Ws 3503000 WM

Freightliner Rear Axles 35.
03
General Information
General Information
Although these axles are a Freightliner proprietary
product, in some applications they may be referred to
as "M-B components."
Freightliner rear axles are compatible with industry-
standard brakes, hubs, and wheel bearings.
The following explains an example of the number
found on a Freightliner rear axle identification tag,
which is located on the carrier. See Fig. 1.
Typical Model Number: ART-40.0-4
ART = tandem rear axle
40.0 = weight rating (times 1000 lb)
4 = basic model number
02/05/2008 f080152
Fig. 1, Rear Axle ID Tag
Freightliner rear axles may have a main differential

lock, which is commonly known as the "DCDL"
(Driver-Controlled Differential Lock). The DCDL is an
optional feature that can lock the differential assem-
bly to improve traction on icy road conditions. When
the differential lock is engaged, the clutch collar com-
pletely locks the differential case, gearing, and axle
shafts together to maximize traction of both wheels
and protect against spinout. Each part of the DCDL
is replaceable; see Subject 180.
On tandem axles there are three possible differential
lock options: forward-rear carrier only, rear-rear car-
rier only, or both rear carriers.
Western Star Workshop Manual, Supplement 12, May 2009 050/1

Freightliner Rear Axles 35.03
Single or Rearmost Axle Removal and Installation
Removal 15. If necessary, back off the slack adjusters, then

remove the brake drums.
For rear axle components, see Fig. 1. 16. Remove the hubs from the axle spindles. For
instructions, see Section 35.01, Subject 100.
1. Park the vehicle on a level surface, shut down
the engine, set the parking brake, and chock the 17. Remove the brake shoes. For instructions, see
tires. Put the transmission in neutral. the applicable service brake section in
Group 42.
2. Using a suitable jack, raise the vehicle enough to
take the weight off the axles, but not enough to 18. If applicable, disconnect the leveling valve rod(s)
raise the tires off the ground. from the suspension.
3. At both ends of the axle, loosen all the wheel 19. At the frame rail or crossmember, disconnect the
nuts. wiring for the ABS sensors. Remove any tie
straps that hold the wires to the frame rails.
4. Continue to raise the vehicle evenly until there is
room to fit a stand underneath the axle housing. 20. Disconnect the air lines from the rear brake
chambers.
WARNING 21. Remove the brake air chambers and the slack
adjusters from the axle housing. For instructions,
Never work around or under a vehicle that is sup- see Group 42.
ported only by a jack. Always support the vehicle
with safety stands. Jacks can slip, allowing the 22. Remove the ABS sensors and wiring, and the
vehicle to fall, which could result in serious in- fasteners that hold the brake spiders to the axle
jury or death. flanges. Remove the spiders from the axle.
5. Support the vehicle with safety stands. 23. Using a suitable jack, support the axle housing.
6. Remove the tire and wheel assemblies. 24. If applicable, remove the hexnuts that hold the
bottom of each suspension air bag to its suspen-
7. Drain the oil from the differential housing. Install sion bracket.
the drain plug.
25. Remove the suspension components that attach
8. Disconnect the driveshaft from the differential the axle to the vehicle. If applicable, remove the
carrier. For instructions, see Section 41.00, Sub- U-bolt nuts from the U-bolts. Discard the U-bolt
ject 120. Using suitable straps, support the end nuts and U-bolts.
of the driveshaft by attaching it to the frame rail.
26. Lower the axle enough to clear the suspension
9. Release the parking brakes. components.
10. Cage the parking brake springs to prevent the 27. Remove the axle from the vehicle.
parking brakes from engaging. For instructions,
see Group 42. 28. If you are going to replace the differential carrier,
place the axle on a secure axle stand.
11. If DCDL is installed on the vehicle, use the
DCDL switch in the cab to engage the lock. An
indicator light comes on when the differential lock Installation
is engaged. Turn the appropriate hubs to ensure
the lock is fully engaged. 1. Position the axle underneath the vehicle.
12. Drain the air system. 2. Install the suspension components that attach
the axle to the vehicle, as follows.
13. Place a basin under the axle shaft flanges to
catch any oil, then remove the axle shafts. For NOTE: U-bolts and U-bolt nuts cannot be
instructions, see Subject 120. reused.
14. Disconnect the DCDL air line from the carrier 2.1 On vehicles with conventional suspen-
housing. sions, install the upper U-bolt brackets,

35.03 Freightliner Rear Axles
1
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7
05/23/2005 f350459
1. Differential Carrier 4. Carrier Yoke 6. Rear Axle Housing
2. Radial Shaft Seal 5. Carrier Capscrew 7. Axle Shaft
3. Yoke Nut
Fig. 1, Single or Rearmost Axle Components
new U-bolts, lower U-bolt brackets, and 4. Install the brake spiders on the axle flanges. For
new U-bolt nuts. instructions, see the applicable service brake
section in Group 42.
On vehicles with air suspensions, in addi-
tion to the U-bolts, install the hexnuts that 5. Install the ABS sensors and connect the wiring at
attach the air springs to the suspension the frame rail. Secure the wiring with tie straps
brackets. For torque values, see as needed.
Group 32. 6. Install the brake air chambers and slack adjust-
On vehicles without U-bolts, install the ers on the axle housing brackets. For instruc-
walking beams. tions, see Group 42.
2.2 If applicable, tighten the new U-bolt nuts 7. Connect the air lines to the brake air chambers.
in a diagonal pattern. For torque values, 8. Install the brake shoes, as removed. For instruc-
see Group 32. tions, see the applicable service brake section in
3. Connect the driveshaft to the differential carrier Group 42.
yoke. For instructions, see Section 41.00, Sub- 9. Fill each hub with approved axle oil until you can
ject 120. see a little amount of oil trickling out of the back
of the hub (use about 0.8 quart, or 0.75 liter).
Install the hubs on the axle spindles, and adjust
100/2 Western Star Workshop Manual, Supplement 12, May 2009

the wheel bearings. For instructions, see the ap- correctly. Make sure the ride height is correct.
plicable subject in Section 35.01. For instructions, see Group 32.
NOTE: See Table 1 for approved axle oils. 21. Check the oil level in the axle housing. The level
should be up to the bottom of the fill hole. Add
10. If DCDL is installed on the vehicle, connect the approved axle oil, if needed.
DCDL air line, fill the air system, and use the
DCDL switch in the cab to engage the lock. An 22. Set the parking brake.
indicator light comes on when the differential lock
is engaged.
11. Using new gaskets, install the axle shafts. For
instructions, see Subject 120.
12. Install the brake drums on the hubs.
13. Install the wheels and tires. For instructions, see
Group 40.
14. Adjust the brakes. For instructions, see the appli-
cable service brake section in Group 42.
15. Uncage the parking brake springs.
16. Using approved axle oil, fill the axle housing to
the bottom of the fill hole, or until filled to capac-
ity as shown in Table 1.
Single Rear Axle Oil Type and Capacity

Capacity: quarts (liters)
Approved Oil Type
Hubs Full Hubs Dry
80W-90 Gear Oil
10.6 (10.0) 12.2 (11.5)
75W-90 Synthetic Gear Oil
Table 1, Single Rear Axle Oil Type and Capacity
17. Raise one side of the vehicle about 8 inches (20

cm) to let the oil flow into the hub on the oppo-
site side, then raise the other side in the same
manner. On each side, hold the tilted position for
three minutes to allow oil to run into the wheel
end.
NOTICE
Make sure the hubs are filled. Driving with the
hubs dry will cause bearing damage.
18. Turn the wheels, wait one minute, and check the
lubricant level.
19. Raise the vehicle, remove the safety stands,
then lower the vehicle.
20. If applicable, connect the suspension leveling
valve(s). Start the engine, build the air pressure,
and make sure the suspension air bags inflate

Single or Rearmost Axle Differential Carrier
Removal and Installation
Do not disassemble the differential carrier. There are 2. If DCDL is installed on the vehicle, ensure the
no serviceable parts in the differential assembly; it lock is engaged. Turn the appropriate wheels to
must be replaced as a unit. However, it is possible to verify it is fully engaged.
remove the differential carrier to repair an oil leak, or
to remove the wheel lock (differential lock). WARNING
When the wheel lock is removed, inspect the carrier
The differential carrier is heavy. Do not try to
for damage and replace it if damage is found. If no
move it without a suitable support. To do so
damage is found, install the carrier again.
could result in the carrier falling, which could
cause serious personal injury and component
Removal damage. Support the carrier with a suitable jack
and chain it to the jack, or use a hoist if the axle
NOTE: The differential carrier can be removed has been removed from the vehicle.
either with the rear axle installed on the vehicle 3. Remove the carrier capscrews that hold the dif-
or with the rear axle removed from the vehicle. ferential carrier to the axle housing. See Fig. 1.
4. With the differential carrier securely supported,
Axle Installed on Vehicle remove it from the axle housing.
the engine, set the parking brake, and chock the Installation
tires. Put the transmission in neutral.
2. If applicable, release the suspension air pres- IMPORTANT: If you replace the yoke on the dif-
sure. ferential carrier, use a new nut when installing
3. Using suitable jacks, raise the vehicle evenly the new yoke.
until there is room to fit a jack underneath the NOTE: Use a cleaning solvent and clean rags to
axle housing. remove dirt. Blow dry the cleaned areas with air.
4. Remove the tire and wheel assemblies. For in- 1. Remove any old sealant material from the mating
structions, see Group 40. surfaces of the axle housing. Clean the inside of
5. Drain the oil from the axle housing. the rear axle housing and the forward carrier
mating surface.
6. Disconnect the driveshaft from the carrier yoke.
For instructions, see Section 41.00, Sub- 2. Inspect the axle housing for damage. Repair or
ject 120. Using suitable straps, support the end replace the axle housing as necessary.
of the driveshaft by attaching it to the frame rail. 3. Apply a thin bead of Loctite 5900 sealant all the
7. If DCDL is installed on the vehicle, use the way around the mating surface of the axle hous-
DCDL switch in the cab to engage the lock. An ing, and around each bolt hole.
indicator light comes on when the differential lock NOTE: Alignment dowels for installing the differ-
is engaged. Turn the appropriate hubs to ensure ential carrier can be made by sawing off the
the lock is fully engaged.
heads of two M16 x 1.5 x 100 mm bolts.
8. Place a basin under the axle shaft flanges, then
remove the axle shafts. For instructions, see 4. Install alignment dowels 180 degrees apart at the
Subject 120. 3 oclock and 9 oclock positions on the axle
housing flange.
9. Do the steps under the heading, "Axle Removed
from Vehicle." 5. If DCDL is installed on the vehicle, ensure it is
engaged.
Axle Removed from Vehicle
1. Using a suitable jack, support the differential car-
rier. Chain the differential carrier to the jack.

1
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05/23/2005 f350459
1. Differential Carrier 4. Carrier Yoke 6. Rear Axle Housing
2. Radial Shaft Seal 5. Carrier Capscrew 7. Axle Shaft
3. Yoke Nut
Fig. 1, Single or Rearmost Axle Components
IMPORTANT: The end caps fit tightly into the

NOTICE axle housing. Be very careful not to cock the
Make sure the differential carrier is centered and carrier.
straight on the axle housing before you install 9. Install the carrier capscrews finger-tight. Make
the mounting capscrews. Attempting to install sure the carrier capscrews turn easily in the axle
the carrier when it is not centered or straight may housing.
cause damage to the carrier.
10. In a star pattern, gradually tighten the M16 car-
6. Using a hoist (if the axle is removed from the rier capscrews 200 lbfft (270 Nm).
vehicle) or a suitable transmission jack, install
the differential carrier into the axle housing. Use 11. If removed, install the axle on the vehicle. For
the alignment dowels to center the carrier on the instructions, see Subject 100.
axle housing. If the axle is already on the vehicle, go to the
7. Install the end caps on the sides of the carrier next step.
into the corresponding slots in the axle housing. 12. Connect the driveshaft to the carrier yoke. For
See Fig. 2. instructions, see Section 41.00, Subject 120.
8. For the last 3/4 inch (19 mm) or so of travel, 13. Using new gaskets, install the axle shafts. For
walk the carrier slowly into the housing. instructions, see Subject 120.

1 19. Start the engine, build the air pressure, and

check that the suspension air bags inflate evenly
2 and correctly. Make sure the ride height is cor-
rect.
20. Check the oil level in the axle housing. The level
should be up to the bottom of the fill hole. Add
approved axle oil, if needed.
11/10/2004 f350438
1. Differential Carrier
2. End Cap Bolt
3. End Cap
Fig. 2, Carrier End Caps

Group 40.
Axle Oil Capacities

Oil Capacity: quarts (liters)
Axle Model
Hubs Full Hubs Dry
Model 4 10.6 (10.0) 12.2 (11.5)
Table 1, Axle Oil Capacities
16. Raise one side of the vehicle about 8 inches (20

cm) to let the oil flow into the hub on the oppo-
site side, then raise the other side in the same
manner. On each side, hold the tilted position for
three minutes to allow oil to run into the wheel
end.
NOTICE
17. Turn the wheels, wait one minute, and check the
lubricant level.
18. Raise the vehicle, remove the safety stands,
then lower the vehicle.

Axle Shaft Removal and Installation
Removal
1. Chock the front tires.
2. Raise the rear of the vehicle with a suitable jack 3
high enough to clear the axle. Support the axle
with jack stands.
3. If DCDL is installed on the vehicle, use the
DCDL switch in the cab to engage the lock. An
indicator light comes on when the differential lock 2
is engaged. Turn the appropriate wheels to en-
sure the lock is fully engaged.
4. Place a basin under the axle shaft flanges to
catch any oil. Dispose of used oil properly.
1
5. If necessary, remove the tires. For procedures,
see Group 40. 12/13/2004 f350440
NOTE: This procedure can be done with the Apply light pressure with the hand or knee at the arrow.
wheels and tires installed or with the wheels Use the adjustable wrench to center the shaft.
and tires removed. 1. Axle Shaft 3. Adjustable Wrench
2. Axle Flange
6. Remove the drive axle stud nuts that attach the
axle shaft to the wheel hub. Fig. 1, Installing the Axle Shaft
7. Tap the axle shaft flange if necessary to loosen 4. If removed, install the tires and tighten the wheel
it, then slide the axle shaft out of the axle. Re- nuts according to the procedures in Group 40.
move and discard the gasket.
5. Remove the supports and lower the vehicle.
Installation 6. As needed, replace any oil that was drained from
the hub when the axle shaft was removed.
1. Position a new gasket on the axle shaft flange.
2. If DCDL is installed on the vehicle, ensure it is
engaged.
3. Install the axle shaft, as follows. See Fig. 1.
3.1 Carefully raise the axle with a floor jack,
and support the axle with jack stands.
Slide the axle shaft into the axle.
3.2 Apply light pressure with the hand or knee
to the axle flange.
3.3 Use an adjustable wrench to center the
shaft. Turn the shaft with a slight rotating
motion.
3.4 Install the drive axle stud nuts and tighten
them to the values given.
1/220 nuts: 75 to 115 lbfft (102 to
156 Nm)
5/818 nuts: 150 to 170 lbfft (203 to
230 Nm)

Forward-Rear Tandem Axle Removal and
Installation
Removal 2. Using a suitable jack, raise the vehicle enough to

take the weight off the axles, but not enough to
raise the tires off the ground.
For forward-rear axle components of a tandem instal-
lation, see Fig. 1. 3. At both ends of the axle, loosen all the wheel
nuts.
the engine, set the parking brake, and chock the 4. Using a suitable jack, continue to raise the ve-
front tires. Put the transmission in neutral. hicle evenly until there is room to fit a stand un-
derneath the axle housing.
4
5
6
7
05/05/2005 f350456
1. Axle Shaft 4. Input Seal 6. Input Yoke Nut
2. Forward-Rear Axle Housing 5. Carrier Yoke 7. Forward Differential Carrier
3. Carrier Capscrew
Fig. 1, Forward-Rear Axle Components

Installation
20. If applicable, disconnect the leveling valve rod(s)

WARNING from the suspension.
Never work around or under a vehicle that is sup- 21. At the frame rail or crossmember, disconnect the
ported only by a jack. Always support the vehicle wiring for the ABS sensors. Remove any tie
with safety stands. Jacks can slip, allowing the straps that hold the wires to the frame rails.
vehicle to fall, which could result in serious in- 22. Disconnect the air lines from the rear brake
jury or death. chambers.
5. Support the vehicle with safety stands. 23. Remove the brake air chambers and the slack
6. Remove the oil drain plug from the bottom of the adjusters from the axle housing. For instructions,
axle housing and drain the oil from the axle see Group 42.
housing. Install the drain plug after emptying. 24. Using a suitable jack, support the axle housing.
7. Remove the wheels and tires. For instructions, 25. If applicable, remove the hexnuts that hold the
see Group 40. bottom of each suspension air bag to its suspen-
8. Release the parking brakes. sion bracket.
9. If necessary, back off the slack adjusters, then 26. Remove the suspension components that attach
remove the brake drums. the axle to the vehicle. If applicable, remove the
U-bolt nuts from the U-bolts. Discard the U-bolt
10. If installed, make sure the optional DCDL (main
nuts and U-bolts.
differential lock) has been shifted into the en-
gaged (locked) position. 27. Lower the axle enough to clear the suspension
components.
11. Disconnect the air lines at the interaxle lock and
(if installed) the wheel lock. 28. Remove the axle from the vehicle.
12. Disconnect the main driveshaft from the forward 29. If you are going to replace the differential carrier,
differential carrier. For instructions, see Sec- place the axle on a secure axle stand.
tion 41.00, Subject 120. Using suitable straps,
support the end of the driveshaft by attaching it Installation
to the frame rail.
13. Disconnect the interaxle driveshaft from the out- 1. Position the axle underneath the vehicle.
put yoke of the forward tandem axle and the
2. Install the suspension components that attach
input yoke of the rear tandem axle. For instruc-
the axle to the vehicle, as follows.
tions, see Section 41.00, Subject 120.
14. Cage the parking brake springs to prevent the NOTE: U-bolts and U-bolt nuts cannot be
parking brakes from engaging. For instructions, reused.
see Group 42. 2.1 On vehicles with conventional suspen-
15. Drain the air system. sions, install the upper U-bolt brackets,
new U-bolts, lower U-bolt brackets, and
16. Place a basin under the axle shaft flanges to new U-bolt nuts.
catch any oil; then remove the axle shafts. For
instructions, see Subject 120. On vehicles with air suspensions, in addi-
tion to the U-bolts, install the hexnuts that
17. Remove the hubs from the axle spindles. For
attach the air springs to the suspension
brackets. For torque values, see
18. Remove the brake shoes. For instructions, see Group 32.
the applicable service brake section in
Group 42. On vehicles without U-bolts, install the
walking beams.
19. Remove the ABS sensors and wiring, and the
fasteners that hold the brake spiders to the axle
flanges. Remove the spiders from the axle.

Installation
2.2 If applicable, tighten the new U-bolt nuts 18. Using approved axle oil, fill the forward-rear tan-
in a diagonal pattern. For torque values, dem axle housing to the bottom of the fill hole, or
see Group 32. until filled to capacity as shown in Table 1.
3. Connect the interaxle driveshaft to the output
yoke of the forward carrier and the input yoke of Forward-Rear Axle Oil Type and Capacity
the rear carrier. For instructions, see Sec- Capacity: quarts (liters)
tion 41.00, Subject 120. Approved Oil Type
Hubs Full Hubs Dry
4. Install the brake spiders on the axle flanges. For 80W-90 Gear Oil
instructions, see the applicable service brake 14.3 (13.5) 15.9 (15.0)
section in Group 42. 75W-90 Synthetic Gear Oil
5. Install the ABS sensors and connect the wiring at Table 1, Forward-Rear Axle Oil Type and Capacity
the frame rail. Secure the wiring with tie straps
as needed. 19. Raise one side of the vehicle about 8 inches (20
6. Install the brake air chambers and slack adjust- cm) to let the oil flow into the hub on the oppo-
ers on the axle housing brackets. Connect the air site side, then raise the other side in the same
lines to the brake air chambers. For instructions, manner. On each side, hold the tilted position for
see Group 42. three minutes to allow oil to run into the wheel
end.
7. Install the brake shoes, as removed. For instruc-
tions, see the applicable service brake section in
Group 42. NOTICE
8. If installed, disengage the DCDL (main differen- Make sure the hubs are filled. Driving with the
tial lock). hubs dry will cause bearing damage.
9. Using new gaskets, install the axle shafts. For 20. Turn the wheels, wait one minute, and check the
instructions, see Subject 120. lubricant level.
10. Connect the main driveshaft to the forward input 21. Raise the vehicle, remove the safety stands,
yoke. For instructions, see Section 41.00, Sub- then lower the vehicle.
ject 120. 22. If applicable, connect the suspension leveling
11. Connect the air hoses to the air cylinder for the valve(s). Start the engine, build the air pressure,
interaxle lock and (if installed) the wheel lock. and make sure the suspension air bags inflate
correctly. Make sure the ride height is correct.
12. Connect the electrical connector of the sensor For instructions, see Group 32.
unit for axles equipped with a wheel lock.
23. Check the operation of the wheel lock, if in-
13. Fill each hub with approved axle oil until you can stalled.
see a little amount of oil trickling out of the back
of the hub (use about 0.8 quart, or 0.75 liter). 24. Check the oil level in the axle housing. The level
Install the hubs on the axle spindles, and adjust should be up to the bottom of the fill hole. Add
the wheel bearings. For instructions, see the ap- approved axle oil, if needed.
plicable subject in Section 35.01. See Table 1 25. Set the parking brake.
for approved axle oils.
14. Install the brake drums on the hubs.
Group 40.
16. Adjust the brakes. For instructions, see the appli-
cable service brake section in Group 42.
17. Uncage the parking brake springs.

Forward-Rear Tandem Axle Differential Carrier
Removal and installation
For forward-rear axle components of a tandem instal- 9. Remove the differential carrier from the axle
lation, see Fig. 1. housing, as follows.
Do not disassemble the forward differential carrier. 9.1 If equipped with a wheel lock, engage the
There are no serviceable parts in the differential as- lock with air. This will help separate the
sembly; it must be replaced as a unit. However, it is carrier assembly from the axle housing.
possible to remove the differential carrier to repair an 9.2 Remove all but the top two carrier cap-
oil leak. screws.
9.3 Loosen and back off, but do not remove,
Removal the top two fasteners. The fasteners will
hold the carrier in the housing.
the engine, set the parking brake, and chock the 9.4 Using a pry bar, separate the mating sur-
front tires. Put the transmission in neutral. faces of the forward differential carrier and
axle housing.
2. If applicable, release the suspension air pres-
sure. NOTE: Use a pry bar that has a round end
3. Using suitable jacks, raise the vehicle evenly to help separate the carrier from the hous-
until there is room to fit a jack underneath the ing.
axle housing. 9.5 When the surfaces are separated, finish
4. Remove the tires and wheels. For instructions, removing the top two capscrews.
see Group 40.
9.6 With the carrier on the jack, slide the car-
5. Remove the oil drain plug from the bottom of the rier away from the rear axle housing.
axle housing and drain the oil from the axle
housing. Install the drain plug after emptying. 9.7 Lift the carrier assembly onto a suitable
stand.
6. Disconnect the driveshaft from the carrier yoke.
For instructions, see Section 41.00, Sub-
ject 120. Using suitable straps, support the end Installation
NOTE: Use a cleaning solvent and clean rags to
7. Place a basin under the axle shaft flanges to remove dirt. Blow dry the cleaned areas with air.
catch any oil; then remove the axle shafts. For
instructions, see Subject 120. 1. Remove any old sealant material from the mating
surfaces of the axle housing. Clean the inside of
the axle housing and the carrier mating surface.
WARNING
2. Inspect the axle housing for damage. Repair or
The differential carrier is heavy. Do not try to replace the axle housing as necessary.
move it without a suitable support. To do so
could result in the carrier falling, which could 3. Apply a thin bead of Loctite 5900 sealant all the
cause serious personal injury and component way around the mating surface of the axle hous-
damage. Support the carrier with a suitable jack ing, and around each bolt hole.
and chain it to the jack, or use a hoist if the axle NOTE: Alignment dowels for installing the differ-
has been removed from the vehicle. ential carrier can be made by sawing off the
8. Using a suitable jack, support the differential car- heads of two M16 x 1.5 x 100 mm bolts.
rier. Chain the differential carrier to the jack. 4. Install alignment dowels 180 degrees apart at the
3 oclock and 9 oclock positions on the axle
NOTICE housing flange.
When using a pry bar, be careful not to damage
the carrier or housing flange. Damage to these
surfaces will cause oil leaks.

4
5
6
7
05/05/2005 f350456
1. Axle Shaft 4. Input Seal 6. Input Yoke Nut
2. Forward-Rear Axle Housing 5. Carrier Yoke 7. Forward Differential Carrier
3. Carrier Capscrew
Fig. 1, Forward-Rear Tandem Axle Components
5. Position the forward differential carrier in front of

WARNING the axle housing, using an axle jack or other suit-
able lifting tool.
The differential carrier is heavy. Do not try to
move it without a suitable support. To do so 6. If equipped with a wheel lock, engage the lock
could result in the carrier falling, which could with air. This will help the carrier assembly join
cause serious personal injury and component the axle housing.
damage. Support the carrier with a suitable jack
and chain it to the jack, or use a hoist if the axle
has been removed from the vehicle.


NOTICE the bottom of the fill hole, or until filled to capac-
Do not use a hammer or a mallet to install the
differential carrier. A hammer or a mallet will
damage the mounting flange of the carrier and Forward-Rear Axle Oil Type and Capacity
cause oil leaks. Capacity: quarts (liters)
Approved Oil Type
7. Install the end caps on the sides of the forward Hubs Full Hubs Dry
differential carrier into the corresponding slots in 80W-90 Gear Oil
the axle housing. See Fig. 2. 14.3 (13.5) 15.9 (15.0)
1 Table 1, Forward-Rear Axle Oil Type and Capacity
2
15. If the hubs are dry, raise one side of the vehicle
about 8 inches (20 cm) to let the oil flow into the
hub on the opposite side, then raise the other
side in the same manner. On each side, hold the
tilted position for three minutes to allow oil to run
into the wheel end.
3
NOTICE
11/10/2004 f350438 16. Turn the wheels, wait one minute, then check the
lubricant level.
1. Differential Carrier
2. End Cap Bolt 17. Raise the vehicle, remove the safety stands,
3. End Cap then lower the vehicle.
Fig. 2, Carrier End Caps

18. Start the engine, build the air pressure, and
check that the suspension air bags inflate evenly
8. For the last 3/4 inch (19 mm) or so of travel, and correctly. Make sure the ride height is cor-
walk the carrier slowly into the housing. rect.
IMPORTANT: The end caps fit tightly into the 19. Check the oil level in the axle housing. The level
axle housing. Be very careful not to cock the should be up to the bottom of the fill hole. Add
carrier. approved axle oil, if needed.
9. Install the forward carrier capscrews finger-tight.

Make sure the carrier capscrews turn easily in
the axle housing.
10. In a star pattern, gradually tighten the M16 cap-
screws 200 lbfft (270 Nm).
11. Connect the driveshaft to the carrier yoke. For
12. Using new gaskets, install the axle shafts. For
instructions, see Subject 120.
Group 40.

Thru-Shaft Repair
Repair 9. Install the outer bearing race onto the thru-shaft

and bore.
1. Remove the output yoke nut, washer, and output 10. Install the snap ring and spacer. Use the next
yoke. Then remove the output oil seal from the thicker snap ring from the snap ring pack sup-
thru-shaft bore. See Subject 170. plied with the bearings.
2. Remove the snap ring and spacer from the thru- 11. Install a new output oil seal. See Subject 170.
shaft. See Fig. 1.
12. Install the output yoke, and the new nut and
washer. See Subject 170. Make sure the output
yoke nut is firmly tightened, but do not tighten
3 the nut to specifications at this time.
1
13. Attach a dial indicator to the flat surface of the
4 2 output yoke.
5
6 14. Using a pry bar or other lever, apply force to the
base of the output yoke. If the dial indicator
7 shows a deflection of 0.0012 to 0.0024 inch
8
9 (0.03 to 0.06 mm), the end play is correct.
10
11 If the deflection is too large, use a thicker snap
12 ring. If the deflection is too small, use a thinner
snap ring.
13 15. Remove the yoke nut, and coat its threads with
Loctite 577. Install the nut, and tighten it 516
lbfft (700 Nm).
05/04/2005 f350451
1. Output Yoke Nut 8. Outer Bearing

2. Washer 9. Outer Bearing Cup
3. Output Yoke 10. Inner Bearing Cup
4. Output Oil Seal 11. Inner Bearing
5. Spacer 12. Inner Bearing Race
6. Snap Ring 13. Thru-Shaft
7. Outer Bearing Race
Fig. 1, Thru-Shaft Components
3. Using a suitable shaft puller, draw the thru-shaft

out of the bore.
4. Using a suitable bearing puller on the outer
races, remove both the inner and outer bearings
from the thru-shaft.
5. Inspect the bearings for wear and damage. Re-
place both bearings if any damage is found.
6. Install the inner bearing race in the thru-shaft
bore.
7. Using an arbor press or other suitable pressing
tool, press the bearings and bearing cups onto
the thru-shaft.
8. Insert the thru-shaft into its bore.

Single or Rearmost Axle Yoke and Seal
Replacement
Special Tools
Special tools are required for this procedure. See
Table 1.
Special Tools
Tool Description Manufacturer Part Number
Universal Handle* Kent-Moore J-8092

f580400
Rear Pinion Seal Installer* Kent-Moore J-47354
f580406
Yoke Nut Socket Axle Alliance Special Tool DDE W742589020700
f580450
* To order Kent-Moore tools call 1-800-328-6657.

The yoke nut socket is needed to remove the round, slotted yoke nut installed on some vehicles. It can be ordered through Paragon.
Table 1, Special Tools
Replacement 4. Remove the carrier yoke from the input shaft. Be

careful not to damage the seal bore.
1. Park the vehicle on a level surface, shut down 5. Pry up the seal, using a prybar or large screw-
the engine, set the parking brake, and chock the driver. Clean any old sealant from the axle hous-
tires. ing. Do not allow dirt or grease to contaminate
2. Disconnect the driveshaft from the input yoke. the seal bore or shaft bearings. See Fig. 2.
For instructions, see Section 41.00, Sub- 6. Install a new rear pinion seal on the input shaft.
ject 120. Using suitable straps, support the end See Fig. 3.
6.1 Inspect the area around the seal for dam-
3. Remove the yoke nut from the center of the car- age. Use emery paper to remove
rier yoke. If the yoke nut is round and slotted, scratches, nicks, or burrs on the seal
use the yoke nut socket shown in Table 1. See bore.
Fig. 1. Be careful not to damage the seal bore.
6.2 Assemble the rear pinion seal installer
NOTE: Older models may not require the spe- onto the threaded end of the universal
cial socket for yoke nut removal. handle. See Table 1.
Western Star Workshop Manual, Supplement 13, November 2009 160/1

Single or Rearmost Axle Yoke and Seal
Replacement
IMPORTANT: Be careful not to cock the seal

1 2
during installation.
6.3 Using the rear pinion seal installer assem-
bly, press the seal into the bore until the
seal surface is flush with the bottom sur- 3
face of the counterbore.
7. Install the carrier yoke on the input shaft. If the
yoke is damaged or worn, install a new yoke.
NOTE: It is not necessary to replace the yoke
when replacing the seal.
8. Install a new M45 x 1.5 pinion nut on the carrier
yoke, and tighten the nut 627 lbfft (850 Nm).
9. Punch in the cylindrical area at the pinion groove
to lock the nut in place.
IMPORTANT: The bent area has to reach the
bottom of the pinion groove.
05/05/2005 f350450
10. Connect the driveshaft. For instructions, see
Section 41.00, Subject 120. 1. Input Shaft 3. Carrier Housing
2. Rear Pinion Seal
Fig. 2, Rear Pinion Seal
1
2
1
2
04/01/2008 f350496
3
NOTE: The yoke nut may be a hexnut rather than the
round, slotted nut shown here.
1. Yoke 2. Yoke Nut
Fig. 1, Yoke Nut on the Carrier
05/12/2005 f350448
1. Universal Handle
2. Rear Pinion Seal Installer
3. Carrier Housing
Fig. 3, Installing the Rear Pinion Seal
160/2 Western Star Workshop Manual, Supplement 13, November 2009

Forward-Rear Axle Yoke and Seal Replacement
Special Tools
Table 1.
Special Tools for Forward-Rear Axle Yoke and Seal Replacement


f580400
Input Seal Installer* Kent-Moore J-47369
f580410
Output Seal Installer* Kent-Moore J-47368
f580408
Yoke Nut Socket Axle Alliance Special Tool DDE W742589020700
f580450

Table 1, Special Tools for Forward-Rear Axle Yoke and Seal Replacement
Replacement 2. Disconnect the main driveshaft from the forward

carrier input yoke. For instructions, see Sec-
Forward Carrier Input Yoke and support the end of the driveshaft by attaching it
Seal to the frame rail.
1. Park the vehicle on a level surface, shut down 3. Remove the input yoke nut and washer from the
center of the forward carrier input yoke.
the engine, set the parking brake, and chock the
tires. 4. Remove the old forward carrier input yoke from
the forward input shaft.

5. If there is an oil leak at the threaded ring, repair

it; for instructions, see Subject 200.
6. If there is a leak between the bearing cage and
the axle housing, remove the bearing cage, as
follows. See Fig. 1.
3 1
4
2 5
3
1
7 04/01/2005 f350447
1. Universal Handle 3. Carrier Housing
01/21/2008 f350452a
2. Input Seal Installer
1. Forward Carrier Housing Fig. 2, Installing the Forward Carrier Input Seal
2. Bearing Cage Mounting Capscrew
3. Input Yoke Nut 8.2 Assemble the input shaft seal installer
4. Input Shaft onto the threaded end of the universal
5. Bearing Cage
6. Interaxle Lock Bore
handle. See Table 1.
7. Threaded Ring 8.3 Using the input shaft seal installer assem-
Fig. 1, Bearing Cage seal surface is flush with the threaded
ring.
6.1 Remove the bearing cage capscrews.
9. On the mating surface of the bearing cage, lay
6.2 Pry the bearing cage from the forward car- down a bead of Loctite 5900 sealant, or equiva-
rier housing. Clean any remnants of seal- lent. Go around all of the bolt holes and other
ant clinging to the mating surfaces of the openings in the inside cover of the bearing cage.
carrier housing and the bearing cage. See Fig. 3.
7. Pry up the input seal, using a prybar or large IMPORTANT: Do not allow sealant to get into
screwdriver. Clean any old sealant from the axle
housing. Do not allow dirt or grease to contami-
the interaxle lock bore. See Fig. 4. Do not at-
nate the seal bore or shaft bearings. tempt to repair the interaxle lock (IAD). No re-
pairs to this component are possible.
8. Install a new seal in the input shaft bore, as fol-
lows. See Fig. 2. 10. Install the bearing cage onto the forward carrier
housing. Tighten the M12 bearing cage cap-
8.1 Inspect the area around the seal for dam- screws 107 lbfft (145 Nm).
age. Use emery paper to remove
scratches, nicks, or burrs on the seal 11. Install the forward carrier input yoke on the for-
bore. ward input shaft. If the yoke is damaged or worn,
install a new yoke.

input yoke nut on the yoke. Tighten the nut 627

1 2 3 lbfft (850 Nm).
4 13. Connect the main driveshaft. For instructions,
see Section 41.00, Subject 120.
Output Yoke and Seal

tires.
2. Disconnect the interaxle driveshaft from the out-
put yoke. For instructions, see Sec-
support the end of the driveshaft by attaching it
5 to the frame rail.
3. Remove the output yoke nut and washer.
4. Remove the output yoke from the thru-shaft. See
Fig. 5.
06/21/2005 f350453
Apply a bead of sealant to the inner mating surface as
shown.
1. Inside Cover 3. Interaxle Lock Bore
2. Mounting Capscrew 4. Sealant
Hole 5. Mating Surface
Fig. 3, Sealant Application
2
3
4
1
05/05/2005 f350455
1. Output Yoke 3. Thru-Shaft
2. Output Yoke Nut 4. Axle Housing
Fig. 5, Output Yoke
5. Pry up the output oil seal, using a prybar or large

05/04/2005 f350454
screwdriver. Clean any old sealant from the axle
Keep sealant away from this bore. housing. Do not allow dirt or grease to contami-
Fig. 4, Interaxle Lock Bore nate the seal bore or thru-shaft bearings.
6. Install a new seal on the thru-shaft, as follows.
12. Coat the threads of a new M45 x 1.5 input yoke
nut with Loctite 277. Install the new washer and

6.1 Inspect the area around the output oil seal

for damage. Use emery paper to remove
scratches, nicks, or burrs on the seal
bore.
6.2 Assemble the output seal installer onto the
threaded end of the universal handle. See
Table 1.
6.3 Using the output seal installer assembly,
press the seal into the bore until the seal
surface is flush with the thru-shaft recep-
tacle.
7. Install the output yoke on the thru-shaft. If the
yoke is damaged or worn, install a new yoke.
8. Coat the threads of a new M39 x 1.5 output yoke
nut with Loctite 577. Install the new washer and
output yoke nut on the yoke. Tighten the nut 516
lbfft (700 Nm).
9. Connect the interaxle driveshaft. For instructions,
see Section 41.00, Subject 120.

Main Differential Lock Disassembly and
Assembly
General Information 6. Remove the three bolts that attach the air inter-
face to the carrier housing.
Commonly known as DCDL (Driver-Controlled Differ- 7. Remove the air interface and gasket.
ential Lock), a main differential lock is available on 8. Remove the shift shaft piston from the bore in
single and tandem rear axles. On tandem rear axles the carrier housing, and note the number of
DCDL is available for the forward, rear, or both axles. shims found on the piston. There should be at
The following procedures only apply to Model 4 rear least one shim, and a maximum of three.
axles with optional DCDL.
9. Compress the spring and pull the shift fork from
Each part of the main differential lock is replaceable. the carrier housing.
See Fig. 1.
10. Remove the spring from the carrier housing.
Assembly
12
1. Install the spring in the carrier housing, and com-
1 press it to install the shift fork in the housing. En-
2 3 sure that the spring is centered in the bore.
5 2. Ensure the O-ring on the shift shaft piston is
6 properly installed and lubricated. Then install the
4 7 piston, being careful to properly align it in the
8 bore. Do not force the piston into the bore.
9
10 11 3. Place the air interface and gasket over the air
01/22/2008 f350495
interface bore, and insert the three capscrews
1. Capscrew 7. Spring that attach the air interface to the carrier hous-
2. Air Intake 8. Fork ing. Tighten the capscrews in a regular sequence
3. Air Interface Gasket 9. Alignment Boss
4. Sending Unit 10. Snap Ring
that ensures it seats evenly. Tighten the cap-
5. O-Ring 11. Clutch Collar screws 19 lbfft (25 Nm).
6. Shift Shaft Piston 12. Retaining Clip 4. Install the clutch collar.
Fig. 1, DCDL Components 5. Install the retaining clip on the shift fork.
6. Install the DCDL sending unit in the carrier hous-
Disassembly ing, as removed.
7. Connect the DCDL air line, and engage the
1. Park the vehicle on a level surface, shut down DCDL. Ensure the teeth of the lock fully engage
the engine, set the parking brake, and chock the the teeth of the gear inside the carrier housing.
front tires.
8. The clearance between the clutch collar and ring
2. Remove the differential carrier, and place it on a gear must be between 0.4 and 1.4 mm. Engage
work stand. the DCDL, and use a feeler gauge to measure
To remove a single or rearmost axle differential the gap.
carrier, see Subject 110. If the gap between the clutch collar and ring gear
To remove a forward-rear differential carrier, see measured between 0.4 and 1.4 mm, ensure the
Subject 140. same number of shims are on the shift shaft pis-
ton (as when it was removed).
3. Unlatch the retaining clip, and remove it. See
Fig. 1. If the gap between the clutch collar and ring gear
was not between 0.4 and 1.4 mm, add or re-
4. Remove the clutch collar.
move shims to vary the gap until it measures
5. Remove the DCDL sending unit from the carrier within the acceptable range. The acceptable
housing.

Main Differential Lock Disassembly and
Assembly
maximum number of shims is three, and the

minimum is one.
9. Install the differential carrier.
For instructions on installing a single or rearmost
axle differential carrier, see Subject 110.
For instructions on installing a forward-rear axle
differential carrier, see Subject 140.
10. Remove the chocks.

Interaxle Differential Lock Adjustment
Adjustment
The Interaxle Differential (IAD) has an adjustment
screw that can become loose or even fall out, caus-
ing an oil leak, and malfunction of the IAD. To ensure
the adjustment screw is properly tightened and se- 1
cured, follow the steps below. The IAD is sometimes
called the power divider. See Fig. 1.
1. Chock the front tires.
2. Use the IAD switch in the cab to engage the
lock.
3
3. At the forward-rear axle, rotate one of the wheels 2
to ensure the teeth of the lock fully engage the
teeth of the gear inside the carrier housing.
4. Remove the adjustment screw, and using a suit-
able solvent (such as brake cleaner), clean the
threads of the screw and bore. Dry the surfaces 01/21/2008 f350494
completely, making sure no cleaning solvent re- 1. Carrier Housing 3. Adjustment Screw
mains. 2. Locknut
5. Coat the threads of the adjustment screw with Fig. 1, Interaxle Differential and Adjustment Screw
Loctite 577, install it, and hand-tighten it until it
hits the shaft.
6. Disengage the IAD to relieve the air pressure
exerted on the adjustment screw.
7. Hand-tighten the adjustment screw one quarter
turn, then tighten the locknut 30 lbfft (41 Nm).

Threaded Ring Repair
Special Tools
Table 1.
Special Tools for Threaded Ring Repair


f580400
f580410
Table 1, Special Tools for Threaded Ring Repair
Repair
1. Apply the parking brakes, shut down the engine,
and chock the tires. 3
2
2. Disconnect the main driveshaft from the forward
carrier input yoke. For instructions, see Sec-
support the end of the driveshaft by attaching it
to the frame rail.
3. Remove the yoke nut and washer from the input 4
shaft of the forward differential carrier, then re-
move the yoke. 5
4. Remove the capscrew and the locking plate from
the bearing cage on the front of the differential 1
carrier. See Fig. 1. 09/15/2006 f350472
5. Using a spanner wrench, remove the threaded 1. Bearing Cage
ring to expose the bearing cavity. See Fig. 2. 2. Threaded Ring
3. Input Shaft (yoke removed)
6. Using a suitable solvent, such as brake cleaner, 4. Capscrew
clean the surface of the bearing cavity. See 5. Locking Plate
Fig. 2. Dry the surface, making sure no cleaning
solvent remains. Fig. 1, Forward-Rear Axle Differential Housing
7. Coat the threads of the threaded ring with Loc-
then spread the sealant evenly over the threads,
tite 577 sealant. Apply a 1/8-inch (3-mm) diam-
so that all threads are thoroughly covered with
eter bead all the way around the bottom thread,
the sealant.

9. Install the old yoke nut on the input shaft to pro-

tect the threads, then strike the nut sharply with
A a brass mallet to unseat the bearing.
10. Adjust the initial bearing preload to 0.002 inch
(0.05 mm), as follows:
10.1 Install a dial indicator on the bearing cage,
and using two pry bars, pry up evenly on
the yoke nut (and the input shaft) to deter-
mine the bearing preload. See Fig. 4.
09/18/2006 f350468
A. Clean and dry this entire surface. 2
Fig. 2, Bearing Cavity Exposed
8. Install the threaded ring (without the new input-

shaft seal) and turn it clockwise (tighten it)
enough to form a uniform bead of sealant all the
way around the threaded ring. See Fig. 3.
09/18/2006 f350473
1. Dial Indicator 2. Old Yoke Nut
Fig. 4, Measuring Bearing Preload
10.2 Tighten the threaded ring until the dial in-

1
dicator reads 0.002 inch (0.05 mm).
A
11. Using a suitable marker or paint, mark the center
of one of the teeth on the threaded ring and the
surface of the bearing cage. See Fig. 5.
09/14/2006 f350470 IMPORTANT: The next step is critical. Tighten-
A. Loctite Bead from the Threads ing the threaded ring by advancing it one tooth
will set the bearing preload to 0.00 to 0.0012
1. Threaded Ring
inch (0.00 to 0.03 mm). If you tighten the
Fig. 3, Preliminary Installation of the New Threaded
threaded ring beyond this tolerance, you cannot
Ring back it off; you will need to remove the threaded
ring and repeat the entire installation procedure.

09/14/2006 f350471 09/14/2006 f350469

A. Measure preload at this point. At final tightening,
Fig. 5, Marking the Tooth and Bearing Cage this mark should be opposite the center of the next
tooth, but no further.
12. Very carefully advance the threaded ring one
tooth while checking the paint mark. Stay close
Fig. 6, Advancing the Threaded Ring
to a one-tooth advancement when making the
final adjustment. Bear in mind that the new lock-
ing plate must fit into place once the correct
tightness is achieved. The locking tab should fit
in place either slightly before or slightly past a
one-tooth advancement of the threaded ring. You
cannot back off the threaded ring once it is tight-
ened.
Try fitting the new locking plate in place by turn- 1
ing and flipping it over as you slowly tighten the
threaded ring. Tighten the threaded ring so the
bearing preload is 0.00 to 0.0012 inch (0.00 to
0.03 mm). When the correct tolerance is
reached, the mark on the surface of the bearing
cage should line up with the center of the next
tooth. See Fig. 6. Do not tighten the threaded 2
ring any further.
3
13. When the bearing preload is correct, install the
new locking plate and capscrew. Tighten the cap-
screw 18 lbfft (24 Nm).
04/01/2005 f350447
14. Install the new input-shaft seal as follows (see
1. Universal Handle (Kent-Moore tool, J-8092)
Fig. 7): 2. Input Seal Installer (Kent-Moore tool, J-47369)
14.1 Inspect the area around the seal for dam- 3. Carrier Housing
age. Use emery paper to remove
scratches, nicks, or burrs on the seal Fig. 7, Installing the Forward Carrier Input Seal
bore. 14.4 Assemble the input shaft seal installer
14.2 Apply a light coating of axle oil to the seal onto the threaded end of the universal
bore. handle. See Fig. 7.
14.3 Coat the mating surfaces of the new seal
with Loctite 5900 sealant, or equivalent.

14.5 Using the input shaft seal installer assem-

seal surface is flush with the threaded
ring.
15. Apply Loctite 242 to the threads of the new yoke
nut, then using it and a new washer, install the
existing yoke on the input shaft. Tighten the yoke
nut 628 lbfft (850 Nm).
16. Connect the main driveshaft to the input shaft.
For instructions, see Section 41.00, Sub-
ject 120.

Interaxle Differential Replacement
The following on-vehicle procedure replaces the in-

teraxle differential (IAD) assembly and accomplishes
a minor carrier rebuild by replacing the bearing races
and, as needed, the shift shaft bushing. The front
cover is resealed and the input shaft seal is re-
placed. See Fig 1.
Special Tools
Table 1.
17
18 16
15
12 14
19
11
20 13
21
22
10
4 9
3 8
2
1 7
6
09/28/2010 f350514
1. Yoke Nut 9. Piston Spring 16. IAD Adjustment Screw
2. Washer 10. Shift Fork 17. Output Bearing Race
3. Input Shaft Seal 11. Shift Shaft Bushing O-ring 18. IAD Assembly
4. Threaded Ring 12. Shift Shaft Bushing 19. Clutch Collar
5. Bearing Cage Capscrews 13. Cover Plate 20. Input Bearing Race
6. Bearing Cage 14. Carrier Housing 21. Locking Plate
7. Shift Shaft Piston O-ring 15. Locknut 22. Locking Plate Capscrew
8. Shift Shaft Piston
Fig. 1, The Interaxle Differential and Carrier Housing Components

Special Tools for Interaxle Differential Replacement

Output Bearing Remover and

Axle Alliance Special Tool MBA 420589003300
Installer
f580478
Shift Shaft Bushing Remover

and Installer
f580480
Slide Hammer Axle Alliance Special Tool MBA 060589003300
f580476
Half-Moon Device Axle Alliance Special Tool MBA 420589006300
f580479
Push-Pull Device Axle Alliance Special Tool MBA 420589001600
f580477

Special Tools for Interaxle Differential Replacement

Shift Shaft Piston Installer Axle Alliance Special Tool MBA 420589023300
f580481
Table 1, Special Tools for Interaxle Differential Replacement
Replacement
front tires.
2. Ensure the interaxle differential is disengaged
and the system is charged with air. The rear
wheels will need to turn near the end of this pro-
cedure.
3. Place a suitable strap around the driveshaft and
frame to hold the driveshaft out of the way after
it is disconnected.
4. Disconnect the main driveshaft from the forward
carrier input yoke (for instructions, see Sec-
tion 41.00, Subject 120), and support it with the
strap.
5. Clean the carrier housing and surrounding area
as needed to remove any debris that could enter
the housing.
6. Drain the oil from the carrier housing.
07/15/2010 f350515
7. Disconnect the air line connected to the bearing
cage. Fig. 2, Tapping the Bearing Cage Loose
8. Remove the yoke nut and washer from the input 12. Remove the IAD adjustment screw and locknut.
shaft of the forward differential carrier, then re-
move the yoke.
9. Remove the capscrew and the locking plate. See
NOTICE
Fig 1. When unseating the shift shaft piston, multiple
10. Using a spanner wrench, remove the threaded taps may be needed, but use moderate force only
ring by turning it counterclockwise. and be careful to hit the piston only (not the
housing). Stop tapping it once it protrudes from
11. Remove the bearing cage capscrews from the the housing. The use of excessive force, or tap-
bearing cage, and pry the bearing cage from the ping it while it protrudes from the housing can
carrier housing. It may help to tap the bearing damage the piston and the housing.
cage loose with a chisel; see Fig. 2.

13. Using a brass or plastic mallet, squarely tap the

shift shaft piston to unseat it, and then remove it
from the carrier housing.
14. Remove the piston spring, clutch collar, and shift
fork.
NOTICE
The IAD assembly is heavy. Use appropriate sup-
port while removing and transporting it to pre-
vent dropping and damaging it. Do not allow it to
rest on the oil slinger; see Fig. 3. Resting the IAD
assembly on the oil slinger could damage the oil
slinger.
07/15/2010 f350517
15. Remove the IAD assembly.
16. Align the output bearing remover (see Table 1) Fig. 4, Removing the Output Bearing Race
with the notches in the rear of the carrier hous-
ing, then attach it to the housing with bearing
cage capscrews, and use it to remove the output
bearing race. See Fig. 4. 1
17. If the brass shift shaft bushing is damaged or 2
worn, assemble the slide hammer and shift shaft
bushing remover (see Table 1), and slide the
hammer handle to remove the bushing. See
Fig. 5.
18. Using a suitable solvent (such as brake cleaner),
clean any remaining sealant from the threaded
ring and mating surfaces of the carrier housing 3
and the bearing cage. Dry the surfaces with
compressed air, ensuring no cleaning solvent
remains.
08/04/2010 f350526
1. Shift Shaft Bushing
2. Shift Shaft Bushing Remover
3. Slide Hammer
Fig. 5, Installing the Bushing Remover
19. As in the previous step, clean the groove at the

piston bushing bore.
20. If the brass shift shaft bushing was removed, in-
stall a new one using a mallet and the Shift Shaft
Bushing Installer. See Fig. 6.
07/15/2010 f350516
21. A new output bearing race is included with the
Fig. 3, Oil Slinger new IAD. Install it as follows.
21.1 To get it started, lightly tap the race into
place with a hammer handle or wood

2
1
08/04/2010 f350527
1. Shift Shaft Bushing Installer

2. Shift Shaft Bushing
Fig. 6, Installing the Bushing
block. The race must be square in the

housing or damage will occur when it is
pressed. See Fig. 7.
07/15/2010 f350518
21.2 Fasten the output bearing installer to the
carrier housing, and use it to press the Fig. 7, Setting the Race
race into the housing. As the race is in-
stalled, slight jerks can be felt and heard.
See Fig. 8.
22. Lubricate the output gear and bearing of the new
IAD assembly with white grease.
23. Install the IAD assembly and output gear. Do not
allow the assembly to rest on the oil slinger.
24. Install the clutch collar and shift fork.
25. Apply a thin film of white grease to the shift shaft
piston, and insert it with the piston spring into the
housing until about 1 inch (2.5 cm) of the piston
protrudes from the bore.
26. The half-moon device (see Table 1) helps align
the shift fork and shift shaft piston. To install it,
slide it between the oil slinger and the shift fork.
See Fig. 9.
27. Install the shift shaft piston as follows.
27.1 The shift shaft piston installer (see
Table 1) is designed to install the piston 07/15/2010 f350519
without damaging it or the carrier housing.

Fig. 8, Pressing a New Race into the Housing
Use two bearing cage capscrews to mount
it to the carrier housing. See Fig. 10. 27.3 In a single movement of moderate force,
27.2 Adjust the hex screw until the shift fork is use the lever of the installer to press the
snug but not bound. piston into the bore until only about 1/8 to

28. Remove the input bearing race from the bearing

cage. Place the new race into the cage so that it
is more forward than in the final position. As the
preload is adjusted, the race will seat to its final
position.
29. Apply Loctite 577 sealant to the threads of the
threaded ring and tighten it until it is snug
against the race.
IMPORTANT: Do not overapply sealant. Do not
allow sealant to enter the oil return or touch the
shift shaft piston.
30. Apply a small bead of Loctite 5900 to the carrier
housing. See Fig. 11. To help ensure a good
seal, spread it uniformly over the surface area.
07/19/2010 f350520
1
Fig. 9, The Half-Moon Device, Installed
2
2
08/31/2010 f350522a
1. Oil Return 2. Shift Shaft Piston
08/04/2010 f350521
1. Capscrews 2. Hex Screw Fig. 11, Sealant Applied to Carrier Housing
31. Install the bearing cage, and using a star pattern

Fig. 10, Shift Shaft Piston Installer, Mounted tighten the capscrews to 103 lbfft (140 Nm).
1/16 inch (2 to 3 mm) of the piston pro- 32. The push-pull device (see Table 1) is used to set
trudes from the carrier housing. When the pre-load on the input bearing. Remove the two
piston seats, a "click" sound may be au- upper capscrews from the cover plate and install
dible. If the piston does not seat readily, the device as shown in Fig. 12.
adjust the hex screw, and try again.
33. Set the correct end play as follows.
27.4 Once the piston is seated, remove the
33.1 Set up a dial indicator as shown in
shift shaft piston installer and the half-
Fig. 13.
moon device.

07/16/2010 f350523 07/21/2010 f350524
Fig. 12, Push-Pull Device, Installed Fig. 13, Dial Indicator and Push-Pull Device
33.2 Turn the input shaft three revolutions and

tighten the threaded ring until there is be-
tween 0.002 and 0.003 inch (0.05 and
0.08 mm) of end play. Turn the input shaft
three more revolutions and verify the mea-
surement.
33.3 When there is between 0.002 and 0.003
inch (0.05 and 0.08 mm) of end play, align
a mark on the threaded ring with one on
the bearing cage. See Fig. 14.
33.4 Tighten the threaded ring almost one
notch. 07/19/2010 f350525
IMPORTANT: Do not loosen the threaded
Fig. 14, Threaded Ring and Bearing Cage, Marked
ring. If the threaded ring is loosened, the
bearing cage must be removed and the race 33.6 Remove the push-pull device and dial indi-
re-installed. cator, and install the the two upper cap-
screws on the cover plate. Tighten the
33.5 The locking plate has six positions that
capscrews 63 lbfft (85 Nm).
can lock the threaded ring. Find the posi-
tion that fits best, install it, and tighten the 34. Install a new input shaft seal and the yoke, nut,
capscrew 18 lbfft (24 Nm). and washer; see Subject 170 for instructions.

35. Clean, install, and adjust the IAD adjustment

screw and locknut as follows.
35.1 Clean the IAD adjustment screw and lock-
nut with a suitable solvent (such as brake
cleaner). Dry the cleaned surfaces, ensur-
ing no solvent remains.
35.2 Connect an air line at the interaxle lock.
35.3 Apply air, and by hand, turn the input shaft
to ensure the gear cogs fully engage.
35.4 Coat the threads of the adjustment screw
with Loctite 577.
35.5 Install the adjustment screw, with the lock-
nut, into the carrier housing, and
handtighten the screw until it touches the
engaged shift shaft piston.
35.6 Disengage the IAD to relieve the air pres-
sure exerted on the adjustment screw.
35.7 Hand-tighten the adjustment screw one
quarter turn, then tighten the locknut 30
lbfft (41 Nm).
36. Connect the main driveshaft; for instructions, see
Section 41.00, Subject 120.
Forward-Rear Axle Oil Type and Capacity

Capacity: quarts (liters)
Approved Oil Type
Hubs Full Hubs Dry
80W-90 Gear Oil
14.3 (13.5) 15.9 (15.0)
Table 2, Forward-Rear Axle Oil Type and Capacity
38. To lubricate the wheel ends, tilt the axle to the

left and right by jacking the opposite side 8
inches (20 cm). Hold the tilted position for two
minutes on each side to allow oil to run into the
wheel end. Return the axle to a level position,
and add oil through the axle housing filler hole.
About two more pints (1 liter) of lubricant will be
needed to bring the oil level even with the base
of the filler hole.

Specifications
Torque Values
Application Size Torque: lbfft (Nm)
All Model 4 Axles
Carrier Capscrews M16 200 (270)
1/220 75115 (102156)
Drive Axle Stud Nuts
5/818 150170 (203230)
Yoke Nut (model 4 axles) M45 x 1.5 627 (850)
Forward-Rear Axles
Bearing Cage Capscrews M12 107 (145)
Input Yoke Nut M45 x 1.5 627 (850)
Output Yoke Nut M39 x 1.5 516 (700)
Table 1, Torque Values
Rear Axle Lubricant Type and Capacity

Oil Capacity: quarts (liters)
Approved Lubricant Type Axle
Hubs Full Hubs Dry
80W/90 Gear Oil
Forward-Rear 14.3 (13.5) 15.9 (15.0)
75W/90 Synthetic Gear Oil
80W/90 Gear Oil Single and Rearmost
10.6 (10.0) 12.2 (11.5)
75W/90 Synthetic Gear Oil Tandem
Table 2, Rear Axle Lubricant Type and Capacity
Special Tools for Freightliner Rear Axles


f580400
Rear Pinion Seal Installer* Kent-Moore J-47354
f580406

Specifications

f580410
Output Seal Installer* Kent-Moore J-47368
f580408
Yoke Nut Socket Axle Alliance Special Tool MBA 742589020700
f580450
Output Bearing Remover and

Installer
f580478
Shift Shaft Bushing Remover

and Installer
f580480
Slide Hammer Axle Alliance Special Tool MBA 060589003300
f580476

Specifications

Half-Moon Device Axle Alliance Special Tool MBA 420589006300
f580479
Push-Pull Device Axle Alliance Special Tool MBA 420589001600
f580477
Shift Shaft Piston Installer Axle Alliance Special Tool MBA 420589023300
f580481

Table 3, Special Tools for Freightliner Rear Axles

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Freightliner Rear Axles 35.

Fig. 1, Rear Axle ID Tag

Freightliner rear axles may have a main differential

Western Star Workshop Manual, Supplement 12, May 2009 050/1

Removal 15. If necessary, back off the slack adjusters, then

Western Star Workshop Manual, Supplement 12, May 2009 100/1

Fig. 1, Single or Rearmost Axle Components

100/2 Western Star Workshop Manual, Supplement 12, May 2009

Single Rear Axle Oil Type and Capacity

17. Raise one side of the vehicle about 8 inches (20

Western Star Workshop Manual, Supplement 12, May 2009 100/3

Western Star Workshop Manual, Supplement 12, May 2009 110/1

Fig. 1, Single or Rearmost Axle Components

IMPORTANT: The end caps fit tightly into the

110/2 Western Star Workshop Manual, Supplement 12, May 2009

1 19. Start the engine, build the air pressure, and

Fig. 2, Carrier End Caps

14. Install the wheels and tires. For instructions, see

Axle Oil Capacities

16. Raise one side of the vehicle about 8 inches (20

Western Star Workshop Manual, Supplement 12, May 2009 110/3

Western Star Workshop Manual, Supplement 12, May 2009 120/1

Removal 2. Using a suitable jack, raise the vehicle enough to

Fig. 1, Forward-Rear Axle Components

Western Star Workshop Manual, Supplement 12, May 2009 130/1

20. If applicable, disconnect the leveling valve rod(s)

130/2 Western Star Workshop Manual, Supplement 12, May 2009

Western Star Workshop Manual, Supplement 12, May 2009 130/3

Western Star Workshop Manual, Supplement 12, May 2009 140/1

Fig. 1, Forward-Rear Tandem Axle Components

5. Position the forward differential carrier in front of

140/2 Western Star Workshop Manual, Supplement 12, May 2009

14. Using approved axle oil, fill the axle housing to

Fig. 2, Carrier End Caps

9. Install the forward carrier capscrews finger-tight.

Western Star Workshop Manual, Supplement 12, May 2009 140/3

Repair 9. Install the outer bearing race onto the thru-shaft

1. Output Yoke Nut 8. Outer Bearing

Fig. 1, Thru-Shaft Components

3. Using a suitable shaft puller, draw the thru-shaft

Western Star Workshop Manual, Supplement 12, May 2009 150/1

Universal Handle* Kent-Moore J-8092

Rear Pinion Seal Installer* Kent-Moore J-47354

Yoke Nut Socket Axle Alliance Special Tool DDE W742589020700

* To order Kent-Moore tools call 1-800-328-6657.

Table 1, Special Tools

Replacement 4. Remove the carrier yoke from the input shaft. Be

Western Star Workshop Manual, Supplement 13, November 2009 160/1

IMPORTANT: Be careful not to cock the seal

Fig. 2, Rear Pinion Seal

Fig. 1, Yoke Nut on the Carrier

Fig. 3, Installing the Rear Pinion Seal

160/2 Western Star Workshop Manual, Supplement 13, November 2009

Special Tools for Forward-Rear Axle Yoke and Seal Replacement

Universal Handle* Kent-Moore J-8092

Input Seal Installer* Kent-Moore J-47369

Output Seal Installer* Kent-Moore J-47368

Yoke Nut Socket Axle Alliance Special Tool DDE W742589020700

* To order Kent-Moore tools call 1-800-328-6657.