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
42
Power Divider
Measure and Adjust Input Shaft End-Play
Note: After power divider overhaul and installation on carrier,
check and adjust input shaft end-play.
Without Input Shaft Axial Spring Thrust
Button
In September 1988, a axial spring and thrust button were
added between the input and output shafts. End-play toler-
ances are the same for axles with or without this spring and
button. However, end-play measurement procedure is dif-
ferent than described here. Refer to page 44 of this manual
for procedure variances.
The correct end-play when new parts are used in overhaul is
0.003" to 0.007", with reused parts the maximum is 0.14".
1. Remove input shaft nut, flat washer and yoke. Re-
move input bearing cover capscrews. Remove bear-
ing cover (and shim pack if installed).
2. Reinstall bearing cover without shims. Hold in posi-
tion with hand pressure and measure clearance be-
tween power divider cover and bearing cover, using a
feeler gauge.
3. The bearing cover clearance measured in Step 2 plus
0.005" will equal shim pack thickness required for de-
sired end-play (rebuild with new parts). Add 0.015" to
shim pack for rebuild with used parts.
4. Install shim pack and bearing cover. Install cap-
screws. Torque screws to 75–85 lbs. ft. (101–115
N•m). Make sure shims are flat with no kinks or
bends.
5. Install yoke. Tighten nut snugly. Tap end of input
shaft lightly to seat bearings.
6. Check input shaft end-play with dial indicator posi-
tioned at yoke end of input shaft. Move input shaft ax-
ially and measure end-play. If end-play is correct, seal
shim pack with Dana approved RTV compound to
prevent lube leakage. Then torque input shaft nut.
Input Shaft End Play Chart
New or Rebuild
with new parts
0.003" to 0.007"
NOTE: Because of manufacturing varia-
tions in individual parts, correctly ad-
justed end-play could vary 0.010", after
the unit is rotated.
Acceptable End-Play Tolerances when measuring as a regu-
lar maintenance procedure with axle in truck.
Up to 0.060" with
over 100,000
miles or 1 year
service off-road
NOTE: If end-play exceeds limits, disas-
semble power divider and replace worn
parts.
Up to 0.040" with
less than 100,000
miles or 1 year
service on-road
CAUTION