Beruflich Dokumente
Kultur Dokumente
Service Notes
This publication provides failure analysis
information for Meritor drive axle components.
The information contained in this publication was
current at the time of printing and is subject to
revision without notice or liability.
Service Notes
CAUTION
A CAUTION alerts you to a procedure that
you must follow exactly to avoid damage to
equipment or components. Serious personal
injury can also occur.
TORQUE
The TORQUE symbol indicates that you must
tighten fasteners to a specific torque value.
NOTE:
A NOTE can either indicate a procedure or
instruction that is important for correct service,
or provide service suggestions.
Table of Contents
Section 1: Overview of Component Damage
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Shock Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Fatigue Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Typical Fatigue
Identification
Surface Fatigue Pitting, Spalling and Flank Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Surface or Contact Fatigue
Pitting Fatigue
Spalling Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Spalled Gear Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Flank Cracking
Rotating Bending Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Torsional Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Bending Root Beam Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Bending Deep Root Tooth Fatigue
Typical Spinout Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Other Indications of Spinout Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Lubrication-Related Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Contamination Damage
Types of Lubrication-Related Damage
Depleted Additive Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Incorrect Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Overheated Operation Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Low Lubricant Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Lack of Lubrication
Fretting and Brinelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Indications to Look Further Secondary Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Table of Contents
Section 3: Damaged Axle Review
Tapered Roller Bearing Damage Analysis Printed Courtesy of Timken
Identifying Axle Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Adjusting Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pinion Root Beam Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driveline/Torsional Vibration Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver-Controlled Differential Lock (DCDL) Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flange Side Differential Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hypoid Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hypoid Set (Both Ring and Drive Pinion Gears) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hypoid Gear Set (Inner Drive Pinion Bearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IAD Spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Differential Spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Flange Side Differential Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plain Half Differential Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Differential Case-to-Case Joint Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Systems Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Side Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Gear Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
45
46
47
49
50
52
54
55
56
57
58
59
60
63
65
66
67
68
69
70
71
72
73
76
80
81
82
Section 1
Overview of Component Damage
Overview
Section 1
Overview of Component Damage
Shock Damage
45 fracture
Section 1
Overview of Component Damage
The overhanging pinion in Figure 1.3 was
damaged due to a rotating shock load. The
fracture has a rough, crystalline appearance and is
broken at a 45 angle.
Section 1
Overview of Component Damage
Fatigue Damage
Typical Fatigue
When the bending or torsional load is large, the
part will fail after a small number of load
applications. As the load is reduced, it requires a
greater number of applications to cause failure.
When the load is decreased even further, the part
can withstand an infinite number of applications
without failing. The load corresponding to the
horizontal part of the diagram is called the
endurance limit of the material.
Plotting both lines on the same graph shows the
relationship between the fatigue due to surface
loads and that due to bending and/or torsional
loads. Figure 1.7.
1 Point of origin
2 Beach marks (witness)
3 Final fracture
Identification
r Torsional fatigue
r Root beam fatigue
Surface or contact fatigue affects contact surfaces
of the gearing and bearings. Rotating bending
fatigue affects shafts. Torsional or contact fatigue
affects shafts. Root beam fatigue affects gear
teeth.
LOAD
BENDING
OR
TORSIONAL
SMALL
FEW
MANY
NUMBER OF APPLICATIONS
Section 1
Overview of Component Damage
Surface Fatigue Pitting,
Spalling and Flank Cracking
Pitting Fatigue
Section 1
Overview of Component Damage
Spalling Fatigue
Section 1
Overview of Component Damage
Spalled Gear Teeth
Flank Cracking
Flank cracking usually causes a metal surface to
flake away much like a spalling condition would. A
gear with flank cracking, however, will first
develop longitudinal cracks that run the length of
the gear tooth face. Once these cracks appear,
failure occurs rapidly. Frequently, a single tooth
may show signs of deterioration, while the
remaining teeth remain intact. Once the cracks
appear, the metal between them begins to flake
away. Figure 1.13.
Crack
Section 1
Overview of Component Damage
Rotating Bending Fatigue
Section 1
Overview of Component Damage
Table A: Typical Rotating Bending Fatigue Failures in Shafts
Stress
Condition
Case
No Stress Concentration
Low
Overload
Low
Overload
Low
Overload
High
Overload
High
Overload
High
Overload
Torsional Fatigue
Section 1
Overview of Component Damage
Bending Root Beam Fatigue
LOAD
LOAD
10
1
2
3
4
Ratchet marks
Beach marks
Marred area
Final fracture
Section 1
Overview of Component Damage
Typical Spinout Damage
11
Section 1
Overview of Component Damage
The following illustrations show progressive wear
of the spider, from light to catastrophic:
12
Section 1
Overview of Component Damage
The heavy wear and galling most likely resulted in
multiple spinout events but not one spinout event
was long enough in duration to cause a seizure,
although several such events can cause
catastrophic damage. This damage can also be
caused by mismatched tires or axle ratios. Figure
1.23 and Figure 1.24.
13
Section 1
Overview of Component Damage
The catastrophic damage in Figure 1.26 is an
example of a severe spinout.
14
Section 1
Overview of Component Damage
If spinout damage is suspected and the IAD case
did not separate, Figure 1.29, check the following:
15
Section 1
Overview of Component Damage
Another example is galling on spider legs and one
or more of the pinions twisting the leg from the
spider hub. The assembly could not continue to
function. The primary damage is due to a spinout.
Figure 1.30.
Other Indications of
Spinout Damage
Friction from spinout can cause galling at the
helical gear journal and the rear side gear journal.
Figure 1.31. Spinout damage can also show up on
a scored rear side gear bearing. Figure 1.32. We
know the bearing was not damaged from preload
because the input shaft bearing was not damaged.
Improper preload of a bearing generally shows up
as spalling. The rear side gear can also be friction
welded to the input shaft. Figure 1.33.
16
Section 1
Overview of Component Damage
Sometimes spinout damage is caused from a rear
wheel spinning and the front axle sitting
stationary, not allowing the hypoid gear set to
splash oil on the internal parts. Figure 1.33.
Generally there is evidence of localized heat and
burnt or carbonized oil in the input shaft area. The
rear side gear is usually seized to the input shaft
journal, and in addition, the rear side gear bearing
will be scored.
17
Section 1
Overview of Component Damage
Lubrication-Related Damage
Contamination Damage
If the lubricant becomes contaminated with water,
dirt or wear particles, the wear between mating
surfaces can significantly increase. The source of
the contamination must be determined. This must
include inspection of all seals and breathers.
Contaminants are particularly harmful to bearing
surfaces. Figure 1.34.
Types of Lubrication-Related
Damage
Etching Corrosion
Etching or corrosion appears as a dull matte
surface stain or blemish that can indicate
problems primarily caused by moisture
contamination of the axle lubricant. Moisture and
water may enter the carrier through breathers or a
broken or worn seal or develop from condensation
during humid weather conditions. In any case,
water in the lubricant causes specific harm to the
bearing races and cups and will affect wear of the
hypoid gear set.
Corrosion from water appears on the bearing
surface. In this case the corrosion showed up on
the spigot bearing roller ends. Figure 1.35.
18
Section 1
Overview of Component Damage
Etching on the bearing rollers, corrosion on
non-contact surfaces and worn cage windows
indicate water contamination of the lubricant.
Figure 1.34 and Figure 1.36.
19
Section 1
Overview of Component Damage
Bruising (Particle Denting)
Scuffing
Scuffing is a localized type of surface wear caused
by the breakdown of the lubricating oil film. This
permits a tearing of one metal surface and a
welding transfer (galling) to another metal surface.
The contact area of bearing cone rollers and the
mating inner race surface is a good example of an
area in which scuffing, scoring, and spalling can
appear before primary failure occurs.
Flat spots appearing on rollers are an indication of
bearing scuffing. The scoring condition of the
remaining assembly suggests insufficient
lubricant as the primary cause. Figure 1.38.
If a rough, scuffed surface develops in the early
stages of bearing wear, scuffing, scoring and
ridging (crows-feet in gears) can impede
bearing roller operation. This will cause flat edges
that progressively develop into total bearing
failure.
20
Section 1
Overview of Component Damage
Crows-foot scoring is inherent in hypoid gears
when the wrong or depleted lubricant is used. The
hypoid gears used in Meritor axles develop a
tremendous amount of loading in the gear contact
area. If oil without the proper level of extreme
pressure (EP) additive is used, the force developed
during loaded gear engagement will cause
metal-to-metal contact between drive and driven
gears. Because of the combination of sliding and
rolling action seen in hypoid gearing,
crows-footing will appear on tooth surfaces.
Figure 1.39.
Crows-foot pattern
Crowss-foot pattern
21
Section 1
Overview of Component Damage
Incorrect Lubrication
22
Section 1
Overview of Component Damage
Overheated Operation Damage
23
Section 1
Overview of Component Damage
Low Lubricant Levels
Lack of Lubrication
If an assembly was not filled with lubricant,
damage most likely occurs at relatively low miles
after installation. Bluing of internal parts and
plastic deformation of loaded gear teeth are
commonly seen with no initial lubricant. Of
course, there would be no burned oil because
none was put in the unit.
24
Section 1
Overview of Component Damage
Fretting and Brinelling
Flat spotting
25
Section 1
Overview of Component Damage
Indications to Look Further
Secondary Damage
1 Original pattern
2 Secondary pattern
26
Section 1
Overview of Component Damage
Top lands of the pinion teeth have been smeared.
Figure 1.51. The top lands of the ring gear have
been smeared and several teeth have been broken
off at the toe-end. Figure 1.52. This damage is an
indication to look further. The gear teeth broke
from a foreign object going through the gear
mesh. The lands were smeared after the ring and
pinion ran out of position.
27
Section 1
Overview of Component Damage
If a carrier is heavily loaded due to load weight,
engine torque or application, the wear on the ring
gear teeth can be a visible indication.
Smooth face
28
Section 1
Overview of Component Damage
The side gear teeth in Figure 1.56 have been shock
loaded. More than one adjacent tooth, where each
pinion would ride, has been broken at the root.
The fracture is rough, crystalline in appearance.
These are known characteristics of an
instantaneous shock load.
1. Brittle appearance
2. Broken at pitch line, not root
29
Section 2
Causes of Drive Axle Damage
Drive Axle Damage
Section of
Causes
2 Drive Axle Damage
2. Vehicle operation
3. Maintenance
4. Vehicle or powertrain modification
Vehicle Application/Vocation
Preventing damage starts with understanding the
application or vocation intended for the vehicle.
All vehicles and their components are designed to
give satisfactory service under given operating
conditions. Axles in particular are available in a
wide range of capacities to meet the requirements
of a wide variety of applications. Axles used in
operations which exceed their design limitations
will result in premature damage and reduced axle
service life.
GVW
30
GCW
Section 2
Causes of Drive Axle Damage
Axle Fatigue
Fatigue is a common type of component damage
in an axle assembly. It results from repeated cyclic
loading of a component. A single load cycle may
not be great enough to cause the part to break
down, but repeated load cycles will gradually
weaken the part to the point of failure.
Three types of fatigue components are common in
axle carrier:
Figure 2.2
SURFACE FATIGUE
LARGE
BREAKDOWN LINE
LOAD
SMALL
FEW
MANY
NUMBER OF CYCLES
31
Section 2
Causes of Drive Axle Damage
Figure 2.3 represents the characteristics of parts
subjected to bending or torsional fatigue. When
the load is large, component failure occurs within
a small number of cycles. As the load becomes
smaller, the number of cycles required to damage
the part increases. When the load decreases even
further, the part can withstand an infinite number
of cycles without damage. The load corresponding
to the horizontal part of the diagram is the
endurance limit of the material. Shafts are
subjected to both bending and torsional loads.
Thus, their fatigue characteristics follow the
bending/torsional fatigue breakdown line.
Gears are subjected to both surface loads and
bending loads. Lightly loaded gears tend to suffer
damage from surface fatigue. As the load
increases, the damage changes from surface to
bending fatigue. Heavy loads on the gear teeth
will cause bending fatigue damage.
The two causes of fatigue damage to the carrier
assembly are:
r Exceeding the GVW/GCW rating of the carrier
r Operating the vehicle at a weight that exceeds
the carriers GVW/GCW rating reduces the
fatigue life of the components. The rated GVW/
GCW of a carrier changes with the road grade
and surface. As the grade increases, so does the
torque (load) required to move the vehicle.
Likewise, as the road surface changes from
hard to soft, the rolling resistance increases and
more torque is needed. Again, as the load
increases, fatigue life of the components
decreases.
Figure 2.3
BENDING/TORSIONAL FATIGUE
LARGE
BREAKDOWN LINE
LOAD
ENDURANCE LIMIT
SMALL
FEW
MANY
NUMBER OF CYCLES
Figure 2.4
HEAVY
GAW
LOAD
GAWR
Housing Overload
The main contributor to axle housing damage is
structural or operational overload. This takes place
when the vehicle is loaded in excess of the plated
Gross Axle Weight Ratings (GAWR). When the
Gross Axle Weight (GAW) increases, axle housing
life decreases. Figure 2.4. Axle housing life is
virtually infinite if the load is at the plated GAWR.
32
LIGHT
SHORT
LONG
Section 2
Causes of Drive Axle Damage
Vehicle Operation
Vehicle operation or abuse, can damage a vehicle
and its components no matter how closely they
are matched to the job and how well they are
maintained.
Improper operation can cause either
instantaneous failure, or problems which will
result in reduced component life.
The operator must be properly trained to avoid
situations which would be harmful to the axle. The
vehicle operator must be aware that poor driving
habits may reduce component life.
Operational Component
Damage
Proper identification of these causes, and initiating
action to prevent reoccurrence will extend
component service life.
The most common types of drive axle component
damage result from spinout and shock loading.
33
Section 2
Causes of Drive Axle Damage
Figure 2.5a
Figure 2.5b
INTER-AXLE DIFF. ACTION
Figure 2.5c
Figure 2.5d
INTER-AXLE DIFF. ACTION
Figure 2.5e
Figure 2.5f
MAIN DIFF. ACTION
34
Section 2
Causes of Drive Axle Damage
Potential Differential
Spinout Scenarios
Figure 2.6
Figure 2.7
SLIPPERY SURFACE
Figure 2.8
SLIPPERY SURFACE
35
Section 2
Causes of Drive Axle Damage
Typical Shock Load Damage
Figure 2.9
Figure 2.10
36
DRY
PAVEMENT
SLIPPERY
SURFACE
Section 2
Causes of Drive Axle Damage
Missing a Shift
Figure 2.11
Figure 2.12
Figure 2.13
DIFFERENTIAL
LOCK
UNLOCK
POOR
GOOD
TRACTION
37
Section 2
Causes of Drive Axle Damage
DCDL Lock Profile
38
Section 2
Causes of Drive Axle Damage
Improper Use of Creeper Gears
Main transmission creeper gears are designed for
specialized very low speed vehicle control or
positioning. Creeper gears are not typically used
during normal highway vehicle operation. If used
for high torque transfer, shock loading damage
may result to the axle carrier, drive shafts or
driveline components. Figure 2.14.
If severe enough, shock loads can cause instant
failure of the part. Less severe shock loads can
create a crack or point of origin from which
bending or torsional fatigue can start, even under
normal or reduced loads. No matter how small,
these cracks can result in fatigue within only a few
load cycles.
Figure 2.14
39
Section 2
Causes of Drive Axle Damage
Maintenance and Rebuilding
Maintenance and
Rebuilding Practices
2. Change lubricant
40
Section 2
Causes of Drive Axle Damage
Lubrication-Related
Component Damage
Another cause of axle component damage
originates with the lubricant, or with lubricant
change practices. The lubricant which protects the
axle components has three key functions:
Figure 2.15
Oil level must be even with
bottom of fill plug hole.
FILL PLUG
Contaminated Lubricant
Another common cause of axle damage is
contaminated lubricant. This is defined as
lubricant which contains water, dirt, or wear
particles.
Lubricant can become contaminated by:
r Water and dirt entering the carrier through a
faulty wheel or shaft seal, the carrier-to-housing
joint or the axle housing breather.
r Wear particles generated from normal or
abnormal vehicle service.
Meritor axles contain magnetic drain plugs and
magnets as a standard feature. These magnets
isolate metallic particles as they settle to the
bottom of the axle housing.
In addition, Meritor offers tandem axles that
incorporate oil pumps. This system provides
pressurized lubrication. A spin-on oil filter
removes contaminants from the lubricant. It is still
essential to always follow the recommended
schedule for lubrication changes. Refer to
Maintenance Manual 1, Lubrication.
41
Section 2
Causes of Drive Axle Damage
Tire Matching
Figure 2.16
Procedure
The vehicle should be on a level surface and
carrying a properly distributed rated capacity load.
Make sure that all tires are the same size. Measure
new tires to confirm that they are correctly
matched.
1. Inflate all tires to the same pressure.
2. Carefully measure the rolling circumference of
each tire with a steel tape.
3. Mark the size on each tire with chalk. Then
arrange them in order of size, from largest to
smallest.
4. Mount the two largest tires on one side of one
axle and mount the two smallest on the
opposite side of the same axle.
5. Mount the four tires on the other axle in the
same way.
6. Test run the vehicle to obtain accurate rear
axle lubricant temperature readings on the
two axle lubricant temperature gauges.
7. Vary tire air pressure (within the tire
manufacturer's recommended range) so the
temperature of both axles is within 30F of
each other and no higher than 220F. This
helps to ensure uniform loading and optimum
life of the tires.
42
Section 2
Causes of Drive Axle Damage
Torsional Vibration
Torsional vibration results from several factors,
most notably the power characteristics of today's
high-efficiency diesel engines, which can run at
lower rpm. It can be difficult to detect because the
driver is often well isolated within the cab. At
certain speeds, however, the driver may notice a
low-frequency growl or the rearview mirror
shaking, which may be signs of torsional
vibration. If unchecked, torsional vibration can
lead to major damage or total failure of the axle
components.
Axle components are generally less susceptible to
damage from torsional vibration than other
components in the powertrain. Some tandem
axles have experienced loosened nuts at the input
end and yoke wear, but most of these problems
have been resolved through the manufacturing
process. Tandem axle power dividers, however,
have shown component wear which may have
resulted from vibration. Meritor recommends
using an axle pump to supply increased
lubrication to axle gears and offset some vibration
problems. Single axles have larger rotating
components and thus experience fewer vibrationrelated problems. Check any noises coming from
the rear of the vehicle. These could either be axle
noises or warnings of driveline vibration.
43
HANDLING
DAMAGE
EXCESSIVE
PRELOAD OR
OVERLOAD
EXCESSIVE END
PLAY
Scalloping Uneven
localized wear resulting from
excessive end play.
INADEQUATE
LUBRICATION*
Roller nicking/denting
Rough handling or
installation damage.
WARNING!
FATIGUE SPALLING
Geometric stress
concentration Spalling
from misalignment,
deflections or heavy loading.
If a hammer and mild steel bar are used for bearing removal,
fragments from the hammer, bar or the bearing can be released
with sufficient velocity to create a risk of serious bodily injury
including damage to your eyes.
FOREIGN
MATERIAL
HIGH SPOTS IN
CUP SEATS
CORROSION/
ETCHING
IMPROPER FIT
ELECTRIC CURRENT
PEELING
CAGE DAMAGE
FALSE BRINELLING
MISALIGNMENT
Cage Deformation
Improperly installed or
dropped bearing.
Fluting
Series of small axial
burns caused by electric
current passing through the
bearing while it is rotating.
Wear caused
by vibration
or relative
axial movement
between rollers and races.
TRUE BRINELLING
Damage
from shock
or impact.
FOREIGN
MATERIAL
HIGH SPOTS IN
CUP SEATS
CORROSION/
ETCHING
IMPROPER FIT
ELECTRIC CURRENT
PEELING
CAGE DAMAGE
FALSE BRINELLING
MISALIGNMENT
Cage Deformation
Improperly installed or
dropped bearing.
Fluting
Series of small axial
burns caused by electric
current passing through the
bearing while it is rotating.
Wear caused
by vibration
or relative
axial movement
between rollers and races.
TRUE BRINELLING
Damage
from shock
or impact.
HANDLING
DAMAGE
EXCESSIVE
PRELOAD OR
OVERLOAD
EXCESSIVE END
PLAY
Scalloping Uneven
localized wear resulting from
excessive end play.
INADEQUATE
LUBRICATION*
Roller nicking/denting
Rough handling or
installation damage.
WARNING!
FATIGUE SPALLING
Geometric stress
concentration Spalling
from misalignment,
deflections or heavy loading.
If a hammer and mild steel bar are used for bearing removal,
fragments from the hammer, bar or the bearing can be released
with sufficient velocity to create a risk of serious bodily injury
including damage to your eyes.
Section 3
Damaged Axle Review
Identifying Axle Damage
44
Section 3
Damaged Axle Review
Bearing Adjusting Ring
Visual Conditions
r Drive pinion teeth are fractured in root beam
fatigue mode. (Primary) Figure 3.1.
r The flange side adjusting ring shows parting
marks at the cap-to-case area. (Secondary)
Figure 3.2.
r The cotter pin on the main differential bearing
cap for the adjusting ring is bent outward.
(Secondary)
Preventive Actions
Operate vehicle within design specifications.
Part Code: Gear, Pinion
Condition Code: Root Beam Fatigue
45
Section 3
Damaged Axle Review
Drive Pinion
Preventive Actions
Visual Conditions
46
Section 3
Damaged Axle Review
Drive Pinion Gear
Visual Conditions
r Pinion teeth are broken off at the heel of the
drive pinion gear. (Primary) Figure 3.6.
r Ring gear teeth may have secondary damage.
Figure 3.7.
Preventive Actions
Incorrect maintenance or rebuild practices. Refer
to the appropriate maintenance manual.
Part Code: Further investigation is required.
Primary cause of failure will determine proper
codes.
Condition Code: Identify primary cause to
determine code.
1 Original pattern
2 Secondary pattern
47
Section 3
Damaged Axle Review
Drive Pinion Gear
Visual Conditions
r The ring gear is worn to knife-like edges,
indicating extreme premature wear.
(Secondary) Figure 3.8 and Figure 3.9.
r The drive pinion gear premature wear is so
severe that the hardened tooth surfaces have
been worn away to the point that they no
longer mesh with the ring gear. Figure 3.8.
r Little evidence of heat, fairly clean gear set, and
no burnt lube indicate incorrect lube, metal
debris present.
r Check vehicle lubricant change history.
Preventive Actions
Maintain scheduled intervals for lubrication
maintenance. Refer to Maintenance Manual 1,
Lubrication.
Part Code: Lubricant
Condition Code: Incorrect
48
Section 3
Damaged Axle Review
Drive Pinion Root
Beam Fatigue
Visual Conditions
r Drive pinion gear teeth are broken off with deep
root bending fatigue beach marks. (Primary)
Figure 3.10 and Figure 3.11.
r Ring gear teeth damage is secondary.
Figure 3.10.
Preventive Actions
Operate vehicle according to design rated limits.
Part Code: Gear, Pinion
1
2
3
4
Ratchet marks
Beach marks
Marred area
Final fracture
49
Section 3
Damaged Axle Review
Driveline/Torsional
Vibration Issues
Visual Conditions
r Flattened to concave wear pattern on bevel
teeth of side gear and IAD pinions. Figure 3.12.
r Output shaft and side gear spline wear.
Figure 3.12 and Figure 3.13.
NOTE: These conditions are often accompanied
by looseness of the U-joint or previous
transmission synchronizer pin service.
Preventive Actions
Perform action checklist:
r Driveline inspection
r Driveline repair/adjustment
r Suspension adjustment
Part Code: Gear, Rear Side IAD
Condition Code: Bevel Teeth Worn
50
Section 3
Damaged Axle Review
Driveline/Torsional
Vibration Issues
Visual Conditions
r Flattened to concave wear pattern on bevel
teeth of side gear and IAD pinions. Figure 3.14.
r Output shaft and side gear spline wear.
Figure 3.15.
NOTE: These conditions are often accompanied
by looseness of the U-joint or previous
transmission synchronizer pin service.
Preventive Actions
Perform action checklist:
r Driveline inspection
r Driveline repair/adjustment
r Suspension adjustment
Part Code: Gear, Rear Side IAD
Condition Code: Bevel Teeth Worn
51
Section 3
Damaged Axle Review
Driver-Controlled Differential
Lock (DCDL) Collar
Figure 3.1639170d10
Visual Conditions
r Axle shaft splines are twisted and distorted.
(Primary) Figure 3.16.
r The Driver-Controlled Differential Lock (DCDL)
shift collar is broken. (Secondary) Figure 3.17.
Preventive Actions
Driver education/operational training.
Part Code: Shift Collar, Main Diff Lock
Condition Code: Broken
or
Part Code: Shaft, Axle Long
Condition Code: Broken, Body Diameter
52
Section 3
Damaged Axle Review
Driver-Controlled Differential
Lock (DCDL) Collar
Visual Conditions
r The DCDL collar is broken into many pieces.
(Primary) Figure 3.18.
r Shift fork leg is broken off. (Secondary)
Figure 3.19.
r The fracture surface is rough crystalline.
Preventive Actions
Driver education/operational training.
Part Code: Shift Collar, Main Diff Lock
Condition Code: Broken
53
Section 3
Damaged Axle Review
Flange Side
Differential Bearing
Visual Conditions
r Flange side bearing rollers and race are spalled
at outer half of rollers. (Primary) Figure 3.20.
r Pinion teeth have severely spalled, subsurface
fatigue. (Primary) Figure 3.21.
Preventive Actions
Operate vehicle according to design rated limits.
Follow recommended maintenance practices.
Part Code: Brg Cone, Main Diff (Flange Side)
Condition Code: Spalled, Rollers
or
Part Code: Gear, Pinion
Condition Code: Pinion Teeth, Spalled
54
Section 3
Damaged Axle Review
Housings
Visual Conditions
r The housings are cracked at the 10 oclock
position of the differential lock clearance notch.
(Primary) Figure 3.22.
r The cracks originate at the inner rib flange of
the housings and then run farther through the
bowl weld and into the axle housing cover.
(Primary) Figure 3.23.
Preventive Actions
Operate the vehicle according to design rated
limits.
Part Code: Hsg, Forward Axle or Hsg, Rear Axle
1. Crack
2. Indication of heavy loading
55
Section 3
Damaged Axle Review
Hypoid Set
Visual Conditions
r Polished gear teeth on the ring gear.
Figure 3.24.
r Milling marks and phosphate coating still
present on gear teeth. Figure 3.25.
Preventive Actions
Incorrect maintenance or rebuild practices. Refer
to the appropriate maintenance manual.
Part Code: Further investigation is required.
Primary cause of failure will determine proper
codes.
Condition Code: Identify primary cause to
determine code.
Smooth face
56
Section 3
Damaged Axle Review
Hypoid Set (Both Ring and
Drive Pinion Gears)
Visual Conditions
r There is crows-footing on both the ring and
drive pinion gears. (Primary) Figure 3.26 and
Figure 3.27.
r The lubricant appears black and has a burnt
odor. (Primary)
r There is a large build up of burnt lube on the
non-working surfaces.
Preventive Actions
Maintain scheduled intervals for lubricant
maintenance.
Part Code: Causal Part or Lubricant
57
Section 3
Damaged Axle Review
Hypoid Gear Set (Inner Drive
Pinion Bearing)
Preventive Actions
Follow recommended lubrication maintenance
schedules in Maintenance Manual 1, Lubrication.
Part Code: Causal Part or Lubricant
Condition Code: Low Lube/Unidentified Cause
58
Section 3
Damaged Axle Review
Inner Pinion Bearing
Preventive Actions
Visual Conditions
59
Section 3
Damaged Axle Review
IAD
Visual Conditions
r Component 1 is worn with galling. (Primary)
Figure 3.33.
r Component 2 is showing signs of excessive
wear. (Primary) Figure 3.33.
r Component 3 has one leg that is bent and one
gear that has seized to its leg. (Primary)
Figure 3.34.
r Component 4 has no legs remaining with the
spline collar. (Primary) Figure 3.34.
Preventive Actions
Driver education/operational training.
Part Code: 1 Spider, IAD; 2 Spider, IAD;
3 Spider, IAD; 4 Spider, IAD
Condition Code: 1 Galled Legs; 2 Worn Legs,
No Galling; 3 Galled Legs; 4 Galled Legs
60
Section 3
Damaged Axle Review
IAD
Visual Conditions
r Pinions excessively loose on spider legs.
(Primary)
r The pinions have worn into the IAD case.
(Primary) Figure 3.35.
r The pinion washers have broken up due to
fatigue. (Secondary) Figure 3.36.
r One pinion washer is paper thin. (Secondary)
r The lubricant is highly contaminated with
abrasive particles. (Secondary)
r The thrust washers have been destroyed from
fatigue. Figure 3.37.
Preventive Actions
Driver education/operational training.
Part Code: Spider, IAD
Condition Code: Galling
Figure 3.36 39192d13
61
Section 3
Damaged Axle Review
IAD
Visual Conditions
r The exposed spider leg has galling. (Primary)
Figure 3.38.
r All spider legs show evidence of galling.
(Primary) Figure 3.38.
r One pinion is missing from the IAD assembly.
(Secondary) Figure 3.39.
r The IAD case inside walls are gouged and
scuffed. (Secondary) Figure 3.39.
r There is no case separation. Figure 3.39.
Preventive Actions
Driver education/operational training.
Part Code: Spider, IAD
Condition Code: Galling
62
Section 3
Damaged Axle Review
IAD Spider
Visual Conditions
r The IAD spider has severe scoring on spider
legs. (Primary) Figure 3.40.
r The IAD spider has excessive wear on three
non-seized legs. (Primary) Figure 3.40.
r One leg of the spider is bent with severe wear.
(Primary) Figure 3.40.
r The pinions are galled, chipped and excessively
worn. (Primary) Figure 3.41.
r One pinion spins but will not slide off its spider
leg. (Primary) Figure 3.40.
Preventive Actions
Driver education/operational training.
63
Section 3
Damaged Axle Review
IAD Spider
Visual Conditions
r The pinions have severe galling. (Primary)
Figure 3.42.
r Two loose IAD spider legs have seized inside
the pinions. (Primary) Figure 3.42.
r The four spider legs have been sheared from
the spider at the splined hub area. (Secondary)
Figure 3.42.
r The differential case halves have separated and
are broken into pieces. (Secondary) Figure 3.42.
Preventive Actions
Driver education/operational training.
Part Code: Spider, IAD
Condition Code: Galling
64
Section 3
Damaged Axle Review
Low Lube
Visual Conditions
r Bearing is blackened and dry. (Primary)
Figure 3.43.
r Bearing rollers are scored and deformed.
(Primary) Figure 3.43.
r Ring gear is black with burned lube coating.
(Secondary) Figure 3.44.
Preventive Actions
Check axle lube levels regularly. Follow
recommended maintenance lubrication intervals
in Maintenance Manual 1, Lubrication.
Part Code: Lubricant
65
Section 3
Damaged Axle Review
Main Differential Spider
Visual Conditions
r Several main differential spider legs have a
seized gear. (Primary) Figure 3.45.
r Three legs are broken off the spider. (Primary)
Figure 3.45.
r Two gears have a broken leg seized inside.
(Primary) Figure 3.45.
r One thrust washer is distorted and loose inside
main differential case. (Primary)
r Three washers have excessive abrasive wear.
(Primary) Figure 3.46.
Preventive Actions
Driver education/operational training.
Part Code: Spider, Main Diff
Condition Code: Spinout
66
Section 3
Damaged Axle Review
Main Flange Side
Differential Bearings
Visual Conditions
r Flange side differential bearing rollers are pitted
and spalled. (Primary) Figure 3.47.
r The flange half of the main differential case is
missing its bearing cage and rollers. (Primary)
Figure 3.48.
r The flange side differential bearing inner cone
is scuffed and galled. (Primary) Figure 3.48.
Preventive Actions
Maintain proper lubrication intervals.
Part Code: Brg Cone, Main Diff (Flange Side)
Condition Code: Spalled Rollers or Spalled Inner
Race
67
Section 3
Damaged Axle Review
Pinion Nut
Visual Conditions
r There is evidence on the drive pinion end
threads that some nut backoff may have
occurred. (Primary) (1) Figure 3.49.
r Drive pinion spline shows evidence of wear
from a loose yoke. (Primary) (2)
r Shifting drive pinion contact pattern indicates
the assembly was running out of position.
(Primary) (2)
r Two different contact wear patterns are visible
on the drive pinion teeth. (Primary) (2)
r The spigot bearing inner cone is on the shaft
and shows excessive wear. (Secondary) (3)
NOTE: The cage and rollers are missing.
r The inner pinion bearing rollers are spalled
toward the large end of the rollers. (Secondary)
r Bearing spacer shows light galling at bearing
contact surfaces. (Secondary)
Preventive Actions
Torque the drive pinion nut according to
maintenance procedures.
Part Code: Nut, Drive Pinion
Condition Code: Loose
68
Section 3
Damaged Axle Review
Plain Half Differential Case
Visual Conditions
r DCDL splines are worn away on both examples.
(Primary) Figure 3.50 and Figure 3.51.
Preventive Actions
Driver education/operational training on correct
DCDL operation.
Part Code: Main Diff Case Plain Half
Condition Code: Damaged DCDL Splines
69
Section 3
Damaged Axle Review
Main Differential Case-to-Case
Joint Separation
Visual Conditions
r Case-to-case bolts broke by a bending fatigue.
Figure 3.52. Galling between bolt holes at the
main differential case joint. Notches on main
differential case halves for cross shaft often
wallowed out. Figure 3.53.
Preventive Actions
Misapplication and/or driver abuse (i.e., excessive
chucking).
Part Code: Bolt, Main Diff Case
Condition Code: 603 Fatigue
70
Section 3
Damaged Axle Review
Pump Systems Screens
Visual Conditions
r Oil screens are shown for reference purposes.
Preventive Actions
Maintain scheduled lubrication changes according
to intervals of accumulated mileage, along with
periodic checking of axle lubricant fill levels.
Screens must be inspected, cleaned or replaced
during axle overhaul. When applying silicone
gasket material, the bead diameter must not
exceed 0.125-inch (3 mm). Too much gasket
material can block lubrication passages, resulting
in damage to the components.
71
Section 3
Damaged Axle Review
Rear Side Gear
Visual Conditions
r Rear side gear has excessive tooth wear deep
into the material. (Secondary) Figure 3.56.
r IAD pinion teeth are excessively worn.
(Secondary) Figure 3.57.
Preventive Actions
Vehicle inspection is required to determine
specific cause. Check driveline conditions
(specifically driveline angles) and air ride height.
Perform action checklist:
r Driveline inspection
r Driveline repair/adjustment
r Suspension adjustment
Part Code: Gear, Rear Side IAD
Condition Code: Bevel Teeth Worn
72
Section 3
Damaged Axle Review
Ring Gear
Visual Conditions
r The ring gear segmented into many pieces.
(Primary) Figure 3.58.
r The drive pinion gear shows evidence of recent
distinct change of contact pattern. (Secondary)
r All ring gear teeth show fatigue fracture
cracking at separation. Figure 3.59.
r The ring gear teeth cracks originate on coast
side of tooth roots. Figure 3.59.
Preventive Actions
73
Section 3
Damaged Axle Review
Ring Gear
Visual Conditions
r The ring gear is segmented into pieces, each
showing root beam fatigue originating at the
coast side root. (Primary) Figure 3.60 and
Figure 3.61.
r The main differential bearing components are
heavily spalled. (Shared Primary) Figure 3.62.
r The flange of the differential case half is
separating. (Secondary) Figure 3.63.
r The gear-to-case bolts were reported as loose.
(Secondary)
r Heavy thrust screw contact on backside of ring
gear.
Preventive Actions
Operate vehicle according to design rated limits.
Part Code: Gear, Ring
Condition Code: Root Beam Fatigue
74
Section 3
Damaged Axle Review
Ring Gear (Continued)
Figure 3.62 39182d19
75
Section 3
Damaged Axle Review
Seals
Visual Conditions
r This forward output through shaft area is not
entirely dry and looks like a weeper. Signs of
weeping may be acceptable and may not
require immediate seal replacement.
Figure 3.64.
Preventive Actions
Clean oil and dirt from carrier. Check fluid level
and monitor the area carefully for future leaks.
Part Code: Seal, Rear Pinion
Condition Code: Leaking
76
Section 3
Damaged Axle Review
Seals
Visual Conditions
r Lubricant is leaking at the seal area. Figure 3.65.
Preventive Actions
Replace the seal, using proper tools/techniques.
Check the lubricant level and refill to the required
level.
Refer to the appropriate axle maintenance manual.
Part Code: Seal, Output Shaft
Condition Code: Leaking
77
Section 3
Damaged Axle Review
Seals
Visual Conditions
r Lubricant is leaking at the seal area. Figure 3.66.
Preventive Actions
Replace the seal, using proper tools/techniques.
Check the lubricant level and refill to the required
level.
Refer to Maintenance Manual 1, Lubrication.
Refer to the appropriate axle maintenance manual.
Part Code: Seal, Output Shaft
Condition Code: Leaking
78
Section 3
Damaged Axle Review
Seals
Visual Conditions
r Lubricant is leaking at the seal area. Figure 3.67.
Preventive Actions
Replace the seal, using proper tools/techniques.
Check the lubricant level and refill to the required
level.
Refer to Maintenance Manual 1, Lubrication.
Refer to the appropriate axle maintenance manual.
Part Code: Seal, Output Shaft
Condition Code: Leaking
79
Section 3
Damaged Axle Review
Side Gear
Visual Conditions
r Carrier noise was reported.
r One tooth from main differential pinion is
broken off. (Primary)
r One tooth from side gear is broken off and
several others are cracked. (Primary)
r Side gear teeth adjacent to the broken tooth are
cracked at base. (Primary) Figure 3.68.
r Both gear tooth breaks have rough crystalline
fractures. (Primary) Figure 3.68.
Preventive Actions
Driver education/operational training.
Part Code: Gear, Side Main Diff
Condition Code: Bevel Teeth Broken
or
Part Code: Gear, Pinion Main Diff
Condition Code: Pinion Teeth Broken
80
Section 3
Damaged Axle Review
Side Gear Thrust Washer
Visual Conditions
r Thrust washer has seized onto the side gear.
(Primary) Figure 3.69.
r Thrust washer has signs of dark burned
lubricant and galled areas. (Primary)
Preventive Actions
Driver education/operational training.
Part Code: Washer, Thrust Main Diff Side Gear
Condition Code: Worn
81
Section 3
Damaged Axle Review
Thrust Washers
Visual Conditions
r One leg has broken from the spider and seized
within the journal of the pinion gear. (Primary)
Figure 3.70.
r All four legs of spider show excessive wear and
galling. (Primary) Figure 3.70.
r The thrust washers are worn. (Secondary)
Figure 3.71.
Preventive Actions
Driver education/operational training.
Part Code: Spider, IAD
Condition Code: Galling
82
Information contained in this publication was in effect at the time the publication was approved for printing and is
subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the
information presented or discontinue the production of parts described at any time.
Copyright 2000
ArvinMeritor, Inc.
All Rights Reserved
TP-9955
Issued 06-00
16579/24240