Service Bulletin

Mack Trucks, Inc.

Greensboro, NC USA Trucks
Date Group No. Release Page
5.2013 465 02 01 1(8)

Differential Carrier, Replacement

CRD 125/126 Differential Carriers
CHU, CXU

Differential Carrier, Replacement

This service bulletin covers the procedures for replacing the CRD 125 (front) and CRD 126
(rear) differential carriers used on MACK Model CHU and CXU vehicles. A separate
procedure is included for each differential carrier.

Contents
• “Differential Carrier, First Axle, Replacement”, page 2

• “Differential Carrier, Second Axle, Replacement”, page 6

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.

PV776-89096685 USA58355
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 02 01 2(8)

Service Procedures
4651-03-02-03
Differential Carrier, First Axle, Replacement
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.

1
Disconnect all cables from the negative (ground) battery ter-
minals to prevent personal injury from electrical shock and
prevent damage to electrical components.

2
Drain the oil from the axle housing and front differential car-
rier. Inspect the oil for metal shavings and other debris. If you
find debris, more disassembly, cleaning, and inspection will
be necessary.

3
Remove the rear lateral torque rod, fasteners, and spacer
block.

4
Remove the fasteners that attach the hubs. Put a suitable
container below the hub to collect oil leakage. Remove the
axles and locks.

5
Remove the input driveshaft and fasteners from the carrier
yoke.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 02 01 3(8)

6
Remove the inter-axle driveshaft and fasteners from the rear
yoke of the front differential carrier.

7
Disconnect the air line from the power divider.

8
Remove the side cover from the carrier.

9
Remove the rear yoke from the carrier.

10
Remove the torque rod bracket and fasteners.

11
Remove the fasteners that attach the differential carrier to
the axle housing.
Note: Three fasteners are inside the carrier housing.

12
Use an assistant and a suitable lifting device to remove the
differential carrier from the axle housing. If you find metal
shavings or other debris in the axle housing, more disassem-
bly, cleaning, and inspection will be necessary.

Front Differential Carrier Removed

13
Remove the replacement carrier from the shipping container.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 02 01 4(8)

14
Remove the torque rod bracket studs from the defective dif-
ferential carrier and install them onto the replacement differ-
ential carrier.

15
Move the input shaft yoke from the defective carrier to the
new carrier. Torque fasteners to 746 ±68 Nm (550 ±50 ft-lb).

16
Move the power divider air fitting from the defective carrier to
the new carrier.

17
Clean the mating surfaces of the axle housing and differential
carrier.

18
Apply a 1.6 mm (.0625 in) bead of sealant to the carrier mat-
ing surface on the axle housing.

19
Use an assistant and a suitable lifting device to install the re-
placement differential carrier in the axle housing.

20
Install the fasteners that attach the carrier to the axle
housing.
Note: Three fasteners are inside the carrier housing.

21
Torque the carrier fasteners to 207 ±19 Nm (153 ±14 ft-lb).

22
Install the torque rod bracket, spacers, and fasteners. Torque
the fasteners to 339 ±34 Nm (250 ±25 ft-lb).

23
Inspect the O-ring. Install the side cover and fasteners. Tor-
que the fasteners to 41 ±4 Nm (30 ±3 ft-lb).

24
Fill the upper and lower gear cases with the correct weight
and quantity of gear oil.

25
Move the rear yoke from the defective carrier to the new car-
rier. Torque fastener to 1016.5 ±203.5 Nm (750 ±150 ft-lb).

26
Install the inter-axle driveshaft. Torque the fasteners to
166 ±10 Nm (122.5 ±7.5 ft-lb).
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 02 01 5(8)

27
Make sure the vehicle is at the correct ride height. Install the
spacer block, lateral torque rod, and fasteners. Torque the
fasteners to 339 ±34 Nm (250 ±25 ft-lb).

28
Install the input driveshaft and fasteners. Torque the fasten-
ers to 166 ±10 Nm (122.5 ±7.5 ft-lb).

29
Clean the mating surfaces of the axles and hubs. With a re-
placement gasket, install the axles, locks, and fasteners. Tor-
que the fasteners to 203 ±20 Nm (150 ±15 ft-lb).

30
Connect the power divider air line.

31
Reconnect all previously removed cables to the negative
(ground) battery terminals.

32
Start the engine. Road test to check for proper operation.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 02 01 6(8)

4651-03-02-04
Differential Carrier, Second Axle, Replacement
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.

1
Disconnect all cables from the negative (ground) battery ter-
minals to prevent personal injury from electrical shock and
prevent damage to electrical components.

2
Drain the oil from the axle housing and rear differential car-
rier. Inspect the oil for metal shavings and other debris. If you
find debris, more disassembly, cleaning, and inspection will
be necessary.

3
Remove the fasteners that attach the hubs. Put a suitable
container below the hub to collect oil leakage. Remove the
axles and locks.

4
Remove the lateral torque rod and fasteners from the frame
rail and carrier.

5
Remove the torque rod mounting bracket and fasteners.

6
Remove the fasteners and caps that attach the inter-axle
driveshaft to the rear carrier. Remove the driveshaft.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 02 01 7(8)

7
Remove the side cover from the carrier.

8
Remove the differential carrier fasteners.
Note: Three fasteners are inside the carrier housing.

9
Use an assistant and a suitable lifting device to remove the
differential carrier from the axle housing. If you find metal
shavings or other debris in the axle housing, more disassem-
bly, cleaning, and inspection will be necessary.

Rear Differential Carrier Removed

10
Remove the replacement carrier from the shipping container.

11
Move the input shaft yoke from the defective carrier to the re-
placement carrier. Torque the fasteners to 1220.5 ±135.5 Nm
(900 ±100 ft-lb).

12
Move the torque rod bracket studs from the defective carrier
to the new carrier.

13
Clean the mating surfaces of the axle housing and differential
carrier.

14
Apply a 1.6 mm (.0625 in) bead of sealant to the carrier mat-
ing surface on the axle housing.

15
Use an assistant and a suitable lifting device to install the re-
placement differential carrier in the axle housing.

16
Install the fasteners that attach the carrier to the axle hous-
ing. Torque the fasteners to 207 ±19 Nm (153 ±14 ft-lb).
Note: Three fasteners are inside the carrier housing.

17
Install the torque rod bracket and fasteners. Torque the fas-
teners to 339 ±34 Nm (250 ±25 ft-lb).
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2013 465 02 01 8(8)

18
Inspect the O-ring. Install the side cover and fasteners. Tor-
que the fasteners to 41 ±4 Nm (30 ±3 ft-lb).

19
Fill the housing with the correct weight and quantity of gear
oil.

20
Install the driveshaft and fasteners. Torque the fasteners to
166 ±10 Nm (122.5 ±7.5 ft-lb).

21
Make sure the vehicle is at the correct ride height. Install the
spacer block, lateral torque rod, and fasteners. Torque the
fasteners to 339 ±34 Nm (250 ±25 ft-lb).

22
Clean the mating surfaces of the axles and hubs. With a re-
placement gasket, install the axles, locks, and fasteners. Tor-
que the fasteners to 203 ±20 Nm (150 ±15 ft-lb).

23
Reconnect all previously removed cables to the negative
(ground) battery terminals.

24
Start the engine. Road test to check for proper operation.