Service Bulletin

Mack Trucks, Inc.

Greensboro, NC USA Trucks
Date Group No. Release Page
5.2013 465 04 01 1(14)

Bevel Gear Set, Replacement (Carrier

Removed)
Front (CRD 125) Differential Carrier
CHU, CXU

Bevel Gear Set, Replacement (Carrier Removed)

This service bulletin covers the procedure for replacement of the bevel gear set in the front
rear axle differential carrier assembly (CRD 125) used on MACK Model CHU and CXU
vehicles. The procedure steps are for the replacement of the bevel gear set after the
differential carrier has been removed from the vehicle.

Contents
• “Bevel Gear Set, Replacement (Carrier Removed)”, page 2

Note: Information is subject to change without notice.

Illustrations are used for reference only and may differ slightly from the actual vehicle being
serviced. However, key components addressed in this information are represented as
accurately as possible.

PV776-89094583 USA58280
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Service Bulletin 5.2013 465 04 01 2(14)

Service Procedures
4657-03-02-06
Bevel Gear Set, Replacement (Carrier Removed)
DANGER
Do not attempt to repair or service this vehicle without hav-
ing 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 guide-

lines in Service Information, Function Group 40, "General
Safety Practices, Power Transmission" before performing
this procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training before
you perform it.

Special tools: J-33107, 9996161, 9996889,

9995454, 9996159, 9809726, 9996077, J-
8129, 9996062, 9996873, 9996176, 9992671,
J-39447-1, 88800449
Replace Front Bevel Gear Set (Front Carrier
Removed)
1
After the front 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.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 04 01 3(14)

2
Remove the fastener securing the front driveshaft yoke to the
differential carrier assembly. Then, using a gear puller, re-
move the yoke from the differential carrier assembly.

3
Remove the front power divider lock-out (PDLO) assembly
from the carrier.

4
Remove the fasteners securing the through shaft rear bear-
ing retainer. Then, remove the seal and cover.

5
Remove the through shaft and bearing as an assembly.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 04 01 4(14)

6
Install two fasteners to secure the through shaft oil tube dur-
ing removal of the PDLO housing.

7
Install the J-33107 holding fixture onto the power divider
housing to prevent movement of the outer cam. Remove the
bevel pinion nut.

J-33107

Bevel pinion with retaining nut installed

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Service Bulletin 5.2013 465 04 01 5(14)

8
Remove the fasteners securing the bevel pinion housing to
the main carrier housing. Install alignment dowels in place of
the fasteners to maintain alignment when the bevel pinion
housing is removed from the carrier. Install a button/shaft pro-
tector (such as SNAP-ON™ P/N CJ85-6) onto the end of the
bevel pinion. Attach the puller bar to the power divider hous-
ing with the puller screw end on the button protector and pull
off the power divider housing. The outer cam will come off
with the housing. Remove the power divider outer cam from
the bevel pinion shaft, then remove the bevel pinion housing.
Note: The tube will support the bevel pinion. Retain all shims
for later reuse.

9996161, 9996889, 9995454, 9996159, 9809726, 88800449

9
With the aid of an assistant, use two jack screws to remove
the oil tube.

10
Remove the fasteners securing the inboard clamp plate to
the spur shaft bevel gear, then remove the clamp plate.

11
Remove the bevel pinion through the large side opening of
the carrier housing.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 04 01 6(14)

12
Remove the fasteners retaining the helical pinion-shaft as-
sembly cover onto the carrier assembly, then remove the
cover.

13
Remove the outboard clamp plate bolt and the clamp plate.
Note: Be sure to have a new bolt on hand for final
reassembly.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 04 01 7(14)

14
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
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 04 01 8(14)

15
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.

16
Place the helical pinion shaft into a hydraulic press. Press
the helical pinion shaft from the bevel gear.

1 Press
2 Press Extension
3 Bevel Gear
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Service Bulletin 5.2013 465 04 01 9(14)

17

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 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

18
Using a hammer and drift, remove the helical-pinion retainer
bearing outer cup.

19
Thoroughly clean and inspect the spur shaft components for
damage or excessive wear. Replace any spur shaft compo-
nents not suitable for reuse.
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Service Bulletin 5.2013 465 04 01 10(14)

20
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

21
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.

1 Press J-8129
2 Plate
3 Scale

22

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 for safety.

Using suitable tooling, press the bearing off the bevel pinion
shaft and remove the races from the bevel pinion shaft
housing.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 04 01 11(14)

23
Thoroughly clean the removed bevel pinion shaft compo-
nents and inspect for damage or excessive wear. Replace
any components not suitable for reuse.

24
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, and install the bevel pinion
shaft/bearing into the bevel pinion housing using the spacer
previously removed. During the reassembly, oil the bearing
and races before installation.

25
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 the old bearing is reused. When that is accomplished,
the correct preload is attained.

J-8129

26
Using suitable tooling, disassemble the bevel pinion shaft as-
sembly by removing the bevel pinion shaft from the housing
in preparation for final assembly.

27
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.

28
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.

29
Install the spur shaft and bevel gear subassembly into the
carrier through the large side opening.
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Service Bulletin 5.2013 465 04 01 12(14)

30
Install the bearing cone and outboard clamp plate using a
new fastener; tighten the fastener and torque to 475 ±68 Nm
(350 ±50 ft-lb).

31
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).

32
Begin the installation of the bevel pinion shaft and housing
by installing alignment studs for the bevel pinion housing to
ensure proper alignment.

33
Install the bevel pinion assembly into the carrier housing
through the large side opening.

1 Bearing Cone

34
Install the bevel gear clamp plate. Tighten the three screws
and torque to 108 ±10 Nm (80 ±7 ft-lb).
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35
Install the oil tube to help hold the bevel pinion in place. Use
two screws (lightly torqued) to hold the oil tube in place.

36
With the aid of an assistant, install the shims, power divider
housing and power divider outer cam. Ensure that the com-
ponents properly align and that the splines match. When in-
stalling the power divider housing, use two screws (lightly
torqued) to hold the housing in place.
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Service Bulletin 5.2013 465 04 01 14(14)

37
Using the appropriate tooling (hydraulic cylinder, hydraulic
pump, rod and drivers), press the bevel pinion shaft into the
outer power divider cam. Remove the tools.

9996062, 9996873, 9996176, 9992671, 9809726

38
Install the J-33107 holding fixture onto the power divider
housing. Install the bevel pinion nut; tighten and torque the
nut to 1898 ±136 Nm (1400 ±100 ft-lb). Remove the holding
fixture.

J-33107

39
Install the power divider housing screws; tighten and torque
to 261 ±28 Nm (193 ±21 ft-lb).

40
With the aid of an assistant, install the PDLO assembly into
the power divider housing. Apply threadlocking compound to
the fastener threads then use the fasteners to secure the
PDLO assembly to the housing. Tighten the fasteners and
torque to 48 ±5 Nm (35 ±4 ft-lb).

41
Install a replacement oil seal into the rear through shaft
retainer.

42
Apply threadlocking compound to the fasteners and install
the oil tube, through shaft bearing retainer, seal retainer and
through shaft. Tighten the fasteners and torque to 41 ±4 Nm
(30 ±3 ft-lb) using a crossing pattern.

43
Replace the oil seal for the front input shaft yoke, then install
the front yoke and secure with the fasteners; tighten the fas-
teners and torque to 746 ±68 Nm (550 ±50 ft-lb).