CRD 126-#2 Diff Carrier - Overhaul

Service Bulletin
Mack Trucks, Inc.

Greensboro, NC USA Trucks
Date Group No. Release Page
4.2013 465 02 1 1(25)
Differential Carrier, Second Rear Axle,

Overhaul
CRD 126 Differential Carrier
CHU, CXU
Differential Carrier, Second Rear Axle, Overhaul
This service bulletin covers the procedure for overhauling the rear (CRD 126) differential
carrier assembly used on MACK Model CHU and CXU vehicles. The procedure steps cover
overhauling the rear differential carrier after it has been removed from the vehicle and
mounted on an approved work stand.
The CRD 125 (front) and CRD 126 (rear) rear axle differential carriers have numerically
higher axle ratios designed specifically to achieve higher fuel economy for on-highway line-
haul type applications.
Contents
• “Differential Carrier, Second Rear Axle, Overhaul”, page 2
PV776-89096349 USA58333
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 4.2013 465 02 1 2(25)
Service Procedures
4651-04-04-03
Differential Carrier, Second Rear Axle, Overhaul
Removed
DANGER
Do not attempt to repair or service this vehicle without
sufficient training, the correct service literature, and the
proper tools. Failure to follow this could make the vehicle
unsafe and lead to serious personal injury or death.
You must read and understand the precautions and guidelines in Service Information,
Function Group 40, "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.
Note: Information is subject to change without notice.

Illustrations are used for reference only and may differ slightly from the actual vehicle. How-
ever, key components addressed in this information are represented as accurately as
possible.
Special tools: 9996077, J-26437, J-26440, J-

8129
1
After the rear differential carrier assembly is removed from
the vehicle, mount it in a sturdy work stand using a minimum
of four bolts to attach the carrier assembly to the stand. Tight-
en the bolts securely. Rotate the assembly on the stand so
that the bull gear assembly is facing down.
2
Remove the yoke nut and install a special nut or button (such
as SNAP-ON™ P/N CJ85-6) onto the end of the bevel pinion.
Then, using a gear puller, remove the yoke from the differen-
tial carrier assembly.
3
Rotate the assembly on the stand so that the bull gear as-
sembly is facing up.
4
Remove the cotter pin and straight (lock) pin securing the bull
gear bearing adjusting nut.
1 Cotter Pin
2 Straight (Lock) Pin

5
Using a punch, mark the bearing caps and their mating ped-
estals so they can be reassembled in their original positions.
6
Using a J-26437 differential bearing nut adjusting wrench,
loosen the bearing adjusting nut approximately one full turn.
J-26437
7
Remove the bearing retainer fasteners.
8
Remove the bearing caps.
Note: The bearing caps and the carrier housing are ma-
chined as a set. Therefore, if replacement is necessary, the
carrier housing and bearing caps must all be replaced as a
set.
9
With the aid of an assistant, use a suitable lifting device to lift
and remove the bull gear assembly from the differential
carrier.
1 Lifting Tool
10
Rotate the assembly on the stand.
11
Remove the back cover.
12
Remove the fasteners securing the bevel pinion housing to
the main differential carrier. Using jack bolts, remove the
housing from the carrier.
Note: Retain the removed shims for later reuse.
13
Remove the bevel gear interior clamp plate from the spur
shaft bevel gear.
14
Remove the bevel pinion shaft from the differential carrier
through the large side opening.
15
Remove the fasteners retaining the helical pinion-shaft as-
sembly cover onto the carrier assembly, then remove the
cover.
16
Remove the outboard clamp plate bolt and the clamp plate.
Note: Be sure to have a new bolt on hand for final
reassembly.
17
With the aid of an assistant to prevent the spur shaft from fall-
ing, use a puller to remove the spur shaft from the main car-
rier housing. Remove the bearing cone, then remove the
spur shaft and bevel gear through the large opening in the
side of the carrier housing.
J-39447-1
18
Install jack bolts and alignment dowels into the spur shaft
bearing retainer. Using a crossing pattern to minimize bind-
ing, remove the spur shaft bearing retainer. Mark the location
of the alignment slot in the remaining race, then remove the
race from the main carrier housing.
Note: Retain all shims for later reuse.
19
Before starting to disassemble the bull gear/differential com-
ponents, mark the position of each differential half in relation
to the bull gear.
Note: These components are line-reamed and turned togeth-
er. Therefore, marking is essential to reassemble them in the
same position.
20
Clamp the bull gear/differential assembly in a suitable vise.
Loosen the bolts that secure the side casings to the bull gear.
Side casing bolts shown loosened
21
During disassembly, mark the bull gear relationship to the
casing. Mark both sides of the bull gear for reassembly
purposes.
1 Bull Gear Mark

2 Casing Mark
22
Remove the bull gear from the differential side-casing splined
half. Do this by tapping around the bull gear with a deadblow
hammer or a piece of brass bar stock and a hammer.
Use a deadblow hammer to separate differential half
Alternate method to separate differential half

23
Remove the differential half.
24
Remove the side gear thrust washer.
25
Remove the side gear off the spider gear assembly.
Removing the side gear
Side gear removed

26
Remove the spider gear assembly from the differential. This
assembly includes the spider, the four pinion (spider) gears
and the four pinion (spider) gear thrust washers.
Spider gear assembly
Differential with spider gear assembly removed
27
CAUTION
Exercise extreme caution during the pressing operation,
even when using specified tools. The bearing cone may fly
apart during removal. For safety, use a scatter shield.
Using suitable tools, press the tapered roller bearing from

each differential half.
28
Thoroughly clean all components of the disassembled differ-
ential assembly and inspect for damage or excessive wear.
Replace any differential assembly component not suitable for
reuse.
29
Using suitable tooling, carefully press the tapered roller bear-
ing onto each differential half.
Note: Lubricate the bearings before installation.
30
Before reassembly, lubricate each component of the differen-
tial assembly (differential halves, fasteners, bull gear, side
gears, thrust washers, spiders and cross). Reassemble the
components, taking care to use the alignment marks on the
two differential halves to properly align them onto each side
of the bull gear. Install the fasteners; tighten and torque to
339 ±16 Nm (250 ±12 ft-lb).
31
Place the pinion shaft into a hydraulic press. Press the helical
pinion shaft from the bevel gear.
1 Press
2 Press Extension
3 Bevel Gear
32
CAUTION
apart during removal. Use a scatter shield for safety.
Press the helical shaft from the bearing using the bearing
cup for support . This action applies pressing force through
the bearing rollers.
1 Helical Pinion
2 Press
3 Press Extension
4 Bearing
33
Using a hammer and drift, remove the helical-pinion retainer
bearing outer cup.
34
Thoroughly clean and inspect the spur shaft components for
damage or excessive wear. Replace any spur shaft compo-
nents not suitable for reuse.
35
Using suitable tooling, reassemble the spur shaft compo-
nents along with the previously-used spacer. Press the bevel
gear onto the spur shaft, but do not attach the clamp plates
at this time. During the reassembly, lubricate each bearing
before installation, and ensure that the retainer lock pin
aligns with the slot in the inner race.
1 Press
2 Press Plate
3 Bevel Gear
4 Pinion Shaft
36
Check the spur shaft assembly preload. To do this, place the
spur shaft assembly into a press and apply 9,072 kilograms
[20,000 pounds (10 tons)] of pressure to the spur shaft. Then,
wrap a cord around the bearing retainer and attach a J-8129
spring scale to the end of the cord. Steadily pull on the scale
and cord until the retainer rotates slowly and steadily. If
needed, adjust the spacer thickness until the retainer rotates
with either 2 ±0.6 kilograms (4.4 ±1.3 lb) when a new bearing
is used or 1.35 ±0.45 kilograms (3 ±1 lb) when the old bear-
ing is reused. When that is accomplished, the correct preload
is attained.
Note: Be sure to lubricate the bearings before performing the
preload check.
J-8129
1 Press
2 Plate
3 Scale
37
CAUTION
apart during removal. Use a scatter shield for safety.
Using suitable tooling, press the bearing off the bevel pinion
shaft and remove the races from the bevel pinion shaft
housing.
38
Thoroughly clean the removed bevel pinion shaft compo-
nents and inspect for damage or excessive wear. Replace
any components not suitable for reuse.
39
Using a hydraulic press and other suitable tooling, reassem-
ble the bevel pinion shaft assembly components by pressing
the bearing onto the bevel pinion shaft. Install the races into
the bevel pinion shaft housing. Install the bevel pinion shaft/
bearing into the bevel pinion housing using the spacer previ-
ously removed. During the reassembly, oil the bearing and
races before installation.
40
Check the bevel pinion assembly preload. Place the bevel
pinion shaft and housing assembly into a press and apply
9,072 kilograms [20,000 pounds (10 tons)] of pressure. Then,
wrap a cord around the bevel pinion shaft housing and attach
a scale to the end of the cord. Steadily pull on the scale and
cord until the bevel pinion shaft housing rotates slowly and
steadily. If needed, adjust the spacer thickness until the
housing rotates with either 2 ±0.6 kilograms (4.4 ±1.3 lb)
when a new bearing is used or 1.35 ±0.45 kilograms (3 ±1 lb)
when a new bearing is used or 0.9 to 1.8 kilograms (2 to 4
pounds) when the old bearing is reused. When that is accom-
plished, the correct preload is attained.
J-8129
41
Using suitable tooling, disassemble the bevel pinion shaft as-
sembly by removing the bevel pinion shaft from the housing
in preparation for final assembly.
42
Clean the fasteners that are to be reused. Clean the threads
and chase the threaded fastener holes to remove any re-
maining threadlock residue.
43
Clean the differential carrier housing. Remove any sealing
compound from the differential carrier and its respective sub-
assemblies, paying special attention to the mating surfaces
of the differential carrier housing. Use a parts cleaner or pres-
sure washer to thoroughly clean the interior and exterior
surfaces.
44
Begin the installation of the bull gear (differential) assembly
into the carrier housing by installing the bearing adjusting nut
onto the threaded bearing cup. Tighten the nut about two
turns.
45
With the aid of an assistant, use a suitable lifting device to lift
and position the differential assembly for installation into the
carrier housing.
46
Lubricate the bearings with GO-J lubricant and position the
bearing cups on the differential assembly. The twelve bolt
heads of the bull gear assembly go to the side with the ad-
justable bearing cup, and has the cap with the two pin holes.
1 Lift
2 Bull Gear (Differential) Assembly
3 Carrier Housing
47
Lower the differential assembly into the housing.
48
Seat the bearing cups on the differential bearing pedestals in
the carrier housing.
1 Hoist
2 Bull Gear (Differential) Assembly
3 Support Stand
49
Position the bearing caps over the bearing cups. Align the
punch marks (made at disassembly) on the bearing caps with
those on the bearing pedestals.
50
Install the bearing cap bolts snugly, but not too tight. This will
permit bearing adjustment. Do not apply threadlocking com-
pound to the bearing cap bolts at this time.
51
Check to make sure the bearing caps are still properly
aligned.
Note: The bearing retainer caps and the carrier housing are
machined as a set. Therefore, if replacement is necessary,
the carrier housing and bearing retainer caps must all be re-
placed as a set.
1 Alignment marks made earlier
52
Position the bearing adjustment fixture onto the carrier
housing.
J-26440
53
Lubricate the differential bearings with GO-J gear oil. Then,
while turning the differential assembly with a spanner
wrench, adjust the differential bearing nut until the bearings
have a slight preload.
J-26437
54
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.
55
Readjust the differential bearing nut to create a slight pre-
load. Repeat the procedure of adjusting preload and hitting
the bearing cap and/or bull gear to relieve preload pressure,
until a constant preload is maintained.
56
Tighten the bearing-cap retaining bolts and torque to 400 ±34
Nm (295 ±25 ft-lb).
57
Wrap a cord around the outside of the diameter of the bull
gear several times.
58
Attach a spring scale to the end of the cord and steadily pull
on the scale until the bull gear rotates slowly and evenly. If
correct, the load on the scale will read 1.1 ±0.2 kilograms
(2.4 ±0.45 lb) .
J-8129
59
If the preload is not within specifications, loosen the bearing
cap retaining bolts and turn the adjusting nut to attain the
proper preload.
60
Once preload is attained, remove the bearing cap bolts one
at a time. Apply threadlocking compound to the bolt threads,
then reinstall, tighten and torque the bolts to 295 ±25 Nm
(218 ±18 ft-lb).
61
Check for proper alignment of the pin hole in the bearing cap
and the adjusting nut. If required, tighten the bearing adjust-
ing nut slightly, until the hole and nut are aligned to provide
for installation of the lock pin. Note that it may be necessary
to loosen the bearing cap bolts to allow the adjusting nut to
turn. Recheck the torque on the bearing cap bolts.
62
Recheck the preload on differential bearings by measuring
the rolling drag. Adjust as required.
63
Remove the differential adjustment fixture.
J-26440
64
Install the lock pin in the bearing cap and secure it with a new
cotter pin. This completes the installation of the bull gear
assembly.
Note: Reusing a cotter pin that has been repeatedly bent
and unbent could cause the cotter pin to break.
1 Cotter Pin
65
Begin the installation of the spur shaft assembly by installing
the spur shaft bearing retainer and shim stack. Use align-
ment dowels to install the retainer without binding. Secure
the retainer using the fasteners; tighten the fasteners until
snug to prevent movement.
66
Using a soft-faced hammer, install the race into the main car-
rier housing, making sure to align the slot in the race with the
pin in the bearing retainer during the installation.
67
Install the spur shaft and bevel gear subassembly into the
carrier through the large side opening.
68
Install the outboard clamp plate using a new fastener; tighten
the fastener and torque to 475 ±68 Nm (350 ±50 ft-lb).
69
Apply a 2 mm bead of sealant to the spur gear cover mating
surface and install it using the fasteners; tighten the fasteners
and torque to 95 ±11 Nm (70 ±8 ft-lb).
70
Begin the installation of the bevel pinion shaft and housing
by installing alignment studs for the bevel pinion housing to
ensure proper alignment.
71
Install the bevel pinion assembly into the carrier through the
large side opening.
1 Bearing Cone
72
Install the bevel gear clamp plate and bolt. Torque the bolt to
108 ±10 Nm (80 ±7 ft-lb).
73
Install the through shaft tube assembly and hold in place with
two (or more) screws.
74
Push the bevel pinion head end onto the oil tube. This will
support the pinion for the bevel pinion housing installation.
75
Install the bevel pinion housing (with two bearing cups in-
stalled) onto the main housing.
76
Slide the bearing preload spacer and the #1 bearing cone on-
to the bevel pinion.
77
Install the #1 bearing cone into place.
78
Install the oil seal by pressing it into place.
Note: Do not tap the oil seal into place. This will damage the
seal (spring comes loose).
79
Install the yoke and secure with the nut. Torque the nut to
1220 ±135 Nm (900 ±96 ft-lb).
80
Remove the oil tube.
81
Attach the back cover with the fasteners and torque to 41 ±4
Nm (30 ±3 ft-lb).

CRD 126-#2 Diff Carrier - Overhaul

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Service Bulletin

Mack Trucks, Inc.

Differential Carrier, Second Rear Axle,

Differential Carrier, Second Rear Axle, Overhaul

Note: Information is subject to change without notice.

Special tools: 9996077, J-26437, J-26440, J-

1 Straight (Lock) Pin

Side casing bolts shown loosened

1 Bull Gear Mark

Use a deadblow hammer to separate differential half

Alternate method to separate differential half

Removing the side gear

Side gear removed

Spider gear assembly

Differential with spider gear assembly removed

Using suitable tools, press the tapered roller bearing from

1 Alignment marks made earlier

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