Cariers Serie 200

CRD200 SERIES

13-502 (NEW ISSUE) JANUARY 2003

CARRIER SERVICECHARTS

CARRIER SERVICE CHARTS CRD 200 SERIES

JANUARY 2003 (NEW ISSUE) MACK TRUCKS, INC. 2003

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ATTENTIONThe information presented here is not all inclusive andcannot take into account all unique situations. Note thatsome illustrations are typical and may not reflect the exactarrangement of every component installed on a specificchassis.The information, specifications, and illustrations shown hereare based on information that was current at the time ofpublication.No part of this information may be reproduced, stored in aretrieval system, or be transmitted in any form by any meansincluding (but not limited to) electronic, mechanical,photocopying, recording, or otherwise without prior writtenpermission of Mack Trucks, Inc.

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TABLE OF CONTENTS

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TABLE OF CONTENTSSAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

SPECIAL INSTRUCTIONS AND NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20DETERMINING GEAR RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21IDENTIFICATION OF: AXLE CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

RATIO CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23CRD 200 SERIES RATIO CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

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NOTES

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SAFETY INFORMATION

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SAFETY INFORMATION

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SAFETY INFORMATION

SAFETY INFORMATIONAdvisory LabelsCautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this manual. Information accented by one of these signal words must be observed to minimize the risk of personal injury to service personnel, or the possibility of improper service methods which may damage the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of procedural importance and provide suggestions for ease of repair. The following definitions indicate the use of these advisory labels as they appear throughout the manual:

Activities associated with Danger indicate that death or serious personal injury may result from failing to heed the advisory. Serious personal injury may be equated to career-ending injury.

Activities associated with Warning indicate that personal injury may result from failing to heed the advisory. In this case, personal injury is not equated to career-ending injury, but results in possible change in quality of life.

Activities associated with Caution indicate that product damage may result from failing to heed the advisory. Caution is not used for personal injury.

A procedure, practice, or condition that is essential to emphasize.


SAFETY INFORMATION

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A helpful suggestion that will make it quicker and/or easier to perform a procedure, while possibly reducing service cost.

Service Procedures and Tool UsageAnyone using a service procedure or tool not recommended in this manual must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects. Individuals deviating in any manner from the instructions provided assume all risks of consequential personal injury or damage to equipment involved.

Also note that particular service procedures may require the use of a special tool(s) designed for a specific purpose. These special tools must be used in the manner described, whenever specified in the instructions.

1. Before starting a vehicle, always be seated in the drivers seat, place the transmission in neutral, be sure that parking brakes are set, and disengage the clutch.

2. Before working on a vehicle, place the transmission in neutral, set the parking brakes, and block the wheels.

3. Before towing the vehicle, place the transmission in neutral and lift the rear wheels off the ground, or disconnect the driveline to avoid damage to the transmission during towing.


SAFETY INFORMATION

Engine-driven components such as Power Take-Off (PTO) units, fans and fan belts, driveshafts and other related rotating assemblies, can be very dangerous. Do not work on or service engine-driven components unless the engine is shut down. Always keep body parts and loose clothing out of range of these powerful components to prevent serious personal injury. Be aware of PTO engagement or nonengagement status. Always disengage the PTO when not in use.

REMEMBER, SAFETY. . .IS NO ACCIDENT!

Mack Trucks, Inc. cannot anticipate every possible occurrence that may involve a potential hazard. Accidents can be avoided by recognizing potentially hazardous situations and taking necessary precautions. Performing service procedures correctly is critical to technician safety and safe, reliable vehicle operation.


SAFETY INFORMATION

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The following list of general shop safety practices can help technicians avoid potentially hazardous situations and reduce the risk of personal injury. DO NOT perform any services, maintenance procedures or lubrications until this manual has been read and understood.r Perform all service work on a flat, level surface.

Block wheels to prevent vehicle from rolling.r DO NOT wear loose-fitting or torn clothing.

Remove any jewelry before servicing vehicle.r ALWAYS wear safety glasses and protective

shoes. Avoid injury by being aware of sharp corners and jagged edges.

r Use hoists or jacks to lift or move heavy objects.r NEVER run engine indoors unless exhaust

fumes are adequately vented to the outside.

r Be aware of hot surfaces. Allow engine to cool sufficiently before performing any service or tests in the vicinity of the engine.

r Keep work area clean and orderly. Clean up any spilled oil, grease, fuel, hydraulic fluid, etc.

r Only use tools that are in good condition, and always use accurately calibrated torque wrenches to tighten all fasteners to specified torques. In instances where procedures require the use of special tools which are designed for a specific purpose, use only in the manner described in the instructions.

r Do not store natural gas powered vehicles indoors for an extended period of time (overnight) without first removing the fuel.

r Never smoke around a natural gas powered vehicle.


NOTES


INTRODUCTION

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INTRODUCTION


INTRODUCTION

INTRODUCTION1

Figure 1 Carrier Gearing, Rear Axle


INTRODUCTION

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The illustrations on the following pages are to be used as a guide. They show exploded views of the typical CRD 200 series carriers. Some parts may appear different than what you are actually working on. Improvements over the life of any component will show up in successive models as they are incorporated into the part. Remember to use the illustrations as a guide ONLY.

The replacement parts that are recommended in this manual are genuine MACK parts. They are the best parts available at this printing for repairing CRD 200 series carriers.


INTRODUCTION

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Figure 2 Exploded View CRDP 200, 202 Series Inter-Axle Power Divider Assembly


INTRODUCTION

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1. Oil Seal 14. Outer Cam2. Capscrew 15. Inner Cam3. Gasket 16. Capscrew4. Bearing 17. Cover5. Retainer 18. Yoke6. O-Ring 19. IAPD Housing7. Cage 20. Shims8. Wedge 21. Spacer9. Inner Ring 22. Spacer

10. Outer Ring 23. Bearing Cup11. Nut 24. Bearing Cone12. Bearing Cup 25. Bevel Pinion13. Bearing Cone 26. Housing


INTRODUCTION

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Figure 3 Exploded View CRD 200 Series Helical Pinion Shaft Assembly


INTRODUCTION

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1. Helical Pinion Shaft 10. Helical Pinion Bearing Retainer2. Bearing Cup 11. Bearing Cup3. Bearing Cone 12. Bearing Cone4. Helical Pinion Gear 13. Clamp Plate5. Clamp Plate 14. Gasket6. Capscrew 15. Helical Pinion Shaft Bearing Retainer Cover7. Spacer 16. Capscrew8. O-Ring 17. Capscrew9. Shims


INTRODUCTION

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Figure 4 Exploded View CRD 201, 203 Series Bevel Pinion Shaft Assembly


INTRODUCTION

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1. Bevel Pinion Shaft Housing Cover 9. Shim Pack2. Outer Bearing Cone 10. Capscrew3. Spacer 11. Outer Bearing Cup4. Bevel Pinion Housing 12. Gasket5. Carrier Housing 13. Seal6. Bevel Pinion Shaft 14. Yoke7. Inner Bearing Cone 15. Capscrew8. Inner Bearing Cup


INTRODUCTION

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Figure 5 Exploded View CRD 200 Series Differential Assembly


INTRODUCTION

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1. Cotter Pin and Adjusting Nut Lock Pin 12. Nut2. Bearing Cup 13. Side Gear Thrust Washer3. Adjusting Nut 14. Side Gear4. Bearing Cone 15. Spider5. Bull Gear 16. Bearing Cap Capscrew6. Side Gear Thrust Washer 17. Bearing Cap7. Pinion Thrust Washer 18. Side Gear8. Pinion (Spider Gear) 19. Differential Half9. Differential Half 20. Washer

10. Bearing Cone 21. Capscrew11. Bearing Cup


INTRODUCTION

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Figure 6 Exploded View CRDP 20212031, CRD 2011 Series Inter-Wheel Power Divider Assembly


INTRODUCTION

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1. Spacer (CRD 2011 only) 10. Cotter Pin and Adjusting Nut Lock Pin2. Inner Cam 11. Capscrew3. Retaining Ring 12. Outer Cam4. Bushing 13. Bushing5. Wedges (24) 14. Bull Gear6. Driving Cage 15. Side Casing7. Bearing Cone 16. Bearing Cone8. Adjusting Nut 17. Bearing Cup9. Bearing Cup


INTRODUCTION

PURPOSEThe purpose of this publication is to inform the field of service instructions for mating gear assemblies, bull gears and helical pinion shafts for the CRD 200 series carriers.

The service instructions are laid out in the form of charts. The charts are an attempt at simplifying the process by which we locate the proper and most recent parts for a carrier. We have tried to cover all possible combinations of gear components and have grouped the carriers by ratio. Particular attention should be paid to SPECIAL INSTRUCTIONS AND NOTES regarding gear service combinations.

SPECIAL INSTRUCTIONS AND NOTESAlthough the CRD 200 and 201 are listed in the following charts, only the CRD 202 and 203 are in production currently.

Beginning 12/18/00, axle shafts for the CRD 200 series carriers were changed from 46 tooth to a 43-tooth spline shaft. To accommodate this change, the differential side gears and the inter-wheel power divider cams were also changed to accept the 43-tooth axle shaft splines.

The CRD 200/201 series carriers originally used an axle shaft having a 46-tooth spline. On these carriers, changing the axle shafts from a 46-tooth spline to a 43-tooth spline has resulted in the elimination of the carrier series because it is now the same as the CRD 202/203 series carrier which had always used an axle shaft having a 43-tooth spline. The axle shafts for the CRD 2011 series carrier have been changed from a 46-tooth spline to a 43-tooth spline. The differential side gears and differential power divider cams have also been changed to accommodate the 43-tooth spline axle shafts.


INTRODUCTION

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Axle shafts having the 43-tooth splines are not interchangeable with the 46-tooth splined shafts. If an axle shaft requires replacement, it must be replaced with the same part number shaft.

If it should be decided to change a 46-tooth splined axle shaft to a 43-tooth splined axle shaft, the differential side gears or the differential power divider cams must also be changed.

To replace the differential side gears for CRD 200/201 series carriers, use part number 34KH331 (43-tooth spline) to replace 34KH262 (46-tooth spline).

DETERMINING GEAR RATIOBy counting the number of teeth on a gear, you can determine the gear ratio of a carrier. As an example, lets use a CRD 203 carrier with a 4.35 ratio. Use the following formula, and let R equal ratio.

R = Bevel Gear x Bull GearBevel Pinion Pinion Shaft

R = 19 (teeth) x 55 (teeth)15 (teeth) 16 (teeth)

R = 1.27 x 3.44R = 4.35


INTRODUCTION

IDENTIFICATION OF: AXLE CARRIER7

Figure 7 Axle Carrier Identification Example


RATIO CHARTS

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RATIO CHARTSCRD 200 SERIES


RATIO CHARTS

CRD 200 SERIES RATIO CHARTS

UNIT RATIOMATING GEAR

ASSY.BEVEL PINION

BEVEL GEAR PINION SHAFT BULL GEAR

CRDP 2022021*CRD 2032031*2011**

3.63 24KH11047 (18x19)24KH11043

46KH412146KH4116

47KH3443 56KH435 (16 T) 61KH435 (55 T)

CRDP 2022021*CRD 2032031*2011**

3.94 24KH11047 (18x19)24KH11043

46KH412146KH4116

47KH3443 56KH436 (15 T) 61KH436 (56 T)

CRDP 2022021*CRD 2032031*2011**

4.35 24KH11048 (15x19)24KH11044

46KH412246KH4118

47KH3444 56KH435 (16 T) 61KH435 (55 T)

CRDP 2022021*CRD 2032031*2011**

4.73 24KH11048 (15x19)24KH11044

46KH412246KH4118

47KH3444 56KH436 (15 T) 61KH436 (56 T)

CRDP 2022021*CRD 2032031*2011**

5.02 24KH11041 (13x19)24KH11042

46KH412546KH4117

47KH3442 56KH435 (16 T) 61KH435 (55 T)

CRDP 2022021*CRD 2032031*2011**

5.46 24KH11041 (13x19)24KH11042

46KH412546KH4117

47KH3442 56KH436 (15 T) 61KH436 (56 T)


RATIO CHARTS

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* All current CRD 200 family production carriers have 43-tooth axle shaft splines.** CRD 2011 are the same as CRD 2031 plus spacer.

CRDP 2022021*CRD 2032031*2011**

5.95 24KH11041 (13x19)24KH11042

46KH412546KH4117

47KH3442 56KH437 (14 T) 61KH437 (57 T)

CRDP 2022021*CRD 2032031*2011**

6.41 24KH11041 (13x19)24KH11042

46KH412546KH4117

47KH3442 56KH438 (13 T) 61KH438 (57 T)

CRDP 2022021*CRD 2032031*2011**

7.08 24KH11049 (13x19)24KH11045

46KH412346KH4119

47KH3445 56KH438 (13 T) 61KH438 (57 T)

CRDP 2022021*CRD 2032031*2011**

8.37 24KH11051 (11x21)24KH11052

46KH412646KH4127

47KH3447 56KH438 (13 T) 61KH438 (57 T)

UNIT RATIOMATING GEAR

ASSY.BEVEL PINION

BEVEL GEAR PINION SHAFT BULL GEAR


NOTES


13-502 MACK TRUCKS INC. 2003 PRINTED IN THE U.S.A.

CRD200 SERIES

CARRIERSERVICECHARTS

Cariers Serie 200

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