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
23
Inspection
Inspection
Power Divider - Parts Exploded View
1 - Output shaft
2 - Bushings*
3 - O-rings
4 - Bearing cup
5 - Bearing cone
6 - Side gear
7 - Snap ring
8 - Spring
9 - Button
10 - Inter-axle differential assembly
11 - Capscrew
12 - Case half
13 - Spider
14 - Nut
* Removed in September 1994
15 - Case half
16 - Side pinion
17 - Thrust washer
18 - Snap ring
19 - Helical gear
20 - Bushings
21 - Thrust washer
22 - “D” washer
23 - Lockout sliding clutch
24 - Input shaft
25 - Bearing cone
25 - Shift fork and push rod
27 - Power divider cover
28 - Lock washer
29 - Capscrew
30 - Lockout unit
31 - Bearing cup
32 - Shim
33 - Bearing cover
34 - Capscrew
35 - Oil seal
36 - Yoke
37 - Flat washer
38 - Nut
Lube Pump Parts
39 - Lock nut
40 - Pump drive gear
41 - Expansion plug
42 - Pipe plug
43 - Magnetic screen
44 - Pump gears
45 - O-ring
46 - Dowel pin
47 - Pump cover
48 - Lock washer
49 - Capscrew
1
18
20
19 21 22 23 24 25 27 28 29 31 32 33 35
34
30
26
36 37 38
2* 3 4 5
678 910
11
12
1517 16
13
14
39
41
42 44 45 47 48
49
4643
40