Diferencial Mack

Service Information
Mack Trucks, Inc.
MACK Dual-Reduction Tandem Carrier
Group 460-001
Release 01
GU, CHU, CXU, LEU,
MRU, TD, CMH, CMM
Foreword
The descriptions and service procedures contained in this manual are based on designs and techni-
cal studies carried out through May 2013.
The products are under continuous development. Vehicles and components produced after the
above date may therefore have different specifications and repair methods. When this is deemed to
have a significant bearing on this manual, an updated version of this manual will be issued to cover
the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a reference to an V.S.
T. (Volvo Standard Times).
Service procedures which do not include an operation number in the title are for general information
and no reference is made to an V.S.T.
Each section of this manual contains specific safety information and warnings which must be re-
viewed before performing any procedure. If a printed copy of a procedure is made, be sure to also
make a printed copy of the safety information and warnings that relate to that procedure. The follow-
ing levels of observations, cautions and warnings are used in this Service Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to have the vehicle
or component function in the manner intended.
Caution: Indicates an unsafe practice where damage to the product could occur.
Warning: Indicates an unsafe practice where personal injury or severe damage to the product could
occur.
Danger: Indicates an unsafe practice where serious personal injury or death could occur.
Mack Trucks, Inc.

Greensboro, NC USA
Order number: PV776-89092622

This Service Manual replaces Service Manual “PV776–88934877, MACK Dual-Reduction
Tandem Carrier”, (USA37177) dated (06/2010) This Service Manual replaces Service Manual
“PV776–88934877, MACK Dual-Reduction Tandem Carrier”, (USA37177) dated (06/2010)
©2013 Mack Trucks, Inc., Greensboro, NC USA
USA58010
Specifications ................................................................................................................................1
Specifications ................................................................................................................................1
Assembly Specifications ................................................................................................................3
Tools ........................................................................................................................................... 10
Special Tools.............................................................................................................................. 10
Using Adapters/Extensions with Torque Wrenches........................................................................... 10
Design and Function .................................................................................................................... 12

Differential Carrier, Function............................................................................................................. 12
Front Rear Carrier....................................................................................................................... 12
Rear Rear Carrier ....................................................................................................................... 12
Inter-Wheel Differential Lock......................................................................................................... 12
Features.................................................................................................................................... 13
Power Divider Operation .............................................................................................................. 14
Inter-Axle Power Divider .............................................................................................................. 14
Inter-Wheel Power Divider............................................................................................................ 14
Power Divider Lockout................................................................................................................. 15
Carrier Components and Operation ............................................................................................... 18
Differential Components and Operation .......................................................................................... 18
Lubrication................................................................................................................................. 19
Overhaul Recommendations ........................................................................................................ 20
Carrier Identification .................................................................................................................... 21
Power Divider Identification .......................................................................................................... 21
Carrier Component Inspection ...................................................................................................... 21
Overview ................................................................................................................................... 21
Pinion Shaft Wear Limits .............................................................................................................. 22
Gear Wear Limits ........................................................................................................................ 22
Differential Spider Wear Limits ...................................................................................................... 22
Bearings, Bushings and Thrust Washers ........................................................................................ 23
Power Divider............................................................................................................................. 23
Axle Shafts ................................................................................................................................ 24
Cleaning.................................................................................................................................... 24
Complete Assemblies.................................................................................................................. 24
Disassembled Parts .................................................................................................................... 24
Bearings.................................................................................................................................... 24
Rough Parts............................................................................................................................... 25
Drying ....................................................................................................................................... 25
Corrosion Prevention................................................................................................................... 25
Gearset Updating........................................................................................................................ 25
CRD 151 Rear Carrier ................................................................................................................. 27
Troubleshooting........................................................................................................................... 35
Carrier Troubleshooting ............................................................................................................... 35
Troubleshooting and Diagnosing Mismatched Carrier Ratios for Tandem Carriers ................................. 36
Carrier Identification Stamping ...................................................................................................... 37
Gear Set Inspection..................................................................................................................... 38
Service Procedures ...................................................................................................................... 39

Differential Carrier, Dissassemble-Assemble................................................................................... 39
Differential Removal .................................................................................................................... 39
Removing the Inter-Axle Through Shaft .......................................................................................... 44
Bevel Pinion Housing Removal (Front Rear or Rear) ........................................................................ 47
Removing the Helical or Pinion Shaft ............................................................................................. 49
Four-Pinion Type Differential......................................................................................................... 53
Inter-Wheel Power Divider Differential — Disassembly ..................................................................... 59
Inter-Axle Power Divider Cage — Disassembly................................................................................ 63
Front Rear Bevel Pinion — Disassembly ........................................................................................ 66
Rear Rear Bevel Pinion — Disassembly ......................................................................................... 71
Helical (Spur) Pinion Shaft — Disassembly ..................................................................................... 75
Power Divider Lockout — Disassembly .......................................................................................... 79
Inter-Axle Through Shaft — Disassembly........................................................................................ 87
Inter-Axle Through Shaft — Reassembly ........................................................................................ 88
Power Divider Lockout — Reassembly........................................................................................... 88
Inter-Axle Power Divider without Lockout — Reassembly .................................................................. 96
Front Rear Bevel Pinion — Reassembly ....................................................................................... 100
Setting the Bevel Pinion Preload ................................................................................................. 104
Setting the Preload.................................................................................................................... 104
Determining Bevel Pinion to Carrier Housing Shim Pack ................................................................. 107
Rear Rear Bevel Pinion — Reassembly ....................................................................................... 108
Setting Bevel Pinion Preload....................................................................................................... 112
Determining Bevel Pinion to Carrier Housing Shim Pack ................................................................. 114
Helical (Spur) Pinion Shaft — Reassembly.................................................................................... 115
Setting the Gear Patterns ........................................................................................................... 120
Bevel Pinion Installation............................................................................................................. 122
Setting the Backlash.................................................................................................................. 126
Setting Spiral Bevel Gears.......................................................................................................... 126
Four-Pinion Type Differential — Reassembly................................................................................. 127
Inter-Wheel Power Divider Differential — Reassembly .................................................................... 129
Differential Installation ............................................................................................................... 131
Bull Gear Tooth-Contact Pattern .................................................................................................. 136
Final Assembly......................................................................................................................... 138
Front Rear or Rear Rear Bevel Pinion Installation........................................................................... 140
Inter-Axle Power Divider Installation (with or without Lockout) .......................................................... 140
Inter-Axle Power Divider Without Lockout Only .............................................................................. 142
Inter-Axle Power Divider With Lockout Only .................................................................................. 142
Inter-Axle Through Shaft Installation ............................................................................................ 143
Carrier Installation Into Chassis................................................................................................... 145
Preventive Maintenance....................................................................................................................1
Magnetic Strips and Oil Troughs......................................................................................................1
Checking Oil ................................................................................................................................1
Changing Oil ................................................................................................................................2
Air Breathers................................................................................................................................3
Operation Numbers ........................................................................................................................5

Group 46
Specifications
Make MACK Trucks, Inc.
Type Dual-Reduction Carrier
Case Cast Iron
Gears Durapoid Spiral Bevel Gears, 1st Reduction
Coarse-Pitch, Wide-Faced Helical Gears, 2nd Reduction
Lubrication Splash Lubrication
Drain Plug Magnetic
Oil Capacity, Pints Carrier Bowl, each approximately 26 pints (12.3 Liters)
Bevel Gear Compartment, each 8 pints (3.8 Liters)
Inter-Axle Power Divider, 1 pint (0.5 Liter)
Note: Proper oil level is best determined by checking oil level in reference to the filler plug holes.
Recommended SAE Grade Gear Oil
• MACK® GO-J Specification 80W-90, 85W-140

• MACK® GO-J Plus Specification 75W-90 (Synthetic)
Tandem Axle Models — With Gear-type Differentials: Gearing:1st Reduction: DURAPOID Spiral Bevel
2nd Reduction: Coarse Pitch Helical
CRDPC150, CRD151 Ratios: 3.11 ,3.25 ,3.40, 3.56, 3.79, 3.98, 4.19, 4.80, 5.04,
5.31, 5.66
Tandem Axle Models — With MACK Power Divider Ratios:
Differentials:
CRDPC1501, CRD1511 3.79, 3.98, 4.19, 4.80, 5.04, 5.31, 5.66
Single Axle Models — With Gear-type Differentials: Splines, number and type:
43, Involute
CRD151
Single Axle Models — With MACK Power Divider Side Gear Splines
Differentials: 43, Involute
CRD1511
Type: Top-Mounted, Dual Reduction
1
Group 46
Dimensions and Fits (All dimensions are in inches except where otherwise stated)
Inter-Axle Power Divider: Minimum Maximum
Wedges
Wedges MUST be used in sets of 24 having length within 0.002 inch and within the length dimension, NEVER "BREAK SETS"
Cams, Male, distance across any two al- 2.808 2.814
ternate lobes
Female, distance across any two alter- 4.746 4.758
nate recesses
Air-Actuated Inter-Axle Power Divider Lockout:
Shifter Fork and Clutch, Side Clearance 0.005 0.020
Air-Shift Piston Return Spring, free — —
height 3-9/16
Test at 2-inch height 180 lb. 220 lb.
4-Pinion Closed-Type Differential:
Pinion Bore, finished I.D. (steel-on-steel) 1.256 1.259
Spider Leg, diameter 1.248 1.249
Spider-to-Pinion Bore, clearance 0.007 0.011
Pinion Thrust Washer, thickness 0.064 0.066
Side Gear Thrust Washer, thickness 0.092 0.094
Side Gear Hub and Casing, clearance 0.050 nominal
2
Group 46 Assembly Specifications
Assembly Specifications
Torque Specifications of Fasteners for CRDP150
FASTENER NAME Nm LB-FT TORQUE
Breather 24–37 18-27
Input Drive Yoke Screw (Part of Yoke 678–813 500-600 P
Arrangement)
Input Oil Seal Cover Screw 54–68 40-50
Power Divider Housing Mounting Screw 235–289 173-213 P
Plug, Power Divider Housing Fill 30–45 22-33 P
Plug, Power Divider Housing Drain 30–45 22-33 P
Bevel Gear Compartment Cover Screw 33–49 24-36 P
Output Oil Seal Cover Screw 37–45 27-33 P
Output Drive Yoke Nut (Part of Yoke 813–1220 600-900 P
Arrangement)
Power Divider Cam Nut 1763–2034 1300-1500 P
Bevel Gear Clamp Plate Screw 678–813 500-600 P
Helical Pinion Shaft Bearing Clamp Plate 407–542 300-400 P
Screw
Helical Pinion Shaft Bearing Cover 84–106 62-78 P
Screw
Bull Gear Mounting Screw 323–355 238-262 P
Differential Bearing Cap Screw 360–441 265-325 L
Plug, Carrier Housing Drain 24–37 18-27
Additional Torque Specifications of Fasteners for CRD151

Input Oil Seal Cover Screw 33–48 24-36 P
Carrier Housing Rear Cover Plate Screw 37–45 27-33 P
Bevel Pinion Housing Mounting Screw 235–289 173-213 P
Bevel Pinion Yoke Clamp Nut 1085–1356 800-1000 P
Additional Torque Specifications of Fasteners for Units with Inter-Axle Power Divider Air-Actuated Lockout
Input Oil Seal Cover Screw 42–53 31-39
Air Cylinder Housing Screw 42–53 31-39
Lockout Housing Cover Plate Screw 26–37 19-27
Lockout Fork Staking Screw 47–61 35-45 P
Lockout Housing Mounting Screw 42–53 31-39
Nut, Air Cylinder Piston 81–102 60-75 P
3
Additional Torque Specification of fasteners for Units with Differential Power Divider for CRDP1501 and CRD1511
Bull Gear Mounting Screw 323–355 238-262 P
Oil Duct Screw 11–14 8-10 P
Orientation of Power Divider Lockout shall be with the cen-

ter line of air cylinder located 30º below horizontal center
line of carrier input (8 o’clock position as viewed from front
of carrier).
Additional Torque Specifications of Fasteners for Differential Lock Mechanism.
Indicator Switch 5/6 44/56 inch lb
Fork Clamp Bolt 33/35 24/26 ft. lb P
Cover Screw 28/37 21/27 ft. lb
Bullgear mounting screws/nuts must be torqued in a dou-

ble torque method (torque all screws/nuts to an initial tor-
que*, then re-torque to the final specification) using a star
torquing pattern (either individually torqued by hand or us-
ing a multi-spindle torquing device). An acceptable alter-
nate method is to press the subassembly together*, and
torquing the screws using a 68 Nm plus 61˚ ± 3˚ (50 lb-ft
plus 61˚+/-3˚) angle method.(*To properly seat differential cas-
ings to bullgear).
SETTING
• Bevel Pinion Bearing Preload: Assemble pinion and bear-

ings in bearing housing and apply 20,000 lb. load to bearing
cones. Adjust variable spacer to produce a rolling drag on
bearings of 1-3 Nm (10-27 in-lb). W4054135
• Helical Pinion Shaft Bearing Preload: Assemble pinion

1. Wear Ring Assembly O- 4. Wear Ring Loading
shaft and bearings in bearing retainer and apply 20,000 lb.
load to bearing cones. Adjust variable spacer to produce a ring Mandrel
rolling drag on bearings of 1-3 Nm (10-27 in-lb). 2. Wear Ring Assembly 5. Differential Lock Piston
• Differential Bearing Preload: Assemble differential com- Seal Rod
pletely and install in carrier housing with bearing cap screws 3. Wear Ring Seal Pusher
finger tight. Install differential bearing adjustment fixture
(J26440) on bearing cap lugs and tighten adjusting nut to
1. Install the O-ring part into the groove on the piston
produce a rolling drag on bearings of 2-4 Nm (16-36 in-lb).
head.
Tighten bearing cap screws to specified torque and recheck
rolling drag to same specifications. 2. Using two tool pieces, loading mandrel and seal pusher,
install the wear ring part onto the outside of the O-ring in
• Differential bearing cap pedestal diameter after assembly
the groove on the piston head.
bearing cap pedestals should measure 34.298:/34.267 cm
(13.503:/13.491 in) diameter. (after bearing preload adjust- 3. Re-size the wear ring part using the sizing/assembly
ment using 13.494 +/- .001 ID ring and final bolt torquing). tool.
• Seal Installation: Input and output oil seals are to be in- 4. The sizing/assembly tool can also be used to install the
stalled squarely with respect to normal shaft center line. Seal piston (with wear ring) into the carrier main housing.
face runout to be a maximum of .010 with TIR.
• Installing the two piece Wear Ring on the Differential
Lock Piston
4
W4054136 W4054137
1. CRD 150/151 Carrier 6. Piston Spring 1. CRD 150/151 Carrier 9. Washer

Housing Housing
2. Piston Rod Wear Ring 7. Washer 2. Differential Lock Piston 10. Piston O-ring
Sizing Tool Cover
3. Ratchet Extension, 6.35 8. Piston Rod O-ring 3. Ratchet Extension, 11. Clutch Gear
mm (.25 in) 6.35 mm (.25 in)
4. Ratchet, 6.35 mm (.25 in) 9. Clutch Fork 4. Ratchet, 6.35 mm (.25 12. Piston Rod
in)
5. Wear Ring Assembly 10. Piston Rod
5. Cover Bolt 13. Clutch Fork Set Screw
• CRD150-151 Carrier Differential Lock Adjustment Proce- 6. Cover Lockwasher 14. Clutch Fork
dure: To begin the procedure, the o-ring and washer are as-
7. Cover O-ring 15. Piston Ring
sembled in the housing bore, the piston rod has the spring
and the two piece wear ring in place, the piston cover has 8. Wear Ring Assembly
the o-ring in place, the fork has the fork bolt partially in-
stalled, and a cut off axle shaft pushed through the differen- 5 A cut off axle shaft should be used to hold the sliding
tial half (with clutch teeth) into the differential side gear is clutch in position. Pushing the clutch inward against the
holding the sliding clutch and fork in place. fork and slightly rotating the cut off axle shaft, continue
1 Start the cylinder into the carrier housing bore using a pis- turning the piston rod until the teeth of the sliding clutch
ton rod wear ring sizing tool to get the ring started into the just hit the end of the teeth on the differential half.
bore. The cylinder and wear ring should have a light coat- 6 Backout the piston rod 1.5 turns. Then backout the piston
ing of gear oil. rod to align the nearest flat area (on the piston rod
2 Rotate the piston rod to assist the seal going into the bore threaded section) under the end of the partly installed fork
and to thread the piston rod into the fork. A ¼ inch ratchet bolt. The total backout of the piston rod will be between
extension can be used. 1.5 and 2.0 turns.
3 When the piston rod is in the bore roughly 5/16 inch, in- 7 Finish installing the fork bolt and torque.
stall the piston cover and torque the three screws that • Carrier with Differential Lock - Assembly into an Axle
hold the cap. Housing.
4 Using a ¼ inch ratchet extension inserted through the 1 With assembled carrier out of the axle housing, com-
hole in the cover, where the air supply fitting would be, pletely install the axle shaft (with extended splines to en-
continue rotating the piston rod to move the fork inward. gage differential lock clutch) through the differential lock
clutch and into side gear.
2 Engage the lock (moves clutch into engagement with the
differential half spline).
3 Keeping engagement, take out the axle shaft.
4 Keeping engagement, install the carrier into the axle
housing.
5
5 Install axle shafts, completely. (Can rotate shaft enough • Differential parts assembly into the helical gear.
to align studs on wheel ends and holes on axle shaft).
1. Install the differential casing (RH) into the helical gear
6 Dis-engage differential lock. using a light press.
• P.D.L.O. and Bevel Pinion Housing O-ring (new location) 2. Install the side gears, pinions, thrust washers, and
and Oil Passage Sealing Ring spider.
1 The o-ring is installed onto the housing over the 6.8765
inch diameter. Care must be taken to not damage the o- 3. Install the differential casing (LH) lockout differential
casing (LH) into the helical gear using a light press. Two
ring during assembly of the housing past the bevel pinion
bolts should be used to keep the spider locations of the
adjusting shims, into the main housing.
two differential casings aligned during this assembly. The
2 The oil passage sealing ring is installed into the carrier differential casing can cock very easily but can easily be
main housing. The shims are cut out to fit over the sealing tapped back into alignment.
ring.
4. Install and torque the Bull Gear Mounting Screws.
Note: “P” indicates prevailing torque features (example: nylon

patch, epoxy patch or scotch grip).
Note: “L” indicates Loctite No. # 262 or equivalent

(023GS17007).
Note: Pipe plugs must be sealed using 023GS17002-P

sealant.
Note: For fasteners not listed in Section 2.0, refer to

412GS218.
W4080978
1. Oil Passage Sealing Ring installed into Main

Housing
OIL CAPACITY
CARRIER INTER-AXLE POWER DIVIDER BEVEL GEAR COMPARTMENT
CRDP150, 1501 1.5 PINTS 8.0 PINTS
CRD151, 1511 8.0 PINTS
SHAFT-SPLINE
Input Shaft: Diameter Splines CRDP150 2.300”PD - 46 Teeth
CRD151 2.687”PD - 43 Teeth
Output Shaft: Diameter Splines 1.950” PD - 39 Teeth
Axle Shaft: CRD150, 1501, 151, 1511 2.150”PD - 43 Teeth
Series — Diameter Splines
Spiral Bevel Gear Set Contact Pattern

Contact pattern overlay sheets for spiral bevel gear sets.
6
W4054139
1. Drive
2. Coast
3. 20890240 Gear, 21130953 Set Dwg
4. 100% Pattern Inside Area
5. Pattern Height (Min)
6. Pinion 20898247
7
W4054140
1. Drive
2. Coast
3. 21016162 Gear, 25542859 Set Dwg
4. 100% Pattern Inside Area
5. Pattern Height (Min)
6. Pinion 21016132
8
W4054141
1 Drive
2 Coast
3 21016163 Gear, 25542860 Set Dwg
4 100% Pattern Inside Area
5 Pattern Height (Min)
6 Pinion 21016133
9
Group 46 Special Tools
Tools
Special Tools
For special tools ordering instructions, see service information in group 08.
J 26437 WRENCH, Differential Bearing Adjusting Nut

J 26440 FIXTURE, Differential Bearing Adjustment
J 8129 SCALE, Spring Tension
J 3409-D STAND, Carrier Repair
J 29327 ADAPTER, Torque Wrench for torquing nut inside carrier housing when
mounting to axle housing.
J 28506 ADAPTER, Torque Wrench Bevel Pinion Housing to Carrier Housing
J 33107 FIXTURE, Bevel Pinion Bearing Nut
J 38585 ADAPTER, Nut
J 26900-8 SET, Feeler Gauge
J 28721-906 WRENCH, 3" Socket
J 39477-1 PULLER, Bar Type
OEM 6642 WRENCH, Torque (Dial Type)
OEM 6107 MULTIPLIER, Torque
S 574 ADAPTER RING, Tapered Roller Bearing Puller
S 573 ADAPTER RING, Tapered Roller Bearing Puller
S 574D SEGMENT, Adapter Ring, Bevel Pinion Shaft, Rear
S 574E SEGMENT, Adapter Ring, Pinion Shaft, L.H.
S 573A SEGMENT, Adapter Ring, Pinion Shaft, R.H.
S 574C SEGMENT, Adapter Ring, Differential and Differential Power Divider, L.H.
and R.H.
88800293 Drift/Mandrel
88800294 Plastic Sealing Retainer
88800295 Guide
88800296 Steel Sealing Retainer
Using Adapters/Extensions with Torque Wrenches

Some screws have limited wrench clearance or are otherwise purpose.When an adapter is attached to the square drive end
difficult to access. Use Bosch special offset wrench J 29327 for of a dial-indicator type torque wrench, the dial reading (com-
this purpose. This wrench has a 1/2-inch square drive end and pared to the actual torque applied) will be affected if the lever-
a 15/16-inch wrench end. It will service CRD 150/151 series age length of the torque wrench is increased. A correction
carriers.For accurate torque readings, use a dial-indicator type factor is then needed to achieve an accurate dial reading. Ob-
rather than the click-type torque wrench. Click-type torque tain the correction factor as follows:
wrenches are accurate only when the point or pull remains at
the center of the hand grip.A dial-indicator type torque wrench Divide the total length "A" by the torque wrench length "B":
can be used accurately, with or without an extension, as long
as the force is applied anywhere along the handle or the exten-
sion. Do not use a handle extension with the click-type torque
wrench, unless it is designed and calibrated specifically for that
10
Group 46 Using Adapters/Extensions with Torque Wrenches
W4081604
Fig. 1 Dial-Indicator Type Torque Wrench with Adapter
• Total Length "A" = 24

• Total Wrench Length "B" = 12"
• A/B = 24/12 = 2 (Quotient)
Multiply the dial reading by the quotient found above to deter-

mine the torque at the end of the adapter:
• Dial Reading = 50 lbs.
• Quotient = 2
• Torque at End of Adapter = 50 x 2 = 100 lbs.
If the required torque is known, divide by the quotient to deter-

mine what the torque reading should be:
• Required Torque = 100 lbs.
• Quotient = 2
• Desired Torque Reading = 100/2 = 50 lbs.
11
Group 46 Differential Carrier, Function
Design and Function

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

Most MACK four-wheel-drive tandems are provided with a
MACK inter-axle power divider, which can be defined as a third
differential. The exclusive MACK inter-axle power divider splits
driving torque evenly or unevenly, as required between the tan-
dem axles. This power divider is fully automatic, contains no
gears and preserves traction in the toughest conditions. MACK
power dividers automatically provide a 3-to-1 torque biasing ca-
pability to the axle with the best traction.
During certain off-highway (low traction) situations, there is an

advantage to coupling the tandem carriers together in a
straight-through positive drive arrangement. An optional power
divider with lockout feature is available for this purpose. The
driver can control the power divider lockout from the cab of the
vehicle. The lockout consists of an air-actuated piston assem-
bly which controls a shift fork and gear-type sliding clutch. The
clutch is splined to the cage assembly and is moved to engage
with the outer cam of the power divider. This couples the cage
and outer cam together and effectively locks out the function of
the power divider for emergency traction situations.
Tire matching is still required on units with or without an inter-

axle power divider as mismatched tires equate to mismatched
ratios. Tire matching is required with a power divider or prema-
ture unit failure will occur.
Rear Rear Carrier

In the rear rear carrier, the main drive pinion design is borrowed by a pair of tapered roller bearings mounted in a separable
from the front carrier and is carried in an overhung arrangement housing.
Inter-Wheel Differential Lock

Optional inter-wheel differential lock with the following function/
attributes:
• Mechanical mechanism that locks both the left and right axle
shafts together
• Used for vehicle speeds below 20 mph
• To be used for vocational off-road use (only the most slippery
terrain)
• Driver controlled
Availability: Both axles of tandem, Rear rear axle of tandem.
Forward rear axle of tandem, single rear drive axle.
12
Group 46 Features
W4033819
1 Main Drive Pinion

Another important feature of both the front rear and rear carriers
is the inter-wheel or differential power divider with a command
wedge-type differential, instead of the conventional gear-type
differential. Similar to the inter-axle power divider the inter-
wheel power divider is also fully automatic, contains no gears
and provides a 3-to-1 torque biasing capability to the wheel with
the best traction.
Features
Current production dual-reduction carriers are provided with:
• Durapoid spiral bevel gears for first reduction

• Coarse-pitch, wide-faced helical gearset for second
reduction
• Four-pinion, closed-type gear differential (unless otherwise
specified)
W4031735
Dual-Reduction Carrier
1. 1st Reduction 4. Bull Gear

2. 2nd Reduction 5. Bevel Gear
3. Helical Pinion (Spur Shaft) 6. Bevel Pinion
13
Group 46 Power Divider Operation
Power Divider Operation

The power divider is a torque-proportioning differential that pre- axle or wheel loses traction (resistance) the other wheel with
vents loss of traction by directing up to 75 percent of the total good traction only receives a torque equal to the torque ca-
available torque to the axle with the best traction. By the nature pacity of the spinning wheel. Commonly this is not enough to
of its design, a conventional differential will either apply torque move the vehicle and the majority of the available torque is lost
to the axle or the wheel with the least resistance or equally dis- at the spinning wheel. When this same situation occurs with the
tribute torque if resistance is equal at all wheels. When good MACK power divider, power is automatically diverted to the
traction conditions exist, a resistance occurs at each wheel, non-spinning wheel(s) for maximum traction.
transmitting torque equally to all wheels. However, when an
Inter-Axle Power Divider

The MACK inter-axle power divider provides torque biasing be-
tween axles of the tandem rear carrier. If one axle (one or both
wheels of the axle) has limited traction, the torque applied to
each wheel of the axle is immediately multiplied by three and
transferred to the axle with more traction. Even when no trac-
tion is available at the spinning wheel, the operator can apply
the brakes slightly, creating enough resistance at that wheel to
allow power to the axle with traction.
W4031737
75% of available power is transferred to the axle with traction
1. No Traction
2. NO Applicable Power
3. Power
W4031736
Normal conditions — All wheels have traction
1. Power
Inter-Wheel Power Divider

The MACK inter-wheel power divider functions in much the
same manner as the inter-axle power divider with torque bias-
ing occurring from wheel to wheel. The inter-wheel power divid-
er may be used in conjunction with the inter-axle power divider
to provide increased manoeuvrability in poor traction situations.
14
Group 46 Power Divider Lockout
W4031738
The inter-wheel power divider replaces the conventional carrier differential
W4031739
75% of available power is transferred to the wheel with traction
1. No Traction
2. Power
Power Divider Lockout

A power divider lockout is available for exceptionally severe op- engaged, couples the cage to the outer cam to effectively lock
erating conditions, where road surfaces are so slippery that out the function of the power divider differential.
traction is difficult to achieve even with the MACK power divider.
The advantage of the power divider lockout is that tandem car-
riers can be coupled together in a straight-through positive drive
arrangement, thus enabling the operator to achieve maximum
traction under these severe conditions. For this type of opera-
tion, a lockout device, controlled from the cab by the driver, may
be incorporated with the power divider.
The lockout device inhibits the operation of the power divider. It

consists of an air-actuated, gear-type sliding clutch which, when
15
W4031740
All parts of power divider operate normally
1. Piston moves forward when air pressure exhausts

2. Fork
3. Sliding clutch disengages teeth on outer cam
W4030709
16
W4031741
1. Piston pushed rearward by air pressure

2. Fork
3. Power divider cage and outer cam turn together
4. Outer cam of power divider
5. Sliding clutch engages teeth on outer cam
The power divider and lockout are mounted in separate hous-

ings. The power divider housing also contains the hollow bevel
pinion, carried in an overhung arrangement by a pair of tapered
roller bearings and the through shaft in quill arrangement.
W4031742
Front Rear Carrier Arrangement
1. Power Divider Lockout

2. Power Divider
3. Hollow Bevel Pinion
4. Through Shaft
17
Group 46 Carrier Components and Operation
Carrier Components and Operation

Except for the differences just noted, both carriers are the mesh is achieved by varying the thickness of shim packs be-
same. The helical pinion shaft and Durapoid bevel gear are tween the pinion gear housings and the carrier housing. The
mounted at right angles to the bevel pinion shaft. Both compo- mating bevel gear must be adjusted to the proper backlash.
nents are straddle-mounted by a pair of tapered roller bearings
mounted at the gear end in the carrier housing bulkhead and at
the outer end in a separable bearing retainer. Proper bevel gear
Differential Components and Operation

The differential assembly consists of four bevel pinions in steel-
on-steel bearing engagement with the spider and two axle-driv-
ing side gears with steel-backed, ball-indented thrust washers
behind bevel pinions and side gears. Lubricant trapped in the
ball indentations forms small reservoirs which provide adequate
lubrication at these points when differential action is taking
place. These parts are enclosed in the differential casing con-
sisting of two mated halves. In addition to the bolting flange of
the RH casing half, a ring of splines around the circumference
engages mating splines on the inside diameter of the bull gear
bolting flange. When assembled, driving torque from the bull
gear is transferred from the differential casing through the
splines. This relieves the bull gear mounting bolts of all shear-
ing stresses.
The entire assembly is straddle mounted in a pair of tapered

roller bearings, one at each outer end of the casing halves. The
bearings are mounted in the carrier pedestals. Bearing preload-
ing is accomplished by a slotted adjusting nut threaded to the
inboard side of the RH bearing cup which is otherwise free to
move laterally. The LH bearing cup flange holds itself stationary
against the LH bearing pedestal chamfer.
W4030710
1 Differential lock
18
Group 46 Lubrication
Lubrication
When the vehicle is in motion, all moving parts in both tandem
carriers are constantly bathed in oil by the various pumping ac-
tions of the moving parts.
W4031749
Splash Lubrication
A pump on the rear half of the inter-axle through shaft sends oil
under pressure to the inter-axle power divider. A rolled groove
in the inner axle through the shaft carries fluid collected forward
to the Power Divider (PD) through the oil tube when the vehicle
is in forward motion. The fluid is collected from the intake port at
the rear of the oil tube. The oil tube is integral to the though
shaft bearing retainer.
W4031750
Inter-Axle Power Divider Pump Operation
19
Group 46 Overhaul Recommendations
A collector trough, integral with the bevel-gear compartment

cover, supplies the pump intake port on top of the rear bearing
retainer with lubricant collected from bevel gear throw-off. In for-
ward vehicle motion, the helical groove slinger of the pump
forces oil forward along the through shaft between the tube and
hollow-bevel pinion shaft to the internal parts of the power divid-
er. The oil returns to the banjo reservoir by the pumping action
of the parts and through drilled passages in the housings.
Another collector trough, integral with the carrier housing, di-
rects throw-off oil from the Durapoid gearset directly to the
drive-pinion tapered roller bearings through drilled and cast-in
oil passages. This oil returns to the reservoir by gravity. All other
gears and bearings are lubricated by their own pumping action
created when running in oil.
Overhaul Recommendations
Unless your shop is equipped with holding stands, a heavy-duty
hydraulic press, various gear and bearing pullers, and the
means to make your own holding devices where required, it is
highly recommended that the carriers be taken to the nearest
MACK dealer for overhauling. The following recommendations
are for shops that can handle this type of overhaul.
• Do not disturb parts with heavy press fits unless replacement

is necessary.
• Use proper press setups and/or pullers during disassembly
to avoid damaging usable parts during removal.
• Tighten all yoke or flange nuts as recommended (see Speci- W4031751
fications). If a heavy-duty air impact wrench with one-inch

drive is available, high torques should be no problem. How- Gear Jamming Tool
ever, conventional methods of tightening or relieving these
1 Approximately 0.61 m (2 ft.)
heavy torques require a way to hold the pinions to prevent
them from rotating. Unless proper precautions are taken, this 2 5.08 cm (2 in.)
can be a very dangerous operation. 3 1.27 cm (1/2 in). diameter
• Make a special tool if the gear-jamming method is to be 4 0.635 or 0.95 cm (1/4 or 3/8 in. diameter)
used. The tool is a short rod (slug), about two inches long,
and made of a 1/2-inch-diameter mild steel. Attach a handle
at one end of the slug tool by welding a rod that is two feet
long and 1/4 or 3/8 inch in diameter. One person can safely
hold this gear-jamming tool in the gear mesh while someone
else pulls the wrench. Because of the long handle, this tool
cannot be left accidentally in the bevel gear compartment
where it could cause damage.
• At reassembly, make sure the bench, tools and working
areas are clean.
20
Group 46 Carrier Identification
Carrier Identification
Before disassembly, using carrier designations, determine 1. Ratio
which type of carrier is being serviced.
2. Part number
3. Serial number
4. Carrier Identification
5. Indicates Inter-Wheel Power Divider used
Information stamped into the unit indicates features included by

the manufacturer.
W4031752
Carrier Stamping location and information
Power Divider Identification

Pay special attention to units with the initial "P" and the numeral
"1". The letter "P" in the prefix indicates that the carrier is
equipped with an inter-axle power divider. The numeral "1" after
the model number indicates that the carrier is equipped with an
inter-wheel power-divider type differential. Absence of the nu-
meral "1" indicates that a four-pinion type differential is used.
Each type of differential is covered in its own disassembly and
reassembly section. Refer only to the section covering the par-
ticular type of carrier being serviced.
W4031753
Power Divider Stamping Locations
1. Indicates Inter-Wheel Power Divider Used

2. Indicates Inter-Axle Power Divider Used
Carrier Component Inspection

Overview
It is very important to carefully and thoroughly inspect drive unit Whenever possible, use Magnaflux or similar non-destructive
parts before reassembly. Replacement of worn or damaged inspection method on all steel parts except ball and roller bear-
components will eliminate costly and avoidable drive unit ings. This method is especially suited for inspecting machined
failure. or highly finished surfaces for wear and cracks, which otherwise
21
Group 46 Pinion Shaft Wear Limits
would not be visible. It is essential to completely demagnetize

the parts before using the Magnaflux method.
Pinion Shaft Wear Limits

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

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

A slightly worn differential spider may be reused if:
• Wear does not exceed 0.127 mm (0.005 in.)

• Spider-to-pinion bore clearance does not exceed 0.178–
0.279 mm (0.007–0.011 in.)
• Wear surfaces are not scored, pitted, cracked or otherwise
damaged.
Install the spider in the opposite position. This will place the
original drive side, which experiences the most wear, on the
coast side, which has the lighter load.
22
Group 46 Bearings, Bushings and Thrust Washers
Bearings, Bushings and Thrust Washers

Check ball and roller bearings for:
• Flaking
• Cracks and fractures
• Cavities and indentations
• Staining
• Measurable Wear
• Brinelling
• Fretting
• Corrosion
• Banking
• Seizing
• Galling
• Scoring
• Arching
• Nicking
• Cage failures
Replace bearings if any of these conditions are present.
Tapered roller bearings are set up in a preload condition ac-
cording to adjustment specifications for each carrier. For reus-
able or run-in tapered bearings, adjust preload to one half the
value specified for new bearings.
If bearings pass inspection, dip them in the recommended dif-
ferential lubricant. Then wrap bearings in clean cloth or paper
until ready to reassemble the axle.
Bushings (inter-wheel power-divider driving cage) and thrust
washers must be replaced if they are pitted, scored or show
any signs of surface damage or have broken locking tabs. Do
not use tabbed thrust washers in a differential casing without
the blind hole provision. Latest versions of these differentials
are manufactured with thrust washers having tabs. Thrust
washers without tabs may be used in old casing halves having
the blind hole provision without any adverse effects.
Wear must not exceed 0.25 mm (0.010 in.) maximum. Thrust
washers must be replaced in sets. Combining old and new
thrust washers can cause premature failure.
Power Divider
The frictional forces created by loads imposed on the cams and
wedges cause moderate scoring on the highly stressed rubbing
surfaces of cam tracks. This is a normal condition. Replace the
affected cam and wedge items only if working surfaces are
badly worn, pitted, scored or cracked. Replace the driving cage
member if it is damaged or the wedge hole diameter has worn
more than 0.25 mm (0.010 in.) over the original limit.
Never run new wedges against a used inner cam or vice versa.
It is permissible, however, to use slightly worn outer cams and
driving cages during rebuild. Always replace wedges in
matched sets. Do not mix wedges from different sets.
23
Group 46 Axle Shafts
Axle Shafts
Inspect axle shafts for bends, torsional fractures or other condi-
tions that may result in failure. Inspect splines for wear, cracks
or distortion. If evidence of any of these conditions is found, in-
stall new parts.
Install each axle shaft between lathe centers. Using a dial indi-
cator, check shaft runout at the center and 152.4 mm (6 in.)
from each end. Discard shaft if total indicated runout (TIR) ex-
ceeds 1.5 mm (0.060 in.) at the center, or
0.76 mm (0.030 in.) at the end locations.
Position the dial indicator so that the indicator shaft contact
point contacts the inner surface near the outer edge. Then
check flange runout. Discard axle shaft if flange runout exceeds
0.20 mm (0.008 in.).
Cleaning
Clean parts with machined and polished surfaces (e.g., gears,
bearings and shafts) in a suitable solvent, such as kerosene or
diesel fuel.
Do not clean these parts in a hot solution tank or with water and
alkaline solutions such as sodium hydroxide, orthosilicates or
phosphates. Do not steam clean assembled drive units after
they have been removed from the housing. Steam cleaning
traps water in the cored passage of the castings and within
close clearances on and between parts. This can cause corro-
sion (rust) on critical parts of the assembly and rust particles cir-
culating in the lubricant. Steam cleaning can also lead to
premature failure of bearings, gears and other parts.
Note: Assembled drive units cannot be properly cleaned by

steam cleaning, dipping or slushing. For thorough cleaning, the
drive unit must be completely disassembled.
Complete Assemblies
Completely assembled axles may be steam cleaned on the out-
side only, to facilitate initial removal and disassembly. Breath-
ers, vented shift units, and all other openings must be tightly
covered or closed to prevent water from entering the assembly.
Disassembled Parts
Immerse all parts in suitable cleaning fluid and clean parts thor-
oughly. Use a stiff bristle brush to remove all old lubricant. Re-
move gasket particles which may adhere to mating faces of
axle housing, carrier housing, hubs and axle shaft flanges.
Clean out lubricant channels in the pinion cage and carrier
housing. Clean the housing breather. Make certain that the inte-
rior of the axle housing is thoroughly cleaned.
Bearings
The importance of proper bearing cleaning cannot be overem- 2 After old lubricant is loosened, hold bearing races so that the
phasized. Clean bearings separately from other axle parts us- bearing cannot rotate. Then brush bearings with a soft-bris-
ing the following steps: tled brush until all grit and dirt have been removed.
1 Soak differential and drive pinion bearings in clean kero- 3 Rinse bearings in clean fluid. Then, while holding races,
sene, diesel fuel oil, or other cleaning solvent. Do not use blow dry with compressed air. Be sure air stream is moisture
gasoline. free. Never spin bearings with compressed air as they may
score due to the absence of any lubricant.
24
Group 46 Rough Parts
Rough Parts
Rough parts, such as differential carrier castings, and cast
brackets may be cleaned in hot solution tanks with mild alkali
solutions, providing these parts are not machined or polished.
The parts must remain in the tank long enough to be thoroughly
cleaned and heated throughout. This will aid the evaporation of
the rinse water. After cleaning, rinse parts completely to remove
all traces of alkali.
CAUTION
Do not clean parts with highly volatile fluids such as gasoline
or harmful chemicals such as carbon tetrachloride. Also exer-
cise care to avoid skin rashes and inhalation of vapors when
using alkali cleaners.
Drying
Using moisture-free, compressed air, thoroughly dry component
parts immediately after cleaning and rinsing. If compressed air
is not available, use soft, clean, lintless absorbent paper towels
or clean wiping cloths that are free of abrasive material.
Corrosion Prevention
Parts that have been cleaned, dried and inspected and are to
be reassembled immediately must be coated with light oil to
prevent corrosion. If the parts will be stored for any length of
time, treat them with a good rust-preventive agent and wrap in
special paper or other material designed to prevent corrosion.
Gearset Updating
To assist field personnel in obtaining the desired bevel gearset
tooth contact, all service replacement bevel gear matched sets
are furnished with the desired tooth contact pattern indicated on
the gear teeth in yellow gear-marking compound.
Before proceeding with the installation of the replacement bevel
gearset, lift and transfer the tooth contact pattern onto a piece
of paper for reference when "setting up" the replacement gear-
set in the carrier. Use transparent tape (Scotch® brand or
equivalent) to make a transfer of the contact pattern.
Cut off a piece of tape slightly longer than the gear tooth. Place
the piece of tape on the gear tooth profile, sticky side down,
covering the total tooth length and depth. Rub the back of the
tape to ensure good contact between the tape and tooth. Do
not permit the tape to slide. Gently lift the tape off the gear tooth W4031754
and apply it to a piece of paper to transfer the tooth contact

pattern. Lifting Tooth Contact Pattern
Repeat the procedure on the opposite side of the gear tooth
and identify the tooth patterns as drive side and coast side. If
no tape is available, make a sketch of the patterns.
25
Group 46 Gearset Updating
W4080979
Reassembly Flow Chart
26
Group 46 CRD 151 Rear Carrier
CRD 151 Rear Carrier
W4034817
CRD 151 Bevel Pinion Shaft Assembly
W4049396
1. Clamp plate 6. Bearing cup 11. Bearing cone

2. Yoke 7. Bevel pinion 12. Oil passage seal-
housing and ing ring
bolts
3. Slinger 8. Bevel pinion 13. Shim
housing o-ring
4. Seal 9. Spacer 14. Bevel pinion gear
5. Bearing cone 10. Bearing cup 15. Side cover
27
CRD 150 Bevel Pinion and Inter-Axle Power Divider Assem-
Group 46
bly (without Air Actuated Control)
CRD 150 Bevel Pinion and Inter-Axle Power Divider Assembly (without Air
Actuated Control)
W4081367
1. Bolt 13. Inner Ring 26. Through Shaft

Housing
2. Clamp Plate 14. Outer Ring 27. Housing
3. Yoke 15. Inner Cam 28. Bolt
4. Bolt 16. Nut 29. Lock Washer
5. Lock Washer 17. Outer Cam 30. Shim
6a. Seal 18. Cone 31. Thrust Washer
6b. Retainer 19. Cup 32. Spacer
7. Gasket 20. Gasket 33. Cup and cone
8. Bearing 21. Seal 34. Bevel Pinion
9. Bearing 22. Seal Retainer 35. Carrier
Retainer Housing
10. Gasket 23. Gasket 36. Bolt
11. Cage 24. Bearing
12. Wedge 25. Through Shaft
28
Group 46 CRD 150 Air Actuated Power Divider Lockout
CRD 150 Air Actuated Power Divider Lockout
W4049398
1. Gasket 14. Housing 27. Bolt

2. Cover 15. Lock Washer 28. Shaft
3. Lock Washer 16. Bolt 29. Spring
4. Bolt 17. Bearing 30. Sleeve
5. Bolt 18. Yoke Spacer 31. Spacer
6. Fork 19. O-ring 32. Felt
7. Clutch 20. Gasket 33. O-ring
8. Inner Cam 21. Cover 34. Piston
9. Outer Ring 22. Lock Washer 35. Nut
10. Inner Ring 23. Bolt 36. Bolt
11. Wedge 24. Oil Seal 37. Lock Washer
12. Cage 25. Yoke 38. Housing
13. Gasket 26. Clamp Plate 39. Gasket
29
Group 46 CRD 150/151 Helical (Spur) Pinion Shaft
CRD 150/151 Helical (Spur) Pinion Shaft
W4030714
1. Bolt 12. Helical Pinion Shaft

2. Cover and gasket 13. Bearing & Race
3. Bolt 14. Bevel gear
4. Clamp plate 15. Key
5. Bearing & Race 16. Clamp plate
6. Helical pinion housing 17. Bolt
7. Pin 18. O-ring
8. Shims 19. Side cover
9. O-ring 20. Plug
10. Spacer 21. Bolt
11. Transverse torque rod
bracket
30
Group 46 CRD 150/151 Four Pinion Type Differential Assembly
CRD 150/151 Four Pinion Type Differential Assembly
W4049399
1. Bearing Cup 11. Bearing Cup

2. Adjusting Nut 12. Bearing Cone
3. Bearing Cone 13. Bolt
4. Bull Gear 14. Side Gear
5. Side Gear Thrust Washer 15. Spider
6. Side Gear 16. Bearing Cap Bolt
7. Pinion (Spider Gear) 17. Bearing Caps
8. Pinion Thrust Washer 18. Differential Half
9. Side Gear Thrust Washer 19. Cotter Pin and Adjusting
Nut Lock Pin
10. Differential Half
31
Group 46 CRD 150/151 Inter-Wheel Power Divider Assembly
CRD 150/151 Inter-Wheel Power Divider Assembly
W4031770
1. Inner Cam 8. Cup

2. Retaining Ring 9. Bolt
3. Bushing 10. Outer Cam
4. Wedge 11. Bull Gear
5. Driving Cage 12. Side Casing
6. Cone 13. Cone
7. Adjusting Nut 14. Cup
32
Group 46 Differential Lock Assembly
Differential Lock Assembly
W4031137
W4031696
W4031697
W4031698
1. Clutch Gear, 6. Spring 11. Lock Washer

Differential Lock
2. Clutch Fork, Dif- 7. Flat Washer 12. Bolt, Differen-
ferential Lock tial Lock Cover
3. Clutch Fork, Dif- 8. O-ring, Piston 13. Switch, Back
ferential Lock Shaft up
4. Set Screw, 12 9. Cover, Differen-
point tial Lock Piston
5. Wear Ring, Pis- 10. O-ring, Differ-
ton Rod ential Lock Cover
33
Group 46 Differential Lock Assembly
W4034818
1. Differential Lock
34
Group 46 Carrier Troubleshooting
Troubleshooting
Carrier Troubleshooting
The troubleshooting chart summarizes some common carrier
complaints, probable causes and possible remedies.
Symptom Probable Cause Remedy

Noise 1. Low lubrication level. 1. Fill to proper level using recommended lubricant.
2. Improper lubrication. 2. Drain and refill with recommended lubricant to proper level.
3. Contamination of lubricant. 3. Check servicing intervals. Check for oil contaminated with
water. Drain and refill to proper level with recommended
lubricant.
4. Driveline phasing. 4. Correct phasing.
5. Driveline angle. 5. Correct 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 10. Adjust by adding or removing shims to establish proper
mesh. tooth contact.
11. Mixed gear ratios. 11. Check ratios, both carriers must have same ratio.
Oil Leakage 1. Clogged breather. 1. Replace breather.
2. Failed seals or gaskets. 2. Replace failed seals or gaskets.
3. Cracked housing. 3. Replace housing.
Bearing Failure 1. Improper lubrication. 1. Check specification for proper lubrication, replace failed
bearing.
2. Worn, damaged or failed yoke. 2. Repair using speedi-sleeve on shaft or replace failed parts.
3. Wrong preload on bearings. 3. Replace failed parts and adjust preload to specification.
4. Pump failure. 4. Repair or replace failed parts.
5. Misaligned gears. 5. Replace failed parts, make certain gears are properly
aligned and check tooth contact pattern.
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 nut. 5. Tighten nut to recommended torque.
6. Worn or failed bearings. 6. Replace bearings.
7. Mixed gear ratios. 7. Check ratios, both carriers must have same ratio.
35
Troubleshooting and Diagnosing Mismatched Carrier Ratios
Group 46
for Tandem Carriers
Symptom Probable Cause Remedy

Gear Failure 1. Low lubrication. 1. Fill to proper level using recommended lubricant.
2. Improper lubrication. 2. Check Maintenance and Lubrication Manual (TS494) for
proper lubrication.
3. Contamination of lubricant. 3. Check servicing intervals, check for oil contaminated with
water. Replace failed parts and fill to proper level using recom-
mended lubricant.
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 nuts. 6. Replace failed parts. Torque nuts to proper torque.
7. Improper ratio for application 7. Recalculate drive train ratios. Replace as required.
8. Improper tooth contact, gear 8. Replace failed parts. Make certain tooth contact pattern is
mesh. 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 nuts. 3. Replace damaged parts. Tighten nuts to proper torque.
4. Loose drive pinion nut. 4. Repair failed parts. Torque to specification.
5. Collector trough missing. 5. Repair, make certain front rear axle carrier cover has collec-
tor trough.
6. Pump failure. 6. Repair or replace as required.
7. Worn wedges and cams. 7. Replace.
8. Mixed gear ratios. 8. Check ratios; both carriers must have same ratio.
9. Air leak or restricted line. 9. Repair or replace as required.
10. Seal failure. 10. Replace failed seal.
11. Faulty control valve. 11. Replace.
12. Failed spring. 12. Replace.
13. Seized components. 13. Disassemble and investigate.
14. Failed shifter fork. 14. Replace.
Excessive Tire Scuffing 1. Mixed gear ratios. 1. Check ratios, both carriers must have same ratio.
or Wear
Troubleshooting and Diagnosing Mismatched Carrier Ratios for Tandem

Carriers
Check the tandem carrier for mismatched carrier ratios if any
of the following conditions occur:
• Tire scuffing or wear

• Noise in the power divider or shortened power divider life
• Noise in the transmission in various gears
Mismatched carrier ratios can transmit noise through the drive

line and transmission.
36
Group 46 Carrier Identification Stamping
Carrier Identification Stamping

If mismatched carrier ratios are suspected, check the carrier
identification stampings for matched ratios.
W4031771
Fig. 2 Carrier Ratio Stamping Location

1. Ratio
If mismatched carrier ratios are suspected, check the carrier

identification stampings for matched ratios.
If the stampings are compatible and mismatched ratios are still

suspected, mark the tandem axle tires with a piece of chalk so
that one complete wheel rotation can be monitored when the
chassis is moved across the floor. Also, mark the propeller
shaft and intermediate shaft yoke in reference to the pinion,
carrier or power divider housing.
CAUTION
Make sure the eight tandem rear tires are properly matched.
Refer to MACK Service Manual 15-101 Wheels, Rims and
Tires.
1
With an operator in the cab and the transmission in neutral, re-
lease the spring brakes. Make sure there is sufficient room to
push the chassis forward one complete wheel rotation.
2
Push the chassis forward and count the number of shaft rota-
tions during one complete wheel rotation. For example, with a
5.31 carrier ratio, the driveshaft will rotate 5 times to one tire ro-
tation.If a variation exists between tire revolution and/or drive-
line rotation between front rear and rear rear carriers, a physical
inspection of each gear set must be made.
37
Group 46 Gear Set Inspection
Gear Set Inspection

Drain the upper gear case. Remove the bevel gear compart-
ment side access cover. Count the teeth of the bevel gear set
(1) in each carrier.
W4031772
Dual Reduction Carrier Gear Train
If the bevel gear sets are compatible, drain the tandem axle
housing and remove the carrier assemblies. Count the teeth of
each helical pinion shaft and bull gear (2).Example: Correct all
mismatched gear sets.
1. Bevel gear — 23 teeth

2. Bevel pinion — 15 teeth
3. 23/15 = 1.53
4. Helical bull gear — 45 feet
5. Helical pinion gear — 13 teeth
6. 45/13 = 3.46
7. 1.53 x 3.46 = 5.31 Ratio
Correct all mismatched gear sets.
38
Group 46 Differential Carrier, Dissassemble-Assemble Differential Removal
Service Procedures
4651-04-11-01
Differential Carrier, Dissassemble-Assemble
You must read and understand the precautions and guide-
lines in Service Information, groups 40 and 70, "General
Safety Practices" before performing this procedure. If you are
not properly trained and certified in this procedure, ask your
supervisor for training before you perform it.
Differential Removal
Note: Set all major components on a clean work surface for lat-
er disassembly.
Note: This procedure is also used when removing the inter-

wheel power divider or the four-pinion type differential.
1
Remove the 5th wheel.
W4034628
1. Hidden Mounting Bolts
2
Remove driveshaft (s).
3
Remove torque rods and bracket.
4
If equipped, disconnect Power Divider Lock Out (PDLO) air line.
5
Remove the bevel gear compartment cover and both of the in-
side carrier mounting bolts.
6
Remove the remaining 14 bolts and washers retaining the car-
rier housing to the axle housing.
7
Remove the carrier from the vehicle. Note this may require re-
moval of the entire axle housing to access the carrier.
39
8
Set the carrier in an approved carrier repair stand such as J
3409-D.
J 3409–D
W4032183
9
Secure the carrier to the stand with a minimum of four bolts and
tighten securely.
10
Rotate stand holding the carrier housing so the differential as-
sembly is on top.
40
11
Remove the cotter pin and the straight pin in the adjustable dif-
ferential bearing cap.
W4032184
1. Cotter Pin
2. Straight Pin
W4032185
1. Straight Pin
41
12
Punch-mark bearing caps and their mating pedestals to ensure
reassembly in their original positions.
W4032186
W4032187
13
Using differential bearing-nut adjusting wrench J 26437, loosen
the bearing adjusting nut approximately one turn.
Note: Bearing retainer caps and the carrier housing are ma-
chined as a set. Therefore, when bearing retainer caps are lost
or broken, the carrier housing and bearing retainer caps must
be replaced as a set.
J 26437
W4032188
42
14
Remove the bearing retainer bolts.
W4032189
15
Remove the bearing retainer caps. Be very careful not to lose
them.
W4032190
16
Using a hoist and appropriate lifting tool to remove the differen-
tial/bull gear assembly.
W4032191
1. Appropriate Lifting Tool
43
Group 46 Differential Carrier, Dissassemble-Assemble Removing the Inter-Axle Through Shaft
Removing the Inter-Axle Through Shaft

1
Remove the bolts from the inter-axle through-shaft rear bearing
cover.
W4032192
2
Remove the cover and gasket from the through-shaft rear bear-
ing cover.
W4033408
1 Cap
2 Gasket
3
Pull out the inter-axle through shaft and the inter-axle through-
shaft bearing together.
Note: The non-current axle through shaft was constructed of a
driveshaft combined with a spring to form the oil groove on the
through shaft. The current axle through shaft is constructed with
a formed, rolled oil groove on the shaft. The two versions are
interchangeable.
W4032194
44
4
Install two 3/8 jack screws into the threaded holes in the
through-shaft housing.
W4032195
5
Back out the bearing retainer by alternately turning the jack-
screws. Alternate, even turning of the jackscrews is essential to
prevent the retainer from binding or becoming cocked in the
bore.
Note: Before removal, note the position of the inter-axle
through-shaft retainer oil trough so that it can be reinstalled in
the proper position.
W4032196
1. Jackscrews
W4032197
1. Oil Trough
45
6
Remove the gasket from the inter-axle through-shaft retainer
cap that mounts to the housing surface.
CAUTION
Removing the gasket may require using a gasket scraper.
Use caution to prevent damage to the mating surface.
W4032198
7
Remove the front power-divider lockout-assembly bevel pinion
assembly (if equipped).
WARNING
If removing the inter-axle power divider as a unit, be ex-
tremely careful. It is very heavy. Get help or secure it to a
hoist to prevent it from falling and causing personal injury.
W4032199
46
Group 46 Differential Carrier, Dissassemble-Assemble Bevel Pinion Housing Removal (Front Rear or Rear)
Bevel Pinion Housing Removal (Front Rear or Rear)

Note: This section shows the removal of the front bevel pinion.
At the front of the bevel pinion is the Inter-Axle Power Divider
(IAPD). Because the IAPD with bevel pinion units are very
heavy, you may want to remove the cage assembly first.
1
Remove the bolts that retain the front rear or rear rear bevel
housing to the carrier housing.
W4032200
2
Install alignment dowels in bolt holes at the two-o'clock and ten-
o'clock positions to support bevel housing during removal. This
is necessary to prevent damage to the shim packs.
Note: Alignment dowels can be manufactured on site from bolts
obtained locally. Dowels should be about
63.6 mm (2.5 in.) long and with 13 mm (0.5 in.) threads.
W4032201
Fig. 3 Making Alignment Dowels
W4032202
1. Aligning Dowels
47
Group 46 Differential Carrier, Dissassemble-Assemble Bevel Pinion Housing Removal (Front Rear or Rear)
3
Loosen bevel housing by tapping with a deadblow hammer and
then turning slightly. Using jack bolts, back assembly out on
alignment pins and remove from carrier. Wire shims together
and tag for reuse at assembly. Using a micrometer, measure
the shim pack for reassembly purposes.
W4031122
W4030932
1. Shim Pack
2. Aligning Dowel
48
Group 46 Differential Carrier, Dissassemble-Assemble Removing the Helical or Pinion Shaft
Removing the Helical or Pinion Shaft

1
Remove the four bolts retaining the helical pinion-shaft assem-
bly cover.
W4032203
2
Remove the pinion cover and separate the gasket from the cov-
er. It may be necessary to use a gasket scraper to remove some
gaskets from the cover.
Note: A steel-core gasket coated on both sides with foam rub-
ber has replaced Silastic sealer which was applied to the pinion
shaft cover. Make sure a new steel-core gasket is available for
reassembly to eliminate oil leakage in this area.
W4034630
1. Gasket
2. Cover
49
3
Remove the clamp plate bolts and the clamp plate. Replace the
clamp plate bolts with new grade 8 bolts at final reassembly.
Note: Be sure to have new bolts on hand for final reassembly.
Note: The clamp-plate side stamped "OUT" faces outward. This

ensures that the clamping force is evenly distributed upon
installation.
W4034631
W4034632
4
Set up a gear puller to push the helical pinion-shaft assembly in-
to the carrier housing. This action will release the helical pinion
from the outer bearing cone. Be prepared for the weight of the
helical pinion assembly.
W4032204
50
5
Remove the bearing cone from the outboard side.
W4034633
6
Remove the pinion shaft assembly.
W4032206
7
Using two jackscrews, remove the helical pinion-shaft bearing
retainer.
W4032207
51
8
Remove the bearing retainer and shim pack. Remove shims,
and wire together. Using a micrometer, measure the shim pack.
Tag for reuse at reassembly.
W4032208
52
Group 46 Differential Carrier, Dissassemble-Assemble Four-Pinion Type Differential
Four-Pinion Type Differential

Before starting to disassemble the bull gear/differential compo-
nents, mark the position of each differential half/side casing in
relation to the bull gear. These components are line-reamed
and turned together. Therefore, it is essential to reassemble
them in the same position.
1
Clamp the bull gear/differential assembly in a suitable vise.
Loosen the bolts that secure the side casings to the bull gear.
W4031773
Fig. 4 Bull Gear/Differential Bolts Loosened
2
During disassembly, mark the bull gear relationship to the cas-
ing. Mark both sides of the bull gear for reassembly purposes.
W4031825
1. Bull Gear Mark

2. Casing Mark
53
3
Remove the bull gear from the differential side-casing splined
half. Do this by tapping around the bull gear with a deadblow
hammer, or by forcing the components apart with a piece of
brass bar stock and a machinist's hammer.
W4031826
Fig. 5 Using Deadblow Hammer to Separate Differential

Half
W4058493
Fig. 6 Separating Bull Gear from Side Casing — Alternate

Method
54
4
Remove the differential half.
W4031835
5
Remove the side-gear thrust washer.
W4031842
55
6
Remove the side gear.
W4031846
Fig. 7 Removing Side Gear
W4058492
Fig. 8 Side Gear Removed
56
7
Remove the spider gear assembly. This assembly includes the
spider, the four pinion (spider) gears and the four pinion (spider)
gear thrust washers.
W4031848
Fig. 9 Spider Gear Assembly
W4058491
Fig. 10 Differential with Spider Gear Assembly Removed
1
When the spider gears are removed, the other side gear is visi-
ble. Remove the remaining side gear and thrust washer.
W4031850
57
2
If inspection reveals the need to do so, replace the bearings on
the differential halves using a hydraulic press and the appropri-
ate segment and adapter rings. Press the bearings off the side
casings.
CAUTION
Exercise extreme caution during the pressing operation, even
when using specified tools. The bearing cone may fly apart
during removal. Use a scatter shield and be sure to have a
new bearing cone ready for installation.
Note: Note the timing marks on the bull gear and the splined dif-
ferential half.
W4031856
Fig. 11 Removing Bearing Cone from Side Casing
W4058490
Fig. 12 Bull Gear Timing Marks
3
The two timing marks on the bull gear (twelve o'clock) must fall
on each side of the single timing mark on the differential half
(twelve o'clock).
58
Group 46 Differential Carrier, Dissassemble-Assemble Inter-Wheel Power Divider Differential — Disassembly
Inter-Wheel Power Divider Differential — Disassembly

1
Remove the bolts from the splined side of the inter-wheel power
divider. It may be helpful to support the assembly in a vise.
W4031868
2
Mark both sides of the unsplined differential half and the bull
gear for proper reassembly.
3
Remove the unsplined differential half.
W4031875
4
Remove the outer cam.
W4031876
59
5
Remove the inner cam.
W4031878
6
Remove outer retaining ring.
W4031879
7
Remove the wedges.
8
Using a suitable hydraulic press, press out the splined inner half
of the power divider from the bull gear.
W4031880
1. Press
2. Plate
9
Remove the oil-trough bolts.
W4031881
10
Remove oil trough.
W4031882
11
Remove inner wedge retaining ring.
W4031883
12
If inspection reveals that the power-divider driving cage bushing
must be replaced, remove the bushing.
61
13
If inspection reveals the need to do so, replace the bearings on
the inner wheel power-divider driving cage and side casing us-
ing a hydraulic press and the appropriate segment and adapter
rings. Press the bearing off the inner wheel power-divider driv-
ing cage.
CAUTION
W4031884
Fig. 13 Removing Bearing Cone from Driving Cage
W4058489
Fig. 14 Removing Bearing Cone from Side Casing
62
Group 46 Differential Carrier, Dissassemble-Assemble Inter-Axle Power Divider Cage — Disassembly
Inter-Axle Power Divider Cage — Disassembly

1
Remove the bolts from the inter-axle power-divider cover plate.
W4031886
2
With the cover plate removed, insert two 7/16-14 jackscrews to
separate the bearing, housing, cage and wedge assembly from
the bevel pinion housing.
W4058163
1. Jack Screw
3
Remove the inner cam, cage and wedge assemblies as a unit.
W4031888
1. Inner Cam
2. Cage
63
4
Remove the O-ring from the bearing retainer groove of the cage
and wedge assembly.
W4031889
1. O-Ring
5
To replace the wedges, the retaining ring must first be removed.
Push all upper wedges in as far as possible. Then remove re-
taining ring with expansion pliers.
Note: Before removing the wedges, note the alpha character
(an arrow on early production carriers) on the part of the wedges
pointing outward. Reinstall the wedges with the alpha character
or arrow pointing outward.
W4031890
1. Outer Retaining Ring
6
Remove the wedges by pulling straight out with finger pressure.
W4031891
Fig. 15 Arrow on Wedges (May Also Be an Alpha

Character)
64
7
The inner ring can now be removed easily. Use two screw-
drivers to compress the retaining ring until the ends overlap to
allow removal.
WARNING
Be careful when removing the inner ring. It may be sharp and
can cause serious personal injury.
W4031892
8
Use a hydraulic press to separate the cage from the bearing re-
tainer cover. Support the bearing inner race. Do not apply force
through the bearings.
9
Remove the O-ring from the cover plate.
W4031893
1. O-Ring
10
Remove seal from cover plate using a suitable driver.
W4031894
1. Driver
Group 46 Differential Carrier, Dissassemble-Assemble Front Rear Bevel Pinion — Disassembly
Front Rear Bevel Pinion — Disassembly

1
Using a torque multiplier (OEM 6107) or equivalent and socket
(J 28721-906) or equivalent, loosen and remove the retaining
nut on the front bevel pinion. Bosch tool J 33107 is recom-
mended for holding the outer cam.
OEM 6107, J 28721-906, J 33107
W4031895
1. Socket, 76.2 mm (3.0 in)

2. J33107
2
Install the holding fixture in a press stand or other stand capable
of holding the fixture secure against the 1762 to 2034 Nm
(1,300 to 1,500 lb-ft ) of torque necessary to release the retain-
ing nut.
J331071762 to 2034 Nm (1,300 to 1,500 lb-ft )
W4031896
3
Install the socket in the holding fixture.
J28721–906
W4031897
66
4
Using a torque multiplier and a press stand or other suitable
method, hold the fixture in the power-divider lockout housing
and remove the retaining nut.
W4031898
Fig. 16 Using Torque Multiplier to Loosen Nut

1. Torque Multiplier OEM 6107
2. Ratchet Handle
W4031900
Fig. 17 Retaining Nut Removed

1. Retaining Nut
67
5
Using a hydraulic press, separate the bevel pinion shaft and
gear from the bevel housing. Also remove outer cam from bevel
housing.
W4031899
1. Suitable Press
2. Press Extension
6
Using a drift and hammer, remove the inner bearing cup in the
housing.
W4032048
1. Bearing Race
7
Turn the housing over. Then use a drift and hammer to remove
the outer bearing cup.
W4032049
1. Bearing Race
8
If the bearings on the bevel pinion must be replaced, remove
them using a hydraulic press and the appropriate segment and
adapter rings. Press the bearing off the front bevel pinion.
CAUTION
W4032071
Fig. 18 Pressing Bearing Off Bevel Pinion
W4058488
Fig. 19 Pressing Bearing Off Outer Cam
69
9
Note and record the numerals stamped into the pinion. They
represent the mating number (U337) and the mounting distance
105 mm (4.135 in.).
Note: The actual mating number and mounting distance num-
ber will probably differ from U337 and
105 mm (4.135 in.) which are used here as examples.
The mating numbers on the bevel pinion and the bevel gear will
always be the same. These components must always be re-
placed as a set.The mounting distance represents the distance
from the backface of the head of the bevel pinion to the center
line of the bevel gear. This number helps in determining how
many shims must be installed to get the proper gear pattern.
W4032073
Fig. 20 Mating Number and Mounting Distance Number

1. Mating Number
2. Gear Mounting Distance
3. Pinion Mounting Distance
W4032074
1. Bevel Pinion Head

2. Bevel Pinion Housing
3. Mounting Distance
4. Centerline of Bevel Gear
70
Group 46 Differential Carrier, Dissassemble-Assemble Rear Rear Bevel Pinion — Disassembly
Rear Rear Bevel Pinion — Disassembly

1
Remove the bolts from the rear bevel pinion bearing retainer
cover and remove the cover.
Remove clamp plate nut.
Remove yoke.
W4034828
W4034073
W4034075
71
2
Press out pinion.
W4049400
1. Press
2. Press Extension
3. Bevel Pinion
W4049401
1. Bevel Pinion Gear

2. Rear Rear Bevel Pinion Housing
72
3
Remove outer bearing cup and seal.
W4034077
4
Remove the inner bearing cup.
W4034076
5
Remove the spacer from the bevel pinion shaft.
73
6
Remove bearing cone from pinion.
W4034078
W4030832
W4058484
1. Mating Number
74
Group 46 Differential Carrier, Dissassemble-Assemble Helical (Spur) Pinion Shaft — Disassembly
7
Note and record the numerals stamped into the pinion. These
numerals represent the mating number (A13) and the mounting
distance 124 mm (4.875 in.).
Note: The actual mating number and mounting distance num-
ber will probably differ from A13 and 124 mm (4.875 in.), which
are used here as examples.
The mating numbers on the bevel pinion and the bevel gear will
always be the same. These components must always be re-
placed as a set. The mounting distance represents the distance
from the backface of the head of the bevel pinion to the center
line of the bevel gear. This number helps in determining how
many shims must be installed to get the proper gear pattern.
W4058487

Helical (Spur) Pinion Shaft — Disassembly

1
Secure the helical pinion shaft assembly. Remove and discard
the bolt that retains the inboard clamp plate. Replace with new
grade 8 nuts at reassembly.
Note: Be sure to have replacement bolts for final reassembly.
W4030833
75
2
Remove the clamp plate.
W4034618
3
Place the pinion shaft into a hydraulic press. Press the helical
pinion shaft from the helical gear.
W4032078
1. Press
2. Press Extension
3. Bevel Gear
4
Remove the key from the helical pinion shaft using a pin punch
and hammer. Helical pinion shaft key use depends on ratio.
W4032080
5
Press out the helical shaft from the bearing using the bearing
cup for support or suitable puller. This action applies pressing
force through the bearing rollers.
CAUTION
Note: Be sure a replacement bearing is available for final

reassembly.
W4032081
1. Helical Pinion
2. Press
3. Press Extension
4. Bearing
6
Using a hammer and drift, remove the helical-pinion retainer
bearing outer cup.
W4032083
77
7
Remove the O-ring from the retainer.
W4032084
8
Using a hammer and drift, remove the remaining helical pinion
bearing cup from the carrier housing.
W4032085
78
Group 46 Differential Carrier, Dissassemble-Assemble Power Divider Lockout — Disassembly
Power Divider Lockout — Disassembly

WARNING
Be very careful when removing the power-divider lockout cyl-
inder housing from the unit. It is spring loaded and the spring
can release if the nut on the inside is broken or stripped, or
the shaft is broken.
1
Remove the bolts retaining the cylinder housing onto the power-
divider lockout housing.
W4032086
2
Remove the cylinder housing.
W4032087
3
Remove the nut and washer that hold the piston and spring in
place.
WARNING
Be careful when removing the nut that holds the piston and
spring. The piston or spring can suddenly release, causing
serious personal injury.
79
4
Remove the piston from the shaft by sliding it straight off.
W4032088
5
Remove the piston return spring.
W4032089
6
Remove the spacer and remaining washer from the piston
shaft.
W4032090
1. Spacer
80
7
The graphic shows the components and assembly order that
complete the piston and spring assembly. Ensure all of these
components are present. Set them aside for reuse if all are in
good condition.
W4032091
1. Spacer
2. Spring
3. Washer
4. Piston
5. Locknut
8
Remove the air cylinder gasket.
W4032092
1. Gasket
81
9
Remove the cover plate bolts from the power divider lockout
housing.
W4032093
10
Remove the cover plate.
W4032094
11
Remove the cover plate gasket (or Silastic sealer if applicable).
Make sure the surface of the cover plate is clean.
W4032095
1. Gasket
82
12
Remove the locking bolt from the shaft and fork.
W4032096
13
Remove the shift fork shaft.
W4032097
14
Remove the nuts from the bearing retainer cover.
W4032098
83
15
Remove the bearing retainer cover.
W4032099
16
Remove the bearing retainer cover O-ring.
W4033420
17
Using a hammer and driver, remove the seal from the bearing
retainer.
W4032101
84
18
Using a hydraulic press, separate the shaft and cage assembly
from the power divider clutch.
CAUTION
During the pressing procedure, take special care to avoid
binding the fork, which can cause the fork to break.
19
Remove the fork and clutch from the power-divider lockout
housing.
W4032102
1. Power Divider Cage

2. Shift Fork
3. Clutch
20
Using a drift and hammer, remove the ball bearing from the
housing. Apply force only to the outer race of the bearing.
W4032103
1. Brass Drift
2. Bearing Outer Race
85
21
Press all the wedges into the cage as far as possible. Then re-
move the outer retaining ring from the shaft and cage assembly.
Note: Before removing the wedges, note the alpha character
(or arrow on early production carriers) on the part of the wedges
pointing outward. The wedges must be reinstalled with the al-
pha character or arrow pointing outward.
W4032104
22
Remove the wedges from the cage.
W4032106
23
Locate the inner ring in the cage.
W4032107
1. Inner Ring
86
Group 46 Differential Carrier, Dissassemble-Assemble Inter-Axle Through Shaft — Disassembly
24
Using two screwdrivers, compress the inner retaining ring until
the ends overlap to allow removal. Remove the inner ring.
WARNING
Be careful when removing the inner ring. It may be sharp and
can cause serious personal injury.
W4032137
1. Inner Ring
Inter-Axle Through Shaft — Disassembly
W4032138
If the through-shaft bearing must be replaced, remove the

bearing using a suitable hydraulic press arrangement.
87
Group 46 Differential Carrier, Dissassemble-Assemble Inter-Axle Through Shaft — Reassembly
Inter-Axle Through Shaft — Reassembly

Note: The reassembly procedures in the first part of this section
for Inter-axle Through-shaft, Inter-axle Power Divider with/with-
out Lockout and Front Rear Bevel Pinion will only be encoun-
tered on vehicles with a tandem rear axle.
Install the through-shaft bearing using a suitable hydraulic

press arrangement and driver.
WARNING
Ensure that the hydraulic press support blocks are on the
flats of the shaft and not on the taper of the shaft. This pre-
vents the blocks from shifting as hydraulic pressure is
applied.
W4032139
1. Press Extension
2. Bearing
Power Divider Lockout — Reassembly

1
Position a new seal on the power-divider bearing retainer cover.
W4032140
88
Group 46 Differential Carrier, Dissassemble-Assemble Power Divider Lockout — Reassembly
2
Install the seal into the bearing retainer cover using seal driver
and a hammer.
W4032141
1. Driver
2. Cover
3
Install the power-divider wedge inner ring into the cage.
WARNING
Be careful when inserting the inner ring, because it may be
sharp.
W4032137
Fig. 21 Installing Inner Ring

1. Inner Ring
W4032107
Fig. 22 Inner Ring Installed

1. Inner Ring
89
4
Install a matched set of 24 wedges from inside the cage, making
sure the alpha character (or arrow on early production carriers)
is pointing outward. The alpha character or arrow must be visi-
ble on each wedge from outside of the cage.
Note: The wedges must be reinstalled with the alpha character
or arrow pointing outward as shown in the illustration.
W4032106
5
Push all the wedges in as far as possible and install the outer
retaining ring into the slot provided in the cage.
W4032104
6
Drive the bearing assembly into the retainer of the inter-axle
power-divider shifter housing.
Note: Apply driving force only on the bearing outer race during
bearing installation.
W4032143
1. Bearing Race
2. Bearing Driver
90
7
Insert the fork and clutch into the housing. Do this by installing
the fork into the clutch groove and then angling them as a unit
into position. Make sure that the flat side of the fork faces the
clutching teeth.
W4032144
1. Flat side toward clutching teeth
8
Insert the shaft and cage assembly into the sliding clutch.
9
Using a suitable hydraulic press, press the power divider cage
into the bearing.
CAUTION
During the pressing procedure, take special care to avoid
binding the fork, which can cause the fork to break.
W4032145
1. Press
2. Press Extension
3. Power Divider Cage
4. Press Plate
10
Install a gasket on the power-divider lockout housing face.
91
11
Lightly lubricate the O-ring and install into the groove in the
bearing retainer (oil seal) cover.
W4032146
12
Install the oil seal cover onto the power divider lockout housing
with nuts finger tight. Check the gap between the housing and
the cover using a feeler gage. This gap should not exceed
0.254 mm (0.010 in.). If a gap exists and exceeds 0.254 mm
(0.010 in.), install a gasket (shim) or gaskets (shims) as required
to fill the gap.
Note: This gasket (shim) will support the bearing retainer and
prevent bearing retainer oil seal bore deflection. This deflection
causes a bell mouth condition of the seal bore, resulting in a
loose oil seal installation.
0.254 mm (0.010 in.)

13
Install the bearing retainer cover onto the power divider lockout
housing with gasket (shims), if required.
W4032099
92
14
Install the bolts through the bearing retainer cover and into the
housing. Torque nuts to specification.
W4032147
15
Install a new felt ring and O-ring on the shift piston. Install the
O-ring in the top groove and the felt washer in the lower groove.
Lubricate the O-ring and the felt ring with GO-J gear oil.
16
Place the shift fork shaft, threaded end up, into a soft-jawed
vise. Install the special washer, the piston assembly, an addi-
tional special washer and a new Nylok nut on the shaft. Tighten
nut to specification. Remove the shift fork shaft from the vise.
17
Position the long spacer (sleeve) and the return spring onto the
shift fork shaft. Install the shaft assembly into the housing. Align
shaft with shift fork opening and insert shaft into fork.
93
18
Using a hydraulic press, compress the piston spring assembly
until the setscrew holes in both the shaft and fork align. Insert
the setscrew and tighten to specification.
Note: Use a screwdriver or wooden wedge to support the shift
fork while compressing the spring to avoid binding the fork on
the shaft.
W4032148
1. Press
2. Press Extension
3. Piston
W4032149
19
Install the shifter cylinder housing gasket.
W4032150
94
20
Install the cylinder housing and housing nuts.
W4032087
21
Install cover gasket or apply a bead of Silastic or equivalent to
the cover plate, completely encircling the screw holes.
W4032151
1. Gasket
22
Install the cover plate.
W4032152
95
Group 46 Differential Carrier, Dissassemble-Assemble Inter-Axle Power Divider without Lockout — Reassembly
23
Torque the cover plate bolts on the power divider lockout to
specification.
W4032153
24
Torque the bolts on the cylinder housing to specification. Dip the
inner cam in axle lubricant and position it inside the cage. It will
fit only one way. Push all the wedges in until they contact the in-
ner cam lobes. Set the assembly on a clean work surface, with
the cage up to keep the inner cam from falling out. A coating of
heavy grease may be applied to the inner cam face to hold it in
place during assembly. This assembly will be installed into the
bevel pinion housing at a later time.
W4032154
Inter-Axle Power Divider without Lockout — Reassembly

1
Align bearing with the bearing retainer. Then install the ball
bearing into the retainer using a plastic hammer. Drive the bear-
ing into the retainer until it is seated. Apply force only to the out-
er race.
W4032155
96
2
Use a press to install the ball bearing and retainer onto the shaft
of the power divider cage.
W4032156
1. Press
2. Press Extension
3. Bearing
3
Install the inner ring into the center of the power divider cage.
WARNING
Be careful when inserting the inner ring. It may be sharp and
capable of causing serious personal injury.
W4031892
1. Inner Ring
4
Install the power divider wedges into the cage assembly.
Note: Before inserting the wedges, note the arrow or alpha
character on the part of the wedges pointing outward. The
wedges must be installed with the arrow or alpha character
pointing outward.
W4031891
97
5
Push the top row of wedges in even with the cage surface to al-
low installation of the outer ring.
W4032157
6
Using the proper snap ring pliers, install the power-divider
wedge outer retaining ring.
W4031890
1. Outer Retaining Ring
7
Install the O-ring onto the power-divider bearing retainer plate.
Note: Lubricate the power divider inner cam and wedge assem-
bly with GO-J before installation.
W4031889
1. O-Ring
98
8
Install the inner cam into the cage and wedge assembly. A coat-
ing of heavy grease may be applied to the inner cam face to
hold it in place during assembly.
Note: Be sure the oil grooves on the face of the inner cam go to-
ward the pinion.
9
Install a new seal in the cover plate using a driver and a
hammer.
W4032158
1. Driver
10
Lightly lubricate the O-ring and install it into the groove in the oil
seal cover.
W4031893
1. O-Ring
11
Loosely install the bolts through the inter-axle power-divider oil
seal cover and bearing retainer. Set the assembly on a clean
work surface, with the cage up to keep the inner cam from fall-
ing out. This assembly will be installed into the bevel pinion
housing at a later time.
99
Group 46 Differential Carrier, Dissassemble-Assemble Front Rear Bevel Pinion — Reassembly
Front Rear Bevel Pinion — Reassembly

Note: The bevel pinion-shaft front rear assembly will only be en-
countered on vehicles with a tandem rear axle. If the vehicle
being worked on has a single rear axle, this section does not
apply.
1
Press the inner bearing cup into the bevel pinion housing.
W4032159
1. Extension Plate
2. Plate
3. Press Spacer
4. Bearing Cup Installed in Hub
5. Bevel Housing Bearing Hub
2
Turn over the housing and press the outer bearing cup into the
bevel pinion housing.
W4032160
1. Press
3. Press Plate
100
3
The numerals on the back of the bevel pinion gear and the mat-
ing bevel gear represent the mating number and the mounting
distance.
W4032073
1. Mating Number
2. Gear Mounting Distance
3. Pinion Mounting Distance
4
Note and record the mounting distance. These distances are
needed to determine the shim pack thickness.
Note: Make sure the bevel pinion and mating bevel gear are
identified as a matched set.
5
Press the bearing cone onto the bevel pinion shaft.
W4032161
1. Bearing
2. Press
3. Press Spacer
4. Bevel Pinion
101
6
Place the selective bearing spacer on the pinion, with the cham-
fer side down.
W4032162
1. Spacer: Chamfer Down

2. For Some Ratios, extra spacer may be needed under-
neath washer
7
Install the power divider housing onto the bevel pinion.
W4032163
8
Press outer bearing core on pinion.
W4034079
102
9
Position the power divider outer cam on the bevel pinion shaft.
W4030836
10
Using a hydraulic press, install the outer cam of the power divid-
er onto the bevel pinion shaft.
W4032164
1. Plate
3. Press
4. Outer Cam
103
Group 46 Differential Carrier, Dissassemble-Assemble Setting the Bevel Pinion Preload
Setting the Bevel Pinion Preload

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

Set bearing preload after the bevel pinion is assembled into
the housing. Apply 20,000 pounds (10 tons) of pressure to the
bearing in a hydraulic press. Rotate the pinion housing (bear-
ings) before applying full pressure to the bearings. This will
prevent premature bearing failure.
Note: Make sure to lubricate the bearings with oil before per-
forming the bearing preload check.
1
Wrap several turns of cord around the bevel pinion housing at
the pilot area. Attach scale J 8129, or equivalent, to the cord
and slowly and evenly pull on the scale until the housing ro-
tates. The correct load on the scale should be between 3 and 6
pounds for new bearings, and 2 to 4 pounds for used bearings.
If the reading on the scale is not within the correct specifica-
tions, it is necessary to replace the original spacer. Use a thin-
ner spacer if it takes less than the specified amount of pull to
rotate the housing. Use a thicker spacer if the required load ex-
ceeds specification.
Note: A thinner spacer increases preload.
A thicker spacer reduces preload.
Note: If bearings are in good condition, they can be reused for

W4032165 rebuilding a carrier. If used bearings are placed back into a car-
rier, a good rule of thumb is that the force needed to turn the
scale while under 20,000 pounds of preload is about one half
the requirement of new bearings. This is why used bearings
have a 2-4 pound specification rather than the 3-6 pounds
specified for new bearings.
W4032166
1. Selective Bearing Spacer
104
Group 46 Differential Carrier, Dissassemble-Assemble Setting the Preload
2
After determining the correct bearing preload, install a new
power divider retaining nut. Coat the threads with
Loctite® 262 before installing.
Note: In emergency cases, the old nut may be used. In either
case (using new or old nut), thoroughly clean and prime the
threads of the bevel pinion and the cam nut. The threads must
then be coated with Loctite 262.
CAUTION
Do not allow the Loctite 262 to drip into the bearings, as it can
cause bearing failure.
W4032167
3
Install the holding fixture in a stand capable of holding the fixture
secure against the 1762 to 2034 Nm (1,300 to
1,500 lb-ft ) of torque necessary to tighten the retaining nut.
1762 to 2034 Nm (1,300 to 1,500 lb-ft )
W4031896
4
Install the socket in the holding fixture.
5
Tighten the retaining nut to the specified torque.
W4032168
1. Torque Multiplier OEM 6107
105
6
After tightening the nut to the correct torque, the assembly
should look like the illustration.
W4032169
Fig. 23 Correctly Assembled Bevel Pinion
106
Group 46 Differential Carrier, Dissassemble-Assemble Determining Bevel Pinion to Carrier Housing Shim Pack
Determining Bevel Pinion to Carrier Housing Shim Pack
W4032170

4. Centerline of Helical Pinion Shaft
When reusing the bevel pinion that was removed from the car-
rier, also use the shim pack that was removed at disassembly
upon reassembly and installation of the bevel pinion. When re-
building a carrier, it is sometimes necessary to use a new bev-
el pinion. When this occurs, use the following procedure:
• Determine the mounting distance on the disassembled bev-

el pinion (etched into original pinion) and compare it with
the mounting distance on the new bevel pinion (etched into
new pinion).
• If the new bevel pinion mounting distance is longer than the
old (higher number), this amount of shim will have to be
added to the new shim pack.
• If the new bevel pinion mounting distance is shorter than
the old (lower number), this amount of shim will have to be
removed from the shim pack.
For example: 4.878" OLD PINION - 4.875" NEW PINION =

0.003" SHIM DIFFERENCE In this case, remove 0.076 mm
(0.003 in.) from the original shim pack. This procedure pro-
vides a good starting point for setting the gear patterns.
1
Set the assembly on a clean work surface to be installed into
the carrier housing at a later time.
107
Group 46 Differential Carrier, Dissassemble-Assemble Rear Rear Bevel Pinion — Reassembly
Rear Rear Bevel Pinion — Reassembly

1
Press the outer bearing cup into the bevel pinion housing.
108
W4034081
W4032077
1. Mating Number
109
2
Press the inner bearing cone into the bevel pinion. The numbers
on the back of the bevel pinion and bevel teeth represent the
mating number and mounting distance.
W4030832
3
Record the mounting distance. These distances are needed to
determine shim pack thickness. Make sure that the bevel pinion
and mating bevel gear are identified as a matched set.
4
Using a suitable hydraulic press arrangement, press the inner
bearing cone onto the bevel pinion shaft.
W4032161
1. Bearing
2. Press
3. Press Spacer
4. Bevel Pinion
110
5
Install the selective spacer with the tapered side toward the
bearing.
W4034082
6
Install the bevel pinion housing over the bevel pinion. Place
bevel pinion and housing assembly on a press stand.
7
Position the outer bearing cone onto the bevel pinion shaft and
press it into place.
W4034083
111
Group 46 Differential Carrier, Dissassemble-Assemble Setting Bevel Pinion Preload
Setting Bevel Pinion Preload

For maximum efficiency, tapered roller bearings must operate
under a predetermined preload. This also ensures a rigid
mounting for the gears.
Setting the Preload
W4034110
Set bearing preload after the bevel pinion is assembled into

the housing. Use a hydraulic press to apply 20,000 pounds
(10 tons) of pressure to the bearing. Rotate the pinion housing
(bearings) as you apply full pressure to the bearings. This will
prevent premature bearing failure.
Note: Make sure to lubricate the bearings before performing the

bearing preload check.
1
Wrap a cord around the bevel pinion housing as shown. Attach
scale J 8129, or equivalent, to the cord. Pull on the scale slowly
and evenly until the housing rotates.
J 8129
W4034110
112
2
To keep the housing rotating steadily, the correct load on the
scale should read 3 to 6 pounds for new bearings, and 2 to 4
pounds for used bearings. If the reading is not within specifica-
tions, replace the original spacer. Use a thinner spacer if it takes
less than the specified pounds of pull, or a thicker spacer if it
takes more than the specified pounds to rotate the housing.
Note: Bearings that are in good condition can be reused to re-
build a carrier. When reusing bearings, remember that the force
needed to turn the scale while under 20,000 pounds of preload
is about one half the requirement of new bearings. This is why
used bearings have a 2-4 pound specification rather than the 3-
6 pounds specified for new bearings.

3
After the correct bearing preload has been determined, install
the seal.
88800296
W4034111
W4034112
Group 46 Differential Carrier, Dissassemble-Assemble Determining Bevel Pinion to Carrier Housing Shim Pack
4
Install O-Ring on pinion housing.
W4034113
1. O-Ring
Determining Bevel Pinion to Carrier Housing Shim Pack

When reusing the original bevel pinion, also reuse the shim
pack that was removed from the carrier at disassembly. Some-
times it is necessary to use a new bevel pinion to rebuild the
carrier.
• Determine the mounting distance on the disassembled bev-

el pinion (etched into original pinion) and compare it with
the mounting distance on the new bevel pinion (etched into
new pinion).
• If so, use the following procedure: If the new bevel pinion
mounting distance is longer than the old (higher number),
this amount of shim will have to be added to the new shim
pack
• If the new bevel pinion mounting distance is shorter than
the old (lower number), this amount of shim will have to be
removed from the shim pack
For example: 4.876" OLD PINION - 4.874" NEW PINION =

0.002" SHIM DIFFERENCE In this case, 0.051 mm (0.002 in.)
must be removed from the original shim pack. This simple pro-
cedure provides a good starting point for setting the gear
patterns.
1
Set the bevel pinion assembly (with the correct shim pack)
aside temporarily on a clean work surface.
114
Group 46 Differential Carrier, Dissassemble-Assemble Helical (Spur) Pinion Shaft — Reassembly
Helical (Spur) Pinion Shaft — Reassembly

The exploded view shows the parts of the helical pinion shaft
assembly.
1
Using a suitable hydraulic press, install the bearing cone onto
the helical pinion shaft. Note the direction of the bearing.
2
The pinion shaft will be either splined or keyed, depending on
the ratio.
W4034619
1. Keyed Shaft
3
Using a machinist's hammer, install the key into the helical pin-
ion shaft (if shaft requires a key).
W4034621
4
Start the bevel gear onto the helical pinion shaft, making sure
that key slot in gear aligns with the shaft.
W4032171
5
Press the bevel gear onto the helical pinion shaft.
W4032172
1. Press
2. Press Plate
3. Bevel Gear
4. Pinion Shaft
6
Apply Loctite 262 to the threads of the nuts that will hold the
clamp plate to the helical pinion shaft.
7
Secure the helical pinion shaft assembly in a soft-jawed vise. In-
sert the nuts that hold the clamp plate in place.
8
Tighten the nut to specification.
W4030850
9
Install the slotted inner bearing cup over the pinion and bearing
cone.
116
10
Install the selective bearing spacer, with the tapered side down
toward gear. Note that the thickness of this spacer determines
bearing preload.
W4032173
1. Taper
11
Press the outer bearing cup into the helical pinion-bearing
retainer.
12
Press the outer bearing cup into the helical pinion-bearing
retainer.
13
Install a new O-ring on the helical pinion bearing retainer.
W4032174
1. O-Ring
14
Install the bearing retainer over the pinion shaft.
15
Ensure that the retainer lock pin aligns with the slot in the inner
bearing cup.
W4032175
16
Install the outer bearing cone on the helical pinion shaft.
117
17
Press the outer bearing cone into place.
Setting the Preload

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

W4032176
1. Press
2. Plate
3. Scale J8129
The correct load on the scale should read about 3–6 pounds
for new bearings, and 2–4 pounds for used bearings. If it takes
more than the specified amount of pull, use a thicker spacer. If
it takes less than the specified amount of pull, use a thinner
spacer.
118
W4032177
1. A thinner space increases the preload

2. A thicker spacer reduces the preload
W4033407
1. Scale
2. Selective Bearing Spacer
1
After the correct bearing preload has been established, remove
the assembly from the press. Disassemble the outer bearing
cone, spacer and bearing retainer from the shaft assembly. Re-
move the inner bearing cup from the shaft assembly.
119
Group 46 Differential Carrier, Dissassemble-Assemble Setting the Gear Patterns
Setting the Gear Patterns

After setups for the bevel pinion and helical pinion subassem-
blies have been completed, the gear patterns must be properly
set. If the disassembly instructions for these subassemblies
have been followed as described, the existing shim pack thick-
ness should have been measured and recorded, providing a
basis on which to begin the gear pattern adjustment
procedure.
Note: The mounting distance stamped on the back of the bevel

pinion teeth represents the distance from the backface of the
head of the bevel pinion to the centerline of the bevel gear. The
mounting distance on the back of the bevel gear teeth repre-
sents the distance from the backface of the bevel gear to the
centerline of the bevel pinion. This number helps in determining
the shims which will have to be installed to achieve the desired
gear pattern.
W4032074
1. Scale
Note: If the dimension number on the new bevel pinion or bevel

gear is greater than the old, the shim pack must be increased
by the same amount. If the dimension number on the new bevel
pinion or bevel gear is less than the old, the shim pack must be
decreased by the same amount.
120
Group 46 Differential Carrier, Dissassemble-Assemble Setting the Gear Patterns
1
Install the established shim pack onto the helical pinion bearing
retainer.
W4032179
1. Shim Pack
2
Using alignment pins, install the bearing retainer into the carrier
housing. Position the retainer so that the opening faces the bull
gear.
Note: Make alignment pins from bolts obtained locally. Pins
should be about 63.5 mm (2.5 in.) long with 13 mm (0.5 in.) of
thread.
3
Install two cover bolts to hold the bearing retainer in the carrier
housing for installation of the inner bearing cup.
4
Torque the bearing retainer nuts to specification.
5
Mark the carrier housing next to the location of the lock pin.
6
Position the inner bearing cup so that the slot in the cup aligns
with the mark.
7
Install the slotted inner bearing cup into the carrier housing us-
ing hand pressure to start, then tapping with a driver and
hammer.
Note: The inner bearing cup slot must align with the bearing re-
tainer locating pin.
W4032180
1. Driver
8
Insert the shaft assembly, with the established spacer, into the
carrier housing. Position a block of wood in the housing to sup-
port the shaft assembly.
9
Install the outer bearing cone onto the end of the pinion shaft.
121
Group 46 Differential Carrier, Dissassemble-Assemble Bevel Pinion Installation
10
Install the clamp plate and old bolts. Torque nuts to specification
using a pinch bar or jamming tool between the spiral bevel gear
and housing to jam the gear.
Note: Tighten the nuts retaining the clamp plate in stages until
the recommended torque is obtained.
11
Rotate the assembly. The unit should turn with some drag. If it
will not turn, return to and recheck bearing preload.
12
Loosen the three clamp-plate nuts to relieve the preload. Tap
with a hammer to loosen the bearing.
13
Retorque the three clamp-plate bolts to specification using the
pinch bar or jamming tool to jam the gear.
Bevel Pinion Installation

The bevel pinion (which was preassembled in a previous sec-
tion) is now ready to be fitted to the carrier housing for back-
lash and gear pattern checks. The bevel pinion can be
installed only after the helical pinion shaft. Make sure the drive
yoke is installed and properly tightened before performing the
backlash check. Otherwise, a false reading will be obtained.
1
Install the established bevel pinion shim pack over the align-
ment pins. The alignment pins should be used because they will
retain the shim pack while installing the bevel pinion.
Note: Make alignment pins from bolts obtained locally. Pins
should be about 63.5 mm (2.5 in.) long with 5/8-inch threads.
CAUTION
Shims must not block oil holes.
122
2
Shims must not block oil holes.
Note: Make sure to install and properly tighten the drive yoke to
the rear bevel pinion assembly. A false backlash reading will be
obtained without a properly torqued drive yoke.
W4030931
1. Oil Passage Sealing Ring
3
Install front rear bevel pinion.
W4080980
1. Alignment Dowel
123
4
Install oil passage sealing ring.
W4034114
Fig. 24 Rear rear pinion housing assembly.

1. Oil passage sealing ring
5
Install shims.
W4058481
Fig. 25 Rear rear pinion housing assembly

1. Shims
124
6
Install power divider housing on the main carrier housing.
W4034116
Fig. 26 Power Divider Housing
125
Group 46 Differential Carrier, Dissassemble-Assemble Setting the Backlash
7
Install some of the bolts. Remove the alignment pins after the
bevel pinion is in position. Install the remaining bolts.
8
Torque bevel pinion bolts to specification.
Setting the Backlash

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

2
A dial indicator with a magnetic or bolt-on type base is used to
make the measurement.
Note: A bolt-on type base is required on aluminium housings.
W4032182
1. Dial Indicator Needle
Setting Spiral Bevel Gears

1
Check the gear patterns using marking compound. Mark four of
the teeth, approximately 180 degrees apart.
W4034626
126
Group 46 Differential Carrier, Dissassemble-Assemble Four-Pinion Type Differential — Reassembly
2
Rotate at least two full turns in both directions while applying
braking force to the helical pinion. This will squeeze the gear-
marking compound away from the contact areas.
Note: In some cases, it may be necessary to slightly readjust
the setting made by the dial indicator to obtain the correct tooth
contacts. However, make sure that there are no dirt particles
under the shim packs and that all fasteners are tightened to the
proper torque. Then recheck the tooth contact pattern.
3
After reaching proper tooth contact pattern and gear backlash
limits, temporarily remove the bevel pinion and the helical (spur)
pinion shaft from the carrier housing. Wire the bevel pinion
shims together for use at final assembly. Wire the helical (spur)
pinion shaft assembly shims together to use when checking
tooth contact pattern between the helical (spur) pinion shaft as-
sembly and the bull gear.
Four-Pinion Type Differential — Reassembly

1
Using a suitable hydraulic press, press the bearing cones onto
the differential halves. Generously lubricate the bearing cones
and the internal components with GO-J lubricant.
Note: The bearing cones on the two sides of the differential
halves are different. The thicker bearing goes on the unsplined
half and the thinner bearing goes on the splined differential half.
Note: The differential bearing cup which fits the unsplined cas-
ing has an external flange which engages a machined surface
on the inner side of the bearing pedestal and cap when in-
stalled. This arrangement fixes the position of the differential
and bull gear and provides for differential bearing preload ad-
justment. The bull gear position cannot vary.
2
Apply GO-J lubricant to the thrust washer. Install the thrust
washer in the unsplined differential casing.
3
Apply GO-J lubricant to the unsplined differential casing and in-
stall the side gear into the casing.
4
Assemble the four pinion gears and the four thrust washers onto
the differential spider.
5
Install the pinion, spider and thrust washer assembly into the
unsplined side casing. Apply GO-J lubricant before installation.
6
Ensure the gears are properly engaged and that the pinion
thrust washer tabs are properly positioned in the casing.
7
Install the other side gear so that it meshes with the pinion and
spider assembly, applying GO-J lubricant before installing.
127
Group 46 Differential Carrier, Dissassemble-Assemble Four-Pinion Type Differential — Reassembly
8
Install the remaining thrust washer after lubricating it with GO-J
lubricant.
9
Align the side casing halves with the match marks made at dis-
assembly and couple the casing halves together.
10
Mark the side casing halves with a marking pencil at the "o"
marked on the splined half. Mark the tooth between the "oo"
marks on the bull gear.
11
Align the match mark on the bull gear with that on the casing
halves. Index the bull gear internal splines with the external
splines on the differential side casing.
Note: Install a differential casing bolt in the match-mark hole to
help align and install the bull gear.
12
Apply Loctite 262, or equivalent, to four equally spaced casing
bolt threads. Place Loctite in the middle of the bolts as the bolts
extend through the casing.
13
Tighten the four equally spaced bolts evenly to pull the bull gear
onto the casing. Turn the bolts equally and evenly to pull gear
down before torquing.
14
Place the differential in a soft-jawed vise and install the remain-
ing eight bolts. Torque the bolts to specification.
15
Place Loctite 262 on the extended threads of the 12 (previously
installed) bolts used to retain the bull gear.
16
Ensure the differential gears turn freely. If any binding is de-
tected, disassemble the unit and correct the cause.
128
Group 46 Differential Carrier, Dissassemble-Assemble Inter-Wheel Power Divider Differential — Reassembly
Inter-Wheel Power Divider Differential — Reassembly

1
If removed, insert a new presized bushing into the power-divid-
er driving cage until the bushing bottoms. DO NOT OVER-
DRIVE. A correctly installed bushing must be recessed below
the inner-cam thrust surface of the cage.
2
Using a hydraulic press, press the thinner bearing cone on the
hub of the driving cage.
Note: The bearing cones on the two sides of the differential
halves are different. The thicker bearing goes on the unsplined
half and the thinner bearing goes on the splined differential half.
3
Using a hydraulic press, press the thicker bearing cone on the
hub of the non-splined power-divider differential side casing.
4
Install the oil trough on the splined differential power divider
cage.
5
Examine the splined half of the power divider differential half.
The differential half has one mark (shown at the twelve o'clock
position).
6
Examine the bull gear. Note that it has two timing marks (shown
at the twelve o'clock position).
7
Mark the bull gear tooth directly between the timing marks.
8
Align the timing marks so the timing mark from the differential
half is between the two bull gear timing marks. Press the splined
differential power divider cage into the bull gear.
9
Flip over the splined differential power divider cage (now seated
into the bull gear) and continue with the assembly.
10
Install the wedges with the arrow or alpha character pointed out-
ward. Lube all parts during assembly.
Note: Wedges must be replaced only as sets. Never mix
wedges of different sets.
11
Dip the hub of inner cam in GO-J oil. Install the cam in the cage.
12
With the inner cam installed, press all the driving wedges inward
so they all contact the inner cam. Align the wedges for outer
cam installation.
129
Group 46 Differential Carrier, Dissassemble-Assemble Inter-Wheel Power Divider Differential — Reassembly
13
Install the outer cam over the wedges. Turn outer cam back and
forth until cam aligns and falls in place.
WARNING
Be careful when installing the outer cam, possible subse-
quent personal injury can result. The outer cam can drop sud-
denly into place when all wedges are contacting the inner
cam.
14
Align the unsplined differential side casing with the alignment
marks made on the bull gear when disassembling the power
divider
15
Install the unsplined differential side casing.
16
Install and tighten the power-divider differential bolts that retain
the unsplined differential housing.
17
Mount the assembly in a soft-jawed vise.
18
Torque bolts to specification.
130
Group 46 Differential Carrier, Dissassemble-Assemble Differential Installation
Differential Installation
Note: This same procedure is used when installing the inter-
wheel power divider or the four-pinion type differential.
1
Install the bearing adjusting nut onto the threaded bearing cup.
Tighten the nut about two turns.
W4032209
2
Use a suitable lifting device to position the differential assembly
for installation into the carrier housing.
3
Lubricate the bearings with GO-J lubricant and position the
bearing cups on the differential assembly.
W4032210
1. Lift
2. Differential Assembly
3. Carrier Housing
4
Lower the differential assembly into the housing.
131
5
Seat the bearing cups on the differential bearing pedestals in
the carrier housing.
W4032211
1. Hoist
2. Differential/Bull Gear Assembly
3. Stand
6
Align punch marks made at disassembly on the bearing caps
with those on the bearing pedestals. Position the bearing caps
over the bearing cups.
7
Install the bearing cap bolt, snugly, but not too tight. This will
permit bearing adjustment. Do not apply Loctite at this time.
W4032212
132
8
Ensure bearing caps are properly aligned.
Note: Lost or broken bearing caps must be replaced with a new
carrier housing and bearing caps. Bearing caps and the carrier
housing are machined as a set and cannot be intermixed.
W4032213
1. Marks Made Earlier
9
Position bearing adjustment fixture J 26440 or equivalent on the
carrier housing.
J 26440
W4032214
10
Lubricate the differential bearings with GO-J gear oil. Then,
while turning the differential assembly, adjust the differential
bearing nut until the bearings have a slight preload.
W4032215
133
11
Relieve bearing preload by hitting the bearing cap and/or bull
gear with a plastic mallet while rotating the differential.
Note: To properly measure the bull gear drag, make sure that
the helical pinion shaft has been removed. This must be done in
order to ensure accurate preload (drag) measurements.
12
Readjust the differential bearing nut to create a slight preload.
Repeat the procedure of adjusting preload and hitting the bear-
ing cap and/or bull gear to relieve preload pressure, until a con-
stant preload is maintained.
W4032216
13
Torque the bearing-cap retaining bolts to specification.
W4032217
14
Wrap a cord around the outside of the diameter of the bull gear
several times.
15
Attach scale J 8129 or equivalent to the cord and steadily pull
on the scale until the bull gear rotates slowly and evenly. If cor-
rect, the load on the scale will read 2–3 pounds (0.9–1.3 kg).
J81290.9–1.3 kg (2–3 lb)
W4032218
16
If the preload is not within specifications, loosen the bolts and
turn the adjusting nut to attain the proper preload.
134
17
Once preload is attained, remove the bearing cap bolts one at a
time. Apply Loctite 262 to the threads and retorque to
specification.
18
Check for proper alignment of the pin hole in the bearing cap
and the adjusting nut. If required, tighten the bearing adjusting
nut slightly, until the hole and nut are aligned to provide for in-
stallation of the lock pin. Note that it may be necessary to loos-
en the bearing cap bolts to allow the adjusting nut to turn.
Recheck the torque on the bearing cap bolts.
19
Recheck the preload on differential bearings by measuring the
rolling drag. Adjust as required.
20
Remove the differential adjustment fixture J 26440.
J 26440
21
Install the lock pin in the bearing cap and secure it with a cotter
pin.
W4032184
135
Group 46 Differential Carrier, Dissassemble-Assemble Bull Gear Tooth-Contact Pattern
Bull Gear Tooth-Contact Pattern

Earlier in this procedure, the helical pinion shaft was removed
and the differential was installed. Now, a measurement must
be taken for the bull gear tooth-contact pattern. This requires
reinstallation of the helical (spur) pinion shaft. Refer to “Helical
(Spur) Pinion Shaft — Reassembly”, page 115. Torque the old
bolts so the clamp plate is tight. This ensures the correct pre-
load on the bearings and an accurate measurement of the
gear tooth patterns.
1
Temporarily install the helical (spur) pinion shaft with spacer into
the carrier housing as previously outlined. Make certain to en-
gage the helical (spur) pinion with the bull gear.
2
Install the helical-pinion shaft bearing retainer with the predeter-
mined shim pack into the carrier housing.
CAUTION
Shim installation must not block top or bottom oil
passageways.
3
Install the bearing cone onto the end of the pinion shaft. The
bearing must be seated before attaching the clamp plate.
W4032219
4
Attach the clamp plate and install the old clamp-plate bolts
(without Loctite). Jam the bevel gear with a pinch bar or jam-
ming bar and torque the clamp-plate bolts to specification.
5
Coat the bull gear and the helical pinion gear with gear-marking
compound.
W4032220
136
Group 46 Differential Carrier, Dissassemble-Assemble Bull Gear Tooth-Contact Pattern
6
Rotate the bull gear in forward and reverse directions while applying resistance to the helical pinion set to determine the tooth
contact pattern. The pattern must be within the limits shown on the following Bull Gear Tooth-Contact Pattern Chart. The contact
pattern is either acceptable or unacceptable, because there is no adjustment option. If the gear tooth pattern is unacceptable, re-
place both the bull gear and the helical pinion with its shaft.
1. Acceptable 10. Sixth

2. Less than 10% Length 11. Seventh
3. Ideal 12. Eighth: End Loading left-hand Side
4. Minimum 13. Ninth: End Loading Right-hand Side
5. First 14. Tenth: Tip Loading
6. Second 15. Eleventh: Split Bearing
7. Third 16. Twelfth: End Loading Seft and Right Sides
8. Fourth 17. Total Length
9. Fifth
W4032221
137
Group 46 Differential Carrier, Dissassemble-Assemble Final Assembly
Final Assembly
Provided the instructions of this manual have been followed
correctly, the differential assembly is now complete and the
helical (spur) pinion shaft has been temporarily installed. The
helical (spur) pinion shaft installation must be completed at this
point.
1
Remove the three helical (spur) pinion-clamp plate bolts one at
a time and replace using new bolts. Apply Loctite 262 to the
threads and install the new bolts. Torque each bolt to specifica-
tion while jamming the bevel gear with a pinch bar or jamming
tool.
2
Remove the short bolts used to temporarily retain the helical
(spur) pinion-shaft assembly retainer.
Note: A steel-core gasket coated on both sides with foam rub-
ber has replaced the Silastic sealer which was applied to the
pinion shaft cover formerly. Use a steel-core gasket for reas-
sembly to eliminate oil leakage.
3
Install a new steel-core/foam-rubber gasket onto the helical-pin-
ion bearing retainer.
W4034634
1. Retainer Gasket
4
Install the helical-pinion bearing retainer cover.
W4032223
1. Bearing Retainer Cover
138
Group 46 Differential Carrier, Dissassemble-Assemble Final Assembly
5
Remove the guide pins used to temporarily align the helical
(spur) pinion-shaft bearing retainer assembly and use the prop-
er self-locking bolts to secure the cover.
6
Torque the bolts retaining the helical pinion-shaft bearing re-
tainer cover to specification.
W4032224
139
Group 46 Differential Carrier, Dissassemble-Assemble Front Rear or Rear Rear Bevel Pinion Installation
Front Rear or Rear Rear Bevel Pinion Installation

1
Use the shims as determined while adjusting the bevel pinion
assembly for proper tooth contact pattern and proper backlash
between the gears.
CAUTION
Position the shims to align with all oil holes. Blocked oil holes
will cause lubrication failure.
2
Install the bevel pinion and housing assembly onto the carrier
housing. Align bevel pinion housing with oil passages.
3
Install proper self-locking bolts into the bevel housing and tor-
que to specification.
4
When assembling a carrier with power divider (with or without
lockout), it is necessary to use an offset extension J 28506, or
equivalent, with the torque wrench OEM-6642.
J 28506, OEM-6642
W4032225
Inter-Axle Power Divider Installation (with or without Lockout)

1
Dip the inner cam in GO-J lubricant and position it inside the
cage of the power divider. Push all the wedges in until they con-
tact the inner cam lobes and install the inner cam. The cam will
fit only one way.
Note: Be sure the grooves on the face of the inner cam face in
toward the bevel pinion.
W4032226
140
Group 46 Differential Carrier, Dissassemble-Assemble Inter-Axle Power Divider Installation (with or without Lockout)
2
Install the power divider housing gasket.
W4032227
1. Gasket
3
Position the carrier housing in the stand so the cage assembly
may be installed into the outer cam of the bevel pinion. The in-
ner cam will be held in position by the driving wedges.
4
Install the power divider into the housing.
Note: The cage assembly must be perfectly centered or the
wedges will hang up.
W4032228
141
Group 46 Differential Carrier, Dissassemble-Assemble Inter-Axle Power Divider Without Lockout Only
Inter-Axle Power Divider Without Lockout Only

1
On inter-axle models without lockout, ensure that a new oil seal
was installed in the seal cover.
2
Install a lightly lubricated O-ring into the groove in the oil-seal
cover plate.
3
Attach the inter-axle power-divider oil seal cover over the
power-divider cage bearing retainer plate.
W4032229
4
Install the bolts through the inter-axle power-divider oil seal cov-
er. Torque to the correct specification.
Inter-Axle Power Divider With Lockout Only

1
Install the bolts through the inter-axle power divider housing
flange. Torque to the correct specification.
W4032230
142
Group 46 Differential Carrier, Dissassemble-Assemble Inter-Axle Through Shaft Installation
Inter-Axle Through Shaft Installation

1
Position the through-shaft housing gasket onto the surface of
the carrier housing.
W4033409
1. Shim Gasket
2
Install the inter-axle through-shaft housing into the carrier
housing.
CAUTION
The power divider wedges are lubricated through the
through-shaft bearing retainer and the bevel pinion. When the
through-shaft bearing retainer is installed, ensure that the oil
inlet is on top. If the retainer is rotated so the oil inlet is not in
the top position, the inter-axle power divider will be damaged
because of a lack of lubricant.
W4032232
3
Lubricate the through shaft with GO-J lubricant.
4
Carefully install the through-shaft assembly, aligning the shaft
splines with the internal splines of the inter-axle power divider
inner cam while making certain that the oil inlet is properly
positioned.
143
Group 46 Differential Carrier, Dissassemble-Assemble Inter-Axle Through Shaft Installation
5
Ensure the through-shaft bearing is properly seated when the
through shaft is installed.
W4032233
6
Determine the proper gasket thickness for the through-shaft
bearing retainer.
Note: The thickness of this gasket is critical because the gasket
seals the joint and determines how much pressure bears on the
outer bearing race to keep it from spinning.
1 Temporarily install the retainer over the through shaft and

press on it until the ridge bottoms on the outer bearing race.
2 Using feeler gauges J 26900-8 or equivalent, measure the
gap between the bearing cover and retainer flanges. Add
0.13-0.25 mm (0.005-0.010 in.) to the measured amount for
proper gasket thickness. This is done to provide enough
W4032234
clamping force to prevent the bearing from rotating within the
bearing retainer, and to provide a seal to prevent oil leakage.
1. Feeler Gauge
J26900–8
7
Align the bearing cover and install the bolts.
W4032235
8
Torque bolts to specification.
144
Group 46 Differential Carrier, Dissassemble-Assemble Carrier Installation Into Chassis
Carrier Installation Into Chassis

1
If not yet installed, dip end of yokes in GO-J lubricant and posi-
tion them on the input shaft of the input and through-shafts of
the front rear carrier. Position the clamp plate and install the
self-locking bolts finger tight.
Note: Drive yokes for the 151 series carriers were installed in
previous steps.
2
Install a holding bar on output yoke and with a socket wrench,
tighten yoke self-locking bolt to the required torque.
3
Check the carrier for free turning and proper operation of work-
ing components. If an unusual amount of bind is felt, or noise is
heard, correct the cause before proceeding.
4
All units with the four-pinion type differential which are being in-
stalled into the axle housing must immediately have the differ-
ential filled with one pint of GO-J lubricant before the carrier is
installed into the vehicle.
5
Apply a 2.0 mm (0.8 in) continuous bead of Silastic 732 RTV
sealant, or equivalent, to axle housings without provisions for a
large O-ring seal prior to assembly of the carrier onto the axle
housing. This includes all CRD 92/93 series carriers. The CRD
112/113 series carrier housings have a large O-ring groove. In-
stall O-ring in the groove. Then mount the carrier. DO NOT use
a sealant on carriers using an O-ring.
6
Install differential carrier into axle housing.
W4080977
145
7
Install bolts and washers. Torque bolts to specification.
W4032238
Installation of Hidden bolts, stepped washer and O-ring;

Used on CRD150 and 151 series carriers.
Note: O-rings are used only on tandem carriers over

46,000 pound rating.
8
Install the cover assembly and new O-ring. Make sure that a
cover containing the oil trough with magnetic strips is used in
the front rear carrier.
CAUTION
Do not use a plain cover on a front rear axle with power divid-
er provisions. The front rear cover for a carrier with a power
divider must have a trough to feed oil to the oil pump (through
shaft) to prevent damage to the power divider.
W4031127
9
Ensure all plugs are installed in the assembly.
Pipe Plug Torque in Nm Torque in lb-ft
Location
1. Power Divider 54–61 40–45
Fill Plug — 1 NPT
2. Housing Fill n/a n/a
Plug
3. Housing Drain 27–34 20–25
Plug (Magnetic) —
W4032239
1/2 NPT
4. Axle Housing 54–61 40–45
Drain Plug — NPT
5. Power Divider 27–34 20–25
Drain Plug — 1/2
NPT
146
10
Torque the bevel compartment cover to specification.
W4031129
11
When the rear axle is completely assembled, it is important to fill
the inter-axle power divider (if equipped), and both the carrier
and axle housings to their respective proper capacities. Fill the
axles with GO-J (or GO-J Plus) lubricant until the oil is level with
the filler plug hole.
W4031132
147
Group 46 Differential Carrier, Dissassemble-Assemble Preventive Maintenance
Preventive Maintenance
Magnetic Strips and Oil Troughs
An oil trough with magnetic strips is attached to the inside of the bevel gear compartment cover. Clean the oil trough and magnetic
strips each time the oil is changed or when the cover is removed. Replace the O-ring whenever the cover is removed.
W4032240
W4031127
1. O-Ring
Checking Oil
WARNING
Be careful not to burn your finger in hot gear oil when check-
ing 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 op-
erating temperature and chassis is parked on level . Check the
oil level by removing the filler plugs from the axle housings
and the bevel gear compartments. The level is correct when
oil runs out of the filler plug hole in the axle housing, and
slightly below the filler plug hole in the bevel gear compart-
ment. If the level in the axle housing is low, add oil to the axle
housing and the bevel gear compartment until the oil is level
with the bottom of the filler plug holes.
W4080981
W4080982
1
Group 46 Differential Carrier, Dissassemble-Assemble Changing Oil
DO NOT add oil if the level in the axle housing is sufficient. Re-
install the plugs and tighten to specifications.
W4032243
1. Inter-Axle Power Divider Housing 5. Tandem Axle Housings

2. Bevel Gear Compartment Filler Plug 6. Divider Housing Drain Plug
3. Drain Plug 7. Divider Housing Filler Plug
4. Axle Housing Filler Plug
Changing Oil
When changing the oil in the carrier unit, the oil should be at
normal operating temperature. Remove the magnetic drain
plug from the bottom of the axle housing(s), the drain plug in
the bevel gear compartment(s) and the drain plug in the inter-
axle power divider housing (if equipped). Then drain the hot oil
from the unit into an industry-approved recovery container.
Clean and reinstall the magnetic drain plug(s). Then torque to
specification. Remove the filler plug(s) from the axle housing
(s), the bevel gear compartment(s) and the inter-axle power di-
vider housing (if equipped). Fill each of the carrier compart-
ments with specified oil to the level of the filler plug hole.
Reinstall and snug the filler plugs in the carrier housing, power
divider and bevel pinion compartment. Then tighten each to
specified torque. Change the oil at the specified intervals.
2
Group 46 Differential Carrier, Dissassemble-Assemble Air Breathers
Air Breathers
W4032244
The 150/151 carriers both have one breather cap located on

the uppermost portion of each carrier housing. Remove the
carrier housing breather(s) every time the rear axle(s) oil is
changed. Clean the breather in a suitable nonflammable sol-
vent and check for damage. Also check to be sure that airflow
through the breather is unobstructed. Reinstall the breather
onto the carrier housing and tighten until snug.
3
4
Operation Numbers
The operation numbers used in this manual refer to Labor Code.
4651-04-11-01 Differential Carrier, Dissassemble-Assemble........................................................ 39
Last page

Diferencial Mack

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Diferencial Mack

Caricato da

Copyright:

Formati disponibili

Service Information

Mack Trucks, Inc.

MACK Dual-Reduction Tandem Carrier

The new edition of this manual will update the changes.

Mack Trucks, Inc.

Order number: PV776-89092622

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

Design and Function .................................................................................................................... 12

Service Procedures ...................................................................................................................... 39

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

Recommended SAE Grade Gear Oil

• MACK® GO-J Specification 80W-90, 85W-140

Additional Torque Specifications of Fasteners for CRD151

Orientation of Power Divider Lockout shall be with the cen-

Bullgear mounting screws/nuts must be torqued in a dou-

• Bevel Pinion Bearing Preload: Assemble pinion and bear-

• Helical Pinion Shaft Bearing Preload: Assemble pinion

1. CRD 150/151 Carrier 6. Piston Spring 1. CRD 150/151 Carrier 9. Washer

Note: “P” indicates prevailing torque features (example: nylon

Note: “L” indicates Loctite No. # 262 or equivalent

Note: Pipe plugs must be sealed using 023GS17002-P

Note: For fasteners not listed in Section 2.0, refer to

1. Oil Passage Sealing Ring installed into Main

Spiral Bevel Gear Set Contact Pattern

J 26437 WRENCH, Differential Bearing Adjusting Nut

Using Adapters/Extensions with Torque Wrenches

Fig. 1 Dial-Indicator Type Torque Wrench with Adapter

• Total Length "A" = 24

Multiply the dial reading by the quotient found above to deter-

If the required torque is known, divide by the quotient to deter-

Design and Function

Front Rear Carrier

During certain off-highway (low traction) situations, there is an

Tire matching is still required on units with or without an inter-

Rear Rear Carrier

Inter-Wheel Differential Lock

1 Main Drive Pinion

• Durapoid spiral bevel gears for first reduction

1. 1st Reduction 4. Bull Gear

Power Divider Operation

Inter-Axle Power Divider

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

Normal conditions — All wheels have traction

Inter-Wheel Power Divider

The inter-wheel power divider replaces the conventional carrier differential

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

Power Divider Lockout

The lockout device inhibits the operation of the power divider. It

All parts of power divider operate normally

1. Piston moves forward when air pressure exhausts

1. Piston pushed rearward by air pressure

The power divider and lockout are mounted in separate hous-

Front Rear Carrier Arrangement

1. Power Divider Lockout

Carrier Components and Operation

Differential Components and Operation

The entire assembly is straddle mounted in a pair of tapered

Inter-Axle Power Divider Pump Operation

A collector trough, integral with the bevel-gear compartment

• Do not disturb parts with heavy press fits unless replacement

fications). If a heavy-duty air impact wrench with one-inch

Information stamped into the unit indicates features included by

Carrier Stamping location and information