This maintenance manual (MM5) details the service and repair procedures for AxleTech Single Reduction Differential Carriers, specifically models RS-160 and RS-180. These units may be equipped with a Driver-Controlled Main Differential Lock (DCDL), which uses a hydraulic shift assembly to lock the axle shafts together for maximum traction.

1. Key Technical Specifications

The manual establishes strict adjustment parameters for carrier assembly:

Pinion Bearing Preload: This is controlled by bearing spacers. New bearings require a preload of 15-25 lb-in (1.7-2.8 N·m), while used bearings in good condition should be set to 5-25 lb-in (1.7-2.8 N·m).
Differential Bearing Preload: The standard specification is 15-35 lb-in (1.7-3.9 N·m). It can also be measured by cap expansion: 0.002-0.009-inch (0.05-0.229 mm) for RS-160 and 0.006-0.013-inch (0.15-0.33 mm) for RS-180.
Ring Gear Backlash: For gears with a pitch diameter of 17 inches or larger, the range is 0.010-0.020-inch (0.25-0.51 mm), with a nominal setting of 0.015-inch (0.38 mm) for new sets.
Runout and Resistance: Maximum allowable ring gear runout is 0.008-inch (0.20 mm). The maximum rotating resistance for differential gears is 50 lb-ft (68 N·m).

2. Assembly Procedures

Pinion Depth Adjustment: The depth is controlled by shims between the bearing cage and carrier. Technicians must calculate shim thickness using the previous shim pack measurement adjusted by the Pinion Cone (PC) variation numbers marked on the gears .
Ring Gear Installation: Ring gears must be heated in water to 160°F-180°F (71°C-82°C) for 10 to 15 minutes before installation. They must never be pressed on cold, as this damages the case half.
Matched Sets: Ring gears and drive pinions are only available as matched sets and must always be replaced together.

3. Lubrication and Maintenance

Oil Quality: Use API GL-5 hypoid gear oil. Viscosity (e.g., 80W/90 or 75W/140) should be selected based on the minimum outside operating temperature.
Change Intervals: Intervals vary by vocation; for example, heavy-haul vocations require petroleum-based oil changes every 25,000 miles or annually. Axle sump temperatures must never exceed 250°F (121°C).

4. Safety and Towing

Carrier Removal: Before removing or installing a DCDL-equipped carrier, the lock must be manually engaged and held using a manual engaging capscrew to provide necessary clearance from the axle housing.
Towing: To avoid component damage, axle shafts must be removed before towing the vehicle with the drive wheels on the ground.