REDUCTION
TANDEM
CARRIER MAY 1998
(REVISED)
13-103
95/96 SERIES
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NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
ATTENTION
The information in this manual is not all inclusive and
cannot take into account all unique situations. Note that
some illustrations are typical and may not reflect the
exact arrangement of every component installed on a
specific chassis.
The information, specifications, and illustrations in this
publication are based on information that was current at
the time of publication.
No part of this publication may be reproduced, stored in a
retrieval system, or be transmitted in any form by any
means including electronic, mechanical, photocopying,
recording, or otherwise without prior written permission
of Mack Trucks, Inc.
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SAFETY INFORMATION
SAFETY INFORMATION
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SAFETY INFORMATION
Advisory Labels
Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this
manual. Information accented by one of these signal words must be observed to minimize the risk of per-
sonal injury to service personnel, or the possibility of improper service methods which may damage the
vehicle or render it unsafe. Additional Notes and Service Hints are utilized to emphasize areas of proce-
dural importance and provide suggestions for ease of repair. The following definitions indicate the use of
these advisory labels as they appear throughout the manual:
Directs attention to unsafe practices which could result in damage to equipment and
possible subsequent personal injury or death if proper precautions are not taken.
Directs attention to unsafe practices and/or existing hazards which will result
in personal injury or death if proper precautions are not taken.
A helpful suggestion which will make it quicker and/or easier to perform a certain
procedure, while possibly reducing overhaul cost.
000001a
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SAFETY INFORMATION
Service Procedures and Tool Usage
Anyone using a service procedure or tool not recommended in this manual must first satisfy himself
thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects.
Individuals deviating in any manner from the instructions provided assume all risks of consequential
personal injury or damage to equipment involved.
Also note that particular service procedures may require the use of a special tool(s) designed for a
specific purpose. These special tools must be used in the manner described, whenever specified in the
instructions.
1. Before starting a vehicle, always be seated in the driver’s seat, place the
transmission in neutral, be sure that parking brakes are set, and disengage
the clutch.
3. Before towing the vehicle, place the transmission in neutral and lift the rear
wheels off the ground, or disconnect the driveline to avoid damage to the
transmission during towing.
REMEMBER,
SAFETY . . . IS NO ACCIDENT!
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NOTES
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vii
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EXAMPLES: 465 CF 4S 45
BASE OPERATION
CARRIER, INTERMEDIATE DRIVE AXLE
CARRIER ASSEMBLY
MACK CRD 95
REPLACE
401406a
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TABLE OF CONTENTS
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Advisory Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
EXPLANATION OF 3-DIGIT NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
400 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MACK DUAL-REDUCTION TANDEM CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Front Rear Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear Rear Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
New Style Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
400 CARRIER VISUAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CARRIER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Divider Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
400 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWER DIVIDER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inter-Axle Power Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inter-Wheel Power Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power Divider Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CARRIER COMPONENTS AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Differential Components and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OVERHAUL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
400 EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
EXPLODED VIEW OF POWER DIVIDER LOCKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
EXPLODED VIEW OF INTER-AXLE POWER DIVIDER WITHOUT LOCKOUT . . . . . . . . . . . . . . . 18
EXPLODED VIEW OF FRONT REAR BEVEL PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EXPLODED VIEW OF REAR REAR BEVEL PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
EXPLODED VIEW OF HELICAL (SPUR) PINION SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
EXPLODED VIEW OF INTER-WHEEL POWER DIVIDER DIFFERENTIAL . . . . . . . . . . . . . . . . . . 22
EXPLODED VIEW OF FOUR-PINION TYPE DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
EXPLODED VIEW OF INTER-AXLE THROUGH SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 24
400 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CARRIER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TROUBLESHOOTING AND DIAGNOSING MISMATCHED CARRIER RATIOS
FOR TANDEM CARRIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Carrier Identification Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Gear Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
400 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CARRIER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Checking Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Air Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
400 CARRIER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
[465/475] DIFFERENTIAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
[466] REMOVING THE INTER-AXLE THROUGH SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
[466/476] BEVEL PINION HOUSING REMOVAL (FRONT REAR OR REAR REAR) . . . . . . . . . . 42
[466] REMOVING THE HELICAL (SPUR) PINION SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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TABLE OF CONTENTS
400 BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
[465/475] FOUR-PINION TYPE DIFFERENTIAL — DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 48
[465/475] INTER-WHEEL POWER DIVIDER DIFFERENTIAL — DISASSEMBLY . . . . . . . . . . . . 52
[465] INTER-AXLE POWER DIVIDER WITHOUT LOCKOUT — DISASSEMBLY . . . . . . . . . . . . . 53
[466] FRONT REAR BEVEL PINION — DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
[476] REAR REAR BEVEL PINION — DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
[466/476] HELICAL (SPUR) PINION SHAFT — DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 63
[466] POWER DIVIDER LOCKOUT — DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
[466] INTER-AXLE THROUGH SHAFT — DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
400 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
PINION SHAFT WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
GEAR WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DIFFERENTIAL SPIDER WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
BEARINGS, BUSHINGS AND THRUST WASHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
POWER DIVIDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
AXLE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Complete Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Disassembled Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Rough Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Corrosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
GEARSET UPDATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
400 REASSEMBLY FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
400 BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
[466] INTER-AXLE THROUGH SHAFT — REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
[466] POWER DIVIDER LOCKOUT — REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
[466] INTER-AXLE POWER DIVIDER WITHOUT LOCKOUT — REASSEMBLY . . . . . . . . . . . . . 91
[466] FRONT REAR BEVEL PINION — REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Bevel Pinion Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
[476] REAR REAR BEVEL PINION — REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Bevel Pinion Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Determining Bevel Pinion To Carrier Housing Shim Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
[465/475] FOUR-PINION TYPE DIFFERENTIAL — REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 105
[465/475] INTER-WHEEL POWER DIVIDER DIFFERENTIAL — REASSEMBLY . . . . . . . . . . . . 109
[465/475] DIFFERENTIAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
[466/476] HELICAL (SPUR) PINION SHAFT — REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 116
Setting the Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Setting the Gear Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Bull Gear Tooth-Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Front Rear or Rear Rear Bevel Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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TABLE OF CONTENTS
400 CARRIER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Inter-Axle Power Divider Installation (With or Without Lockout) . . . . . . . . . . . . . . . . . . . . . . . . 135
Inter-Axle Through (Drive) Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Carrier Installation into Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
400 CARRIER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
FEATURES AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
400 BEARING ADJUSTMENTS & TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
400 SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
SPECIAL TOOLS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
400 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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NOTES
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400 INTRODUCTION
INTRODUCTION
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400 INTRODUCTION
MACK DUAL-REDUCTION Rear Rear Carrier
TANDEM CARRIER In the rear rear carrier, the main drive pinion has
a solid shank and is carried in an overhung
MACK top-mounted, dual-reduction tandem arrangement by a pair of tapered roller bearings
carriers of the 95/96 series transfer power from mounted in a separable housing.
the transmission to the rear wheels. The carriers
are identical except for the input drive and the
through shaft arrangement of the front carrier.
This differs from the input pinion mounting of the
rear carrier.
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400 INTRODUCTION
These new axle shafts must be used when
1ST REDUCTION replacing existing CRDP95/96 series carrier with
2ND REDUCTION a new carrier assembly, new differential assembly
or new differential spider.
HELICAL
BEVEL PINION
PINION (SPUR It is not necessary to use new axle shafts when
SHAFT) servicing an existing CRDP951/961 series
carrier, but the new shafts may be used if so
BULL desired.
GEAR
BEVEL
GEAR
400552a
New necked down axle shafts may be used with
Figure 2 — Dual-Reduction Carrier an existing differential assembly, but the old style
axle shafts cannot be used with a new differential
New Style Axle Shafts assembly.
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NOTES
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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 distributor for overhauling. The
following recommendations are for shops that can
handle this type of overhaul.
r Do not disturb parts with heavy press fits
unless replacement is necessary.
Figure 15 — Gear Jamming Tool
r Use proper press setups and/or pullers during
disassembly to avoid damaging usable parts r At reassembly, make sure the bench, tools and
during removal. working areas are clean.
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NOTES
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EXPLODED VIEWS
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1. Bearing Cone 6. Pinion Gear Thrust Washer (4) 11. Lock Washer (16)
2. Locknut (16) 7. Pinion Gear (4) 12. Capscrew (16)
3. Differential Half (Side Casing) 8. Spider 13. Bearing Cone
4. Side Gear Thrust Washer (2) 9. Bull Gear
5. Side Gear (2) 10. Differential Half (Side Casing)
Figure 22 — Exploded View of Four-Pinion Type Differential
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400 TROUBLESHOOTING
TROUBLESHOOTING
Page 25
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400 TROUBLESHOOTING
CARRIER TROUBLESHOOTING
The troubleshooting chart summarizes some
common carrier complaints, probable causes and
possible remedies.
401390a
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400 TROUBLESHOOTING
401391a
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400 TROUBLESHOOTING
TROUBLESHOOTING AND 1. With an operator in the cab and the
transmission in neutral, release the spring
DIAGNOSING MISMATCHED brakes. Make sure there is sufficient room to
CARRIER RATIOS FOR push the chassis forward one complete
TANDEM CARRIERS wheel rotation.
2. Push the chassis forward and count the
Check the tandem carrier for mismatched carrier
number of shaft rotations during one
ratios if any of the following conditions occur:
complete wheel rotation. For example, with a
r Tire scuffing or wear 5.02 carrier ratio, the driveshaft will rotate 5
times to one tire rotation.
r Noise in the power divider or shortened power
divider life
If a variation exists between tire revolution and/or
r Noise in the various transmission gears drive-line rotation between front rear and rear
rear carriers, a physical inspection of each gear
Mismatched carrier ratios can transmit noise set must be made.
through the driveline and transmission.
Gear Set Inspection
Carrier Identification Stamping
Drain the upper gear case. Remove the bevel
If mismatched carrier ratios are suspected, check gear compartment side access cover. Count the
the carrier identification stampings for matched teeth of the bevel gear set (1) in each carrier.
ratios. Refer to Figure 25.
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400 TROUBLESHOOTING
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). Refer to Figure 25.
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NOTES
Page 30
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400 MAINTENANCE
MAINTENANCE
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400 MAINTENANCE
CARRIER MAINTENANCE DO NOT add oil if the level in the axle housing is
sufficient. Reinstall the plugs and tighten to
specifications.
Checking Oil
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400 MAINTENANCE
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400 MAINTENANCE
Changing Oil Air Breathers
When changing the oil in the carrier unit, the oil The 95/96 carriers both have one breather cap
should be at normal operating temperature. located under the helical (spur) pinion shaft cover
Remove the magnetic drain plug from the bottom area of each carrier housing. Remove the carrier
of the axle housing(s), the drain plug in the bevel housing breather(s) every time the rear axle(s) oil
gear compartment(s) and the drain plug in the is changed. Clean the breather in a suitable
inter-axle power divider housing (if equipped). nonflammable solvent and check for damage.
Then drain the hot oil from the unit into an Also check to be sure that airflow through the
industry-approved recovery container. Clean and breather is unobstructed. Reinstall the breather
reinstall the magnetic drain plug(s). Then torque onto the carrier housing and tighten until snug.
to specification.
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CARRIER DISASSEMBLY
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400277a
400278a
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LIFTING
Figure 36 — Loosening Bearing Adjusting Nut TOOL
400282a
400280a
Page 38
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Figure 41 — Removing Rear Bearing Cover and Gasket 17. Back out the bearing retainer by alternately
turning the jackscrews. Alternating, even
15. Pull out the inter-axle through shaft and turning of the jackscrews is essential to
bearing together. prevent the retainer from becoming cocked
and binding in the retainer bore.
18. After the bearing retainer has been freed
from the bore of the carrier, remove the
The non-current inter-axle through shaft is jackscrews from the retainer.
constructed of a driveshaft combined with a
spring to form the oil groove on the through shaft.
The current inter-axle through shaft is
constructed with a formed, rolled oil groove on
the shaft. The two versions are interchangeable.
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400292a
Page 41
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400292a
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ALIGNING
PIN
400293a
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1. Bearing Cone 6. Pinion Gear Thrust Washer (4) 10. Differential Half (Side Casing)
2. Locknut (16) 7. Pinion Gear (4) 11. Lock Washer (16)
3. Differential Half (Side Casing) 8. Spider 12. Capscrew (16)
4. Side Gear Thrust Washer (2) 9. Bull Gear 13. Bearing Cone
5. Side Gear (2)
Figure 66 — Exploded View of Four-Pinion Type Differential
Page 48
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BULL
GEAR
MARK
CASING
MARK
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401389a
Page 51
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1. The bull gear, the casing and the cage are 2. Mount the assembly in a vise and remove
line-reamed at assembly. Therefore, punch- the hardware securing the bull gear, cage
mark these parts to ensure reassembly in and casing assembly. Remove the bull gear
the same position. and position the assembly on a work bench
with the cage assembly on its hub end.
3. Lift the casing and the outer cam from the
cage assembly.
There are two different configurations of power
divider differential assemblies. To determine 4. Push the outer cam driving wedges out of
which type you have, check the hardware. One the case. Remove the retaining ring and
type uses three dowel bolts, 120 degrees apart, inner cam driving wedges. Remove the inner
and 12 capscrews to attach the bull gear. The cam.
other type uses 15 dowel bolts to secure the bull 5. If inspection reveals the need for
gear. replacement, pull the bearing cones from the
side casing or cage and press the bushing
from the cage.
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400354a
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400305a
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PRESS
PRESS
EXTENSION
BEVEL
GEAR
400391a
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1. Remove the capscrews retaining the 4. Remove the piston and washer from the
cylinder housing onto the power divider shaft by sliding them straight off.
lockout housing.
2. Remove the cylinder housing and gasket. 5. Remove the piston return spring.
Figure 116 — Removing the Cylinder Figure 118 — Removing the Spring
Housing and Gasket
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400345a
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401402a
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NOTES
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400 INSPECTION
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400 INSPECTION
OVERVIEW DIFFERENTIAL SPIDER WEAR
It is very important to carefully and thoroughly LIMITS
inspect drive unit parts before reassembly. A slightly worn differential spider may be reused
Replacement of worn or damaged components if:
eliminates costly and avoidable drive unit failure.
r Wear does not exceed 0.005 inch
Whenever possible, use the Magnaflux or similar (0.127 mm).
non-destructive inspection method on all steel r Spider-to-pinion bore clearance does not
parts except ball and roller bearings. This method exceed 0.007–0.011 inch (0.178–0.279 mm).
is especially suited for inspecting ground or highly
finished surfaces for wear and cracks, which r Wear surfaces are not scored, pitted, cracked
otherwise would not be visible. It is essential to or otherwise damaged.
completely demagnetize the parts before using
the Magnaflux method. Install the spider in the opposite position. This
places the original drive side, which experiences
the most wear, on the coast side, which has the
PINION SHAFT WEAR LIMITS least wear.
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400 INSPECTION
Tapered roller bearings are set up in a preload AXLE SHAFTS
condition according to adjustment specifications
for each carrier. For reusable or run-in tapered Inspect axle shafts for bends, torsional fractures
bearings, adjust preload to one-half the value or other conditions that may result in failure.
specified for new bearings. Inspect splines for wear, cracks or distortion. If
evidence of any of these conditions is found,
If bearings pass inspection, dip them in the install new parts.
recommended differential lubricant. Then, wrap
bearings in clean cloth or paper until ready to Install each axle shaft between lathe centers.
reassemble the axle. Using a dial indicator, check shaft runout at the
center and 6 inches (152.4 mm) from each end.
Bushings (inter-wheel power divider driving cage) Discard shaft if total indicated runout (TIR)
and thrust washers must be replaced if they are exceeds 0.060 inch (1.5 mm) at the center, or
pitted, scored or show any signs of surface 0.030 inch (0.76 mm) at the end locations.
damage or have broken locking tabs. Do not use
tabbed thrust washers in a differential casing To check axle flange runout, position a dial
without the blind hole provision. Latest versions of indicator so that the indicator shaft contacts the
these differentials are manufactured with thrust inner surface of the flange near the outer edge.
washers having tabs. Thrust washers without Then check runout. Discard the axle shaft if
tabs may be used in old casing halves having the flange runout exceeds 0.008 inch (0.20 mm).
blind hole provision without any adverse effects.
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400 INSPECTION
Complete Assemblies Rough Parts
Completely assembled axles may be steam Rough parts, such as differential carrier castings,
cleaned on the outside only, to facilitate initial and cast brackets may be cleaned in hot solution
removal and disassembly. Breathers, vented shift tanks with mild alkali solutions, providing these
units, and all other openings must be tightly parts are not ground or polished. The parts must
covered or closed to prevent water from entering remain in the tank long enough to be thoroughly
the assembly. cleaned and heated throughout. This will aid the
evaporation of the rinse water. After cleaning,
Disassembled Parts rinse parts completely to remove all traces of
alkali.
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 Do not clean parts with highly volatile fluids such
housing, carrier housing, hubs and axle shaft as gasoline, or harmful chemicals such as carbon
flanges. Clean out lubricant channels in the tetrachloride. Also exercise care to avoid skin
pinion cage and carrier housing. Clean the rashes and inhalation of vapors when using alkali
housing breather. Make certain that the interior of cleaners.
the axle housing is thoroughly cleaned.
Bearings Drying
The importance of proper bearing cleaning Using moisture-free, compressed air, thoroughly
cannot be overemphasized. Clean bearings dry component parts immediately after cleaning
separately from other axle parts, using the and rinsing. If compressed air is not available,
following steps: use soft, clean, lintless absorbent paper towels or
1. Soak differential and drive pinion bearings in clean wiping cloths that are free of abrasive
clean kerosene, diesel fuel oil, or other material.
cleaning solvent. Do not use gasoline.
2. After old lubricant is loosened, hold bearing Corrosion Prevention
races so that the bearing cannot rotate. Parts that have been cleaned, dried and
Then brush bearings with a soft-bristled inspected and are to be reassembled
brush until all grit and dirt have been immediately must be coated with light oil to
removed. prevent corrosion. If the parts will be stored for
3. Rinse bearings in clean fluid. Then, while any length of time, treat them with a good rust-
holding races, blow dry with compressed air. preventive agent and wrap in special paper or
Be sure air stream is moisture free. Never other material designed to prevent corrosion.
spin bearings with compressed air as they
may score due to the absence of any
lubricant.
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400 INSPECTION
GEARSET UPDATING Repeat the procedure on the opposite side of the
gear tooth and identify the tooth patterns as drive
To assist field personnel in obtaining the desired side and coast side. If no tape is available, make
bevel gearset tooth contact, all service a sketch of the patterns.
replacement bevel gear matched sets are
furnished with the desired tooth contact pattern
indicated on the gear teeth in yellow gear-
marking compound.
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PRESS
Procedures for inter-axle through shaft, power EXTENSION
divider lockout, inter-axle power divider without
BEARING
lockout and front rear bevel pinion will only be
used with vehicles having tandem rear axles.
401403a
Ensure that the press support blocks are on Figure 139 — Installing Inter-Axle Through-Shaft
the flats of the shaft and not the taper. This Bearing
prevents the blocks from shifting as hydraulic
pressure is applied.
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400347a
INNER RING
400346a
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400345a
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INNER RING
400347a
Figure 167 — Installing Inner Ring Figure 169 — Installing Outer Ring
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BEVEL
PINION
400417a
Page 96
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r A thinner spacer increases preload. If bearings are in good condition, they can be
reused for rebuilding a carrier. If used bearings
r A thicker spacer reduces preload.
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.
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1. Bearing Cone 6. Pinion Gear Thrust Washer (4) 11. Lock Washer (16)
2. Locknut (16) 7. Pinion Gear (4) 12. Capscrew (16)
3. Differential Half (Side Casing) 8. Spider 13. Bearing Cone
4. Side Gear Thrust Washer (2) 9. Bull Gear
5. Side Gear (2) 10. Differential Half (Side Casing)
Figure 194 — Exploded View of Four-Pinion Type Differential
Page 105
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Make sure to press the side casing into the Figure 197 — Installing Side Gear Thrust Washer
correct side of the bull gear, noting previously
made match marks. 4. Apply GO-J lubricant to the differential
casing and then install the side gear.
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DIFFERENTIAL/
BULL GEAR
ASSEMBLY
STAND
400511a
LIFT
DIFFERENTIAL
ASSEMBLY
CARRIER
HOUSING
400512a
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MARKS
MADE
EARLIER
400515a
Page 113
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400432a
PRESS
PRESS
PLATE
BEVEL
Figure 221 — Pressing Bearing Cone onto the Helical GEAR
(Spur) Pinion Shaft
PINION
SHAFT
2. Using a hammer, install the key into the
helical pinion shaft.
400433a
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400436a
400434a
Page 118
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400440a
Page 119
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Figure 233 — Installing Outer Bearing Cone on Make sure to lubricate the bearings before
Helical Pinion Shaft performing the bearing preload check.
PRESS
SCALE
PLATE J 8129
400444a
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Figure 242 — Torquing Bearing Retainer Capscrews Figure 244 — Aligning Inner Bearing Cup Slot and Mark
22. Mark the carrier housing next to the location 24. Install the slotted inner bearing cup into the
of the retainer lockpin. carrier housing using hand pressure to start,
then tapping with a driver and hammer.
DRIVER
400452a
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400301a
26. Install the outer bearing cone onto the end of Figure 248 — Torquing Clamp-Plate Capscrews
the pinion shaft.
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400521a
Page 125
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DIAL INDICATOR
Figure 257 — Tightening the Retaining Nut NEEDLE
hammer and punch or blunt chisel. Stake the Figure 259 — Checking Backlash
flange of the nut into at least two staking
grooves in the bevel pinion shaft.
SETTING SPIRAL BEVEL GEARS
12. Check the gear patterns, using marking
compound. Mark 4 teeth in 2 places,
approximately 180 degrees apart.
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HEEL
OUTWARD
Adding bevel pinion shims moves the Adding helical pinion shims moves the bevel
bevel pinion outward. This moves the gear outward. This moves the contact area
contact area toward the tooth top land nearer to the tooth heel and slightly toward
and slightly toward the toe on the drive the tooth root on the drive side of the gear.
side of the gear.
OUT
HEEL
400462a
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CARRIER REASSEMBLY
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NOTES
Page 140
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CARRIER SPECIFICATIONS
Page 141
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NOTES
Page 144
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Page 145
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Page 146
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Page 147
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Note: Notations “A-B-C-D” are described on page 147. Notations “X-Y-Z” are described on page 146.
Page 148
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S 578E SEGMENT, Adapter Ring, Differential and Differential Power Divider, L.H. and R.H.
Page 150
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400 INDEX
INDEX
Page 151
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400 INDEX
A F
AIR BREATHERS . . . . . . . . . . . . . . . . . . . . . .34 FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AXLE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . .77 FEATURES AND SPECIFICATIONS . . . . . . 142
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . 134
B FOUR-PINION TYPE DIFFERENTIAL —
BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .78 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 48
BEARING ADJUSTMENTS & TORQUE FOUR-PINION TYPE DIFFERENTIAL —
CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 105
BEARINGS, BUSHINGS AND THRUST FRONT REAR BEVEL PINION —
WASHERS . . . . . . . . . . . . . . . . . . . . . . . . . .76 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 56
BENCH PROCEDURES. . . . . . . . . . . . . . .47, 81 FRONT REAR BEVEL PINION —
BEVEL PINION HOUSING REMOVAL REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 95
(FRONT REAR OR REAR REAR) . . . . . . . .42 FRONT REAR CARRIER . . . . . . . . . . . . . . . . . 2
BEVEL PINION PRELOAD . . . . . . . . . . .97, 102 FRONT REAR OR REAR REAR BEVEL
BULL GEAR TOOTH-CONTACT PINION INSTALLATION . . . . . . . . . . . . . . 127
PATTERN . . . . . . . . . . . . . . . . . . . . . . . . .125
G
C GEAR SET INSPECTION . . . . . . . . . . . . . . . . 28
CARRIER COMPONENTS AND GEAR WEAR LIMITS . . . . . . . . . . . . . . . . . . . 76
OPERATION . . . . . . . . . . . . . . . . . . . . . . . .12 GEARSET UPDATING . . . . . . . . . . . . . . . . . . 79
CARRIER DISASSEMBLY . . . . . . . . . . . . . . . .35
CARRIER REASSEMBLY . . . . . . . . . . . . . . .133 H
CARRIER IDENTIFICATION . . . . . . . . . . . . . . .6 HELICAL (SPUR) PINION SHAFT —
CARRIER IDENTIFICATION STAMPING . . . .28 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 63
CARRIER INSTALLATION INTO HELICAL (SPUR) PINION SHAFT —
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . .138 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 116
CARRIER MAINTENANCE . . . . . . . . . . . . . . .32
CARRIER SPECIFICATIONS. . . . . . . . . . . . .141 I
CARRIER TROUBLESHOOTING . . . . . . . . . .26 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 75
CARRIER VISUAL IDENTIFICATION . . . . . . . .5 INTER-AXLE POWER DIVIDER . . . . . . . . . . . . 8
CHANGING OIL . . . . . . . . . . . . . . . . . . . . . . . .34 INTER-AXLE POWER DIVIDER
CHECKING OIL . . . . . . . . . . . . . . . . . . . . . . . .32 INSTALLATION (WITH OR WITHOUT
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . .77 LOCKOUT) . . . . . . . . . . . . . . . . . . . . . . . . 135
COMPLETE ASSEMBLIES . . . . . . . . . . . . . . .78 INTER-AXLE POWER DIVIDER WITHOUT
CORROSION PREVENTION . . . . . . . . . . . . .78 LOCKOUT — DISASSEMBLY . . . . . . . . . . 53
INTER-AXLE POWER DIVIDER WITHOUT
D LOCKOUT — REASSEMBLY . . . . . . . . . . . 91
DESCRIPTION AND OPERATION . . . . . . . . . .7 INTER-AXLE THROUGH (DRIVE) SHAFT
DETERMINING BEVEL PINION TO INSTALLATION . . . . . . . . . . . . . . . . . . . . . 136
CARRIER HOUSING SHIM PACK . . . . . .104 INTER-AXLE THROUGH SHAFT —
DIFFERENTIAL COMPONENTS AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 73
OPERATION . . . . . . . . . . . . . . . . . . . . . . . .12 INTER-AXLE THROUGH SHAFT —
DIFFERENTIAL INSTALLATION . . . . . . . . . .112 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 82
DIFFERENTIAL REMOVAL . . . . . . . . . . . . . . .36 INTER-WHEEL POWER DIVIDER . . . . . . . . . . 8
DIFFERENTIAL SPIDER WEAR LIMITS . . . .76 INTER-WHEEL POWER DIVIDER
DISASSEMBLED PARTS . . . . . . . . . . . . . . . .78 DIFFERENTIAL — DISASSEMBLY . . . . . . 52
DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 INTER-WHEEL POWER DIVIDER
DIFFERENTIAL — REASSEMBLY . . . . . . 109
E INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . .15
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400 INDEX
L R
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . .12 REAR REAR BEVEL PINION —
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 59
M REAR REAR BEVEL PINION —
MACK DUAL-REDUCTION TANDEM REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 99
CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 REAR REAR CARRIER . . . . . . . . . . . . . . . . . . 2
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . .31 REASSEMBLY FLOW CHART . . . . . . . . . . . . 80
REMOVING THE HELICAL (SPUR)
N
PINION SHAFT . . . . . . . . . . . . . . . . . . . . . . 44
NEW STYLE AXLE SHAFTS . . . . . . . . . . . . . . .3
REMOVING THE INTER-AXLE
O THROUGH SHAFT . . . . . . . . . . . . . . . . . . . 39
OVERHAUL RECOMMENDATIONS . . . . . . . .13 ROUGH PARTS . . . . . . . . . . . . . . . . . . . . . . . 78
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . .76
S
P SETTING THE GEAR PATTERNS . . . . . . . . 122
PINION SHAFT WEAR LIMITS . . . . . . . . . . . .76 SETTING THE PRELOAD . . . . . . . . . . . . . . 120
POWER DIVIDER . . . . . . . . . . . . . . . . . . . . . .77 SPECIAL TOOLS AND EQUIPMENT . . . . . . 149
POWER DIVIDER IDENTIFICATION . . . . . . . .6 SPECIAL TOOLS CHART . . . . . . . . . . . . . . . 150
POWER DIVIDER LOCKOUT . . . . . . . . . . . . . .9
T
POWER DIVIDER LOCKOUT —
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 25
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . .66
TROUBLESHOOTING AND DIAGNOSING
POWER DIVIDER LOCKOUT —
MISMATCHED CARRIER RATIOS FOR
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .83
TANDEM CARRIERS . . . . . . . . . . . . . . . . . 28
POWER DIVIDER OPERATION . . . . . . . . . . . .8
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NOTES
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NOTES
Page 194
MACK DUAL
REDUCTION
TANDEM
CARRIER
95/96 SERIES
PRINTED IN U.S.A.
13 -103 © MACK TRUCKS, INC. 1998