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
51
Carrier Assembly
Carrier Assembly
1 - Nut
2 - Washer (used on DT461-P, DT652P,
DP461-P, DP652-P)
3 - Yoke
4 - Bearing retainer washer (used on
DT440-P, DT485-P, DP440-P, DP650-P)
5 - Oil seal
6 - Snap ring
7 - Bearing & sleeve
8 - Filler plug
9 - Capscrew
10 - Lockwire
11 - Dowel bushing
12 - Adjuster lock
13 - Bearing cap
14 - Dowel bushing
15 - Capscrew
16 - Lockwire
17 - Flat washer
18 - Bearing cap
19 - Cotter pin
20 - Adjuster lock
21 - Expansion plug
22 - Shift fork shaft
23 - Filler plug
24 - Differential carrier
25 - Dowel pin
26 - Expansion plug
27 - Nut
28 - Lock washer
29 -Seal spring
30 - Seal
31 - Stud
32 - Shift fork
33 - Shift fork cover
34 - Lock washer
35 - Capscrew
36 - Differential & ring gear
37 - Sliding clutch (dual range only)
38 - Retainer
39 - Sun gear
40 - Bearing adjuster
41 - Bearing cup
42 - Bearing cone
43 - Ring gear nut
44 - Gear support case
45 - Ring gear
46 - Thrust washer
47 - High-speed clutch plate
48 - Idler pinion pin
49 - Idler pinion
50 - Differential assembly
51 - Differential case with pins
52 - Thrust washer
53 - Side gear
54 - Spider
55 - Thrust washer
56 - Side pinion
57 - Plain differential assembly
58 - Capscrew
59 - Thrust washer
60 - Gear support case
61 - Washer
62 - Ring gear bolt
63 - Bearing cone
64 - Bearing cup
65 - Bearing adjuster