CAPACITACIN FINNING CHILE

ABRIL 2003

797B (JSM) OFF-HIGHWAY TRUCK

DIFERENCIAL

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CAPACITACIN FINNING CHILE

ABRIL 2003
INSTRUCTOR NOTES

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CAPACITACIN FINNING CHILE

ABRIL 2003

Describa los componentes enumerados

1*....................................................

2*....................................................

3*....................................................

4*...................................................

5*...................................................

6*...................................................

Rear Axle
797B rear axle
1. Differential
2. Banjo housing
3. Final drives
4. Rear brakes
5. Rear wheels

Shown is the 797B rear axle arrangement. The differential (1) is installed
into the rear of the banjo housing (2). On all other truck models, the
differential is installed from the front. Power flows from the transmission
to the differential. The differential divides the power to the right and left
axle shafts. Torque is transmitted equally from the differential through
the two axle shafts to the final drives (3). The differential adjusts the
speed of the axle shafts for vehicle cornering, therefore, the power
delivered to the axle shafts is unequal during cornering.

6. Rear spindle

The rear brakes (4) are located inside the rear wheels (5). The hub of the
brakes are connected to and rotate with the rear wheels. The anchor
housing of the brakes is bolted to and held stationary by the rear
spindles (6).

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CAPACITACIN FINNING CHILE

ABRIL 2003

797B WHEEL STATION

SPINDLE

ANCHOR

REAR BRAKE

797B wheel station

HUB

REAR WHEEL

FINAL DRIVE

Shown is a sectional view of the 797B wheel station. Torque is

transmitted equally from the differential through the two axle shafts to the
final drives.
The rear brakes are located inside the rear wheels. The hub of the brakes
are connected to and rotate with the rear wheels. The anchor housing of
the brakes is bolted to and held stationary by the rear spindles.

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CAPACITACIN FINNING CHILE

ABRIL 2003

797B REAR AXLE LUBRICATION

BRAKE/COOLING
ECM

FINAL DRIVE
DIVERTER VALVE

RELIEF/ DIVERTER
VALVE AND SOLENOID

DRIVE
PUMP
FINAL DRIVE
FILTER
MOTOR

DIFF.
FILTER

TEMP.
SENSOR

BANJO
SUCTION
SCREEN

RELIEF
VALVE

PUMP

FINAL DRIVE
OIL LEVEL

797B rear axle

lubrication system

DIFF. HOT
OIL LEVEL

DIFF. COLD
OIL LEVEL

Shown is the rear axle lubrication system. A rear axle lubrication drive
pump provides oil flow to the rear axle lubrication drive motor. A
relief/diverter valve and solenoid controls the pressure in the rear axle
lubrication pump drive circuit. The setting of the relief valve is
13780 kPa (2000 psi).
The rear axle lubrication drive motor rotates a three-section pump that
provides lubrication to the differential and final drives. The two front
sections of the pump pull oil from the rear axle housing (banjo housing)
through a suction screen. The rear section of the pump pulls oil from the
carrier housing through a suction screen located below the differential.

Rear axle lubrication

controlled by
brake/cooling ECM

The amount of oil that flows to the differential and final drives is
controlled by the brake/cooling ECM. The brake/cooling ECM controls a
solenoid on the rear axle lubrication drive pump and a solenoid on the
final drive diverter valve. The solenoids are energized to control the oil
flow depending on the rear axle oil temperature.

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CAPACITACIN FINNING CHILE

ABRIL 2003

Describa los componentes enumerados

1*....................................................

2*....................................................

3*....................................................

Differential and final

drives oil system
1. Rear axle lubrication
drive motor
2. Suction screen

Shown is the front of the 797B rear axle. The bevel gear/differential is
pressure lubricated. The final drive components are lubricated in a
conventional splash manner; however, oil circulation through the wheel
bearings and final drive is provided by the rear axle pump. A rear axle
lubrication drive pump provides oil flow to the rear axle lubrication drive
motor (1). The rear axle lubrication drive motor rotates a three-section
pump that provides pressure lubrication to the differential and oil
circulation through the final drives. The two front sections of the pump
pull oil from the rear axle housing through a suction screen (2). The rear
section of the pump pulls oil from the carrier housing through a suction
screen located below the differential (see Visual No. 34).

Brake/Cooling ECM
controls rear axle
lubrication system

The amount of oil that flows to the differential and final drives is
controlled by the Brake/Cooling ECM. The Brake/Cooling ECM controls
two solenoids that direct oil flow to or away from the final drive and
differential depending on the rear axle oil temperature.

3. Rear axle oil

temperature sensor

A rear axle oil temperature sensor (3) is located at the front of the rear
axle housing (see Visuals No. 30 and 33).

CAPACITACIN FINNING CHILE

ABRIL 2003

-7Describa los componentes enumerados

1*....................................................

2
2*....................................................

3*....................................................

4*...................................................

797B differential
1. Scavenge screen
pan
2. Lubrication oil
distribution and
relief valve manifold

Shown is the 797B differential. Oil is scavenged from the differential

through a screen located in the pan (1) below the differential. Lubrication
and cooling oil flows from the pump to the differential bearings through a
distribution and relief valve manifold (2) and several steel tubes. If the
differential lubrication oil pressure exceeds 689 kPa (100 psi), a relief
valve in the manifold will open. Relief oil flows to the differential sump.

3. TCS axle speed

sensors

The Traction Control System (TCS) axle speed sensors (3) are located on
the differential. There is a sensor located on both sides of the differential.
The sensors can be accessed for service through a cover on the rear axle
housing (see Visual No. 109). The sensors provide input signals to the
Brake/Cooling ECM. The Brake/Cooling ECM uses these sensors to
determine if one of the rear wheels are spinning. If one of the rear wheels
is spinning, the Brake/Cooling ECM sends a signal to engage the brake on
the spinning wheel. Engaging the brake on the spinning wheel generates
a higher level of torque across the differential and therefore an increase in
torque to the wheel with better traction results.

4. Removal and
installation rollers

The differential is removed and installed by resting the two rollers (4) on
tubes in the axle housing. The differential can then slide in or out of the
rear axle housing.

CAPACITACIN FINNING CHILE

ABRIL 2003

-8Describa los componentes enumerados

1*....................................................

2*....................................................

3*....................................................

1
3

1. Rear axle lubrication

drive pump
2. Brake actuation
pump
3. Brake cooling drive
pump

4. Rear axle lube drive

pump relief/diverter
valve and solenoid
Rear axle drive pump
pressure tap

Rear axle lube drive

pump solenoid
ENERGIZED
- Pump turned OFF

Rear axle lube drive

pump solenoid
DE-ENERGIZED
- Pump turned ON

4*...................................................

The rear axle lubrication drive pump (1) is located at the lower rear
section of the pump drive. The rear axle lubrication drive pump is
connected to the brake actuation pump (2) and the brake cooling drive
pump (3). The rear axle lubrication drive pump pulls oil from the small
top hydraulic tank (see Visual No. 86). Oil flows from the rear axle
lubrication drive pump to the rear axle lubrication drive motor located on
the rear axle housing. The pump is driven by the engine, therefore the
differential and final drive components can be cooled and lubricated even
when the truck is stopped. A relief/diverter valve and solenoid (4)
controls the pressure in the rear axle lubrication drive pump circuit. The
setting of the relief valve is 13780 kPa (2000 psi). Rear axle drive pump
pressure can be measured at a pressure tap (not shown) located on the
drive pump.
Banjo oil temperatures less than -4C (25F) produces a condition where
it becomes impractical to pump high viscosity 50 or 60 weight oil. Under
this condition the solenoid on the Rear Axle (RAX) lube drive pump is
energized. This allows the RAX lube pumps to be turned off; however,
there is some pressure drop across the diverter valve which allows a small
amount of rotation of the lube pumps, and therefore, some slight
movement of oil throughout the system When the banjo oil temp reaches
-4C (25F) and the vehicle is moving, the solenoid on the RAX lube
drive pump diverter valve is de-energized and the RAX lube pump begins
to pump charge oil to the rear axle components.

CAPACITACIN FINNING CHILE

ABRIL 2003

-9Describa los componentes enumerados

1*....................................................

2
2*....................................................

3*....................................................

4*...................................................

1. Rear axle oil pump

2. Rear axle drive
motor
3. Axle housing suction
screen cover

4. Rear axle oil

temperature sensor

Shown is a closer view of the rear axle oil pump (1) and the drive
motor (2). The two front sections of the pump pull oil from the axle
housing reservoir through the suction screen behind the cover (3) and
provide charge supply oil to the final drives and the differential. The rear
section of the pump scavenges oil from the differential through a suction
screen (see Visual No. 34) and returns it to the axle housing reservoir.
A rear axle oil temperature sensor (4) is located at the front of the rear
axle housing. The sensor provides input signals to the Brake/Cooling
ECM. The Brake/Cooling ECM sends the signals to the VIMS, which
informs the operator of the rear axle oil temperature. A warning
Category 2 will be logged above 118C (244F). A warning Category 3
will be logged above 126C (259F).

- Differential cold
mode speed limiting

The rear axle oil temperature sensor also provides the input signal
required for the differential cold mode speed limiting function. The
differential cold mode limits the truck top speed until the oil temperature
is high enough to ensure proper lubrication. Shifting is limited to FIFTH
GEAR when the differential oil temperature is below -4C (25F).
Shifting is limited to SIXTH GEAR when the differential oil temperature
is greater than -4C (25F) and below 24C (75F).

- Solenoid activation

The rear axle oil temperature sensor signal is also used by the
Brake/Cooling ECM as the input that tells the ECM when to energize or
de-energize the rear axle drive pump diverter solenoid (see the previous
Visual) and the final drive diverter valve solenoid (see Visual No. 38).

CAPACITACIN FINNING CHILE

ABRIL 2003

-10Describa los componentes enumerados

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2*....................................................

3*....................................................

4*...................................................

5*...................................................
6*...................................................

6
7*...................................................

1. Differential carrier
suction screen

The rear section of the rear axle cooling pump pulls oil from the
differential carrier sump through the suction screen (1). Oil flows from
the rear pump section to the axle housing.

2. Carrier oil level sight

glass

Two compartments must be filled with oil to fill the rear axle housing; the
carrier housing and the axle housing (see Visual No. 26 STMG-1). The
carrier oil level is checked with a sight glass at location (2). The carrier
housing is drained by removing a magnetic plug from the hole (3).

3. Carrier housing drain

plug hole
4. Axle housing fill and
TCS axle sensor
service hole
5. Housing oil level
sight glass
6. Axle housing drain
plug hole
7. TOS sensors

The axle housing can be filled through one of the two access holes (4).
The TCS axle speed sensors are serviced through these two holes. The
axle housing oil level is checked with a sight glass at location (5). The
axle housing is drained by removing a magnetic plug from the hole (6).
The two Transmission Output Speed (TOS) sensors (7) are located near
the differential bevel gear. The TOS sensors are serviced by removing the
large access cover.

CAPACITACIN FINNING CHILE

ABRIL 2003

-11Describa los componentes enumerados

1*....................................................

6
8

2*....................................................

5
3*....................................................

7
2

4*...................................................
5*...................................................
6*...................................................

3
7*...................................................
8*...................................................

1. Differential carrier
housing suction
tube
2. Differential scavenge
pump outlet
3. Rear axle housing
suction tube
4. Differential bearing
lube supply tube to
filter
5. Differential filter
6. Differential bearing
lube supply port to
differential
7. Final drive bearing
lube supply tube to
diverter valve
8. Final drive filter

Shown is the right inside of the axle housing. The rear section of the rear
axle cooling pump pulls oil from the carrier housing through the tube (1)
and a suction screen located below the differential (see previous Visual).
Scavenged oil from the differential flows to the banjo housing through the
tube (2).
The two front sections of the rear axle cooling pump pull oil from the rear
axle housing through the tube (3) and a suction screen (see Visual
No. 33).
Oil flows from the center pump section through the tube (4), the
differential filter (5), and the port (6) to the differential bearings.
Oil flows from the front pump section through the tube (7), the final drive
diverter valve (see Visuals No. 38 and 40), and the final drive filter (8) to
the final drive bearings.

CAPACITACIN FINNING CHILE

ABRIL 2003

-12Describa los componentes enumerados

1*....................................................

5
2*....................................................

3*....................................................

2
4*...................................................

3
1

5*...................................................

1. Final drive lube

supply tube to
diverter valve

2. Tube to differential
for warming oil

3. Final drive lube

supply tube to filter
4. Final drive filter
5. Left and right final
drive lube supply
tubes

Shown is the top left inside of the axle housing. Oil flows from the front
section of the rear axle cooling pump through the tube (1) to the final
drive diverter valve (see Visuals No. 38 and 40). The diverter valve is
controlled by the Brake/Cooling ECM. When the rear axle oil
temperature is below 60C (140F), the Brake/Cooling ECM energizes a
solenoid on the diverter valve. When the solenoid is energized, oil flows
through the tube (2) and sprays on the differential. The differential warms
the oil through the mechanical action of oil churning by the pinion and
ring gears.
When the rear axle oil temperature is above 60C (140F), the
Brake/Cooling ECM de-energizes the solenoid on the diverter valve.
When the solenoid is de-energized, oil flows from the diverter valve
through the tube (3), the final drive filter (4), and the two tubes (5) to the
final drives and wheel bearings on both sides of the truck.

CAPACITACIN FINNING CHILE

ABRIL 2003

-13Describa los componentes enumerados

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2*....................................................

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1. Right final drive and

wheel bearing lube
tube
2. Oil baffle

Shown is the right inside of the axle housing. Oil flows through the
tube (1) to the right final drive and wheel bearings. An oil baffle (2) is
installed on both sides of the rear axle. The oil baffle promotes
circulation of oil around the wall of the axle housing, which increases
heat transfer. The oil baffle also prevents overfilling of the final drives
during short side slope and cornering events.

CAPACITACIN FINNING CHILE

ABRIL 2003

-14Describa los componentes enumerados

1*....................................................

2*....................................................

4
3*....................................................

4*...................................................

1. Differential oil filter

Oil flows from the center section of the rear axle cooling pump through
the differential oil filter (1) to the differential bearings.

2. Final drive diverter

valve

Oil flows from the front section of the rear axle cooling pump through the
final drive diverter valve (2) and the final drive oil filter (3) to the final
drives and wheel bearings on both sides of the truck. The diverter valve
is controlled by the Brake/Cooling ECM. When the rear axle oil
temperature is below 60C (140F), the Brake/Cooling ECM energizes
the solenoid (4) on the diverter valve. When the solenoid is energized, oil
sprays on the differential and the differential warms the oil. In relation to
the final drives this fulfills two functions:

3. Final drive oil filter

4. Final drive diverter

valve solenoid

First, the final drives are not overfilled with cold oil.
Second, the elevated level of oil in the bevel gear group reservoir
allows the bevel gear and pinion to churn the oil, causing rapid
mechanical heating of the oil. The goal is to get the oil in the system
up to 60C (140F) as quick as possible so that normal filtering of the
oil and oil circulation through the final drives can occur.
When the rear axle oil temperature is above 60C (140F), the
Brake/Cooling ECM de-energizes the solenoid on the diverter valve.
When the solenoid is de-energized, oil flows through the filter to the final
drives and wheel bearings on both sides of the truck.

CAPACITACIN FINNING CHILE

ABRIL 2003

-15Describa los componentes enumerados

1*....................................................

2*....................................................

2
3*....................................................

Differential oil filter

1. Filter bypass switch

Shown is the differential oil filter. An oil filter bypass switch (1) is
located on the filter housing. The bypass switch provides an input signal
to the Brake/Cooling ECM. The Brake/Cooling ECM sends the signal to
the VIMS, which informs the operator if the filter is restricted. If the
filter is restricted and oil temperature is above 60C (140F), a warning
Category 1 will be logged after 20 seconds. A warning Category 3 will
be logged after 30 minutes.

Differential oil filter

has in-line bypass

Proper oil flow to the bevel gear bearings must be maintained at all times.
Loss of flow or diminished flow will result in rapid bearing burn-up under
high speed vehicle operating conditions. The oil filter for the bevel gear
group is an in-line bypass type. If the filter bypasses, either due to cold
oil or a plugged filter element, the bevel gear group will receive unfiltered
oil. In the case where the filter plugs due to contaminant build up, dirty
oil is better than no oil since the bevel gear group would progress to
catastrophic failure rapidly without oil.

2. Differential oil
pressure sensor

A differential oil pressure sensor (2) is also located on the filter housing.
The pressure sensor also provides an input signal to the Brake/Cooling
ECM. If the differential oil pressure is less than 117 kPa (17 psi) when
the engine speed is above 1250 rpm and the oil temperature is above
60C (140F), a warning Category 3 (DIFF LUBE PRES LO) will be
logged. The minimum pressure allowed changes when engine speeds and
oil temperatures are greater. Differential oil pressure can be measured at
the tap (3).

3. Differential oil
pressure tap

CAPACITACIN FINNING CHILE

ABRIL 2003

-16Describa los componentes enumerados

1*....................................................

1
3

2*....................................................

3*....................................................

Final drive oil filter

1. Filter bypass switch

Shown is the final drive oil filter. An oil filter bypass switch (1) is located
on the filter housing. The bypass switch provides an input signal to the
Brake/Cooling ECM. The Brake/Cooling ECM sends the signal to the
VIMS, which informs the operator if the filter is restricted. If the filter is
restricted and oil temperature is above 60C (140F), a warning
Category 1 will be logged after 20 seconds.

Final drive oil filter

bypasses to sump

When the filter element plugs the unfiltered oil is bypassed back to the
axle housing (sump) rather than being bypassed in-line which could allow
contaminated oil to flow through the wheel bearings. The final drives can
operate for an extended period of time with the filter in the bypass
condition because the primary lubrication of the final drives is by splash
lube.

2. Final drive oil

pressure switch

A final drive oil pressure switch (2) is also located on the filter housing.
The oil pressure switch also provides input signals to the brake/cooling
ECM. The brake/cooling ECM sends the signals to the VIMS, which
informs the operator of the final drive oil pressure. If the final drive oil
pressure is less than 160 kPa (23 psi) when the engine speed is above
1300 rpm and the diverter solenoid is de-energized, a warning Category 1
(FNL LUB PRES LO) will be logged.

3. Final drive oil

pressure tap

Final drive oil pressure can be measured at the tap (3).

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CAPACITACIN FINNING CHILE

ABRIL 2003

FINAL DRIVE

REACTION
HUB

SECOND REDUCTION
RING GEAR

WHEEL

INNER
THRUST WASHER

FINAL DRIVE
ADAPTER HOUSING
SECOND REDUCTION
CARRIER
SECOND REDUCTION
PLANETARY GEAR

SECOND REDUCTION
SUN GEAR

SPINDLE

AXLE SHAFT

OUTER
THRUST WASHER

FIRST REDUCTION
SUN GEAR
FIRST REDUCTION
CARRIER
FIRST REDUCTION
RING GEAR

FIRST REDUCTION
PLANETARY GEAR

Final Drive
Double reduction
planetary gear final
drive

Shown is a sectional view of the double reduction planetary final drive.

Power is mechanically transmitted from the differential through the axle
shaft to the sun gear of the first reduction planetary. The final drive is a
carrier drive planetary arrangement; therefore, the first and second
reduction ring gears are splined together and grounded to the spindle
through the reaction hub so they don't rotate.
The power input to the first reduction sun gear from the axle shaft causes
rotation of the first reduction planetary gears and carrier and the power is
output at reduced speed and increased torque through the first reduction
carrier. The first reduction carrier is directly connected to the second
reduction sun gear with splines so the power output from the first
reduction planetary is input to the second reduction sun gear. The power
input to the second reduction sun gear causes rotation of the second
reduction planet gears and carrier.