Specifications

97
Driver-Controlled Main Differential Lock
MAINTENANCE MANUAL
5. Install the differential into the housing. See
the Section 5.
6. Install and tighten the differential-to-housing
capscrewstothespeciedtorque.
7. Install the right- and left-hand axle shafts.
See the Section 5.
NOTE:
When the manual engaging capscrew is re-
moved from the service position in the cen-
ter of the DCDL actuator, the main differential
lock is disengaged.
8. Remove the long manual engaging cap-
screw from the center of either the xed
capscrew or Threaded DCDL..
9. Clean the plug, gasket, cylinder cover and
threaded service position hole in the center
ofthexedcapscrewDCDLcylindercover,
or in the center of the Threaded DCDL.
10. Verify that the sealing gasket is under the
head of the capscrew.
11.Install the manual engaging capscrew into
the DCDL storage hole in the xed cap-
screw or the Threaded DCDL assembly.
Figure 6.33 and Figure 6.34.
A. On a xed capscrew DCDL shift assembly,
remove the short plug and gasket from the
storage hole of the DCDL.
Install the short plug and gasket into the ser-
vice position hole in the center of the DCDL.
Figure 6.33..
B. On a Threaded DCDL shift assembly, install
the short screw or plug into the storage hole
located in the top of the Threaded DCDL
shift assembly. Figure 6.34.
12. Tighten the plug to 44-55 lb-ft (60-75 N m).
Tighten the manual engaging capscrew to
22-28lb-ft(30-38Nm) forxedcapscrew
DCDL style cylinders and to 7-11 lb-ft (10-
15 N m) for Threaded DCDL type reverse
shifters.
13. Connect the vehicle air line to the differen-
tial lock actuator assembly.
14. Install the electrical connection on the sen-
sor switch located in the differential, below
the actuator assembly.
15. Remove the security support from under
thedriveaxle.Lowerthevehicletotheoor.
16. Fill the axle with lubricant. See the Section 7.
17. Proceed to Check the Differential Lock in
this section.
Auxiliary Air Supply Method
1. Use a cleaning solvent and rags to clean
the inside of the axle housing and the dif-
ferential mounting surface. See the Section
4.
2. Check the axle housing for damage. If neces-
sary, repair or replace the housing. See the
Section 4.
3. Check for loose studs in the differential
mounting surface. Remove and replace the
studs where required. Apply liquid adhesive
to the holes. Install and tighten the stud to
150-230 lb-ft (204-312 N m).
4. Connect an air line to the main differential
lock actuator Figure 6.33 assembly cou-
pling.
5. Supply 120 psi (827 kPa) regulated air pres-
sure through the air line.
6. Verify that the DCDL engaged.
Figure 6.33
TOP STORAGE HOLE FOR MANUAL
ENGAGING CAPSCREW
BOLT ON DCDL SHIFT ASSEMBLY
WIRE
AIR LINE
SERVICE POSITION CAP-
SCREW HOLE
BOTTOM STORAGE
HOLE FOR PLUG AND
GASKET
PLUG AND
GASKET
MANUAL
ENGAGING
THREADED DCDL SHIFT ASSEMBLY
MANUAL ENGAGING
CAPSCREWl
AIR HOSE
CYLINDER
STORAGE HOLE
Figure 6.34