Taller Repuestos 2014

MACK SR70/80
TANDEM AXLE
SERVICE MANUAL APRIL 2002
(INCLUDES SUSPENSION AND (NEW ISSUE)
13-102
BRAKE INFORMATION)
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-ii
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MACK SR70/80 TANDEM AXLE
SERVICE MANUAL
(INCLUDES SUSPENSION AND BRAKE INFORMATION)
APRIL 2002 © MACK TRUCKS, INC. 2002

(NEW ISSUE) 13-102
front.fm Page ii Monday, February 18, 2002 11:15 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 (but not limited to) electronic,
mechanical, photocopying, recording, or otherwise
without prior written permission of Mack Trucks, Inc.
ii
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TABLE OF CONTENTS
TABLE OF CONTENTS
iii
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TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION & OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SR70/80 AXLE DESIGN FEATURES AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Forward-Rear Carrier with Power Divider/Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear-Rear Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CARRIER SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSING MISMATCHED CARRIER RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Carrier Identification Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gear Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CARRIER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lubricant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Changing Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
AXLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
HUB REDUCTION UNIT — OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Planetary Gear Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Stationary Sun Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Planetary Gear Case Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Planetary Gear Case Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Stationary Sun Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Planetary Gear Case Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
WHEEL HUB — OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hub Reduction Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Wheel Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Wheel Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wheel Hub Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Wheel Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Planetary Gear Case Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SR70/80 CARRIER — OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Carrier Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INTER-AXLE POWER DIVIDER/ADAPTER — OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Inter-Axle Power Divider/Adapter and Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Inter-Axle Power Divider/Adapter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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Inter-Axle Power Divider Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Inter-Axle Through Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Inter-Axle Through Shaft Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Inter-Axle Differential Case Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Inter-Axle Power Divider/Adapter Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Inter-Axle Power Divider/Adapter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INTER-WHEEL DIFFERENTIAL LOCK ASSEMBLY SERVICE PROCEDURES . . . . . . . . . . . . . . 81
Inter-Wheel Differential Lock Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Inter-Wheel Differential Lock Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Inter-Wheel Differential Lock Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Inter-Wheel Differential Lock Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INTER-AXLE DIFFERENTIAL LOCK ASSEMBLY SERVICE PROCEDURES . . . . . . . . . . . . . . . . 86
Inter-Axle Differential Lock Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Inter-Axle Differential Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Inter-Axle Differential Lock Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Inter-Axle Differential Lock Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Inter-Axle Differential Lock Cylinder Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
AXLE/CARRIER CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Pinion Shaft Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Gear Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Differential Spider Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Bearings, Bushings and Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Gearset Updating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Preparation and Precautions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
MECHANICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Features, Materials and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Fits and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
LUBRICANT AND SEALANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Assembly Sealants and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Gear Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
DISASSEMBLED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
SR70/80 AXLE PARTS IDENTIFICATION VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Hub Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Wheel Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Power Divider/Adapter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Inter-Axle Differential Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Inter-Wheel Differential Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
APPENDIX I — SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
REAR SPRING SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Spring Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Spring Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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SPRING TRUNNION SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Trunnion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Trunnion Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Torque Rod and Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Torque Rod and Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
REAR SUSPENSION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
REAR SUSPENSION (6x4) PARTS IDENTIFICATION VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Spring and Trunnion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Torque Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
APPENDIX II — BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
WHEEL BRAKE ASSEMBLY SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Wheel/Hub/Drum Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Wheel Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Wheel Brake Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Wheel/Hub/Drum Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Brake Lining Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Grinding of Brake Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Grinding of Brake Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
WHEEL BRAKE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Dimensional Data, Fits and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
WHEEL BRAKE ASSEMBLY PARTS IDENTIFICATION VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 145
Brake Shoe and Spider Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Camshaft and Slack Adjuster Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
SPECIAL TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
General Purpose Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Locally Fabricated or Procured Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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13_102.bk Page 1 Monday, February 18, 2002 11:16 AM
INTRODUCTION
INTRODUCTION
Page 1
INTRODUCTION
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
personal injury to service personnel, or the possibility of improper service methods which may damage
the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of
procedural importance and provide suggestions for ease of repair. The following definitions indicate the
use of these advisory labels as they appear throughout the manual:
Activities associated with Danger indicate that death or serious personal

injury may result from failing to heed the advisory. Serious personal injury
may be equated to career-ending injury.
Activities associated with Warning indicate that personal injury may result
from failing to heed the advisory. In this case, personal injury is not equated to
career-ending injury, but results in possible change in quality of life.
Activities associated with Caution indicate that product damage may result from
failing to heed the advisory. Caution is not used for personal injury.
A procedure, practice, or condition that is essential to emphasize.
A helpful suggestion that will make it quicker and/or easier to perform a procedure,
while possibly reducing service cost.
Page 2
INTRODUCTION
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.
Engine-driven components such as Power Take-Off (PTO) units, fans and fan
belts, driveshafts and other related rotating assemblies, can be very
dangerous. Do not work on or service engine-driven components unless the
engine is shut down. Always keep body parts and loose clothing out of range
of these powerful components to prevent serious personal injury. Be aware of
PTO engagement or nonengagement status. Always disengage the PTO when
not in use.
REMEMBER,
SAFETY . . . IS NO ACCIDENT!
Page 3
INTRODUCTION
Mack Trucks, Inc. cannot anticipate every r Use hoists or jacks to lift or move heavy
possible occurrence that may involve a potential objects.
hazard. Accidents can be avoided by recognizing
r NEVER run engine indoors unless exhaust
potentially hazardous situations and taking
fumes are adequately vented to the outside.
necessary precautions. Performing service
procedures correctly is critical to technician safety r Be aware of hot surfaces. Allow engine to
and safe, reliable vehicle operation. cool sufficiently before performing any
service or tests in the vicinity of the engine.
The following list of general shop safety practices
r Keep work area clean and orderly. Clean up
can help technicians avoid potentially hazardous
any spilled oil, grease, fuel, hydraulic fluid,
situations and reduce the risk of personal injury.
etc.
DO NOT perform any services, maintenance
procedures or lubrications until this manual has r Only use tools that are in good condition,
been read and understood. and always use accurately calibrated torque
wrenches to tighten all fasteners to specified
r Perform all service work on a flat, level
torques. In instances where procedures
surface. Block wheels to prevent vehicle
require the use of special tools which are
from rolling.
designed for a specific purpose, use only in
r DO NOT wear loose-fitting or torn clothing. the manner described in the instructions.
Remove any jewelry before servicing
r Do not store natural gas powered vehicles
vehicle.
indoors for an extended period of time
r ALWAYS wear safety glasses and protective (overnight) without first removing the fuel.
shoes. Avoid injury by being aware of sharp
r Never smoke around a natural gas powered
corners and jagged edges.
vehicle.
Page 4
INTRODUCTION
EXPLANATION OF NUMERICAL GROUP 400 — STEERING, AXLES, WHEELS
AND TIRES, DRIVELINE
CODE
The organization of MACK service manuals has GROUP 500 — BRAKES, AUXILIARY
been upgraded to standardize manual content SYSTEMS
according to a reference system based on
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 The second two digits of the three-digit code are
bulletins, warranty manuals, and MACK Service used to identify the system, assembly or
Labor Time Standards. 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 SECTION HEADINGS
first digit of which identifies the general as necessary, and may also appear in the TABLE
component grouping as listed here: OF CONTENTS, to guide you to specific
component information.
GROUP 000 — INSPECTIONS &
MISCELLANEOUS Additionally, a two-character alpha code (i.e. [CF]
CARRIER ASSEMBLY) may be shown with an
GROUP 100 — CHASSIS operation. This alpha code, in combination with
the three-digit Group number, identifies the
GROUP 200 — ENGINE specific assembly, subassembly or part, and
directly relates to the first five positions of
GROUP 300 — CLUTCH, TRANSMISSION, operation code listed in MACK Service Labor
TRANSFER CASE AND PTO Time Standards.
Example Numerical Code
Page 5
INTRODUCTION
CONVERSION CHART
Conversion Units Multiply By:
Length Calculations
Inches (in) to Millimeters (mm) 25.40
Inches (in) to Centimeters (cm) 2.540
Feet (ft) to Centimeters (cm) 30.48
Feet (ft) to Meters (m) 0.3048
Yards (yd) to Centimeters (cm) 91.44
Yards (yd) to Meters (m) 0.9144
Miles to Kilometers (km) 1.609
Millimeters (mm) to Inches (in) 0.03937
Centimeters (cm) to Inches (in) 0.3937
Centimeters (cm) to Feet (ft) 0.0328
Centimeters (cm) to Yards (yd) 0.0109
Meters (m) to Feet (ft) 3.281
Meters (m) to Yards (yd) 1.094
Kilometers (km) to Miles 0.6214
Area Calculations
Square Inches (sq-in) to Square Millimeters (sq-mm) 645.2
Square Inches (sq-in) to Square Centimeters (sq-cm) 6.452
Square Feet (sq-ft) to Square Centimeters (sq-cm) 929.0
Square Feet (sq-ft) to Square Meters (sq-m) 0.0929
Square Yards (sq-yd) to Square Meters (sq-m) 0.8361
Square Miles (sq-miles) to Square Kilometers (sq-km) 2.590
Square Millimeters (sq-mm) to Square Inches (sq-in) 0.00155
Square Centimeters (sq-cm) to Square Inches (sq-in) 0.155
Square Centimeters (sq-cm) to Square Feet (sq-ft) 0.001076
Square Meters (sq-m) to Square Feet (sq-ft) 10.76
Square Meters (sq-m) to Square Yards (sq-yd) 1.196
Square Kilometers (sq-km) to Square Miles (sq-miles) 0.3861
Volume Calculations
Cubic Inches (cu-in) to Cubic Centimeters (cu-cm) 16.387
Cubic Inches (cu-in) to Liters (L) 0.01639
Quarts (qt) to Liters (L) 0.9464
Gallons (gal) to Liters (L) 3.7854
Cubic Yards (cu-yd) to Cubic Meters (cu-m) 0.7646
Cubic Centimeters (cu-cm) to Cubic Inches (cu-in) 0.06102
Liters (L) to Cubic Inches (cu-in) 61.024
Liters (L) to Quarts (qt) 1.0567
Liters (L) to Gallons (gal) 0.2642
Cubic Meters (cu-m) to Cubic Yards (cu-yd) 1.308
Page 6
INTRODUCTION
Weight Calculations
Ounces (oz) to Grams (g) 28.5714
Pounds (lb) to Kilograms (kg) 0.4536
Pounds (lb) to Short Tons (US tons) 0.0005
Pounds (lb) to Metric Tons (t) 0.00045
Short Tons (US tons) to Pounds (lb) 2000
Short Tons (US tons) to Kilograms (kg) 907.18486
Short Tons (US tons) to Metric Tons (t) 0.90718
Grams (g) to Ounces (oz) 0.035
Kilograms (kg) to Pounds (lb) 2.205
Kilograms (kg) to Short Tons (US tons) 0.001102
Kilograms (kg) to Metric Tons (t) 0.001
Metric Tons (t) to Pounds (lb) 2205
Metric Tons (t) to Short Tons (US tons) 1.1023
Metric Tons (t) to Kilograms (kg) 1000
Force Calculations
Ounces Force (ozf) to Newtons (N) 0.2780
Pounds Force (lbf) to Newtons (N) 4.448
Pounds Force (lbf) to Kilograms Force (kgf) 0.456
Kilograms Force (kgf) to Pounds Force (lbf) 2.2046
Kilograms Force (kgf) to Newtons (N) 9.807
Newtons (N) to Kilograms Force (kgf) 0.10196
Newtons (N) to Ounces Force (ozf) 3.597
Newtons (N) to Pounds Force (lbf) 0.2248
Torque Calculations
Pound Inches (lb-in) to Newton Meters (N•m) 0.11298
Pound Feet (lb-ft) to Newton Meters (N•m) 1.3558
Pound Feet (lb-ft) to Kilograms Force per Meter (kgf•m) 0.13825
Newton Meters (N•m) to Pound Inches (lb-in) 8.851
Newton Meters (N•m) to Pound Feet (lb-ft) 0.7376
Newton Meters (N•m) to Kilograms Force per Meter (kgf•m) 0.10197
Kilograms Force per Meter (kgf•m) to Pound Feet (lb-ft) 7.233
Kilograms Force per Meter (kgf•m) to Newton Meters (N•m) 9.807
Radiator Specific Heat Dissipation Calculations
British Thermal Unit per Hour (BTU/hr) to Kilowatt per Degree Celsius (kW/°C) 0.000293
Kilowatt per Degree Celsius (kW/°C) to British Thermal Unit per Hour (BTU/hr) 3414.43
Temperature Calculations
Degrees Fahrenheit (°F) to Degrees Celsius (°C) (°F − 32) 0.556
Degrees Celsius (°C) to Degrees Fahrenheit (°F) (1.8 x °C) + 32
Page 7
INTRODUCTION
Pressure Calculations
Atmospheres (atm) to Bars (bar) 1.01325
Atmospheres (atm) to Kilopascals (kPa) 101.325
Bars (bar) to Atmospheres (atm) 0.98692
Bars (bar) to Kilopascals (kPa) 100
Bar (bar) to Pounds per Square Inch (psi) 14.5037
Inches of Mercury (in Hg) to Kilopascals (kPa) 3.377
Inches of Water (in H2O) to Kilopascals (kPa) 0.2491
Pounds per Square Inch (psi) to Kilopascals (kPa) 6.895
Pounds per Square Inch (psi) to Bar (bar) 0.06895
Kilopascals (kPa) to Atmospheres (atm) 0.00987
Kilopascals (kPa) to Inches of Mercury (in Hg) 0.29612
Kilopascals (kPa) to Inches of Water (in H2O) 4.01445
Kilopascals (kPa) to Pounds per Square Inch (psi) 0.145
Power Calculations
Horsepower (hp) to Kilowatts (kW) 0.74627
Kilowatts (kW) to Horsepower (hp) 1.34
Fuel Performance Calculations
Miles per Gallon (mile/gal) to Kilometers per Liter (km/L) 0.4251
Kilometers per Liter (km/L) to Miles per Gallon (mile/gal) 2.352
Velocity Calculations
Miles per Hour (mile/hr) to Kilometers per Hour (km/hr) 1.609
Kilometers per Hour (km/hr) to Miles per Hour (mile/hr) 0.6214
Volume Flow Calculations
Cubic Feet per Minute (cu-ft/min) to Liters per Minute (L/min) 28.32
Liters per Minute (L/min) to Cubic Feet per Minute (cu-ft/min) 0.03531
Page 8
DESCRIPTION & OPERATION
Page 9

SR70/80 AXLE DESIGN However, during certain off-highway (low traction)
situations, it is advantageous to couple the
FEATURES AND OPERATION tandem carriers together in a straight-through
MACK SR70/80 series dual-reduction tandem positive drive arrangement. An optional power
axles feature face-mounted carriers with hypoid divider with lockout feature is available for this
bevel gearing and wheel hub reduction units. The purpose. The driver can control the power divider
first reduction occurs in the hypoid bevel gearset lockout from the cab of the vehicle. The lockout
of the carrier and the second reduction in the consists of an air-actuated piston which controls
wheel hubs. The forward-rear and rear-rear a shift fork and gear-type sliding clutch. The
carriers are identical except for the input drive clutch is splined to the through shaft assembly
and the through shaft arrangement of the and is moved to engage with the rear sun gear of
forward-rear carrier. This differs from the input the differential assembly. This couples the
pinion mounting of the rear-rear carrier. differential front and rear sun gears together and
effectively locks out the function of the power
divider for emergency traction situations.
Forward-Rear Carrier with Power
Divider/Adapter Tire matching is still required on units with or
without an inter-axle power divider as
INTER-AXLE POWER DIVIDER mismatched tires equates to mismatched ratios.
Tire matching is required with a power divider or
The four-wheel-drive arrangement of the
premature unit failure will occur.
SR70/80 series tandems are provided with an
inter-axle power divider which can be defined as
a third differential (Figure 1). The inter-axle power
divider splits driving torque evenly between the
tandem axles. It is a four-pinion planetary gear
arrangement of the type used for the inter-wheel
differential. This arrangement adjusts to the
tracking and traction conditions encountered at
each axle.
1
Figure 1 — Inter-Axle Power Divider
1. Differential Case, Front 4. Sun Gear, Rear

Half 5. Differential Case, Rear
2. Sun Gear, Front Half
3. Pinion Gear (4)
Page 10

ADAPTER ASSEMBLY CARRIER ASSEMBLY
The adapter assembly transmits power from the The carrier includes a bevel gearset (ring gear
forward carrier drive gear on the through shaft via and pinion) and a four-pinion planetary gear inter-
an intermediate gear to the input pinion drive gear wheel differential. As stated earlier, the bevel
(Figure 2). There is no gear reduction in the gearset provides the first gear reduction in the
adapter assembly. axle with optional ratios available from 5.125:1 to
2
9.11:1.
HUB REDUCTION UNITS

The hub reduction unit on each wheel hub uses a
four-pinion differential much like the inter-axle
and inter-wheel differentials (Figure 3). Here, the
inner sun gear is stationary, splined to the axle
housing spindle tube. The outer sun gear is
splined to the axle shaft and rotates with it. The
rotating sun gear, through its interaction with the
pinion gears, causes the differential case and
wheel hub to rotate at a 2:1 reduction in speed.
3
Figure 3 — Hub Reduction Unit
1. Differential Case, Outer 4. Sun Gear, Inner

Figure 2 — Adapter Assembly Gearing Half (Stationary)
2. Sun Gear, Outer 5. Differential Case, Inner
1. Forward Carrier Drive 4. Intermediate Gear (Rotating) Half
Gear 5. Adapter Housing, Front 3. Pinion Gear (4)
2. Pinion Drive Gear Half
3. Adapter Housing, Rear 6. Power Divider Housing
Half
Page 11

Rear-Rear Carrier Features
The rear-rear carrier is identical to the forward- Current production SR70/80 series dual-
rear carrier except that it does not have an inter- reduction carriers are provided with:
axle power divider/adapter assembly. A drive
r Hypoid spiral bevel gears for first reduction
input flange is provided in place of the pinion
drive gear to make the connection to the inter- r Hub-mounted four-pinion planetary gearsets
axle driveshaft (Figure 4). for second reduction
4
r Four-pinion, planetary gearset for inter-axle
power divider
r Four-pinion, planetary gearsets for inter-
wheel differentials
r Optional inter-axle power divider and inter-
wheel differential lock assemblies
Figure 4 — Rear-Rear Carrier Arrangement
1. Input Flange 2. Carrier Housing
Page 12
TROUBLESHOOTING
TROUBLESHOOTING
Page 13
TROUBLESHOOTING
CARRIER SYMPTOM
DIAGNOSIS
The troubleshooting chart summarizes some
common carrier complaints, probable causes and
possible remedies.
CARRIER TROUBLESHOOTING CHART

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 and 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. 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.
have same ratio.
Page 14
TROUBLESHOOTING
Symptom Probable Cause Remedy
Gear Failure 1. Low lubrication. 1. Fill to proper level using
2. Improper lubrication. 2. Check Maintenance and Lubrication
Manual (TS494) for proper
lubrication.
3. Contamination of lubricant. 3. Check servicing intervals and check
for water leaks. Replace failed parts
and fill to proper level using
4. Driver abuse. 4. Instruct driver in proper procedure.
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. Torque
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.
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.
Page 15
TROUBLESHOOTING
DIAGNOSING MISMATCHED 1. With an operator in the cab and the
transmission in neutral, release the spring
CARRIER RATIOS brakes. Make sure there is sufficient room to
(FOR TANDEM CARRIERS) push the chassis forward one complete
wheel rotation.
Check the tandem carrier for mismatched carrier 2. Push the chassis forward and count the
ratios if any of the following conditions occur: number of shaft rotations during one
r Tire scuffing or wear complete wheel rotation. For example, with
a 5.02 carrier ratio, the driveshaft will rotate
r Noise in the power divider or shortened five times to one tire rotation.
power divider life
r Noise in the various transmission gears If a variation exists between tire revolution and/or
drive-line rotation between front-rear and rear-
Mismatched carrier ratios can transmit noise rear carriers, a physical inspection of each gear
through the driveline and transmission. set must be made.
Carrier Identification Stamping Gear Set Inspection

If mismatched carrier ratios are suspected, check Remove the drain plugs from both axle housing
the carrier identification stampings for matched assemblies and from the adapter gear housing on
ratios. the front carrier, and drain the oil. Remove the
carrier assemblies and count the teeth on each
If the stampings are compatible and mismatched drive pinion and ring gear.
ratios are still suspected, mark the tandem axle Ring gear — X = number of teeth
tires with a piece of chalk so that one complete
wheel rotation can be monitored when the Drive pinion — Y = number of teeth
chassis is moved across the floor. Also, mark the X ÷ Y = Gear Ratio
propeller shaft and intermediate shaft yoke in
reference to the pinion, carrier or power divider Correct all mismatched gear sets.
housing.
Make sure the eight tandem rear tires are

properly matched. Refer to MACK Service
Manual, 15-101, Wheels, Rims and Tires.
Page 16
MAINTENANCE
MAINTENANCE
Page 17
MAINTENANCE
CARRIER MAINTENANCE DO NOT add oil if the level in the axle housing is
sufficient (Figure 6). Reinstall the plugs and
[475 CF] tighten to specifications.
6
Lubricant Level Check
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 Figure 6 — Correct Oil Level
and chassis is parked on level ground. Check the
oil level by removing the filler plugs from the axle
housings and the adapter gear housing on the
front carrier. The level is correct when oil runs out
of the filler plug hole in the axle housings, and
slightly below the filler plug hole in the adapter
gear housing. If the level in the axle housing is
low (Figure 5), add oil to the axle housing and
adapter gear housing so that the oil is level with
the bottom of the filler plug holes.
5
Figure 5 — Incorrect Oil Level
Page 18
MAINTENANCE
Changing Lubricant bottom of the fill plug hole, and oil begins to flow
out of the level plug hole in the adapter gear
(Axle Housing and Hub Reduction housing.
Units)
AXLE HOUSINGS Depending upon angle of inclination, it may be

necessary to add oil to the adapter housing until
With the axles at operating temperature, remove
level with the plug hole.
the drain plugs from both axle housing
assemblies and from the adapter gear housing on
the front carrier (Figure 7), and drain the oil. Install the fill plug in the axle housing. Check the
Clean and reinstall the drain plugs. Remove the oil level in the adapter gear housing and add oil
fill plug from the inter-axle power divider on the until level with the plug hole, if necessary, before
front carrier and add 0.5 pint (0.25 liter) of installing the level plug. Remove the fill/level plug
recommended gear oil. Reinstall the fill plug. from the rear axle housing, and add
Remove the fill plug from the front axle housing, recommended gear oil until level with the fill plug
and the level plug from the adapter gear housing. hole. Reinstall the plug.
Add oil to the axle housing until level with the 7
Figure 7 — Axle Housings
Page 19
MAINTENANCE
HUB REDUCTION ASSEMBLIES Rotate wheels until the drain plugs (or drain/fill
plugs) are in the 6 o’clock position. Remove the
plugs and allow the oil to drain completely.
Reinstall the drain plugs and remove the fill plugs
Depending upon axle configuration, hub (or rotate wheels until the drain/fill plug holes are
assemblies may have either a single drain/fill in the 3 o’clock position). Add 4.75 pints
plug, or a separate drain and a separate fill plug (2.25 liters) of the recommended gear oil to each
(Figure 8). hub reduction assembly. (Any surplus oil will
drain into the axle housing.) Reinstall the plugs.
8
Figure 8 — Hub Assembly
Air Breathers
Remove the carrier housing breathers from each
axle assembly, clean with a suitable,
nonflammable solvent, and check for
obstructions. Blow dry with compressed air, then
reinstall.
Page 20
REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS
Page 21
REPAIR INSTRUCTIONS
AXLE REMOVAL AND
INSTALLATION
[470 AX] If the wheel, hub and drum are being removed as
an assembly, it is necessary to back off the slack
adjuster to obtain sufficient clearance between
Removal the brake linings and drum.
If a repair is limited to a hub-reduction unit, the 7. Support the rear axle on a dolly and remove
power divider or carrier, it is not necessary to the spring-to-axle U-bolts.
remove the rear axle assembly from the vehicle.
Instead, refer to the appropriate procedure in this 8. Mount the rear axle on a universal holding
manual for the component being serviced. fixture or support stand as shown in
Figure 9.
9
If performing a complete rear axle overhaul, it is
recommended to remove the rear axle from the
chassis first. Remove the axle as follows:
1. Block the vehicle’s front wheels.
2. Manually cage the parking spring brake on
each rear brake chamber.
3. Disconnect the propeller shaft from the axle
drive input flange.
4. Disconnect and tag electrical and air piping
connections to axle components.
5. Raise the rear of the vehicle with a suitable
lifting device and support the chassis on jack
stands. Also provide support for the rear
suspension. Figure 9 — Axle Support Stand
6. Place a wheel dolly (J 36132, or equivalent)
in position and remove the rear wheel and
tire assemblies.
Page 22
REPAIR INSTRUCTIONS
Installation 5. Remove the jack stands from under the
suspension and chassis and lower the
1. Remove the rear axle from the support stand vehicle to the floor.
and using a dolly, move the axle into position
under the rear suspension. 6. Complete the electrical and air piping
connections to the axle.
2. Install the axle-to-spring U-bolts and tighten
to specification, 184 lb-ft (250 N•m). 7. Connect the propeller shaft to the axle drive
input flange.
3. Check that the mating surfaces of the hub
and wheel, plus nuts and studs, are clean 8. Adjust the brakes as required.
and dry. These surfaces must also be 9. Uncage the parking spring brake on each
undamaged and free of excess paint. rear brake chamber.
4. Place each wheel and tire assembly 10. Remove the blocks from vehicle’s front
(supported on wheel dolly J 36132, or wheels.
equivalent) in position on the hubs and
install the lug nuts. Tighten the lug nuts in
three or four progressive stages until the
final specified torque is achieved. Tighten
following the sequence shown in Figure 10.
10
Figure 10 — Wheel Lug Nut Tightening Sequence
Page 23
REPAIR INSTRUCTIONS
HUB REDUCTION UNIT — OVERHAUL
[477 HU]
The following procedures can be done with the axle installed on the vehicle or mounted in a universal
support stand.
11
Figure 11 — Hub Reduction Unit Disassembled View
1. Shim 6. Outer Sun Gear (Rotating) 11. Housing Capscrew

2. Inner Sun Gear (Stationary) 7. Thrust Washer 12. Pinion Gear (4)
3. Hub Retaining Nut 8. Planetary Gear Case (Outer Half) 13. Needle Bearings
4. Planetary Gear Case (Inner Half) 9. Hub Retaining Bolt 14. Thrust Washer
5. Spider 10. Plug, Oil Fill/Drain 15. O-Ring
Page 24
REPAIR INSTRUCTIONS
Planetary Gear Case Removal 1. Undo the staking holding the retaining nut
using one of the following methods:
r Use a hammer and suitable cape chisel
to relieve the two staked areas of the
If a complete rear axle overhaul is to be done, it is nut.
recommended that the axle be removed from the r Or, center punch and drill out the two
chassis. Refer to “AXLE REMOVAL AND staked areas of the nut. Use a
INSTALLATION” on page 22. 0.236-inch (6 mm) drill bit.
1. Block the vehicle's front wheels. Take care not to damage the threaded
portion of the axle tube.
2. Manually cage the parking spring brake on
each rear brake chamber. 2. Using wrench J 35904, loosen and remove
the hub retaining nut (Figure 12).
3. Raise the rear of the vehicle with a suitable 12
lifting device and support the chassis on jack

stands. Also provide support for the rear
suspension.
4. Place a wheel dolly (J 36132, or equivalent)
in position and remove the rear wheel and
tire assembly from the axle end.
5. Rotate the brake drum so that the hub drain
plug is at the bottom. Place a suitable
container below the hub and drain lubricant
from the hub reduction unit.
6. Remove the bolts holding the reduction gear
unit to the hub (Figure 11).
7. Remove the reduction gear unit.
8. Remove the axle shaft.
9. Repeat steps 4 through 8 to remove the
planetary gear case from the other side of
the axle, if required.
Stationary Sun Gear Removal Figure 12 — Hub Retaining Nut
1. Wrench (J 35904) 2. Centering Ring
The retaining nut is staked to the spindle. The 3. Remove the inner sun gear from the axle
staking must be undone prior to removing the nut spindle tube.
to avoid damaging the threads on the spindle 4. Remove the bearing and inspect and clean it
tube. for reassembly.
5. Remove the shim and set it aside for reuse.
6. Repeat steps 1 through 5 to remove the
stationary sun gear from the other side of
the axle, if required.
Page 25
REPAIR INSTRUCTIONS
Planetary Gear Case Disassembly Cleaning and Inspection
1. Mark the case halves for reassembly Refer to the procedures under “AXLE/CARRIER
(Figure 13). CLEANING AND INSPECTION” on page 95.
13
Planetary Gear Case Reassembly
Hub reduction units must be reassembled using a

matched set/brand of gears. When damage
occurs, always replace mated gears in sets.
1. Install the pinion gears and needle bearings

on the spider.
2. Lubricate the assembly and install the thrust
washers and O-rings.
3. Place the spider/gear assembly, outer sun
gear and spacer in position on the inner
case half.
4. Apply Loctite® 549, or equivalent, to the
mating surface of the outer case half.
Figure 13 — Planetary Gear Case Reassembly Marks
5. Place the outer case half in position over the
2. With the assembly on a bench, remove the spider/gear assembly and inner case.
capscrews and separate the case halves. 6. Apply Loctite® 271, or equivalent, to the
3. Remove the thrust washer. threads of the case capscrews and install
the capscrews to secure the case halves
4. Remove the outer sun gear and spider together. Tighten the capscrews to
assembly. specification, 48 lb-ft (65 N•m).
5. Disassemble the spider by removing the 7. Position new copper washers and install
O-rings, thrust washers, pinion gears and plugs finger-tight in the outer case half. Do
needle bearings from the spider. not tighten the plugs to specification at this
time.
Use care not to lose the needle bearings when

removing the pinion gears.
Page 26
REPAIR INSTRUCTIONS
Stationary Sun Gear Installation 15
The bearing surface of the outer sun gear must

be installed at a depth of 0.709 ± 0.003 inches
(18 ± 0.07 mm) below the reduction unit mounting
surface of the hub, dimension “B” shown in
Figure 14.
14
Figure 15 — Installation Depth Measurement
2. Lubricate the shim and install it on the

bearing surface of the inner sun gear.
3. Install the gear on the axle spindle tube.
4. Thread a new gear retaining nut on the axle
spindle tube.
Figure 14 — Inner Side Gear Installation Depth
5. Using wrench J 35904, or equivalent, tighten
1. Measure the depth from the reduction unit the retaining nut to specification as follows:
mounting surface on the hub to the hub a. Tighten the nut to 369 lb-ft (500 N•m)
outer bearing cup. This is dimension “A” in while rotating the hub several times in
Figure 15. This measurement, minus the both directions.
thickness of the thrust washer, must equal
0.709 inches (18 ± 0.07 mm). b. Back off the nut one-half turn and pull
the hub against the nut.
c. Tighten the nut to 184 lb-ft (250 N•m)
while rotating the hub in both directions.
If any part has been replaced, readjust the setting

completely.
Page 27
REPAIR INSTRUCTIONS
6. Stake the nut to secure it on the spindle tube Planetary Gear Case Installation
(Figure 16).
16 1. Install the axle shaft.
2. Apply Loctite® 549, or equivalent, to the
mating surface of the assembled planetary
gear case.
3. Place the planetary gear case in position on
the wheel hub and install the bolts securing
the case to the hub (Figure 17).
17
Figure 16 — Staking the Retaining Nut
7. Repeat steps 1 through 6 to install the

stationary sun gear on the other side of the
axle, if removed.
Figure 17 — Planetary Gear Case Bolt Installation
4. Tighten the bolts to specification, 111 lb-ft

(150 N•m).
Page 28
REPAIR INSTRUCTIONS
5. Repeat steps 1 through 4 to install the 9. Remove the jack stands from under the
planetary gear case for the other side of the suspension and chassis and lower the
axle, if removed. vehicle to the floor.
6. Fill the hub reduction units and axle with 10. Adjust the brakes as required.
lubricant. Tighten the plugs to specification,
11. Uncage the parking spring brake on each
26 lb-ft (35 N•m).
rear brake chamber.
7. Check that the mating surfaces of the hub
12. Remove the blocks from vehicle’s front
and wheel, plus nuts and studs, are clean
wheels.
and dry. These surfaces must also be
undamaged and free of excess paint.
8. Place each wheel and tire assembly
(supported on wheel dolly J 36132, or
equivalent) in position on the hubs and
install the lug nuts. Tighten the lug nuts in
three or four progressive stages until the
final specified torque is achieved (see
SPECIFICATIONS section). Tighten
following the sequence shown in Figure 18.
18
Figure 18 — Wheel Lug Nut Tightening Sequence
Page 29
REPAIR INSTRUCTIONS
WHEEL HUB — OVERHAUL
[477 HU]
The following procedures can be done with the axle installed on the vehicle or mounted in a universal
support stand.
19
Figure 19 — Wheel Hub (Arrangement 1, Typical)
1. Holder 8. Hub Bearing (Outer) 15. ABS Tone Wheel (N/A in USA)
2. Oil Deflector (Inner) 9. Thrust Washer 16. Oil Deflector (Inner)
3. Seal 10. Hub Retainer Nut 17. Lubrication Tube
4. Oil Slinger 11. Sun Gear (Inner) 18. Clamp
5. Hub Bearing (Inner) 12. Wheel Stud 19. Sleeve
6. Hub 13. Wear Ring 20. Sensor
7. Brake Drum 14. Oil Deflector (Outer)
Page 30
REPAIR INSTRUCTIONS
Hub Reduction Unit Removal 21
Refer to “HUB REDUCTION UNIT —

OVERHAUL” on page 24 for hub reduction unit
removal procedure.
Wheel Hub Removal

1. Using wrench J 35904, loosen and remove
the hub retaining nut (Figure 20).
20
Figure 21 — Brake Drum Removal
1. Brake Drum 3. Hub

2. Remover Screws
9. Support the wheel hub with a suitable lifting

device. Then, using a suitable puller and
adapter, remove the hub (Figure 22).
22
Figure 20 — Hub Retaining Nut Removal
1. Wrench (J 35904) 2. Centering Ring
2. Remove the inner sun gear.

3. Remove the bearing and inspect and clean it
for reassembly.
4. Remove the shim and set it aside for reuse.
5. Repeat steps 1 through 4 to remove the hub
from the other side of the axle.
6. Support the drum for removal using a
suitable lifting device.
7. Remove the two brake drum retainer
screws.
8. Install two remover screws in the holes
provided (Figure 21) and tighten to remove
the drum. Figure 22 — Wheel Hub Removal
1. Puller 2. Adapter
Page 31
REPAIR INSTRUCTIONS
Wheel Hub Disassembly 24
1. Remove the tone wheel of the anti-lock

braking system (ABS), if so equipped. Drill a
15/64-inch (6-mm) diameter hole in the
wheel to remove (Figure 23).
23
Figure 24 — Hub Bearing Removal
1. Puller Support 2. Puller
5. Use a press to remove the stud bolts

(Figure 25).
25
Figure 23 — ABS Tone Wheel Removal
2. Remove the O-ring and save for reuse.

3. Remove the deflector ring.
4. Using a suitable puller, remove the inner and
outer bearing cups and clean and inspect
them for reassembly (Figure 24).
Figure 25 — Wheel Stud Removal
1. Press 2. Wheel Stud
6. Remove the outer oil deflector from the hub.
Page 32
REPAIR INSTRUCTIONS
7. If equipped with ABS, perform the following 26
operations. If not, continue with the next

step.
a. Using spring pliers, remove the spring
and rotate the brake shoe out of way.
b. Remove the ABS sensor and sleeve.
c. Remove the screws and clamp from the
inner oil deflector.
d. Remove the hose clamp and
disconnect the breather hose from the
oil deflector.
8. Remove the inner seal wear ring from the
axle spindle tube as follows:
Arrangement 1 — Apply heat to the seal
wear ring to expand it and then remove the
wear ring from the axle spindle tube
(Figure 26).
Arrangement 2 — Using a “MIG” welder,
attach two 0.551-inch (14-mm) diameter Figure 26 — Wear Ring Removal (Arrangement 1)
threaded rods, 16 inches (406 mm) in
length, to the wear ring (Figure 27). These 1. Wear Ring
rods will provide attachment for the puller.
27
Then, using a suitable puller and adapter
attached to the threaded rods, remove the
wear ring.
Use care when heating the wear ring to avoid

destroying the heat treatment of the axle spindle.
Figure 27 — Wear Ring Removal (Arrangement 2)
1. Adapter 2. Puller
Page 33
REPAIR INSTRUCTIONS
9. Remove the inner oil deflector (Figure 28), if 2. Heat the inner seal wear ring on a hot plate
so equipped. Apply heat to the oil deflector if to 212°F (100°C).
necessary to remove it.
28 3. When heated to temperature, remove the
wear ring from the hot plate. Immediately
install it on the axle spindle tube with the
outer chamfered edge facing outward from
the brake backing plate (Figure 29). Once
seated, allow the wear ring to cool.
29
Figure 28 — Inner Oil Deflector Removal
1. Inner Oil Deflector
Cleaning and Inspection Figure 29 — Wear Ring Installation

Refer to “AXLE/CARRIER CLEANING AND
INSPECTION” on page 95. 1. Wear Ring
4. If equipped with an oil deflector that fits on

Wheel Hub Reassembly the wear ring, heat the deflector on a hot
1. Install the inner oil deflector, if so equipped. plate to 212°F (100°C).
5. When heated to temperature, remove the oil
deflector from the hot plate. Immediately
install it on the wear ring with the oil breather
On one arrangement, the oil deflector is fitted connection facing inward toward the brake
over the spindle tube inward of the wear ring and backing plate (Figure 30). Once seated,
must be installed first. On a second arrangement, allow the wear ring to cool.
the oil deflector fits on the wear ring along with
the seal; here, the wear ring is installed first. Also,
there is a third arrangement that does use a
separate oil deflector.
Page 34
REPAIR INSTRUCTIONS
30
7. Using a press, install the stud bolts in the
hub (Figure 32).
32
Figure 30 — Oil Deflector Installation (Arrangement 2)
1. Inner Oil Deflector Figure 32 — Stud Bolt Installation
6. If equipped with ABS, install the tone wheel 1. Press 2. Wheel Stud
on the hub (Figure 31).
31
8. Install the outer oil deflector in the wheel hub
(Figure 33).
33
Figure 31 — ABS Tone Wheel Installation
1. Press 3. Tone Wheel Figure 33 — Outer Oil Deflector Installation

2. Adapter 4. Hub
1. Installer 2. Hub
Page 35
REPAIR INSTRUCTIONS
9. Using a suitable installer and a press, install 11. Install the bearing oil deflector.
the inner and outer bearing cups in the hub
12. Using a seal adapter and a press, install the
(Figure 34).
inner seal in the hub (Figure 35).
10. Lubricate and install the inner bearing. 35
If any component parts of the hub assembly were

replaced, the assembly must be readjusted to
ensure proper bearing preload. See HUB
REDUCTION UNIT REASSEMBLY for
adjustment procedures.
34
Figure 35 — Inner Seal Installation
1. Press 3. Hub
2. Adapter
Figure 34 — Hub Bearing Cup Installation
1. Bearing Cup Installer 2. Hub
Page 36
REPAIR INSTRUCTIONS
Wheel Hub Installation 5. If equipped with ABS, install the retainer and
sensor in its mounting on the inner oil
1. Install the hub assembly on the axle housing deflector. Adjust the sensor’s position so that
spindle. the specified air gap between the sensor
2. Lubricate and install the hub outer bearing. and the tone wheel is achieved.
Then, place the spacer in position against 6. Rotate the brake shoe into position and
the hub outer bearing. using spring pliers, install the return spring.
3. Install the hub reduction inner side gear on 7. Connect the breather hose to the inner oil
the spindle. Install the retaining nut and step deflector.
tighten to specification as follows:
8. Using a suitable lifting device, place the
a. Using wrench J 35904, tighten the nut brake drum in position on the hub
to 369 lb-ft (500 N•m) while rotating the (Figure 37).
hub several times in both directions. 37
b. Back off the nut approximately one-half

turn and pull the hub against the nut.
c. Tighten the nut to 184 lb-ft (250 N•m),
again while rotating the hub several
times in both directions.
4. Stake the nut to secure it in position
(Figure 36).
36
Figure 37 — Brake Drum Installation
1. Brake Drum 3. Hub

2. Remover Screws
9. Install the axle shafts.
Planetary Gear Case Installation

Figure 36 — Staking Hub Nut in Position Refer to “HUB REDUCTION UNIT —
OVERHAUL” on page 24 for planetary gear case
installation procedure.
Page 37
REPAIR INSTRUCTIONS
SR70/80 CARRIER — Carrier Disassembly
OVERHAUL 1. Mount the removed carrier in a suitable
[475 CF] 39
carrier repair stand (Figure 39).
The carrier removal and installation procedures

apply for an axle installed on the vehicle or
mounted in a universal repair stand.
Carrier Removal
1. Drain the lubricant from the hub reduction
units, the inter-axle power divider assembly
(if so equipped) and from the axle housing.
2. Remove the planetary gear cases following
the procedure under “Planetary Gear Case
Removal” on page 25 in the HUB
REDUCTION UNIT — OVERHAUL section.
3. Remove the axle shafts.
4. Support the carrier assembly with a suitable
lifting device and remove the capscrews
retaining the carrier housing to the axle
housing. Use two remover screws as shown
in Figure 38 to separate the carrier assembly
from the housing. Figure 39 — Carrier Repair Stand
38
1. Repair Stand 3. Support

2. Support
Figure 38 — Carrier Removal
1. Remover Screws 2. Carrier
5. Remove the carrier from the axle housing.
Page 38
REPAIR INSTRUCTIONS
2. Remove the lubrication port plug, O-ring, 41
spring and sleeve from the front of the

carrier.
3. Compress the lock ring and disengage the
sliding clutch. Remove the sliding clutch
using pliers J 39454, or equivalent. Refer to
Figure 40.
40
Figure 41 — Bearing Adjuster Ring Removal
1. Adjuster Ring 2. Spanner Wrench
7. Remove the bearing cap capscrews and

remove the caps.
8. Using a suitable lifting device, remove the
inter-wheel differential assembly from the
Figure 40 — Sliding Clutch Removal
carrier housing (Figure 42).
42
1. Pliers (J 39454) 2. Sliding Clutch
4. Punch mark the bearing caps and their

mating pedestals prior to removal (if
markings are not present) to ensure
reassembly in their original positions.
5. Loosen and remove the stop plate retaining
screws and remove the plates.
6. Using spanner wrench 5000264094, loosen
the bearing adjuster rings (Figure 41).
Figure 42 — Differential Assembly Removal
Page 39
REPAIR INSTRUCTIONS
9. Remove the capscrews securing the bevel 44
pinion assembly to the carrier housing.

Remove the shim(s) and save for
reassembly.
10. Attach a lifting device to the bevel pinion
assembly and remove the assembly from
the housing. Use the appropriate lifting
device for the configuration being serviced.
See Figure 43, Figure 44 and Figure 45.
43
Figure 44 — Pinion Assembly Removal, Forward-Rear

Axle (PMA, PRA and PSA Models — Arrangement 1)
1. Lifting Ring 2. Bevel Pinion Assembly
Figure 43 — Pinion Assembly Removal, Rear-Rear Axle

(P, PM and PR Models)
1. Bevel Pinion Assembly
Page 40
REPAIR INSTRUCTIONS
45
INTER-WHEEL DIFFERENTIAL DISASSEMBLY
1. Mark the bearing cups for reassembly in the
same positions.
2. Remove the lubrication ring and O-ring.
3. Mount the differential assembly in a press
and using a suitable socket, remove the
capscrews retaining the ring gear (Figure
46). Use a suitable adapter to center the
assembly in the press.
46
Figure 45 — Pinion Assembly Removal, Forward-Rear

Axle (PMA, PRA and PSA Models — Arrangement 2)
1. Bevel Pinion Assembly
Figure 46 — Ring Gear Capscrew Removal
1. Adapter 3. Differential Assembly

2. Press
4. Invert the differential assembly in the press

and using a suitable adapter and support
ring, press the ring gear from the assembly
(Figure 47).
Page 41
REPAIR INSTRUCTIONS
47 48
Figure 47 — Ring Gear Removal Figure 48 — Differential Bearing Removal
1. Ring Gear 3. Support Ring 1. Puller 2. Adapter

2. Adapter
5. Mark the two halves of the differential BEVEL PINION DISASSEMBLY

housing for reassembly and separate the 1. Mount the pinion assembly in a protective
halves. soft-jawed vise.
6. Remove the thrust bearings, side gears and 2. Using a torque multiplier tool, loosen and
spider assembly. remove the pinion shaft nut (Figure 49 and
7. Remove the stops and pinion gears from the Figure 50).
spider.
8. Using a suitable adapter and puller, remove
the bearings from the differential assembly
(Figure 48).
Page 42
REPAIR INSTRUCTIONS
49
3. Using a suitable puller, remove the drive
flange (P, PM and PR models) or drive gear
(PMA, PRA and PSA models) as shown in
Figure 51 and Figure 52.
51
Figure 49 — Pinion Shaft Nut Removal, Rear-Rear Axle

1. Pinion Housing 2. Torque Multiplier
50
Figure 51 — Drive Flange Removal, Rear-Rear Axle
1. Puller 2. Pinion Housing
Figure 50 — Pinion Shaft Nut Removal, Forward-Rear

Axle (PMA, PRA and PSA Models)
Page 43
REPAIR INSTRUCTIONS
52
5. Place the pinion housing in a press and
remove the bevel pinion shaft (Figure 53).
53
Figure 52 — Drive Gear Removal, Forward-Rear Axle

(PMA, PRA and PSA Models)
1. Puller 2. Pinion Housing Figure 53 — Pinion Shaft Removal
4. Remove the lubricant seal ring and save for 1. Press 2. Pinion Housing
reassembly.
6. Remove the deflector ring and shim(s). Save
the shim(s) for reassembly.
7. Position a suitable puller between the pinion
P, PM and PR model rear-rear axle carriers are gear and the large bearing at the spline end
fitted with a felt/composite-type lubricant seal ring of the shaft. Then, using a press, remove the
within the housing bore. PMA, PRA and PSA bearing from the bevel pinion shaft
model forward-rear axle carriers are fitted with a (Figure 54).
metal-type ring at the outer perimeter of the bore.
Page 44
REPAIR INSTRUCTIONS
54 55
Figure 54 — Pinion Bearing Removal Figure 55 — Pilot Bearing Removal
1. Press 2. Puller 1. Press 2. Puller
8. Remove the snap ring at the pilot end of the 10. Position the pinion housing in a press and
pinion shaft. remove the remaining pinion bearing from
the housing (Figure 56).
9. Position the puller between the pinion gear 56
and the small bearing at the pilot end of the
shaft. Using a press, remove the bearing
from the shaft (Figure 55).
Figure 56 — Bearing Removal from Housing
1. Press 2. Pinion Housing
Page 45
REPAIR INSTRUCTIONS
11. Using a suitable puller and puller support,
remove the bearing cups from the pinion
(Figure 57).
57
Figure 57 — Pinion Bearing Cup Removal
1. Puller/Support 2. Puller
Cleaning and Inspection

Clean and inspect parts as required to determine
acceptability for reuse when reassembling the
carrier. Refer to “AXLE/CARRIER CLEANING
AND INSPECTION” on page 95 for procedures.
Page 46
REPAIR INSTRUCTIONS
Carrier Reassembly
With the cleaning and inspection of parts
complete, reassemble the carrier as follows:
BEVEL PINION REASSEMBLY

58
Figure 58 — Drive Pinion Disassembled View
1. Drive Input Flange 7. Shim (sets Bearing Preload) 13. Bearing (Outer)
2. Seal 8. Bearing (Inner) 14. Oil Deflector
3. Bearing (Outer) 9. Pinion Shaft 15. Pinion Drive Gear
4. Pinion Housing 10. Pilot Bearing 16. Retainer Nut
5. Oil Deflector 11. Snap Ring
6. Shim (sets Pinion Depth) 12. Pinion Housing
Page 47
REPAIR INSTRUCTIONS
1. Using a suitable bearing installer and a 60
press, install the two bearing cups into the

bevel pinion housing (Figure 59).
59
Figure 60 — Shim Pack Measurement
4. Using a press and an appropriate driver

tube, install the large pinion bearing on the
pinion shaft until it is seated next to the bevel
gear (Figure 61).
61
Figure 59 — Bearing Cup Installation
1. Installer 2. Pinion Housing
2. Position the two pinion bearings in the

housing. Rotate and exert pressure on each
bearing as it is being positioned to ensure a
proper fit.
3. Measure dimensions A, B and C (Figure 60).
Then, calculate dimension D by subtracting
the sum of B plus C from dimension A.
Subtract an additional 0.002 inch (0.05 mm)
from dimension D to determine the shim
pack thickness for the proper bearing
preload.
D = A − [B + C]
D − 0.002 inch (0.05 mm) = Proper Shim Figure 61 — Pinion Bearing Installation
Thickness
1. Oil Deflector 5. Pinion
2. Shim (Pinion Depth) 6. Pilot Bearing
3. Shim (Bearing Preload) 7. Snap Ring
4. Inner Bearing
Page 48
REPAIR INSTRUCTIONS
5. Position the shim pack and the deflector ring 62
on the shaft next to the bearing.

6. Install the shaft in the pinion housing.
7. Again, using a press, install the second
pinion bearing on the shaft until it is firmly
seated against the shim pack.
Tools and parts must be clean when installing the

shaft and bearings to ensure that the proper
bearing preload is maintained.
8. Install the rear-rear axle drive flange (P, PM

and PR models) or forward-axle drive gear
(PMA, PRA and PSA models) on the shaft
and install the retaining nut. Tighten the nut
to specification.
9. Temporarily mount the pinion assembly in
the carrier housing using three capscrews,
Figure 62 — Rotational Torque Check, Rear-Rear Axle
evenly spaced around the perimeter. This (P, PM and PR Models)
will provide a support base for the pinion
assembly while the rotational torque check 1. Pinion Drive Flange 2. Scale
(bearing preload) is made.
63
10. Using spring scale J 8129, or equivalent,
check the rotational torque of the pinion
shaft (Figure 62 and Figure 63). The
specified torque range is 13–23 lb-in
(1.5–2.6 N•m).
If the rotational torque is not within the
specified range, adjust the settings as
required.
Figure 63 — Rotational Torque Check, Forward-Rear

1. Pinion Drive Gear 2. Scale
Page 49
REPAIR INSTRUCTIONS
11. Using a torque multiplier tool, loosen and 12. Using a suitable puller, remove the drive
remove the pinion shaft nut (Figure 64 and flange (P, PM and PR models) or drive gear
Figure 65). (PMA, PRA and PSA models) as shown in
64
Figure 66 and Figure 67.
66
Figure 64 — Pinion Shaft Nut Removal, Rear-Rear Axle

Figure 66 — Drive Flange Removal, Rear-Rear Axle
1. Pinion Housing 2. Torque Multiplier (P, PM and PR Models)
65 1. Puller 2. Pinion Housing
Figure 65 — Pinion Shaft Nut Removal, Forward-Rear

Page 50
REPAIR INSTRUCTIONS
67
13. Install the lubricant seal ring on the pinion
shaft (P, PM and PR models) or on the
housing (PMA, PRA and PSA models). The
felt/composite-type seal ring used on P, PM
and PR models is pressed on the shaft using
seal installer J 39453 (Figure 68).
68
Figure 67 — Drive Flange Removal, Forward-Rear Axle

(PMA, PRA and PSA Models)
1. Puller 2. Pinion Housing
Figure 68 — Lubricant Seal Installation, Rear-Rear Axle

1. Installer (J 39453) 2. Pinion Housing
Page 51
REPAIR INSTRUCTIONS
14. Install the drive flange or drive gear and BEVEL PINION ASSEMBLY INSTALLATION
retaining nut (Figure 69). Tighten the nut to AND ADJUSTMENT
specification and stake in position.
69 1. Position the spacer/shim pack removed
during disassembly on the pinion assembly
mounting surface of the carrier housing.
2. Temporarily install the pinion assembly,
again using three capscrews evenly spaced
around the perimeter.
3. Invert the carrier housing and place gauge
FL1432 in the differential bearing bore as
shown in Figure 70. Measure the distance
between the gauge and differential bearing
cap mounting surface. This measurement
(dimension A) added to the diameter of the
gauge (dimension B) equals dimension “C,”
which is referenced in Figure 72.
70
Figure 69 — Drive Flange and Retaining Nut Installation,

Rear-Rear Axle (Shown, Typical)
15. Remove the three capscrews and remove

the bevel pinion assembly from the carrier
housing.
16. Install the bearing at the pilot end of the
pinion shaft and install the retainer snap
ring.
Figure 70 — Dimension “A” Measurement
1. Depth Gauge 2. Gauge (FL1432)
4. Measure the distance between the bevel

pinion face and the differential bearing cap
mounting surface (dimension D) as shown in
Figure 71.
Page 52
REPAIR INSTRUCTIONS
71
6. Remove the bevel pinion assembly and
spacer shim pack from the carrier housing.
7. If required, adjust the spacer/shim pack to
the specified thickness by adding or
removing shims.
Use as few shims as possible to meet the

specification.
8. Install the shim pack and bevel pinion

assembly on the carrier housing. Use
sealant, MACK P/N 5166-52414, or
equivalent, on the sealing surfaces to
prevent leaks.
9. Install the capscrews and tighten to
specification.
Figure 71 — Dimension “D” Measurement
1. Depth Gauge
5. Determine the spacer/shim pack thickness

as follows:
Dimensions A + B = C
Dimensions C − D = Spacer/Shim Pack
Thickness
Refer to Figure 72 for dimension references.
The specification for the spacer/shim pack
thickness is 0.315 inch (8 mm) for M3
carriers and 0.236 inch (6 mm) for M3E
carriers.
72
Figure 72 — Shim Pack Thickness Determination
Page 53
REPAIR INSTRUCTIONS
INTER-WHEEL DIFFERENTIAL REASSEMBLY
73
Figure 73 — Inter-Wheel Differential Disassembled View
1. Lock Plates 10. Side Gear (LH) 19. Carrier Housing

2. Adjusting Nut 11. Thrust Washer 20. Planetary Gear (4)
3. Bearing 12. Case (LH) 21. Thrust Washer
4. Bearing Cap (RH) 13. Bearing Cap (LH) 22. Dowel
5. Ring Gear 14. Dowel 23. Lubrication Tube
6. Case (RH) 15. O-Ring 24. Spring
7. Thrust Washer 16. Oil Slinger 25. Seal
8. Side Gear (RH) 17. Bearing Adjusting Nut 26. Plug
9. Spider 18. Bearing
Page 54
REPAIR INSTRUCTIONS
1. Using a suitable driver and a press, install 9. Using emery paper, remove any residual
the bearings on each half of the differential materials/coatings from the inner
housing. circumference and mounting surface of the
ring gear. Clean these contact surfaces
2. Place the differential housing half on the
thoroughly.
bench with the ring gear mounting surface
down. Apply grease (EP2) to the thrust 10. Install the locating dowels, locally fabricated,
bearing and install it into the housing. on the ring gear (Figure 75).
75
3. Install the differential side gear in the
housing.
4. Apply grease (EP2) to the differential spider
and install the four pinion gears and thrust
washers.
5. Install the spider assembly in the differential
half and pack with grease (EP2).
6. Apply grease and place the other differential
side gear and thrust washer in position on
the spider assembly.
7. Place the other housing half on the
assembly while aligning the positioning
marks on the two halves.
8. Apply sealant, MACK P/N 5166-27121, or
equivalent, to the threads of the housing
capscrews. With the assembly mounted in a
soft-jawed vise, install the capscrews and
tighten to specification in the sequence
shown in Figure 74.
74
Figure 75 — Locating Dowel Installation
1. Ring Gear 3. Match Marks

2. Locating Dowels
11. Heat the ring gear to ambient temperature

plus 104°F (40°C) in an oven (preferred —
an old kitchen oven is sufficient) or on an
industrial grade hot plate used in
combination with temperature-sensing
equipment. Adequate heating will require
two hours.
12. When sufficiently heated, place the ring gear
in a press.
equivalent, to the ring gear mating surface of
the differential case. Align the match-marks
and using a suitable adapter, press the case
into the ring gear (Figure 76).
Figure 74 — Housing Capscrew Torque Sequence
Page 55
REPAIR INSTRUCTIONS
76 77
Figure 77 — Ring Gear Capscrew Torque Sequence

Figure 76 — Ring Gear Installation
15. Oil the large O-ring and place it in position at
1. Ring Gear (Heated) 4. Locating Dowels the outer perimeter of the differential case.
2. Press 5. Match Marks 16. Install the grease seal ring.
3. Adapter
14. Remove the locating dowels from the ring differential assembly in position in the carrier
gear and install the mounting capscrews. housing.
Apply sealant, MACK P/N 5166-27121, or 18. Install the bearing cups and adjustment nuts
equivalent, to the capscrew threads and in the carrier housing bores at each end of
tighten the capscrews to specification in the the differential assembly according to the
sequence shown in Figure 77. position match-marks made during
disassembly.
19. Check that locating dowels are in place on
the bearing caps and install the bearing
caps. The capscrews should be tightened
snugly, but not too tight to allow adjustment.
20. Using spanner wrench 5000264094, adjust
the backlash to specification (Figure 78).
Check the backlash with alternate rotations
of the ring gear. Readjust as required by
moving the ring gear in or out of the pinion
gear to decrease or increase backlash
respectively.
Page 56
REPAIR INSTRUCTIONS
79
Backlash adjustment is accomplished by

loosening the adjustment nut on one side and
tightening the other. An equal number of turns
must be applied to each side so that bearing
separation (dimension A) is maintained at 10.551
+0/ −0.002 inches (268 +0/ −0.052 mm) for
proper bearing preload (Figure 79).
78
Figure 79 — Bearing Preload Set Dimension
21. After backlash is properly set, tighten the

bearing cap capscrews to specification.
22. Install the lock plates and screws to secure
the bearing adjusting nuts in position.
23. Tighten the capscrews to specification.
24. Install the lubrication tube in the carrier
housing. Make sure that it is positioned
properly as shown in Figure 80.
Figure 78 — Ring Gear Backlash Check
1. Gauge 3. Spanner Wrench

2. Ring Gear
Page 57
REPAIR INSTRUCTIONS
80 81
Figure 80 — Lubrication Tube Installation Figure 81 — Inter-Wheel Differential Lock Hub

Installation
1. Rear-Rear Axle 2. Forward-Rear Axle
1. Lock Hub 2. Retainer Ring
25. Install the spring, seal and plug in the
lubrication port. Tighten the plug to
specification.
26. Install the retaining ring on the differential
lock hub so that the looped ends of the ring
extend into the bore of the hub.
27. Install the inter-wheel differential lock hub
into its housing until it locks (Figure 81).
Page 58
REPAIR INSTRUCTIONS
Carrier Installation INTER-AXLE POWER DIVIDER/
1. Check dimension “B” in the axle housing ADAPTER — OVERHAUL
prior to installing the carrier (Figure 82). The [466 AA]
dimension should be 10.551 −0/ +0.002
inches (268 −0/ +0.052 mm). If the The inter-axle power divider assembly removal
measurement exceeds 10.553 inches and installation procedures apply for an axle
(268.052 mm), replace the housing. installed on the vehicle or mounted in a universal
82
repair stand.
Inter-Axle Power Divider/Adapter

and Carrier Removal
1. Drain the lubricant from the hub reduction
units, the inter-axle power divider and carrier
assembly and from the axle housing.
2. Remove the hub reduction units (see
“Planetary Gear Case Removal” on page 25
under HUB REDUCTION UNITS —
OVERHAUL).
3. Remove the axle shafts from the axle
housing.
4. Remove the capscrews holding the inter-
axle differential lock cylinder to the inter-axle
power divider assembly and remove the
cylinder and spacer plate.
5. Rotate the output drive flange so that the
Figure 82 — Axle Housing Dimension Check rear bearing cover capscrews are visible
through the flange access holes and remove
2. Install a new O-ring on the mounting flange the capscrews (Figure 83).
of the carrier housing and using a suitable
lifting device, position the carrier assembly
on the axle housing.
3. Install the carrier mounting capscrews and
tighten to specification.
4. Install the axle shafts and hub reduction
units (see “Planetary Gear Case Installation”
on page 28 under HUB REDUCTION UNITS
— OVERHAUL).
5. Fill the inter-axle power divider assembly (if
so equipped), axle housing and hub
reduction units with lubricant.
Page 59
REPAIR INSTRUCTIONS
83 84
Figure 83 — Output Flange Capscrew Access Holes Figure 84 — Inter-Axle Power Divider/Adapter and
Carrier Assembly Removal
6. Remove the inter-axle through shaft
assembly from the rear of the axle housing 1. Carrier Housing 2. Jackscrews
and inter-axle power divider.
7. Remove the inter-axle differential lock hub. 10. Remove the carrier-to-axle housing
capscrews and then use two jackscrews to
8. Remove the rear bearing retainer O-ring. separate the carrier assembly from the axle.
9. Using a suitable lifting device, support the 11. Remove the inter-axle power divider and
inter-axle power divider and carrier carrier assembly.
assembly (Figure 84).
12. Remove the carrier-to-axle housing O-ring.
Page 60
REPAIR INSTRUCTIONS
Inter-Axle Power Divider/Adapter 2. With the input drive flange facing up, remove
the inter-axle power divider housing
Disassembly mounting capscrews.
1. Mount the removed assembly in a carrier 3. Using a suitable lifting device, remove the
repair stand with suitable supports inter-axle power divider housing from the
(Figure 85). adapter (Figure 86).
85 86
Figure 85 — Carrier Repair Stand Figure 86 — Inter-Axle Power Divider Housing Removal
1. Repair Stand 3. Support 1. Adapter Housing 2. Power Divider Housing

2. Support
Page 61
REPAIR INSTRUCTIONS
4. Remove the capscrews joining the adapter
front and rear housing halves.
5. Use three jackscrews to separate the front Heating the nut with the guide reduces the
and rear halves and lift the front half from the holding power of the adhesive sealant.
assembly (Figure 87).
87 88
Figure 87 — Housing Front Half Removal Figure 88 — Collar Nut Removal
1. Jackscrews 2. Housing, Front Half 1. Torque Multiplier 3. Guide

2. Spanner Wrench
6. Remove the housing halves’ O-ring.
11. Remove the carrier input pinion drive gear
7. Remove the forward carrier drive gear. as follows:
8. Remove the intermediate gear and shaft by Arrangement 1 — Remove the plate
driving the shaft out from its bore in the rear retaining screws and remove the plate from
housing half. the oil drip pan. Using a suitable adapter,
9. Heat guide tool 3195 to red hot, spanner wrench and torque multiplier,
approximately 1472°F (800°C) and place it remove the drive gear retaining nut from the
in the collar nut in the through-shaft bore. input pinion and remove the drive gear from
the pinion shaft (Figure 89 and Figure 90).
10. Allow the heated guide to sit in the nut for Using a suitable puller, remove the drive
3–4 minutes before removing it. After gear from the pinion shaft. Then remove the
removing the guide, use spanner wrench oil drip pan retaining screws and remove the
5000263167 and torque multiplier to remove pan.
the nut (Figure 88).
Arrangement 2 — Using a suitable puller,
remove the drive gear from the pinion shaft
and then remove the oil drip pan.
Page 62
REPAIR INSTRUCTIONS
89
12. Support the adapter rear housing half with a
suitable lifting device. Remove the
capscrews attaching the housing to the
carrier assembly and remove the rear
housing (Figure 91).
91
Figure 89 — Pinion Drive Gear Retaining Nut Removal

(Arrangement 1)
1. Torque Multiplier 3. Adapter (FL3194)

2. Spanner Wrench
90
Figure 91 — Housing Rear Half Removal
1. Adapter Housing, Rear 2. Carrier Housing

Half
Figure 90 — Pinion Drive Gear Removal (Arrangement 2)
1. Puller 2. Pinion Drive Gear
Page 63
REPAIR INSTRUCTIONS
13. Remove the spacer from the through shaft 15. Remove the retaining screws and oil drip
bore in the rear housing. pan from the adapter front housing half.
14. Using a suitable puller and support, remove 16. Remove the thrust washer retaining screws,
the bearing cup from the input bearing bore washer and shim.
in the rear housing half (Figure 92).
92 17. Using a suitable puller and support, remove
the bearing cup from the adapter front
housing half (Figure 93).
93
Figure 92 — Through Shaft Rear Bearing Cup Removal

Figure 93 — Bearing Cup Removal, Housing Front Half
Page 64
REPAIR INSTRUCTIONS
18. Remove the pinion shaft front bearing cover 20. Remove the seals, bearings, spacer and
screw, cover and cover O-ring. shaft from the intermediate gear.
19. Remove the snap ring retaining the pinion 21. Using a suitable puller and support, remove
bearing in the front cover and using a the bearing cups from the intermediate gear
suitable puller, remove the bearing (Figure 95).
(Figure 94). 95
94
Figure 95 — Intermediate Gear Bearing Cup Removal

Figure 94 — Pinion Bearing Removal, Front
1. Puller Support 3. Intermediate Gear
1. Puller 2. Front Cover 2. Puller
Page 65
REPAIR INSTRUCTIONS
Inter-Axle Power Divider 2. Using a press, remove the differential case
from the housing.
Disassembly
3. Apply heat to the seal support to help
1. With the inter-axle power divider housing release the adhesive sealant and using
mounted in a soft-jawed vise, remove the spanner wrench 5000264107, remove the
drive flange as follows: seal support (Figure 97).
97
Arrangement 1 — Remove the three
capscrews and plate retaining the drive
flange to the input shaft (Figure 96) and
remove the flange, seal and spacer as
applicable.
Arrangement 2 — Using a combination of
spanner wrenches (5000269134 and
5000261549) and torque multiplier, remove
the retaining nut from the input shaft and
remove the flange, seal and spacer as
applicable.
96
Figure 97 — Seal Support Removal
1. Spanner Wrench 2. Power Divider
Figure 96 — Drive Flange Removal
1. Power Divider Housing 2. Drive Flange
Page 66
REPAIR INSTRUCTIONS
4. Remove the cup and using a driver tube and Inter-Axle Through Shaft
press, remove the rotor and stator assembly
from the front of the housing. Disassembly
5. Remove the bearing retainer snap ring. 1. Mount the through shaft housing assembly
Then, using a driver tube and press, remove in a soft-jawed vise.
the bearing out the rear of the housing. 2. With the inter-axle through shaft housing
6. Remove the plug from the housing. mounted in a soft-jawed vise, remove the
output flange as follows:
7. Remove the seal and deflector ring from the
drive flange. Arrangement 1 — Remove the three
capscrews and plate retaining the output
8. Mount the inter-axle differential in a soft- flange to the inter-axle through shaft
jawed vise with the input shaft facing up. (Figure 99) and remove the flange.
9. Make sure that the differential case halves Arrangement 2 — Using a combination of
are match marked for reassembly spanner wrenches (5000262198 and
(Figure 98). 5000269134) and torque multiplier, remove
98
the retaining nut from the through shaft.
99
Figure 98 — Inter-axle Differential Case

Figure 99 — Output Flange Removal
1. Differential Case 2. Match Marks
1. Through Shaft Assembly 2. Output Flange
10. Remove the capscrews and separate the
front and rear casing halves. 3. Using a press, drive the through shaft from
11. Remove the front thrust washer and the side the housing and output flange.
gear. 4. Remove the output flange from the housing.
12. Remove the spider assembly and 5. Remove the pins, bearing cover, spacer/
disassemble, removing the four pinion thrust shim and O-ring from the housing.
washers and pinion gears.
6. Using a driver tube and press, remove the
13. Remove the remaining side gear and rear bearing from the housing.
thrust washer.
7. Remove the seals from the bearing cover.
Page 67
REPAIR INSTRUCTIONS
Cleaning and Inspection
Refer to the procedures under “AXLE/CARRIER
CLEANING AND INSPECTION” on page 95.
Inter-Axle Through Shaft Reassembly

100
Figure 100 — Through Shaft Assembly
1. O-Ring 6. O-Ring 11. Retainer Plate

2. Pin 7. Bearing Cover 12. Retainer Nut
3. Bearing Housing 8. Seal (Inner) 13. Through Shaft
4. Bearing (Rear) 9. Seal (Outer)
5. Spacer/Shim 10. Output Flange
Page 68
REPAIR INSTRUCTIONS
1. Using a driver tube and press, install the 3. Using a suitable installer and a press, install
through shaft rear bearing in the through the inner rear seal until it is fully seated in
shaft housing. the bearing cover (Figure 102). Then, install
the outer rear seal to a depth of 0.079 inch
2. Install the appropriate shim against the
(2 mm), again using the driver and press.
bearing in the housing. Determine the 102
thickness of the shim (dimension E in
Figure 101) as follows:
A - B = E (shim thickness) +0/ -0.2 mm
101
Figure 102 — Inner Rear Seal Installation
1. Press 3. Bearing Cover

2. Installer
Figure 101 — Shim Thickness Measurement
Page 69
REPAIR INSTRUCTIONS
4. Apply lubricant liberally to the installed Arrangement 2 — As of September 1996, a
seals. single mounting nut is used to secure the
output flange. Place the output flange in
5. Install the O-ring and bearing cover in
position on the through shaft. Apply a
position on the through shaft housing.
sealant, Loctite® 549, or equivalent, to the
Secure the housing and cover with two
threads of the nut and install the nut. Using a
cotter pins.
combination of spanner wrenches
6. Using a press, install the through shaft in the (5000262198 and 5000269134) and torque
housing. multiplier, tighten the nut to specification in
four steps: twice at 530 lb-ft (720 N•m) and
7. Install the output flange on the through shaft
twice at 650 lb-ft (880 N•m). Stake the nut to
as follows:
lock it in position.
Arrangement 1 — Prior to September 1996,
a three Allen screw and bolt plate
arrangement was used. Place the output
flange and bolt plate in position on the
through shaft. It may be necessary to use a
press. Apply a sealant, Loctite® 573, or
equivalent, to the threads of the Allen
screws and install the screws. Tighten the
screws to specification, 86–106 lb-ft
(117–143 N•m).
Page 70
REPAIR INSTRUCTIONS
Inter-Axle Differential Case Reassembly
103
Figure 103 — Inter-Axle Differential Assembly
1. Retainer Plate/Nut 9. Stator 17. Side Gear (Front)

2. Drive Input Flange 10. Rotor Support 18. Spider
3. Seal 11. Power Divider Housing 19. Planetary Gear (4)
4. Seal Support 12. Plug 20. Side Gear (Rear)
5. Oil Deflector 13. Bearing 21. Thrust Washer
6. Oil Cup/Spacer 14. Retainer Snap Ring 22. Case (Rear Half)
7. Rotor 15. Case (Front Half) 23. Thrust Washer
8. Oil Scraper 16. Thrust Washer
Page 71
REPAIR INSTRUCTIONS
1. Place the rear case of the inter-axle 105
differential in a soft-jawed vise.

2. Lubricate the rear thrust washer and sun
gear and install the washer and gear in the
case.
3. Lubricate and install the pinion gears and
thrust washers on the spider.
4. Place the spider assembly in position on the
rear case.
5. Pack the assembly with grease.
6. Lubricate the front side gear and place it in
position on the spider assembly.
7. Lubricate the front thrust washer and install
it on the sun gear.
8. Place the front case in position on the
assembly with the match marks aligned
(Figure 104).
104
Figure 105 — Oil Scraper Installation

106
Figure 104 — Differential Case Match-Mark Alignment
1. Differential Case 2. Match Marks Figure 106 — Input Shaft Inner Seal Installed
9. Apply sealant, MACK P/N 5166-27121, or 1. Sealant Application 2. Power Divider Housing
Surfaces
equivalent, to the threads of the capscrews
and install the screws.
10. Using a driver tube and press, install the
bearing in the inter-axle differential housing.
Page 72
REPAIR INSTRUCTIONS
11. Assemble and install the input shaft inner driver tube and press, install the rotor
seal in the housing as follows: against the shims on the rotor holder.
Remove the shims from between the rotor
Arrangement 1 — Place the oil scraper in
and stator. Place the oil scraper in the stator
the stator (Figure 105) and place the stator
(Figure 105) and press it firmly in place
on the rotor holder. Apply sealant, MACK
against the shims on the rotor holder.
P/N 5166-52414, or equivalent, as shown in
Remove the shims. Apply sealant, MACK
Figure 106, and install the assembly. Next,
install the rotor. Apply sealant to the
Figure 106, and install the assembly. Next,
perimeter of the cup and install it.
apply sealant to the perimeter of the cup and
Arrangement 2 — Place the oil scraper in install it.
the stator (Figure 105) and place the stator 107
on the rotor holder. Apply sealant, MACK

Figure 106, and install the assembly and the
rotor.
Arrangement 3 — This arrangement
requires shims and preliminary assembly to
determine shim thickness. Place the oil
scraper in the stator (Figure 105) and place
the stator on the rotor holder. Install a
standard 0.315-inch (0.8-mm) shim against
the stator. Install the rotor and seat it firmly in
place on the rotor holder. Measure the
dimensions “A” and “B” (Figure 107). The
difference between these dimensions is the
thickness of the shim required.
A – B = E (shim thickness)
Choose the appropriate shim that provides
the calculated thickness. Remove the rotor
and the standard 0.315-inch (0.8-mm) shim.
Apply sealant, MACK P/N 5166-52414, or Figure 107 — Shim Measurement (Arrangement 3)
108
equivalent, to the rotor and reinstall it. Install
the adjusted shim as determined above. And
last, apply sealant to the perimeter of the
cup and install it.
Arrangement 4 — As with Arrangement 3,
this arrangement requires shims and
preliminary assembly to determine shim
thickness. Referring to Figure 108,
dimension “A” is 0.350 inch (8.9 mm) by
design. To achieve this design dimension, a
shim is required to be placed between the
rotor holder flange and the stator. To
determine the thickness of the shim required
(dimension E), measure the thickness of the
flange (dimension B) and subtract it from
dimension A.
A – B = E (shim thickness)
Place the oil scraper in the stator and press
the stator firmly in place on the rotor holder.
Temporarily install two shims on opposite
sides of the stator (Figure 109). Using a Figure 108 — Shim Measurement (Arrangement 4)
Page 73
REPAIR INSTRUCTIONS
109
13. Using installer FL1502 and a press, install
the outer input shaft seal (Figure 111).
111
Figure 109 — Rotor Installation (Arrangement 4)
1. Rotor 2. Temporary Shims
12. Using a suitable installer, install the grease Figure 111 — Outer Seal Installation
catcher in the outer seal support until it
extends 0.118 inch (3 mm) beyond the rear 1. Press 3. Seal Support
of the support (Figure 110). 2. Installer (1502)
110
14. Apply a sealant, MACK P/N 5166-52414, or

equivalent, to the seal support and using
spanner wrench 4107, install the support on
the inter-axle differential case.
15. Install the drive flange as follows:
Arrangement 1 — Prior to September 1996,
a three Allen screw and bolt plate
arrangement was used. Place the drive
flange and bolt plate in position on the input
shaft. Apply a sealant, MACK
P/N 5166-52414, or equivalent, to the
threads of the Allen screws and install the
screws. Tighten the screws to specification,
86–106 lb-ft (117–143 N•m).
Arrangement 2 — As of September 1996, a
single mounting nut is used to secure the
drive flange. Place the drive flange in
position on the input shaft. Apply a sealant,
MACK P/N 5166-54941, or equivalent, to the
threads of the nut and install the nut. Using a
Figure 110 — Grease Catcher Installation combination of spanner wrenches and
torque multiplier, tighten the nut to
1. Installer 3. Seal Support specification in four steps: twice at 665 lb-ft
2. Press (900 N•m) and twice at 810 lb-ft (1100 N•m).
Stake the nut to lock it in position.
Page 74
REPAIR INSTRUCTIONS
Inter-Axle Power Divider/Adapter Reassembly
112
Figure 112 — Adapter Housing Assembly
1. Washer 13. Spacer 25. Intermediate Gear

2. Shim 14. Dowel 26. Spacer
3. Adapter Housing (Front Half) 15. Washer 27. Bearing
4. O-Ring 16. Drain Plug 28. Oil Pan (Front)
5. Bearing 17. Oil Pan (Rear) 29. Retainer Plate
6. Forward Carrier Drive Gear 18. Oil Pan Cover Plate 30. Washer
7. Bearing 19. Pinion Drive Gear 31. Fill Plug
8. Lock Cylinder 20. Retainer Nut 32. Snap Ring
9. Plate 21. Seal 33. Bearing
10. Sliding Clutch 22. Intermediate Shaft 34. O-Ring
11. Collar Nut 23. Seal 35. Bearing Cover
12. Adapter Housing (Rear Half) 24. Bearing
Page 75
REPAIR INSTRUCTIONS
1. Using a press and suitable driver, install the 114
intermediate through shaft bearing in the

rear housing half of the power divider
adapter (Figure 113).
113
Figure 114 — Shim/Spacer Thickness Determination
5. Increase the thickness of the shim/spacer

(A) to take up the gap (B) in the bore. The
adjusted shim/spacer thickness (A + B)
Figure 113 — Intermediate Through Shaft Bearing should equal dimension C −0 +0.002 inch
Installation (−0 +0.05 mm).
1. Installer 3. Adapter Housing, Rear
2. Press Half
When the shim/spacer is installed, there should

2. Temporarily install the adapter housing half be no gap in the bore between the housings.
to the axle housing. Tighten the capscrews
to specification.
6. Remove the capscrews and remove the
3. Measure the shim/spacer taken from power divider adapter housing half.
disassembly and adjust it as necessary to
0.551 inch (14 mm). Place the adjusted 7. Apply sealant, MACK P/N 5166-54941, or
shim/spacer in position in the through shaft equivalent, to the shim/spacer and install it
bore. in the housing through shaft bore.
4. Measure any remaining gap in the through

shaft bore between the adapter and axle
housings, dimension “B” (Figure 114) and If the bearings or bearing cups are to be replaced
then remove the shim/spacer from the bore. with new, the shim/spacer adjustment must be re-
evaluated.

equivalent, to the mounting surface of the
adapter housing half and place it in position
on the axle housing.
9. Install the housing mounting capscrews and
hand-tighten at this time.
Page 76
REPAIR INSTRUCTIONS
10. Apply sealant, MACK P/N 5166-54941, or 17. Install the grease sealer plate in the front
equivalent, to the threads of the nut and housing half. Tighten the screws to
install the nut in the through shaft bore. specification.
Tighten the nut to specification.
18. Using a driver and press, install the pinion
11. Using guide FL3195, spanner wrench drive gear bearing in the front bearing cover.
5000263167 and torque multiplier, install the
19. Install the bearing retainer snap ring.
collar nut in the through shaft bore
(Figure 115). Tighten the nut to specification. 20. Install the O-ring and front bearing cover on
115
the front housing half. Tighten the
capscrews to specification.
21. Using a suitable driver and a press, install
the bearing cups in the intermediate gear
(Figure 116).
116
Figure 115 — Collar Nut Installation
1. Torque Multiplier 3. Guide

2. Spanner Wrench
12. Install the oil drip pan and retaining screws Figure 116 — Bearing Cup Installation
on the adapter rear housing half. Tighten the
screws to specification. 1. Press 3. Intermediate Gear
13. Slide the drive gear on the carrier input 2. Installer
pinion shaft.
22. Measure the width of both intermediate gear
14. Using adapter FL3194, spanner wrench
inner bearing cups. These are dimensions
5000269134 and torque multiplier, install the
“B” and “C” which will be used in determining
drive gear retaining nut on the pinion shaft
bearing preload (Figure 117).
and tighten to specification.
23. Position both bearings in the intermediate
15. Install the oil drip pan cover plate
gear. Rotate and exert pressure on the
(arrangement 1) or the oil drip pan
bearings to ensure that they are properly
(arrangement 2) and tighten the retaining
seated.
screws to specification.
24. Measure the distance from the bearing outer
16. Make sure that the locating dowels are
edges through the gear bore. This is
installed in the mating surface of the rear
dimension “A” (Figure 117).
housing half.
Page 77
REPAIR INSTRUCTIONS
117 118
Figure 117 — Shim/Spacer Measurements

(Bearing Preload) Figure 118 — Intermediate Gear Rotational Torque
25. Calculate dimension “D” as follows: Measurement
D = A - (B + C) 1. Scale 3. Adapter Housing, Front

2. Intermediate Gear Half
D – 0.001 inch (0.02 mm) = Shim/
Spacer Thickness
31. Remove the capscrews, the shaft retainer
26. Based on the above calculation, select the plate and the intermediate shaft assembly
appropriate spacer and shim(s) as required from the adapter housing front half.
to produce the required bearing preload.
32. Using a driver tube and press, install the
27. Install the intermediate gear, spacer/shim bearings on the forward carrier drive gear.
and bearings on the intermediate shaft.
33. Lubricate and install the drive gear and
28. Secure the adapter front housing half in a bearing assembly.
soft-jawed vise.
34. Position the housing front half on the rear
29. Place the intermediate shaft assembly in half. Install the capscrews and tighten to
position on the front housing. Install the shaft specification. This is a temporary installation
retainer plate and tighten the capscrews to so that shim/spacer requirements can be
specification. determined for final assembly.
30. Measure the rotational torque of the 35. Install the input drive gear bearing cup into
intermediate gear using scale, J 8129, or the housing front half. Rotate and exert
equivalent (Figure 118). The rotational pressure on the cup to ensure that it is
torque should be 4.4–8.9 lb-in (0.5–1 N•m). properly seated.
If the rotational force is not to specification,
readjust as necessary. 36. Measure the depth (dimension A) from the
face of the bearing cup to the thrust washer
mounting surface of the front housing half
(Figure 119) to determine shim thickness as
Use the following formula to determine the force follows:
required to produce the specified rotational Dimension A + 0.003 inch
torque: (0.08 mm) = Shim Thickness.
F = Rotational Torque ÷ Pinion Radius
Page 78
REPAIR INSTRUCTIONS
119 120
Figure 119 — Shim/Spacer Measurement Figure 120 — Input Gear Rotational Torque
Measurement
1. Gauge 2. Adapter Housing, Front
Half 1. Gauge 3. Rear Sun Gear
2. Adapter Housing
37. Select the appropriate spacer and shim, if
required, based on the shim thickness 41. Remove the rear side gear, front housing
determined above. half capscrews and remove the housing half.
38. Install the spacer/shim, thrust washer and 42. Install the seals and thrust bearing carrier on
capscrews. Tighten the capscrews to the intermediate shaft. Lubricate the
specification. assembly and place it in position in the rear
housing half.
39. Position the inter-axle differential rear sun
gear in the input gear. 43. Place the O-ring in position on the mating
surface of the housing halves.
40. Measure the rotational torque of the input
gear using scale J 8129, or equivalent 44. Install the front housing half and tighten the
(Figure 120). The rotational torque should capscrews to specification.
be 4.4–8.9 lb-in (0.5–1 N•m). If the rotational 45. Apply sealant, Loctite® P/N 21463, or
force is not to specification, readjust as equivalent, to the threads of the intermediate
necessary. shaft retainer plate and install the retainer
plate and capscrews. Tighten the capscrews
in four steps: twice at 74 lb-ft (100 N•m) and
twice at 96 lb-ft (130 N•m).
46. Apply sealant to the mounting surface of the
inter-axle power divider assembly and place
it in position on the adapter housing. Install
the capscrews and tighten to specification.
Page 79
REPAIR INSTRUCTIONS
Inter-Axle Power Divider/Adapter 5. Apply sealant, MACK P/N 5166-52414, or
equivalent, to the lock cylinder spacer plate
Installation and place it in position on the carrier
1. Install the O-ring on the power divider/ housing.
adapter assembly-to-carrier housing mating 6. Apply sealant, MACK P/N 5166-52414, or
surface. equivalent, to the lock cylinder assembly
2. Position the power divider/adapter assembly and install the assembly on the carrier
on the carrier housing, install the retaining housing. Tighten the capscrews to
capscrews and tighten to specification. specification.
3. Place the inter-axle differential lock sliding 7. Adjust the lock cylinder assembly (see
clutch on the differential output gear splines. section “INTER-WHEEL DIFFERENTIAL
LOCK ASSEMBLY SERVICE
4. Install the O-ring on the carrier housing and PROCEDURES” on page 81for procedure).
install the through shaft assembly. Install the
assembly retainer capscrews through the 8. Install the axle shafts and hub reduction
access hole in the output flange units (see “Planetary Gear Case Installation”
(Figure 121). on page 28 under HUB REDUCTION UNITS
121 — OVERHAUL).
9. Fill the axle housing and hub reduction units
with lubricant.
Figure 121 — Through Shaft Assembly Capscrew

Installation
Page 80
REPAIR INSTRUCTIONS
INTER-WHEEL DIFFERENTIAL 122
LOCK ASSEMBLY SERVICE

PROCEDURES
[475 ES]
Figure 122 — Inter-Wheel Differential Lock Assembly
1. Lock Cylinder 5. Clutch (Inner Hub) 9. Fork Pivot

2. Pin 6. Retainer Ring 10. Washer
3. Fork 7. Retainer Strap 11. Cotter Pin
4. Clutch (Outer Hub) 8. Fork Pads 12. Capscrews
Page 81
REPAIR INSTRUCTIONS
Inter-Wheel Differential Lock 6. Separate the outer clutch hub from the shift
fork pads.
Assembly Removal
7. Remove the shift pads from the fork and
1. Depending on carrier being serviced, retain for reassembly.
forward-rear carriers require removal of the
inter-axle power divider with carrier housing, 8. Remove the shift pad retaining flange.
while rear-rear carriers require removal of 9. Remove the nut and washer retaining the
the carrier housing for access. Refer to shift fork pivot and remove the pivot from the
“SR70/80 CARRIER — OVERHAUL” on axle housing.
page 38 for removal instructions.
10. Remove the now-released shift fork from the
2. Remove the capscrews holding the inter- axle housing.
wheel differential lock cylinder to the carrier
housing assembly
Inter-Wheel Differential Lock
3. Remove the lock pin (cotter key) from the
shift fork to shift cylinder plunger. Then Assembly Installation
remove the now-released washer from the
1. Using pliers J 39454, or equivalent, install
pin and the pin from the cylinder plunger.
the retainer ring onto the locking clutch inner
4. Remove the two screws securing the shift hub. Then, slide the clutch into the
cylinder to the carrier housing and remove differential assembly until the retainer ring
the shift cylinder by pulling straight back. snaps into place. See Figure 124.
124
5. Compress the lock ring using pliers J 39454,
or equivalent, and disengage the locking
(dog) clutch by carefully prying outward with
a flat-tipped screwdriver (Figure 123).
Remove the clutch from the carrier.
123
Figure 124 — Installing Locking Clutch
1. Clutch (Inner Hub) 2. Retainer Ring
Figure 123 — Clutch Removal
1. Pliers (J 39454) 2. Clutch (Inner Hub)
Page 82
REPAIR INSTRUCTIONS
2. Position the shift fork into the axle housing 5. Apply sealant, MACK P/N 5166-54941, or
with the offset toward the outside. Install the equivalent, to the threads and install the two
pivot pin through the axle housing screws securing the shift cylinder to the
connecting with the shift fork pivot hole as it carrier housing and tighten to specifications.
passes through.
6. Align the shift plunger hole with shift fork and
3. Apply sealant, MACK P/N 5166-54941, or insert the pin. Install the washer and lock pin
equivalent, to the threads of the pivot pin (cotter key) onto the pin.
and install the washer and nut. Tighten nut
7. Install the shift pad retaining flange.
to specifications.
8. Install the shift pads onto the fork arms.
4. Install the shift cylinder into the carrier
housing by inserting the shift plunger into the 9. Slide shift ring portion of the outer locking
carrier opening (Figure 125). Ensure that the clutch onto the shift fork pads.
shift plunger hole aligns with the shift fork.
125 10. Depending on carrier being serviced, front
rear carriers require removal of the inter-axle
power divider with carrier housing, while
rear-rear carriers require removal of the
carrier housing for access. Refer to
“SR70/80 CARRIER — OVERHAUL” on
page 38 for removal instructions.
Figure 125 — Installing Lock Cylinder
1. Capscrews 5. Shift Fork

2. Cylinder 6. Washer
3. Link Pin 7. Lock Pin
4. Axle Housing
Page 83
REPAIR INSTRUCTIONS
Inter-Wheel Differential Lock 7. Remove and discard the O-ring from the
piston groove. Remove the small O-ring and
Cylinder Disassembly washer from the threaded end of the shift
126 plunger.
127
Figure 126 — Inter-Wheel Differential Lock Cylinder
Refer also to Figure 127 for identification of parts

referenced in the following procedure.
1. Remove the engagement switch and ball
from the side of the cylinder. Retain ball for
reassembly.
2. Straighten the four crimped areas securing
the base plate to the bottom of the shift
cylinder housing. Remove the base plate.
Base plate is spring loaded and may cause

injury as the base plate is loosened. Remove
the four crimped areas carefully. Figure 127 — Exploded View of Lock Cylinder
3. Recover the spring from the bottom of 1. Housing 7. Washer

piston. 2. Nut, Piston Retainer 8. Spring
3. O-Ring 9. Plate
4. Remove the now-exposed O-ring from the 4. O-Ring 10. Shaft
groove at the bottom of the shift cylinder. 5. Piston 11. Ball
6. O-Ring 12. Switch
5. Remove the piston and shift plunger from
the shift cylinder.
6. Place the shift plunger in a protected vise
and remove the piston nut. Then remove the
piston from the end of the plunger shaft.
Page 84
REPAIR INSTRUCTIONS
Inter-Wheel Differential Lock 5. Position the spring on the bottom of piston to
the base of the bore.
Cylinder Reassembly
6. Align the base plate hole with the plunger
Refer to Figure 127. and install the base plate until the spring is
1. Place the flattened end of the shift plunger compressed. The base plate should now be
into a protected vise and install the piston even with the bottom of the cylinder.
onto the threaded end of the plunger. Then 7. Recrimp the four metal strips to secure the
install the piston nut onto the end of the base plate to the bottom of the shift cylinder
plunger shaft and tighten to specifications. housing.
2. Remove the shift plunger from the vise. 8. Apply sealant, Loctite® P/N 21453, or
3. Install a new O-ring into the groove at the equivalent, to the engagement switch
bottom shift cylinder and lubricate with clean threads and install the ball into the side of
gear oil. the cylinder. Install the engagement switch
after the ball and tighten to specifications.
4. Install the piston and shift plunger into the
shift cylinder and flip the assembly over on
the top of the cylinder.
Page 85
REPAIR INSTRUCTIONS
INTER-AXLE DIFFERENTIAL Inter-Axle Differential Lock Removal
LOCK ASSEMBLY SERVICE 1. Drain the lubricant from the inter-axle power
PROCEDURES divider assembly and from the axle housing.
[466 CS] 2. Remove the capscrews holding the inter-
axle differential lock cylinder to the inter-axle
In order to obtain access to the inter-axle power divider assembly and remove the
differential lock gear and bearings, the inter-axle cylinder and spacer plate (Figure 128).
128
power divider/adapter must be removed. Refer to
the removal and installation under “INTER-AXLE
POWER DIVIDER/ADAPTER — OVERHAUL” on
page 59.
Figure 128 — Inter-Axle Differential Lock Assembly
1. Plug 4. Adapter-to-Carrier Housing Collar 7. Output Flange

2. Lock Cylinder 5. Through Shaft 8. Bearing Housing
3. Plate 6. O-Ring
Page 86
REPAIR INSTRUCTIONS
3. Rotate the output drive flange so that the 4. Remove the inter-axle through shaft
rear bearing cover capscrews are visible assembly from the rear of the axle housing
through the flange access holes and remove and inter-axle power divider.
the capscrews (Figure 129).
129 5. Remove the inter-axle differential lock hub.
6. Remove the three capscrews from the
retainer plate securing the outer portion of
the intermediate gear shaft to the inter-axle
power divider adapter (front half). Then
remove the plate (Figure 130).
7. Using a suitable lifting device, support the
weight of the front half of the inter-axle
power divider/adapter assembly.
8. Remove the adapter housing capscrews and
then use two jackscrews to separate the
front half from the rear half of the adapter
housing assembly.
9. Remove the front half of the inter-axle power
divider/adapter using the suitable lifting
device.
10. Remove the adapter housing O-ring.
11. Remove the now-accessible forward carrier
drive gear, bearings and shim (Figure 130).
Tag shims for reassembly purposes.
Figure 129 — Output Flange Capscrew Access Holes
Page 87
REPAIR INSTRUCTIONS
130
Figure 130 — Power Divider/Adapter Housing Assembly
1. Shim 4. Adapter Housing, Rear Half 7. Retainer Plate

2. Forward Carrier Drive Gear 5. O-Ring
3. Seal 6. Adapter Housing, Front Half
Page 88
REPAIR INSTRUCTIONS
Cleaning and Inspection 7. Install a new O-ring on the rear bearing
support at the carrier housing and install the
Refer to “AXLE/CARRIER CLEANING AND through shaft assembly. Install the assembly
INSPECTION” on page 95 for procedures. retainer capscrews through the access hole
in the output flange (Figure 131).
131
Inter-Axle Differential Lock
Installation
If either of the two intermediate gear bearings

was replaced as a result of the cleaning and
inspection, a new shim will be required. Selection
of the appropriate spacer is based on the spare
part value as follows:
r 43,80 — 44,19
r 44,11 — 44,40
r 44,41 — 44,70
Select the appropriate shim based on the above
values for reassembly.
1. Position the two bearings on the front and

rear of the forward carrier drive gear and
install the gear and bearings as an assembly
Figure 131 — Through Shaft Assembly Capscrew
into the adapter housing (rear half) opening Installation
(Figure 130).
2. Install the original shim tagged at 8. Apply sealant, MACK P/N 5166-52414, or
disassembly or the appropriate shim based equivalent, to the lock cylinder spacer plate
the spare part values. Install the shim on the and place it in position on the carrier
forward portion of the forward carrier drive housing.
gear. 9. Apply sealant, MACK P/N 5166-52414, or
3. Install a new O-ring on the adapter housing equivalent, to the lock cylinder assembly
front half-to-rear half mating surface. and install the assembly on the carrier
housing. Align the lock cylinder shift fork with
4. Install a new O-ring on the end of the the lock hub during installation. Tighten the
intermediate gear shaft. capscrews to specification.
5. Using a suitable lifting device, position the 10. Adjust the lock cylinder assembly following
adapter housing (front half) on the adapter the instructions under “Inter-Axle Differential
housing (rear half), install the retaining Lock Cylinder Adjustment” at the end of this
capscrews and tighten to specification. section.
6. Place the inter-axle differential lock hub on 11. Fill the axle housing and hub reduction units
the differential output gear splines. with lubricant.
Page 89
REPAIR INSTRUCTIONS
Inter-Axle Differential Lock Cylinder 5. Using a press and an appropriate sized
driver such as a socket wrench, apply
Disassembly pressure to the lock cylinder rear cover to
132 overcome spring pressure until it begins to
compress (Figure 133).
133
Figure 132 — Cross Section View of Shift Cylinder
Refer also to Figure 135 for identification of parts Figure 133 — Lock Cylinder Rear Cover Removal
referenced in this procedure.
6. Remove the retaining snap ring from the
1. Remove the engagement switch from the lock cylinder rear cover using an appropriate
lock cylinder housing. sized snap ring pliers.
2. Separate the O-ring from the switch and 7. Slowly release the press pressure until all
discard. the spring pressure is relieved.
3. Remove the adjustment plug from the end of
the lock cylinder using a flat tip screwdriver.
4. Remove the air fitting from the lock cylinder Lock cylinder rear cover is under spring
rear cover. pressure and may cause injury when
released.
Page 90
REPAIR INSTRUCTIONS
8. Withdraw the lock cylinder from the press
and remove the now-released cylinder end
cover.
Care should be exercised while positioning
9. Remove the O-ring from the groove on the shift fork to prevent the spring from being
cylinder end cover. prematurely released and possibly causing
10. Tap the lock cylinder housing on a table top injury.
until the shift rail/piston assembly and the 134
spacer can be removed.
11. Using the appropriate sized snap ring pliers,
remove the snap ring from the shift rail/
piston assembly and separate the piston
from the rail. Remove and discard the small
O-ring sealing between the piston and the
end of the rail.
12. Remove and discard the O-ring from the
piston groove.
13. Place the lock cylinder housing in a
protected vise with the adjustment end down
and clamped in the vise.
14. Position the shift fork towards the lock
cylinder housing opening as far as possible
without releasing the spring. Compress the
spring using a long dowel through the large
piston opening. Refer to Figure 134.
Figure 134 — Compressing Shift Fork Spring
15. Remove the now-released shift fork from the

square opening of the lock cylinder housing.
Page 91
REPAIR INSTRUCTIONS
135
Figure 135 — Exploded View of Shift Cylinder
1. Housing 7. Rear Cover 13. Spacer

2. O-Ring 8. Snap Ring 14. Spring
3. Switch 9. Piston (Inner) 15. Fork
4. Air Fitting 10. O-Ring 16. Plug
5. Snap Ring 11. O-Ring
6. O-Ring 12. Shaft
Page 92
REPAIR INSTRUCTIONS
Inter-Axle Differential Lock Cylinder 5. Install a new O-ring on the piston groove
and lubricate with clean gear lubricant.
Reassembly
6. Install a new small O-ring which seals
1. Place the lock cylinder housing in a between the piston and the end of the rail.
protected vise with the adjustment end down
and clamped in the vise. 7. Assemble the piston on the shift rail and
install the snap ring using the appropriate
2. Position the shift fork spring in the lower sized snap ring pliers.
(forward) portion of the lock cylinder
housing. 8. Assemble the spacer onto the shift rail with
the taper toward the piston. The tapered
3. Compress the spring using a long dowel portion of the spacer will fit tight into the rear
through the large piston opening at the rear of the piston.
of the cylinder (Figure 136).
136 9. Install a new O-ring on the lock cylinder rear
cover and lubricate with clean gear lubricant.
10. Position the lock cylinder into a press and
install the assembled shift rail, spacer and
piston into the cylinder opening and insert
the shift rail into the shift fork. The shift rail
must also align with the spring opening
located below the shift fork (Figure 137).
137
Figure 136 — Compressing Shift Fork Spring
4. Insert the rail end of the shift fork over the

compressed spring until the fork can be slid
into a position that will secure the spring.
Shift fork is installed with the offset to the
rear of the cylinder.
Figure 137 — Lock Cylinder Assembly
Care should be exercised while positioning

the shift fork to prevent the spring from being
accidentally released and possibly causing
injury.
Page 93
REPAIR INSTRUCTIONS
11. Install the rear cover over the end of the Inter-Axle Differential Lock Cylinder
cylinder directly on top of the shift piston.
Position the press ram over the rear cover Adjustment
and apply press pressure to compress the 1. Remove the adjustment plug using a flat tip
cover into the cylinder bore to the point the screwdriver.
snap ring groove on the inside of the
cylinder is exposed. Refer to Figure 138. 2. Apply sealant, Loctite® P/N 21453, or
138 equivalent, to the threads of the plug.
Reinstall the plug into the end of the
cylinder.
3. Connect shop air supply to the air fitting
located on the end of the rear cover. Apply
and maintain an air pressure of 116 psi
(8 bar) to shift the inter-axle clutch into
engagement.
4. Screw in the plug until it comes in contact
with the end of the shift rail.
5. Disconnect the shop air and allow the shift
cylinder to declutch. Then tighten the plug
an additional 3/4 turn.
Figure 138 — Lock Cylinder Rear Cover Installation
12. Install the lock cylinder rear cover snap ring

using appropriate sized snap ring pliers.
13. Slowly release the press pressure and
ensure that the snap ring locks in the
cylinder groove.
14. Install the air fitting into the lock cylinder rear
cover and tighten to specification.
15. Install the adjustment plug into the end of
the lock cylinder using a flat tip screwdriver.
Adjustment of this plug is found under “Inter-
Axle Differential Lock Cylinder Adjustment”
at the end of this section.
16. Apply sealant, Loctite® P/N 21453, or
equivalent, to the threads of the
engagement switch and install a new O-ring
to the switch over the threads.
17. Install the engagement switch into the lock
cylinder and tighten to specifications.
Page 94
REPAIR INSTRUCTIONS
AXLE/CARRIER CLEANING Differential Spider Wear Limits
AND INSPECTION A slightly worn differential spider may be reused
[470 AX] if:
r Wear does not exceed 0.005 inch
(0.127 mm).
Overview
r Spider-to-pinion bore clearance does not
It is very important to carefully and thoroughly exceed 0.007–0.011 inch
inspect drive unit parts before reassembly. (0.178–0.279 mm).
Replacement of worn or damaged components
eliminates costly and avoidable drive unit failure. r Wear surfaces are not scored, pitted,
cracked or otherwise damaged.
Whenever possible, use the Magnaflux or similar
non-destructive inspection method on all steel Install the spider in the opposite position. This
parts, except ball and roller bearings. This places the original drive side, which experiences
method is especially suited for inspecting ground the most wear, on the coast side, which has the
or highly finished surfaces for wear and cracks, least wear.
which otherwise would not be visible. It is
essential to completely demagnetize the parts Bearings, Bushings and Thrust
before using the Magnaflux method.
Washers
Pinion Shaft Wear Limits Check ball and roller bearings for:
Check shafts carefully for cracks or other surface r Flaking

damage that can lead to early failure. Bearing r Cracks and fractures
journals must conform to the concentricity
requirements. Replace components if the r Cavities and indentations
specified wear limit of 0.002 inch (0.05 mm) is r Staining
exceeded by more than 0.001 inch (0.025 mm).
Inspect shaft press-fit surfaces to ensure a press- r Measurable wear
fit condition with mating gears and bearings. r Brinelling
Splined ends require no less than a tap fit with
their mating drive yoke or flange. Make sure that r Fretting
shafts show no signs of twist. r Corrosion
r Banking
Gear Wear Limits r Seizing
Replace gears if teeth show any signs of abrasive r Galling
wear, scratching, ridging, scoring, surface fatigue,
pitting, spalling, corrosive wear, digging in or r Scoring
cracking. Always replace mated gears, such as r Arching
spiral bevel gears, hypoid gears and differential
pinion and side gears, in sets. r Nicking
r Cage failures
Gear backlash, which may be adjusted by shims
(as in the case of spiral bevels), must never
exceed 0.018 inch (0.46 mm) relative to a gearset
of fixed centers.
Page 95
REPAIR INSTRUCTIONS
Replace bearings if any of these conditions are
present.
Tapered roller bearings are set up in a preload Assembled drive units cannot be properly
condition according to adjustment specifications cleaned by steam cleaning, dipping or slushing.
for each carrier. For reusable or run-in tapered For thorough cleaning, the drive unit must be
bearings, adjust preload to one-half the value completely disassembled.
specified for new bearings.
If bearings pass inspection, dip them in the COMPLETE ASSEMBLIES

recommended differential lubricant. Then, wrap
Completely assembled axles may be steam
bearings in clean cloth or paper until ready to
cleaned on the outside only, to facilitate initial
reassemble the axle.
removal and disassembly. Breathers, vented shift
units, and all other openings must be tightly
Bushings and thrust washers must be replaced if
covered or closed to prevent water from entering
they are pitted, scored or show any signs of
the assembly.
surface damage or have broken locking tabs.
Wear must not exceed 0.010 inch (0.25 mm)
maximum. Thrust washers must be replaced in DISASSEMBLED PARTS
sets. Combining old and new thrust washers can
Immerse all parts in suitable cleaning fluid and
cause premature failure.
clean parts thoroughly. Use a stiff bristle brush to
remove all old lubricant. Remove gasket particles
Axle Shafts which may adhere to mating faces of axle
housing, carrier housing, hubs and axle shaft
Inspect axle shafts for bends, torsional fractures flanges. Clean out lubricant channels in the
or other conditions that may result in failure. pinion cage and carrier housing. Clean the
Inspect splines for wear, cracks or distortion. If housing breather. Make certain that the interior of
evidence of any of these conditions is found, the axle housing is thoroughly cleaned.
install new parts.
Install each axle shaft between lathe centers. BEARINGS

Using a dial indicator, check shaft runout at the The importance of proper bearing cleaning
center and 6 inches (152.4 mm) from each end. cannot be overemphasized. Clean bearings
Discard shaft if total indicated runout (TIR) separately from other axle parts, using the
exceeds 0.060 inch (1.5 mm) at the center, or following steps:
0.030 inch (0.76 mm) at the end locations.
1. Soak differential and drive pinion bearings in
clean kerosene, diesel fuel oil, or other
Cleaning cleaning solvent. Do not use gasoline.
Clean parts with ground and polished surfaces 2. After old lubricant is loosened, hold bearing
(e.g., gears, bearings and shafts) in a suitable cups so that the bearing cannot rotate. Then
solvent, such as kerosene or diesel fuel. Do not brush bearings with a soft-bristled brush
clean these parts in a hot solution tank or with until all grit and dirt have been removed.
water and alkaline solutions such as sodium 3. Rinse bearings in clean fluid. Then, while
hydroxide, orthosilicates or phosphates. holding cups, blow dry with compressed air.
Be sure air stream is moisture free. Never
Do not steam clean assembled drive units after spin bearings with compressed air as they
they have been removed from the housing. may score due to the absence of any
Steam cleaning traps water in the cored passage lubricant.
of the castings and within close clearances on
and between parts. This can cause corrosion
(rust) on critical parts of the assembly and rust
particles circulating in the lubricant. Steam
cleaning can also lead to premature failure of
bearings, gears and other parts.
Page 96
REPAIR INSTRUCTIONS
ROUGH PARTS Gearset Updating
Rough parts, such as differential carrier castings, To assist field personnel in obtaining the desired
and cast brackets may be cleaned in hot solution bevel gearset tooth contact, all service
tanks with mild alkali solutions, providing these replacement bevel gear matched sets are
parts are not ground or polished. The parts must furnished with the desired tooth contact pattern
remain in the tank long enough to be thoroughly indicated on the gear teeth in yellow gear-
cleaned and heated throughout. This will aid the marking compound.
evaporation of the rinse water. After cleaning,
rinse parts completely to remove all traces of Before proceeding with the installation of the
alkali. 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
Do not clean parts with highly volatile fluids such (Scotch brand, or equivalent) to make a transfer
as gasoline, or harmful chemicals such as carbon of the contact pattern.
tetrachloride. Also exercise care to avoid skin
rashes and inhalation of vapors when using alkali Cut off a piece of tape slightly longer than the
cleaners. gear tooth. Place the piece of tape on the gear
tooth profile, sticky side down, covering the total
tooth length and depth. Rub the back of the tape
DRYING to ensure good contact between the tape and
tooth. Do not permit the tape to slide. Gently lift
Using moisture-free, compressed air, thoroughly the tape off the gear tooth and apply it to a piece
dry component parts immediately after cleaning of paper to transfer the tooth contact pattern.
and rinsing. If compressed air is not available,
use soft, clean, lintless absorbent paper towels or Repeat the procedure on the opposite side of the
clean wiping cloths that are free of abrasive gear tooth and identify the tooth patterns as drive
material. side and coast side. If no tape is available, make
a sketch of the patterns.
139
CORROSION PREVENTION
Parts that have been cleaned, dried and
inspected and are to be reassembled
immediately must be coated with light oil to
prevent corrosion. If the parts will be stored for
any length of time, treat them with a good rust-
preventive agent and wrap in special paper or
other material designed to prevent corrosion.
Figure 139 — Lifting Tooth Contact Pattern
Page 97
REPAIR INSTRUCTIONS
Preparation and Precautions for r Always use a driver or adapter of an
appropriate size to press bearings and seals
Reassembly into place. This will help avoid metallic
After cleaning and inspecting all parts, take the particles or shavings from getting into the
following precautions before beginning any assemblies and causing premature wear
reassembly of components: and failure.
r Immediately prior to assembly, lubricate r Do not use copper or brass punches or

bearings with thin oil. drifts to force-fit parts.
r Do not unpack a new bearing until you are r Parts that are a shrink fit must be heated
ready to install it. with a hot air blower, an oven or an industrial
grade hotplate. Do not attempt to heat the
r Do not clean the protective grease off new parts with a torch. This method will only
bearings. provide localized heating, will not permit
r Do not reuse seals and lock plates. Discard proper expansion and may affect heat
them and replace with new ones. treatment.
r Apply a coat of grease to the inside of lips on When using a torque multiplier, be sure to
seal rings. calibrate the torque wrench-torque multiplier
assembly to the desired torque.
r Apply a coat of oil to the mating surfaces of
parts to be pressed into place.
Page 98
SPECIFICATIONS
SPECIFICATIONS
Page 99
SPECIFICATIONS
MECHANICAL Hub Reduction Units — Four pinion gear
type
SPECIFICATIONS
Available Ratios —
(SR70/80 TANDEM AXLE)
r M3 Carrier — 2:56, 2:93, 3:15, 3:42,
3:73, 4:10, 5:13
Features, Materials and Dimensions r M3E Carrier — 2:16, 2:28, 2:41, 2:56
Make — RVI r Hub Reduction Units — 2:1
GVWR — SR70 model: 70,000 lbs r Overall with M3 Carrier — 5:13, 5:86,
(31 800 kg); SR80 model: 80,000 lbs 6:31, 6.83, 7.45, 8.20, 10.25
(36 400 kg)
r Overall with M3E Carrier — 4.32, 4.56,
GCWR — SR70/SR80 models: up to 4.82, 5.13
250,000 lbs (113 400 kg)
Lubricant Capacities —
Housings — One-piece cast iron
r Carrier Bowl: 36 pints (17.0L)
Carriers — Face-mounted with hypoid bevel
gear and inter-axle differential lockout r Hub Reduction Unit: 4 pints (2.0L)
(standard), inter-wheel differential lockout
(optional)
Fits and Limits
Component English Metric

Bevel Depth
— M3 model 3.465 ± 0.002 in. 88 ± 0.05 mm
— M3E model 3.386 ± 0.002 in. 86 ± 0.05 mm
Backlash 0.010–0.013 in. 0.25–0.33 mm
Hub Bearing Preload See “Hub Reduction Unit Reassembly” procedures.
Inter-axle Through Shaft Bearing Preload
— New Bearings 13.3–23.0 lb-in 1.5–2.6 N•m
— Run-In Bearings 8.9–17.7 lb-in 1–2 N•m
Differential Bearing Preload
— New Bearings 30.1–35.4 lb-in 3.4–4 N•m
— Run-In Bearings 15.0–17.7 lb-in 1.7–2 N•m
Page 100
SPECIFICATIONS
Torque Specifications
TORQUE SPECIFICATIONS FOR CRITICAL FASTENERS
140
Figure 140 — Fastener Torque Specifications (M3 Carrier)
Page 101
SPECIFICATIONS
141
Figure 141 — Fastener Torque Specifications (M3E Carrier)
Page 102
SPECIFICATIONS
142
Figure 142 — Fastener Torque Specifications (Wheel Hub)
Page 103
SPECIFICATIONS
143
Figure 143 — Fastener Torque Specifications (Power Divider/Adapter Housing)
Page 104
SPECIFICATIONS
TORQUE SPECIFICATIONS FOR WHEEL STUD NUTS
Spoke Wheels
Tightening Torques (a)

Description Size Lb-Ft N•m
Rear Wheel Clamp Stud Nuts 3/4-10 UNC 175–225 237–305
Hub-Piloted Wheels
Tightening Torques (a)

Description Size Lb-Ft N•m
Cap Nuts — inner and outer with shoulder 3/4-16 UNF, shoulder 450–500 610–678
or head-type studs
1-1/8-16 UNF, shoulder (3/4 backnut) 450–500 610–678
1-1/8-16 UNF, shoulder (7/8 or 1 backnut) 650–750 881–1017
1-1/8-16 UNF, head 450–500 610–678
15/16-12 UNF, shoulder or head 750–900 1017–1220
1-5/16-12 UNF, shoulder or head 750–900 1017–1220
Backnut — inner end of wheel stud: 3/4-16 UNF 175–200 237–271
shoulder-type studs with threads on both
ends 7/8-14 UNF 175–250 237–339
1-14 UNF 175–300 237–407
Flange Nuts — for hub-piloted wheels M22 x 1.5, metric threads 450–500 (b) 610–678 (b)
(a) Threads must be dry.
(b) If the wheels have been removed, apply a small amount of oil to the lead threads of the stud and between the nut body
and flange of the cone locknut when reinstalling. Avoid getting oil on the face of the nut, wheels or tires.
Page 105
SPECIFICATIONS
TORQUE SPECIFICATIONS FOR NON-CRITICAL FASTENERS
PROPERTY CLASS 8.8
Tightening Torques
Size (mm) Pitch Lb-Ft N•m
6 0.75 6 8
6 1.00 6 8
8 1.00 15 20
8 1.25 14 19
10 1.25 30 41
10 1.50 28 38
12 1.25 55 75
12 1.75 50 68
14 1.50 86 117
14 2.00 80 109
16 1.50 133 180
16 2.00 124 168
18 1.50 193 262
18 2.50 172 233
20 1.50 270 366
20 2.50 244 331
22 1.50 365 495
22 2.50 332 450
24 2.00 459 622
24 3.00 421 571
27 2.00 666 903
27 3.00 618 838
30 2.00 928 1258
30 3.50 838 1136
33 2.00 1250 1695
33 3.50 1140 1546
36 3.00 1551 2103
36 4.00 1465 1986
Page 106
SPECIFICATIONS
PROPERTY CLASS 9.8
Tightening Torques
6 0.75 7 10
6 1.00 6 8
8 1.00 16 22
8 1.25 15 20
10 1.25 33 45
10 1.50 31 42
12 1.25 59 80
12 1.75 54 73
14 1.50 94 127
14 2.00 87 118
16 1.50 144 195
16 2.00 135 183
18 1.50 210 285
18 2.50 187 254
20 1.50 293 397
20 2.50 264 358
22 1.50 395 536
22 2.50 360 488
24 2.00 498 675
24 3.00 456 618
27 2.00 722 979
27 3.00 669 907
30 2.00 1005 1363
30 3.50 908 1231
33 2.00 1355 1837
33 3.50 1235 1674
36 3.00 1681 2279
36 4.00 1587 2152
Page 107
SPECIFICATIONS
PROPERTY CLASS 10.9
Tightening Torques
6 0.75 9 12
6 1.00 8 11
8 1.00 21 29
8 1.25 20 27
10 1.25 42 57
10 1.50 40 54
12 1.25 76 103
12 1.75 69 94
14 1.50 120 163
14 2.00 111 151
16 1.50 184 250
16 2.00 172 233
18 1.50 268 363
18 2.50 239 324
20 1.50 374 507
20 2.50 337 457
22 1.50 505 685
22 2.50 460 624
24 2.00 636 862
24 3.00 583 790
27 2.00 922 1250
27 3.00 855 1159
30 2.00 1284 1741
30 3.50 1159 1571
33 2.00 1730 2346
33 3.50 1578 2140
36 3.00 2146 2910
36 4.00 2027 2748
Page 108
SPECIFICATIONS
LUBRICANT AND SEALANT SPECIFICATIONS
Assembly Sealants and Lubricants
Location Sealant or Lubricant

Adapter-to-Carrier Housing and Shim/Spacer MACK P/N 5166-54941
Adapter-to-Carrier Housing Collar Nut MACK P/N 5166-54941 (on threads)
Bevel Pinion Assembly-to-Carrier Housing MACK P/N 5166-52414
Holding metal parts in place Mack MG-C grease or petroleum jelly (Vaseline®)
Hub Reduction Planetary Gear Case Capscrews MACK P/N 5166-27121 (on threads)
Hub Reduction Planetary Gear Case Halves MACK P/N 5166-54941
Hub Reduction Planetary Gear Case-to-Wheel Hub MACK P/N 5166-54941
Input Flange Retaining Nut MACK P/N 5166-54941 (on threads)
Input Flange Retaining Plate Screws MACK P/N 5166-52414 (on threads)
Inter-Axle Differential Case Capscrews MACK P/N 5166-27121 (on threads)
Inter-Axle Differential Lock Adjustment Plug Loctite® P/N 21453
Inter-Axle Differential Cylinder and Spacer Plate MACK P/N 5166-52414
Inter-Axle Power Divider-to-Adapter Housing MACK P/N 5166-54941
Inter-Axle Power Divider: MACK P/N 5166-52414
r Input Shaft Inner Seal
r Rotor and Holder Assembly
r Outer Seal and Support
Inter-Axle Differential Lock Engagement Switch Loctite® P/N 21453 (on threads)
Intermediate Shaft Retainer Plate Capscrews Loctite® P/N 21453 (on threads)
Inter-Wheel Differential Case Capscrews MACK P/N 5166-27121 (on threads)
Inter-Wheel Differential Case-to-Ring Gear MACK P/N 5166-54941
Inter-Wheel Differential Lock Cylinder Capscrews MACK P/N 5166-54941 (on threads)
Inter-Wheel Differential Lock Cylinder Shift Fork Pivot Pin MACK P/N 5166-54941 (on threads)
Inter-Wheel Differential Lock Engagement Switch Loctite® P/N 21453 (on threads)
Manual Slack Adjuster RVI Lever Retaining Nut MACK P/N 5166-27121 (on threads)
Ring Gear-to-Inter-Wheel Differential Capscrews MACK P/N 5166-27121 (on threads)
Output Flange Retaining Plate Screws MACK P/N 5166-52414 (on threads)
Output Flange Retaining Nut MACK P/N 5166-54941 (on threads)
Trunnion Cover MACK P/N 5166-54941
Trunnion Sleeve Clean engine oil
Trunnion Inner and Outer Thrust Washers Clean engine oil
Trunnion Thrust Washer Retaining Screws Loctite® P/N 21453
Page 109
SPECIFICATIONS
Gear Oils
(Carrier, Power Divider and Hub
Reduction Units)
GO-J and GO-J PLUS specification oils are
compounded gear oils (mineral or synthetic base)
for use in all MACK components which require
gear oil as a lubricant. These two classes of oils
have different drain intervals, with GO-J used for
standard drain intervals and GO-J PLUS used for
extended drain intervals.
r Mineral — 90, 140, 80W90, 80W140,
85W140
r Synthetic — 75W90, 75W140, 80W140
Page 110
DISASSEMBLED VIEWS
DISASSEMBLED VIEWS
Page 111
DISASSEMBLED VIEWS
SR70/80 AXLE PARTS IDENTIFICATION VIEWS
Hub Reduction Unit 144
[477 HU]
Figure 144 — Hub Reduction Unit
1. Thrust Washer 6. Sun Gear (Rotating) 11. Capscrew (12)

2. Sun Gear (Stationary) 7. Thrust Washer 12. Planetary Gear
3. Hub Retaining Nut 8. Planetary Gear Case (Outer Half) 13. Needle Bearings
4. Planetary Gear Case (Inner Half) 9. Capscrew (4) 14. Thrust Washer
5. Spider 10. Plug, Drain/Fill 15. O-Ring
Page 112
DISASSEMBLED VIEWS
Wheel Hub
[473 AA]
ARRANGEMENT 1
145
Figure 145 — Wheel Hub Arrangement 1
1. Holder 8. Hub Bearing (Outer) 15. ABS Tone Wheel

2. Oil Deflector (Inner) 9. Thrust Washer 16. Oil Deflector (Inner)
3. Seal 10. Hub Retainer Nut 17. Lubrication Tube
4. Oil Slinger 11. Sun Gear (Inner) 18. Clamp
5. Hub Bearing (Inner) 12. Wheel Stud 19. Sleeve
6. Hub 13. Wear Ring 20. Sensor
7. Brake Drum 14. Oil Deflector (Outer)
Page 113
DISASSEMBLED VIEWS
ARRANGEMENT 2
146
Figure 146 — Wheel Hub Arrangement 2
1. Oil Deflector 6. Wheel Stud 11. Spoke Wheel

2. Wear Ring 7. Wheel Hub 12. Hub Bearing (Outer)
3. Seal 8. Wheel Hub (Integral) 13. Thrust Washer
4. Oil Slinger 9. Brake Drum 14. Sun Gear (Stationary)
5. Hub Bearing (Inner) 10. Drum Retainer Screw 15. Hub Retainer Nut
Page 114
DISASSEMBLED VIEWS
Power Divider/Adapter Housing 147
INTER-AXLE DIFFERENTIAL ASSEMBLY

[466 AA]
Figure 147 — Inter-Axle Differential Assembly
1. Retainer Plate/Nut 9. Stator 17. Side Gear (Front)

2. Drive Input Flange 10. Rotor Support 18. Spider
3. Seal 11. Power Divider Housing 19. Planetary Gear (4)
4. Seal Support 12. Plug 20. Side Gear (Rear)
5. Oil Deflector 13. Bearing 21. Thrust Washer
6. Oil Cup/Spacer 14. Retainer Snap Ring 22. Case (Rear Half)
7. Rotor 15. Case (Front Half) 23. Thrust Washer
8. Oil Scraper 16. Thrust Washer
Page 115
DISASSEMBLED VIEWS
THROUGH SHAFT ASSEMBLY
148
Figure 148 — Through Shaft Assembly
1. O-Ring 6. O-Ring 11. Retainer Plate

2. Pin 7. Bearing Cover 12. Retainer Nut
3. Bearing Housing 8. Seal (Inner) 13. Through Shaft
4. Bearing (Rear) 9. Seal (Outer)
5. Spacer/Shim 10. Output Flange
Page 116
DISASSEMBLED VIEWS
ADAPTER HOUSING ASSEMBLY
149
Figure 149 — Adapter Housing Assembly
1. Washer 13. Spacer 25. Intermediate Gear

2. Shim 14. Dowel 26. Spacer
3. Adapter Housing (Front Half) 15. Washer 27. Bearing
4. O-Ring 16. Drain Plug 28. Oil Pan (Front)
5. Bearing 17. Oil Pan (Rear) 29. Retainer Plate
6. Forward Carrier Drive Gear 18. Oil Pan Cover Plate 30. Washer
7. Bearing 19. Pinion Drive Gear 31. Fill Plug
8. Lock Cylinder 20. Retainer Nut 32. Snap Ring
9. Plate 21. Seal 33. Bearing
10. Sliding Clutch 22. Intermediate Shaft 34. O-Ring
11. Collar Nut 23. Seal 35. Bearing Cover
12. Adapter Housing (Rear Half) 24. Bearing
Page 117
DISASSEMBLED VIEWS
Carrier
[475 CF]
DRIVE PINION ASSEMBLY

150
Figure 150 — Drive Pinion Assembly
1. Drive Input Flange 7. Shim (sets Bearing Preload) 13. Bearing (Outer)
2. Seal 8. Bearing (Inner) 14. Oil Deflector
3. Bearing (Outer) 9. Pinion Shaft 15. Pinion Drive Gear
4. Pinion Housing 10. Pilot Bearing 16. Retainer Nut
5. Oil Deflector 11. Snap Ring
6. Shim (sets Pinion Depth) 12. Pinion Housing
Page 118
DISASSEMBLED VIEWS
INTER-WHEEL DIFFERENTIAL ASSEMBLY
151
Figure 151 — Inter-Wheel Differential Assembly
1. Lock Plates 10. Side Gear (LH) 19. Carrier Housing

2. Adjusting Nut 11. Thrust Washer 20. Planetary Gear (4)
3. Bearing 12. Case (LH) 21. Thrust Washer
4. Bearing Cap (RH) 13. Bearing Cap (LH) 22. Dowel
5. Ring Gear 14. Dowel 23. Lubrication Tube
6. Case (RH) 15. O-Ring 24. Spring
7. Thrust Washer 16. Oil Slinger 25. Seal
8. Side Gear (RH) 17. Bearing Adjusting Nut 26. Plug
9. Spider 18. Bearing
Page 119
DISASSEMBLED VIEWS
Inter-Axle Differential Lock Cylinder 152
[466 CS]
Figure 152 — Inter-Axle Differential Lock Cylinder
1. Housing 7. Rear Cover 13. Spacer

2. O-Ring 8. Snap Ring 14. Spring
3. Switch 9. Piston (Inner) 15. Fork
4. Air Fitting 10. O-Ring 16. Plug
5. Snap Ring 11. O-Ring
6. O-Ring 12. Shaft
Page 120
DISASSEMBLED VIEWS
Inter-Wheel Differential Lock
Cylinder
[475 ES]
153
Figure 153 — Inter-Wheel Differential Lock Cylinder
1. Housing 7. Washer
2. Nut, Piston Retainer 8. Spring
3. O-Ring 9. Plate
4. O-Ring 10. Shaft
5. Piston 11. Ball
6. O-Ring 12. Switch
Page 121
NOTES
Page 122
APPENDIX I — SUSPENSION
Page 123
REAR SPRING SERVICE 5. Loosen and remove the axle bracket U-bolts
at each end of the spring (Figure 155).
PROCEDURES 155
Spring Assembly Removal

[135 NH]
1. Loosen the wheel nuts.
2. Using a suitable lift, raise the vehicle and
place jackstands under each axle and under
the spring trunnion brackets.
3. Remove the wheels.
4. Remove the retaining nuts, spring clips and
spacer blocks (Figure 154).
154
Figure 155 — Axle Bracket U-Bolt
1. Bracket 3. U-Bolts
2. Rubber Pad
6. Remove the axle bracket and rubber pad.

7. Using a suitable lifting device, remove the
spring assembly.
8. Repeat steps 1–7 for the spring assembly on
the opposite side as required.
Figure 154 — Spring Clips
1. Spring Clip 2. Spacer
Page 124
Spring Assembly Installation SPRING TRUNNION SERVICE
[135 NH] PROCEDURES
spring assembly in position over the axles
and spring trunnion. Trunnion Disassembly
2. Place the axle brackets and rubber bumpers
in position over each axle.
[137 AA]
3. Install the U-bolts and retaining nuts 1. Remove the spring assembly (see “REAR
(Figure 155). Tighten the nuts to SPRING SERVICE PROCEDURES” on
specification, 184 lb-ft (250 N•m). page 124 for procedure).
4. Place the spacer blocks and spring clips in 2. Drain lubricant from the spring trunnion.
position on the spring assembly and 3. Remove the trunnion cover plate
trunnion (Figure 154). (Figure 156).
156
5. Install the spring clip retaining nuts and
tighten to specification, 553 lb-ft (750 N•m).
6. Install the wheels.
7. Repeat steps 1–7 for the spring assembly on
the opposite side as required.
8. Remove the jackstands from under the axles
and trunnion and lower the vehicle to the
floor.
Figure 156 — Trunnion Cover Plate
1. Cover Plate
Page 125
4. Bend back the lock plate tabs and remove 5. Remove the stop and adjusting washer.
the bushing retaining plate bolts
6. Remove the outer thrust washer and
(Figure 157).
157 trunnion (Figure 158).
158
Figure 158 — Trunnion Removal

Figure 157 — Trunnion Retainer Plate Bolts
1. Thrust Washer 2. Trunnion

1. Lock Plate 3. Retainer
2. Bolts (6)
7. Remove the inner thrust washer and seal
(Figure 159).
159
Figure 159 — Seal Removal
1. Seal
Page 126
8. Drive the two pins from the sleeve and 161
spindle tube (Figure 160).

160
Figure 161 — Trunnion Assembly
1. Screws 2. Thrust Washer

Figure 160 — Sleeve Pin Removal
11. Using a press and suitable remover/installer,
1. Sleeve 2. Pin
remove the bushing from the trunnion
9. Using a torch, cut the sleeve from the (Figure 162).
162
spindle.
Care should be taken when cutting the sleeve to

avoid damage to the trunnion spindle and its heat
treatment.
10. Remove the retaining screws, thrust washer

and O-ring from the trunnion (Figure 161).
Figure 162 — Trunnion Bushing Removal
1. Remover/Installer 2. Handle
Page 127
Trunnion Reassembly 2. Place the O-ring and thrust washer in
position on the trunnion (Figure 161). Apply
[137 AA] sealant, Loctite® Oleoetanche, or
equivalent, to the threads and install the
1. Using a press and suitable remover/installer, screws.
install the bushing in the trunnion. Make sure
that the lubrication grooves are properly 3. Using an oven, heat the spindle sleeve to
aligned with the trunnion as shown in 248°F (120°C). When heated to
Figure 163. temperature, remove the sleeve from the
163 oven and immediately install it on the
spindle, making sure that the pin holes in the
sleeve and spindle are aligned (Figure 164).
Wear protective gloves when handling the

heated sleeve.
164
Figure 163 — Trunnion Bushing Alignment
1. Lubrication Groove
Figure 164 — Sleeve Installation
1. Sleeve 2. Pin
Page 128
4. Install new pins through the sleeve and 7. Apply clean engine oil to the sleeve and
spindle. inner and outer thrust washers.
5. Apply grease to the seal rear surface 8. Install the trunnion and outer thrust washer.
(rubber) and oil to front surface (cork). Install Make sure that the lubricating grooves of the
the seal. thrust washer are also facing outward
(Figure 166).
6. Install the inner thrust washer, making sure 166
the lubrication grooves are facing outward
(Figure 165).
165
Figure 166 — Trunnion Installation
Figure 165 — Thrust Washer and Seal, Installed 1. Retainer 3. Trunnion

2. Thrust Washer
1. Thrust Washer 2. Seal

9. Temporarily install the trunnion retainer, and
install and tighten two bolts.
10. Using a depth gauge, measure the distance
between the outer thrust washer and the end
of the spindle (Figure 167). This
measurement +0/ −0.002 inch
(+0/ −0.05 mm), is the thickness of the shim
to be installed (Figure 168).
Page 129
167
11. Remove the trunnion retainer, install the
shim and reinstall the retainer, lock plates
and bolts (Figure 169). When positioning the
retainer, make sure that the vent hole is as
high as possible. Also, use only new lock
plates when installing the bolts.
169
Figure 167 — Shim Measurement
1. Thrust Washer 2. Depth Gauge
168
Figure 169 — Trunnion Retainer Installation
1. Lock Plate 3. Retainer

2. Bolt (6)
Figure 168 — Shim Installation
1. Shim 2. Trunnion
Page 130
12. Tighten the retainer bolts to specification,
111 lb-ft (150 N•m).
13. Apply sealant, Loctite® Autoform or
equivalent, to the mating surface of the
cover and install the cover and capscrews
(Figure 170).
170
Figure 170 — Trunnion Cover Installation
1. Cover Plate
14. Fill the trunnion with HD 90 oil.
Page 131
Torque Rod and Bracket Removal 3. Remove the two pinch-bolts on the
underside of the mounting bracket.
[135 UP] 4. Using a chisel, open the clamp tangs and
remove the bracket from the cross tube.
Refer to Figure 171 for location of parts.
5. If a torque rod is to be replaced, loosen and
1. Loosen and remove the torque rod bar end remove the torque rod bar end bolts and
nuts at the center mounting bracket. nuts from the axle end bracket and remove
2. Remove the bolts and spacers and lower the the rod.
171
torque rod ends to the ground.
Figure 171 — Torque Rod and Bracket
1. Torque Rod (Lower) 4. Center Bracket

2. Axle Bracket (Lower) 5. Pinch Bolt and Nut
3. Bar End Retainer Nut
Torque Rod and Bracket Installation 3. Place the two torque rod bar ends and
spacers in position on the bracket. Install the
[135 UP] bolts and nuts and tighten to specification,
258 lb-ft (350 N•m).
1. Slide the center mounting bracket on the
cross tube, making sure it is aligned with the 4. If a torque rod has been replaced, place the
bracket on the opposite side of the chassis. other bar end in position on the axle bracket.
Install the bolts and nuts and tighten to
2. Install the two pinch bolts and tighten the specification, 258 lb-ft (350 N•m).
nuts to specification, 89 lb-ft (120 N•m).
Page 132
REAR SUSPENSION SPECIFICATIONS
Fastener Torque Specifications
172
Figure 172 — Fastener Torque Specifications (Rear Suspension)
Page 133
REAR SUSPENSION (6x4) PARTS IDENTIFICATION VIEWS
(FOR SR70/80 AXLE)
Spring and Trunnion Assembly

[137 AA]
173
Figure 173 — Spring and Trunnion Assembly
1. Frame Bracket (Inner) 8. Spring Assembly 15. Plug

2. Frame Bracket (Outer) 9. Spring Trunnion 16. Capscrew
3. Sleeve 10. Bushing 17. Cover Plate
4. Seal 11. Thrust Washer (Outer) 18. Suspension Bracket
5. Thrust Washer (Inner) 12. Shim 19. O-Ring
6. Retainer 13. Retainer 20. Suspension Cross Tube
7. O-Ring 14. Lock Plate
Page 134
Torque Rod Assembly 174
[135 UP]
Figure 174 — Torque Rod Assembly
1. Frame Bracket 4. Spacer 7. Center Bracket

2. Torque Rod (Upper) 5. Axle Bracket (Lower) 8. Cross Tube (Torque Rod Bracket)
3. Axle Bracket (Upper) 6. Torque Rod (Lower)
Page 135
NOTES
Page 136
APPENDIX II — BRAKES
Page 137
WHEEL BRAKE ASSEMBLY 5. Remove the brake slack adjuster, manual or
automatic, as follows:
SERVICE PROCEDURES
Manual (RVI Lever) — Unhook the lever
(SR70/80 TANDEM AXLE) return spring. Heat the retaining nut with a
heat gun and remove the nut from the
Wheel/Hub/Drum Removal camshaft.
Automatic — Using a pair of pliers, remove
Refer to “WHEEL HUB — OVERHAUL” on page the snap ring and washer from the camshaft.
30 for wheel hub and drum removal procedures. Remove the nut from the link pin, uncouple
the link and remove the slack adjuster.
Wheel Brake Disassembly 6. Remove the camshaft and washer, if so
equipped, from the bearing bracket.
[516 BC and 517 BC]
7. Remove the O-ring and seal from the brake
1. Using spring pliers, remove the shoe return spider.
spring (Figure 175).
175 8. Remove the two seals from the bearing
bracket.
9. Inspect the camshaft and bushings in the
spider and bearing bracket for wear and/or
damage. If the bushings require
replacement, use a suitable puller, adapter
and a 18 x 250 threaded rod 15.75 inches
(400 mm) in length, to remove and install the
bushings (Figure 176). Use new seals on
reassembly.
176
Figure 175 — Return Spring Removal
1. Spring Pliers 2. Return Spring
2. Remove the rubber plugs from the brake

backing plate.
3. Using a pair of pliers, remove the four snap
rings from the anchor pins.
Figure 176 — Camshaft Bushing Removal and
4. Using a bronze punch, drive the anchor pins Installation
from the bores and remove the brake shoes.
1. Puller and Adapter
10. Remove the capscrews and remove the

brake spider and dust shield.
Page 138
Component Inspection 177
Refer to the AIR BRAKE SYSTEM SERVICE

MANUAL, 16-104, for inspection procedures
covering anchor pins, brake linings, brake shoes
and springs, brake spiders, camshafts, rollers,
bushings and dust shields/backing plates.
Wheel Brake Reassembly

[516 BC and 517 BC]
1. Place the brake spider and dust shield in
position and install four new capscrews.
Tighten the capscrews to specification,
74 lb-ft (100 N•m).
2. Install the oil deflector, if so equipped.
3. Install the preheated oil seal wear ring (see
“WHEEL HUB — OVERHAUL” on page 30
for installation procedure).
4. If removed, install the bushings in the brake Figure 177 — Camshaft Seal Installation
spider and bearing bracket, using a suitable
puller, adapter and a 18 x 250 threaded rod 1. Adapter Ring 2. Handle
15.75 inches (400 mm) in length
(Figure 176). 6. Pack the seals with grease.
5. Using a suitable handle and adapter ring, 7. Clean the threads of the camshaft and lightly
install new seals in camshaft bores of the lubricate the camshaft lobes. Also, lubricate
spider and bearing bracket (Figure 177). the spider and bearing bracket bores and
Make sure the lips of the seals are facing out the slack adjuster splines.
from the camshaft bores of the brake spider
and bearing bracket.
Page 139
8. Install the camshaft assembly as follows: c. Install the washer and snap ring on the
end of the shaft, making sure the snap
Camshaft Installation (with Manual Slack
ring is properly seated.
Adjuster)
d. Slide the camshaft back so that the
a. Temporarily install the camshaft in the
center snap ring contacts the bearing
spider and bearing bracket, and install
bracket. Measure the clearance
the brake slack adjuster and retaining
between the spider and the center snap
nut. Tighten the retaining nut hand-tight
ring. Subtract 0.008 inch (0.2 mm) from
at this time. It will be tightened to
the measurement taken to determine
specification later when the final
the thickness of the washer to be
adjustments are made.
installed in that position.
b. Slide the slack adjuster back, away
e. Remove the end snap ring, washer,
from the bearing bracket. Measure the
slack adjuster, center snap ring and
clearance between the bracket and
camshaft.
lever. Subtract 0.008 inch (0.2 mm)
from the measurement taken to f. Reinstall the camshaft with the proper-
determine the thickness of the washer size washer (as determined above)
to be installed. positioned on the shaft between the
spider and the bearing bracket and
c. Remove the nut and slack adjuster.
install the center snap ring.
d. Install the proper-size washer (as
g. Install the slack adjuster, end washer
determined above) on the camshaft
and snap ring. Make sure that the link
next to the bearing bracket and reinstall
pin is properly inserted in the tab and
the slack adjuster.
secured.
e. Connect the air chamber rod clevis pin
h. Connect the air chamber rod clevis pin
and return spring to the lever. Install a
and install a new cotter pin to retain the
new cotter pin to retain the clevis pin.
clevis pin.
f. Install the lever retaining nut and
9. Clean the brake spider and the axle spindle
tighten to specification.
tube.
Camshaft Installation (with Automatic Slack
10. Insert the rollers, pins and retainers in the
Adjuster)
brake shoes.
a. Temporarily install the camshaft in the
11. Place the brake shoes in position on the
spider and bearing bracket. Install the
spider. Grease the anchor pins and press
center snap ring, using care to ensure
them into the spider bores to secure the
that it is properly seated.
shoes.
b. Install the slack adjuster on the cam
12. Using suitable pliers, install the snap rings
shaft with the arrow on the lever
on each end of the anchor pins.
pointing in the direction of brake
application and with the link pin aligned 13. Install the two rubber plugs in the dust
with the opening in the tab. Do not shield.
tighten the nut and lock nut.
14. Using spring pliers, install a new shoe return
spring.
Page 140
Wheel/Hub/Drum Installation 4. Turn the adjuster to change the free travel of
the lever. The free travel should be within a
Refer to “WHEEL HUB — OVERHAUL” on page range of 0.591–0.787 inch (15–20 mm)
30 for wheel hub and drum installation measured at the end of the lever.
procedures.
5. Repeat steps 1–4 at the remaining wheels.
6. Actuate the brake pedal several times and
Adjustments check the drum-to-lining clearances at each
After completing the service operations, use the wheel. The clearance should be
following applicable procedure to adjust the approximately 0.024 inch (0.6 mm). If not,
brakes at each wheel: readjust the brakes to attain the specified
clearance.
Manual Slack Adjusters (RVI Lever) 7. Install the slotted washer and a new cotter
pin on the adjuster at each wheel.
1. At one wheel, check that the brake chamber
push rod is fully retracted (brakes released
position). Automatic Slack Adjuster
2. Apply a sealant such as Loctite® 1. At one wheel, check that the brake chamber
FRENETANCH, or equivalent, to the threads push rod is fully retracted (brakes released
of the lever retaining nut. Install the nut and position) and that the drum-to-lining
tighten it to specification, 148 lb-ft clearance is greater than 0.024 inch
(200 N•m). See Figure 178. (0.6 mm).
178
2. Turn the hex-head adjuster clockwise to
bring the hole in the lever in line with the
hole in the brake chamber push rod clevis
(Figure 179). Install the clevis pin and a new
cotter pin.
179
Figure 178 — Manual Slack Adjuster
1. Slotted Washer 3. Adjustment Shaft (Hex)

2. Lever Retaining Nut 4. Cotter Pin
3. Remove the cotter pin and slotted washer Figure 179 — Automatic Slack Adjuster
from the hex-head adjuster.
1. Adjustment Shaft (Hex) 3. Control Arm
2. Link Rod
Page 141
3. Move the control arm in the direction of Brake Lining Replacement
camshaft brake application until the link rod
contacts the end of the slotted hole in the [516 GC and 517 GC]
control arm. Tighten the lock nuts on the link
rod to retain the control arm in this position. If brakes shoes are not being exchanged for
replacement, worn brake linings can be removed
from the existing shoes and new linings installed
as follows:
When tightening the lock nuts to secure the
control arm, ensure that the arm is centered 1. Using a punch press, remove the rivets and
along the rod so that the arm IS NOT subjected to worn linings from the brake shoe.
lateral strain as the slack adjuster lever rotates 2. Place the new lining in position on the shoe.
during brake application.
3. Starting from the middle of the lining, use a
riveter to attach the lining to the shoe
4. Turn the adjuster clockwise until the brake (Figure 180). Be sure to apply the
linings contact the drum and drum cannot be installation pressure specified for the rivet
rotated. Back off the adjuster by 3/4 turn (a size and material.
loud click must be heard). 180
5. Repeat steps 1–4 at the remaining wheels.

6. Actuate the brake pedal several times to
take up any excess clearance and check the
drum-to-lining clearances at each wheel.
The clearance should be approximately
0.024 inch (0.6 mm). If not, readjust the
brakes to attain the specified clearance.
As part of an annual inspection, check the

position of the clevis pin and measure the release
torque (anti-clockwise) of the hex-head adjuster.
Measure the torque three times and calculate the
average. The average torque MUST NOT exceed
13 lb-ft (18 N•m).
Figure 180 — Brake Lining Installation
1. Riveter 3. Brake Lining

2. Brake Shoe
Page 142
Grinding of Brake Linings Grinding of Brake Drums
[516 GC and 517 GC] [516 DD and 517 DD]
Brake drums must be reground in sets by axle.
1. Determine which brake drum of a set is the
Always use brake linings of the same quality as most distorted and in need of grinding.
the originals.
2. Mount the most distorted drum (or the
wheel/hub/drum assembly) on the grinder
If the condition of the used brake drums is within first (Figure 182).
specification and regrinding is not required, the 182
replacement linings must be ground to conform to

the inside radius of the drum. This is
accomplished by using a lining grinder and
removing enough material from the linings to
match the inside radius of the drum –0.020 inch
(0.5 mm) with the brakes in the applied position
(Figure 181).
181
Figure 182 — Drum Grinding
1. Drum Grinder 2. Wheel/Hub/Drum

Assembly
3. Remove the minimum amount of metal from

the braking surface of the drum to bring it
within specification.
Figure 181 — Grinding Brake Linings
4. Remove the drum from the grinder and
1. Lining Grinder 2. Brake Lining mount the second drum of the axle set.
5. Remove sufficient metal from the second
If regrinding of the brake drums is required, use drum to bring to the same dimension as the
replacement linings conforming to the same first drum. Then, remove the drum from the
service specification. Regrinding of the linings is grinder.
not required. 6. Clean both drums of all metal shavings and
dirt and prepare them for installation.
Page 143
WHEEL BRAKE SPECIFICATIONS
Dimensional Data, Fits and Limits
Description English Metric

BRAKE DRUMS
Original diameter 16.3 in. 414 mm
Grinding diameter — maximum 16.398 in. 416.5 mm
Wear diameter allowed — maximum 16.437 in. 417.5 mm
BRAKE LININGS (F 532)
Width 6.9 in. 175 mm
Length 16.2 in. 412 mm
Thickness — new 0.75 in. 19 mm
Thickness — minimum allowed (worn) 0.28 in. 7 mm
Lining-to-drum clearance 0.024 in. 0.6 mm
LINING RIVETS (STEEL)
Diameter 0.315 in. 8 mm
Length under head 0.709 in. 18 mm
Riveting force 3,600 lbf (1.8 ton) 16 014 N
Fastener Torque Specifications
Fastener Name Torque (Lb-Ft) Torque (N•m)

Brake Chamber Attachment Nuts 133 180
Brake Spider Retaining Nuts 74 100
Hub Reduction Unit Drain Plug 44 60
Hub Reduction Unit End Plug 184 250
Hub Reduction Unit Mounting Capscrews 96 130
Wheel Hub Nut
Initial 369 500
Final (after backing out 1/2 turn) 184 250
Wheel Lug Nuts 369 500
Page 144
WHEEL BRAKE ASSEMBLY PARTS IDENTIFICATION VIEWS
(FOR SR70/80 AXLE)
Brake Shoe and Spider Assembly

[516/517 GL and 516/517 LB]
183
Figure 183 — Brake Shoe and Spider Assembly
1. Brake Shoe and Lining 6. Seal 11. Roller Pin

2. Snap Ring 7. Spider 12. Snap Ring
3. Anchor Pin 8. Bushing 13. Return Spring
4. Plug 9. Seal
5. Dust Shield 10. Cam Roller
Page 145
Camshaft and Slack Adjuster Assembly
[516/517 KF and 516/517 SB] 184
Figure 184 — Camshaft and Slack Adjuster Assembly
1. Camshaft 8. Lever (Manual Adjuster) 15. Lever (Automatic Adjuster)

2. Seal 9. Retainer Nut 16. Bearing Bracket
3. Bearing Bracket 10. Link Pin 17. Seal
4. Bushing 11. Seal 18. Snap Ring
5. Seal 12. Bushing 19. Washer
6. Thrust Washer 13. Snap Ring
7. Return Spring 14. Washer
Page 146
SPECIAL TOOLS & EQUIPMENT
Page 147

TOOLS AND EQUIPMENT
General Purpose Tools
Tool No. Description

50 00 26 0822 Pinion Drive Gear Puller
50 00 26 0827 Wheel Hub Puller
50 00 26 0828 Bearing Cup Puller
50 00 26 0829 Support (use with puller)
50 00 26 0843 Flange Puller
50 00 26 0854 Spring Pliers
50 00 26 1000 Universal Repair Stand
50 00 26 2351 Set of Seal/Bearing Drivers
50 00 26 2363 Set of Seal/Bearing Drivers
50 00 26 9774 Torque Multiplier Wrench
50 00 26 9777 Dial Indicator
J 8129 Spring Tension Scale
J 35904 Wheel Bearing Locknut Wrench (for wheel hub retaining nut removal/installation)
J 36132 Wheel Dolly
J 39453 Seal Installer
J 39454 Pliers (for sliding clutch removal)
Page 148

Special Tools

Axle
50 00 26 1432 Bevel Pinion Gauge
50 00 26 1549 Spanner Wrench (for drive flange removal/installation)
50 00 26 2198 Spanner Wrench
50 00 26 3166 Bearing Cup Installer (for drive flange removal/installation)
50 00 26 3167 Spanner Wrench (for collar nut removal /installation)
50 00 26 4094 Spanner Wrench (for bearing adjuster removal/installation)
50 00 26 4107 Spanner Wrench
50 00 26 9134 Spanner Wrench (for pinion drive gear removal/installation)
Suspension
50 00 26 3016 Handle (used in combination with 6102)
50 00 26 6102 Bushing Remover/Installer
Wheel Brake
50 00 26 3016 Handle (used in combination with 3171)
50 00 26 3037 Mandrel (used in combination with 4073)
50 00 26 3166 Wheel Hub Bearing Driver
50 00 26 3171 Adapter Ring (for camshaft seal installation)
50 00 26 3172 Axle Shaft Remover/Installer
50 00 26 3182 Wheel Hub Seal Driver
50 00 26 4073 Hub/Drum Assembly Puller
50 00 26 6048 Puller (used with 7055)
50 00 26 7055 Adapter Ring (for camshaft bushing removal/installation)
Locally Fabricated or Procured Tools

TOOL LIST

FL1502 Seal Installer
FL2238 Seal Installer
FL3194 Adapter (for pinion drive gear removal)
FL3195 Guide (for collar nut installation)
FL1432 Gauge
Page 149

TOOL PRINTS 185
All dimensions shown on the tool prints are in

metric units. Multiply millimeters (mm) by 0.03937
to obtain inches.
Figure 185 — M95 Socket

186
Figure 186 — Tool No. FL1432
Page 150

187

188
Page 151

189

190
Page 152
Index.fm Page 153 Monday, February 18, 2002 11:15 AM
INDEX
INDEX
Page 153
INDEX
A F
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . .141 FASTENER TORQUE
ADVISORY LABELS . . . . . . . . . . . . . . . . . . . . .2 SPECIFICATIONS . . . . . . . . . . . . . 133, 144
AIR BREATHERS . . . . . . . . . . . . . . . . . . . . . .20 FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ASSEMBLY SEALANTS AND FEATURES, MATERIALS AND
LUBRICANTS . . . . . . . . . . . . . . . . . . . . .109 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . 100
AXLE REMOVAL AND INSTALLATION . . . . .22 FITS AND LIMITS . . . . . . . . . . . . . . . . . . . . . 100
AXLE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . .96 FORWARD-REAR CARRIER WITH POWER
AXLE/CARRIER CLEANING AND DIVIDER/ADAPTER . . . . . . . . . . . . . . . . . 10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .95
G
B
GEAR OILS . . . . . . . . . . . . . . . . . . . . . . . . . . 110
BEARINGS, BUSHINGS AND THRUST GEAR SET INSPECTION . . . . . . . . . . . . . . . . 16
WASHERS . . . . . . . . . . . . . . . . . . . . . . . . .95 GEAR WEAR LIMITS . . . . . . . . . . . . . . . . . . . 95
BRAKE LINING REPLACEMENT . . . . . . . . .142 GEARSET UPDATING . . . . . . . . . . . . . . . . . . 97
BRAKE SHOE AND SPIDER ASSEMBLY . .145 GENERAL PURPOSE TOOLS . . . . . . . . . . . 148
GRINDING OF BRAKE DRUMS . . . . . . . . . . 143
C GRINDING OF BRAKE LININGS . . . . . . . . . 143
CAMSHAFT AND SLACK ADJUSTER
H
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .146
CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 HUB REDUCTION UNIT — OVERHAUL . . . . 24
CARRIER DISASSEMBLY . . . . . . . . . . . . . . .38 HUB REDUCTION UNIT . . . . . . . . . . . . . . . . 112
CARRIER IDENTIFICATION STAMPING . . . .16 HUB REDUCTION UNIT REMOVAL . . . . . . . 31
CARRIER INSTALLATION . . . . . . . . . . . . . . .59
CARRIER MAINTENANCE . . . . . . . . . . . . . . .18 I
CARRIER REASSEMBLY . . . . . . . . . . . . . . . .47 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 23
CARRIER REMOVAL . . . . . . . . . . . . . . . . . . .38 INTER-AXLE DIFFERENTIAL CASE
CARRIER SYMPTOM DIAGNOSIS . . . . . . . .14 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 71
CHANGING LUBRICANT . . . . . . . . . . . . . . . .19 INTER-AXLE DIFFERENTIAL LOCK
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . .96 ASSEMBLY SERVICE PROCEDURES . . 86
CLEANING AND INTER-AXLE DIFFERENTIAL LOCK
INSPECTION . . . . . . . . . . .26, 34, 46, 68, 89 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 120
COMPONENT INSPECTION . . . . . . . . . . . .139 INTER-AXLE DIFFERENTIAL LOCK
CONVERSION CHART . . . . . . . . . . . . . . . . . . .6 CYLINDER ADJUSTMENT . . . . . . . . . . . . 94
INTER-AXLE DIFFERENTIAL LOCK
D
CYLINDER DISASSEMBLY . . . . . . . . . . . 90
DIAGNOSING MISMATCHED CARRIER INTER-AXLE DIFFERENTIAL LOCK
RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . .16 CYLINDER REASSEMBLY . . . . . . . . . . . . 93
DIFFERENTIAL SPIDER WEAR LIMITS . . . .95 INTER-AXLE DIFFERENTIAL LOCK
DIMENSIONAL DATA, FITS AND LIMITS . .144 INSTALLATION . . . . . . . . . . . . . . . . . . . . . 89
INTER-AXLE DIFFERENTIAL LOCK
E REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 86
EXPLANATION OF NUMERICAL CODE . . . . .5 INTER-AXLE POWER DIVIDER
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . 66
INTER-AXLE POWER DIVIDER/ADAPTER —
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . 59
INTER-AXLE POWER DIVIDER/ADAPTER AND
CARRIER REMOVAL . . . . . . . . . . . . . . . . 59
INTER-AXLE POWER DIVIDER/ADAPTER
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . 61
Page 154
INDEX
INTER-AXLE POWER DIVIDER/ADAPTER R
INSTALLATION . . . . . . . . . . . . . . . . . . . . .80
REAR SPRING SERVICE
INTER-AXLE POWER DIVIDER/ADAPTER
PROCEDURES . . . . . . . . . . . . . . . . . . . . 124
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .75
REAR SUSPENSION (6X4) PARTS
INTER-AXLE THROUGH SHAFT
IDENTIFICATION VIEWS . . . . . . . . . . . . 134
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . .67
REAR SUSPENSION SPECIFICATIONS . . . 133
INTER-AXLE THROUGH SHAFT
REAR-REAR CARRIER . . . . . . . . . . . . . . . . . 12
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .68
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INTER-WHEEL DIFFERENTIAL LOCK
ASSEMBLY INSTALLATION . . . . . . . . . . .82 S
INTER-WHEEL DIFFERENTIAL LOCK
ASSEMBLY REMOVAL . . . . . . . . . . . . . . .82 SAFETY INFORMATION . . . . . . . . . . . . . . . . . 2
INTER-WHEEL DIFFERENTIAL LOCK SERVICE PROCEDURES AND TOOL
ASSEMBLY SERVICE PROCEDURES . .81 USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INTER-WHEEL DIFFERENTIAL LOCK SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . 149
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . .121 SPRING AND TRUNNION ASSEMBLY . . . . 134
INTER-WHEEL DIFFERENTIAL LOCK SPRING ASSEMBLY INSTALLATION . . . . . 125
CYLINDER DISASSEMBLY . . . . . . . . . . .84 SPRING ASSEMBLY REMOVAL . . . . . . . . . 124
INTER-WHEEL DIFFERENTIAL LOCK SPRING TRUNNION SERVICE
CYLINDER REASSEMBLY . . . . . . . . . . . .85 PROCEDURES . . . . . . . . . . . . . . . . . . . . 125
SR70/80 AXLE DESIGN FEATURES AND
L OPERATION . . . . . . . . . . . . . . . . . . . . . . . 10
SR70/80 AXLE PARTS IDENTIFICATION
LOCALLY FABRICATED OR PROCURED
VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . .149
SR70/80 CARRIER — OVERHAUL . . . . . . . . 38
LUBRICANT AND SEALANT
STATIONARY SUN GEAR
SPECIFICATIONS . . . . . . . . . . . . . . . . . .109
INSTALLATION . . . . . . . . . . . . . . . . . . . . . 27
LUBRICANT LEVEL CHECK . . . . . . . . . . . . . .18
STATIONARY SUN GEAR REMOVAL . . . . . . 25
M
T
MECHANICAL SPECIFICATIONS . . . . . . . .100
TOOLS AND EQUIPMENT . . . . . . . . . . . . . . 148
TORQUE ROD AND BRACKET
O
INSTALLATION . . . . . . . . . . . . . . . . . . . . 132
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . .95 TORQUE ROD AND BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 132
P TORQUE ROD ASSEMBLY . . . . . . . . . . . . . 135
PINION SHAFT WEAR LIMITS . . . . . . . . . . . .95 TORQUE SPECIFICATIONS . . . . . . . . . . . . 101
PLANETARY GEAR CASE TRUNNION DISASSEMBLY . . . . . . . . . . . . . 125
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . .26 TRUNNION REASSEMBLY . . . . . . . . . . . . . 128
PLANETARY GEAR CASE
INSTALLATION . . . . . . . . . . . . . . . . . .28, 37
PLANETARY GEAR CASE
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .26
PLANETARY GEAR CASE REMOVAL . . . . . .25
POWER DIVIDER/ADAPTER HOUSING . . .115
PREPARATION AND PRECAUTIONS
FOR REASSEMBLY . . . . . . . . . . . . . . . . .98
Page 155
INDEX
W
WHEEL BRAKE ASSEMBLY PARTS
IDENTIFICATION VIEWS . . . . . . . . . . . .145
WHEEL BRAKE ASSEMBLY SERVICE
PROCEDURES . . . . . . . . . . . . . . . . . . . .138
WHEEL BRAKE DISASSEMBLY . . . . . . . . .138
WHEEL BRAKE REASSEMBLY . . . . . . . . . .139
WHEEL BRAKE SPECIFICATIONS . . . . . . .144
WHEEL HUB — OVERHAUL . . . . . . . . . . . . .30
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . .113
WHEEL HUB DISASSEMBLY . . . . . . . . . . . . .32
WHEEL HUB INSTALLATION . . . . . . . . . . . . .37
WHEEL HUB REASSEMBLY . . . . . . . . . . . . .34
WHEEL HUB REMOVAL . . . . . . . . . . . . . . . . .31
WHEEL/HUB/DRUM INSTALLATION . . . . . .141
WHEEL/HUB/DRUM REMOVAL . . . . . . . . . .138
Page 156
MACK SR70/80
TANDEM AXLE
SERVICE MANUAL
(INCLUDES SUSPENSION AND BRAKE INFORMATION)
PRINTED IN U.S.A.
13-102 MACK TRUCKS, INC. 2002

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APRIL 2002 © MACK TRUCKS, INC. 2002

Activities associated with Danger indicate that death or serious personal

A procedure, practice, or condition that is essential to emphasize.

Example Numerical Code

DESCRIPTION & OPERATION

DESCRIPTION & OPERATION

DESCRIPTION & OPERATION

Figure 1 — Inter-Axle Power Divider

1. Differential Case, Front 4. Sun Gear, Rear

DESCRIPTION & OPERATION

HUB REDUCTION UNITS

Figure 3 — Hub Reduction Unit

1. Differential Case, Outer 4. Sun Gear, Inner

DESCRIPTION & OPERATION

Figure 4 — Rear-Rear Carrier Arrangement

1. Input Flange 2. Carrier Housing

CARRIER TROUBLESHOOTING CHART

Carrier Identification Stamping Gear Set Inspection

Make sure the eight tandem rear tires are

Lubricant Level Check

Be careful not to burn your finger in hot gear

When checking the oil level in the rear axles,

Figure 5 — Incorrect Oil Level

AXLE HOUSINGS Depending upon angle of inclination, it may be

Figure 7 — Axle Housings

Figure 8 — Hub Assembly

Figure 10 — Wheel Lug Nut Tightening Sequence

Figure 11 — Hub Reduction Unit Disassembled View

1. Shim 6. Outer Sun Gear (Rotating) 11. Housing Capscrew

lifting device and support the chassis on jack

Stationary Sun Gear Removal Figure 12 — Hub Retaining Nut

1. Wrench (J 35904) 2. Centering Ring

Planetary Gear Case Reassembly

Hub reduction units must be reassembled using a

1. Install the pinion gears and needle bearings

Use care not to lose the needle bearings when

The bearing surface of the outer sun gear must

Figure 15 — Installation Depth Measurement

2. Lubricate the shim and install it on the

If any part has been replaced, readjust the setting

Figure 16 — Staking the Retaining Nut

7. Repeat steps 1 through 6 to install the

Figure 17 — Planetary Gear Case Bolt Installation

4. Tighten the bolts to specification, 111 lb-ft

Figure 18 — Wheel Lug Nut Tightening Sequence

Figure 19 — Wheel Hub (Arrangement 1, Typical)

Refer to “HUB REDUCTION UNIT —

Wheel Hub Removal

Figure 21 — Brake Drum Removal

1. Brake Drum 3. Hub

9. Support the wheel hub with a suitable lifting