Anda di halaman 1dari 172

MACK DUAL

REDUCTION

TANDEM
CARRIER MAY 1998
(REVISED)
13-103

95/96 SERIES
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PLEASE LET US KNOW!


Your comments and suggestions will help
us improve this manual!
Please complete and mail this form or FAX
your comments to: (610) 709-3800.
Manual: _______________________________ Publication Number: _______
Vehicle Model: _________________________ Model Year: ______________
Do you find procedures properly organized and easy to follow? m Yes m No
If not, please explain: ______________________________________________
_______________________________________________________________
_______________________________________________________________
Manual page numbers: _____________________________________________
Are there any important procedures or other information presently not in this
manual that you would like to see included? m Yes m No
If yes, please describe: _____________________________________________
_______________________________________________________________
_______________________________________________________________
Did you find any errors in the procedures or illustrations? m Yes m No
If yes, what pages? _______________________________________________
Please explain: ___________________________________________________
_______________________________________________________________
Please include a copy of each page in question and mark your comments and
suggestions.
Name: ________________________________ Phone: (_____) _____-_______
Company: _______________________________________________________
Address: ________________________________________________________
City: _________________________________ State: _______ Zip: _______
Position Title: ____________________________________________________

Thank You For Your Assistance


Mack Trucks, Inc.
(ATTENTION: RTS STAFF, 6S3)

DO NOT STAPLE — USE TRANSPARENT TAPE


Busreply.fm Page 1 Thursday, April 30, 1998 11:15 AM

FOLD ALONG THIS LINE • DO NOT STAPLE • USE TRANSPARENT TAPE

NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES

BUSINESS REPLY MAIL


FIRST CLASS MAIL PERMIT NO. 1602 ALLENTOWN, PA

POSTAGE WILL BE PAID BY ADDRESSEE

SERVICE PUBLICATIONS (RTS), 6S3


MACK TRUCKS INC
WORLD HEADQUARTERS
PO BOX M
ALLENTOWN PA 18105-9972

FOLD ALONG THIS LINE


MACK DUAL REDUCTION
TANDEM CARRIER
95/96 SERIES

MAY 1998 © MACK TRUCKS, INC. 1998


(REVISED) 13-103
front.fm Page ii Thursday, April 30, 1998 9:08 AM

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.

ii
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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 which could result in 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.

An operating procedure, practice, condition, etc., which is essential to emphasize.

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.

2. Before working on a vehicle, place the transmission in neutral, set the


parking brakes, and block the wheels.

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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EXPLANATION OF NUMERICAL CODE

EXPLANATION OF NUMERICAL CODE

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EXPLANATION OF NUMERICAL CODE


EXPLANATION OF 3-DIGIT GROUP 300 — CLUTCH, TRANSMISSION,
TRANSFER CASE AND PTO
NUMERICAL CODE GROUP 400 — STEERING, AXLES, WHEELS
The organization of MACK service manuals has AND TIRES, DRIVELINE
been upgraded to standardize manual content GROUP 500 — BRAKES, AUXILIARY
according to a reference system based on SYSTEMS
component identification. The new reference GROUP 600 — CAB, TRUCK BODY
system will help to link the information contained
in this publication with related information GROUP 700 — ELECTRICAL
included in other MACK service-warranty
publications, such as associated service bulletins, The second two digits of the 3-digit code
warranty manuals, and the TS477 Labor Time are used to identify the system, assembly or
Standards Manual. subassembly, as appropriate, within each of
the groupings. The codes applicable to this
The system is based on a numerical code, the publication are shown at the TOP OF EACH
first digit of which identifies the general PAGE and at SECTION HEADINGS as
component grouping as listed here: necessary, and may also appear in the TABLE
OF CONTENTS, to guide you to specific
GROUP 000 — INSPECTIONS AND component information.
MISCELLANEOUS
Additionally, a two-character alpha code (i.e. [CF]
GROUP 100 — CHASSIS CARRIER ASSEMBLY) may be shown with an
GROUP 200 — ENGINE operation. This alpha code, in combination with
the three-digit Group number, identifies the
specific assembly, subassembly or part, and
directly relates to the first five positions of
operation code listed in the Service Labor Time
Standards Manual, TS477.

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

Page 1
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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.

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. Figure 1 — Rear Rear Carrier Arrangement
MACK power dividers automatically provide a
3-to-1 torque-biasing capability to the axle with Another important feature of both the front rear
the best traction. and rear rear carriers is the inter-wheel or
However, during certain off-highway (low traction) differential power divider with a command wedge-
situations, it is advantageous to couple the type differential, instead of the conventional gear-
tandem carriers together in a straight-through type differential. Similar to the inter-axle power
positive drive arrangement. An optional power divider, the inter-wheel power divider is also fully
divider with lockout feature is available for this automatic, contains no gears and provides a
purpose. The driver can control the power divider 3-to-1 torque biasing capability to the wheel with
lockout from the cab of the vehicle. The lockout the best traction.
consists of an air-actuated piston which controls
a shift fork and gear-type sliding clutch. The Features
clutch is splined to the cage assembly and is
moved to engage with the outer cam of the power Current production dual-reduction carriers are
divider. This couples the cage and outer cam provided with:
together and effectively locks out the function of r Durapoid™ spiral bevel gears for first reduction
the power divider for emergency traction
situations. r Coarse-pitch, wide-faced helical gearset for
second reduction
Tire matching is still required on units with or
without an inter-axle power divider as r Four-pinion, closed-type gear differential
mismatched tires equates to mismatched ratios. (unless otherwise specified)
Tire matching is required with a power divider or
premature unit failure will occur.
Other carriers are available without the inter-axle
power divider, in which case the carriers are
coupled together in a straight-through drive
arrangement. This combination is quite rare and
will not be covered in this manual.

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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.

New design axle shafts for the 95/96 series


carriers contain a “necked down” area near the
outside end of the shaft. This necked down area
is designed to act as a fuse so that the drivetrain
may be protected from overload. These shafts
must be installed in the axle housing with the
necked down area facing outward. The word
“OUTSIDE” is stamped on the outer face of the
shaft to prevent confusion during installation.
Refer to Figure 3 for illustration of new axle with
necked down area.

Figure 3 — New Design Axle Shaft

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NOTES

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400 CARRIER VISUAL IDENTIFICATION

CARRIER VISUAL IDENTIFICATION

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400 CARRIER VISUAL IDENTIFICATION


CARRIER IDENTIFICATION Power Divider Identification
Before disassembly, determine which type of Pay special attention to units with the initial “P”
carrier is being serviced. Carriers use the and the numeral “1”. The letter “P” in the prefix
designations shown in Figure 4 to define specific indicates that the carrier is equipped with an
descriptive information. 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.
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.

Figure 4 — Carrier Stamping Location and Information

Information stamped into the unit indicates


features included by the manufacturer.

Figure 5 — Power Divider Stamping Location

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400 DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

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400 DESCRIPTION AND OPERATION


POWER DIVIDER OPERATION
The power divider is a torque-proportioning
differential 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
Figure 7 — Axle Loss of Traction
capacity of the spinning wheel. Generally this is
not enough to move the vehicle and the majority
of the available torque is lost at the spinning Inter-Wheel Power Divider
wheel. When this same situation occurs with the
The MACK inter-wheel power divider functions in
MACK power divider, power is automatically
much the same manner as the inter-axle power
diverted to the non-spinning wheel(s) for
divider with torque biasing occurring from wheel
maximum traction.
to wheel. The inter-wheel power divider may be
used in conjunction with the inter-axle power
Inter-Axle Power Divider divider to provide increased maneuverability in
The MACK inter-axle power divider provides poor traction situations.
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 the wheel
to allow power to the axle with traction.

Figure 8 — Inter-Wheel Power Divider

Figure 6 — Normal Traction Conditions

Figure 9 — One Wheel Loss of Traction

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400 DESCRIPTION AND OPERATION


Power Divider Lockout The lockout device prevents the operation of the
power divider. It consists of an air-actuated,
A power divider lockout is available for gear-type sliding clutch which, when engaged,
exceptionally severe operating conditions, where couples the cage to the outer cam to effectively
road surfaces are so slippery that traction is lock out the function of the power divider
difficult to achieve even with the MACK power differential as shown in Figures 10 and 11.
divider. The advantage of the power divider
lockout is that tandem carriers can be coupled
together in a straight-through positive drive
arrangement. This enables the operator to Once good traction is re-established, power
achieve maximum traction under these severe divider lockout should be disengaged.
conditions. For this type of operation, a lockout
device, controlled from the cab by the driver, may
be incorporated with the power divider.

Figure 10 — Inter-Axle Power Divider Lockout Disengaged

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400 DESCRIPTION AND OPERATION

Figure 11 — Inter-Axle Power Divider Lockout Engaged

The power divider with lockout is mounted in a


separate housing from the bevel pinion assembly.
The bevel pinion housing contains the hollow
bevel pinion, carried in an overhung arrangement
by a pair of tapered roller bearings and the outer
cam portion of the power divider assembly. The
through (inter-axle drive) shaft splines with the
power divider inner cam and is mounted through
the bevel pinion in a quill arrangement.

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400 DESCRIPTION AND OPERATION

Figure 12 — Front Rear Carrier Arrangement

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400 DESCRIPTION AND OPERATION


CARRIER COMPONENTS AND Lubrication
OPERATION When the vehicle is in motion, all moving parts in
Except for the differences just noted, both carriers both tandem carriers are constantly bathed in oil
are the same. The helical pinion shaft and by the various pumping actions of the moving
Durapoid bevel gear are mounted at right angles parts.
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
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.

Differential Components and


Operation
The differential assembly consists of four bevel
pinions in steel-on-steel bearing engagement Figure 13 — Splash Lubrication
with the spider and two axle-driving side gears A pump on the rear half of the through (inter-axle
with steel-backed, ball-indented thrust washers drive) shaft sends oil to the inter-axle power
behind pinions and side gears. Lubricant trapped divider. The entire length of the pump is enclosed
in the ball indentations forms small reservoirs in a close-fitting tube, anchored to the rear
which provide adequate lubrication at these bearing retainer and oil trough assembly for the
points when differential action is taking place. through (inter-axle drive) shaft.
These parts are enclosed in the differential
casing consisting of two mated and matching
halves. In addition to the bolting flange of the
casing halves, 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 to the differential casings
through the splines. This relieves the bull gear
mounting capscrews 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 preload is
accomplished by a slotted adjusting nut threaded
to the inboard side of the RH bearing cup which is Figure 14 — Inter-Axle Power Divider Pump Operation
otherwise free to move laterally. The LH bearing
cup flange holds itself stationary against the LH Bevel gear throw-off supplies the pump intake
bearing pedestal leg. port on top of the through (inter-axle drive) shaft
bearing retainer with lubricant. In forward vehicle
motion, the helix band of the pump forces oil
forward along the through (inter-axle drive) 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.

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400 DESCRIPTION AND OPERATION


Another collector trough, integral with the carrier r Tighten all yoke or flange nuts as
housing, directs throw-off oil from the Durapoid recommended. Refer to the BEARING
gearset directly to the drive-pinion tapered roller ADJUSTMENTS & TORQUE CHART section.
bearings through drilled and cast-in oil passages. If a heavy-duty air impact wrench with one-inch
This oil returns to the reservoir by gravity. All drive is available, high torques should be no
other gears and bearings are lubricated by their problem. However, conventional methods of
own pumping action created when running in oil. 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
This information applies to all 95/96 series top- operation.
mounted, dual-reduction, tandem carriers. This r Make a special tool if the gear-jamming
includes the front rear-axle tandem carriers method is to be used. The tool is a short rod
having either the lockout or non-lockout type (slug), about two inches long, and made of a
inter-axle power divider differentials. However, all 1/2-inch-diameter mild steel. Attach a handle at
95/96 series carriers are identical, except for the one end of the slug tool by welding a rod that is
optional input through-drive arrangement of the two feet long and 1/4 or 3/8 inch in diameter.
lead carrier. Skip all information that does not One person can safely hold this gear-jamming
apply to the particular unit being serviced, such tool in the gear mesh while someone else pulls
as a CRD-96 which has neither a lockout nor an the wrench. Because of the long handle, this
inter-axle power divider. tool cannot be left accidentally in the bevel
gear compartment where it could cause
damage.

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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400 EXPLODED VIEWS

EXPLODED VIEWS

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400 EXPLODED VIEWS

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400 EXPLODED VIEWS

1. Capscrew (5) 13. Shift Fork Shaft 25. Capscrew (10)


2. Lock Washer (5) 14. Capscrew (4) 26. Lock Washer (10)
3. Cylinder Housing 15. Lock Washer (4) 27. Power Divider Lockout Housing
4. Gasket 16. Cover Plate 28. O-Ring
5. Locknut 17. Shift Fork 29. Ball Bearing (2)
6. Washer 18. Locking Capscrew (Setscrew) 30. Sliding Clutch
7. O-Ring 19. Oil Seal 31. Cage
8. Felt Ring 20. Capscrew (6) 32. Wedge (24)
9. Piston 21. Lock Washer (6) 33. Inner Ring
10. Washer 22. Bearing Retainer Cover 34. Outer Ring
11. Spacer 23. Gasket (Shim) 35. Inner Cam
12. Spring 24. O-Ring
Figure 16 — Exploded View of Power Divider Lockout

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400 EXPLODED VIEWS

1. Capscrew 8. Cover (Bearing Retainer) 15. Cage


2. Clamp Plate 9. O-Ring 16. Inner Ring
3. Yoke 10. Ball Bearing (2) 17. Outer Ring
4. Yoke Sleeve 11. Capscrew (10) 18. Inner Cam
5. Oil Seal 12. Lock Washer (10) 19. Wedge (24)
6. Capscrew (7) 13. Power Divider Housing
7. Lock Washer (7) 14. O-Ring
Figure 17 — Exploded View of Inter-Axle Power Divider Without Lockout

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400 EXPLODED VIEWS

1. Nut 6. Capscrew (6) 10. Spacer


2. Outer Cam 7. Lock Washer (6) 11. Bearing Cup
3. Bearing Cone 8. Selective Shim 12. Bearing Cone
4. Bearing Cup 9. Selective Spacer 13. Bevel Pinion
5. Bevel Pinion Housing
Figure 18 — Exploded View of Front Rear Bevel Pinion

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400 EXPLODED VIEWS

1. Capscrew 8. Gasket 14. Lock Washer (6)


2. Clamp Plate 9. Oil Seal 15. Bevel Pinion Housing
3. Yoke 10. Bearing Cone 16. Selective Shim
4. Yoke Sleeve 11. Bearing Cup 17. Bearing Cup
5. Capscrew (6) 12. Selective Spacer 18. Bearing Cone
6. Lock Washer (6) 13. Capscrew (6) 19. Bevel Pinion
7. Bearing Retainer Cover
Figure 19 — Exploded View of Rear Rear Bevel Pinion

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400 EXPLODED VIEWS

1. Helical Pinion Shaft 8. Capscrew (3) 15. Bearing Cone


2. Key 9. Capscrew (3) 16. Clamp Plate (Helical Pinion End)
3. Slotted Bearing Cup 10. Pin 17. Gasket
4. Bearing Cone 11. Selective Spacer 18. Cover
5. Bevel Gear 12. Shim 19. Lock Washer (6)
6. Clamp Plate Shim 13. Bearing Retainer 20. Capscrew (6)
7. Clamp Plate (Bevel Gear End) 14. Bearing Cup
Figure 20 — Exploded View of Helical (Spur) Pinion Shaft

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400 EXPLODED VIEWS

1. Inner Cam 5. Cage 9. Casing


2. Retaining Ring 6. Bearing Cone 10. Bull Gear
3. Bushing 7. Dowel Bolt (15) 11. Washer (15)
4. Wedge 8. Outer Cam 12. Nut (15)
Figure 21 — Exploded View of Inter-Wheel Power Divider Differential

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400 EXPLODED VIEWS

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 EXPLODED VIEWS

1. Gasket 6. Gasket 11. Yoke Sleeve


2. Through Shaft Housing 7. Bearing Cover 12. Yoke
3. Ball Bearing 8. Lock Washer (4) 13. Clamp Plate
4. Oil Pump (Not Serviced Separately) 9. Capscrew (4) 14. Capscrew
5. Through Shaft 10. Oil Seal
Figure 23 — Exploded View of Inter-Axle Through Shaft Assembly

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400 TROUBLESHOOTING

TROUBLESHOOTING

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400 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
lubricant.
2. Improper lubrication. 2. Drain and refill with recommended
lubricant to proper level.
3. Contamination of lubricant. 3. Check servicing intervals. Check for
water leaks. Drain and refill to proper
level with recommended lubricant.
4. Driveline phasing. 4. Correct phasing.
5. Driveline angle. 5. Correct angle.
6. Worn, damaged or failed yoke. 6. Replace yoke.
7. Universal joint 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.
Oil Leakage 1. Clogged breather. 1. Replace breather.
2. Failed seals or gaskets. 2. Replace failed seals or gaskets.
3. Cracked housing. 3. Replace housing.
Bearing Failure 1. Improper lubrication. 1. Check specification for proper
lubrication, replace failed bearing.
2. Worn, damaged or failed yoke. 2. Replace yoke.
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.
Vibration 1. Driveline phasing. 1. Correct phasing.
2. Driveline angle. 2. Correct angle.
3. Worn, damaged or failed yoke. 3. Replace yoke.
4. Universal joint failure. 4. Replace universal joint.
5. Loose clamp plate capscrew. 5. Tighten capscrew to recommended
torque.
6. Worn or failed bearings. 6. Replace bearings.
7. Mixed gear ratios. 7. Check ratios, both carriers must have
same ratio.

401390a

Continued on next page.

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400 TROUBLESHOOTING

Symptom Probable Cause Remedy


Gear Failure 1. Low lubrication. 1. Fill to proper level using recommended
lubricant.
2. Improper lubrication. 2. Check Maintenance and Lubrication
Manual (TS494) for proper lubrication.
3. Contamination of lubricant. 3. Check servicing intervals, check for
water leaks. Replace failed parts and
fill to proper level using recommended
lubricant.
4. Driver abuse. 4. Instruct driver in proper operating
procedures.
5. Worn or failed bearings. 5. Replace failed parts. Make certain
gears are properly aligned. Check
tooth contact pattern.
6. Loose clamp plate capscrews. 6. Replace failed parts. Tighten
capscrews 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.
Power Divider Failure 1. Driver abuse. 1. Instruct driver in proper operating
procedures.
2. Tire size. 2. Check for proper matching of tires.
3. Loose clamp plate capscrews. 3. Replace damaged parts. Tighten
capscrews to specified 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. Mixed gear ratios. 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 seal.
11. Faulty control valve. 11. Replace.
12. Failed spring. 12. Replace.
13. Seized components. 13. Replace.
14. Failed shifter fork. 14. Replace.
Excessive Tire Scuffing or Wear 1. Mixed gear ratios. 1. Check ratios. Both carriers must have
same ratio.

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.

Figure 24 — Carrier Ratio Stamping Location

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. Figure 25 — Dual Reduction Carrier Gear Train

Make sure the eight tandem rear tires are


properly matched. Refer to MACK Service
Manual 15-101 Wheels, Rims and Tires.

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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.

Example: Bevel gear — 19 teeth


Bevel pinion — 13 teeth
19/13 = 1.46

Helical bull gear — 55 teeth


Helical pinion gear — 16 teeth
55/16 = 3.44

1.46 x 3.44 = 5.02 Ratio

Correct all mismatched gear sets.

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NOTES

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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

Be careful not to burn your finger in hot gear


oil when checking the oil level in the carrier.

When checking the oil level in the rear axles,


check after the vehicle has been operated, make
sure the unit is at normal operating temperature
and chassis is parked on level ground. Check the
oil level by removing the filler plugs from the axle
housings and the bevel gear compartments. The
level is correct when oil runs out of the filler plug Figure 27 — Correct Oil Level
hole in the axle housing, and slightly below the
filler plug hole in the bevel gear compartment. If
the level in the axle housing is low, add oil to the
axle housing and the bevel gear compartment
until the oil is level with the bottom of the filler
plug holes.

Figure 26 — Incorrect Oil Level

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400 MAINTENANCE

Figure 28 — Filler and Drain Plug Locations

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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.

Remove the filler plug from the inter-axle power


divider (if equipped) and add two pints of the
recommended oil. Remove the filler plug(s) from
the axle housing(s) and the bevel gear
compartment. Fill each of the carrier
compartments with specified oil to the level of the
filler plug hole.

Reinstall and snug the filler plugs in the carrier


housing, power divider and bevel pinion
compartment. Then tighten each to specified
torque. Change the oil at the intervals specified in
the Maintenance and Lubrication Manual, TS494.

Figure 29 — Carrier Housing Air Breather Cap

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400 CARRIER DISASSEMBLY

CARRIER DISASSEMBLY

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400 CARRIER DISASSEMBLY


[465/475] DIFFERENTIAL 2. Remove the remaining 11 capscrews and
washers retaining the carrier housing to the
REMOVAL axle housing.
3. Remove the carrier from the vehicle. Note
this may require removal of the entire axle
housing to access the carrier.
Set all major components on a clean work
surface for later disassembly. 4. Set the carrier in an approved carrier repair
stand such as J 3409-D.

This procedure is used when removing either the


inter-wheel power divider type or the four-pinion
type differential.

1. Remove the bevel gear compartment cover


and all three of the inside carrier mounting
bolts.

Figure 31 — Mounting Carrier in Stand

5. Secure the carrier to the stand with a


minimum of four bolts and tighten securely.
6. Rotate stand, holding the carrier housing so
the differential assembly is on top.

Figure 30 — Bevel Gear Compartment Cover Removed


and Hidden Mounting Bolts Accessible

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400 CARRIER DISASSEMBLY


7. Remove the cotter pin and the straight pin in 8. Punch-mark bearing caps and their mating
the differential bearing caps. pedestals to ensure reassembly in their
original positions.

400277a

Figure 34 — Marking Bearing Retaining Cap


Figure 32 — Removing Cotter Pin

400278a

Figure 35 — Marking Bearing Retaining Cap Mated Part


(Carrier Housing)

Figure 33 — Removing Straight Pin


Also mark the relationship of the bull gear to the
side casings.
1. Mark bull gear to side casings:
r Single markings for gear to 1st casing
r Double markings for gear to 2nd casing
2. This maintains relationship of bull gear to
each side casing, plus the casings to each
other (i.e., casings must line up).
Marking the relationship of these components
eliminates a great deal of confusion at time of
reassembly.

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400 CARRIER DISASSEMBLY


9. Using differential bearing-nut adjusting 11. Remove the bearing retainer caps. Be very
wrench J 26437, loosen the bearing careful not to lose them.
adjusting nut approximately one turn.

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.

Figure 38 — Removing Bearing Retainer Caps

12. Using a hoist, remove the differential/bull


gear assembly.

LIFTING
Figure 36 — Loosening Bearing Adjusting Nut TOOL

10. Remove the bearing retainer capscrews.

400282a

Figure 39 — Removing the Differential Assembly from


the Carrier Housing

400280a

Figure 37 — Removing Bearing Cap Capscrews

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400 CARRIER DISASSEMBLY


[466] REMOVING THE
INTER-AXLE THROUGH SHAFT
13. Remove the capscrews from the inter-axle
through shaft rear bearing cover.

Figure 42 — Removing Inter-Axle Through Shaft

16. Install two 1/2-13 jackscrews into the


through shaft housing.

Figure 40 — Removing Capscrews from the Rear


Bearing Cover

14. Remove the gasket from the through shaft


rear bearing cover.

Figure 43 — Installing Jackscrews

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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400 CARRIER DISASSEMBLY

Before removal, note the position of the inter-axle


through shaft retainer trough so that it can be
reinstalled in the proper position. The trough
faces up.

Punch mark the top lip of through shaft retainer


and the mating surface of the carrier housing.

Figure 45 — Removing Front Power Divider


Capscrews

22. Install two 1/2-13 jackscrews at


approximately the 11 o’clock and the
5 o’clock positions on the power divider
housing.
Figure 44 — Trough Position 23. Install alignment pins in bolt holes at
horizontally opposed positions to support
19. Remove the gasket from the inter-axle power divider housing during removal. This
through shaft retainer cap that mounts to the is necessary to maintain alignment of the
housing surface. power divider wedges to aid in removal of
the unit.

Removing the gasket may require using a gasket


scraper. Use caution to prevent damage to the Alignment pins can be manufactured on site from
mating surface. bolts obtained locally. Pins should be about 2-1/2
inches long and with 1/2-13 inch threads.
20. Install a sling-type lifting strap onto the
power divider (with or without lockout)
assembly.
21. Remove the front power divider (with or
without lockout) assembly capscrews.

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400 CARRIER DISASSEMBLY

Use protective eye wear when performing this


grinding procedure to prevent personal injury.

400292a

Figure 46 — Making Alignment Pins

24. Back out the power divider housing from


front bevel housing by alternately turning the
jackscrews. Alternating, even turning of the
jackscrews is essential to prevent the power
divider from becoming cocked and binding in
the bevel housing bore.
25. After the power divider has been freed from
the bore of the bevel housing, remove the
jackscrews from the power divider.
26. Remove the front power divider (with or
without lockout) assembly.
Figure 48 — Removing Cam Nut Staking

28. Install the prefabricated gear jamming tool or


a brass drift between the bevel pinion and
bevel gear to prevent bevel pinion rotation
while removing the cam nut. Refer to
OVERHAUL RECOMMENDATIONS in the
DESCRIPTION AND OPERATION section
for gear jamming tool dimensions.

Figure 47 — Removing Front Power Divider


Assembly

27. Remove the power divider cam nut staking,


using a die grinder and thin cut-off wheel.

Remove enough material between the lands of


the bevel pinion end, to allow removal of the nut
and prevent damage to the bevel pinion.

Figure 49 — Gear Jamming Tool or Brass Drift Installed

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400 CARRIER DISASSEMBLY


29. Install a jack stand or other stand capable of [466/476] BEVEL PINION
holding the extension handle of the torque
multiplier secure against the 1,300 to HOUSING REMOVAL (FRONT
1,500 lb-ft (1763 to 2034 NNm) of torque REAR OR REAR REAR)
necessary to release the cam nut.
31. Remove the capscrews retaining the front
30. Remove the power divider cam nut, using rear or rear rear bevel pinion housing to the
special wrench J 26577 and torque multiplier carrier housing.
setup.

An extreme amount of torque is applied to the


power divider cam nut which requires
considerable force to remove. Support the handle
of the torque multiplier with a jackstand.

Figure 52 — Remove Bevel Housing Capscrews

32. Install alignment pins in bolt holes at


horizontally opposed positions to support
bevel housing during removal. This is
necessary to prevent damage to the shim
packs.

Alignment pins can be manufactured on site from


bolts obtained locally. Pins should be about
Figure 50 — Removing Power Divider Cam Nut 2-1/2 inches long and with 5/8-11 inch threads.

400292a

Figure 53 — Making Alignment Pins

Figure 51 — Power Divider Cam Nut Wrench

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400 CARRIER DISASSEMBLY

ALIGNING
PIN

400293a

Figure 54 — Housing Supported on Alignment Pins


Figure 55 — Removing Front Rear Bevel Pinion Housing
33. Install two 1/2-13 jackscrews into the bevel
pinion housing.
34. Back out the bevel pinion housing by
alternately turning the jackscrews.
Alternating, even turning of the jackscrews is
essential to prevent the housing pilot from
becoming cocked and binding in the carrier
housing bore.
35. After the bevel pinion has been freed from
the bore of the carrier, remove the
jackscrews from the bevel pinion housing.
36. Wire the shims together and tag for reuse at
assembly. Using a micrometer, measure the
shim pack for reassembly purposes. Figure 56 — Removing Rear Rear Bevel Pinion Housing

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400 CARRIER DISASSEMBLY


[466] REMOVING THE HELICAL 39. Install a suitable gear-jamming tool between
the helical pinion gear and the bull gear.
(SPUR) PINION SHAFT
40. Remove the clamp plate capscrews and the
37. Remove the six capscrews retaining the clamp plate. Replace the clamp plate
helical pinion shaft assembly cover. capscrews with new grade 8 capscrews at
final reassembly.

Be sure to have new capscrews on hand for final


reassembly.

Figure 57 — Removing Pinion Cover Capscrews

38. Remove the pinion cover and separate the


gasket from the cover. It may be necessary
to use a gasket scraper to remove some
gasket material from the cover. Figure 59 — Removing Clamp Plate Capscrews

Figure 58 — Removing Pinion Cover and


Separating Gasket
Figure 60 — Clamp Plate Removed

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400 CARRIER DISASSEMBLY


43. Remove the pinion shaft assembly.

The clamp-plate side stamped “OUT” faces


outward. This ensures that the clamping force is
evenly distributed upon installation.

41. 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.
400301a

Figure 63 — Removing Pinion Shaft Assembly

44. Using two 1/2-13 jackscrews, remove the


helical pinion shaft bearing retainer.
45. Remove the bearing retainer and shim pack.
Remove shims, and wire together. Using a
micrometer, measure the shim pack. Tag for
reuse during assembly.

Figure 61 — Gear Puller Installed to Push Helical Pinion

42. Remove the bearing cone.

Figure 64 — Removing Bearing Retainer and Shims

Figure 62 — Removing Bearing Cone

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400 CARRIER DISASSEMBLY


46. After the bearing retainer has been freed
from the bore of the carrier, remove the
jackscrews from the retainer.
47. Using a hammer and drift, remove the
remaining helical pinion retainer bearing cup
from the carrier housing.

Figure 65 — Removing Helical Pinion Bearing Cup

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400 BENCH PROCEDURES

BENCH PROCEDURES — COMPONENT


DISASSEMBLY

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400 BENCH PROCEDURES


[465/475] FOUR-PINION TYPE DIFFERENTIAL — DISASSEMBLY

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

Before starting to disassemble the bull gear/


differential components, mark the position of
each side in relation to the bull gear. These
components are line-reamed and turned
together. Therefore, it is essential to reassemble
them in the same position.

1. Clamp the bull gear/differential assembly in


a suitable vise. Loosen and remove the nuts
and capscrews that secure the differential
side casings to the bull gear.

Figure 67 — Removing Nuts and Capscrews

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400 BENCH PROCEDURES


3. Temporarily install two side-casing
capscrews and nuts to hold the side casings
together. Then, turn the assembly over.
During disassembly, mark the bull gear in relation Remove the side casing capscrews and the
to the casing. Mark both sides of the bull gear for previously pressed off differential half.
reassembly purposes, as side casings are
identical. This prevents changing the original
rotation of the bull gear and mismatching bearing
cups and cones.

BULL
GEAR
MARK
CASING
MARK

Figure 70 — Install Temporary Support Bolts and Nuts


400482a

Figure 68 — Marking Both Sides

2. Remove the bottom differential side casing


from the bull gear and install the differential
assembly in a press. Apply pressure to the
center of the spider assembly. Use a driver
that will fit through the opening in the side
gear, yet is large enough to apply broad
force to the center of the spider.

Figure 71 — Removing Differential Half

Figure 69 — Separating Differential Half

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400 BENCH PROCEDURES


4. Remove the side-gear thrust washer. 6. Remove the spider and pinion gear
assembly. This assembly includes the
spider, four-pinion gears and four-pinion
gear thrust washers.

Figure 72 — Removing Side-Gear Thrust Washer

5. Remove the side gear. Note position of


pinion gear thrust washer locating tab. Figure 75 — Removing Spider and Pinion
Gear Assembly

7. Remove the second side gear.

Figure 73 — Removing Side Gear

Figure 76 — Removing Side Gear

Figure 74 — Pinion Gear Thrust Washer Locating Tabs

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400 BENCH PROCEDURES


8. Remove the remaining side-gear thrust
washer.

Note the direction of each side-gear thrust


washer. The dimpled side of the thrust washer
must face the side gear. The dimples provide
improved lubrication retention on the thrust face
of the side gear.

Figure 78 — Removing Remaining Differential


Side Casing

10. 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 as
shown in Figure 79. Refer to the Special
Tools Chart in the SPECIAL TOOLS AND
EQUIPMENT section for the correct
segments and adapter rings.

Figure 77 — Remaining Side-Gear Thrust


Washer Removed
Exercise extreme caution during the pressing
9. Press the remaining differential side casing operation, even when using specified tools. The
from the bull gear, using a hydraulic press bearing cone may fly apart during removal. Use a
and press extension. scatter shield and be sure to have a new bearing
cone ready for installation.

401389a

Figure 79 — Removing Bearing Cone from Side Casing

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400 BENCH PROCEDURES


[465/475] INTER-WHEEL POWER DIVIDER
DIFFERENTIAL — DISASSEMBLY

1. Inner Cam 5. Cage 9. Casing


2. Retaining Ring 6. Bearing Cone 10. Bull Gear
3. Bushing 7. Dowel Bolt (15) 11. Washer (15)
4. Wedge 8. Outer Cam 12. Nut (15)
Figure 80 — Exploded View of Inter-Wheel Power Divider Differential

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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400 BENCH PROCEDURES


[465] INTER-AXLE POWER DIVIDER WITHOUT
LOCKOUT — DISASSEMBLY

1. Capscrew 8. Cover (Bearing Retainer) 15. Cage


2. Clamp Plate 9. O-Ring 16. Inner Ring
3. Yoke 10. Ball Bearing (2) 17. Outer Ring
4. Yoke Sleeve 11. Capscrew (10) 18. Inner Cam
5. Oil Seal 12. Lock Washer (10) 19. Wedge (24)
6. Capscrew (7) 13. Power Divider Housing
7. Lock Washer (7) 14. O-Ring
Figure 81 — Exploded View of Inter-Axle Power Divider Without Lockout

The disassembly procedures for inter-axle power


divider without lockout, front rear bevel pinion,
power divider lockout, and inter-axle through
shaft, will only be found on vehicles with a
tandem rear axle.

1. Remove the capscrews from the inter-axle


power divider cover plate (bearing retainer).

Figure 82 — Removing Bearing Retainer Capscrews

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400 BENCH PROCEDURES


2. Remove the bearing retainer cover from the 5. To replace the wedges, the retaining ring
housing. must first be removed. Push all upper
wedges in as far as possible. Then remove
3. If not already done, remove the inner cam
the retaining ring with expansion pliers.
from the cage assembly.

Figure 85 — Removing Retaining Ring


Figure 83 — Removing the Inner Cam

4. Use a hydraulic press to separate the cage


from the housing.
Before removing the wedges, note the alpha
character (arrow on early production carriers) on
the part of the wedges pointing outward. Reinstall
the wedges with the alpha character visible or
arrow pointing outward, as shown in Figure 86.

6. Remove the wedges by pulling straight out


with finger pressure.

Figure 84 — Pressing Cage Assembly Out of Housing

400354a

Figure 86 — Arrow on Wedges (May Also Be an


Alpha Character)

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400 BENCH PROCEDURES


7. Remove the inner ring. Use two 8. Remove the two ball bearings from the
screwdrivers to compress the inner retaining housing. Use a suitable drift and hammer.
ring until the ends overlap to allow removal.

Be careful when removing the inner retaining


ring. It may be sharp and can cause serious
personal injury.

Figure 88 — Removing the Ball Bearings

9. Remove the O-ring from the housing.


10. Remove the seal from the bearing retainer
cover using a suitable driver.

Figure 87 — Removing Inner Ring

Figure 89 — Removing Seal from Bearing


Retainer Cover

11. Remove the O-ring from the bearing retainer


cover groove.

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400 BENCH PROCEDURES


[466] FRONT REAR BEVEL PINION — DISASSEMBLY

1. Nut 6. Capscrew (6) 10. Spacer


2. Outer Cam 7. Lock Washer (6) 11. Bearing Cup
3. Bearing Cone 8. Selective Shim 12. Bearing Cone
4. Bearing Cup 9. Selective Spacer 13. Bevel Pinion
5. Bevel Pinion Housing
Figure 90 — Exploded View of Front Rear Bevel Pinion
1. Using a hydraulic press, push the bevel
pinion shaft through the outer cam, outer
bearing cone and bevel pinion housing.

Figure 91 — Pressing Out Bevel Pinion Shaft

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400 BENCH PROCEDURES


2. Using a drift and hammer, remove the outer
bearing cup from the housing.

Figure 92 — Removing Outer Bearing Cup


Figure 94 — Removing Thicker Spacer
3. Turn the housing over. Then in the same
manner, remove the inner bearing cup.
4. Remove the thinner selective spacer and the
thicker spacer from the bevel pinion shaft.

The chamfered ends of the spacers are installed


toward the bevel pinion gear.

Figure 93 — Removing Thinner Selective Spacer

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400 BENCH PROCEDURES


5. If the bearing on the bevel pinion must be The mating numbers on the bevel pinion and the
replaced, remove it using a hydraulic press bevel gear will always be the same. These
and the appropriate segment and adapter components must always be replaced as a set.
rings. Press the bearing off the bevel pinion
as shown in Figure 95. Refer to the Special The mounting distance represents the distance
Tools Chart in the SPECIAL TOOLS AND from the backface of the head of the bevel pinion
EQUIPMENT section for the correct to the center line of the bevel gear. This number
segments and adapter rings. helps in determining how many shims must be
installed to get the proper gear pattern.

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.

Figure 96 — Mating Number and Mounting Distance


Number

Figure 95 — Pressing Bearing off Bevel Pinion

6. Note and record the numerals stamped into


the pinion. They represent the mating
number (F7-18) and the mounting distance
(5.255 inches).

The actual mating number and mounting distance


number will probably differ from F7-18 and 5.255
inches, which are used here as examples.
Figure 97 — Determining the Mounting Distance

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400 BENCH PROCEDURES


[476] REAR REAR BEVEL PINION — DISASSEMBLY

1. Capscrew 8. Gasket 14. Lock Washer (6)


2. Clamp Plate 9. Oil Seal 15. Bevel Pinion Housing
3. Yoke 10. Bearing Cone 16. Selective Shim
4. Yoke Sleeve 11. Bearing Cup 17. Bearing Cup
5. Capscrew (6) 12. Selective Spacer 18. Bearing Cone
6. Lock Washer (6) 13. Capscrew (6) 19. Bevel Pinion
7. Bearing Retainer Cover
Figure 98 — Exploded View of Rear Rear Bevel Pinion

1. Remove the capscrews (item 5) from the


rear rear bevel pinion bearing retainer cover
GASKET
(item 7) and then remove the cover.
2. Remove gasket from bearing retainer cover.

400305a

Figure 99 — Removing Gasket from Bearing Retainer

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400 BENCH PROCEDURES


3. Remove the seal from the bearing retainer 5. Remove the spacer from the bevel pinion
cover, using a suitable drift punch and shaft.
hammer.

Figure 102 — Removing Spacer


Figure 100 — Removing Cover Seal
6. Remove the outer bearing from the bevel
4. Using a hydraulic press, separate the bevel pinion housing.
pinion shaft, selective spacer and inner
bearing cone from the bevel housing. Catch
or cushion the bevel pinion shaft during
disassembly.

Figure 103 — Removing Outer Bearing from Bevel


Pinion Housing

Figure 101 — Pressing Out Bevel Pinion Shaft

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400 BENCH PROCEDURES


7. If the bearing cone on the bevel pinion must 8. Using a hammer and drift punch, remove the
be replaced, position the pinion shaft in a bearing cups (inner and outer) from the
hydraulic press. Use the proper segments bevel pinion housing. Recesses are cast into
and adapter rings to remove the bearing. the housing for this purpose.
Refer to Figure 104 for the proper press
setup. Refer to the Special Tools Chart in the
SPECIAL TOOLS AND EQUIPMENT
section for the correct segments and adapter
rings.

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.

Figure 105 — Removing Bearing Cups from Housing

Figure 104 — Removing Inner Bearing Cone

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400 BENCH PROCEDURES


9. Note and record the numerals stamped into
the pinion. These numerals represent the
mating number (E7-53) and the mounting
distance (5.255 inches).

The actual mating number and mounting distance


number will probably differ from E7-53 and 5.255
inches, 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 Figure 106 — Mating Number and Mounting Distance
helps in determining how many shims must be Number Location
installed to get the proper gear pattern.

Figure 107 — Determining the Mounting Distance

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400 BENCH PROCEDURES


[466/476] HELICAL (SPUR) PINION SHAFT — DISASSEMBLY

1. Helical Pinion Shaft 8. Capscrew (3) 15. Bearing Cone


2. Key 9. Capscrew (3) 16. Clamp Plate (Helical Pinion End)
3. Slotted Bearing Cup 10. Pin 17. Gasket
4. Bearing Cone 11. Selective Spacer 18. Cover
5. Bevel Gear 12. Shim 19. Lock Washer (6)
6. Clamp Plate Shim 13. Bearing Retainer 20. Capscrew (6)
7. Clamp Plate (Bevel Gear End) 14. Bearing Cup
Figure 108 — Exploded View of Helical (Spur) Pinion Shaft

1. Secure the helical pinion shaft assembly in a


vise. Remove and discard the three
capscrews that retain the clamp plate.
Replace with new grade 8 capscrews at Be sure to have replacement capscrews for final
reassembly. Refer to Figure 108. reassembly.

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400 BENCH PROCEDURES

PRESS

PRESS
EXTENSION

BEVEL
GEAR

400391a

Figure 110 — Pressing Helical Pinion Shaft from


Bevel Gear
Figure 109 — Removing Clamp-Plate Capscrews
5. Remove the key from the helical pinion shaft
2. Remove the clamp plate. using a pin punch and hammer.
3. Remove the bevel gear clamp plate shims
and tag and secure for reassembly.
4. Place the pinion shaft into a hydraulic press.
Press the helical pinion shaft from the bevel
gear.

The hydraulic pressure required to move the


helical gear from the shaft may be as high as
40 tons. Press equipment must be capable of
reaching these pressures to replace the gear or
shaft. Figure 111 — Removing Key from Shaft

Make sure the press setup for this operation


is secure to prevent personal injury.

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400 BENCH PROCEDURES


6. Press out the helical pinion shaft from the 7. Using a hammer and drift, remove the
bearing cone, using the bearing cup for helical pinion retainer bearing outer cup. A
support. This action applies pressing force recess is cast into the retainer for this
through the bearing rollers. Refer to Figure purpose.
112.

Be sure a replacement bearing is available for


final reassembly.

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.
Figure 113 — Removing Helical Pinion Retainer
Bearing Cup

8. Remove the gasket from the retainer.

Figure 112 — Pressing Shaft Out of Bearing

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400 BENCH PROCEDURES


[466] POWER DIVIDER LOCKOUT — DISASSEMBLY

1. Capscrew (5) 13. Shift Fork Shaft 25. Capscrew (10)


2. Lock Washer (5) 14. Capscrew (4) 26. Lock Washer (10)
3. Cylinder Housing 15. Lock Washer (4) 27. Power Divider Lockout Housing
4. Gasket 16. Cover Plate 28. O-Ring
5. Locknut 17. Shift Fork 29. Ball Bearing (2)
6. Washer 18. Locking Capscrew (Setscrew) 30. Sliding Clutch
7. O-Ring 19. Oil Seal 31. Cage
8. Felt Ring 20. Capscrew (6) 32. Wedge (24)
9. Piston 21. Lock Washer (6) 33. Inner Ring
10. Washer 22. Bearing Retainer Cover 34. Outer Ring
11. Spacer 23. Gasket (Shim) 35. Inner Cam
12. Spring 24. O-Ring
Figure 114 — Exploded View of Power Divider Lockout

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400 BENCH PROCEDURES


3. Remove the nut and washer that hold the
piston and spring in place.
Be very careful when removing the power
divider lockout cylinder housing from the unit.
The housing may be spring loaded by the
spring on the piston and shaft assembly. A Be careful when removing the nut that holds
broken or stripped piston retaining nut, or a the piston and spring. The piston or spring
broken shaft can cause the spring to can suddenly release, causing serious
prematurely release. personal injury.

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.

Figure 115 — Removing Capscrews from


Cylinder Housing Figure 117 — Removing the Piston and Washer

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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400 BENCH PROCEDURES


6. Remove the spacer and remaining washer 9. Remove the cover plate capscrews from the
from the piston shaft. power divider lockout housing.
10. Remove the cover plate.

Figure 119 — Removing the Spacer and Washer

Figure 121 — Removing Cover Plate


7. Figure 120 shows the components and
assembly order that complete the piston and
11. Remove the cover plate gasket (or Silastic
spring assembly minus the shaft. Ensure all
sealer if applicable). Make sure the surface
of these components are present. Set them
of the cover plate and housing are clean.
aside for reuse if all are in good condition.
12. Remove the locking capscrew from the shaft
and fork.

Figure 120 — Spacer, Spring and Piston Assembly

8. Remove the O-ring (item 7) and felt ring


(item 8) from the cylinder piston. Refer to the
exploded view (Figure 114) for proper Figure 122 — Removing Locking Capscrew
location.

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400 BENCH PROCEDURES


13. Remove the shift fork shaft. 16. Remove the bearing retainer cover O-ring.

Figure 125 — Removing O-Ring

17. Using a hammer and driver, remove the seal


from the bearing retainer.

Figure 123 — Removing Shift Fork Shaft

14. Remove the capscrews from the bearing


retainer cover.
15. Remove the bearing retainer cover and
gasket (shim).

Figure 126 — Removing Seal from Bearing Retainer

Figure 124 — Removing Bearing Retainer Cover

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400 BENCH PROCEDURES


18. Fabricate two clutch holding brackets as
shown in Figure 127. The brackets are used
to support the clutch during the shaft and
cage press operation.

Figure 128 — Clutch Holding Brackets Installed

20. Using a hydraulic press, separate the shaft


and cage assembly from the power divider
dual ball bearing set and housing.

Figure 127 — Clutch Holding Brackets

19. Install the two clutch holding brackets over


the housing ridge to support the clutch
during the pressing operation.

Use flat washers or spacers as needed to shim


the brackets even with the housing ridge.

Figure 129 — Pressing Out Shaft and Cage Assembly

During the pressing procedure, take special care


to avoid binding the fork, which can cause the
fork to break. Support the fork using a heavy pry
bar.

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400 BENCH PROCEDURES


21. Remove the fork and clutch from the power 23. Press all the wedges into the cage as far as
divider lockout housing. possible. Then remove the outer retaining
ring from the shaft and cage assembly.

Figure 130 — Removing Fork and Clutch


as an Assembly Figure 132 — Removing Outer Retaining Ring

22. Using a drift and hammer, remove the dual


ball bearing set from the housing. Apply
force only to the outer race of the bearings.
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 visible or arrow pointing outward as
shown in Figure 133.

24. Remove the wedges from the cage.

Figure 131 — Removing Bearings from Housing

400345a

Figure 133 — Removing Wedges

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400 BENCH PROCEDURES


25. Locate the inner ring in the cage.
26. Using two screwdrivers, compress the inner
retaining ring until the ends overlap to allow
removal. Remove the inner ring.

Be careful when removing the inner ring. It


may be sharp and can cause serious personal
injury.

Figure 134 — Removing Inner Ring

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400 BENCH PROCEDURES


[466] INTER-AXLE THROUGH SHAFT — DISASSEMBLY

1. Gasket 6. Gasket 11. Yoke Sleeve


2. Through Shaft Housing 7. Bearing Cover 12. Yoke
3. Ball Bearing 8. Lock Washer (4) 13. Clamp Plate
4. Oil Pump (Not Serviced Separately) 9. Capscrew (4) 14. Capscrew
5. Through Shaft 10. Oil Seal
Figure 135 — Exploded View of Inter-Axle Through Shaft Assembly

If the through shaft bearing must be replaced,


remove the bearing using a suitable hydraulic
press arrangement as shown in Figure 136.

401402a

Figure 136 — Removing Through Shaft Bearing

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NOTES

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400 INSPECTION

CARRIER COMPONENT 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.

Check shafts carefully for cracks or other surface


damage that can lead to early failure. Bearing BEARINGS, BUSHINGS AND
journals must conform to the concentricity THRUST WASHERS
requirements. Replace components if the
specified wear limit of 0.002 inch (0.05 mm) is Check ball and roller bearings for:
exceeded by more than 0.001 inch (0.025 mm).
Inspect shaft press-fit surfaces to ensure a r Flaking
press-fit condition with mating gears and r Cracks and fractures
bearings. Splined ends require no less than a tap
fit with their mating drive yoke or flange. Make r Cavities and indentations
sure that shafts show no signs of twist. r Staining
r Measurable wear
GEAR WEAR LIMITS r Brinelling
Replace gears if teeth show any signs of abrasive r Fretting
wear, scratching, ridging, scoring, surface fatigue,
r Corrosion
pitting, spalling, corrosive wear, digging in or
cracking. Always replace mated gears, such as r Banking
spiral bevel gears, hypoid gears and differential
r Seizing
pinion and side gears, in sets.
r Galling
Gear backlash, which may be adjusted by shims
r Scoring
(as in the case of spiral bevels), must never
exceed 0.018 inch (0.46 mm) relative to a gearset r Arching
of fixed centers. Bull gears in dual-reduction
r Nicking
carriers have no adjustment. Therefore, at this
point, the backlash can be as high as 0.030 inch r Cage failures
(0.76 mm) before any serious difficulty is
encountered. Replace bearings if any of these conditions are
present.

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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.

Wear must not exceed 0.010 inch (0.25 mm) CLEANING


maximum. Thrust washers must be replaced in
sets. Combining old and new thrust washers can Clean parts with ground and polished surfaces
cause premature failure. (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
POWER DIVIDER water and alkaline solutions such as sodium
hydroxide, orthosilicates or phosphates.
The frictional forces created by loads imposed on
the cams and wedges cause moderate scoring Do not steam clean assembled drive units after
on the highly stressed rubbing surfaces of cam they have been removed from the housing.
tracks. This is a normal condition. Replace the Steam cleaning traps water in the cored passage
affected cam and wedge items only if working of the castings and within close clearances on
surfaces are badly worn, pitted, scored or and between parts. This can cause corrosion
cracked. Replace the driving cage member if it is (rust) on critical parts of the assembly and rust
damaged or the wedge hole diameter has worn particles circulating in the lubricant. Steam
more than 0.010 inch (0.25 mm) over the original cleaning can also lead to premature failure of
limit. bearings, gears and other parts.

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 Assembled drive units cannot be properly
rebuild. Always replace wedges in matched sets. cleaned by steam cleaning, dipping or slushing.
Do not mix wedges from different sets. For thorough cleaning, the drive unit must be
completely disassembled.
With lock-out type power dividers, clearance
between the shift fork and clutch should not
exceed 0.035 inch (0.89 mm).

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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.

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
(Scotchh brand or equivalent) to make a transfer
of the contact pattern.
400541a
Cut off a piece of tape slightly longer than the
gear tooth. Place the piece of tape on the gear Figure 137 — Lifting Tooth Contact Pattern
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.

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400 REASSEMBLY FLOW CHART

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400 BENCH PROCEDURES

BENCH PROCEDURES — COMPONENT


REASSEMBLY

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400 BENCH PROCEDURES


[466] INTER-AXLE THROUGH SHAFT — REASSEMBLY

1. Gasket 6. Gasket 11. Yoke Sleeve


2. Through Shaft Housing 7. Bearing Cover 12. Yoke
3. Ball Bearing 8. Lock Washer (4) 13. Clamp Plate
4. Oil Pump (Not Serviced Separately) 9. Capscrew (4) 14. Capscrew
5. Through Shaft 10. Oil Seal
Figure 138 — Exploded View of Inter-Axle Through Shaft Assembly

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.

r Install the through shaft bearing, using a


suitable hydraulic press arrangement and
driver as shown in Figure 139.

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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400 BENCH PROCEDURES


[466] POWER DIVIDER LOCKOUT — REASSEMBLY

1. Capscrew (5) 13. Shift Fork Shaft 25. Capscrew (10)


2. Lock Washer (5) 14. Capscrew (4) 26. Lock Washer (10)
3. Cylinder Housing 15. Lock Washer (4) 27. Power Divider Lockout Housing
4. Gasket 16. Cover Plate 28. O-Ring
5. Locknut 17. Shift Fork 29. Ball Bearing (2)
6. Washer 18. Locking Capscrew (Setscrew) 30. Sliding Clutch
7. O-Ring 19. Oil Seal 31. Cage
8. Felt Ring 20. Capscrew (6) 32. Wedge (24)
9. Piston 21. Lock Washer (6) 33. Inner Ring
10. Washer 22. Bearing Retainer Cover 34. Outer Ring
11. Spacer 23. Gasket (Shim) 35. Inner Cam
12. Spring 24. O-Ring
Figure 140 — Exploded View of Power Divider Lockout

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400 BENCH PROCEDURES


1. Install a new felt ring and O-ring on the shift
piston with the O-ring in the top groove and
the felt ring in the lower groove. Lubricate
the O-ring and felt ring with GO-J gear oil.

Figure 143 — Installing the Power Divider


Housing O-Ring

4. Install the inner ring into the cage.

Figure 141 — Installing O-Ring and Felt Ring


Be careful when inserting the inner ring,
2. Place the shift fork shaft with the threaded because it may be sharp.
end exposed, 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.
INNER RING

400347a

Figure 144 — Installing Inner Ring

Figure 142 — Assembling the Piston and Shaft

3. Position the O-ring onto the power divider


housing.

INNER RING
400346a

Figure 145 — Inner Ring Installed

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400 BENCH PROCEDURES


5. Install a matched set of 24 wedges from 7. For proper bearing installation into the
inside the cage, making sure the alpha housing, the bearings must be oriented as
character is visible (or arrow on early shown in the following illustration. Place the
production carriers) is pointing outward as open side (side showing ball bearings) of
shown in Figure 146. The alpha character or each bearing together when installing.
arrow must be visible on each wedge from
outside of the cage. Also, coat the wedges
with heavy grease to help keep them in
place during power divider installation.

The wedges must be reinstalled with the alpha


character or arrow pointing outward as shown in
the illustration.

Figure 148 — Bearing Orientation

8. Position the two ball bearing assemblies into


the housing.

400345a

Figure 146 — Install Wedges with Alpha Character or


Arrow Pointing Out

6. Push all the wedges in as far as possible


and install the outer retaining ring into the
slot provided in the cage.

Figure 149 — Positioning Bearings

Figure 147 — Install Outer Retainer Ring

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400 BENCH PROCEDURES


9. Drive the bearing assembly into the retainer 11. Insert the fork and clutch into the housing.
of the inter-axle power divider housing. Do this by installing the fork into the clutch
groove and then angling them as a unit into
position as shown in Figure 151.

Apply driving force only on the bearing outer race


during bearing installation.

Figure 151 — Inserting the Fork and Clutch

12. Install the clutch holding brackets that were


created for the disassembly process. These
brackets are used to hold the clutch during
the pressing operation.
Figure 150 — Driving Bearings into Retainer

10. Temporarily install the bearing retainer cover


to hold the bearing set in place.

The bearing retainer oil seal is not installed until a


later step.

Figure 152 — Clutch Holding Brackets Installed

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400 BENCH PROCEDURES


13. Position the housing assembly (with clutch
suspended by brackets) in a press over the
cage and shaft of the power divider. Align
shaft splines with the sliding clutch splines.

It may be necessary to slightly loosen the clutch


holding brackets to allow full clutch spline
engagement during the pressing operation.

Figure 154 — Pressing Power Divider Housing Bearings


onto Cage and Shaft

15. Remove the bearing retainer cover that was


temporarily installed earlier.
16. Lightly lubricate the O-ring and install into
the groove in the bearing retainer cover.

Figure 153 — Housing and Cage Assembled in Press

14. Using a suitable hydraulic press, press the


power divider cage into the bearings. Make
sure the press adapter contacts and applies
pressure only to the inner race during the
pressing operation.

During the pressing procedure, take special care


to avoid binding the fork, which can cause the Figure 155 — Installing O-Ring into Bearing
fork to break. Retainer Cover

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400 BENCH PROCEDURES


17. Position a new seal on the power divider 20. Install the bearing retainer cover onto the
bearing retainer cover. power divider lockout housing with gaskets
(shims), as required.
18. Install the seal into the bearing retainer
cover, using a seal driver and hammer.

Figure 157 — Install Bearing Retainer Cover

21. Install the capscrews through the bearing


Figure 156 — Install Seal in Cover
retainer cover and into the housing. Torque
capscrews to specification.
19. Install the bearing retainer cover onto the 22. Position the long spacer (sleeve) and the
power divider lockout housing without the return spring onto the shift fork shaft. Install
gasket (shim). Install the capscrews the shaft assembly into the housing (Figure
finger-tight. Check the gap between the 158). Align shaft with shift fork opening and
housing and the cover, using a feeler gauge. insert shaft into fork.
This gap should not exceed 0.010 inch
(0.254 mm). If a gap exists and exceeds
0.010 inch (0.254 mm), use a gasket (shim)
or gaskets (shims) as required to fill the gap.

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.

Figure 158 — Installing Piston, Shaft, Spring and Spacer


as an Assembly

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400 BENCH PROCEDURES


23. Using a hydraulic press, compress the 24. Install the shifter cylinder housing gasket
piston spring assembly until the setscrew and housing.
holes in both the shaft and fork align. Insert
the setscrew and tighten to specification.

Use a screwdriver, pry bar or wooden wedge to


support the shift fork while compressing the
spring to avoid binding the fork on the shaft.

Figure 161 — Install Cylinder Housing and Gasket

25. Install the cylinder housing capscrews and


tighten to the specified torque.
26. Install cover gasket or apply a bead of
Silastic or equivalent to the cover plate,
completely encircling the screw holes. Then,
install the cover plate.

Figure 159 — Press Set Up to Compress Spring

Figure 162 — Install Cover Plate

Figure 160 — Aligning Shaft and Fork

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400 BENCH PROCEDURES


27. Install the cover plate capscrews on the
power divider lockout and torque to
specification.
28. Dip the inner cam in axle lubricant and
position it inside the cage. 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. This assembly will be
installed into the bevel pinion housing at a
later time.

Figure 163 — Installing Inner Cam

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400 BENCH PROCEDURES


[466] INTER-AXLE POWER DIVIDER WITHOUT
LOCKOUT — REASSEMBLY

1. Capscrew 8. Cover (Bearing Retainer) 15. Cage


2. Clamp Plate 9. O-Ring 16. Inner Ring
3. Yoke 10. Ball Bearing (2) 17. Outer Ring
4. Yoke Sleeve 11. Capscrew (10) 18. Inner Cam
5. Oil Seal 12. Lock Washer (10) 19. Wedge (24)
6. Capscrew (7) 13. Power Divider Housing
7. Lock Washer (7) 14. O-Ring
Figure 164 — Exploded View of Inter-Axle Power Divider Without Lockout

1. For proper bearing installation into the


housing, the bearings must be oriented as
shown in the following illustration. Place the
open side (side showing ball bearings) of
each bearing together when installing.

Figure 165 — Bearing Orientation

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400 BENCH PROCEDURES


2. Position the two ball bearing assemblies into 5. Install the power divider wedges into the
the housing. cage assembly. Also, coat the wedges with
heavy grease to help keep them in place
3. Use a hammer and driver to install the ball
during power divider installation.
bearing set into the power divider housing.

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 pointing outward or alpha
character visible.

Figure 166 — Installing Ball Bearing Set


400345a
4. Install the inner ring into the center of the
power divider cage. Figure 168 — Install Wedges

6. Push the top row of wedges in even with the


cage surface to allow installation of the outer
Be careful when inserting the inner ring. It ring.
may be sharp and capable of causing serious 7. Using the proper expansion pliers, install the
personal injury. wedge outer retaining ring.

INNER RING

400347a

Figure 167 — Installing Inner Ring Figure 169 — Installing Outer Ring

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400 BENCH PROCEDURES


8. Lightly lubricate the O-ring and install it onto 12. Remove the temporarily installed bearing
the flange of the power divider housing. retainer cover.
13. Install a new seal in the bearing retainer
cover, using a driver and hammer.

Figure 170 — Installing O-Ring onto Housing

9. Temporarily install the bearing retainer cover


without the oil seal, onto the housing to
retain the bearing set.
10. Position the power divider housing and
bearing assembly over the cage and shaft
and place the entire assembly into a
hydraulic press.
11. Press the power divider housing and Figure 172 — Driving Seal into Cover
bearings onto the cage and shaft.
14. Install the O-ring onto the bearing retainer
cover. Then install the cover and capscrews
and tighten the capscrews to proper torque
specification.

Lubricate the power divider inner cam and wedge


assembly with the specified lubricant before
installation.

Figure 171 — Pressing the Housing and Bearings onto


Cage and Shaft

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400 BENCH PROCEDURES


15. Install the inner cam into the cage and
wedge assembly. Push all the wedges in
until they contact the inner cam lobes. A
coating of heavy grease may be applied to
the inner cam face to hold it in place during
assembly.

Figure 173 — Installing Inner Cam

16. 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.

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400 BENCH PROCEDURES


[466] FRONT REAR BEVEL PINION — REASSEMBLY

1. Nut 6. Capscrew (6) 10. Spacer


2. Outer Cam 7. Lock Washer (6) 11. Bearing Cup
3. Bearing Cone 8. Selective Shim 12. Bearing Cone
4. Bearing Cup 9. Selective Spacer 13. Bevel Pinion
5. Bevel Pinion Housing
Figure 174 — Exploded View of Front Rear Bevel Pinion

The front rear bevel pinion assembly will only be


found on vehicles with a tandem rear axle. If the
vehicle being worked on has a single rear axle,
this section does not apply.

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400 BENCH PROCEDURES


1. Press the inner bearing cup into the bevel
pinion housing.

Figure 176 — Mating Number and Mounting Distance

4. Note and record the mounting distance.


These distances are needed to determine
the shim pack thickness.

Make sure the bevel pinion and mating bevel gear


are identified as a matched set.
Figure 175 — Pressing Bearing Cup into Bevel Pinion
Housing (Typical)
5. Press the bearing cone onto the bevel pinion
2. Turn over the housing and press the outer shaft.
bearing cup into the bevel pinion housing.
3. The numerals on the back of the bevel pinion
gear and the mating bevel gear represent PRESS
the mating number and the mounting
distance.
BEARING PRESS
SPACER

BEVEL
PINION

400417a

Figure 177 — Pressing Bearing Cone onto Bevel


Pinion Shaft

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400 BENCH PROCEDURES


6. Place the larger bearing spacer and then the Bevel Pinion Preload
selective bearing spacer onto the pinion,
with the chamfered ends of the spacers To perform at maximum efficiency, tapered roller
facing the bearing and bevel pinion gear. 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 using
a hydraulic press. Rotate the pinion housing
(bearings) before applying full pressure to the
bearings. This will prevent premature bearing
failure.

Make sure to lubricate the bearings before


Figure 178 — Placing Spacers on Pinion Shaft
assembling the bevel pinion to perform the
bearing preload check.
7. Lubricate the bevel pinion bearing and install
the bevel pinion housing over the bevel
pinion shaft. 11. Wrap several turns of cord around the bevel
pinion housing at the pilot area. Attach
8. Lubricate the bevel pinion outer bearing
spring tension scale J 8129, or equivalent, to
cone and install the bearing over the pinion
the cord and slowly and evenly pull on the
shaft and into the bevel housing.
scale until the housing rotates. The correct
9. Position the power divider outer cam (item 2) load on the scale should be 3 to 6 pounds
on the bevel pinion shaft. Refer to the pull for new bearings and 2 to 4 pounds pull
exploded view (Figure 174). for used bearings. If the reading on the scale
is not within the correct specifications, it is
10. Using a hydraulic press, press the outer cam
necessary to replace the original spacer.
of the power divider onto the bevel pinion
Use a thinner spacer if it takes less than the
shaft.
specified amount of pull to rotate the
housing. Use a thicker spacer if the required
pull exceeds specification.

Figure 179 — Pressing Outer Cam onto Bevel


Pinion Shaft

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400 BENCH PROCEDURES

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.

12. After determining the correct bearing


preload, set the assembly aside for later
assembly and installation. The helical pinion
must be installed into the carrier so that the
retaining nut can be tightened properly.

Figure 180 — Checking Bearing Preload

Figure 181 — Selective Spacer Location

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400 BENCH PROCEDURES


[476] REAR REAR BEVEL PINION — REASSEMBLY

1. Capscrew 8. Gasket 14. Lock Washer (6)


2. Clamp Plate 9. Oil Seal 15. Bevel Pinion Housing
3. Yoke 10. Bearing Cone 16. Selective Shim
4. Yoke Sleeve 11. Bearing Cup 17. Bearing Cup
5. Capscrew (6) 12. Selective Spacer 18. Bearing Cone
6. Lock Washer (6) 13. Capscrew (6) 19. Bevel Pinion
7. Bearing Retainer Cover
Figure 182 — Exploded View of Rear Rear Bevel Pinion

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400 BENCH PROCEDURES


1. Press the outer bearing cup into the bevel The numbers on the back of the bevel pinion and
pinion housing. bevel gear teeth represent the mating number
and mounting distance (Figure 185).

Figure 185 — Mating Number and Mounting Distance


Figure 183 — Pressing Outer Bearing Cup into Bevel Number
Pinion Housing
3. Record the mounting distance. These
2. Press the inner bearing cup into the bevel distances are needed to determine shim
pinion housing. pack thickness. Make sure that the bevel
pinion and mating bevel gear are identified
as a matched set.

Figure 184 — Pressing Inner Bearing Cup into Bevel


Pinion Housing

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400 BENCH PROCEDURES


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

Figure 188 — Pressing Outer Bearing Cone onto Bevel


Pinion Shaft

Figure 186 — Pressing Inner Bearing Cone onto Bevel


Pinion Shaft

5. Install the selective spacer with the tapered


side toward the bearing.

Figure 187 — Installing the Selective Spacer

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400 BENCH PROCEDURES


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


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.

Make sure to lubricate the bearings before


performing the bearing preload check.

8. Wrap a cord around the bevel pinion housing


as shown. Then attach spring tension scale
J 8129, or equivalent, to the cord. Pull on the Figure 190 — Selective Spacer Location
scale slowly and evenly until the housing
rotates. 9. 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.

Figure 191 — Spacer Thickness Chart

Figure 189 — Checking the Bearing Preload on the


Bevel Pinion

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400 BENCH PROCEDURES


12. Install the bearing cover onto the bevel
pinion assembly with a new gasket and
tighten the cover capscrews to specification.
Bearings that are in good condition can be
reused to rebuild a carrier. When reusing 13. Dip end of drive yoke in the recommended
bearings, remember that the force needed to turn lubricant and position it on the input shaft.
the scale while under 20,000 pounds of preload is Position the clamp plate and install the self-
about one-half the requirement of new bearings. locking capscrew finger-tight.
This is why used bearings have a 2 to 4 pound 14. Torque the self-locking capscrew to
specification rather than the 3 to 6 pounds specification.
specified for new bearings.

Make sure to lubricate the bearings before


performing the bearing preload check.

10. After the correct bearing preload has been


determined, position the seal in the bearing
retainer cover.
11. Drive the bearing cover seal into position,
using a seal installation tool. Note seal
direction during installation.

Figure 192 — Installing Seal in Cover

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400 BENCH PROCEDURES


Determining Bevel Pinion To Carrier For example:
Housing Shim Pack 4.876" OLD PINION
When reusing the original bevel pinion, also s 4.874" NEW PINION
reuse the shim pack that was removed from the 0.002" SHIM DIFFERENCE
carrier at disassembly.
In this case, 0.002 inch must be removed from
Sometimes it is necessary to use a new bevel the original shim pack.
pinion to rebuild the carrier. If so, use the
following procedure: This simple procedure provides a good starting
point for setting the gear patterns.
r Determine the mounting distance on the
disassembled bevel pinion (etched into original
pinion) and compare it with the mounting MOUNTING
distance on the new bevel pinion (etched into BEVEL DISTANCE
PINION
new pinion). HEAD
r 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. BEVEL PINION
HOUSING
r If the new bevel pinion mounting distance is CL
shorter than the old (lower number), this
amount of shim will have to be removed from
the shim pack. CENTERLINE OF HELICAL PINION SHAFT
400414a

Figure 193 — Determining the Mounting Distance

15. Set the bevel pinion assembly (with the


correct shim pack) aside temporarily on a
clean work surface.

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400 BENCH PROCEDURES


[465/475] FOUR-PINION TYPE DIFFERENTIAL — REASSEMBLY

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

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.

...continued next page

Figure 195 — Pressing Bearing onto Differential Hub

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400 BENCH PROCEDURES


...continued

The differential bearing cup which fits the left


casing has an external flange that 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 adjustment. The bull gear position cannot
vary.

2. Press the differential side casing into the bull


gear.

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.

Figure 198 — Installing Side Gear into


Differential Casing

Figure 196 — Pressing Side Casing into Bull Gear

3. Apply GO-J lubricant to the thrust washer.


Install the thrust washer into the differential
casing. The dimpled side of the thrust
washer faces the side gear.

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400 BENCH PROCEDURES


5. Assemble the four-pinion gears and the four 7. Make sure the gears are properly engaged
thrust washers onto the differential spider. and that the pinion thrust washer tabs are
properly positioned in the casing.

Figure 199 — Installing Pinion Gears and Thrust


Washers on Spider
Figure 201 — Position Tabs of Thrust Washers Between
6. Install the pinion, spider and thrust washer Casing Halves
assembly into the differential side casing.
Apply GO-J lubricant while assembling. 8. Install the second side gear so that it
meshes with the pinion and spider assembly,
applying GO-J lubricant after installing.

Figure 200 — Installing Assembled Pinion Spider

Figure 202 — Installing Second Side Gear

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400 BENCH PROCEDURES


9. Install the remaining thrust washer after 11. Press the second side casing into the bull
lubricating it with GO-J. The dimpled side of gear.
the thrust washer faces the side gear.

Figure 203 — Installing Side Gear Thrust Washer

10. Align the second side casing with the match


marks made at disassembly and place the
assembly in a hydraulic press. Figure 205 — Pressing the Side Casing

12. Place the differential in a soft-jawed vise and


install the capscrews, lock washers and
locknuts. Torque the capscrews and nuts to
specification.

Figure 204 — Aligning Marks Made at Disassembly

Figure 206 — Torquing Capscrews and Locknuts


to Specification

13. Make sure the differential gears turn freely. If


any binding is detected, disassemble the
unit and correct the cause.

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400 BENCH PROCEDURES


[465/475] INTER-WHEEL POWER DIVIDER
DIFFERENTIAL — REASSEMBLY

1. Inner Cam 5. Cage 9. Casing


2. Retaining Ring 6. Bearing Cone 10. Bull Gear
3. Bushing 7. Dowel Bolt (15) 11. Washer (15)
4. Wedge 8. Outer Cam 12. Nut (15)
Figure 207 — Exploded View of Inter-Wheel Power Divider Differential

1. Press new pre-sized bushing in bore


provided in power divider driving cage hub
until it just bottoms. DO NOT OVERDRIVE.
A correctly installed bushing should be
recessed below inner cam thrust surface of
the cage. See Figure 208 on the following
page.

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400 BENCH PROCEDURES


Each wedge has two flats milled across its
length with an integral land between the
flats. The word “OUT” is stamped in 1/8-inch
letters on the top flat. This means that this is
BUSHING
the outside end, which contacts the female
cam lobes. The top or outside flat engages
the wedge retainer ring, which prevents the
wedge from turning as it reciprocates
between the cams during differential action.
.061
.031 During assembly or disassembly, the wedge
land, acting as a stop, contacts the retaining
3.1405
3.1375 ring which prevents it from falling out of the
cage as long as the inner cam is in position.
4. Install all 24 wedges from inside the cage so
DIAMETER that the word “OUT” on each wedge is
AFTER radially outside the cage. Make sure all
ASSEMBLY wedges are pushed outward as far as they
will go so that the land of each contacts the
retaining ring. Dip hub of inner cam in GO-J
gear oil and install in cage. After inner cam is
in place, press all driving wedges inward so
they all contact inner cam tracks. Oil all parts
liberally with gear oil.
400483a
5. With cage assembly still positioned on its
Figure 208 — Driving Cage Bushing Installation hub end, install outer cam down over the
assembled wedges. Do not try to force it.
2. Press left-hand bearing cone on hub of
power divider differential casing and lay
assembly aside temporarily.
3. Press right-hand bearing cone on hub of
Be careful of your fingers as cam will drop in
power divider driving cage. Position cage
place when all wedges are contacting inner
assembly on its hub end on a work bench.
cam tracks.
Install power divider driving cage outer
retaining ring in groove provided between
the cage wedge holes. 6. Position the casing on the cage assembly.
Be sure to align the casing and the cage
assembly, using the punch marks made
when disassembling the power divider. The
Replacement power divider wedges are packed bull gear, also marked to ensure proper
at the factory in matched sets of 24 which have mating, should be positioned to enable the
been graded within 0.001 inch in length. A full attaching hardware to be hand tightened. If
package of 24 matched wedges MUST be used any of the mating components (cage, casing
when overhauling a power divider. NEVER mix or bull gear) have been replaced for any
new wedges with old or wedges from other used reason, it may be necessary to line ream the
units, as unmatched wedges would guarantee cage and casing using the bull gear
short life and early failure of the differential. mounting holes as a guide. The correct
diameter for the dowel bolts is 0.764 to
0.765 inches.

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400 BENCH PROCEDURES

Current production requires 3 dowel bolts spaced


120 degrees apart, while future production will
utilize 15 dowel bolts. Before reaming, make
certain which power divider differential you have,
so holes for the machine bolts on the current
production differential are not enlarged
unnecessarily.

7. Mount the assembly in a vise and tighten the


hardware to the specified torque. Install
cotter pins or stake jam nut as required.
8. Check the assembly for proper operation. If
any binding is detected, disassemble the
assembly and correct the problem.

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400 BENCH PROCEDURES


[465/475] DIFFERENTIAL 4. Lower the differential assembly into the
housing.
INSTALLATION
5. Seat the bearing cups on the differential
bearing pedestals in the carrier housing.

This same procedure is used when installing the


inter-wheel power divider differential or the four-
pinion type differential.

1. Install the bearing adjusting nut onto the HOIST


threaded bearing cup. Tighten the nut about
two turns.

DIFFERENTIAL/
BULL GEAR
ASSEMBLY

STAND

400511a

Figure 209 — Installing Adjusting Nut on the Threaded


Bearing Cup

2. Use a suitable lifting device to position the 400513a

differential assembly for installation into the


Figure 211 — Installing the Differential Assembly into
carrier housing. the Carrier Housing
3. Lubricate the bearings with GO-J lubricant
and position the bearing cups on the
differential assembly.

LIFT

DIFFERENTIAL
ASSEMBLY

CARRIER
HOUSING

400512a

Figure 210 — Positioning Bearing Cups

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400 BENCH PROCEDURES


6. Align punch marks made at disassembly on 9. Position bearing adjustment fixture J 26441
the bearing caps with those on the bearing on the carrier housing.
pedestals. Position the bearing caps over
the bearing cups.
7. Install the bearing cap capscrews snugly, but
not too tight. This will permit bearing
adjustment. DO NOT apply Loctite 262 at
this time.

Figure 214 — Position the Bearing Adjustment Fixture

10. Lubricate the differential bearings with GO-J


gear oil. Then, while turning the differential
assembly, adjust the differential bearing nut
400514a until the bearings have a slight preload.
Figure 212 — Installing Bearing Caps

8. Make sure bearing caps are properly


aligned.

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.

MARKS
MADE
EARLIER

400515a

Figure 215 — Adjusting Differential Bearing Preload


Figure 213 — Bearing Caps Aligning with Mating Parts

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400 BENCH PROCEDURES


11. Relieve bearing preload by hitting the 14. Wrap a cord around the outside of the
bearing cap and/or bull gear with a plastic diameter of the bull gear several times.
mallet while rotating the differential.
15. Attach scale J 8129 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 (0.9–1.4 kg).
To properly measure the bull gear drag, make
sure that the helical pinion shaft has been
removed. This must be done 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.

Figure 218 — Setting Differential Bearing Preload

16. If the preload is not within specification,


loosen the capscrews and turn the adjusting
nut to attain the proper preload.
17. Once preload is attained, remove the
bearing cap capscrews one at a time. Apply
Loctite 262 to the threads and retorque to
specification.
Figure 216 — Striking Bull Gear to Relieve Bearing 18. Check for proper alignment of the pin hole in
Preload the bearing cap and the adjusting nut. If
required, tighten the bearing adjusting nut
13. Torque the bearing-cap retaining capscrews slightly, until the hole and nut are aligned to
to specification. provide for installation of the lockpin. Note
that it may be necessary to loosen the
bearing cap capscrews to allow the
adjusting nut to turn. Recheck the torque on
the bearing cap capscrews.
19. Recheck the preload on differential bearings
by measuring the rolling drag. Adjust as
required.
20. Remove the differential adjustment fixture
J 26441.

Figure 217 — Torquing Bearing Retaining-Cap


Capscrews

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400 BENCH PROCEDURES


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

Figure 219 — Installing Cotter Pin

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400 BENCH PROCEDURES


[466/476] HELICAL (SPUR) PINION SHAFT — REASSEMBLY

1. Helical Pinion Shaft 8. Capscrew (3) 14. Bearing Cone


2. Key 9. Pin 15. Clamp Plate (Helical Pinion End)
3. Slotted Bearing Cup 10. Selective Spacer 16. Gasket
4. Bearing Cone 11. Shim 17. Cover
5. Bevel Gear 12. Bearing Retainer 18. Lock Washer (6)
6. Clamp Plate (Bevel Gear End) 13. Bearing Cup 19. Capscrew (6)
7. Capscrew (3)
Figure 220 — Exploded View of Helical (Spur) Pinion Shaft

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400 BENCH PROCEDURES


1. Using a suitable hydraulic press, install the 3. Start the bevel gear onto the helical pinion
bearing cone onto the helical pinion shaft. shaft, making sure that key slot in gear
Note the direction of the bearing. aligns with the shaft.

400432a

Figure 223 — Starting Bevel Gear on Helical Pinion


Shaft

4. Press the bevel gear onto the helical pinion


shaft.

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

Figure 224 — Pressing Bevel Gear on Helical Pinion


Shaft

5. Using a depth measurement tool, measure


the distance from the bevel gear surface to
the end of the helical pinion shaft.

...continued next page

Figure 222 — Installing Key into Helical Pinion Shaft

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400 BENCH PROCEDURES


... continued 8. Secure the helical pinion shaft assembly in a
soft-jawed vise. Install the clamp plate,
6. Install shims onto the end of the helical previously determined shim pack and insert
pinion shaft to a depth of 0.005 to 0.015 inch three old capscrews to hold the clamp plate
(0.127 to 0.381 mm) between the end of the in place.
shaft and the surface of the bevel gear.
9. Tighten the capscrews to specification.

Figure 227 — Torquing Clamp-Plate Capscrews

10. Install the slotted inner bearing cup over the


pinion and bearing cone.

Figure 225 — Measuring Shaft to Gear Depth

7. Apply Loctiteh 262 to the threads of the


capscrews that hold the clamp plate to the
helical pinion shaft.

APPLY LOCTITE 262


TO THREADS

400436a

Figure 228 — Installing the Slotted Bearing Cup

400434a

Figure 226 — Applying Loctite 262 to Capscrew Threads

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400 BENCH PROCEDURES


11. Install the selective bearing spacer, with the 13. Install the bearing retainer over the pinion
tapered side toward gear. Note that the shaft.
thickness of this spacer determines bearing
preload.

400440a

Figure 231 — Installing Bearing Retainer over


Pinion Shaft

14. Make sure that the retainer lockpin aligns


with the slot in the inner bearing cup.

Figure 229 — Installing the Selective Bearing Spacer

12. Press the outer bearing cup into the helical


pinion bearing retainer.

Figure 232 — Align Retainer Lockpin with Slot in


Inner Bearing Cup

Figure 230 — Pressing Outer Bearing Cup into


Bearing Retainer

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400 BENCH PROCEDURES


15. Lubricate the outer bearing cone and install Setting the Preload
the bearing on the helical pinion shaft.
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 in Figure 235. Attach spring tension 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.

Figure 233 — Installing Outer Bearing Cone on Make sure to lubricate the bearings before
Helical Pinion Shaft performing the bearing preload check.

16. Lubricate the helical pinion inner bearing


with GO-J and press the outer bearing cone
into place.

PRESS
SCALE
PLATE J 8129

Figure 234 — Pressing Outer Bearing Cone into Position

400444a

Figure 235 — Checking for Correct Preload of Helical


Pinion

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400 BENCH PROCEDURES


The correct load on the scale should read about 17. After the correct bearing preload has been
3 to 6 pounds for new bearings, and 2 to 4 established, remove the assembly from the
pounds for used bearings. If it takes more than press. Remove the outer bearing cone,
the specified amount of pull, use a thicker spacer. spacer and bearing retainer from the shaft
If it takes less than the specified amount of pull, assembly. Remove the inner bearing cup
use a thinner spacer. from the shaft assembly.

Figure 236 — Spacer Thickness Chart

Figure 238 — Pulling Bearing Cone and Retainer


Off Shaft

Figure 237 — Selective Spacer Location

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400 BENCH PROCEDURES


Setting the Gear Patterns 18. Install the established shim pack onto the
helical pinion bearing retainer. Make sure to
After setups for the bevel pinion and helical pinion align the shim pack oil drain-back holes with
subassemblies have been completed, the gear the drain-back hole in the bearing retainer.
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.

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 Figure 240 — Installing the Shim Pack
bevel gear to the centerline of the bevel pinion.
This number helps in determining the shims 19. Using alignment pins, install the bearing
which will have to be installed to achieve the retainer into the carrier housing. Position the
desired gear pattern. Refer to the illustration retainer so that the opening faces the bull
below. gear. Make sure to align the oil drain-back
holes.

Make alignment pins from bolts obtained locally.


Pins should be about 2-1/2 inches long with
1/2-13 inch threads.

Figure 239 — Determining the Mounting Distance

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.

Figure 241 — Aligning and Installing the Bearing


Retainer

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400 BENCH PROCEDURES


20. Install four cover bolts to secure the bearing 23. Position the inner bearing cup so that the
retainer to the carrier housing for installation slot in the cup aligns with the mark on the
of the slotted inner bearing cup. housing and the pin on the retainer.
21. Torque the bearing retainer capscrews to
specification.

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.

The inner bearing cup slot must align with the


bearing retainer locating pin.

DRIVER

Figure 243 — Marking Housing Next to Lockpin

400452a

Figure 245 — Installing Inner Bearing Cup into


Carrier Housing

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400 BENCH PROCEDURES


25. Insert the shaft assembly, with the 27. Install the clamp plate and old capscrews.
established selective spacer, into the carrier Torque capscrews to specification. Use a
housing. Position a block of wood in the pinch bar or jamming tool between the spiral
housing to support the shaft assembly. bevel gear and housing to jam the gear so
that the capscrews can be tightened.

400301a

Figure 246 — Installing Shaft with Spacer

26. Install the outer bearing cone onto the end of Figure 248 — Torquing Clamp-Plate Capscrews
the pinion shaft.

Tighten the capscrews retaining the clamp plate


in stages until the recommended torque is
obtained.

28. Rotate the assembly. The unit should turn


with some drag. If it will not turn, return to
SETTING THE PRELOAD in this section
and recheck bearing preload.
29. Loosen the three clamp-plate capscrews to
relieve the preload. Tap with a hammer to
loosen the bearing.

Figure 247 — Installing Outer Bearing Cone onto


30. Retorque the three clamp-plate capscrews
Pinion Shaft to specification using the pinch bar or
jamming tool to jam the gear.

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400 BENCH PROCEDURES


Bull Gear Tooth-Contact Pattern
1. Coat the bull gear and the helical pinion gear
with gear-marking compound.

400521a

Figure 249 — Bull Gear with Gear-Marking Compound

2. 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 Bull Gear Tooth
Contact Pattern Chart (Figure 250). 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 shaft.

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400 BENCH PROCEDURES

Figure 250 — Bull Gear Tooth Contact Patterns

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400 BENCH PROCEDURES


Front Rear or Rear Rear Bevel 2. Install the front rear or the rear rear bevel
pinion into the carrier housing. Position the
Pinion Installation bevel pinion assembly to align the oil
The bevel pinion is now ready to be fitted to the passages and slide onto the alignment pins.
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 on the rear rear bevel pinion and
the outer cam retaining nut is installed on the
front rear bevel pinion. The yoke or nut must be
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 to prevent damage to
the shim pack and to retain the shim pack
while installing the bevel pinion.

Make alignment pins from bolts obtained locally.


Pins should be about 2-1/2 inches long with
5/8-11 inch threads.

Figure 252 — Installing Front Rear Bevel Pinion

Position the shims to align with all oil holes.


Blocked oil holes will cause lubrication failure.

Figure 253 — Installing Rear Rear Bevel Pinion

Make sure to install and properly tighten the drive


yoke of the rear rear bevel pinion assembly. An
Figure 251 — Installing Shims over Guide Pins improperly torqued drive yoke will render a false
backlash reading. This is also true for the outer
cam retaining nut on the front rear bevel pinion.

3. Install some of the capscrews. Remove the


alignment pins after the bevel pinion is in
position. Install the remaining capscrews.

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400 BENCH PROCEDURES


4. Torque bevel pinion capscrews to 6. Obtain a jackstand, special pinion bearing
specification. nut wrench J 26577, torque multiplier and
torque wrench. Set up the tools to prepare
for tightening the outer cam retaining nut.

Figure 254 — Torquing the Bevel Pinion Capscrews


Figure 255 — Retaining Nut Installation Set-Up with
Torque Multiplier
INSTALLING FRONT REAR BEVEL PINION
OUTER CAM RETAINING NUT 7. Install the prefabricated gear-jamming tool
or a brass drift between the bevel pinion and
bevel gear to prevent bevel pinion rotation
while installing the outer cam retaining nut.
In emergency cases, the old nut may be used. In Refer to OVERHAUL RECOMMENDATIONS
either case (using old or new nut), thoroughly in the DESCRIPTION AND OPERATION
clean and prime the threads of the bevel pinion section for gear-jamming tool dimensions.
shaft and the outer cam retaining nut. Then, coat
the threads with Loctite 262.

Do not allow the Loctite 262 to drip into the


bearings, as it can cause bearing failure.

5. The bevel pinion assembly must be installed


into the carrier housing to secure it against
the 1,300 to 1,500 lb-ft (1763 to 2034 N•m)
of torque necessary to tighten the outer cam
retaining nut.

Figure 256 — Gear-Jamming Tool or Brass Drift Installed

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400 BENCH PROCEDURES


8. Tighten the outer cam retaining nut to the SETTING THE BACKLASH
specified torque. 10. Set the backlash between the bevel pinion
and the bevel gear. The backlash should be
0.006 to 0.018 inch (0.15 to 0.46 mm). Add
or remove shims as necessary to attain the
correct backlash.
11. A dial indicator with a magnetic or bolt-on
type base is used to make the
measurement.

DIAL INDICATOR
Figure 257 — Tightening the Retaining Nut NEEDLE

9. Stake the retaining nut in place, using a 400460a

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.

Figure 258 — Staking the Retaining Nut

Figure 260 — Bevel Gear and Bevel Pinion Coated with


Marking Compound

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400 BENCH PROCEDURES


13. Rotate at least two full turns in both
directions while applying braking force to the
helical pinion. This will squeeze the gear-
marking compound away from the contact
areas.
14. Compare the readings from the axle being
serviced to those in Figures 261 and 262.

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.

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400 BENCH PROCEDURES

SETTING THE GEAR CONTACT PATTERN


MATED-GEAR ADJUSTMENT
MOVING THE BEVEL PINION . . . MOVING THE BEVEL GEAR . . .
If tooth contact pattern is not correct, it can be Removing helical pinion shims moves the
adjusted by removing or adding shims. bevel gear inward. This moves the contact area
Removing bevel pinion shims moves the bevel nearer to the toe and slightly towards the tooth
pinion inward. This moves the contact area top land on the drive side of the gear.
toward the tooth root and slightly toward the
heel on the drive side of the gear.
INWARD
REAR
DRIVE
SIDE
IN
IN TOP LAND
TOE
ROOT

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

TOE ROOT OUT


TOP LAND

HEEL
400462a

Figure 261 — Setting Gear Contact Pattern

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400 BENCH PROCEDURES

Figure 262 — Common Gear Contact Patterns

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400 CARRIER REASSEMBLY

CARRIER REASSEMBLY

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400 CARRIER REASSEMBLY


FINAL ASSEMBLY 4. Install the helical pinion bearing retainer
cover.
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 Make sure to install the bearing retainer cover so
(spur) pinion shaft installation must be completed that the oil drain-back notch in the cover (bottom
at this point. of cover) is aligned with the oil drain-back holes in
1. Remove the three helical (spur) pinion the gasket and retainer.
clamp plate capscrews one at a time.
Replace with new grade 8 capscrews. Apply
Loctite 262 to the threads and install the
new capscrews. Torque each capscrew to
specification while jamming the bevel gear
with a pinch bar or jamming tool.
2. Remove the short capscrews used to
temporarily retain the helical (spur) pinion
shaft assembly retainer. Also remove the
guide pins used to temporarily align the
bearing retainer.
3. Install a new gasket onto the helical pinion
bearing retainer.

Figure 264 — Installing Helical Pinion Bearing


Make sure the gasket is installed with the oil Retainer Cover
drain-back hole matching the drain-back hole in
the retainer. 5. Install the proper capscrews and lock
washers to secure the cover. Torque the
capscrews retaining the helical pinion
bearing retainer cover to specification.

Figure 265 — Torquing Bearing Retainer


Cover Capscrews
Figure 263 — Installing Bearing Retainer Gasket

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400 CARRIER REASSEMBLY


Inter-Axle Power Divider Installation 9. Install the power divider into the housing.
Coat the wedges with heavy grease to help
(With or Without Lockout) keep them in place during power divider
6. Dip the inner cam in GO-J lubricant and installation.
position it inside the cage of the power
divider. Push all the wedges in until they
contact the inner cam lobes. This will aid in
the installation of the power divider. The cage assembly must be perfectly centered or
the wedges will hang up on the outer cam during
installation.

Figure 266 — Installing the Power Divider Inner Cam

7. Make sure the power divider housing O-ring


is in position around the flange of the Figure 267 — Installing the Power Divider
housing.
8. Position the carrier housing and stand 10. Install the ten capscrews through the inter-
horizontally so that the cage assembly can axle power divider housing flange. Torque to
be installed into the outer cam of the bevel specification.
pinion assembly. The inner cam will be held
in position by the driving wedges.

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400 CARRIER REASSEMBLY


Inter-Axle Through (Drive) Shaft
Installation
11. Position the through shaft housing gasket
(shim) onto the surface of the carrier
housing.
12. Install the inter-axle through shaft housing
into the carrier housing. Install the four
capscrews and tighten to specification.

Figure 269 — Through Shaft Housing Position

13. Check the clearance between the end of the


through shaft bearing retainer tube and the
bevel pinion. This clearance must not
exceed 0.010 inch.

Figure 268 — Installing Through Shaft Housing and


Gasket (Shim)

The power divider wedges are lubricated by the


through shaft bearing retainer and the bevel Figure 270 — Checking Gap Between Retainer
pinion. When the through shaft bearing retainer is Tube and Bevel Pinion
installed, ensure that the oil inlet is on top. If the
retainer is rotated so the oil inlet is not in the top 14. If the through shaft bearing retainer tube
position, lack of lubricant will cause damage to bottoms on the bevel pinion, insert an
the inter-axle power divider. additional gasket between the bearing
retainer and the carrier housing.
15. If the clearance is greater than 0.010 inch,
remove the shaft and bearing retainer
assembly. Break out the staked portion of
Align punch marks made previously between the the retainer securing the tube.
carrier housing and the top of the through shaft
housing. 16. Install the bearing retainer and one gasket to
the carrier housing. Install the capscrews
and tighten them to specification.

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400 CARRIER REASSEMBLY


17. Slide the oil tube into the retainer until the
correct clearance of 0.010 inch is obtained FEELER GAUGE
between the tube and bevel pinion. Restake
the tube into the bearing retainer in the new
position.
18. Remove the bearing retainer and check to
see that the oil hole of the tube aligns with
the trough cast into the retainer. If not, drill or
ream the oil tube hole to the required size of
1.380 inches. Make sure to flush all cuttings
from the assembly.
19. Lubricate the through shaft with GO-J 400534a
lubricant.
20. Carefully install the through shaft assembly, Figure 271 — Measuring Gap Between Bearing
aligning the shaft splines with the internal Cover and Flange
splines of the inter-axle power divider inner
cam. Make sure the oil inlet is properly 23. Align the bearing cover and install the
positioned. capscrews.
21. Make sure the through shaft bearing is 24. Torque capscrews to specification.
properly seated when the through shaft is
installed.
22. Determine the proper gasket thickness for
the through shaft bearing retainer.

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.

a. Temporarily install the retainer cover


over the through shaft without the
gasket. Press on the cover until the
Figure 272 — Torquing Bearing Cover Capscrews
ridge bottoms on the outer bearing
race.
b. Using feeler gauges J 26900-8 or
equivalent, measure the gap between
the bearing cover and retainer flanges.
Add 0.005–0.010 inch 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.

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400 CARRIER REASSEMBLY


Carrier Installation into Chassis
25. If not yet installed, dip end of yokes in
specified 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 capscrews
finger-tight.

Drive yoke for the 96 carrier was previously


installed in the BENCH PROCEDURES section.

26. Install a holding bar on the yoke being


worked on and with a socket wrench, tighten
yoke self-locking capscrew to the required
torque.
27. 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. 1. Bolt 3AX1369 and flatwasher 35AX683 (8)
2. Stud 8AX1045, flatwasher 37AX226 and
28. All four-pinion type differentials must be filled nut 21AX440 (3)
with one pint of specified lubricant just 3. Bolt 3AX1699*, stepped washer 15QD169-P2 and
before installing into the axle housing. O-ring 56AX292 (between washer and carrier
flange) (3)
29. The CRD 95/96 series carrier housings have 4. O-ring groove in carrier
a large O-ring groove. Install the proper * These bolts are located inside the bevel compartment
O-ring in the groove. Then mount the carrier
Figure 273 — Carrier Mounting Arrangement CRD 95/96
to the axle (banjo) housing. DO NOT use
sealant on carriers that use an O-ring.
30. Install capscrews and washers. Torque
capscrews to specification.

Figure 274 — Stepped Washer and O-Ring Arrangement

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400 CARRIER REASSEMBLY


31. Make sure all plugs are installed in the 33. When the rear axle is completely
assembly. assembled, it is important to fill to the inter-
axle power divider (if equipped), and both
the carrier and axle housings to their proper
capacities. Fill the axles with GO-J (or GO-J
Plus) lubricant until the oil is level with the
filler plug hole. Refer to the CARRIER
MAINTENANCE section of this manual.

Figure 277 — Carrier Filler Plug

Figure 275 — Carrier and Axle Plugs

32. Torque the bevel compartment cover to


specification. Refer to the CARRIER
SPECIFICATIONS section.

Figure 276 — Torquing Bevel Compartment


Cover Capscrews

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NOTES

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400 CARRIER SPECIFICATIONS

CARRIER SPECIFICATIONS

Page 141
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400 CARRIER SPECIFICATIONS


FEATURES AND 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 26.0 Pints (12.3 Liters)
Bevel Gear Compartment, Each 10.0 Pints (4.7 Liters)
Inter-Axle Power Divider, 2.0 Pints (0.9 Liter)
Note: Proper oil level is best determined by checking oil level in
reference to the filler plug holes.
Recommended SAE Grade Gear Oil
r MACK GO-J Specification 80W-90, 85W-140, 80W-140
(Synthetic)

MACK Geared Component Extended Service Drain Interval


r MACK GO-J Plus Specification 75W-90 (Synthetic)
401582a

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400 CARRIER SPECIFICATIONS

Tandem Axle Models with Gear-Type Gearing:


Differentials:
1st Reduction: DURAPOID spiral bevel
CRDP-95, CRD-96
2nd Reduction: coarse-pitch, wide-faced helical
Tandem Axle Models with MACK Power Ratios:
Divider Differentials:
CRDP-951, CRD-961 Current: 4.60, 5.22, 5.88, 6.73, 7.58, 8.27, 9.10, 10.11 and 11.38
Type: Top-mounted, dual reduction Axle Shaft Spline, Diameter: 2.625
Splines, Number and Type: 17, Involute
NOTE: Ratios 4.60, 5.22 and 6.73 are not available in power divider differential.
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 0.001 inch
and within the length dimension. NEVER “BREAK” SETS.
Cams
Male, distance across any two alternate lobes . . . . . . . . . . . . . . . . . . . . . 4.1335 4.1375
Female, distance across any two alternate recesses . . . . . . . . . . . . . . . . 6.508 6.512
Air-Actuated Inter-Axle Power Divider Lockout:
Shifter fork and clutch, clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .020 .035
Air-shift piston return spring, free height 3-1/16. . . . . . . . . . . . . . . . . . . . . . . — —
Test at 2-inch height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 lbs. 220 lbs.
Four-Pinion Closed-Type Differential (Current):
Pinion, finished ID (steel-on-steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.256 1.259
Spider leg, diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.248 1.249
Spider-to-pinion, clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.007 0.011
Pinion thrust washer, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.064 0.066
Side gear thrust washer, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.122 0.126
Side gear hub and casing, clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.027 0.055
401583a

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NOTES

Page 144
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400 BEARING ADJUSTMENTS & TORQUE CHART

BEARING ADJUSTMENTS & TORQUE CHART

Page 145
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400 BEARING ADJUSTMENTS & TORQUE CHART

Note: Notations “A-B-C-D” are described on page 147.

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400 BEARING ADJUSTMENTS & TORQUE CHART

Note: Notations “X-Y-Z” are described on page 146.

Page 147
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400 BEARING ADJUSTMENTS & TORQUE CHART

Note: Notations “A-B-C-D” are described on page 147. Notations “X-Y-Z” are described on page 146.

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400 SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS AND EQUIPMENT

Page 149
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400 SPECIAL TOOLS AND EQUIPMENT


SPECIAL TOOLS CHART
Tool Number Description

J 26437 WRENCH, Differential Bearing Adjusting Nut

J 26441 FIXTURE, Differential Bearing Adjustment (Special Order Only)

J 26577 WRENCH, Bevel Pinion Bearing Nut (Special Order Only)

J 26900-8 SET, Feeler Gauge

J 39477-1 PULLER, Bar Type

OEM 6642 WRENCH, Dial Type Torque

OEM 6107 MULTIPLIER, Torque

J 8129 SCALE, Spring Tension

J 3409-D STAND, Carrier Repair

The above listed tools may be obtained from:


KENT-MOORE
O.E. TOOL AND EQUIPMENT GROUP
SPX CORPORATION
28635 Mound Road
Warren, Michigan 48092

S 574 ADAPTER RING, Tapered Roller Bearing Puller

S 578 ADAPTER RING, Tapered Roller Bearing Puller

S 578F SEGMENT, Adapter Ring, Bevel Pinion Shaft, Rear

S 578C SEGMENT, Adapter Ring, Pinion Shaft, L.H.

S 574D SEGMENT, Adapter Ring, Pinion Shaft, R.H.

S 578E SEGMENT, Adapter Ring, Differential and Differential Power Divider, L.H. and R.H.

The above listed tools may be obtained from:


Shel’s Supplies and Equipment Company
496 Orange Avenue
West Haven, CT 06516
401587a

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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

Page 153
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NOTES

Page 154
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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

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