Diferencial Mack[1]

Service Information Mack Trucks, Inc.

Group Release 01 GU, CHU, CXU, LEU, MRU, TD, CMH, CMM

Foreword The description descriptions s and service procedur procedures es contained contained in this manual are based on designs and technitechnical studie studies s carried carried out through through May 2013. The products products are under under continuous continuous developmen development. t. Vehicle Vehicles s and and componen components ts produced produced after the above date date may therefo therefore re have differen differentt specificati specifications ons and repair repair methods. methods. When this this is deemed deemed to have a signific significant ant bearing bearing on this manual manual,, an updated updated version version of this manual manual will be be issued to to cover the changes. The new edition edition of this manual will update update the changes. In service procedure procedures s where the title incorpor incorporates ates an operation operation number number,, this is a reference to an V.S. T. (Volvo Standard Times). Service Service procedures procedures which do not include include an operation number number in the title are for general information information and no reference is made to an V.S.T. V.S.T. Each section section of this manual contains contains specific specific safety informati information on and warnings warnings which must must be reviewed viewed before before performing performing any procedur procedure. e. If a printed printed copy of a proced procedure ure is made, made, be sure to also make a printed printed copy of the safety safety information information and warnings warnings that relate relate to that procedure. procedure. The followfollowing levels of observations, observations, cautions and warnings warnings are used in this Service Documentation:

Note: Indicates Indicates a procedure, procedure, practice, practice, or condition condition that must must be followe followed d in order order to have the the vehicle vehicle or componen componentt function function in the manner manner intended. intended. Caution: Indicates Indicates an unsafe practic practice e where damag damage e to the product product could occur occur.. Warning: Indicates Indicates an unsafe practice practice where persona personall injury injury or severe severe damage damage to the product product could occur. Indicates an unsafe practice practice where seriou serious s personal personal injury injury or death could could occur. occur. Danger: Indicates

Mack Trucks, Inc. Greensboro Greensboro,, NC USA

Order number: PV776-89092622 This Service Service Manual Manual replaces replaces Service Service Manual Manual “PV776–889 “PV776–88934877 34877,, MACK Dual-Re Dual-Reduct duction ion Tandem Carrier”, Carrier”, (USA37177 (USA37177)) dated dated (06/2010) (06/2010) This Service Service Manual Manual replaces replaces Service Service Manual Manual “PV776–889 “PV776–88934877 34877,, MACK MACK Dual-Red Dual-Reducti uction on Tandem Carrier”, Carrier”, (USA37177 (USA37177)) dated (06/2010) (06/2010)

©2013 Mack Trucks, Trucks, Inc., Greensboro, NC USA

USA58010

Specif Specifica icati tions................................................................................................................................1 ons................................................................................................................................1 Specif Specifica icati tions................................................................................................................................1 ons................................................................................................................................1 Assembly Specifications .... .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ... .... .. ..... ... .. ... ... .... .. .... .... .. ... .... .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 3 Tools ools ........................................................................................................................................... 10 Spec Specia iall Tools..............................................................................................................................10 ools..............................................................................................................................10 Using Using Adapte Adapters/E rs/Exte xtensi nsions ons with with Torque orque Wrench Wrenches..... es..... ...... ...... ...... ...... ...... ....... ....... ..... ....... ....... ...... . 10 Design Design and Functio Function n .................................................................................................................... 12 Diffe Differen rentia tiall Carrie Carrierr, Functi Function on...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ....... ..... ....... ....... ...... ...... ... 12 Fron Frontt Rear Rear Carr Carrie ier....................................................................................................................... r....................................................................................................................... 12 Rear Rear Rear Rear Carr Carrie ierr ....................................................................................................................... 12 Inter Inter-W -Whe heelDif elDiffer feren enti tial al Lock......................................................................................................... Lock......................................................................................................... 12 Feat Featur ures....................................................................................................................................13 es....................................................................................................................................13 Powe Powerr Divi Divide derr Oper Operat atio ion n .............................................................................................................. 14 Inter Inter-A -Axl xle e Powe Powerr Divi Divide derr .............................................................................................................. 14 Inter Inter-W -Whe heelPowe elPowerr Divi Divide der............................................................................................................ r............................................................................................................ 14 Powe Powerr Divi Divide derr Lock Lockou out................................................................................................................. t................................................................................................................. 15 Carr Carrie ierr Comp Compon onen ents ts and and Oper Operat atio ion n ............................................................................................... 18 Differ Different ential ial Compon Component ents s and Operati Operation. on. ....... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .. 18 Lubr Lubric icat atio ion................................................................................................................................. n................................................................................................................................. 19 Over Overha haul ul Reco Recomm mmen enda dati tion ons s ........................................................................................................ 20 Carr Carrie ierr Iden Identi tifi fica cati tion.................................................................................................................... on.................................................................................................................... 21 Powe Powerr Divi Divide derr Iden Identi tifi fica cati tion on .......................................................................................................... 21 Carr Carrie ierr Comp Compon onen entt Inspe Inspect ctio ion n ...................................................................................................... 21 Overview...................................................................................................................................21 Pini Pinion on Shaft Shaft Wear Wear Limi Limits.............................................................................................................. ts.............................................................................................................. 22 Gear Gear Wear Wear Limi Limits........................................................................................................................ ts........................................................................................................................ 22 Diff Differ eren enti tial al Spid Spider er Wear Wear Limi Limits ts ...................................................................................................... 22 Bearin Bearings, gs, Bushin Bushings gs and Thrust Thrust Washe Washers rs ...... ...... ....... ..... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... .. 23 Powe Powerr Divi Divide der............................................................................................................................. r............................................................................................................................. 23 Axle Shafts . .. ... ... .... .. .... .... .. ... .... .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ... .... .. ..... ... .. 24 Clea Cleani ning....................................................................................................................................24 ng....................................................................................................................................24 Comp Comple lete te Asse Assemb mbli lies.................................................................................................................. es.................................................................................................................. 24 Disa Disass ssem embl bled ed Parts Parts .................................................................................................................... 24 Bear Bearin ings....................................................................................................................................24 gs....................................................................................................................................24 Roug Rough h Parts............................................................................................................................ Parts............................................................................................................................... ... 25 Drying.......................................................................................................................................25 Corr Corros osio ion n Prev Preven enti tion...................................................................................................................25 on...................................................................................................................25 Gear Gearse sett Upda Updati ting ng........................................................................................................................ ........................................................................................................................ 25 CRD CRD 151 151 Rear Rear Carr Carrie ierr ................................................................................................................. 27 Trouble roublesho shooti oting...........................................................................................................................35 ng...........................................................................................................................35 Carr Carrie ierr Troub rouble lesh shoo ooti ting ng ............................................................................................................... 35 Troub Troubles leshoo hootin ting g and Diagno Diagnosin sing g Misma Mismatch tched ed Carrie Carrierr Ratios Ratios for Tandem andem Carrie Carriers rs ...... ...... ...... ...... ...... ... 36 Carr Carrie ierr Iden Identi tifi fica cati tion on Stam Stampi ping ng ...................................................................................................... 37 Gear Gear Set Set Inspe Inspect ctio ion.............. n..................................................................................................................... ....................................................................................................... 38 Servic Service e Proced Procedure ures s ...................................................................................................................... 39 Differ Different ential ial Carrie Carrierr, Dissa Dissasse ssemb mblele-Ass Assemb emble...... le...... ...... ...... ....... ....... ....... ..... ....... ....... ...... ...... ...... ...... . 39 Diff Differ eren enti tial al Remo Remova vall .................................................................................................................... 39 Remo Removi ving ng the the Inter Inter-A -Axl xle e Thro Throug ugh h Shaf Shaftt .......................................................................................... 44 Bevel Bevel Pini Pinion on Hous Housing ing Remova Removall (Fron (Frontt Rear Rear or Rear Rear)) ...... ...... ...... ...... ....... ....... ..... ....... ....... ...... ...... ... 47 Removi Removing ng the Helica Helicall or Pinion Pinion Shaft Shaft ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... . 49 Four-P Four-Pini inion on Type Differe Differenti ntial........... al........... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ..... ....... ....... ...... .. 53 Inter-W Inter-Whee heell Power Power Divi Divider der Dif Differ ferent ential ial — Disass Disassemb embly ly ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... . 59 Inter-A Inter-Axle xle Power Power Divide Dividerr Cage Cage — Disa Disasse ssemb mbly.......... ly.......... ...... ...... ....... ....... ..... ....... ....... ...... ...... ...... ...... . 63

Front Rear Bevel Pinion — Disassembly ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... .. 66 Rear Rear Bevel Pinion — Disassembly.........................................................................................71 Helical (Spur) Pinion Shaft — Disassembly.. ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 75 Power Divider Lockout — Disassembly ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ..... 79 Inter-Axle Through Shaft — Disassembly...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... .. 87 Inter-Axle Through Shaft — Reassembly........................................................................................ 88 Power Divider Lockout — Reassembly.... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... .. 88 Inter-Axle Power Divider without Lockout — Reassembly...... ...... ...... ....... ....... ..... ....... ....... ...... ...... ... 96 Front Rear Bevel Pinion — Reassembly.. ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... 100 Setting the Bevel Pinion Preload ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ..... ....... ....... ...... ...... .... 104 Setting the Preload.................................................................................................................... 104 Determining Bevel Pinion to Carrier Housing Shim Pack ..... ...... ...... ...... ....... ....... ..... ....... ....... ...... ... 107 Rear Rear Bevel Pinion — Reassembly ....................................................................................... 108 Setting Bevel Pinion Preload......... ...... ...... ....... ..... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... .. 112 Setting the Preload.................................................................................................................... 112 Determining Bevel Pinion to Carrier Housing Shim Pack ..... ...... ...... ...... ....... ....... ..... ....... ....... ...... ... 114 Helical (Spur) Pinion Shaft — Reassembly...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... 115 Setting the Preload.................................................................................................................... 118 Setting the Gear Patterns........................................................................................................... 120 Bevel Pinion Installation............................................................................................................. 122 Setting the Backlash.................................................................................................................. 126 Setting Spiral Bevel Gears.......................................................................................................... 126 Four-Pinion Type Differential — Reassembly...... ...... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .. 127 Inter-Wheel Power Divider Differential — Reassembly.. ...... ....... ....... ....... ..... ....... ....... ...... ...... ...... .. 129 Differential Installation ...... ...... ....... ....... ..... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... 131 Bull Gear Tooth-Contact Pattern...... ...... ...... ...... ...... ...... ...... ....... ....... ....... ..... ....... ....... ...... ...... .... 136 Final Assembly......................................................................................................................... 138 Front Rear or Rear Rear Bevel Pinion Installation........... ..... ....... ...... ...... ...... ...... ...... ...... ...... ...... .... 140 Inter-Axle Power Divider Installation (with or without Lockout) ...... ...... ...... ...... ...... ....... ....... ..... ....... .. 140 Inter-Axle Power Divider Without Lockout Only ..... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... 142 Inter-Axle Power Divider With Lockout Only ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 142 Inter-Axle Through Shaft Installation ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ..... ....... ....... ...... 143 Carrier Installation Into Chassis.. ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ..... ....... ....... ...... ...... .... 145 Preventive Maintenance....................................................................................................................1 Magnetic Strips and Oil Troughs....... ...... ...... ...... ...... ...... ...... ...... ....... ....... ....... ..... ....... ....... ...... ...... .1 Checking Oil ................................................................................................................................1 Changing Oil ................................................................................................................................2 Air Breathers ..................................................................................... ....... ....... .. ... ... .... ... .............. 3

Operation Numbers ........................................................................................................................5

Group 46

Specifications Make

MACK Trucks, Inc.

Type

Dual-Reduction Carrier

Case

Cast Iron

Gears

Durapoid Spiral Bevel Gears, 1st Reduction Coarse-Pitch, Wide-Faced Helical Gears, 2nd Reduction

Lubrication

Splash Lubrication

Drain Plug

Magnetic

Oil Capacity, Pints

Carrier Bowl, each approximately 26 pints (12.3 Liters) Bevel Gear Compartment, each 8 pints (3.8 Liters) Inter-Axle Power Divider, 1 pint (0.5 Liter)

Note: Proper oil level is best determined by checking oil level in reference to the filler plug holes. Recommended SAE Grade Gear Oil

• •

MACK® GO-J Specification 80W-90, 85W-140 MACK® GO-J Plus Specification 75W-90 (Synthetic)

Tandem Axle Models — With Gear-type Differentials: CRDPC150, CRD151

Gearing:1st Reduction: DURAPOID Spiral Bevel 2nd Reduction: Coarse Pitch Helical Ratios: 3.11 ,3.25 ,3.40, 3.56, 3.79, 3.98, 4.19, 4.80, 5.04, 5.31, 5.66

Tandem Axle Models — With MACK Power Divider Differentials:

Ratios:

CRDPC1501, CRD1511

3.79, 3.98, 4.19, 4.80, 5.04, 5.31, 5.66

Single Axle Models — With Gear-type Differentials:

Splines, number and type: 43, Involute

CRD151

Single Axle Models — With MACK Power Divider Differentials:

Side Gear Splines 43, Involute

CRD1511

Type: Top-Mounted, Dual Reduction

1

Group 46

Dimensions and Fits (All dimensions are in inches except where otherwise stated) Inter-Axle Power Divider:

Minimum

Maximum

Wedges Wedges MUST be used in sets of 24 having length within 0.002 inch and within the length dimension, NEVER "BREAK SETS" Cams, Male, distance across any two alternate lobes

2.808

2.814

Female, distance across any two alternate recesses

4.746

4.758

Air-Actuated Inter-Axle Power Divider Lockout: Shifter Fork and Clutch, Side Clearance

0.005

0.020

Air-Shift Piston Return Spring, free height 3-9/16

—

—

Test at 2-inch height

180 lb.

220 lb.

Pinion Bore, finished I.D. (steel-on-steel)

1.256

1.259

Spider Leg, diameter

1.248

1.249

Spider-to-Pinion Bore, clearance

0.007

0.011

Pinion Thrust Washer, thickness

0.064

0.066

Side Gear Thrust Washer, thickness

0.092

0.094

Side Gear Hub and Casing, clearance

0.050 nominal

4-Pinion Closed-Type Differential:

2

Group 46

Assembly Specifications

Assembly Specifications Torque Specifications of Fasteners for CRDP150 FASTENER NAME

Nm

Breather

24–37

Input Drive Yoke Screw (Part of Yoke Arrangement) Input Oil Seal Cover Screw

678–813 54–68

Power Divider Housing Mounting Screw

235–289

LB-FT TORQUE 18-27 500-600 P 40-50 173-213 P

Plug, Power Divider Housing Fill

30–45

22-33 P

Plug, Power Divider Housing Drain

30–45

22-33 P

Bevel Gear Compartment Cover Screw

33–49

24-36 P

Output Oil Seal Cover Screw

37–45

27-33 P

Output Drive Yoke Nut (Part of Yoke Arrangement)

813–1220

600-900 P

Power Divider Cam Nut

1763–2034

1300-1500 P

Bevel Gear Clamp Plate Screw

678–813

500-600 P

Helical Pinion Shaft Bearing Clamp Plate Screw

407–542

300-400 P

Helical Pinion Shaft Bearing Cover Screw

84–106

62-78 P

Bull Gear Mounting Screw

323–355

238-262 P

Differential Bearing Cap Screw

360–441

265-325 L

Plug, Carrier Housing Drain

24–37

18-27

Additional Torque Specifications of Fasteners for CRD151 Input Oil Seal Cover Screw

33–48

24-36 P

Carrier Housing Rear Cover Plate Screw

37–45

27-33 P

Bevel Pinion Housing Mounting Screw Bevel Pinion Yoke Clamp Nut

235–289 1085–1356

173-213 P 800-1000 P

Additional Torque Specifications of Fasteners for Units with Inter-Axle Power Divider Air-Actuated Lockout Input Oil Seal Cover Screw

42–53

31-39

Air Cylinder Housing Screw

42–53

31-39

Lockout Housing Cover Plate Screw

26–37

19-27

Lockout Fork Staking Screw

47–61

35-45 P

Lockout Housing Mounting Screw

42–53

31-39

Nut, Air Cylinder Piston

81–102

60-75 P

3

Group 46


Additional Torque Specification of fasteners for Units with Differential Power Divider for CRDP1501 and CRD1511 Bull Gear Mounting Screw

323–355

Oil Duct Screw

11–14

238-262 P 8-10 P

Orientation of Power Divider Lockout shall be with the center line of air cylinder located 30º below horizontal center line of carrier input (8 o’clock position as viewed from front of carrier). Additional Torque Specifications of Fasteners for DifferentialLock Mechanism. Indicator Switch

5/6

44/56 inch lb

Fork Clamp Bolt

33/35

24/26 ft. lb P

Cover Screw

28/37

21/27 ft. lb

Bullgear mounting screws/nuts must be torqued in a double torque method (torque all screws/nuts to an initial torque*, then re-torque to the final specification) using a star torquing pattern (either individually torqued by hand or using a multi-spindle torquing device). An acceptable alternate method is to press the subassembly together*, and torquing the screws using a 68 Nm plus 61˚ ± 3˚ (50 lb-ft plus 61˚+/-3˚) angle method.(*To properly seat differential casings to bullgear). SETTING

• • •

Bevel Pinion Bearing Preload: Assemble pinion and bearings in bearing housing and apply 20,000 lb. load to bearing cones. Adjust variable spacer to produce a rolling drag on bearings of 1-3 Nm (10-27 in-lb). Helical Pinion Shaft Bearing Preload: Assemble pinion shaft and bearings in bearing retainer and apply 20,000 lb. load to bearing cones. Adjust variable spacer to produce a rolling drag on bearings of 1-3 Nm (10-27 in-lb). Differential Bearing Preload: Assemble differential completely and install in carrier housing with bearing cap screws finger tight. Install differential bearing adjustment fixture (J26440) on bearing cap lugs and tighten adjusting nut to produce a rolling drag on bearings of 2-4 Nm (16-36 in-lb). Tighten bearing cap screws to specified torque and recheck rolling drag to same specifications.

• Differential bearing cap pedestal diameter after assembly bearing cap pedestals should measure 34.298:/34.267 cm (13.503:/13.491 in) diameter. (after bearing preload adjustment using 13.494 +/- .001 ID ring and final bolt torquing).

• •

4

Seal Installation: Input and output oil seals are to be installed squarely with respect to normal shaft center line. Seal face runout to be a maximum of .010 with TIR. Installing the two piece Wear Ring on the Differential Lock Piston

W4054135

1. Wear Ring Assembly Oring

4. Wear Ring Loading Mandrel

2. Wear Ring Assembly Seal

5. Differential Lock Piston Rod

3. Wear Ring Seal Pusher 1. Install the O-ring part into the groove on the piston head. 2. Using two tool pieces, loading mandrel and seal pusher, install the wear ring part onto the outside of the O-ring in the groove on the piston head. 3. Re-size the wear ring part using the sizing/assembly tool. 4. The sizing/assembly tool can also be used to install the piston (with wear ring) into the carrier main housing.

Group 46


W4054136

•

W4054137

1. CRD 150/151 Carrier Housing

6. Piston Spring

1. CRD 150/151 Carrier Housing

9. Washer

2. Piston Rod Wear Ring Sizing Tool

7. Washer

2. Differential Lock Piston Cover

10. Piston O-ring

3. Ratchet Extension, 6.35 mm (.25 in)

8. Piston Rod O-ring

3. Ratchet Extension, 6.35 mm (.25 in)

11. Clutch Gear

4. Ratchet, 6.35 mm (.25 in)

9. Clutch Fork

12. Piston Rod

5. Wear Ring Assembly

10. Piston Rod

4. Ratchet, 6.35 mm (.25 in) 5. Cover Bolt

13. Clutch Fork Set Screw

6. Cover Lockwasher

14. Clutch Fork

7. Cover O-ring

15. Piston Ring

CRD150-151 Carrier Differential Lock Adjustment Procedure: To begin the procedure, the o-ring and washer are assembled in the housing bore, the piston rod has the spring and the two piece wear ring in place, the piston cover has the o-ring in place, the fork has the fork bolt partially installed, and a cut off axle shaft pushed through the differential half (with clutch teeth) into the differential side gear is holding the sliding clutch and fork in place.

8. Wear Ring Assembly 5 A cut off axle shaft should be used to hold the sliding clutch in position. Pushing the clutch inward against the fork and slightly rotating the cut off axle shaft, continue turning the piston rod until the teeth of the sliding clutch just hit the end of the teeth on the differential half.

1 Start the cylinder into the carrier housing bore using a piston rod wear ring sizing tool to get the ring started into the bore. The cylinder and wear ring should have a light coating of gear oil.

6 Backout the piston rod 1.5 turns. Then backout the piston rod to align the nearest flat area (on the piston rod threaded section) under the end of the partly installed fork bolt. The total backout of the piston rod will be between 1.5 and 2.0 turns.

2 Rotate the piston rod to assist the seal going into the bore and to thread the piston rod into the fork. A ¼ inch ratchet extension can be used. 3 When the piston rod is in the bore roughly 5/16 inch, install the piston cover and torque the three screws that hold the cap. 4 Using a ¼ inch ratchet extension inserted through the hole in the cover, where the air supply fitting would be, continue rotating the piston rod to move the fork inward.

7 Finish installing the fork bolt and torque.

•

Carrier with Differential Lock - Assembly into an Axle Housing. 1 With assembled carrier out of the axle housing, completely install the axle shaft (with extended splines to engage differential lock clutch) through the differential lock clutch and into side gear. 2 Engage the lock (moves clutch into engagement with the differential half spline). 3 Keeping engagement, take out the axle shaft. 4 Keeping engagement, install the carrier into the axle housing. 5

Group 46


5 Install axle shafts, completely. (Can rotate shaft enough to align studs on wheel ends and holes on axle shaft). 6 Dis-engage differential lock.

•

P.D.L.O. and Bevel Pinion Housing O-ring (new location) and Oil Passage Sealing Ring 1 The o-ring is installed onto the housing over the 6.8765 inch diameter. Care must be taken to not damage the oring during assembly of the housing past the bevel pinion adjusting shims, into the main housing. 2 The oil passage sealing ring is installed into the carrier main housing. The shims are cut out to fit over the sealing ring.

•

Differential parts assembly into the helical gear. 1. Install the differential casing (RH) into the helical gear using a light press. 2. Install the side gears, pinions, thrust washers, and spider. 3. Install the differential casing (LH) lockout differential casing (LH) into the helical gear using a light press. Two bolts should be used to keep the spider locations of the two differential casings aligned during this assembly. The differential casing can cock very easily but can easily be tapped back into alignment. 4. Install and torque the Bull Gear Mounting Screws.

Note: “P” indicates prevailing torque features (example: nylon patch, epoxy patch or scotch grip). Note: “L” indicates Loctite No. # 262 or equivalent (023GS17007). Note: Pipe plugs must be sealed using 023GS17002-P sealant. Note: For fasteners not listed in Section 2.0, refer to 412GS218.

W4080978

1. Oil Passage Sealing Ring installed into Main Housing

OIL CAPACITY CARRIER

INTER-AXLE POWER DIVIDER

BEVEL GEAR COMPARTMENT

CRDP150, 1501

1.5 PINTS

8.0 PINTS

CRD151, 1511

8.0 PINTS

SHAFT-SPLINE Input Shaft: Diameter Splines

CRDP150

2.300”PD - 46 Teeth

CRD151

2.687”PD - 43 Teeth

Output Shaft: Diameter Splines

1.950” PD - 39 Teeth

Axle Shaft: CRD150, 1501, 151, 1511 Series — Diameter Splines

2.150”PD - 43 Teeth

Spiral Bevel Gear Set Contact Pattern Contact pattern overlay sheets for spiral bevel gear sets.

6

Group 46


W4054139

1. Drive 2. Coast 3. 20890240 Gear, 21130953 Set Dwg 4. 100% Pattern Inside Area 5. Pattern Height (Min) 6. Pinion 20898247

7

Group 46


W4054140

1. Drive 2. Coast 3. 21016162 Gear, 25542859 Set Dwg 4. 100% Pattern Inside Area 5. Pattern Height (Min) 6. Pinion 21016132

8

Group 46


W4054141

1 Drive 2 Coast 3 21016163 Gear, 25542860 Set Dwg 4 100% Pattern Inside Area 5 Pattern Height (Min) 6 Pinion 21016133

9

Group 46

Special Tools

Tools Special Tools For special tools ordering instructions, see service information in group 08. J 26437

WRENCH,Differential BearingAdjustingNut

J 26440

FIXTURE, Differential BearingAdjustment

J 8129

SCALE, Spring Tension

J 3409-D

STAND, Carrier Repair

J 29327

ADAPTER, Torque Wrench for torquing nut inside carrier housing when mounting to axle housing.

J 28506

ADAPTER, Torque Wrench Bevel Pinion Housing to Carrier Housing

J 33107

FIXTURE, Bevel Pinion Bearing Nut

J 38585

ADAPTER, Nut

J 26900-8

SET, Feeler Gauge

J 28721-906

WRENCH, 3" Socket

J 39477-1

PULLER, Bar Type

OEM 6642

WRENCH,Torque (DialType)

OEM 6107

MULTIPLIER, Torque

S 574

ADAPTER RING, Tapered Roller Bearing Puller

S 573

ADAPTER RING, Tapered Roller Bearing Puller

S 574D

SEGMENT, Adapter Ring, Bevel Pinion Shaft, Rear

S 574E

SEGMENT, AdapterRing, Pinion Shaft, L.H.

S 573A

SEGMENT, AdapterRing, Pinion Shaft, R.H.

S 574C

SEGMENT, Adapter Ring, Differential and Differential Power Divider, L.H. and R.H.

88800293

Drift/Mandrel

88800294

Plastic Sealing Retainer

88800295

Guide

88800296

Steel Sealing Retainer

Using Adapters/Extensions with Torque Wrenches Some screws have limited wrench clearance or are otherwise difficult to access. Use Bosch special offset wrench J 29327 for this purpose. This wrench has a 1/2-inch square drive end and a 15/16-inch wrench end. It will service CRD 150/151 series carriers.For accurate torque readings, use a dial-indicator type rather than the click-type torque wrench. Click-type torque wrenches are accurate only when the point or pull remains at the center of the hand grip.A dial-indicator type torque wrench can be used accurately, with or without an extension, as long as the force is applied anywhere along the handle or the extension. Do not use a handle extension with the click-type torque wrench, unless it is designed and calibrated specifically for that 10

purpose.When an adapter is attached to the square drive end of a dial-indicator type torque wrench, the dial reading (compared to the actual torque applied) will be affected if the leverage length of the torque wrench is increased. A correction factor is then needed to achieve an accurate dial reading. Obtain the correction factor as follows: Divide the total length "A" by the torque wrench length "B":

Group 46

Using Adapters/Extensions with Torque Wrenches

W4081604

Fig. 1 Dial-Indicator Type Torque Wrench with Adapter

• • •

Total Length "A" = 24 Total Wrench Length "B" = 12" A/B = 24/12 = 2 (Quotient)

Multiply the dial reading by the quotient found above to determine the torque at the end of the adapter:

• • •

Dial Reading = 50 lbs. Quotient = 2 Torque at End of Adapter = 50 x 2 = 100 lbs.

If the required torque is known, divide by the quotient to determine what the torque reading should be:

• • •

Required Torque = 100 lbs. Quotient = 2 Desired Torque Reading = 100/2 = 50 lbs.

11

Group 46

Differential Carrier, Function

Design and Function Differential Carrier, Function MACK top-mounted, dual-reduction tandem carriers of the 150/151 series transfer the power from the transmission to the rear wheels. The carriers are identical except for the input drive and the through-shaft arrangement of the front carrier.

Front Rear Carrier Most MACK four-wheel-drive tandems are provided with a MACK inter-axle power divider, which can be defined as a third differential. The exclusive MACK inter-axle power divider splits driving torque evenly or unevenly, as required between the tandem axles. This power divider is fully automatic, contains no gears and preserves traction in the toughest conditions. MACK power dividers automatically provide a 3-to-1 torque biasing capability to the axle with the best traction. During certain off-highway (low traction) situations, there is an advantage to coupling the tandem carriers together in a straight-through positive drive arrangement. An optional power divider with lockout feature is available for this purpose. The driver can control the power divider lockout from the cab of the vehicle. The lockout consists of an air-actuated piston assembly which controls a shift fork and gear-type sliding clutch. The clutch is splined to the cage assembly and is moved to engage with the outer cam of the power divider. This couples the cage and outer cam together and effectively locks out the function of the power divider for emergency traction situations. Tire matching is still required on units with or without an interaxle power divider as mismatched tires equate to mismatched ratios. Tire matching is required with a power divider or premature unit failure will occur.

Rear Rear Carrier In the rear rear carrier, the main drive pinion design is borrowed from the front carrier and is carried in an overhung arrangement

Inter-Wheel Differential Lock Optional inter-wheel differential lock with the following function/ attributes:

• • •

Mechanical mechanism that locks both the left and right axle shafts together Used for vehicle speeds below 20 mph To be used for vocational off-road use (only the most slippery terrain)

• Driver controlled Availability: Both axles of tandem, Rear rear axle of tandem. Forward rear axle of tandem, single rear drive axle.

12

by a pair of tapered roller bearings mounted in a separable housing.

Group 46

Features

W4033819

1 Main Drive Pinion Another important feature of both the front rear and rear carriers is the inter-wheel or differential power divider with a command wedge-type differential, instead of the conventional gear-type differential. Similar to the inter-axle power divider the interwheel power divider is also fully automatic, contains no gears and provides a 3-to-1 torque biasing capability to the wheel with the best traction.

Features Current production dual-reduction carriers are provided with:

• • •

Durapoid spiral bevel gears for first reduction Coarse-pitch, wide-faced helical gearset for second reduction Four-pinion, closed-type gear differential (unless otherwise specified)

W4031735

Dual-Reduction Carrier

1. 1st Reduction

4. Bull Gear

2. 2nd Reduction

5. Bevel Gear

3. Helical Pinion (Spur Shaft)

6. Bevel Pinion

13

Group 46

Power Divider Operation

Power Divider Operation The power divider is a torque-proportioningdifferential that prevents loss of traction by directing up to 75 percent of the total available torque to the axle with the best traction. By the nature of its design, a conventional differential will either apply torque to the axle or the wheel with the least resistance or equally distribute torque if resistance is equal at all wheels. When good traction conditions exist, a resistance occurs at each wheel, transmitting torque equally to all wheels. However, when an

axle or wheel loses traction (resistance) the other wheel with good traction only receives a torque equal to the torque capacity of the spinning wheel. Commonly this is not enough to move the vehicle and the majority of the available torque is lost at the spinning wheel. When this same situation occurs with the MACK power divider, power is automatically diverted to the non-spinning wheel(s) for maximum traction.

Inter-Axle Power Divider The MACK inter-axle power divider provides torque biasing between axles of the tandem rear carrier. If one axle (one or both wheels of the axle) has limited traction, the torque applied to each wheel of the axle is immediately multiplied by three and transferred to the axle with more traction. Even when no traction is available at the spinning wheel, the operator can apply the brakes slightly, creating enough resistance at that wheel to allow power to the axle with traction.

W4031737

75% of available power is transferredto the axle with traction

1. No Traction 2. NO Applicable Power 3. Power W4031736

Normal conditions — All wheels have traction

1. Power

Inter-Wheel Power Divider The MACK inter-wheel power divider functions in much the same manner as the inter-axle power divider with torque biasing occurring from wheel to wheel. The inter-wheel power divider may be used in conjunction with the inter-axle power divider to provide increased manoeuvrability in poor traction situations.

14

Group 46

Power Divider Lockout

W4031738

The inter-wheel power divider replaces the conventional carrier differential

W4031739

75% of available power is transferred to the wheel with traction

1. No Traction 2. Power

Power Divider Lockout A power divider lockout is available for exceptionally severe operating conditions, where road surfaces are so slippery that traction is difficult to achieve even with the MACK power divider. The advantage of the power divider lockout is that tandem carriers can be coupled together in a straight-through positive drive arrangement, thus enabling the operator to achieve maximum traction under these severe conditions. For this type of operation, a lockout device, controlled from the cab by the driver, may be incorporated with the power divider.

engaged, couples the cage to the outer cam to effectively lock out the function of the power divider differential.

The lockout device inhibits the operation of the power divider. It consists of an air-actuated, gear-type sliding clutch which, when 15

Group 46


W4031740

All parts of power divider operate normally

1. Piston moves forward when air pressure exhausts 2. Fork 3. Sliding clutch disengages teeth on outer cam

W4030709

16

Group 46


W4031741

1. Piston pushed rearward by air pressure 2. Fork 3. Power divider cage and outer cam turn together 4. Outer cam of power divider 5. Sliding clutch engages teeth on outer cam The power divider and lockout are mounted in separate housings. The power divider housing also contains the hollow bevel pinion, carried in an overhung arrangement by a pair of tapered roller bearings and the through shaft in quill arrangement.

W4031742

Front Rear Carrier Arrangement

1. Power Divider Lockout 2. Power Divider 3. Hollow Bevel Pinion 4. Through Shaft

17

Group 46

Carrier Components and Operation

Carrier Components and Operation Except for the differences just noted, both carriers are the same. The helical pinion shaft and Durapoid bevel gear are mounted at right angles to the bevel pinion shaft. Both components are straddle-mounted by a pair of tapered roller bearings mounted at the gear end in the carrier housing bulkhead and at the outer end in a separable bearing retainer. Proper bevel gear

Differential Components and Operation The differential assembly consists of four bevel pinions in steelon-steel bearing engagement with the spider and two axle-driving side gears with steel-backed, ball-indented thrust washers behind bevel pinions and side gears. Lubricant trapped in the ball indentations forms small reservoirs which provide adequate lubrication at these points when differential action is taking place. These parts are enclosed in the differential casing consisting of two mated halves. In addition to the bolting flange of the RH casing half, a ring of splines around the circumference engages mating splines on the inside diameter of the bull gear bolting flange. When assembled, driving torque from the bull gear is transferred from the differential casing through the splines. This relieves the bull gear mounting bolts of all shearing stresses. The entire assembly is straddle mounted in a pair of tapered roller bearings, one at each outer end of the casing halves. The bearings are mounted in the carrier pedestals. Bearing preloading is accomplished by a slotted adjusting nut threaded to the inboard side of the RH bearing cup which is otherwise free to move laterally. The LH bearing cup flange holds itself stationary against the LH bearing pedestal chamfer.

W4030710

1 Differential lock

18

mesh is achieved by varying the thickness of shim packs between the pinion gear housings and the carrier housing. The mating bevel gear must be adjusted to the proper backlash.

Group 46

Lubrication

Lubrication When the vehicle is in motion, all moving parts in both tandem carriers are constantly bathed in oil by the various pumping actions of the moving parts.

W4031749

Splash Lubrication

A pump on the rear half of the inter-axle through shaft sends oil under pressure to the inter-axle power divider. A rolled groove in the inner axle through the shaft carries fluid collected forward to the Power Divider (PD) through the oil tube when the vehicle is in forward motion. The fluid is collected from the intake port at the rear of the oil tube. The oil tube is integral to the though shaft bearing retainer.

W4031750

Inter-Axle Power Divider Pump Operation

19

Group 46

Overhaul Recommendations

A collector trough, integral with the bevel-gear compartment cover, supplies the pump intake port on top of the rear bearing retainer with lubricant collected from bevel gear throw-off. In forward vehicle motion, the helical groove slinger of the pump forces oil forward along the through shaft between the tube and hollow-bevel pinion shaft to the internal parts of the power divider. The oil returns to the banjo reservoir by the pumping action of the parts and through drilled passages in the housings. Another collector trough, integral with the carrier housing, directs throw-off oil from the Durapoid gearset directly to the drive-pinion tapered roller bearings through drilled and cast-in oil passages. This oil returns to the reservoir by gravity. All other gears and bearings are lubricated by their own pumping action created when running in oil.

Overhaul Recommendations Unless your shop is equipped with holding stands, a heavy-duty hydraulic press, various gear and bearing pullers, and the means to make your own holding devices where required, it is highly recommended that the carriers be taken to the nearest MACK dealer for overhauling. The following recommendations are for shops that can handle this type of overhaul.

• • •

•

•

20

Do not disturb parts with heavy press fits unless replacement is necessary. Use proper press setups and/or pullers during disassembly to avoid damaging usable parts during removal. Tighten all yoke or flange nuts as recommended (see Specifications). If a heavy-duty air impact wrench with one-inch drive is available, high torques should be no problem. However, conventional methods of tightening or relieving these heavy torques require a way to hold the pinions to prevent them from rotating. Unless proper precautions are taken, this can be a very dangerous operation. Make a special tool if the gear-jamming method is to be used. The tool is a short rod (slug), about two inches long, and made of a 1/2-inch-diameter mild steel. Attach a handle at one end of the slug tool by welding a rod that is two feet long and 1/4 or 3/8 inch in diameter. One person can safely hold this gear-jamming tool in the gear mesh while someone else pulls the wrench. Because of the long handle, this tool cannot be left accidentally in the bevel gear compartment where it could cause damage. At reassembly, make sure the bench, tools and working areas are clean.

W4031751

Gear Jamming Tool

1 Approximately 0.61 m (2 ft.) 2 5.08 cm (2 in.) 3 1.27 cm (1/2 in). diameter 4 0.635 or 0.95 cm (1/4 or 3/8 in. diameter)

Group 46

Carrier Identification

Carrier Identification Before disassembly, using carrier designations, determine which type of carrier is being serviced.

1. Ratio 2. Part number 3. Serial number 4. Carrier Identification 5. Indicates Inter-Wheel Power Divider used Information stamped into the unit indicates features included by the manufacturer.

W4031752

Carrier Stamping location and information

Power Divider Identification Pay special attention to units with the initial "P" and the numeral "1". The letter "P" in the prefix indicates that the carrier is equipped with an inter-axle power divider. The numeral "1" after the model number indicates that the carrier is equipped with an inter-wheel power-divider type differential. Absence of the numeral "1" indicates that a four-pinion type differential is used. Each type of differential is covered in its own disassembly and reassembly section. Refer only to the section covering the particular type of carrier being serviced.

W4031753

Power Divider Stamping Locations

1. Indicates Inter-Wheel Power Divider Used 2. Indicates Inter-Axle Power Divider Used

Carrier Component Inspection Overview It is very important to carefully and thoroughly inspect drive unit parts before reassembly. Replacement of worn or damaged components will eliminate costly and avoidable drive unit failure.

Whenever possible, use Magnaflux or similar non-destructive inspection method on all steel parts except ball and roller bearings. This method is especially suited for inspecting machined or highly finished surfaces for wear and cracks, which otherwise 21

Group 46

would not be visible. It is essential to completely demagnetize the parts before using the Magnaflux method.

Pinion Shaft Wear Limits Check shafts carefully for cracks or other surface damage that can lead to early failure. Bearing journals must conform to the concentricity requirements. Replace components if the specified wear limit of 0.05 mm (0.002 in.) is exceeded by more than 0.025 mm (0.001 in.). Inspect shaft press fit surfaces to ensure a press fit condition with mating gears and bearings. Splined ends require no less than a tap fit with their mating drive yoke or flange. Make sure that shafts show no signs of twist.

Gear Wear Limits Replace gears if teeth show any signs of abrasive wear, scratching, ridging, scoring, surface fatigue, pitting, spalling, corrosive wear, digging in or cracking. Always replace mated spiral bevel gears, hypoid gears, differential pinion and side gears in sets. Gear backlash, which may be adjusted by shims (as in the case of spiral bevels), must never exceed 0.46 mm (0.018 in.) relative to a gearset of fixed centers. Bull gears in dual-reduction carriers have no adjustment. Therefore, at this point, the backlash can be as high as 0.76 mm (0.030 in.) before any serious difficulty will be encountered.

Differential Spider Wear Limits A slightly worn differential spider may be reused if:

• • •

Wear does not exceed 0.127 mm (0.005 in.) Spider-to-pinion bore clearance does not exceed 0.178– 0.279 mm (0.007–0.011 in.) Wear surfaces are not scored, pitted, cracked or otherwise damaged.

Install the spider in the opposite position. This will place the original drive side, which experiences the most wear, on the coast side, which has the lighter load.

22

Pinion Shaft Wear Limits

Group 46

Bearings, Bushings and Thrust Washers

Bearings, Bushings and Thrust Washers Check ball and roller bearings for:

• Flaking • Cracks and fractures • Cavities and indentations • Staining • Measurable Wear • Brinelling • Fretting • Corrosion • Banking • Seizing • Galling • Scoring • Arching • Nicking • Cage failures Replace bearings if any of these conditions are present. Tapered roller bearings are set up in a preload condition according to adjustment specifications for each carrier. For reusable or run-in tapered bearings, adjust preload to one half the value specified for new bearings. If bearings pass inspection, dip them in the recommended differential lubricant. Then wrap bearings in clean cloth or paper until ready to reassemble the axle. Bushings (inter-wheel power-divider driving cage) and thrust washers must be replaced if they are pitted, scored or show any signs of surface damage or have broken locking tabs. Do not use tabbed thrust washers in a differential casing without the blind hole provision. Latest versions of these differentials are manufactured with thrust washers having tabs. Thrust washers without tabs may be used in old casing halves having the blind hole provision without any adverse effects. Wear must not exceed 0.25 mm (0.010 in.) maximum. Thrust washers must be replaced in sets. Combining old and new thrust washers can cause premature failure.

Power Divider The frictional forces created by loads imposed on the cams and wedges cause moderate scoring on the highly stressed rubbing surfaces of cam tracks. This is a normal condition. Replace the affected cam and wedge items only if working surfaces are badly worn, pitted, scored or cracked. Replace the driving cage member if it is damaged or the wedge hole diameter has worn more than 0.25 mm (0.010 in.) over the original limit. Never run new wedges against a used inner cam or vice versa. It is permissible, however, to use slightly worn outer cams and driving cages during rebuild. Always replace wedges in matched sets. Do not mix wedges from different sets. 23

Group 46

Axle Shafts

Axle Shafts Inspect axle shafts for bends, torsional fractures or other conditions that may result in failure. Inspect splines for wear, cracks or distortion. If evidence of any of these conditions is found, install new parts. Install each axle shaft between lathe centers. Using a dial indicator, check shaft runout at the center and 152.4 mm (6 in.) from each end. Discard shaft if total indicated runout (TIR) exceeds 1.5 mm (0.060 in.) at the center, or 0.76 mm (0.030 in.) at the end locations. Position the dial indicator so that the indicator shaft contact point contacts the inner surface near the outer edge. Then check flange runout. Discard axle shaft if flange runout exceeds 0.20 mm (0.008 in.).

Cleaning Clean parts with machined and polished surfaces (e.g., gears, bearings and shafts) in a suitable solvent, such as kerosene or diesel fuel. Do not clean these parts in a hot solution tank or with water and alkaline solutions such as sodium hydroxide, orthosilicates or phosphates. Do not steam clean assembled drive units after they have been removed from the housing. Steam cleaning traps water in the cored passage of the castings and within close clearances on and between parts. This can cause corrosion (rust) on critical parts of the assembly and rust particles circulating in the lubricant. Steam cleaning can also lead to premature failure of bearings, gears and other parts.

Note: Assembled drive units cannot be properly cleaned by steam cleaning, dipping or slushing. For thorough cleaning, the drive unit must be completely disassembled.

Complete Assemblies Completely assembled axles may be steam cleaned on the outside only, to facilitate initial removal and disassembly. Breathers, vented shift units, and all other openings must be tightly covered or closed to prevent water from entering the assembly.

Disassembled Parts Immerse all parts in suitable cleaning fluid and clean parts thoroughly. Use a stiff bristle brush to remove all old lubricant. Remove gasket particles which may adhere to mating faces of axle housing, carrier housing, hubs and axle shaft flanges. Clean out lubricant channels in the pinion cage and carrier housing. Clean the housing breather. Make certain that the interior of the axle housing is thoroughly cleaned.

Bearings The importance of proper bearing cleaning cannot be overemphasized. Clean bearings separately from other axle parts using the following steps:

2 After old lubricant is loosened, hold bearing races so that the bearing cannot rotate. Then brush bearings with a soft-bristled brush until all grit and dirt have been removed.

1 Soak differential and drive pinion bearings in clean kerosene, diesel fuel oil, or other cleaning solvent. Do not use gasoline.

3 Rinse bearings in clean fluid. Then, while holding races, blow dry with compressed air. Be sure air stream is moisture free. Never spin bearings with compressed air as they may score due to the absence of any lubricant.

24

Group 46

Rough Parts

Rough Parts Rough parts, such as differential carrier castings, and cast brackets may be cleaned in hot solution tanks with mild alkali solutions, providing these parts are not machined or polished. The parts must remain in the tank long enough to be thoroughly cleaned and heated throughout. This will aid the evaporation of the rinse water. After cleaning, rinse parts completely to remove all traces of alkali.

CAUTION Do not clean parts with highly volatile fluids such as gasoline or harmful chemicals such as carbon tetrachloride. Also exercise care to avoid skin rashes and inhalation of vapors when using alkali cleaners.

Drying Using moisture-free, compressed air, thoroughly dry component parts immediately after cleaning and rinsing. If compressed air is not available, use soft, clean, lintless absorbent paper towels or clean wiping cloths that are free of abrasive material.

Corrosion Prevention Parts that have been cleaned, dried and inspected and are to be reassembled immediately must be coated with light oil to prevent corrosion. If the parts will be stored for any length of time, treat them with a good rust-preventive agent and wrap in special paper or other material designed to prevent corrosion.

Gearset Updating To assist field personnel in obtaining the desired bevel gearset tooth contact, all service replacement bevel gear matched sets are furnished with the desired tooth contact pattern indicated on the gear teeth in yellow gear-marking compound. Before proceeding with the installation of the replacement bevel gearset, lift and transfer the tooth contact pattern onto a piece of paper for reference when "setting up" the replacement gearset in the carrier. Use transparent tape (Scotch® brand or equivalent) to make a transfer of the contact pattern. Cut off a piece of tape slightly longer than the gear tooth. Place the piece of tape on the gear tooth profile, sticky side down, covering the total tooth length and depth. Rub the back of the tape to ensure good contact between the tape and tooth. Do not permit the tape to slide. Gently lift the tape off the gear tooth and apply it to a piece of paper to transfer the tooth contact pattern. Repeat the procedure on the opposite side of the gear tooth and identify the tooth patterns as drive side and coast side. If no tape is available, make a sketch of the patterns.

W4031754

Lifting Tooth Contact Pattern

25

Group 46

Gearset Updating

W4080979

Reassembly Flow Chart

26

Group 46

CRD 151 Rear Carrier

CRD 151 Rear Carrier

W4034817

CRD 151 Bevel Pinion Shaft Assembly

W4049396

1. Clamp plate

6. Bearingcup

11. Bearingcone

2. Yoke

7. Bevel pinion housing and bolts

12. Oil passage sealing ring

3. Slinger

8. Bevel pinion housing o-ring

13. Shim

4. Seal

9. Spacer

14. Bevel pinion gear

5. Bearing cone

10. Bearing cup

15. Side cover 27

CRD 150 Bevel Pinion and Inter-Axle Power Divider Assembly (without Air Actuated Control)

Group 46

CRD 150 Bevel Pinion and Inter-Axle Power Divider Assembly (without Air Actuated Control)

W4081367

1. Bolt

13. Inner Ring

26. Through Shaft Housing

2. Clamp Plate

14. Outer Ring

27. Housing

3. Yoke

15. Inner Cam

28. Bolt

4. Bolt

16. Nut

29. Lock Washer

5. Lock Washer

17. Outer Cam

30. Shim

6a. Seal

18. Cone

31. Thrust Washer

6b. Retainer

19. Cup

32. Spacer

7. Gasket

20. Gasket

33. Cup and cone

8. Bearing

21. Seal

34. Bevel Pinion

9. Bearing Retainer

22. Seal Retainer

35. Carrier Housing

10. Gasket

23. Gasket

36. Bolt

11. Cage

24. Bearing

12. Wedge

25. Through Shaft

28

Group 46

CRD 150 Air Actuated Power Divider Lockout

CRD 150 Air Actuated Power Divider Lockout

W4049398

1. Gasket

14. Housing

27. Bolt

2. Cover

15. Lock Washer

28. Shaft

3. Lock Washer

16. Bolt

29. Spring

4. Bolt

17. Bearing

30. Sleeve

5. Bolt

18. Yoke Spacer

31. Spacer

6. Fork

19. O-ring

32. Felt

7. Clutch

20. Gasket

33. O-ring

8. Inner C am

21. Cover

34. Piston

9. Outer Ring

22. Lock Washer

35. Nut

10. Inner Ring

23. Bolt

36. Bolt

11. Wedge

24. Oil Seal

37. Lock Washer

12. Cage

25. Yoke

38. Housing

13. Gasket

26. Clamp Plate

39. Gasket

29

Group 46

CRD 150/151 Helical (Spur) Pinion Shaft

CRD 150/151 Helical (Spur) Pinion Shaft

W4030714

1. Bolt

12. Helical Pinion Shaft

2. Cover and gasket

13. Bearing & Race

3. Bolt

14. Bevel gear

4. Clamp plate

15. Key

5. Bearing & Race

16. Clamp plate

6. Helical pinion housing

17. Bolt

7. Pin

18. O-ring

8. Shims

19. Side cover

9. O-ring

20. Plug

10. Spacer

21. Bolt

11. Transverse torque rod bracket

30

Group 46

CRD 150/151 Four Pinion Type Differential Assembly

CRD 150/151 150/151 Four Pinion Pinion Type Differen Differential tial Assembly Assembly

W4049399

1. Bearing Cu C up

11. Bearing Cu C up

2. Adjusting N ut ut

12. Bearing Co C one

3. Bearing Co Cone

13. Bolt

4. Bull Gear

14. Side Gear

5. Side Side Gear Gear Thru Thrust st Washe asherr

15. 15. Spid Spider er

6. Side Gear

16. Bearing Ca Cap Bolt

7. Pini Pinio on (Spi (Spide derr Gear) ear)

17. 17. Bear Bearin ing g Caps aps

8. Pini Pinion on Thru Thrust st Washe asherr

18. 18. Diff Differ eren enti tial al Half Half

9. Side Side Gear Gear Thrust Thrust Washe Washerr

19. Cotter Cotter Pin and Adjust Adjusting ing Nut Lock Pin

10. Differen Differential tial Half

31

Group 46

CRD 150/151 150/151 Inter-Wheel Inter-Wheel Power Divider Divider Assembly Assembly

CRD 150/151 150/151 Inter-W Inter-Whee heell Power Power Divider Divider Assembl Assembly y

W4031770

1. Inner Cam

8. Cup

2. Retaining Ri Ring

9. Bolt

3. Bushing

10. Outer Ca Cam

4. Wedge

11. Bull Gear

5. Driving C ag age

12. Side Casing

6. Cone

13. Cone

7. Adjusting Nu Nut

14. Cup

32

Group 46

Differential Differential Lock Assembly Assembly

Differential Differential Lock Assembly

W4031137 W4031696

W4031697 W4031698

1. Clutch Gear, Gear, Differentia Differentiall Lock

6. Spring

11. Lock Washer

2. Clutch Clutch Fork, Differential ferential Lock

7. Flat Flat Washe asherr

12. 12. Bolt Bolt,, Diff Differ eren en-tial Lock Cover

3. Clutch Clutch Fork, Differential ferential Lock

8. O-ring, O-ring, Piston Piston Shaft

13. Switch, Switch, Back up

4. Set Screw, 12 point

9. Cover, Differential Lock Piston

5. Wear Ring, Piston Rod

10. O-ring, DifferDifferential ential Lock Cover Cover 33

Group 46

Differential Lock Assembly

W4034818

1. Differential Lock

34

Group 46

Carrier Troubleshooting

Troubleshooting Carrier Troubleshooting The troubleshooting chart summarizes some common carrier complaints, probable causes and possible remedies.

Symptom

Probable Cause

Remedy

Noise

1. Low lubrication level.

1. Fill to proper level using recommended l ubricant.

2. Improperlubrication.

2. Drain and refill with recommended lubricant to proper level.

3. Contamination of lubricant.

3. Check servicing intervals. Check for oil contaminated with water. Drain and refill to proper level with recommended lubricant.

4. Driveline phasing.

4. Correct phasing.

5. Driveline angle.

5. Correct a ngle.

6. Worn, damaged or failed yoke

6. Replace yoke.

7. Universaljoint failure.

7. Replace failed parts.

8. Loose pinion drive nut.

8. Tighten nut to torque. Stake if required.

9. Worn or failed bearings.

9. Replace bearings.

10. Improper tooth contact, gear mesh.

10. Adjust by adding or removing shims to establish proper tooth contact.

11. Mixed gear ratios.

11. Check ratios, both carriers must have same ratio.

1. Clogged breather.

1. Replace breather.

2. Failed seals or gaskets.

2. Replace failed seals or gaskets.

3. Cracked housing.

3. Replace housing.

1. Improperlubrication.

1. Check specificationfor properlubrication, replacefailed bearing.

2. Worn, damaged or failed yoke.

2. Repair using speedi-sleeve on shaft or replace failed parts.

3. Wrong preload on bearings.

3. Replace failed parts and adjust preload to specification.

4. Pump failure.

4. Repair or replace failed parts.

5. Misaligned gears.

5. Replace failed parts, make certain gears are properly aligned and check tooth contact pattern.

1. Driveline phasing.

1. Correct phasing.

2. Driveline angle.

2. Correct a ngle.

3. Worn, damaged or failed yoke.

3. Replace yoke.

4. Universal joint failure.

4. Replace universaljoint.

5. Loose clamp plate nut.

5. Tighten nut to recommended torque.


6. Replace bearings.


7. Check ratios, both carriers must have same ratio.

Oil Leakage

BearingFailure

Vibration

35

Troubleshooting and Diagnosing Mismatched Carrier Ratios for Tandem Carriers

Group 46 Symptom

Probable Cause

Remedy

Gear Failure

1. Low lubrication.

1. Fill to proper level using recommended l ubricant.

2. Improper lubrication.

2. Check Maintenance and Lubrication Manual (TS494) for proper lubrication.

3. Contamination of lubricant.

3. Check servicing intervals, check for oil contaminated with water. Replace failed parts and fill to proper level using recommended lubricant.

4. Driver abuse.

4. Instruct driver in proper procedure.


5. Replace failed parts. Make certain gears are properly aligned. Check tooth contact pattern.

6. Loose clamp plate nuts.

6. Replace failed parts. Torque nuts to proper torque.

7. Improper ratio for application

7. Recalculate drive train ratios. Replace as required.

8. Improper tooth contact, gear mesh.

8. Replace failed parts. Make certain tooth contact pattern is correct.

1. Driver abuse.

1. Instruct driver in proper operating procedures.

2. Tire size.

2. Check for proper m atching of tires.

3. Loose clamp plate nuts.

3. Replace damaged parts. Tighten nuts to proper torque.

4. Loose drive pinion nut.

4. Repair failed parts. Torque to specification.

5. Collector trough missing.

5. Repair, make certain front rear axle carrier cover has collector trough.

6. Pump failure.

6. Repair or replace as required.

7. Worn wedges and cams.

7. Replace.


8. Check ratios; both carriers must have same ratio.

9. Air leak or restricted line.

9. Repair or replace as required.

10. Seal failure.

10. Replace failed s eal.

11. Faulty control valve.

11. Replace.

12. Failed spring.

12. Replace.

13. Seized components.

13. Disassemble and investigate.

14. Failed shifter fork.

14. Replace.


1. Check ratios, both carriersmust have same ratio.

Power Divider Failure

Excessive Tire Scuffing or Wear

Troubleshooting and Diagnosing Mismatched Carrier Ratios for Tandem Carriers Check the tandem carrier for mismatched carrier ratios if any of the following conditions occur:

• • •

Tire scuffing or wear Noise in the power divider or shortened power divider life Noise in the transmission in various gears

Mismatched carrier ratios can transmit noise through the drive line and transmission. 36

Group 46

Carrier Identification Stamping

Carrier Identification Stamping If mismatched carrier ratios are suspected, check the carrier identification stampings for matched ratios.

W4031771

Fig. 2 Carrier Ratio Stamping Location 1. Ratio If mismatched carrier ratios are suspected, check the carrier identification stampings for matched ratios. If the stampings are compatible and mismatched ratios are still suspected, mark the tandem axle tires with a piece of chalk so that one complete wheel rotation can be monitored when the chassis is moved across the floor. Also, mark the propeller shaft and intermediate shaft yoke in reference to the pinion, carrier or power divider housing.

CAUTION Make sure the eight tandem rear tires are properly matched. Refer to MACK Service Manual 15-101 Wheels, Rims and Tires.

1 With an operator in the cab and the transmission in neutral, release the spring brakes. Make sure there is sufficient room to push the chassis forward one complete wheel rotation. 2 Push the chassis forward and count the number of shaft rotations during one complete wheel rotation. For example, with a 5.31 carrier ratio, the driveshaft will rotate 5 times to one tire rotation.If a variation exists between tire revolution and/or driveline rotation between front rear and rear rear carriers, a physical inspection of each gear set must be made.

37

Group 46

Gear Set Inspection

Gear Set Inspection Drain the upper gear case. Remove the bevel gear compartment side access cover. Count the teeth of the bevel gear set (1) in each carrier.

W4031772

Dual Reduction Carrier Gear Train

If the bevel gear sets are compatible, drain the tandem axle housing and remove the carrier assemblies. Count the teeth of each helical pinion shaft and bull gear (2).Example: Correct all mismatched gear sets. 1. Bevel gear — 23 teeth 2. Bevel pinion — 15 teeth 3. 23/15 = 1.53 4. Helical bull gear — 45 feet 5. Helical pinion gear — 13 teeth 6. 45/13 = 3.46 7. 1.53 x 3.46 = 5.31 Ratio Correct all mismatched gear sets.

38

Group 46 Differential Carrier, Dissassemble-Assemble

Differential Removal

Service Procedures 4651-04-11-01 Differential Carrier, Dissassemble-Assemble You must read and understand the precautions and guidelines in Service Information, groups 40 and 70, "General Safety Practices" before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it.

Differential Removal Note: Set all major components on a clean work surface for later disassembly. Note: This procedure is also used when removing the interwheel power divider or the four-pinion type differential. 1 Remove the 5th wheel.

W4034628

1. Hidden Mounting Bolts

2 Remove driveshaft (s). 3 Remove torque rods and bracket. 4 If equipped, disconnect Power Divider Lock Out (PDLO) air line. 5 Remove the bevel gear compartment cover and both of the inside carrier mounting bolts. 6 Remove the remaining 14 bolts and washers retaining the carrier housing to the axle housing. 7 Remove the carrier from the vehicle. Note this may require removal of the entire axle housing to access the carrier. 39



8 Set the carrier in an approved carrier repair stand such as J 3409-D. J 3409–D

W4032183

9 Secure the carrier to the stand with a minimum of four bolts and tighten securely. 10 Rotate stand holding the carrier housing so the differential assembly is on top.

40



11 Remove the cotter pin and the straight pin in the adjustable differential bearing cap.

W4032184

1. Cotter Pin 2. Straight Pin

W4032185

1. Straight Pin

41



12 Punch-mark bearing caps and their mating pedestals to ensure reassembly in their original positions.

W4032186

W4032187

13 Using differential bearing-nut adjusting wrench J 26437, loosen the bearing adjusting nut approximately one turn. Note: Bearing retainer caps and the carrier housing are machined as a set. Therefore, when bearing retainer caps are lost or broken, the carrier housing and bearing retainer caps must be replaced as a set. J 26437

W4032188

42



14 Remove the bearing retainer bolts.

W4032189

15 Remove the bearing retainer caps. Be very careful not to lose them.

W4032190

16 Using a hoist and appropriate lifting tool to remove the differential/bull gear assembly.

W4032191

1. Appropriate Lifting Tool

43


Removing the Inter-Axle Through Shaft

Removing the Inter-Axle Through Shaft 1 Remove the bolts from the inter-axle through-shaft rear bearing cover.

W4032192

2 Remove the cover and gasket from the through-shaft rear bearing cover.

W4033408

1

Cap

2

Gasket

3 Pull out the inter-axle through shaft and the inter-axle throughshaft bearing together. Note: The non-current axle through shaft was constructed of a driveshaft combined with a spring to form the oil groove on the through shaft. The current axle through shaft is constructed with a formed, rolled oil groove on the shaft. The two versions are interchangeable.

W4032194

44



4 Install two 3/8 jack screws into the threaded holes in the through-shaft housing.

W4032195

5 Back out the bearing retainer by alternately turning the jackscrews. Alternate, even turning of the jackscrews is essential to prevent the retainer from binding or becoming cocked in the bore. Note: Before removal, note the position of the inter-axle through-shaft retainer oil trough so that it can be reinstalled in the proper position.

W4032196

1. Jackscrews

W4032197

1. Oil Trough

45



6 Remove the gasket from the inter-axle through-shaft retainer cap that mounts to the housing surface.

CAUTION Removing the gasket may require using a gasket scraper. Use caution to prevent damage to the mating surface.

W4032198

7 Remove the front power-divider lockout-assembly bevel pinion assembly (if equipped).

WARNING If removing the inter-axle power divider as a unit, be extremely careful. It is very heavy. Get help or secure it to a hoist to prevent it from falling and causing personal injury.

W4032199

46


Bevel Pinion Housing Removal (Front Rear or Rear)

Bevel Pinion Housing Removal (Front Rear or Rear) Note: This section shows the removal of the front bevel pinion. At the front of the bevel pinion is the Inter-Axle Power Divider (IAPD). Because the IAPD with bevel pinion units are very heavy, you may want to remove the cage assembly first. 1 Remove the bolts that retain the front rear or rear rear bevel housing to the carrier housing.

W4032200

2 Install alignment dowels in bolt holes at the two-o'clock and teno'clock positions to support bevel housing during removal. This is necessary to prevent damage to the shim packs. Note: Alignment dowels can be manufactured on site from bolts obtained locally. Dowels should be about 63.6 mm (2.5 in.) long and with 13 mm (0.5 in.) threads.

W4032201

Fig. 3 Making Alignment Dowels

W4032202

1. Aligning Dowels

47


Bevel Pinion Housing Removal (Front Rear or Rear)

3 Loosen bevel housing by tapping with a deadblow hammer and then turning slightly. Using jack bolts, back assembly out on alignment pins and remove from carrier. Wire shims together and tag for reuse at assembly. Using a micrometer, measure the shim pack for reassembly purposes.

W4031122

W4030932

1. Shim Pack 2. Aligning Dowel

48


Removing the Helical or Pinion Shaft

Removing the Helical or Pinion Shaft 1 Remove the four bolts retaining the helical pinion-shaft assembly cover.

W4032203

2 Remove the pinion cover and separate the gasket from the cover. It may be necessary to use a gasket scraper to remove some gaskets from the cover. Note: A steel-core gasket coated on both sides with foam rubber has replaced Silastic sealer which was applied to the pinion shaft cover. Make sure a new steel-core gasket is available for reassembly to eliminate oil leakage in this area.

W4034630

1. Gasket 2. Cover

49


Removing the Helical or Pinion Shaft

3 Remove the clamp plate bolts and the clamp plate. Replace the clamp plate bolts with new grade 8 bolts at final reassembly. Note: Be sure to have new bolts on hand for final reassembly. Note: The clamp-plate side stamped "OUT" faces outward. This ensures that the clamping force is evenly distributed upon installation.

W4034631

W4034632

4 Set up a gear puller to push the helical pinion-shaft assembly into the carrier housing. This action will release the helical pinion from the outer bearing cone. Be prepared for the weight of the helical pinion assembly.

W4032204

50

Group 46 46 Differential Differential Carrier, Dissassemble-Assemble

Removing Removing the Helical Helical or Pinion Shaft

5 Remove Remove the bearing bearing cone from from the outboard outboard side.

W4034633

6 Remove the pinion shaft assembly.

W4032206

7 Using Using two jackscrews, jackscrews, remove remove the helical pinion-s pinion-shaft haft bearing bearing retainer.

W4032207

51


Removing Removing the Helical Helical or Pinion Shaft

8 Remove Remove the bearing bearing retainer retainer and shim pack. pack. Remove shims, shims, and wire together. together. Using a micrometer, micrometer, measure the shim pack. Tag for reuse at reassembly.

W4032208

52


Four-Pinion Four-Pinion Type Type Differential Differential

Four-Pinion Type Differential Differential Before Before starting starting to disassemble disassemble the bull gear/dif gear/differenti ferential al compocomponents, nents, mark the position position of each differ differentia entiall half/side half/side casing casing in relation to the bull gear. gear. These components components are line-reamed and turned together together.. Therefore, Therefore, it is essential to reassemble reassemble them in the same position. position.

1 Clamp Clamp the bull gear/different gear/differential ial assembly assembly in a suitable suitable vise. Loosen the bolts that secure the side casings to the bull gear.

W4031773

Fig. 4 Bull Gear/Differential Gear/Differential Bolts Loosened

2 During During disassemb disassembly ly,, mark the bull gear relationsh relationship ip to the casing. Mark both sides of the bull gear for reassembly reassembly purposes. purposes.

W4031825

1. Bull Gear Mark 2. Casing Mark

53


Four-Pinion Type Differential

3 Remove the bull gear from the differential side-casing splined half. Do this by tapping around the bull gear with a deadblow hammer, or by forcing the components apart with a piece of brass bar stock and a machinist's hammer.

W4031826

Fig. 5 Using Deadblow Hammer to Separate Differential Half

W4058493

Fig. 6 Separating Bull Gear from Side Casing — Alternate Method

54



4 Remove the differential half.

W4031835

5 Remove the side-gear thrust washer.

W4031842

55



6 Remove the side gear.

W4031846

Fig. 7 Removing Side Gear

W4058492

Fig. 8 Side Gear Removed

56



7 Remove the spider gear assembly. This assembly includes the spider, the four pinion (spider) gears and the four pinion (spider) gear thrust washers.

W4031848

Fig. 9 Spider Gear Assembly

W4058491

Fig. 10 Differential with Spider Gear Assembly Removed

1 When the spider gears are removed, the other side gear is visible. Remove the remaining side gear and thrust washer.

W4031850

57



2 If inspection reveals the need to do so, replace the bearings on the differential halves using a hydraulic press and the appropriate segment and adapter rings. Press the bearings off the side casings.

CAUTION Exercise extreme caution during the pressing operation, even when using specified tools. The bearing cone may fly apart during removal. Use a scatter shield and be sure to have a new bearing cone ready for installation.

Note: Note the timing marks on the bull gear and the splined differential half. W4031856

Fig. 11 Removing Bearing Cone from Side Casing

W4058490

Fig. 12 Bull Gear Timing Marks

3 The two timing marks on the bull gear (twelve o'clock) must fall on each side of the single timing mark on the differential half (twelve o'clock).

58


Inter-Wheel Power Divider Differential — Disassembly

Inter-Wheel Power Divider Differential — Disassembly 1 Remove the bolts from the splined side of the inter-wheel power divider. It may be helpful to support the assembly in a vise.

W4031868

2 Mark both sides of the unsplined differential half and the bull gear for proper reassembly. 3 Remove the unsplined differential half.

W4031875

4 Remove the outer cam.

W4031876

59



5 Remove the inner cam.

W4031878

6 Remove outer retaining ring.

W4031879

7 Remove the wedges. 8 Using a suitable hydraulic press, press out the splined inner half of the power divider from the bull gear.

W4031880

1. Press 2. Plate



9 Remove the oil-trough bolts.

W4031881

10 Remove oil trough.

W4031882

11 Remove inner wedge retaining ring.

W4031883

12 If inspection reveals that the power-divider driving cage bushing must be replaced, remove the bushing.

61



13 If inspection reveals the need to do so, replace the bearings on the inner wheel power-divider driving cage and side casing using a hydraulic press and the appropriate segment and adapter rings. Press the bearing off the inner wheel power-divider driving cage.


W4031884

Fig. 13 Removing Bearing Cone from Driving Cage

W4058489

Fig. 14 Removing Bearing Cone from Side Casing

62


Inter-Axle Power Divider Cage — Disassembly

Inter-Axle Power Divider Cage — Disassembly 1 Remove the bolts from the inter-axle power-divider cover plate.

W4031886

2 With the cover plate removed, insert two 7/16-14 jackscrews to separate the bearing, housing, cage and wedge assembly from the bevel pinion housing.

W4058163

1. Jack Screw

3 Remove the inner cam, cage and wedge assemblies as a unit.

W4031888

1. Inner Cam 2. Cage

63



4 Remove the O-ring from the bearing retainer groove of the cage and wedge assembly.

W4031889

1. O-Ring

5 To replace the wedges, the retaining ring must first be removed. Push all upper wedges in as far as possible. Then remove retaining ring with expansion pliers. Note: Before removing the wedges, note the alpha character (an arrow on early production carriers) on the part of the wedges pointing outward. Reinstall the wedges with the alpha character or arrow pointing outward.

W4031890

1. Outer Retaining Ring

6 Remove the wedges by pulling straight out with finger pressure.

W4031891

Fig. 15 Arrow on Wedges (May Also Be an Alpha Character)

64



7 The inner ring can now be removed easily. Use two screwdrivers to compress the retaining ring until the ends overlap to allow removal.

WARNING Be careful when removing the inner ring. It may be sharp and can cause serious personal injury.

W4031892

8 Use a hydraulic press to separate the cage from the bearing retainer cover. Support the bearing inner race. Do not apply force through the bearings. 9 Remove the O-ring from the cover plate.

W4031893

1. O-Ring

10 Remove seal from cover plate using a suitable driver.

W4031894

1. Driver


Front Rear Bevel Pinion — Disassembly Disassembly

Front Rear Bevel Bevel Pinion — Disassembly Disassembly 1 Using Using a torque multiplier multiplier (OEM 6107) or equiva equivalent lent and socket socket (J 28721-906) 28721-906) or equivalent, equivalent, loosen loosen and remove the retaining retaining nut on the front bevel pinion. pinion. Bosch tool J 33107 is recomrecommende mended d for holdin holding g the outer outer cam. cam. OEM 6107, 6107, J 28721-906, 28721-906, J 33107

W4031895

1. Socket, 76.2 mm (3.0 in) 2. J33107

2 Install Install the holding holding fixture fixture in a press press stand or other other stand capable capable of holding holding the fixture fixture secure secure against against the 1762 to to 2034 Nm (1,300 to 1,500 lb-ft ) of torque torque necessary necessary to release release the retainretaining nut. J331071762 J331071762 to 2034 2034 Nm (1,300 to 1,500 1,500 lb-ft lb-ft )

W4031896

3 Install Install the socket socket in the holding holding fixture. fixture. J28721–906

W4031897

66



4 Using Using a torque multiplier multiplier and a press stand stand or other suitable suitable method, method, hold the the fixture fixture in the power-di power-divider vider lockout lockout housing housing and remove remove the retaini retaining ng nut.

W4031898

Fig. 16 Using Torque Torque Multiplier Multiplier to Loosen Nut 1. Torque Torque Multiplie Multiplierr OEM 6107 2. Ratchet Ratchet Handle Handle

W4031900

Fig. 17 Retaining Retaining Nut Removed Removed 1. Retaining Retaining Nut

67



5 Using Using a hydraulic hydraulic press, separate separate the bevel pinion pinion shaft and gear gear from the bevel bevel housing housing.. Also Also remove remove outer outer cam from bevel bevel housing.

W4031899

1. Suitable Suitable Press 2. Press Extension

6 Using Using a drift and hammer hammer,, remove the inner inner bearing bearing cup in the housing.

W4032048

1. Bearing Bearing Race

7 Turn Turn the housing over. over. Then use a drift and hammer hammer to remove the outer outer bearin bearing g cup. cup.

W4032049

1. Bearing Bearing Race


Front Rear Bevel Pinion — Disassembly

8 If the bearings on the bevel pinion must be replaced, remove them using a hydraulic press and the appropriate segment and adapter rings. Press the bearing off the front bevel pinion.


W4032071

Fig. 18 Pressing Bearing Off Bevel Pinion

W4058488

Fig. 19 Pressing Bearing Off Outer Cam

69


Front Rear Bevel Pinion — Disassembly

9 Note and record the numerals stamped into the pinion. They represent the mating number (U337) and the mounting distance 105 mm (4.135 in.). Note: The actual mating number and mounting distance number will probably differ from U337 and 105 mm (4.135 in.) which are used here as examples. The mating numbers on the bevel pinion and the bevel gear will always be the same. These components must always be replaced as a set.The mounting distance represents the distance from the backface of the head of the bevel pinion to the center line of the bevel gear. This number helps in determining how many shims must be installed to get the proper gear pattern. W4032073

Fig. 20 Mating Number and Mounting Distance Number 1. Mating Number 2. Gear Mounting Distance 3. Pinion Mounting Distance

W4032074

1. Bevel Pinion Head 2. Bevel Pinion Housing 3. Mounting Distance 4. Centerline of Bevel Gear

70


Rear Rear Bevel Pinion — Disassembly

Rear Rear Bevel Pinion — Disassembly 1 Remove the bolts from the rear bevel pinion bearing retainer cover and remove the cover. Remove clamp plate nut. Remove yoke.

W4034828

W4034073

W4034075

71



2 Press out pinion.

W4049400

1. Press 2. Press Extension 3. Bevel Pinion

W4049401

1. Bevel Pinion Gear 2. Rear Rear Bevel Pinion Housing

72



3 Remove outer bearing cup and seal.

W4034077

4 Remove the inner bearing cup.

W4034076

5 Remove the spacer from the bevel pinion shaft.

73



6 Remove bearing cone from pinion.

W4034078

W4030832

W4058484

1. Mating Number 2. Mounting Distance

74


Helical (Spur) Pinion Shaft — Disassembly

7 Note and record the numerals stamped into the pinion. These numerals represent the mating number (A13) and the mounting distance 124 mm (4.875 in.). Note: The actual mating number and mounting distance number will probably differ from A13 and 124 mm (4.875 in.), which are used here as examples. The mating numbers on the bevel pinion and the bevel gear will always be the same. These components must always be replaced as a set. The mounting distance represents the distance from the backface of the head of the bevel pinion to the center line of the bevel gear. This number helps in determining how many shims must be installed to get the proper gear pattern.

W4058487

1. Bevel Pinion Head 2. Bevel Pinion Housing 3. Mounting Distance 4. Centerline of Bevel Gear

Helical (Spur) Pinion Shaft — Disassembly 1 Secure the helical pinion shaft assembly. Remove and discard the bolt that retains the inboard clamp plate. Replace with new grade 8 nuts at reassembly. Note: Be sure to have replacement bolts for final reassembly.

W4030833

75



2 Remove the clamp plate.

W4034618

3 Place the pinion shaft into a hydraulic press. Press the helical pinion shaft from the helical gear.

W4032078

1. Press 2. Press Extension 3. Bevel Gear

4 Remove the key from the helical pinion shaft using a pin punch and hammer. Helical pinion shaft key use depends on ratio.

W4032080



5 Press out the helical shaft from the bearing using the bearing cup for support or suitable puller. This action applies pressing force through the bearing rollers.


Note: Be sure a replacement bearing is available for final reassembly.

W4032081

1. Helical Pinion 2. Press 3. Press Extension 4. Bearing

6 Using a hammer and drift, remove the helical-pinion retainer bearing outer cup.

W4032083

77



7 Remove the O-ring from the retainer.

W4032084

8 Using a hammer and drift, remove the remaining helical pinion bearing cup from the carrier housing.

W4032085

78


Power Divider Lockout — Disassembly

Power Divider Lockout — Disassembly WARNING Be very careful when removing the power-divider lockout cylinder housing from the unit. It is spring loaded and the spring can release if the nut on the inside is broken or stripped, or the shaft is broken.

1 Remove the bolts retaining the cylinder housing onto the powerdivider lockout housing.

W4032086

2 Remove the cylinder housing.

W4032087

3 Remove the nut and washer that hold the piston and spring in place.

WARNING Be careful when removing the nut that holds the piston and spring. The piston or spring can suddenly release, causing serious personal injury.

79



4 Remove the piston from the shaft by sliding it straight off.

W4032088

5 Remove the piston return spring.

W4032089

6 Remove the spacer and remaining washer from the piston shaft.

W4032090

1. Spacer

80



7 The graphic shows the components and assembly order that complete the piston and spring assembly. Ensure all of these components are present. Set them aside for reuse if all are in good condition.

W4032091

1. Spacer 2. Spring 3. Washer 4. Piston 5. Locknut

8 Remove the air cylinder gasket.

W4032092

1. Gasket

81



9 Remove the cover plate bolts from the power divider lockout housing.

W4032093

10 Remove the cover plate.

W4032094

11 Remove the cover plate gasket (or Silastic sealer if applicable). Make sure the surface of the cover plate is clean.

W4032095

1. Gasket

82



12 Remove the locking bolt from the shaft and fork.

W4032096

13 Remove the shift fork shaft.

W4032097

14 Remove the nuts from the bearing retainer cover.

W4032098

83



15 Remove the bearing retainer cover.

W4032099

16 Remove the bearing retainer cover O-ring.

W4033420

17 Using a hammer and driver, remove the seal from the bearing retainer.

W4032101

84



18 Using a hydraulic press, separate the shaft and cage assembly from the power divider clutch.

CAUTION During the pressing procedure, take special care to avoid binding the fork, which can cause the fork to break.

19 Remove the fork and clutch from the power-divider lockout housing.

W4032102

1. Power Divider Cage 2. Shift Fork 3. Clutch

20 Using a drift and hammer, remove the ball bearing from the housing. Apply force only to the outer race of the bearing.

W4032103

1. Brass Drift 2. Bearing Outer Race

85



21 Press all the wedges into the cage as far as possible. Then remove the outer retaining ring from the shaft and cage assembly. Note: Before removing the wedges, note the alpha character (or arrow on early production carriers) on the part of the wedges pointing outward. The wedges must be reinstalled with the alpha character or arrow pointing outward.

W4032104

22 Remove the wedges from the cage.

W4032106

23 Locate the inner ring in the cage.

W4032107

1. Inner Ring

86


Inter-Axle Through Shaft — Disassembly

24 Using two screwdrivers, compress the inner retaining ring until the ends overlap to allow removal. Remove the inner ring.

WARNING Be careful when removing the inner ring. It may be sharp and can cause serious personal injury.

W4032137

1. Inner Ring

Inter-Axle Through Shaft — Disassembly

W4032138

If the through-shaft bearing must be replaced, remove the bearing using a suitable hydraulic press arrangement.

87


Inter-Axle Through Shaft — Reassembly

Inter-Axle Through Shaft — Reassembly Note: The reassembly procedures in the first part of this section for Inter-axle Through-shaft, Inter-axle Power Divider with/without Lockout and Front Rear Bevel Pinion will only be encountered on vehicles with a tandem rear axle. Install the through-shaft bearing using a suitable hydraulic press arrangement and driver.

WARNING Ensure that the hydraulic press support blocks are on the flats of the shaft and not on the taper of the shaft. This prevents the blocks from shifting as hydraulic pressure is applied.

W4032139

1. Press Extension 2. Bearing

Power Divider Lockout — Reassembly 1 Position a new seal on the power-divider bearing retainer cover.

W4032140

88


Power Divider Lockout — Reassembly

2 Install the seal into the bearing retainer cover using seal driver and a hammer.

W4032141

1. Driver 2. Cover

3 Install the power-divider wedge inner ring into the cage.

WARNING Be careful when inserting the inner ring, because it may be sharp.

W4032137

Fig. 21 Installing Inner Ring 1. Inner Ring

W4032107

Fig. 22 Inner Ring Installed 1. Inner Ring

89



4 Install a matched set of 24 wedges from inside the cage, making sure the alpha character (or arrow on early production carriers) is pointing outward. The alpha character or arrow must be visible on each wedge from outside of the cage. Note: The wedges must be reinstalled with the alpha character or arrow pointing outward as shown in the illustration.

W4032106

5 Push all the wedges in as far as possible and install the outer retaining ring into the slot provided in the cage.

W4032104

6 Drive the bearing assembly into the retainer of the inter-axle power-divider shifter housing. Note: Apply driving force only on the bearing outer race during bearing installation.

W4032143

1. Bearing Race 2. Bearing Driver

90



7 Insert the fork and clutch into the housing. Do this by installing the fork into the clutch groove and then angling them as a unit into position. Make sure that the flat side of the fork faces the clutching teeth.

W4032144

1. Flat side toward clutching teeth

8 Insert the shaft and cage assembly into the sliding clutch. 9 Using a suitable hydraulic press, press the power divider cage into the bearing.

CAUTION During the pressing procedure, take special care to avoid binding the fork, which can cause the fork to break.

W4032145

1. Press 2. Press Extension 3. Power Divider Cage 4. Press Plate

10 Install a gasket on the power-divider lockout housing face.

91



11 Lightly lubricate the O-ring and install into the groove in the bearing retainer (oil seal) cover.

W4032146

12 Install the oil seal cover onto the power divider lockout housing with nuts finger tight. Check the gap between the housing and the cover using a feeler gage. This gap should not exceed 0.254 mm (0.010 in.). If a gap exists and exceeds 0.254 mm (0.010 in.), install a gasket (shim) or gaskets (shims) as required to fill the gap. Note: This gasket (shim) will support the bearing retainer and prevent bearing retainer oil seal bore deflection. This deflection causes a bell mouth condition of the seal bore, resulting in a loose oil seal installation. 0.254 mm (0.010 in.)

13 Install the bearing retainer cover onto the power divider lockout housing with gasket (shims), if required.

W4032099

92



14 Install the bolts through the bearing retainer cover and into the housing. Torque nuts to specification.

W4032147

15 Install a new felt ring and O-ring on the shift piston. Install the O-ring in the top groove and the felt washer in the lower groove. Lubricate the O-ring and the felt ring with GO-J gear oil. 16 Place the shift fork shaft, threaded end up, into a soft-jawed vise. Install the special washer, the piston assembly, an additional special washer and a new Nylok nut on the shaft. Tighten nut to specification. Remove the shift fork shaft from the vise. 17 Position the long spacer (sleeve) and the return spring onto the shift fork shaft. Install the shaft assembly into the housing. Align shaft with shift fork opening and insert shaft into fork.

93



18 Using a hydraulic press, compress the piston spring assembly until the setscrew holes in both the shaft and fork align. Insert the setscrew and tighten to specification. Note: Use a screwdriver or wooden wedge to support the shift fork while compressing the spring to avoid binding the fork on the shaft.

W4032148

1. Press 2. Press Extension 3. Piston

W4032149

19 Install the shifter cylinder housing gasket.

W4032150

94



20 Install the cylinder housing and housing nuts.

W4032087

21 Install cover gasket or apply a bead of Silastic or equivalent to the cover plate, completely encircling the screw holes.

W4032151

1. Gasket

22 Install the cover plate.

W4032152

95


Inter-Axle Power Divider without Lockout — Reassembly

23 Torque the cover plate bolts on the power divider lockout to specification.

W4032153

24 Torque the bolts on the cylinder housing to specification. Dip the inner cam in axle lubricant and position it inside the cage. It will fit only one way. Push all the wedges in until they contact the inner cam lobes. Set the assembly on a clean work surface, with the cage up to keep the inner cam from falling out. A coating of heavy grease may be applied to the inner cam face to hold it in place during assembly. This assembly will be installed into the bevel pinion housing at a later time.

W4032154

Inter-Axle Power Divider without Lockout — Reassembly 1 Align bearing with the bearing retainer. Then install the ball bearing into the retainer using a plastic hammer. Drive the bearing into the retainer until it is seated. Apply force only to the outer race.

W4032155

96



2 Use a press to install the ball bearing and retainer onto the shaft of the power divider cage.

W4032156

1. Press 2. Press Extension 3. Bearing

3 Install the inner ring into the center of the power divider cage.

WARNING Be careful when inserting the inner ring. It may be sharp and capable of causing serious personal injury.

W4031892

1. Inner Ring

4 Install the power divider wedges into the cage assembly. Note: Before inserting the wedges, note the arrow or alpha character on the part of the wedges pointing outward. The wedges must be installed with the arrow or alpha character pointing outward.

W4031891

97



5 Push the top row of wedges in even with the cage surface to allow installation of the outer ring.

W4032157

6 Using the proper snap ring pliers, install the power-divider wedge outer retaining ring.

W4031890

1. Outer Retaining Ring

7 Install the O-ring onto the power-divider bearing retainer plate. Note: Lubricate the power divider inner cam and wedge assembly with GO-J before installation.

W4031889

1. O-Ring

98



8 Install the inner cam into the cage and wedge assembly. A coating of heavy grease may be applied to the inner cam face to hold it in place during assembly. Note: Be sure the oil grooves on the face of the inner cam go toward the pinion. 9 Install a new seal in the cover plate using a driver and a hammer.

W4032158

1. Driver

10 Lightly lubricate the O-ring and install it into the groove in the oil seal cover.

W4031893

1. O-Ring

11 Loosely install the bolts through the inter-axle power-divider oil seal cover and bearing retainer. Set the assembly on a clean work surface, with the cage up to keep the inner cam from falling out. This assembly will be installed into the bevel pinion housing at a later time.

99


Front Rear Bevel Pinion — Reassembly

Front Rear Bevel Pinion — Reassembly Note: The bevel pinion-shaft front rear assembly will only be encountered on vehicles with a tandem rear axle. If the vehicle being worked on has a single rear axle, this section does not apply. 1 Press the inner bearing cup into the bevel pinion housing.

W4032159

1. Extension Plate 2. Plate 3. Press Spacer 4. Bearing Cup Installed in Hub 5. Bevel Housing Bearing Hub

2 Turn over the housing and press the outer bearing cup into the bevel pinion housing.

W4032160

1. Press 2. Bevel Pinion Housing 3. Press Plate

100



3 The numerals on the back of the bevel pinion gear and the mating bevel gear represent the mating number and the mounting distance.

W4032073

1. Mating Number 2. Gear Mounting Distance 3. Pinion Mounting Distance

4 Note and record the mounting distance. These distances are needed to determine the shim pack thickness. Note: Make sure the bevel pinion and mating bevel gear are identified as a matched set. 5 Press the bearing cone onto the bevel pinion shaft.

W4032161

1. Bearing 2. Press 3. Press Spacer 4. Bevel Pinion

101



6 Place the selective bearing spacer on the pinion, with the chamfer side down.

W4032162

1. Spacer: Chamfer Down 2. For Some Ratios, extra spacer may be needed underneath washer

7 Install the power divider housing onto the bevel pinion.

W4032163

8 Press outer bearing core on pinion.

W4034079

102



9 Position the power divider outer cam on the bevel pinion shaft.

W4030836

10 Using a hydraulic press, install the outer cam of the power divider onto the bevel pinion shaft.

W4032164

1. Plate 2. Bevel Pinion Housing 3. Press 4. Outer Cam

103


Setting the Bevel Pinion Preload

Setting the Bevel Pinion Preload To perform at maximum efficiency, tapered roller bearings must operate under a predetermined preload. This also ensures a rigid mounting for the gears.

Setting the Preload Set bearing preload after the bevel pinion is assembled into the housing. Apply 20,000 pounds (10 tons) of pressure to the bearing in a hydraulic press. Rotate the pinion housing (bearings) before applying full pressure to the bearings. This will prevent premature bearing failure.

Note: Make sure to lubricate the bearings with oil before performing the bearing preload check. 1 Wrap several turns of cord around the bevel pinion housing at the pilot area. Attach scale J 8129, or equivalent, to the cord and slowly and evenly pull on the scale until the housing rotates. The correct load on the scale should be between 3 and 6 pounds for new bearings, and 2 to 4 pounds for used bearings. If the reading on the scale is not within the correct specifications, it is necessary to replace the original spacer. Use a thinner spacer if it takes less than the specified amount of pull to rotate the housing. Use a thicker spacer if the required load exceeds specification. Note: A thinner spacer increases preload. A thicker spacer reduces preload. Note: If bearings are in good condition, they can be reused for rebuilding a carrier. If used bearings are placed back into a carrier, a good rule of thumb is that the force needed to turn the scale while under 20,000 pounds of preload is about one half the requirement of new bearings. This is why used bearings have a 2-4 pound specification rather than the 3-6 pounds specified for new bearings.

W4032165

W4032166

1. Selective Bearing Spacer

104


Setting the Preload

2 After determining the correct bearing preload, install a new power divider retaining nut. Coat the threads with Loctite® 262 before installing. Note: In emergency cases, the old nut may be used. In either case (using new or old nut), thoroughly clean and prime the threads of the bevel pinion and the cam nut. The threads must then be coated with Loctite 262.

CAUTION Do not allow the Loctite 262 to drip into the bearings, as it can cause bearing failure. W4032167

3 Install the holding fixture in a stand capable of holding the fixture secure against the 1762 to 2034 Nm (1,300 to 1,500 lb-ft ) of torque necessary to tighten the retaining nut. 1762 to 2034 Nm (1,300 to 1,500 lb-ft )

W4031896

4 Install the socket in the holding fixture. 5 Tighten the retaining nut to the specified torque.

W4032168

1. Torque Multiplier OEM 6107

105


Setting the Preload

6 After tightening the nut to the correct torque, the assembly should look like the illustration.

W4032169

Fig. 23 Correctly Assembled Bevel Pinion

106


Determining Bevel Pinion to Carrier Housing Shim Pack


W4032170

1. Bevel Pinion Head 2. Mounting Distance 3. Bevel Pinion Housing 4. Centerline of Helical Pinion Shaft When reusing the bevel pinion that was removed from the carrier, also use the shim pack that was removed at disassembly upon reassembly and installation of the bevel pinion. When rebuilding a carrier, it is sometimes necessary to use a new bevel pinion. When this occurs, use the following procedure:

• • •

Determine the mounting distance on the disassembled bevel pinion (etched into original pinion) and compare it with the mounting distance on the new bevel pinion (etched into new pinion). If the new bevel pinion mounting distance is longer than the old (higher number), this amount of shim will have to be added to the new shim pack. If the new bevel pinion mounting distance is shorter than the old (lower number), this amount of shim will have to be removed from the shim pack.

For example: 4.878" OLD PINION - 4.875" NEW PINION = 0.003" SHIM DIFFERENCE In this case, remove 0.076 mm (0.003 in.) from the original shim pack. This procedure provides a good starting point for setting the gear patterns.

1 Set the assembly on a clean work surface to be installed into the carrier housing at a later time.

107


Rear Rear Bevel Pinion — Reassembly

Rear Rear Bevel Pinion — Reassembly 1 Press the outer bearing cup into the bevel pinion housing.

108



W4034081

W4032077

1. Mating Number 2. Mounting Distance

109



2 Press the inner bearing cone into the bevel pinion. The numbers on the back of the bevel pinion and bevel teeth represent the mating number and mounting distance.

W4030832

3 Record the mounting distance. These distances are needed to determine shim pack thickness. Make sure that the bevel pinion and mating bevel gear are identified as a matched set. 4 Using a suitable hydraulic press arrangement, press the inner bearing cone onto the bevel pinion shaft.

W4032161

1. Bearing 2. Press 3. Press Spacer 4. Bevel Pinion

110



5 Install the selective spacer with the tapered side toward the bearing.

W4034082

6 Install the bevel pinion housing over the bevel pinion. Place bevel pinion and housing assembly on a press stand. 7 Position the outer bearing cone onto the bevel pinion shaft and press it into place.

W4034083

111


Setting Bevel Pinion Preload

Setting Bevel Pinion Preload For maximum efficiency, tapered roller bearings must operate under a predetermined preload. This also ensures a rigid mounting for the gears.

Setting the Preload

W4034110

Set bearing preload after the bevel pinion is assembled into the housing. Use a hydraulic press to apply 20,000 pounds (10 tons) of pressure to the bearing. Rotate the pinion housing (bearings) as you apply full pressure to the bearings. This will prevent premature bearing failure.

Note: Make sure to lubricate the bearings before performing the bearing preload check. 1 Wrap a cord around the bevel pinion housing as shown. Attach scale J 8129, or equivalent, to the cord. Pull on the scale slowly and evenly until the housing rotates. J 8129

W4034110

112


Setting the Preload

2 To keep the housing rotating steadily, the correct load on the scale should read 3 to 6 pounds for new bearings, and 2 to 4 pounds for used bearings. If the reading is not within specifications, replace the original spacer. Use a thinner spacer if it takes less than the specified pounds of pull, or a thicker spacer if it takes more than the specified pounds to rotate the housing. Note: Bearings that are in good condition can be reused to rebuild a carrier. When reusing bearings, remember that the force needed to turn the scale while under 20,000 pounds of preload is about one half the requirement of new bearings. This is why used bearings have a 2-4 pound specification rather than the 36 pounds specified for new bearings. Note: Make sure to lubricate the bearings before performing the bearing preload check. 3 After the correct bearing preload has been determined, install the seal. 88800296

W4034111

W4034112



4 Install O-Ring on pinion housing.

W4034113

1. O-Ring

Determining Bevel Pinion to Carrier Housing Shim Pack When reusing the original bevel pinion, also reuse the shim pack that was removed from the carrier at disassembly. Sometimes it is necessary to use a new bevel pinion to rebuild the carrier.

• • •

Determine the mounting distance on the disassembled bevel pinion (etched into original pinion) and compare it with the mounting distance on the new bevel pinion (etched into new pinion). If so, use the following procedure: If the new bevel pinion mounting distance is longer than the old (higher number), this amount of shim will have to be added to the new shim pack If the new bevel pinion mounting distance is shorter than the old (lower number), this amount of shim will have to be removed from the shim pack

For example: 4.876" OLD PINION - 4.874" NEW PINION = 0.002" SHIM DIFFERENCE In this case, 0.051 mm (0.002 in.) must be removed from the original shim pack. This simple procedure provides a good starting point for setting the gear patterns.

1 Set the bevel pinion assembly (with the correct shim pack) aside temporarily on a clean work surface.

114


Helical (Spur) Pinion Shaft — Reassembly

Helical (Spur) Pinion Shaft — Reassembly The exploded view shows the parts of the helical pinion shaft assembly.

1 Using a suitable hydraulic press, install the bearing cone onto the helical pinion shaft. Note the direction of the bearing. 2 The pinion shaft will be either splined or keyed, depending on the ratio.

W4034619

1. Keyed Shaft

3 Using a machinist's hammer, install the key into the helical pinion shaft (if shaft requires a key).

W4034621

4 Start the bevel gear onto the helical pinion shaft, making sure that key slot in gear aligns with the shaft.

W4032171



5 Press the bevel gear onto the helical pinion shaft.

W4032172

1. Press 2. Press Plate 3. Bevel Gear 4. Pinion Shaft

6 Apply Loctite 262 to the threads of the nuts that will hold the clamp plate to the helical pinion shaft. 7 Secure the helical pinion shaft assembly in a soft-jawed vise. Insert the nuts that hold the clamp plate in place. 8 Tighten the nut to specification.

W4030850

9 Install the slotted inner bearing cup over the pinion and bearing cone.

116



10 Install the selective bearing spacer, with the tapered side down toward gear. Note that the thickness of this spacer determines bearing preload.

W4032173

1. Taper

11 Press the outer bearing cup into the helical pinion-bearing retainer. 12 Press the outer bearing cup into the helical pinion-bearing retainer. 13 Install a new O-ring on the helical pinion bearing retainer.

W4032174

1. O-Ring

14 Install the bearing retainer over the pinion shaft. 15 Ensure that the retainer lock pin aligns with the slot in the inner bearing cup.

W4032175

16 Install the outer bearing cone on the helical pinion shaft. 117


Setting the Preload

17 Press the outer bearing cone into place.

Setting the Preload With the helical pinion shaft in the press, apply 20,000 pounds (10 tons) of pressure to the helical pinion shaft assembly. Using a spacer between the bevel gear and press (to prevent damage to the clamp-plate screw heads), wrap a cord around the bearing retainer several times as shown. Attach scale J 8129, or equivalent, to the cord and steadily pull on the scale until the retainer rotates slowly and evenly. Begin rotating the assembly before full pressure is applied to the bearings. This will prevent premature bearing failure.

Note: Make sure to lubricate the bearings before performing the bearing preload check.

W4032176

1. Press 2. Plate 3. Scale J8129 The correct load on the scale should read about 3–6 pounds for new bearings, and 2–4 pounds for used bearings. If it takes more than the specified amount of pull, use a thicker spacer. If it takes less than the specified amount of pull, use a thinner spacer.

118


Setting the Preload

W4032177

1. A thinner space increases the preload 2. A thicker spacer reduces the preload

W4033407

1. Scale 2. Selective Bearing Spacer

1 After the correct bearing preload has been established, remove the assembly from the press. Disassemble the outer bearing cone, spacer and bearing retainer from the shaft assembly. Remove the inner bearing cup from the shaft assembly.

119


Setting the Gear Patterns

Setting the Gear Patterns After setups for the bevel pinion and helical pinion subassemblies have been completed, the gear patterns must be properly set. If the disassembly instructions for these subassemblies have been followed as described, the existing shim pack thickness should have been measured and recorded, providing a basis on which to begin the gear pattern adjustment procedure.

Note: The mounting distance stamped on the back of the bevel pinion teeth represents the distance from the backface of the head of the bevel pinion to the centerline of the bevel gear. The mounting distance on the back of the bevel gear teeth represents the distance from the backface of the bevel gear to the centerline of the bevel pinion. This number helps in determining the shims which will have to be installed to achieve the desired gear pattern.

W4032074

1. Scale 2. Bevel Pinion Housing 3. Mounting Distance 4. Centerline of Bevel Gear

Note: If the dimension number on the new bevel pinion or bevel gear is greater than the old, the shim pack must be increased by the same amount. If the dimension number on the new bevel pinion or bevel gear is less than the old, the shim pack must be decreased by the same amount.

120


Setting the Gear Patterns

1 Install the established shim pack onto the helical pinion bearing retainer.

W4032179

1. Shim Pack

2 Using alignment pins, install the bearing retainer into the carrier housing. Position the retainer so that the opening faces the bull gear. Note: Make alignment pins from bolts obtained locally. Pins should be about 63.5 mm (2.5 in.) long with 13 mm (0.5 in.) of thread. 3 Install two cover bolts to hold the bearing retainer in the carrier housing for installation of the inner bearing cup. 4 Torque the bearing retainer nuts to specification. 5 Mark the carrier housing next to the location of the lock pin. 6 Position the inner bearing cup so that the slot in the cup aligns with the mark. 7 Install the slotted inner bearing cup into the carrier housing using hand pressure to start, then tapping with a driver and hammer. Note: The inner bearing cup slot must align with the bearing retainer locating pin.

W4032180

1. Driver

8 Insert the shaft assembly, with the established spacer, into the carrier housing. Position a block of wood in the housing to support the shaft assembly. 9 Install the outer bearing cone onto the end of the pinion shaft. 121


Bevel Pinion Installation

10 Install the clamp plate and old bolts. Torque nuts to specification using a pinch bar or jamming tool between the spiral bevel gear and housing to jam the gear. Note: Tighten the nuts retaining the clamp plate in stages until the recommended torque is obtained. 11 Rotate the assembly. The unit should turn with some drag. If it will not turn, return to and recheck bearing preload. 12 Loosen the three clamp-plate nuts to relieve the preload. Tap with a hammer to loosen the bearing. 13 Retorque the three clamp-plate bolts to specification using the pinch bar or jamming tool to jam the gear.

Bevel Pinion Installation The bevel pinion (which was preassembled in a previous section) is now ready to be fitted to the carrier housing for backlash and gear pattern checks. The bevel pinion can be installed only after the helical pinion shaft. Make sure the drive yoke is installed and properly tightened before performing the backlash check. Otherwise, a false reading will be obtained.

1 Install the established bevel pinion shim pack over the alignment pins. The alignment pins should be used because they will retain the shim pack while installing the bevel pinion. Note: Make alignment pins from bolts obtained locally. Pins should be about 63.5 mm (2.5 in.) long with 5/8-inch threads.

CAUTION Shims must not block oil holes.

122



2 Shims must not block oil holes. Note: Make sure to install and properly tighten the drive yoke to the rear bevel pinion assembly. A false backlash reading will be obtained without a properly torqued drive yoke.

W4030931

1. Oil Passage Sealing Ring

3 Install front rear bevel pinion.

W4080980

1. Alignment Dowel

123



4 Install oil passage sealing ring.

W4034114

Fig. 24 Rear rear pinion housing assembly. 1. Oil passage sealing ring

5 Install shims.

W4058481

Fig. 25 Rear rear pinion housing assembly 1. Shims

124



6 Install power divider housing on the main carrier housing.

W4034116

Fig. 26 Power Divider Housing

125


Setting the Backlash

7 Install some of the bolts. Remove the alignment pins after the bevel pinion is in position. Install the remaining bolts. 8 Torque bevel pinion bolts to specification.

Setting the Backlash 1 Set the backlash between the bevel pinion and the bevel gear. The backlash should be 0.15 to 0.46 mm (0.006 to 0.018 in.). Add or remove shims as necessary to attain the correct backlash. 0.15 to 0.46 mm (0.006 to 0.018 in.)

2 A dial indicator with a magnetic or bolt-on type base is used to make the measurement. Note: A bolt-on type base is required on aluminium housings.

W4032182

1. Dial Indicator Needle

Setting Spiral Bevel Gears 1 Check the gear patterns using marking compound. Mark four of the teeth, approximately 180 degrees apart.

W4034626

126


Four-Pinion Type Differential — Reassembly

2 Rotate at least two full turns in both directions while applying braking force to the helical pinion. This will squeeze the gearmarking compound away from the contact areas. Note: In some cases, it may be necessary to slightly readjust the setting made by the dial indicator to obtain the correct tooth contacts. However, make sure that there are no dirt particles under the shim packs and that all fasteners are tightened to the proper torque. Then recheck the tooth contact pattern. 3 After reaching proper tooth contact pattern and gear backlash limits, temporarily remove the bevel pinion and the helical (spur) pinion shaft from the carrier housing. Wire the bevel pinion shims together for use at final assembly. Wire the helical (spur) pinion shaft assembly shims together to use when checking tooth contact pattern between the helical (spur) pinion shaft assembly and the bull gear.

Four-Pinion Type Differential — Reassembly 1 Using a suitable hydraulic press, press the bearing cones onto the differential halves. Generously lubricate the bearing cones and the internal components with GO-J lubricant. Note: The bearing cones on the two sides of the differential halves are different. The thicker bearing goes on the unsplined half and the thinner bearing goes on the splined differential half. Note: The differential bearing cup which fits the unsplined casing has an external flange which engages a machined surface on the inner side of the bearing pedestal and cap when installed. This arrangement fixes the position of the differential and bull gear and provides for differential bearing preload ad justment. The bull gear position cannot vary. 2 Apply GO-J lubricant to the thrust washer. Install the thrust washer in the unsplined differential casing. 3 Apply GO-J lubricant to the unsplined differential casing and install the side gear into the casing. 4 Assemble the four pinion gears and the four thrust washers onto the differential spider. 5 Install the pinion, spider and thrust washer assembly into the unsplined side casing. Apply GO-J lubricant before installation. 6 Ensure the gears are properly engaged and that the pinion thrust washer tabs are properly positioned in the casing. 7 Install the other side gear so that it meshes with the pinion and spider assembly, applying GO-J lubricant before installing.

127


Four-Pinion Type Differential — Reassembly

8 Install the remaining thrust washer after lubricating it with GO-J lubricant. 9 Align the side casing halves with the match marks made at disassembly and couple the casing halves together. 10 Mark the side casing halves with a marking pencil at the "o" marked on the splined half. Mark the tooth between the "oo" marks on the bull gear. 11 Align the match mark on the bull gear with that on the casing halves. Index the bull gear internal splines with the external splines on the differential side casing. Note: Install a differential casing bolt in the match-mark hole to help align and install the bull gear. 12 Apply Loctite 262, or equivalent, to four equally spaced casing bolt threads. Place Loctite in the middle of the bolts as the bolts extend through the casing. 13 Tighten the four equally spaced bolts evenly to pull the bull gear onto the casing. Turn the bolts equally and evenly to pull gear down before torquing. 14 Place the differential in a soft-jawed vise and install the remaining eight bolts. Torque the bolts to specification. 15 Place Loctite 262 on the extended threads of the 12 (previously installed) bolts used to retain the bull gear. 16 Ensure the differential gears turn freely. If any binding is detected, disassemble the unit and correct the cause.

128


Inter-Wheel Power Divider Differential — Reassembly

Inter-Wheel Power Divider Differential — Reassembly 1 If removed, insert a new presized bushing into the power-divider driving cage until the bushing bottoms. DO NOT OVERDRIVE. A correctly installed bushing must be recessed below the inner-cam thrust surface of the cage. 2 Using a hydraulic press, press the thinner bearing cone on the hub of the driving cage. Note: The bearing cones on the two sides of the differential halves are different. The thicker bearing goes on the unsplined half and the thinner bearing goes on the splined differential half. 3 Using a hydraulic press, press the thicker bearing cone on the hub of the non-splined power-divider differential side casing. 4 Install the oil trough on the splined differential power divider cage. 5 Examine the splined half of the power divider differential half. The differential half has one mark (shown at the twelve o'clock position). 6 Examine the bull gear. Note that it has two timing marks (shown at the twelve o'clock position). 7 Mark the bull gear tooth directly between the timing marks. 8 Align the timing marks so the timing mark from the differential half is between the two bull gear timing marks. Press the splined differential power divider cage into the bull gear. 9 Flip over the splined differential power divider cage (now seated into the bull gear) and continue with the assembly. 10 Install the wedges with the arrow or alpha character pointed outward. Lube all parts during assembly. Note: Wedges must be replaced only as sets. Never mix wedges of different sets. 11 Dip the hub of inner cam in GO-J oil. Install the cam in the cage. 12 With the inner cam installed, press all the driving wedges inward so they all contact the inner cam. Align the wedges for outer cam installation.

129


Inter-Wheel Power Divider Differential — Reassembly

13 Install the outer cam over the wedges. Turn outer cam back and forth until cam aligns and falls in place.

WARNING Be careful when installing the outer cam, possible subsequent personal injury can result. The outer cam can drop suddenly into place when all wedges are contacting the inner cam.

14 Align the unsplined differential side casing with the alignment marks made on the bull gear when disassembling the power divider 15 Install the unsplined differential side casing. 16 Install and tighten the power-divider differential bolts that retain the unsplined differential housing. 17 Mount the assembly in a soft-jawed vise. 18 Torque bolts to specification.

130


Differential Installation

Differential Installation Note: This same procedure is used when installing the interwheel power divider or the four-pinion type differential. 1 Install the bearing adjusting nut onto the threaded bearing cup. Tighten the nut about two turns.

W4032209

2 Use a suitable lifting device to position the differential assembly for installation into the carrier housing. 3 Lubricate the bearings with GO-J lubricant and position the bearing cups on the differential assembly.

W4032210

1. Lift 2. Differential Assembly 3. Carrier Housing

4 Lower the differential assembly into the housing.

131



5 Seat the bearing cups on the differential bearing pedestals in the carrier housing.

W4032211

1. Hoist 2. Differential/Bull Gear Assembly 3. Stand

6 Align punch marks made at disassembly on the bearing caps with those on the bearing pedestals. Position the bearing caps over the bearing cups. 7 Install the bearing cap bolt, snugly, but not too tight. This will permit bearing adjustment. Do not apply Loctite at this time.

W4032212

132



8 Ensure bearing caps are properly aligned. Note: Lost or broken bearing caps must be replaced with a new carrier housing and bearing caps. Bearing caps and the carrier housing are machined as a set and cannot be intermixed.

W4032213

1. Marks Made Earlier

9 Position bearing adjustment fixture J 26440 or equivalent on the carrier housing. J 26440

W4032214

10 Lubricate the differential bearings with GO-J gear oil. Then, while turning the differential assembly, adjust the differential bearing nut until the bearings have a slight preload.

W4032215

133



11 Relieve bearing preload by hitting the bearing cap and/or bull gear with a plastic mallet while rotating the differential. Note: To properly measure the bull gear drag, make sure that the helical pinion shaft has been removed. This must be done in order to ensure accurate preload (drag) measurements. 12 Readjust the differential bearing nut to create a slight preload. Repeat the procedure of adjusting preload and hitting the bearing cap and/or bull gear to relieve preload pressure, until a constant preload is maintained.

W4032216

13 Torque the bearing-cap retaining bolts to specification.

W4032217

14 Wrap a cord around the outside of the diameter of the bull gear several times. 15 Attach scale J 8129 or equivalent to the cord and steadily pull on the scale until the bull gear rotates slowly and evenly. If correct, the load on the scale will read 2–3 pounds (0.9–1.3 kg). J81290.9–1.3 kg (2–3 lb)

W4032218

16 If the preload is not within specifications, loosen the bolts and turn the adjusting nut to attain the proper preload. 134



17 Once preload is attained, remove the bearing cap bolts one at a time. Apply Loctite 262 to the threads and retorque to specification. 18 Check for proper alignment of the pin hole in the bearing cap and the adjusting nut. If required, tighten the bearing adjusting nut slightly, until the hole and nut are aligned to provide for installation of the lock pin. Note that it may be necessary to loosen the bearing cap bolts to allow the adjusting nut to turn. Recheck the torque on the bearing cap bolts. 19 Recheck the preload on differential bearings by measuring the rolling drag. Adjust as required. 20 Remove the differential adjustment fixture J 26440. J 26440

21 Install the lock pin in the bearing cap and secure it with a cotter pin.

W4032184

135


Bull Gear Tooth-Contact Pattern

Bull Gear Tooth-Contact Pattern Earlier in this procedure, the helical pinion shaft was removed and the differential was installed. Now, a measurement must be taken for the bull gear tooth-contact pattern. This requires reinstallation of the helical (spur) pinion shaft. Refer to “Helical (Spur) Pinion Shaft — Reassembly”, page 115. Torque the old bolts so the clamp plate is tight. This ensures the correct preload on the bearings and an accurate measurement of the gear tooth patterns.

1 Temporarily install the helical (spur) pinion shaft with spacer into the carrier housing as previously outlined. Make certain to engage the helical (spur) pinion with the bull gear. 2 Install the helical-pinion shaft bearing retainer with the predetermined shim pack into the carrier housing.

CAUTION Shim installation must not block top or bottom oil passageways.

3 Install the bearing cone onto the end of the pinion shaft. The bearing must be seated before attaching the clamp plate.

W4032219

4 Attach the clamp plate and install the old clamp-plate bolts (without Loctite). Jam the bevel gear with a pinch bar or jamming bar and torque the clamp-plate bolts to specification. 5 Coat the bull gear and the helical pinion gear with gear-marking compound.

W4032220

136


Bull Gear Tooth-Contact Pattern

6 Rotate the bull gear in forward and reverse directions while applying resistance to the helical pinion set to determine the tooth contact pattern. The pattern must be within the limits shown on the following Bull Gear Tooth-Contact Pattern Chart. The contact pattern is either acceptable or unacceptable, because there is no adjustment option. If the gear tooth pattern is unacceptable, replace both the bull gear and the helical pinion with its shaft.

1. Acceptable

10. Sixth

2. Less than 10% Length

11. Seventh

3. Ideal

12. Eighth: End Loading left-hand Side

4. Minimum

13. Ninth: End Loading Right-hand Side

5. First

14. Tenth: Tip Loading

6. Second

15. Eleventh: Split Bearing

7. Third

16. Twelfth: End Loading Seft and Right Sides

8. Fourth

17. Total Length

9. Fifth W4032221

137


Final Assembly

Final Assembly Provided the instructions of this manual have been followed correctly, the differential assembly is now complete and the helical (spur) pinion shaft has been temporarily installed. The helical (spur) pinion shaft installation must be completed at this point.

1 Remove the three helical (spur) pinion-clamp plate bolts one at a time and replace using new bolts. Apply Loctite 262 to the threads and install the new bolts. Torque each bolt to specification while jamming the bevel gear with a pinch bar or jamming tool. 2 Remove the short bolts used to temporarily retain the helical (spur) pinion-shaft assembly retainer. Note: A steel-core gasket coated on both sides with foam rubber has replaced the Silastic sealer which was applied to the pinion shaft cover formerly. Use a steel-core gasket for reassembly to eliminate oil leakage. 3 Install a new steel-core/foam-rubbergasket onto the helical-pinion bearing retainer.

W4034634

1. Retainer Gasket

4 Install the helical-pinion bearing retainer cover.

W4032223

1. Bearing Retainer Cover

138


Final Assembly

5 Remove the guide pins used to temporarily align the helical (spur) pinion-shaft bearing retainer assembly and use the proper self-locking bolts to secure the cover. 6 Torque the bolts retaining the helical pinion-shaft bearing retainer cover to specification.

W4032224

139


Front Rear or Rear Rear Bevel Pinion Installation

Front Rear or Rear Rear Bevel Pinion Installation 1 Use the shims as determined while adjusting the bevel pinion assembly for proper tooth contact pattern and proper backlash between the gears.

CAUTION Position the shims to align with all oil holes. Blocked oil holes will cause lubrication failure.

2 Install the bevel pinion and housing assembly onto the carrier housing. Align bevel pinion housing with oil passages. 3 Install proper self-locking bolts into the bevel housing and torque to specification. 4 When assembling a carrier with power divider (with or without lockout), it is necessary to use an offset extension J 28506, or equivalent, with the torque wrench OEM-6642. J 28506, OEM-6642

W4032225

Inter-Axle Power Divider Installation (with or without Lockout) 1 Dip the inner cam in GO-J lubricant and position it inside the cage of the power divider. Push all the wedges in until they contact the inner cam lobes and install the inner cam. The cam will fit only one way. Note: Be sure the grooves on the face of the inner cam face in toward the bevel pinion.

W4032226

140


Inter-Axle Power Divider Installation (with or without Lockout)

2 Install the power divider housing gasket.

W4032227

1. Gasket

3 Position the carrier housing in the stand so the cage assembly may be installed into the outer cam of the bevel pinion. The inner cam will be held in position by the driving wedges. 4 Install the power divider into the housing. Note: The cage assembly must be perfectly centered or the wedges will hang up.

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Inter-Axle Power Divider Without Lockout Only

Inter-Axle Power Divider Without Lockout Only 1 On inter-axle models without lockout, ensure that a new oil seal was installed in the seal cover. 2 Install a lightly lubricated O-ring into the groove in the oil-seal cover plate. 3 Attach the inter-axle power-divider oil seal cover over the power-divider cage bearing retainer plate.

W4032229

4 Install the bolts through the inter-axle power-divider oil seal cover. Torque to the correct specification.

Inter-Axle Power Divider With Lockout Only 1 Install the bolts through the inter-axle power divider housing flange. Torque to the correct specification.

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142


Inter-Axle Through Shaft Installation

Inter-Axle Through Shaft Installation 1 Position the through-shaft housing gasket onto the surface of the carrier housing.

W4033409

1. Shim Gasket

2 Install the inter-axle through-shaft housing into the carrier housing.

CAUTION The power divider wedges are lubricated through the through-shaft bearing retainer and the bevel pinion. When the through-shaft bearing retainer is installed, ensure that the oil inlet is on top. If the retainer is rotated so the oil inlet is not in the top position, the inter-axle power divider will be damaged because of a lack of lubricant.

W4032232

3 Lubricate the through shaft with GO-J lubricant. 4 Carefully install the through-shaft assembly, aligning the shaft splines with the internal splines of the inter-axle power divider inner cam while making certain that the oil inlet is properly positioned.

143


Inter-Axle Through Shaft Installation

5 Ensure the through-shaft bearing is properly seated when the through shaft is installed.

W4032233

6 Determine the proper gasket thickness for the through-shaft bearing retainer. Note: The thickness of this gasket is critical because the gasket seals the joint and determines how much pressure bears on the outer bearing race to keep it from spinning. 1 Temporarily install the retainer over the through shaft and press on it until the ridge bottoms on the outer bearing race.

W4032234

1. Feeler Gauge

2 Using feeler gauges J 26900-8 or equivalent, measure the gap between the bearing cover and retainer flanges. Add 0.13-0.25 mm (0.005-0.010 in.) to the measured amount for proper gasket thickness. This is done to provide enough clamping force to prevent the bearing from rotating within the bearing retainer, and to provide a seal to prevent oil leakage.

J26900–8

7 Align the bearing cover and install the bolts.

W4032235

8 Torque bolts to specification.

144


Carrier Installation Into Chassis

Carrier Installation Into Chassis 1 If not yet installed, dip end of yokes in GO-J lubricant and position them on the input shaft of the input and through-shafts of the front rear carrier. Position the clamp plate and install the self-locking bolts finger tight. Note: Drive yokes for the 151 series carriers were installed in previous steps. 2 Install a holding bar on output yoke and with a socket wrench, tighten yoke self-locking bolt to the required torque. 3 Check the carrier for free turning and proper operation of working components. If an unusual amount of bind is felt, or noise is heard, correct the cause before proceeding. 4 All units with the four-pinion type differential which are being installed into the axle housing must immediately have the differential filled with one pint of GO-J lubricant before the carrier is installed into the vehicle. 5 Apply a 2.0 mm (0.8 in) continuous bead of Silastic 732 RTV sealant, or equivalent, to axle housings without provisions for a large O-ring seal prior to assembly of the carrier onto the axle housing. This includes all CRD 92/93 series carriers. The CRD 112/113 series carrier housings have a large O-ring groove. Install O-ring in the groove. Then mount the carrier. DO NOT use a sealant on carriers using an O-ring. 6 Install differential carrier into axle housing.

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145



7 Install bolts and washers. Torque bolts to specification.

W4032238

Installation of Hidden bolts, stepped washer and O-ring; Used on CRD150 and 151 series carriers.

Note: O-rings are used only on tandem carriers over 46,000 pound rating. 8 Install the cover assembly and new O-ring. Make sure that a cover containing the oil trough with magnetic strips is used in the front rear carrier.

CAUTION Do not use a plain cover on a front rear axle with power divider provisions. The front rear cover for a carrier with a power divider must have a trough to feed oil to the oil pump (through shaft) to prevent damage to the power divider.

W4031127

9 Ensure all plugs are installed in the assembly. Pipe Plug Location

Torque in Nm

Torque in lb-ft

1. Power Divider Fill Plug — 1 NPT

54–61

40–45

n/a

n/a

3. Housing Drain Plug (Magnetic) — 1/2 NPT

27–34

20–25

4. Axle Housing Drain Plug — NPT

54–61

40–45

5. Power Divider Drain Plug — 1/2 NPT

27–34

20–25

2. Housing Fill Plug

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146



10 Torque the bevel compartment cover to specification.

W4031129

11 When the rear axle is completely assembled, it is important to fill the inter-axle power divider (if equipped), and both the carrier and axle housings to their respective proper capacities. Fill the axles with GO-J (or GO-J Plus) lubricant until the oil is level with the filler plug hole.

W4031132

147


Preventive Preventive Maintenanc Maintenance e

Preventive Preventive Maintenanc Maintenance e Magnet Magnetic ic Strips Strips and Oil Trou Troughs ghs An oil trough with magnetic strips is attached to the inside of the bevel gear compartment cover. cover. Clean the oil trough and magnetic strips strips each time the oil is changed or when the cover is removed. Replace Replace the O-ring whenever whenever the cover is removed. removed.

W4032240

W4031127

1. O-Ring

Checki Checking ng Oil WARNING Be careful not to burn your finger finger in hot gear oil when checkchecking the oil level in the carrier. When checking the oil oil level in the rear axles, check after the vehicle vehicle has been operated, operated, make sure the unit unit is at normal operating erating temperature temperature and chassis chassis is parked parked on level . Check Check the oil level level by removing removing the filler filler plugs from from the axle housings housings and the bevel gear compartme compartments. nts. The level is correct correct when oil runs out of the filler filler plug hole in the axle axle housing, housing, and slightly below the filler plug hole in the bevel gear compartment. If the level in the axle housing is low, low, add oil to the axle housing and the bevel gear compartment compartment until the oil is level with the bottom bottom of the filler filler plug holes. holes.

W4080981

W4080982

1


Changing Oil

DO NOT add oil if the level in the axle housing housing is sufficient. sufficient. Reinstall the plugs and tighten to specifications.

W4032243

1. Inter-Axle Power Divider Housing

5. Tandem Axle Housings

2. Bevel Gear Compartm rtment Filler Plug

6. Divider Housing Drain Plug

3. Drain Plug

7. Divider Housing Filler Pl Plug

4. Axle Housing Housing Filler Plug

Changi Changing ng Oil When changing changing the oil in the carrier carrier unit, the oil should should be at normal normal operating operating temperature. temperature. Remove Remove the magneti magnetic c drain plug from from the bottom bottom of the axle axle housing(s housing(s), ), the drain drain plug in in the bevel gear compartment(s) and the drain plug in the interaxle power power divider divider housing housing (if equipped). equipped). Then drain drain the hot oil from the unit into an industry-ap industry-approve proved d recovery recovery container container.. Clean and reinstall reinstall the magnetic magnetic drain plug(s). plug(s). Then torque to specificati specification. on. Remove Remove the filler filler plug(s) plug(s) from the axle housing housing (s), the bevel gear gear compartment compartment(s) (s) and the inter-axle inter-axle power power divider housing housing (if equipped). equipped). Fill each of the carrier carrier compartcompartments with specified oil to the level of the filler filler plug hole. Reinstall Reinstall and snug snug the filler filler plugs in in the carrier carrier housing, housing, power divider divider and bevel pinion pinion compartme compartment. nt. Then tighten tighten each to specified specified torque. torque. Change Change the oil at the specified specified intervals. intervals.

2


Air Breathers

Air Breathers

W4032244

The 150/151 150/151 carriers carriers both have have one one breather breather cap located located on the uppermost uppermost portion portion of each carrier carrier housing. housing. Remove Remove the carrier carrier housing housing breather(s) breather(s) every time time the rear axle(s) axle(s) oil is changed. changed. Clean Clean the breather breather in a suitable suitable nonflamma nonflammable ble solvent and check for damage. damage. Also check to be sure that airflow through through the breather breather is unobstruct unobstructed. ed. Reinstall Reinstall the breather breather onto the carrier carrier housing housing and tighten until snug. snug.

3

4

Operation Numbers The operation numbers used in this manual refer to Labor Code. 4651-04-11-01 Differential Carrier, Dissassemble-Assemble... ... .... .... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39

Diferencial Mack[1]

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