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
iii
Table of Contents
Introduction .........................................................1
Failure Analysis ...................................................7
Inspection ...........................................................9
Differential Carrier Assembly - Parts .................11
Differential Lockout ...........................................17
Power Divider
Power Divider - Parts Exploded View........................ 23
Remove Power Divider............................................. 24
Remove Power Divider from Differential Carrier
(with carrier removed from axle housing) ................ 25
Disassemble, Assemble and Overhaul
the Power Divider..................................................... 27
Install Power Divider on Differential Carrier
(with carrier assembled to axle housing) .................. 38
Install Power Divider on Differential Carrier
(with carrier removed from axle housing) ................. 40
Dissasemble Differential Carrier
(with power divider removed) ................................... 54
Drive Pinion
Drive Pinion - Parts Exploded View............................ 57
Disassemble and Overhaul Drive Pinion.................... 58
Install Drive Pinion Assembly.................................... 65
Wheel Differential Assembly
Wheel Differential Assembly
- Parts Exploded View ............................................... 68
Housing and Rear Cover Assembly
- Parts Exploded View ............................................... 91
Seals..................................................................92
Housing Breather ..............................................94
Wheel End Seal - Parts Exploded View .............95
Remove and Overhaul Wheel End Seal .............96
Wheel Adjustment Systems ..............................97
Verify Wheel End-play Procedure ......................99
Lubricate Wheel End .......................................100
Lubrication ......................................................102
Lube Change Intervals ....................................103
Change Lube ...................................................104
Standpipes ......................................................105
Torque Chart ...................................................107
Appendix
Wheel Differential Lock ...........................................109
Differential Lock Theory of Operation ....................110
Control Systems ....................................................111
Dual Range Axle Shift Systems ..............................113
Troubleshooting .....................................................120
Proper Vehicle Towing ...........................................122
Axle Shift System Components ..............................124
Inter-Axle Differential Lockout
With Interlock Control Valve (straight-air type) ......126
Theory of Operation ...............................................129
Power Flow and Torque Distribution ......................130
Lubrication .............................................................132
Torque Distribution in Low Range .........................136