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
58
Drive Pinion
Disassemble and Overhaul Drive Pinion
The following procedures cover both forward and rear differ-
ential drive carrier assembly.
Note: Dana drive axles may be equipped with either “press-fit”
or “slip-fit” outer pinion bearings. Procedures are con-
tained in this section for assembly of both types.
1. Rear Axle Pinion Yoke: Remove yoke.
2. If pinion nut was not loosened during earlier disas-
sembly, clamp assembly in vise jaws, use brass pads
to prevent damage. Loosen and remove pinion nut
and flat washer. Remove yoke from pinion.
If pinion nut was not loosened during earlier disassembly,
clamp assembly in vise jaws, use brass pads to prevent
damage.
3. Loosen and remove pinion nut and flat washer. Re-
move yoke from pinion using an appropriate tool.
4. Forward and Rear Axle Pinion Bearing Cage:
• Press-fit. Press pinion out of bearing cage and
bearing cone.
• Slip-fit. For pinion with “slip-fit” bearing cone,
the cage, outer bearing and pinion can usually be
disassembled easily without a press. If difficulty
is experienced, use a press.
5. Rear Axle Pinion Oil Seal and Outer Bearing Cone:
Remove oil seal and bearing cone from cage. Discard
oil seal. Remove bearing cups with suitable puller.
6. Remove bearing spacer and spacer washers from
pinion.
7. Remove pilot bearing from pinion using a split-type
puller. Use two procedure steps to remove each bear-
ing.
a. Mount puller vertically to separate the bearing.
This action will force puller halves under bearing
and start moving bearing off pinion.
b. Mount puller horizontally to press pinion out of
bearing.
1 - Press ram
CAUTION
1