tighten to 13-17 lbs.
ft. (18-23 N•m).
6. Install piston housing, making sure the housing is
correctly seated and piloted in the shoulder washer.
7. Place mounting bracket over housing and position on
power divider cover. Install capscrews and lock
washers and tighten to 48-56 lbs. ft. (65-76 N•m)
Note: If axle is installed in vehicle, apply sealant to air line fit-
ting and connect air line. When tightening air line, hold
piston housing in mounting position using a wrench ap-
plied to the hexagon configuration at outer end of hous-
ing.
CAUTION
1 - Shoulder washer must seat properly
1