Beruflich Dokumente
Kultur Dokumente
CAUTION
A Caution alerts you to an instruction or procedure that you
must follow exactly to avoid damage to components.
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 to
discontinue the production of parts described at any time.
pg. 1 Section 1: Exploded Views pg. 28 New Fasteners with Pre-Applied Adhesive
Original or Used Fasteners
5 Section 2: Introduction
Preparing the Differential for Reassembly
Description
Carrier-to-Housing Joint Sealing Procedure
Forward Tandem Axle
30 General Yoke and U-Joint Reassembly
Optional Pressurized Lubrication System
Identification
Optional Driver-Controlled Main Differential Lock (DCDL)
Gear Sets
Inter-Axle Differential (IAD) Lock
Check for Mismatched Ratios on Tandem Axles
Stall-Testing Can Damage a Drive Axle
31 Gear Set Ratios Listed on the Identification Tags
6 Use of Traction Chains
Rotate the Forward Drive Shaft to Check the Gear Set Ratio
Identification
32 Gear Set Teeth Numbers Stamped on the Forward and
Model Number
Rear Axle Drive Pinions
8 Section 3: Removal and Disassembly 33 Verify the Actual Gear Set Ratios
Removal Inspection
Axle Shafts Yoke
Axle Shaft Removal Methods 34 Tire Matching for Tandem Axles
9 Axle Shafts from the Axle Housing
10 Thru-Shaft
35 Section 5: Assembly and Installation
Installation
11 Differential Carrier from the Axle Housing
“Dry Fit” and “Final” Assembly and Installation Procedures
12 Disassembly
Installing the Drive Pinion, Adjusting Pinion Depth and
Thru-Shaft and Output Bearing Cage
Contact Pattern
13 Removal
Drive Pinion Shim Pack Thickness
Input Shaft and Inter-Axle Differential (IAD)
36 Assembly
17 Disassembly
“Dry Fit”Assembly of the Drive Pinion to Verify Shim Pack
Input Shaft and Inter-Axle Differential
38 Installation
18 Removal
Drive Pinion
Driver-Controlled Main Differential Lock (DCDL)
Assembly
Measure Ring Gear Backlash
Main Differential and Ring Gear
19 Main Differential Case and Ring Gear
41 Check the Rotating Resistance of the Differential Assembly
21 Disassembly
42 Installation
Main Differential Case and Ring Gear
“Dry Fit” Installation of the Main Differential Case and Ring
Removal
Gear Assembly Into the Carrier
Ring Gear from the Differential Case
43 Adjustment of Pinion Shim Pack and Backlash for Contact
Drive Pinion
Pattern
24 Section 4: Prepare Parts for Assembly Ring Gear Backlash
Clean, Dry and Inspect Parts 44 Gear Set Tooth Contact Patterns
Clean and Inspect Yokes 48 Installation
25 Clean Ground and Polished Parts “Final” Installation of the Drive Pinion and Bearing Preload
Clean Rough Parts Adjustment
Clean Axle Assemblies 52 “Final” Installation of the Main Differential Case and Ring
Dry Parts Immediately After Cleaning Gear Assembly Into the Carrier
Prevent Corrosion on Cleaned Parts 53 Adjustment
Inspect Parts Differential Bearings Preload
27 Repair or Replace Parts 55 Ring Gear Runout
28 Welding on Axle Housings 56 Installation
Do Not Bend or Straighten a Damaged Drive Axle Housing Thrust Screw (44,000-Lb Model Only)
Removing Fasteners Secured with Adhesive 57 Assembly
Contents
pg. 57 Input Shaft and Inter-Axle Differential (Oil Pump Model) pg. 101 Section 11: Vehicle Towing Instructions
58 Input Shaft and Inter-Axle Differential (Non-Pump Model) After Towing or Drive-Away
59 Installation
103 Section 12: Diagnostics
Input Shaft Assembly and Cover (Oil Pump Models)
Troubleshooting
63 Input Shaft Assembly and Cover (Non-Pump Models)
Vehicle Will Not Move
66 Inspection
105 Differential Making Noise
Adjust the Input Bearing End Play
107 Oil Leak
68 Installation
108 Contaminated Lubricant Found During Preventive
Multiple-Lip Seal (MLS) and Yoke Sleeve
Maintenance
71 Input Yoke
72 Output Bearings and Thru-Shaft
73 Inspection
Adjust the Output Bearing End Play
74 Output Yoke and Seal for the Output Bearing Cage
75 Driver-Controlled Main Differential Lock
Differential Carrier into the Axle Housing
77 Axle Shaft
Fill the Axle with Lubricant
79 Section 6: Driver-Controlled Main
Differential Lock (DCDL)
Description
Removal
Differential Carrier from the Axle Housing
Engagement or Lockout of the DCDL
81 DCDL Shift Unit
82 Installation
DCDL Shift Unit
85 Check the Differential Lock
DCDL Driver Caution Alert Label
86 Driver Instruction Information Available to Order
87 Section 7: Lubrication
Specifications
89 Section 8: Specifications
Specifications
94 Section 9: Adjustment
Adjustment
96 Section 10: Special Tools
Specifications
Carrier Repair Stand
97 How to Make a Yoke Bar
98 Centering Tool
99 Service Tools
Multiple-Lip Seals, Seal Drivers and Yoke Sleeve Drivers
1 Exploded Views
1 Exploded Views
Figure 1.1
9 10 16
18
8
8 11
7
6 10
9 28 17
5
4 27
7
3 19
20 26
21
2 25 22
1 6 29
24 23
30
23 31
OIL PUMP 5
MODEL 24
4
NON-PUMP 3
MODEL 1 2 32
34
33
39
40
35 41
36
37
42
38 51 50
43
60
52 44
61 45
46
47
48
49
62
63
54 52
64 65
55 53
56
57
58
59 4007390b
Figure 1.2
1
MAIN DIFFERENTIAL CASE AND
2
RING GEAR ASSEMBLY
4 10 11
5
12
13
6 13 18
7 12
8
9 14 21 8
7
6 3
15
16 4
17 19
DCDL
20 1
2
6 10 11 5
1
2
3
4
5 7
8 9
4007390c
Figure 1.3
7 8
6 9
10
11
5
12
1
13
4
3
14
2
7
15
16
17
18 19
20
21
4007391b
DRIVE
HELICAL INTER-AXLE
DIFFERENTIAL
INPUT
GEAR Stall-Testing Can Damage a Drive Axle
SHAFT THRU-SHAFT Stall-testing is a procedure used to troubleshoot transmissions,
evaluate vehicle performance, and test the service and park brakes.
During stall-testing, or any similar procedure, the drive axle input
receives multiplied torque, which can exceed the specified torque
rating. Excessive torque can damage a drive axle, which will affect
axle performance and component life. A drive axle damaged by
RING
GEAR stall-testing will void Meritor’s warranty.
DRIVEN DRIVE
HELICAL
Call OnTrac Customer Service Center at 866-OnTrac1 (668-7221) if
PINION
GEAR 1002702e you have questions regarding stall-testing.
NON-PUMP MODEL
Figure 2.2
Identification
CARRIER PART NO.
CUSTOMER NO.
CARRIER
An identification tag is attached to the axle housing or the
IDENTIFICATION TAG 4008142a
differential carrier. Figure 2.3 and Figure 2.4. Use the model
number and the ratio number marked on the identification tag and Figure 2.4
the number on the carrier to obtain replacement parts.
Refer to Figure 2.5 for an explanation of the model number.
Figure 2.3
Model No. . . . . . . . . . . . . . . . . . . .
Customer No. . . . . . . . . . . . . . . . .
IDENTIFICATION TAG
4008141a
Figure 2.3
Figure 2.5
M x - xx - x x x x x x x x x - x x x - x x x x
M S - 21 - 1 4 X 5 D B B N Q - 1 2 3 - 3 5 5
Figure 2.5
BRASS
Removal HAMMER
Axle Shafts
DRIVING
Before the axle shafts and differential carrier can be removed or LUGS
installed, the driver-controlled differential lock (DCDL), if equipped,
must be shifted into and held in the locked or engaged position. The
locked position gives enough clearance between the shift collar and
the axle housing to permit the removal or installation of the carrier.
Refer to Section 6 for service information on the DCDL. If the drive 1002707b
axle is not equipped with DCDL, continue on with axle shaft removal
Figure 3.1
in this section.
2. Strike the end of the drift with a large hammer, five to six
Axle Shaft Removal Methods pounds, and the axle shaft and tapered dowels, if equipped,
Use Special Tools Recommended by Meritor will loosen.
To help prevent serious personal injury and damage to components 3. Mark each axle shaft before it is removed from the axle
when you remove the axle shaft from the housing, Meritor assembly.
recommends that you use the following tools in the table below. 4. Remove the tapered dowels, if equipped, and separate the axle
Refer to the Service Notes page at the front inside cover of this shafts from the axle hub assembly. Figure 3.2.
manual for information on how to contact the manufacturers to
obtain the tools.
앫 If the tools are not available when you remove the axle
shaft: Follow procedures for using the Brass Drift Method or the
Air Vibration Method.
CAPSCREW AXLE
WASHER SHAFT
SHAFT OR
FLANGE HUB
AXLE 1002708e
1002987c
Figure 3.2
Figure 3.3
5. Install a cover over the open end of each axle assembly hub
where an axle shaft was removed. 3. Mark each axle shaft before it is removed from the axle
assembly.
Air Hammer Vibration Method
4. Remove the tapered dowels, if equipped, and separate the axle
WARNING shaft from the main axle hub assembly. Figure 3.3.
Wear safe eye protection when using an air hammer. When
using power tools, axle components can loosen and break off Axle Shafts from the Axle Housing
causing serious personal injury.
WARNING
CAUTION Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
Do not use a chisel or wedge to loosen the axle shaft and
safety stands. Do not work under a vehicle supported only by
tapered dowels. Using a chisel or wedge can result in damage
jacks. Jacks can slip or fall over. Serious personal injury and
to the axle shaft, the gasket and seal, and the axle hub.
damage to components can result.
1. Use a round hammer bit and an air hammer to loosen the
1. Park the vehicle on a level surface. Block the wheels to prevent
tapered dowels, if equipped, and axle shaft.
the vehicle from moving. Set the parking brake.
2. Place the round hammer bit against the axle shaft or flange
2. Use a jack to raise the vehicle so that the wheels to be serviced
between the hub studs. Operate the air hammer at alternate
are off the ground. Support the vehicle with safety stands.
locations between the studs to loosen the tapered dowels, if
equipped, and axle shaft from the hub. Figure 3.3. 3. Remove the oil drain plug from the bottom of the axle housing.
Drain the axle lubricant from the housing assembly.
4. On an axle with a driver-controlled main differential lock, shift
the lock into and hold the lock in the locked or engaged
position. The locked position provides enough clearance
between the shift collar and the axle housing for carrier
removal. Refer to Section 6.
5. Disconnect the driveline universal joint from the input yoke or
flange on the carrier. Figure 3.4.
Figure 3.4 6. Remove the stud nuts and washers from the flanges of both
axle shafts.
1
EASY SERVICETM,
MXL 7. Loosen the tapered dowels, if equipped, in the axle flanges of
2 both axle shafts. Refer to the procedures in this section for the
9
removal methods.
3
4
Thru-Shaft
8
5 1. Disconnect the inter-axle drive shaft.
6
7 CAUTION
Always use a flange or yoke bar during removal and
10 installation of the flange yoke nut to prevent damage to the
WING SERIES gearing.
11
PERMALUBETM
12 2. Attach a flange bar to the flange or place a yoke bar over the
14
13 input or output yoke to hold the yoke or flange while you
remove the pinion nut. Figure 3.5. Refer to Section 10 to make
a yoke bar.
FULL-ROUND
15 Figure 3.5
16
19 17
18
RPL SERIES,
PERMALUBETM
YOKE BAR 1003451c
25 20
21 Figure 3.5
REMOVING
THE FLANGE
TOP TWO
FASTENERS
REMOVING
THE YOKE
1002712d
Figure 3.6
ROLLER
JACK 1002714d
4. Remove the thru-shaft bearing cage capscrews and washers.
5. Pull the bearing cage, bearings and thru-shaft assembly from Figure 3.8
THRU-SHAFT AND fasteners. The fasteners will hold the carrier in the housing.
BEARING CAGE ASSEMBLY
6. Loosen the differential carrier in the axle housing. Use a plastic
mallet to hit the carrier mounting flange at several points.
7. After the carrier is loosened, remove the top two stud nuts and
washers that hold the assembly in the axle housing.
CAUTION
When using a pry bar, be careful not to damage the carrier or
1002713c
housing flange. Damage to these surfaces will cause oil leaks.
Figure 3.7
8. Use the hydraulic roller jack to remove the carrier from the axle
Differential Carrier from the Axle Housing housing. Use a pry bar that has a round end to help remove the
carrier from the housing.
1. Disconnect the forward drive shaft from the input yoke.
9. On axles with a driver-controlled main differential lock, if air
2. Disconnect the air line from the inter-axle shift unit. pressure is used to shift the differential to the locked or
3. Place a hydraulic roller jack under the differential carrier to engaged position, release the air pressure after the carrier is
support the assembly. Figure 3.8. removed from the axle housing while the carrier is still on the
roller jack. Disconnect the air hose from the shift unit.
NOTE: A carrier stand is available from SPX Kent-Moore. Refer to Figure 3.11
the Service Notes page on the front inside cover of this manual to
SNAP
obtain the stand. RING
10. Use a lifting tool to lift the differential carrier by the input yoke
or flange and place the assembly in a repair stand. Do not lift
by hand. Refer to Section 10 to make a carrier repair stand.
Figure 3.9.
Figure 3.9
THRU-SHAFT
SNAP RING SPACER 4008194b
Figure 3.11
Figure 3.10
3 4
2
7
1 6
5
4008193a
1 THRU-SHAFT
2 BEARING CAGE
3 INNER BEARING CUP AND CONE
4 CUP SPACER
5 OUTER BEARING CUP AND CONE
6 SNAP RING
7 THRU-SHAFT SNAP RING SPACER
Figure 3.10
8 9
7
Input Shaft and Inter-Axle Differential (IAD) 10
5 14
Refer to Figure 3.12 and Figure 3.13 for the correct carrier version. 4
13 15
12
Figure 3.12
6
10 11
8 9
7
3
5 16
4 16 2 17
17 1
15 18
19
14 11 20
1002732d
11 CAPSCREW
12 OIL SCREEN AND PLUG
ASSEMBLY
OIL PUMP MODEL
Figure 3.12
1002715d
Figure 3.14
2. Use the correct tool to hold the input yoke in place. Remove the
input yoke nut and washer. Figure 3.15.
1002725c 4008186a
3. Use a yoke puller or other suitable tool to remove the yoke from 5. Remove the lock plate and capscrew from the adjusting ring.
the input shaft. Figure 3.16. Remove the adjusting ring.
Figure 3.16
6. For oil pump models, use the following procedure to remove
the cover.
A. If equipped with an oil pump, remove the oil screen and
YOKE plug assembly from the cover. Clean the oil screen. Refer
PULLER to Section 4. Figure 3.18.
Figure 3.18
1002733c
Figure 3.16
CAUTION
1002817c
Carefully remove the oil seal from the adjusting ring. Do not
damage the seal bore when you remove the seal. Damage to Figure 3.18
components can result.
B. Remove the capscrews and washers that fasten the cover
4. Pry under the oil seal flange to remove the oil seal from the
to the carrier housing. Figure 3.19.
adjusting ring. Discard the oil seal. Figure 3.17.
1002723d 1002723c
C. Install the front cover puller over the input shaft and B. Remove the input bearing cup. Figure 3.13.
thread it into the adjusting ring threads in the cover.
C. If necessary, remove the capscrews and washers from the
Figure 3.20.
cover and remove the oil baffle.
Figure 3.20
8. Remove the IAD housing O-ring from the face of the housing.
Inspect the O-ring for damage such as cracks, cuts or breaks
TOOL PART
and replace if necessary.
NUMBER
COVER 3256N1236 9. Use a high-powered magnet or the magnetic base of a dial
(OIL PUMP indicator to remove the IAD piston from the carrier housing. If
MODELS)
PRY necessary, tap on the piston to loosen it for removal.
BAR
Figure 3.22 and Figure 3.23.
Figure 3.22
4008153a
6
Figure 3.20
8
5
D. Use a wrench to tighten the screw on the tool using light 4
3
pressure. Use pry bars to loosen the cover from the 2
carrier housing. Continue tightening the screw until the 1
Figure 3.23 13. Loosen the handle on the spring compression tool to release
the spring. Loosen the retaining screws and remove the spring
MAGNET
compression tool from the carrier.
PISTON 14. Remove the spring from the bore.
15. Install a nut modified with a lifting loop. Connect a lifting device
to the nut loop and lift out the input shaft and inter-axle
differential from the carrier. Figure 3.26.
Figure 3.26
4008158a
Figure 3.23
10. Remove the shift shaft and shims from the bore.
11. Install the spring compression tool over the IAD bore and finger
tighten the retaining screws. The ends of the tool fit through
recesses in the housing bore and around the fork. Figure 3.24.
Figure 3.24
1002727c
Figure 3.26
16. Place the assembly on a bench. Remove the lifting nut from the
4008683a
input shaft.
Figure 3.24
17. Remove the rear side gear and the bearing cone from the
12. Tighten the tool handle down until it bottoms to compress the carrier. Figure 3.27.
spring. When the spring is compressed below the fork, pull the
Figure 3.27
COLLAR
SPRING
COMPRESSION
TOOL
1002818c
Figure 3.27
SHIFT FORK 4008154c
Figure 3.25
If you replace either the bearing cup or the cone, replace both 10 11
parts in a fully-matched set from the same manufacturer. Do 8 9
not mix old and new parts. Damage to components can result. 7
5
4 16
18. Use a press, sleeve and bearing puller to remove the bearing
17
cone from the rear side gear. Figure 3.28. 15
14
Figure 3.28
PRESS
6
3
18
2 19
1 20
21
12 13 22
1002732c
8 9
7 HELICAL
10
5 GEAR
14
4
13 15
6 12
THRUST
BEARING
3
16 1002814c
2 17
1 18 Figure 3.32
19
11 20
1002732d 4. Remove the needle bearing assemblies.
1 OIL SEAL 11 INPUT SHAFT 5. On non-pump models, use a bearing separator, sleeve and
2 BEARING ADJUSTING RING 12 NEEDLE BEARING ASSEMBLIES press to remove the bearing cone from the input shaft.
3 BEARING CUP 13 THRUST BEARING
4 CAPSCREW 14 HELICAL GEAR Figure 3.33.
5 LOCK PLATE 15 BEARING CONE
6 COVER 16 REAR SIDE GEAR Figure 3.33
Figure 3.31
HELICAL
GEAR
Removal
Driver-Controlled Main Differential Lock
1002815c (DCDL)
If the axle is equipped with a driver-controlled main differential lock,
Figure 3.31
refer to Section 6 for removal procedures.
2. Remove the spider assembly from the inter-axle differential
case. Remove the four pinion gears from the spider. Inspect the
Measure Ring Gear Backlash
components. Replace any damaged components. Before the carrier is disassembled, use a dial indicator to measure
and record ring gear backlash at three equally spaced teeth on the
3. Remove the helical drive gear and thrust bearing from the input
ring gear. This will help you to correctly reassemble the ring gear
shaft. Figure 3.32.
and drive pinion.
1. Rotate the carrier in the stand to access the ring gear teeth.
2. Install a dial indicator onto the flange of the carrier. Place the Figure 3.35
tip of the indicator against the convex side of a ring gear tooth. BEARING
Adjust the dial indicator to ZERO. Figure 3.34. CAP
Figure 3.34
CARRIER
LEG
DIAL
INDICATOR
MATCH
MARKS
1002994b
Figure 3.34
3. Remove the capscrews and lock plates that hold the bearing
adjusting rings in position. Figure 3.36.
3. Read the dial indicator while you slightly rotate the ring gear in
both directions. When you rotate the ring gear to measure the Figure 3.36
backlash, the drive pinion must not move. Record the reading
on the dial indicator.
LOCK
4. Repeat the procedure at two more locations on the ring gear. PLATE
NOTE: Each bearing cap must be installed on the carrier leg from
1003105f
which it was removed. The caps are matched to the carrier legs. Do
not mix bearing caps on carrier legs. Figure 3.36
2. Use a punch and hammer to mark the position of each bearing 4. Loosen the bearing cap capscrews, but do not remove them
cap on the differential carrier legs. The marks are required to completely. Loosening the capscrews is required to allow the
help you correctly match the caps to the carrier legs during adjusting rings to be loosened.
reassembly. Figure 3.35.
CAUTION
Do not hit the adjusting ring with a hammer. Do not use a
hammer and a drift to loosen the adjusting rings. Damage to
the adjusting rings will result.
ADJUSTING
RING TOOL
ADJUSTING
RING OPPOSITE
RING GEAR 1002747d 1002749h
6. Remove the capscrews and washers that fasten the bearing 9. Use a brass drift and hammer to remove the rear side gear
caps to the differential carrier. Check to ensure the bearing bearing cup from the carrier. Figure 3.40.
caps and the carrier have been marked to help you correctly
install the caps during reassembly.
Figure 3.40
Figure 3.38
BEARING
ADJUSTING
BEARING RING
CAP
1002816c
Figure 3.40
NOTE: If you replace either the bearing cup or the cone, replace
1002748e
both parts in a fully-matched set from the same manufacturer. The
bearing cones are not interchangeable.
Figure 3.38
10. If the bearing cones on the main differential case need to be
8. Use an appropriate lifting device to remove the main differential replaced, use a bearing puller to remove the cones.
case and ring gear assembly from the carrier. Figure 3.39. Figure 3.41.
THRUST
PULLER WASHER
PRESS SIDE
SPIDER, PINIONS
GEAR
AND THRUST
WASHERS
1002750c
Figure 3.41
Disassembly 1002752c
4 5 6
2 3
1
11
10
9
8
7
1002724c 1002755c
not mix old and new parts. Damage to components can result.
PRESS
NOTE: If a new ring gear and drive pinion are being installed, the
PROTECTOR
inner bearing cup must be removed to change the shim pack
DRIVE between the cup and the carrier.
PINION
3. If necessary, remove the inner and the outer bearing cups from
the carrier. Use a hammer and drift to remove the cups from
the carrier. Figure 3.47.
1002756d
Figure 3.47
C. Press the pinion through the outer bearing cone and the
helical driven gear. Remove the drive pinion from the OUTER
bottom of the carrier. BEARING CUP 1002757d
D. Remove the outer bearing cone, outer spacer, helical Figure 3.47
driven gear, inner spacer and shims from the differential
carrier. Figure 3.46.
4. When you remove the inner pinion bearing cup, also remove
the shims from the carrier. Measure and record the thickness
of the shim pack for assembly. Replace any shims that are
damaged. Figure 3.48.
Figure 3.48
BEARING
CUP
SHIMS
1002767b
Figure 3.48
Figure 3.49
PRESS
BEARING
PULLER
1002758b
Figure 3.49
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent Clean and Inspect Yokes
serious personal injury, damage to components, or both.
CAUTION
WARNING Do not install a press-on shaft excluder or POSE™ seal after
you install a unitized pinion seal. The use of a POSE™ seal will
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. prevent correct seating of the unitized pinion seal on the yoke
and will result in lubricant leakage at the seal. POSE™ seal
Solvent cleaners can be flammable, poisonous and cause installation is recommended only for triple-lip and other
burns. Examples of solvent cleaners are carbon tetrachloride, previous design seals.
and emulsion-type and petroleum-base cleaners. Read the
Do not use thin metal wear sleeves to refresh the yoke surface.
manufacturer’s instructions before using a solvent cleaner,
Wear sleeves pressed onto the yoke will prevent correct
then carefully follow the instructions. Also follow the
procedures below. seating of the pinion seal and damage the pinion seal
assembly. Wear sleeve usage will cause the seal to leak.
앫 Wear safe eye protection.
1. Clean the ground and polished surface of the yoke journal
앫 Wear clothing that protects your skin.
using a clean shop towel and a safe cleaning solvent. Do not
앫 Work in a well-ventilated area. use abrasive cleaners, towels or scrubbers to clean the yoke or
앫 Do not use gasoline or solvents that contain gasoline. flange surface. Do not use gasoline.
Gasoline can explode.
NOTE: The unitized seal features a rubber inner sleeve that is
앫 You must use hot solution tanks or alkaline solutions designed to seal and rotate with the yoke. This feature allows you to
correctly. Read the manufacturer’s instructions before reuse a yoke with minor grooves.
using hot solution tanks and alkaline solutions. Then
carefully follow the instructions. 2. Inspect the yoke seal surface for grooves.
앫 If you find grooves on yoke hubs used with single or
Take care when you use Loctite adhesive to avoid serious
personal injury. Read the manufacturer’s instructions before triple-lip seals: Replace the yokes.
using this product. Follow the instructions carefully to prevent 앫 If you find grooves on the yoke: Use calipers to measure
irritation to the eyes and skin. If Loctite adhesive material the groove diameters. If any groove diameter measures less
gets into your eyes, follow the manufacturer’s emergency than the dimensions shown in Figure 4.1, replace the yoke.
procedures. Have your eyes checked by a physician as soon as
possible.
Figure 4.1
Clean Axle Assemblies
UNITIZED PINION SEAL (UPS)
1. A complete axle assembly can be steam cleaned on the
outside to remove dirt.
2. Before the axle is steam cleaned, close or place a cover over all
A B openings in the axle assembly. Examples of openings are
breathers or vents in air chambers.
앫 There are deep cracks or breaks in the cup, cone inner race Figure 4.4
Figure 4.5
Figure 4.5
Figure 4.3
Figure 4.6
WEAR
CRACK
GROOVES
1003018b 1003021b
5. Inspect the axle shafts for wear and cracks at the flange, shaft
CAUTION
and splines. Replace the axle shafts, if required.
A drive pinion and ring gear are machined as a matched set.
When you replace either a drive pinion or a ring gear, you must 6. Inspect the breather.
replace both parts as a matched set. Do not mix old and new
A. Remove the breather from the axle housing.
parts. Damage to components can result.
B. Clean the breather.
3. Inspect hypoid pinions and gears for wear and damage.
앫 If the breather remains dirty after cleaning:
Replace pinions and gears that are worn or damaged.
Replace the breather.
4. Inspect the following main differential assembly parts for wear Repair or Replace Parts
or stress. Replace parts that are damaged. Figure 4.7.
Threads must be without damage and clean so that accurate
앫 Inside surfaces of both case halves adjustments and correct torque values can be applied to fasteners
and parts.
앫 Both surfaces of all thrust washers
1. Replace any fastener if the corners of the head are worn.
앫 The four trunnion legs of the spider
2. Replace the washers if damaged.
앫 Teeth and splines of both differential side gears
3. Replace the gaskets, oil seals or grease seals at the time of
앫 Teeth, bore and spherical back face of all differential
axle or carrier repair.
pinions
4. Clean the parts and apply new silicone gasket material where
Figure 4.7
required when the axle or carrier is assembled. Figure 4.8.
Inspect
inside
surfaces. Figure 4.8
SIDE GEAR
AND THRUST
WASHER
PINION AND
THRUST Inspect.
WASHER
1003023a
Figure 4.8
Inspect.
5. Remove nicks, mars and burrs from parts with machined or
DIFFERENTIAL ground surfaces. Use a fine file, india stone, emery cloth or
GEAR NEST crocus cloth.
SPIDER
ASSEMBLY
6. Clean and repair the threads of fasteners and holes. Use a die
Inspect. OR CROSS 1003022i or tap of the correct size or a fine file.
Figure 4.7
Welding on Axle Housings 2. Apply four or five drops of Meritor liquid adhesive
2297-C-7049, Loctite 638 or 680 liquid adhesive or
For complete welding instructions, refer to Maintenance Manual 8,
equivalent inside each threaded hole or bore. Do not apply
Drive Axle Housings. To obtain this publication, refer to the Service adhesive directly to the fastener threads. Figure 4.9.
Notes page on the front inside cover of this manual.
Figure 4.9
Always replace a damaged drive axle housing. Do not bend or Figure 4.9
straighten a damaged housing, which can misalign or weaken it,
and void Meritor’s warranty. 3. Tighten the fasteners to the required torque value for that size
fastener. There is no drying time required for Meritor liquid
Removing Fasteners Secured with Adhesive adhesive 2297-C-7049, Loctite 638 or 680 liquid adhesive
If it is difficult to remove fasteners secured with Dri-Loc, Meritor or equivalent.
adhesive or Loctite 277 adhesive, use the following procedure.
Preparing the Differential for Reassembly
When you remove fasteners secured with adhesive, slowly heat the
fastener to 350°F (177°C). Do not exceed this temperature, or heat 1. Use a wire brush to remove hardened adhesive material.
fasteners quickly. Damage to components can result. 2. Clean the oil and dirt from the outer diameters of the bearing
1. Heat the fastener for three to five seconds. Try to loosen the cups and bearing bores in the carrier and bearing caps. There
fastener with a wrench. Do not use an impact wrench or hit the is no special cleaning required.
fastener with a hammer. 3. Apply axle lubricant to the bearing cones and the inner
2. Repeat Step 1 until you can remove the fastener. diameters of the bearing cups of the main differential. Do not
get oil on the outer diameter of the bearing cup and do not
permit oil to drip onto the bearing bores.
New Fasteners with Pre-Applied Adhesive
1. Use a wire brush to clean the oil and dirt from threaded holes. Carrier-to-Housing Joint Sealing Procedure
2. Install new fasteners with pre-applied adhesive to assemble 1. Remove the carrier from the housing. Refer to Section 3.
parts. Do not apply adhesives or sealants to fasteners with
pre-applied adhesive, or to fastener holes. 2. Remove all debris from inside the housing.
3. Tighten the fasteners to the required torque value for that size 3. Use a rotary tool with a scour pad to clean all silicone residue
fastener. No drying time is required for fasteners with from the housing and carrier faces. Figure 4.10. Surfaces must
pre-applied adhesive. be clean, dry and free of foreign matter. The surfaces must not
be oily to the touch.
Original or Used Fasteners
1. Use a wire brush to clean the oil, dirt and old adhesive from all
threads and threaded holes.
0.25" (6 MM)
DIAMETER SILICONE
GASKET BEAD 4004435a
Figure 4.11
4000621a 11. Install two long studs in the housing to guide the carrier into
the housing.
Figure 4.10
12. Immediately install the carrier into the housing to enable the
4. Remove metal filings from the magnets inside the housing. silicone gasket material to spread evenly between the faces. If
using a new capscrew kit with blue Dri-Loc STS pre-applied
5. Use solvent to clean the inside of the housing.
threadlocker, skip the next step.
6. Use Loctite ODC Free cleaner or brake cleaner to clean the
13. Apply a 0.125-inch (3 mm) bead of Loctite 242 threadlocker
housing and carrier faces.
around the capscrew threads approximately 0.25-inch (6 mm)
7. Dry the housing and carrier faces. from the end. Apply a 0.125-inch (3 mm) bead of Loctite 242
threadlocker across the length of the threads. Figure 4.12.
CAUTION
New capscrew kits have blue Dri-Loc STS threadlocker, an Figure 4.12
equivalent to Loctite 242 threadlocker, applied to the LOCTITE® 242 THREADLOCKER APPLICATION
capscrews. Do not remove the blue Dri-Loc STS threadlocker 360˚ LOCTITE® BEAD
from the capscrews. Damage to components can result.
10. Apply a 0.25-inch (6 mm) bead of Loctite 5699 silicone 앫 Tighten the 5/8-inch capscrews to 225 lb-ft (305 N폷m). @
gasket material to the housing face. Do not use ThreeBond 15. Wait a minimum of 60 minutes before filling the assembly with
1216E silicone products. Figure 4.11. lubricant. Refer to Section 7.
General Yoke and U-Joint Reassembly Table B: Gear Set Tooth Combination Number
Install the end yoke hub capscrews by hand after seating the U-joint. Drive Pinion Ring Gear
Tighten the capscrews according to the manufacturer’s torque Gear Set Teeth Location Location
specifications. 5-37 = gear set At the end at On the front face
has a five-tooth threads or outer diameter
Identification drive pinion and a
37-tooth ring gear
Gear Sets
NOTE: Meritor drive pinions and ring gears are only available as
Refer to Table A, Table B, Table C and Table D for information on
matched sets. Each gear in a set has an alphanumeric match
identifying gear sets with matched parts. Always check match
number.
numbers to verify that the gear set you will install has matched
parts. Figure 4.13.
Table C: Gear Set Match Number
Figure 4.13
Drive Pinion Ring Gear
ALTERNATE LOCATIONS Match Number Location Location
M29 At the end of the On the front face
pinion gear head or outer diameter
NOTE: Don’t use the pinion cone variation number when you check
for a matched gear set. Use this number when you adjust the pinion
depth of the carrier. Refer to Section 5.
Gear Set Ratios Listed on the Identification Rotate the Forward Drive Shaft to Check the
Tags Gear Set Ratio
1. Locate the identification tags attached to the forward and rear
axle differential carriers. Figure 4.14.
WARNING
Park the vehicle on a level surface. Block the wheels to
Figure 4.14
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
CARR
IER PART
CUS NO.
TOM
SERI ER NO.
Table E:
앫 If the axle ratios shown on the identification tags are Figure 4.15
not within one percent of each other: Refer to the vehicle
manufacturer for further information. 6. Turn the forward drive shaft in one direction by hand until the
forward tire completes two rotations. Figure 4.16. The forward
tire must rotate two times only. If the forward tire rotates more
than or less than two rotations, the angle measurements you
make in Step 7 will be inaccurate.
Figure 4.16
Gear Set Teeth Numbers Stamped on the
Forward and Rear Axle Drive Pinions
When the inter-axle driveline or differential carrier is removed for
service, you can check the gear set teeth numbers stamped on the
forward and rear axle drive pinions.
WARNING
Park the vehicle on a level surface. Block the wheels to
Rotate two full turns prevent the vehicle from moving. Support the vehicle with
of forward tire.
safety stands. Do not work under a vehicle supported only by
1003454b jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
Figure 4.16
4
10 - 7
3.6 3.6
2. Identify and record the gear set teeth numbers stamped on the Figure 4.20
end of the rear axle drive pinion. Figure 4.19. PINION RING
GEAR TEETH GEAR
Figure 4.19
TEETH
4
10 - 7
Figure 4.19 2. Count the number of pinion gear teeth. Figure 4.20.
3. Calculate the gear set ratio by dividing the larger number by 3. Divide the number of ring gear teeth by the number of pinion
the smaller number. Figure 4.19. gear teeth to determine the actual gear set ratio for each axle.
Figure 4.20.
Compare Both Gear Set Ratios 4. Calculate the percentage difference between the gear set
1. Both ratios must be within one percent of each other. To ratios using the equation in Table E. All ratios must match
calculate the percentage difference between the axle ratios, within one percent.
refer to the equation in Table E.
앫 If the actual gear set ratios are not within one percent
앫 If the axle ratios shown on the identification tags are of each other: Refer to the vehicle manufacturer for further
not within one percent of each other: Refer to the vehicle information.
manufacturer for further information.
2. Install the inter-axle drive shaft. Refer to the vehicle Inspection
manufacturer’s procedures.
Yoke
3. Install the carrier cover. Refer to the procedure in Section 5.
All current Meritor axles feature helical splines at the yoke interface.
4. Remove the safety stands and lower the vehicle. This feature provides a tight fit between the yoke and input shaft,
output shaft and pinion shaft. For the axle to operate correctly, the
Verify the Actual Gear Set Ratios input shaft, output shaft and pinion shaft must fit tightly to the
You can check the actual gear set ratios when you remove the corresponding yoke.
differential carriers from the axle housings for service or repair.
Refer to the following procedure to calculate the actual gear set Check for Yoke Wear
ratios.
WARNING
1. Count the number of ring gear teeth. Figure 4.20. Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
2. Use a jack to raise the vehicle so that the wheels to be serviced In addition to matching individual tire rolling radii or rolling
are off the ground. Support the vehicle with safety stands. circumference, Meritor recommends matching, as nearly as
possible, the total tire circumference of one driving axle to the total
3. Remove the driveline.
tire circumference of the other driving axle. This will usually result in
4. Remove the input, output or pinion shaft nut. satisfactory tandem axle lubricant temperatures that lengthen drive
unit service with higher tire mileage.
5. Attempt to remove the yoke by hand.
Park the vehicle on a level surface. The vehicle must carry a
앫 If you can remove the yoke by hand: The yoke is worn.
Replace the yoke. correctly distributed rated capacity load. All the tires must be the
same size. Measure new tires to verify that they will be correctly
6. Use a correct yoke puller tool to remove the yoke. matched.
Check for a Tight-Fit Condition 1. Inflate all tires to the same pressure.
2. Carefully measure the rolling circumference of each tire with a
NOTE: You can check for a tight-fit condition when you install any
steel tape.
serviceable yoke.
3. Mark the size on each tire with chalk and arrange the tires in
1. Attempt to install the yoke by hand. order of size, largest to smallest.
앫 If the yoke bottoms out against the adjacent bearing: 4. Mount the two largest tires onto one side of one axle and
Replace the yoke. mount the two smallest onto the opposite side of the same
axle.
2. Use a correct yoke installation tool to install the yoke.
5. Mount the four other tires onto the other axle in the same
3. As you install the yoke, you should detect resistance between
manner.
the yoke and shaft.
6. Test run the vehicle to gather accurate rear axle lubricant
앫 If you do not detect resistance between the yoke and
temperature readings on the two axle lubricant temperature
shaft: Replace the yoke.
gauges.
4. Install and tighten the input, output or pinion shaft nut to the
7. Vary tire air pressure within the tire manufacturer’s
correct torque. Refer to Section 8.
recommended range so the lubricant temperatures of both
5. Install the driveline. axles are within 30°F or 17°C of each other and not in excess
of 250°F (121°C). This will usually result in uniform tire loading
6. Remove the safety stands.
and good tire life.
7. Lower the vehicle.
The four largest tires should never be installed onto one driving axle
or the four smallest tires onto the other driving axle. Such tire
mounting will cause an inter-axle fight, unusually high axle lubricant
temperatures that result in premature lubricant breakdown and
possible costly axle service.
Hazard Alert Messages pinion position, remove the ring gear and drive pinion. You must
5 Assembly and Installation
then install the drive pinion with the helical gear and two spacers as
Read and observe all Warning and Caution hazard alert messages in well as the correct shims. Once you’ve obtained the correct
this publication. They provide information that can help prevent adjustments, continue a “final” installation of the ring gear and
serious personal injury, damage to components, or both. adjust as necessary.
BEARING
Observe all warnings and cautions provided by the press CUP
manufacturer to avoid damage to components and serious
SHIMS
personal injury.
“Dry Fit” and “Final” Assembly and 1. Use a micrometer to measure the thickness of the shim pack
Installation Procedures that was removed from the differential carrier. Record the
measurement. Figure 5.2.
Correct assembly of the carrier requires a “dry fit” installation of the
drive pinion and ring gear to determine the correct drive pinion shim Figure 5.2
2. Find the pinion cone (PC) variation number on the drive pinion Table F:
you’ll replace. Record the number. Figure 5.3. Refer to the
Examples Inches mm
following examples of pinion cone numbers.
1. Old Shim Pack Thickness 0.030 0.760
앫 PC +6, PC –6, +6 or –6 = 0.006-inch
Old PC Number, PC +2 + 0.002 + 0.050
앫 PC +.15, PC 0.15 mm, +0.15 mm or –0.15 = 0.15 mm
Standard Shim Pack Thickness = 0.032 = 0.810
Figure 5.3 New PC Number, PC +5 – 0.005 – 0.120
New Shim Pack Thickness = 0.027 = 0.690
2. Old Shim Pack Thickness 0.030 0.760
Old PC Number, PC –2 – 0.002 – 0.050
Standard Shim Pack Thickness = 0.028 = 0.710
New PC Number, PC +5 – 0.005 – 0.120
PINION CONE New Shim Pack Thickness = 0.023 = 0.590
VARIATION
NUMBER 3. Old Shim Pack Thickness 0.030 0.760
If you are installing the original ring gear and drive pinion, Figure 5.5
Figure 5.4
PRESS
1002767b
AND SLEEVE
Figure 5.5
BEARING
ROLLER
CAGE
Figure 5.6
PRESS
1002766b
Figure 5.4
A. Place the carrier into a press so that the legs of the carrier
are toward the TOP of the press. 5. If removed, install the outer bearing cup for the drive pinion.
B. Install the correct amount of shims into the bore for the A. Place the carrier into a press so that the legs of the carrier
inner bearing cup of the drive pinion. Figure 5.5. are toward the BOTTOM of the press. Place supports
under the carrier so that the carrier is level.
C. Place the cup into the bore. Figure 5.5.
B. Place the outer bearing cup for the drive pinion into the
D. Place supports under the differential carrier so that the bore of the carrier.
carrier is level.
C. Use a sleeve or a bearing driver tool and a press to install
E. Place a sleeve or a bearing driver tool onto the cup and the cup. Press the cup into the carrier until the bottom of
press the cup into the bore until the bottom of the cup the cup touches the bottom of the bore. If a press is not
touches the shims. If a press is not available, use a available, use a sleeve, a brass drift or a bearing driver
sleeve, a brass drift or a bearing driver tool and a hammer tool and a hammer to install the cup. Figure 5.7.
to install the cup. Figure 5.6.
Figure 5.7 5. Install the drive pinion nut to contact the bearings while
allowing free movement of the pinion.
PRESS
Assembly
Main Differential and Ring Gear
CAUTION
Heat the ring gear before seating it onto the differential case.
Do not press a cold ring gear on the flange case half. A cold
ring gear will damage the case half because of the tight fit.
1002769d
Figure 5.7 1. Wear safe clothing and gloves. Expand the ring gear by heating
the gear in a tank of water to 160-180°F (71-82°C) for 10 to
15 minutes.
Installation
2. Use a lifting tool to safely lift the ring gear from the tank of
Drive Pinion water.
1. Place the drive pinion into the carrier so that the pinion is 3. Install the ring gear onto the flange case half immediately after
through the inner and the outer bearing cups. the gear is heated.
2. Place the carrier into a press so that the legs of the carrier are 앫 If the ring gear does not fit easily on the case half: Heat
toward the BOTTOM of the press. Place supports under the the gear again.
carrier so that the carrier is level. Place a support under the
4. Align the ring gear and flange case half fastener holes. Rotate
head of the drive pinion so that the inner bearing cone on the
the ring gear as necessary.
pinion shaft touches the inner bearing cup in the carrier.
5. Install the bolts, nuts and washers, if equipped, that hold the
3. Place the outer bearing cone onto the pinion shaft.
ring gear to the flange case half.
4. Use a press and a sleeve to install the bearing cone onto the
앫 For gear set ratios 2.47 and 2.64, install the bolts from the
pinion. Apply no more than two tons (1814 kg) of force to verify
flange half side. Figure 5.9.
that the bearing cone is correctly installed. Figure 5.8.
앫 For all other gear set ratios, install the bolts from the ring
Figure 5.8
gear side and install the washers and nuts on the flange
half side. Figure 5.10.
SLEEVE
Figure 5.9
RING
FLANGE GEAR
CASE
HALF
BOLT HEAD
INSTALLED
FROM FRONT
OF FLANGE
CASE HALF
1002770c
Figure 5.9
OF GEAR
1002780e
Figure 5.10
6. Tighten the bolts or nuts to the correct torque value. Follow the
tightening pattern shown in Figure 5.11. Check for
0.001" (0.025 mm)
gap at four
locations. 1002781e
Torque Plus
Fasteners Torque Angle Figure 5.12
PRESS
Figure 5.11
BEARING
CRISSCROSS TIGHTENING PATTERN ROLLER SLEEVE
CAGE
10 BEARING
4
6 CONE
CASE
8 HALF
2
11 12
SUPPORT SUPPORT
1 7
5
3
9 1002782e
4008146a
Figure 5.13
Figure 5.11
10. Place the flange case half onto a bench with the ring gear teeth Figure 5.16
THRUST
WASHER
FLANGE
CASE HALF 1003068c
Figure 5.16
14. Place the plain half of the differential case over the flange half
1003066c and gears. Rotate the plain half as needed to align the match
marks. Figure 5.16 and Figure 5.17.
Figure 5.14
Figure 5.17
SPIDER, PINIONS
AND THRUST MATCH
WASHERS MARKS
1003069g
Figure 5.17
1003067e
Figure 5.15 15. Install Dri-Loc or equivalent fasteners into the case halves
using the following procedure. Refer to Section 4 for more
13. Install the second side gear and thrust washer over the spider information about Dri-Loc fasteners. If you are reinstalling
and differential pinions. Figure 5.16. used fasteners instead of new, apply Loctite 680 adhesive,
Meritor specification 2297-K-5523, to the threads in the
tapped holes before you install the fasteners.
A. Install the capscrews into the case halves.
B. Tighten the capscrews in a crisscross pattern to
105 ± 10 lb-ft (140 ± 15 N폷m). You may also use an
alternate method of tightening the capscrews in a
crisscross pattern to 45 ± 5 lb-ft (60 ± 5 N폷m) then
further tightening them to an angle of 90 degrees ± 5
degrees. Figure 5.18.
14 4
8
10
12
6
16 1003072i
2 4008145a
16. Check the rotating resistance of the differential gears. The 3. Install the tool into the differential until the splines of the tool
differential assembly must rotate freely. are engaged with one side gear. Figure 5.20.
4. Place a torque wrench onto the nut of the tool and rotate the
Check the Rotating Resistance of the differential gears. As the differential gears rotate, read the
Differential Assembly value indicated on the torque wrench. Figure 5.21.
1. Make an inspection tool using an axle shaft that matches the 앫 If the torque value exceeds 50 lb-ft (68 N폷m):
spline size of the differential side gear. Cut the shaft to Disassemble the differential gears from the case halves.
approximately 12-inches (304.8 mm). Weld a nut onto the end Inspect the case halves, spider, gears and thrust washers.
of the shaft. Figure 5.19. Repair or replace parts. Assemble the parts and repeat
Step 2 through Step 4.
Figure 5.19
Figure 5.21
APPROXIMATELY
12" (304.8 MM)
Figure 5.19
2. Place the differential and ring gear assembly flat on a work 1003073e
bench. Figure 5.20.
Figure 5.21
Figure 5.24.
PRESS
Figure 5.24
ADJUSTING
RING
BEARING SLEEVE
CONE
1002786g LEG
1002789f
Figure 5.22
Figure 5.24
2. Install the bearing cups over the bearing cones on the case
halves. Figure 5.23. CAUTION
Correctly install the bearing caps into their original locations
on the carrier. Do not force the bearing caps into position,
which can damage the carrier. If the bearing caps are not
installed correctly, the bores and threads in the cap will not
match the carrier. Damage to the adjusting rings by
cross-threading can result.
5. Install the bearing caps over the bearings and adjusting rings in
the correct location as marked before removal. Figure 5.25.
Figure 5.25 Do not install the capscrews and lock plates that secure the
bearing adjusting rings in position. After the ring gear is
installed, you must adjust the backlash of the ring gear, inspect
the tooth contact patterns, then adjust the preload of the
BEARING
CAP differential bearings before the lock plates and capscrews
MATCH should be installed.
MARKS
Figure 5.25
Ring Gear Backlash
Table G: Specifications
WARNING Initial Backlash Setting Range of Backlash Setting
Use a brass or synthetic mallet for assembly and disassembly
0.012-inch (0.30 mm) 0.008-0.018-inch
procedures. Do not hit steel parts with a steel hammer. Pieces
(0.20-0.46 mm)
of a part can break off. Serious personal injury and damage to
components can result.
After checking the tooth contact patterns for top to root position, the
backlash can be adjusted within the specification limits for toe to
CAUTION heel position, if needed. To change the location of the pattern, use
Correctly install the bearing caps into their original locations the following procedures.
on the carrier. Do not force the bearing caps into position,
which can damage the carrier. If the bearing caps are not 1. Attach a dial indicator onto the carrier mounting flange.
installed correctly, the bores and threads in the cap will not Figure 5.26.
match the carrier. Damage to the adjusting rings by
Figure 5.26
앫 If the backlash reading is within the specification: Gear Set Tooth Contact Patterns
Check the tooth contact patterns.
Old Gear Set and Old Shim Pack
앫 If the backlash reading is not within the specification:
Adjust the backlash as needed. Adjust ring gear tooth contact patterns and backlash to the setting
that was measured before the carrier was disassembled. Refer to
5. Loosen one bearing adjusting ring one notch. Tighten the the previous table for the correct specification.
opposite ring by the same amount.
앫 To increase the backlash: Move the ring gear away from New Gear Set and/or New Shim Pack
the drive pinion. Figure 5.27. Adjust ring gear tooth contact patterns and backlash to the correct
specification from Table G.
앫 To decrease the backlash: Move the ring gear toward the
drive pinion. Figure 5.28. In the following procedures, movement of the contact pattern along
the length of the tooth is indicated as toward the heel or toe of the
Figure 5.27
ring gear. Figure 5.29.
Tighten adjusting
ring this side. Figure 5.29
HEEL
Loosen adjusting
Increase backlash. ring this side. TOE
1002795b
Figure 5.27
1003090h
Figure 5.28
Figure 5.28
NOTE: When you adjust the backlash, only move the ring gear. Do
not move the drive pinion. HEEL
6. Repeat Step 2 through Step 5 until the backlash is within DRIVE SIDE
specification. Record the setting for use when you adjust the (CONVEX)
Figure 5.30
Check Gear Set Tooth Contact Patterns 앫 If the contact patterns are in the center of the gear
teeth: Continue by following Step 5.
1. Apply a marking compound, Multan Gear Mark™ 39SY201
or equivalent, onto approximately 12 gear teeth of the ring Figure 5.32
gear. Rotate the ring gear so that the 12 gear teeth are next to
GOOD HAND-ROLLED
the drive pinion. Figure 5.31. PATTERN
TOP
Figure 5.31
ROOT
CONCAVE
4008131a
Figure 5.32
GOOD HAND-ROLLED
Figure 5.31
PATTERN
2. Rotate the ring gear forward and backward so that the 12 gear
teeth go past the drive pinion six times to get the contact
pattern. Repeat, if needed, to get a more clear pattern.
3. Look at the contact patterns on the ring gear teeth. Compare
the patterns to Figure 5.32, Figure 5.33, Figure 5.34,
Figure 5.35, Figure 5.36, Figure 5.37, Figure 5.38 and
CONVEX 4008132a
Figure 5.39.
The top-to-root pattern position is controlled by the shim pack Figure 5.33
and should be adjusted first. The toe-heel pattern position is
controlled by backlash and should be adjusted last. Figure 5.34
NOTE: When the carrier is in operation under load, a good HIGH PATTERN (BAD)
contact pattern will extend approximately the full length of the
gear tooth. The top of the pattern will be near the top of the
gear tooth. Figure 5.40 and Figure 5.41.
The location of a good hand-rolled contact pattern for a used
gear set will generally follow the new criteria, although the
pattern may be narrower or the center may not be filled in.
CONCAVE
A high contact pattern indicates that the drive pinion was not
4008133a
installed deep enough into the carrier. A low contact pattern
indicates that the drive pinion was installed too deep in the Figure 5.34
carrier.
앫 If the contact pattern requires adjustment: Continue by
following Step 4 to move the contact patterns between the
top and bottom of the gear teeth.
CONCAVE
4008135a CONVEX 4008138b
4. Change the thickness of the shim pack between the pinion Figure 5.43
Figure 5.44 앫 If a 0.003-inch (0.076 mm) shim is ADDED to the shim pack
Move pattern on convex side to INCREASE the depth of the drive pinion: A 0.003-inch
toward toe, loosen (0.076 mm) larger spacer must be installed to keep the preload
adjusting ring this side. on the bearings.
Decrease
backlash.
앫 If a 0.003-inch (0.076-mm) shim is REMOVED from the shim
pack to DECREASE the depth of the drive pinion: A
0.003-inch (0.076 mm) smaller spacer must be installed to keep
Tighten adjusting
ring this side. 4008764a the preload on the bearings.
Figure 5.44 NOTE: If the depth of the drive pinion was changed, then the
amount of the change must be added or subtracted to the thickness
Figure 5.45 of the spacer between the outer bearing cone and the helical driven
Move pattern on convex side gear.
toward heel, tighten
adjusting ring this side. After you obtain the correct gear tooth contact pattern and the
correct shim pack thickness, you must adjust the bearing preload on
the drive pinion. The preload is controlled by the thickness of the
spacer between the helical driven gear and the outer bearing cone.
Increase Loosen adjusting Figure 5.46.
backlash. ring this side.
4008765a
Figure 5.46
Installation 1002779e
Figure 5.47 7. Place the carrier into a press so that the threaded end of the
OUTER
pinion is toward the TOP of the press. Place supports under the
PRESS flange of the carrier so that the carrier is level. Place a wood
BEARING
CONE block under the head of the drive pinion so the inner pinion
bearing cone touches the inner bearing cup. Figure 5.49.
WOOD BLOCK
DRIVE
PINION CAUTION
SUPPORT Do not apply pressure after the helical driven gear touches the
SUPPORT
spacer in front of the inner bearing on the drive pinion. If
pressure is applied after the parts touch each other, the gear
1002772c will damage the spacer.
Figure 5.47
8. Use a press and a sleeve to completely install the helical driven
gear onto the drive pinion. Use a sleeve on the hub of the gear
3. Turn the carrier on its side.
that fits inside the outer pinion bearing cup bore in the carrier.
4. Place the helical driven gear over the pinion bore in the carrier Press the gear onto the drive pinion until the gear touches the
so that the splines inside the gear are toward the outer bearing spacer. Figure 5.49.
cone. Place the large spacer on top of the helical driven gear
so that the spacer is toward the inner bearing cup. Figure 5.49
Figure 5.48.
PRESS SLEEVE
Figure 5.48
WOOD BLOCK
AND END OF
DRIVE PINION WOOD
DRIVE MUST TOUCH BLOCK
PINION
SUPPORT
HELICAL SUPPORT
DRIVEN
GEAR
SPACER
VARIABLE 1002774c
SUPPORT SPACER
SUPPORT Figure 5.49
1002773c
9. Cut two pieces of solder approximately 0.5625-inch (14 mm)
Figure 5.48 long and 0.625-inch (16 mm) wide. Use the two pieces of
solder or lead as gauge blocks to determine the correct
5. Install the drive pinion into the helical driven gear. Verify that thickness of the spacer between the helical driven gear and the
the splines on the pinion engage the splines inside the gear. outer bearing cone.
Figure 5.48.
10. Place the two pieces of solder so that the pieces are opposite
each other on top of the helical driven gear.
CAUTION
Do not apply pressure after the inner bearing cone touches the 11. Place the outer bearing cone into the cup over the two pieces
inner bearing cup. If more pressure is applied, the cup, cone of solder on top of the helical driven gear.
and drive pinion will be damaged. 12. Remove the support from the flange of the carrier. Place a
sleeve on top of the outer bearing cone. Use a press to apply
6. Install a nut modified with a lifting loop onto the pinion threads.
two tons (1814 kg) of force to the outer bearing cone. The
Lift the pinion, helical gear and case.
force of the press compresses the solder pieces to the correct
size. Do not apply more than two tons (1814 kg) of force.
Figure 5.50.
13. Release the pressure and remove the wood block from under
the head of the drive pinion. CAUTION
14. Use a press and a sleeve to press the shaft of the drive pinion Do not apply pressure after the helical driven gear touches the
out of the outer bearing cone. Do not press the shaft of the spacer in front of the inner bearing on the drive pinion. If
drive pinion out of the helical driven gear. pressure is applied after the parts touch each other, the gear
will damage the spacer.
15. Remove the outer bearing cone and the two pieces of solder
from the outer bearing cone. NOTE: The inner bearing cone on the drive pinion must touch the
16. Use a micrometer to measure the thicknesses of the inner bearing cup in the carrier when the helical driven gear is being
compressed pieces of solder. Add the measurements of the installed.
two pieces and divide by two (2) to determine the average size
of the pieces. Add 0.004-inch (0.100 mm) to the average size. 18. Use a press and a sleeve to completely install the helical driven
Use this dimension to determine the size of the spacer to install gear onto the drive pinion. Use a sleeve on the hub of the gear
between the helical driven gear and the outer bearing cone. that fits inside the outer pinion bearing cup bore in the carrier.
Refer to Table H. Press the gear onto the drive pinion until the gear touches the
spacer. Do not remove the wood block at this time.
Table H: Figure 5.50.
Example Inch (mm) 19. Install the correct size spacer onto the shaft of the pinion in
front of the helical driven gear.
Thickness of piece number 1 0.504 (12.800)
Thickness of piece number 2 +0.506 (12.852) NOTE: Verify that the wood block is still under the head of the drive
Total thickness 1.010 (25.652) pinion. The inner bearing cone on the pinion must touch the cup in
the carrier.
Divide by two (2) to determine 0.505 (12.826)
the average thickness
20. Install the outer bearing cone onto the shaft of the drive pinion.
Add 0.004-inch (0.100 mm) to 0.509 (12.926) Figure 5.51.
determine the thickness of the
spacer A. Place the outer bearing cone onto the shaft of the drive
pinion.
17. Place a wood block under the head of the drive pinion so that B. Place a sleeve onto the top, inner race, of the outer
the inner bearing cone on the pinion touches the inner bearing bearing cone.
cup in the carrier. Remove the supports from the carrier.
Figure 5.51.
C. Use a press to apply two tons (1814 kg) of force on the 앫 If the preload is not within the specified limits: Remove
bearing cone to install the cone onto the shaft of the drive and replace the spacer between the outer bearing cone and
pinion. Rotate the carrier in both directions, so that the the helical driven gear. Refer to the procedure below.
carrier pivots on the drive pinion, while the cone is being
— To decrease the preload: Install a thicker spacer.
installed to verify that the bearing cone is correctly
installed. — To increase the preload: Install a thinner spacer.
21. Release the pressure and remove the carrier from the press. Spacer Replacement
Place the carrier in a repair stand.
NOTE: Do not grind spacers by hand. The surfaces must be parallel
22. Install the washer and the nut onto the drive pinion. Prevent the
drive pinion assembly from rotating by using a fixture to hold within 0.0001-inch (0.0020 mm). You must use the correct
spacers.
the teeth of the helical driven gear or place wood blocks
between the head of the pinion and the carrier wall. Tighten the
1. Prevent the drive pinion assembly from rotating by using a
nut to the specified torque. Refer to Section 8. Remove the
fixture to hold the teeth of the helical driven gear or place wood
holding fixture or the wood blocks.
blocks between the head of the pinion and the carrier wall.
23. Use an inch-pound torque wrench or a spring scale to inspect Remove the nut and the washer from the shaft of the drive
the preload of the bearings on the drive pinion. pinion.
Torque Wrench Method 2. Place the carrier into a press so that the threaded end of the
pinion is toward the TOP of the press. Place supports under the
1. Place an inch-pound (N폷m) torque wrench and the correct
flange of the carrier so that the carrier is level. Place a wood
socket onto the drive pinion nut. Figure 5.52. block under the head of the pinion. Verify that the wood block
does not touch the head of the drive pinion. Figure 5.53.
Figure 5.52
Figure 5.53
OUTER
SPACER
BEARING
CONE
Read
DRIVE
rotating PINION
torque. SUPPORT
SUPPORT
1002777d
Figure 5.53
2. Use the torque wrench to rotate the drive pinion assembly.
Inspect and record the torque level. Read while rotating the 3. Press the drive pinion out of the bearing cone. Do not press the
assembly. Record the dynamic or rotating torque not the
shaft of the drive pinion out of the helical gear. Remove the
breakaway torque.
outer bearing cone from the differential carrier.
3. The preload of the drive pinion bearings must be within the 4. Install the correct size spacer onto the shaft of the pinion over
following limits.
the helical driven gear.
앫 For new pinion bearings: 5-45 lb-in (0.56-5.08 N폷m)
5. Repeat Step 20 through Step 23 of the drive pinion bearing
rotational torque preload procedure in this section.
앫 For used pinion bearings: 10-30 lb-in (1.13-3.39 N폷m)
rotational torque
6. When the preload is within the specified range, install the main Figure 5.55
differential case and ring gear assembly into the carrier. Refer ADJUSTING
to “final” installation procedure in this section. RING
Figure 5.54
BEARING
BEARING CAP
CUP MATCH
BEARING MARKS
CUP
LEG
BORE
1002790e
Figure 5.56
1002788e
Figure 5.54
5. Use a lifting device to safely lift the differential and ring gear
assembly and install it into the carrier. The bearing cups must
be flat against the bores between the carrier legs. Figure 5.54.
6. Install the bearing adjusting rings between the carrier legs.
Figure 5.55.
DIAL
CAUTION INDICATOR
Correctly install the bearing caps into their original locations
on the carrier. Do not force the bearing caps into position,
which can damage the carrier. If the bearing caps are not
installed correctly, the bores and threads in the cap will not
match the carrier. Damage to the adjusting rings by
cross-threading can result.
Do not install the capscrews and lock plates that secure the ADJUSTING
bearing adjusting rings in position. After the ring gear is RING TOOL
installed, you must adjust the backlash of the ring gear, inspect
the tooth contact patterns, then adjust the preload of the
differential bearings before the lock plates and capscrews
should be installed.
Adjustment
ADJUSTING
RING OPPOSITE
Differential Bearings Preload RING GEAR 1002747d
Use either the dial indicator or the large micrometer method to Figure 5.58
inspect and adjust the main differential bearing preload.
3. Use one of the following methods to move the differential and
NOTE: The lock plates and capscrews for the adjusting rings are
the ring gear carefully to the left and right while you read the
installed after the tooth contact pattern is rechecked.
dial indicator.
A. Insert two pry bars between the bearing adjusting rings Figure 5.61
and the ends of the differential case. The pry bars must ADJUSTING
not touch the differential bearings. Figure 5.59. RING TOOL
Figure 5.59
Tighten each
ring one notch.
1002794d
Figure 5.61
Figure 5.62
1003081h
1003082d
Figure 5.60
Figure 5.62
4. Tighten the bearing adjusting ring until the dial indicator reads
ZERO end play. Move the differential and ring gear to the left
and right as needed. If necessary, repeat Step A or Step B.
5. Tighten each bearing adjusting ring one notch from ZERO. The
bearings of the differential should have a preload of
15-35 lb-in (1.7-3.5 N폷m). Figure 5.61. @
This procedure should expand the caps 0.002-0.009-inch
(0.05-0.23 mm), and place the correct preload on the bearings
when they are installed into the banjo housing.
adjusting ring tool can be used for this purpose. If the tool does Rotate ring gear.
not correctly fit into the notches, damage to the lugs will occur.
3. Use an adjusting ring tool to tighten each bearing adjusting ring DIAL
one notch. Figure 5.58. INDICATOR
B. Install the main differential case and ring gear assembly Installation
into the carrier. Refer to the procedure in this section.
C. Repeat the procedure for preload adjustment of the Thrust Screw (44,000-Lb Model Only)
differential side bearings. 1. Rotate the carrier in the repair stand until the ring gear is
4. Once the adjustments are complete, tighten the bearing cap toward the TOP.
capscrews down to a final torque of 360 ± 40 lb-ft (485 ± 2. Apply sealant, Meritor specification 2297-D-7076, in a
55 N폷m). You may also use the alternate method of tightening continuous 0.60-inch (1.5 mm) bead around the thread
the capscrews to 150 ± 35 lb-ft (200 ± 50 N폷m) then to an circumference.
angle of 90 degrees ± 5 degrees. @
3. Install the thrust screw with the jam nut into the carrier.
5. Once all adjustments are complete, install the capscrews and
lock plates that hold the two bearing adjusting rings in position. 4. Use a feeler gauge to verify that the clearance between the
Use the following procedures. thrust screw and the back face of the ring gear is
0.025-0.045-inch (0.64-1.14 mm). Figure 5.66.
A. Install the lock plate onto the bearing cap so that the tab
is between the lugs of the adjusting ring. Figure 5.65. Figure 5.66
JAM NUT
Figure 5.65
LOCK
PLATE
THRUST
THREADED HOLES SCREW RING
IN CAP GEAR
4007402b
Figure 5.66
HELICAL
Input Shaft and Inter-Axle Differential (Oil GEAR
Pump Model)
1. Apply axle lubricant, Meritor specification 2297-U-4519, to the
parts as they are being assembled. Figure 5.67.
Figure 5.67
10 11 THRUST
9 BEARING
8
7 1002814d
5 Figure 5.68
4 16
17
15
3. Install the helical gear onto the input shaft. Figure 5.68.
14
4. If disassembled, assemble the inter-axle differential.
A. Apply axle lubricant, Meritor specification 2297-U-4519,
6
to all of the inter-axle differential parts.
3
18 B. Install the spider into the inter-axle differential case.
2 19
1 20 C. Install the pinion gears onto the spider.
21
12 13 22
1002732c 5. Install the inter-axle differential onto the input shaft against the
helical gear. Install the snap ring that fastens the inter-axle
1 OIL SEAL 13 INPUT SHAFT
differential to the shaft. Figure 5.69.
2 BEARING ADJUSTING RING 14 NEEDLE BEARING ASSEMBLIES
3 BEARING CUP 15 THRUST BEARING
4 CAPSCREW 16 HELICAL GEAR Figure 5.69
2. Install the needle bearing assemblies and thrust bearing onto Figure 5.69
the input shaft. Figure 5.68.
NOTE: If you replace either the bearing cup or the cone, replace
both parts in a fully-matched set from the same manufacturer.
Input Shaft and Inter-Axle Differential 3. Install the needle bearing assemblies and thrust bearing onto
(Non-Pump Model) the input shaft. Figure 5.72.
8 9
7
10
5 14
4
13 15
12 THRUST
6 BEARING
1002814c
Figure 5.72
3
16
2 17 4. Install the helical gear onto the input shaft. Figure 5.72.
1 18
19 5. If disassembled, assemble the inter-axle differential.
11 20
1002732d A. Apply axle lubricant, Meritor specification 2297-U-4519,
1 OIL SEAL 12 NEEDLE BEARING ASSEMBLIES to all of the inter-axle differential parts.
2 BEARING ADJUSTING RING 13 THRUST BEARING
3 BEARING CUP 14 HELICAL GEAR
B. Install the spider into the inter-axle differential case.
4 CAPSCREW 15 BEARING CONE
C. Install the pinion gears onto the spider.
5 LOCK PLATE 16 REAR SIDE GEAR
6 COVER 17 SNAP RING 6. Install the inter-axle differential onto the input shaft against the
7 OIL BAFFLE FLANGE 18 IAD CASE
8 WASHER 19 PINION GEAR helical gear. Install the snap ring that fastens the inter-axle
9 CAPSCREW 20 SPIDER differential to the shaft. Figure 5.73.
10 BEARING CONE
11 INPUT SHAFT Figure 5.73
NON-PUMP MODEL
SNAP RING INPUT SHAFT
Figure 5.70
INTER-AXLE
2. Use a press and sleeve to install the bearing cone onto the DIFFERENTIAL
input shaft until it is flat against the shoulder. Figure 5.71.
HELICAL
Figure 5.71 GEAR
PRESS 1002815c
SLEEVE
Figure 5.73
BEARING
CONE NOTE: If you replace either the bearing cup or the cone, replace
both parts in a fully-matched set from the same manufacturer.
1002543c 7. If removed, use a press and sleeve to drive the bearing cone
onto the rear side gear until it is flat against the shoulder.
Figure 5.71
Installation 3. Install a nut modified with a lifting loop onto the end of the
input shaft. Connect a suitable lifting device to the nut loop. Lift
Input Shaft Assembly and Cover (Oil Pump and lower the input shaft assembly into the carrier. Rotate the
shaft to engage the IAD gears with the rear side gear.
Models) Figure 5.76.
The carrier must be positioned upright with the pinion shaft in the
vertical position for installation procedures. Refer to Figure 5.76 for Figure 5.76
Figure 5.74
BEARING
CUP
1002727c
Figure 5.76
4008947a
4. Install and test the IAD lock shift unit using the following
procedure.
Figure 5.74
A. Install the spring in the housing. Figure 5.77.
NOTE: If you replace either the bearing cup or the cone, replace Figure 5.77
2. Install the rear side gear with the bearing cone into the bearing 6
cup in the carrier housing. Figure 5.75. 8
5
Figure 5.75 3 4
2
1
REAR SIDE
GEAR
7
1002743c
1 HOUSING O-RING
2 PISTON
3 PISTON O-RING
4 SHIFT SHAFT
5 SHIMS
6 CLUTCH COLLAR
4008947b 7 SHIFT FORK
8 SPRING
Figure 5.75 Figure 5.77
B. Install the spring compression tool over the IAD bore and Figure 5.80
Figure 5.80
Figure 5.81
Figure 5.79
1002845d
Figure 5.81
I. Install an O-ring in both the shift tester and housing 5. Install two locating dowels, one on each side, into the carrier
groove prior to installing the shift tester. housing face.
J. Install the shift tester over the IAD bore. Tighten the tool
NOTE: The sealant will dry in approximately two hours. You must
screws in the bolt holes used to fasten the cover to the
complete the procedure within two hours from the time you apply
housing. Apply shop air at the tester fitting. Figure 5.82.
the sealant. If two hours have passed since the application, clean
Figure 5.82
the sealant from the parts and apply new sealant.
SHIFTER
TESTER 6. Apply grey sealant, Meritor specification 2297-H-7054, or blue
sealant, Meritor specification 2297-D-7076, in a continuous
SHOP 1/8-inch (3.175 mm) wide bead to the carrier housing face. Do
AIR
not allow the sealant to enter into the IAD piston bore. Be ready
to install the cover within 20 minutes of applying the sealant.
Figure 5.84.
Figure 5.84
4008155a
Figure 5.82
The current
M
piston has an
‘M’ stamped
O-RING
on it. INSTALLED
ON HOUSING
4008192a
Figure 5.83
Figure 5.85 NOTE: Do not install the cup more than part way or you may not be
able to adjust the end play correctly. You will then have to remove
the cover, bearing and cup again for reinstallation.
9. Install the bearing cup over the bearing cone. Use a hammer
and brass drift, or press and sleeve to install the bearing cup
PART WAY into the cover. The cup will be installed and correctly
seated when the adjusting ring is set to the correct end play.
Figure 5.88.
Figure 5.88
1002723d
8. Place the bearing cone onto the input shaft. Use an input
BRASS
bearing installation tool and wrench, or a yoke installation tool DRIFT
and sleeve to press the bearing cone down until it bottoms out
on the shoulder of the input shaft. Figure 5.86 and
Figure 5.87.
BEARING
Figure 5.86
CUP
TOOL PART NUMBER
3256M1235
INPUT BEARING
BEARING
INSTALLATION
TOOL
4008157a
Figure 5.89
YOKE
INSTALLATION
TOOL
BEARING
SLEEVE
1002817d
4008159a
Input Shaft Assembly and Cover (Non-Pump 3. Install a nut modified with a lifting loop onto the end of the
Models) input shaft. Connect a suitable lifting device to the nut loop. Lift
and lower the input shaft assembly into the carrier. Rotate the
The carrier must be positioned upright with the pinion shaft in the shaft to engage the IAD gears with the rear side gear.
vertical position for installation procedures. Refer to Figure 5.92 for Figure 5.92.
correct carrier position.
1. If removed, install the bearing cup for the rear side gear into
Figure 5.92
Figure 5.90
BEARING
CUP
1002727d
Figure 5.92
4008947a
4. Install and test the IAD lock shift unit using the following
Figure 5.90
procedure.
A. Install the spring in the housing. Figure 5.93.
NOTE: If you replace either the bearing cup or the cone, replace
both parts in a fully-matched set from the same manufacturer. Figure 5.93
2. Install the rear side gear with the bearing cone into the bearing
6
cup in the carrier housing. Figure 5.91.
8
Figure 5.91
5
3 4
2
REAR SIDE 1
GEAR
7
1002743c
1 HOUSING O-RING
2 PISTON
3 PISTON O-RING
4 SHIFT SHAFT
5 SHIMS
4008947b 6 CLUTCH COLLAR
7 SHIFT FORK
Figure 5.91 8 SPRING
Figure 5.93
B. Install the spring compression tool over the IAD bore and Figure 5.96
FORK
SPRING
Figure 5.96
Figure 5.95
G. Install the same amount of shims as were removed.
TOOL PART NUMBER H. Apply grease, Meritor specification 2297-U-4519 or
A3256L1234 1199-U-1113, to the O-ring and piston. Install the O-ring
COLLAR onto the piston. Install the piston into the housing with the
SPRING solid flat surface facing the front cover. Figure 5.97.
COMPRESSION
TOOL Figure 5.97
Figure 5.95
1002845d
Figure 5.97
I. Install the shift tester over the IAD bore. Tighten the tool 5. If removed, install the oil baffle, washers and capscrews into
screws in the bolt holes used to fasten the cover to the the housing cover. Tighten the capscrews to 5-7 lb-ft
housing. Apply shop air at the tester fitting. Figure 5.98. (7-10 N폷m). @
Figure 5.98
6. Install two locating dowels, one on each side, into the carrier
housing face.
TOOL PART NUMBER
3256P1238
SHIFTER TESTER NOTE: The sealant will dry in approximately two hours. You must
SHOP complete the procedure within two hours from the time you apply
AIR the sealant. If two hours have passed since the application, clean
the sealant from the parts and apply new sealant.
The current
M Figure 5.101. @
piston has an
‘M’ stamped
O-RING
on it. INSTALLED
ON HOUSING
4008192a
Figure 5.99
Figure 5.101
Inspection
Adjust the Input Bearing End Play
CAUTION
You must be ready immediately to install the adjusting ring and
yoke once you apply adhesive sealant. The adhesive sealant
has a limited time before it dries. You must install and adjust
the end play before it dries or the adhesive sealant will not set
correctly.
1002723c
For gauging end play, the preferred method is to have the carrier in
Figure 5.101 the vertical position.
1. Clean the old sealant from the input bearing adjusting ring.
NOTE: Do not install the cup more than part way or you may not be Figure 5.103.
able to adjust the end play correctly. You will then have to remove
the cover, bearing and cup again for reinstallation. Figure 5.103
Clean sealant
9. Install the bearing cup over the bearing cone. Use a hammer from threads.
and brass drift, or press and sleeve to install the bearing cup
part way into the cover. The cup will be installed and correctly
seated when the adjusting ring is set to the correct end play.
Figure 5.102.
Figure 5.102
HAMMER
BRASS
DRIFT
ADJUSTING CARRIER
RING COVER 4009826a
BEARING
CUP
Figure 5.103
Take care when you use Loctite adhesive to avoid serious DIAL
personal injury. Read the manufacturer’s instructions before INDICATOR
using this product. Follow the instructions carefully to prevent
irritation to the eyes and skin. If Loctite adhesive material
gets into your eyes, follow the manufacturer’s emergency
procedures. Have your eyes checked by a physician as soon as
possible.
Installation
Multiple-Lip Seal (MLS) and Yoke Sleeve
Meritor multiple-lip seals on the MT-14X forward-rear carrier feature
a separable sleeve installed onto the yokes at the tandem
forward-rear input and forward-rear output positions. The MT-14X
rear-rear carrier uses a unitized pinion seal and does not require a
yoke sleeve.
Installation of the new seals requires a set of four seal drivers and
two sleeve drivers. Refer to Table K for part numbers.
Forward input and output seals must be serviced with the seal and
sleeve. The service part number provides both when required.
Check your application carefully before installing the multiple-lip
seal.
Table K: Multiple-Lip Seal (MLS) Seal Drivers and Sleeves Part Numbers
Axle Model and Position Seal Service Part Number Seal Drivers Sleeve Drivers
MT-14X Forward-Rear Unit A1-1205X2728 2728T1 2728T2
Input (FUI)
MT-14X Forward-Rear Unit A1-1205Y2729 2729T1 2729T2
Output (FUO)
Special Tools for Installing Multiple-Lip Seals (MLS) 앫 A sleeve driver and seal driver for the forward-rear output
and Yoke Sleeves
There are six installation drivers required for replacement of the
multiple-lip axle yoke seals. To obtain these sleeves, seals and
drivers, call Meritor’s Commercial Vehicle Aftermarket at
888-725-9355.
앫 A sleeve driver and seal driver for the forward-rear input
WARNING WARNING
Solvent cleaners can be flammable, poisonous and cause Use a brass or synthetic mallet for assembly and disassembly
burns. Examples of solvent cleaners are carbon tetrachloride, procedures. Do not hit steel parts with a steel hammer. Pieces
and emulsion-type and petroleum-base cleaners. Read the of a part can break off. Serious personal injury and damage to
manufacturer’s instructions before using a solvent cleaner, components can result.
then carefully follow the instructions. Also follow the
procedures below. 4. Apply a light coat of axle oil to the yoke seal journal. Position
the sleeve into the forward-rear axle output yoke sleeve driver.
앫 Wear safe eye protection.
Do not touch the greased areas of the sleeve. The sleeve must
앫 Wear clothing that protects your skin. be kept clean prior to assembly into the seal. Use an arbor
press and the appropriate driver to install the sleeve into the
앫 Work in a well-ventilated area.
yoke. Verify that the sleeve is fully-seated on the yoke to
앫 Do not use gasoline or solvents that contain gasoline. prevent damage to components. Figure 5.107.
Gasoline can explode.
The yoke must be fully pressed into the sleeve driver until the
앫 You must use hot solution tanks or alkaline solutions end of the yoke bottoms out in the sleeve driver. This will
correctly. Read the manufacturer’s instructions before correctly position the sleeve on the yoke. When correctly
using hot solution tanks and alkaline solutions. Then seated, the forward-rear output sleeve is positioned
carefully follow the instructions. 0.200-inch ± 0.030-inch (5 mm ± 0.75 mm) from the end of
the yoke. Figure 5.108.
1. Clean the ground and polished surface of the yoke journal
using a clean shop towel and a safe cleaning solvent. Do not 앫 If you do not have a press: Position the yoke on a
five-inch (127 mm) spacer on a workbench. Use a
use abrasive cleaners, towels or scrubbers to clean the yoke or
flange surface. Do not use gasoline. dead-blow hammer and the appropriate driver to install the
sleeve into the yoke. Figure 5.109.
2. Inspect the yoke seal area for damage that could cause
lubricant leaks after you install the seal. Use emery paper or an Figure 5.107
equivalent product to remove scratches, nicks or burrs only. FORWARD REAR OUTPUT
WITHOUT DEFLECTOR
3. Install the deflector, if equipped, onto the yoke. You must install
the deflector before you install the sleeve onto the yoke.
Figure 5.106.
Figure 5.106
SLEEVE
YOKE 4004874a
Figure 5.107
DEFLECTOR,
IF EQUIPPED
SLEEVE
DRIVER 4004889a
Figure 5.106
Figure 5.108 The yoke must be fully pressed into the sleeve driver until the
end of the yoke bottoms out in the sleeve driver. This will
correctly position the sleeve on the yoke. When correctly
seated, the forward-rear input sleeve is positioned 0.030-inch
(0.75 mm) from the end of the yoke. Figure 5.108.
YOKE 앫 If you do not have a press: Position the yoke on a
five-inch (127 mm) spacer on a workbench. Use a
dead-blow hammer and the appropriate driver to install the
sleeve into the yoke. Figure 5.109.
SLEEVE
Figure 5.110
DRIVER
End of the yoke FORWARD-REAR INPUT
must bottom out WITH DEFLECTOR
in the sleeve driver. SLEEVE
INPUT
POSITION
SLEEVE
4004990e 4004875a
Figure 5.109
CAUTION
Hold the sleeve and seal only on the outer diameter. Do not
touch the greased inner diameter of the seal and the greased
area of the sleeve. This can contaminate the seal and cause a
leak between the shaft and the seal. Damage to components
can result.
6. Install the forward-rear axle input seal. Hold the sleeve and
5" (127 MM)
SPACER seal only on the outer diameter. Position the seal into the seal
driver and align it with the adjusting ring on the forward-rear
4004991a axle cover. Do not touch the lips in the inner diameter of the
Figure 5.109
seal. Use a dead-blow hammer and the appropriate driver to
install the seal into the adjusting ring. Figure 5.111.
5. Apply a light coat of axle oil to the yoke seal journal. Position
the sleeve into the forward-rear axle input yoke sleeve driver.
Do not touch the greased areas of the sleeve. The sleeve must
be kept clean prior to assembly into the seal. Use an arbor
press and the appropriate driver to install the sleeve into the
yoke. Verify that the sleeve is fully-seated in the yoke.
Figure 5.110.
FORWARD-REAR INPUT
4004877b
Figure 5.111
Figure 5.114
7. Install the forward-rear axle output seal. Hold the sleeve and SEAL Measure
the gap.
seal only on the outer diameter. Position the seal onto the seal
driver and align it with the forward-rear axle output shaft. Do
not touch the lips in the inner diameter of the seal. Use a
dead-blow hammer and the appropriate driver to install the
seal into the output shaft cage. Figure 5.112.
Figure 5.112
FORWARD-REAR OUTPUT
4008186b
Figure 5.114
Input Yoke
CAUTION
Use a press and a sleeve or yoke installation tool to install the
yoke. Do not use a hammer or mallet. Using a hammer or
mallet can damage the bearings, yoke or flange.
4004878a
1. Use a press and sleeve or special yoke/flange driver tool, SPX
Figure 5.112
Kent-Moore part number J 48718, to install the yoke or flange.
Do not use the nut to draw on the yoke or flange. The yoke or
8. Use a feeler gauge to check the seal gap at the input and
flange must be seated against the outer bearing. If a press and
output positions. The seal is correctly installed if the gap is less
sleeve are used, verify that the input shaft is well supported.
than 0.010-inch (0.25 mm) around the circumference of the
Figure 5.115.
seal flange. Figure 5.113 and Figure 5.114.
앫 If the gap is more than 0.010-inch (0.25 mm): Use a
dead-blow hammer and the appropriate driver to
completely install the seal.
Figure 5.115
Output Bearings and Thru-Shaft
1. Apply axle lubricant to bearing cups and cones. Figure 5.117.
Figure 5.117
BEARING
THRU-SHAFT ASSEMBLIES SNAP
RING
OUTPUT
4008100b YOKE
Figure 5.115
OIL
2. Install a yoke bar or other suitable tool to hold the yoke in SEAL
SPACER 1002824b
place. Figure 5.116.
Figure 5.117
Figure 5.116
NOTE: If you replace either the bearing cup or the cone, replace
both parts in a fully-matched set from the same manufacturer.
PRESS
Figure 5.116
SLEEVE
3. Apply Loctite 270 or 277 adhesive sealant in a 0.12-inch
(3.1 mm) bead around the inside diameter of the yoke nut.
Install the washer and yoke nut onto the input shaft and tighten
to 800 45 lb-ft (1090 60 N폷m). Figure 5.116. @
THRU-SHAFT
4. Rotate the input shaft one complete turn to seat the bearings.
1002825b
Figure 5.118
3. Use a press and sleeve to install the inner bearing cup into the
cage. Place the thru-shaft and bearing assembly into the cage.
4. Use a press and sleeve to install the outer bearing cup into the
cage over the thru-shaft. Figure 5.119.
Figure 5.119
PRESS
Inspection
SLEEVE
Adjust the Output Bearing End Play
OUTER
BEARING The output bearing end play is controlled by the size of the snap ring
CUP that holds the bearings in the output cage. The snap rings are
OUTER available in increments of 0.003-inch (0.076 mm). Install the snap
BEARING ring which results in an end play of 0.004-0.008-inch
CONE
(0.10-0.20 mm).
1. Place the thru-shaft and the bearing cage assembly into a vise
with soft metal covers on the jaws of the vise.
CAGE INNER
2. Use an installation tool to install the yoke or flange onto the
BEARING thru-shaft. Do not use the nut to draw the yoke onto the shaft.
CUP 1002826d Do not install the oil seal at this time.
Figure 5.119 3. Install the nut that fastens the yoke or flange to the thru-shaft.
Place a holding tool on the yoke or flange and tighten the nut to
5. Install the snap ring that fastens the outer cup in the cage. The the specified torque.
snap ring controls the end play of the output bearing.
4. Push the yoke or flange toward the cage and rotate the shaft in
Figure 5.120.
each direction to verify that the bearings are correctly installed.
Figure 5.120
5. Install a dial indicator so that the base of the indicator is on the
BEARING mounting flange of the cage. The pointer of the indicator must
CAGE touch the yoke or flange end of the thru-shaft. Set the dial
SNAP indicator to ZERO. Figure 5.121.
RING
Figure 5.121
THRU-SHAFT
END VIEW
1002717b
Figure 5.120
6. Place pry bars under the yoke or flange and push the yoke or When you install the seal, hold the sleeve and seal only on the
flange away from the cage. Record the reading on the dial outer diameter. Position the seal onto the seal driver and align
indicator. The reading must be 0.004-0.008-inch it with the forward-rear axle output shaft. Do not touch the lips
(0.10-0.20 mm). The reading is the measurement of the end in the inner diameter of the seal. Use a dead-blow hammer and
play on the output bearing. the appropriate driver to install the seal onto the output shaft.
Figure 5.123.
앫 If the end play reading is not 0.004-0.008-inch
(0.10-0.20 mm): Remove and replace the snap ring that Figure 5.123
Figure 5.122
SNAP
RING
4004878a
Figure 5.123
Output Yoke and Seal for the Output Bearing SEAL Measure
the gap.
Cage
CAUTION
Hold the seal only on the outer diameter. Do not touch the lips
in the inner diameter of the seal. If you touch the lips on the
inner diameter of the seal, you will contaminate the lips and
cause a leak between the shaft and the seal.
4008186b
Do not apply pressure after the flange of the seal touches the
top of the cage or you will damage the seal. Figure 5.124
WARNING
When you apply some silicone gasket materials, a small
amount of acid vapor is present. To prevent serious personal
YOKE BAR 1003451c injury, ensure that the work area is well-ventilated. Read the
manufacturer’s instructions before using a silicone gasket
Figure 5.125 material, then carefully follow the instructions. If a silicone
gasket material gets into your eyes, follow the manufacturer’s
5. Rotate the yoke at least one full turn after the yoke nut is emergency procedures. Have your eyes checked by a
tightened to the correct torque specification. This ensures physician as soon as possible.
correct seating of the seal.
CAUTION
Driver-Controlled Main Differential Lock Apply silicone gasket material in a continuous 0.25-inch
Refer to Section 6 for installation procedures. (6 mm) bead. If you use more than this amount, gasket
material can break off and plug lubrication passages. Damage
Differential Carrier into the Axle Housing to components can result.
2.25”
CAPSCREW STUDS
TAPERED
DOWELS
1.75”
CAPSCREW
1.75”
CAPSCREW TAPERED
0.25" (6 MM) DOWELS
2.25”
DIAMETER SILICONE
4004435a CAPSCREW 4008219a
GASKET BEAD
Figure 5.128
Figure 5.126
6. On an axle with a driver-controlled main differential lock, shift 9. Apply Loctite 242 threadlocker to two 1.75-inch and two
2.25-inch capscrews.
the lock into and hold the lock in the locked or engaged
position. The locked position provides enough clearance 10. Install the washers and correct-size capscrews at the tapered
between the shift collar and the axle housing for carrier dowel locations shown in Figure 5.128. Tighten the capscrews
installation. Refer to Section 6. in a crisscross pattern to 80-100 lb-ft (109-136 N폷m). @
11. Apply Loctite 242 threadlocker to the remaining capscrews.
CAUTION
Do not use a hammer or mallet to install the carrier. A hammer 12. Install the remaining washers and correct-size capscrews at
or mallet will damage the mounting flange of the carrier and the locations shown in Figure 5.129. Tighten the capscrews in
cause oil leaks. a crisscross pattern to 80-100 lb-ft (109-136 N폷m). @
7. Use a hydraulic roller jack or a lifting tool to install the carrier Figure 5.129
1.75”
CAPSCREW 1.75”
CAPSCREW
2.25”
CAPSCREW 4008219b
Figure 5.129
ROLLER
JACK 1002714e
13. Tighten all the capscrews in a crisscross pattern to 225 lb-ft
Figure 5.127 (305 N폷m). @
14. Apply Loctite 242 threadlocker to the stud threads.
8. Install tapered dowels at the locations shown in Figure 5.128.
15. Install the stud nuts and tighten to 225 lb-ft (305 N폷m). @
16. Connect the vehicle drive shafts to the input and the thru yokes
or flanges.
17. Connect the air lines to the inter-axle differential air inlet and, if
used, the main differential lock inlet.
18. On axles with a main differential lock, connect the electrical 3. Install solid tapered dowels over each stud and into the flange
connector of the sensor unit. Verify that the main differential of the axle shaft. Use a punch or a drift and hammer, if
lock is disengaged. necessary. Figure 5.130.
4. Install the Grade 8 nuts and hardened washers onto the stud.
Axle Shaft Lock washers are an acceptable alternative. Tighten the stud
nuts to the torque specified in Table L.
WARNING
When you apply some silicone gasket materials, a small Table L: Shaft-to-Hub Torque Fastener Chart
amount of acid vapor is present. To prevent serious personal
Torque Value — Grade 8 Nuts lb-ft
injury, ensure that the work area is well-ventilated. Read the
Thread (N폷m)
manufacturer’s instructions before using a silicone gasket
material, then carefully follow the instructions. If a silicone Fastener Size Plain Nut Locknut
gasket material gets into your eyes, follow the manufacturer’s Stud Nut 0.62-18 180-230 (244-312) 150-190 (203-258)
emergency procedures. Have your eyes checked by a or Axle 0.75-16 310-400 (420-542) 270-350 (366-475)
physician as soon as possible. Shaft
Take care when you use Loctite adhesive to avoid serious Studs All Install the coarse thread end of the stud
personal injury. Read the manufacturer’s instructions before into the hub and tighten to the last thread.
using this product. Follow the instructions carefully to prevent
irritation to the eyes and skin. If Loctite adhesive material 5. Fill the axle with the specified lubricant. Refer to the procedure
gets into your eyes, follow the manufacturer’s emergency in this section.
procedures. Have your eyes checked by a physician as soon as
possible. Straight Holes, Nuts and Hardened Washers
1. Clean the mating surfaces of the axle shaft and wheel hub.
Tapered Dowel, Hardened Washer and Hardened Nut
2. Install the gasket and axle shaft into the axle housing and
1. Clean the mating surfaces of the axle shaft and wheel hub.
carrier. The gasket and flange of the axle shafts must fit flat
2. Install the gasket and axle shaft into the axle housing and against the wheel hub. Figure 5.130.
carrier. The gasket and flange of the axle shafts must fit flat
앫 If a gasket is not available: Apply a 0.125-inch (3 mm)
against the wheel hub. Figure 5.130.
diameter bead of grey sealant, Meritor specification
앫 If a gasket is not available: Apply a 0.125-inch (3 mm) 2297-H-2054, around the mating surface of the hub and
diameter bead of grey sealant, Meritor specification around the edge of each fastener hole. Install the axle shaft
2297-H-2054, around the mating surface of the hub and into the axle housing and carrier.
around the edge of each fastener hole. Install the axle shaft
into the axle housing and carrier. 3. Install the Grade 8 nuts and hardened washers on the stud.
Lock washers are an acceptable alternative. Tighten the stud
Figure 5.130 nuts to the torque specified in Table L.
STUD WASHER STUD
GASKET
4. Fill the axle with the specified lubricant. Refer to procedure in
NUT
this section.
2. Remove the fill plug from the side of the bowl cover of the axle
housing. Figure 5.131.
Figure 5.131
FILL
PLUG
TEMPERATURE
INDICATOR
PLUG – DO
NOT REMOVE
1002591d
Figure 5.131
3. Fill the axle with lubricant until the lubricant level is to the
bottom of the fill plug hole. Refer to Section 7.
4. Install the fill plug. Tighten the fill plug to 35 lb-ft (47 N폷m).
When correctly installed, one complete thread of the fill plug is
visible between the housing and plug head. @
5. Road test the vehicle in an unloaded condition for one to two
miles (1.6-3.2 km) at speeds not more than 25 mph (40 kmh).
Recheck the lubricant levels and all the fasteners.
6. If used, inspect the operation of the driver-controlled main
differential lock. Refer to Section 6.
Hazard Alert Messages 1. Remove the protective covers, if used, from the wheel-end
6 Driver-Controlled Main Differential Lock (DCDL)
hubs.
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent 2. If the drive axles are equipped with a main differential lock,
serious personal injury, damage to components, or both. shift the differential to the unlocked or disengaged position.
Install the axle shaft with two sets of splines and new gaskets
WARNING in the correct location as follows.
To prevent serious eye injury, always wear safe eye protection A. Push the axle shaft and gasket into the hub and housing
when you perform vehicle maintenance or service. until the shaft stops against the differential lock collar.
B. Push down and in on the axle shaft flange and rotate the
Description shaft until the splines of the shaft and the shift collar are
Some Meritor drive axle models have a driver-controlled main engaged.
differential lock (DCDL). This differential lock is operated by a C. Push the axle shaft further into the housing until the shaft
carrier-mounted, air-actuated shift unit. When activated, the shift stops against the differential side gear.
unit moves a sliding collar which is installed on the splines of the
axle shaft. When engaged, the collar locks the axle shaft to a D. Push down on the axle shaft flange and rotate the shaft
second set of splines on the differential case. Both driven wheels until the splines of the shaft and the side gear are
are then simultaneously engaged. Figure 6.1. engaged.
E. Push the axle shaft completely into the housing until the
Figure 6.1
axle shaft flange and gasket are flush against the wheel
SPRING SHIFT FORK DIFFERENTIAL hub.
LOCK COLLAR
SHIFT
WARNING
SHAFT Do not start the engine and engage the transmission during
disassembly of the driver-controlled main differential lock
(DCDL), or when the DCDL is in the locked or engaged position,
PISTON 4007399a
and the vehicle’s wheels are raised from the floor. The vehicle
can move and cause serious personal injury and damage to
Figure 6.1 components.
2. Remove the drain plug from the bottom of the housing and
CAUTION
drain the lubricant.
There will be a small amount of spring resistance felt when
3. Use a jack to raise the left-hand wheel of the drive axle. you turn in the caging bolt. If a high resistance is felt before
reaching the locked or engaged position, stop turning the
4. Place a jackstand under the left-hand spring seat to hold the
caging bolt to prevent damage to the cover, fork and bolt
vehicle in the raised position.
threads.
5. Disconnect the driveline from the input yoke.
10. Turn the caging bolt to the right until the head is approximately
6. Disconnect the wiring harness from the DCDL switch.
0.25-inch (6 mm) from the cylinder cover. Do not turn the
7. Disconnect the vehicle air line from the inter-axle differential caging bolt beyond its normal stop. Figure 6.3.
and main differential lock actuator assemblies.
A high resistance on the caging bolt indicates that the splines
8. Remove the caging bolt from the side of the housing. of the shift collar and the differential case half are not aligned
Figure 6.2. or engaged. To align the splines, use the following procedure.
Figure 6.2
A. Rotate the left-hand wheel to align the splines of the shift
collar and case half while you turn in the caging bolt.
B. When the normal amount of spring resistance is again felt
on the caging bolt, the splines are engaged. Continue to
turn in the caging bolt until the head is approximately
0.25-inch (6 mm) from the cylinder cover. The caging bolt
is now in the service position and the main differential
lock is completely engaged.
CAGING BOLT
IN STORAGE 11. Remove the carrier from the axle housing. Refer to Section 3.
HOLE 4008191a 12. Release the differential lock by removing the caging bolt from
Figure 6.2
the hole in the center of the DCDL cover. Reinstall the caging
bolt with the washer into its original position on the cover.
9. Install the caging bolt into the threaded hole in the center of the Tighten the caging bolt to 7-9 lb-ft (10-12 N폷m). @
DCDL cover. Figure 6.3.
Auxiliary Air Supply Method
Figure 6.3 1. Park the vehicle on a level surface. Block the wheels to prevent
SPRING SHIFT FORK DIFFERENTIAL the vehicle from moving.
LOCK COLLAR
2. Remove the drain plug from the bottom of the housing and
drain the lubricant.
3. Use a jack to raise the left-hand wheel of the drive axle. Place a
SHIFT safety stand under the left-hand axle housing leg to support the
SHAFT
vehicle in the raised position.
4. Disconnect the driveline from the input yoke.
PISTON CAGING BOLT 4007399b 5. Disconnect the wiring harness from the DCDL switch.
Figure 6.3 6. Disconnect the vehicle air line from the inter-axle differential
and main differential lock actuator assemblies.
7. Install a suitable air line coupling into the main differential
actuator assembly.
8. Install the air line into the coupling.
2. Remove the four capscrews and washers that hold the cover.
CAUTION
Remove the cover. Figure 6.6.
When you use an auxiliary air supply to engage the
driver-controlled main differential lock (DCDL), you must Figure 6.6
supply air to the DCDL until you remove the carrier. Do not
disconnect the air line or reduce air pressure to the DCDL
before you remove the carrier from the housing. Damage to
components can result.
9. Supply 85 psi (586 kPa) regulated air pressure through the air
line.
10. Verify that the DCDL is engaged. Figure 6.4. CAPSCREW AND
WASHER, FOUR
CORNERS COVER
Figure 6.4
1002850d
SPRING SHIFT FORK DIFFERENTIAL
LOCK COLLAR Figure 6.6
ENGAGED
PISTON 4007399c
Figure 6.4
11. Remove the carrier from the axle housing. Refer to Section 3.
12. Shut-off the air supply to the DCDL.
13. Disconnect the air line from the main differential actuator
assembly coupling. 1002845c
Figure 6.7
DCDL Shift Unit
1. Remove the sensor switch. Figure 6.5. 4. Remove the shift shaft from the shift fork. Figure 6.8.
Figure 6.8
Figure 6.5
SHIFT
4008149a SHAFT 1002854d
6. Install the spring compression tool over the DCDL bore and
finger tighten the retaining screws. The ends of the tool fit
through recesses in the housing bore and around the fork.
Figure 6.9. SPRING
Figure 6.9
1002847e
Figure 6.11
Figure 6.10
WARNING
When you apply some silicone gasket materials, a small
amount of acid vapor is present. To prevent serious personal
TOOL PART NUMBER injury, ensure that the work area is well-ventilated. Read the
A3256L1234 manufacturer’s instructions before using a silicone gasket
material, then carefully follow the instructions. If a silicone
gasket material gets into your eyes, follow the manufacturer’s
emergency procedures. Have your eyes checked by a
physician as soon as possible.
4008685a Take care when you use Loctite adhesive to avoid serious
personal injury. Read the manufacturer’s instructions before
Figure 6.10 using this product. Follow the instructions carefully to prevent
irritation to the eyes and skin. If Loctite adhesive material
8. Loosen the handle on the spring compression tool to release gets into your eyes, follow the manufacturer’s emergency
the spring. Loosen the retaining screws and remove the spring procedures. Have your eyes checked by a physician as soon as
compression tool from the carrier. possible.
9. Remove the spring. Figure 6.11.
Install the differential shift assembly after the differential carrier is
assembled and the gear and bearing adjustments are made.
1. If removed, reinstall the main differential and ring gear
assembly according to the procedures in Section 5.
2. Install the spring into the housing. Figure 6.12.
4008685a
Figure 6.12
5. While holding the fork in position, loosen the tool handle to
release the spring. Loosen the retaining screws and remove
3. Install the spring compression tool over the DCDL bore and
the spring compression tool.
finger tighten the retaining screws. Tighten the tool handle
down until it bottoms to compress the spring. Figure 6.13. 6. Insert a centering tool, screwdriver or other suitable tool to
align the fork with the shift shaft housing bore. Refer to Section
Figure 6.13
10 for a tool drawing. Figure 6.15.
Figure 6.15
FORK
TOOL
4008683a
Figure 6.13
4008167a
4. Install the clutch collar onto the fork. Slide the clutch collar and Figure 6.15
fork into position. Insert the end of the fork above the
compressed spring while you position the clutch collar to the 7. Apply grease, Meritor specification 2297-U-4519 or
main differential. The teeth of the clutch collar must face the 1199-U-1113, to the tapered surface of the shift shaft. Insert
main differential case teeth. Ensure the spring is correctly the shift shaft into the housing bore through the shift fork and
seated within the raised areas of the fork. Figure 6.14. spring. Figure 6.16. Use a centering tool to seat the shift shaft
in the housing bore. Refer to Section 10 for a tool drawing.
SHIFT
SHAFT
GEAR
SHIMS
TEETH
ENGAGED
SHIFT PISTON 4007399c
SHAFT 1002854d
DCDL IN LOCKED POSITION
Figure 6.16
Figure 6.18
Figure 6.19
CAPSCREW AND
WASHER, FOUR
CORNERS COVER
SHIFT
1002850d SHAFT
Figure 6.17
Figure 6.20 4. Continue to drive the vehicle and place the differential lock
switch in the locked or engaged position. A slight left or right
turn may be required to lock the DCDL. Let up on the
accelerator to remove the driveline torque and permit the shift.
The indicator light must be on when the switch is in the locked
position.
앫 If the indicator light remains ON with the switch in the
unlocked position: The differential is still in the locked
position. A slight left or right turn may be required to unlock
the DCDL. If the indicator light remains on after completing
4008149a a slight left or right turn, check the piston and shift shaft for
binding. If necessary, take them apart and check both for
Figure 6.20
burrs, scratches and damage. Replace the parts if
necessary. Refer to the procedure in this section.
16. Connect a volt-ohm meter to the sensor switch. Select ohms
on the meter. Rotate the switch CLOCKWISE until the meter
reading changes from infinity to less than one ohm. Turn in the DCDL Driver Caution Alert Label
switch fully and tighten to 25-55 lb-ft (35-75 N폷m). @ Verify that the driver caution label is installed in the vehicle cab.
17. Connect the wiring harness to the DCDL switch. Figure 6.21. The caution label must be placed in a location that is
easily visible to the driver. The recommended location is on the
18. Apply 85 psi (586 kPa) of air and verify the DCDL engages. instrument panel, next to the differential lock switch and lock
19. Check the sensor switch operation with the air applied. The indicator light.
differential lock indicator light in the cab of the vehicle should
be ON when the DCDL is engaged, and OFF when disengaged.
Figure 6.21
2. Place the differential lock switch in the cab of the vehicle in the
unlocked or disengaged position.
3. Drive the vehicle at 5-10 mph (8-16 km/h) and check the
differential lock indicator light. The light must be off when the
switch is in the unlocked or disengaged position.
Specifications
7 Lubrication
Filter Change Every 100,000 Every 100,000 miles Every 100,000 miles Every 100,000 miles
Change on axles miles (160 000 km) (160 000 km) (160 000 km) (160 000 km)
with a pump and
filter system.
1
For continuous heavy-duty operation, check the oil level every 1,000 miles (1600 km).
2
This interval applies to approved semi-synthetic and full-synthetic oils only. For a list of approved extended-drain axle oils, refer to TP-9539, Approved Rear
Drive Axle Lubricants. To obtain this publication, refer to the Service Notes page on the front inside cover of this manual.
3
The change interval for transit bus can be increased to 150,000 miles (241 401 km) or three years, whichever comes first, contingent upon the following three
conditions. 폷 Documentation verifies a 10% fleet oil sampling with results that are below the guidelines specified in Maintenance Manual 1, Preventive
Maintenance and Lubrication. To obtain this publication, refer to the Service Notes page on the front inside cover of this manual. 폷 There is a minimum of six
magnets in the housing. Meritor 61163/71163 drive axles come standard with six magnets in the housing. 폷 Approved extended-drain interval lubricants are
used according to TP-9539, Approved Rear Drive Axle Lubricants. (Drive axles excluded are RC-26-633/634 and RC-26/27-720.)
Specifications
8 Specifications
Figure 8.1
OPTION
5
6
7 8
12
13 10
11
14
4007405a
Figure 8.1
Figure 8.2
3 4007406a
Figure 8.2
Figure 8.3
4007407a
Figure 8.3
Adjustment
9 Adjustment
NOTE: If the end play on the output bearing measures ZERO, a thinner snap ring is required.
Table AB: Sensor Switch — Installation (Carriers with Differential Lock (DCDL) Only)
Adjustment Shift the differential to the locked position.
Tighten the sensor switch into the carrier until the test light illuminates indicating the circuit is closed.
Tighten to 25-55 lb-ft (35-75 N폷m). @
Specifications
10 Special Tools
23-1/2" CENTER
TO CENTER OF PIPE
4" DIAMETER
PIPE WELD
CHAMFER END
OF PIPE FOR
WELDING 1002990a
Figure 10.1
To obtain a repair stand, refer to the Service Notes page on the front
inside cover of this manual.
Figure 10.2
YOKE 1003459b
Figure 10.2
Figure 10.3
YOKE BAR
C
1003460b
Figure 10.3
WARNING
Wear safe clothing and eye protection when you use welding
equipment. Welding equipment can burn you and cause
serious personal injury. Follow the operating instructions and
safety procedures recommended by the welding equipment
manufacturer.
Centering Tool
Figure 10.4
10.0
6.75
6.5 0.06 X 45°
1.38 1.5 CHAM
DIA. 0.75 COURSE KNURL
0.12 X 45° CHAM
0.5
0.06 R 0.585
0.976 1.0
DIA. DIA.
0.06 X 45° STAMP TOOL DIA.
CHAM AND DETAIL NO.
NOTE: DCDL use shown as an example.
SPRING
FORK
TOOL
4008166a
Figure 10.4
4008683a
4008161a
Figure 10.9
Figure 10.6
4008165a
Multiple-Lip Seals, Seal Drivers and Yoke
YOKE/FLANGE INSTALLATION TOOL Sleeve Drivers
Figure 10.6 Refer to Table AC for information on multiple-lip seals, seal drivers
and yoke sleeve drivers. To obtain these sleeves, seals and drivers,
Figure 10.7
call Meritor’s Commercial Vehicle Aftermarket at 888-725-9355.
4008162a
Table AC: Multiple-Lip Seals, Seal Drivers and Yoke Sleeve Drivers
Single and
Tandem
Models Axle Model and Position Seal Service Part Number Seal Drivers Yoke Sleeve Drivers
MT-14X 14X Forward-Rear Unit A1-1205X2728 2728T1 2728T2
Input (FUI)
14X Forward-Rear Unit A1-1205Y2729 2729T1 2729T2
Output (FUO)
14X Rear-Rear Unit Input A1-1205Z2730 2730T1 Not Required — Sleeve
(RUI) is unitized
Forward input and output seals must be serviced with the seal and
sleeve. The service part number provides both when required.
Hazard Alert Messages When transporting a vehicle with the wheels of one or both drive
11 Vehicle Towing Instructions
WARNING
After Towing or Drive-Away
To prevent serious eye injury, always wear safe eye protection 1. If an auxiliary air supply was used, apply the vehicle parking
when you perform vehicle maintenance or service. brakes using the switch inside the cab of the vehicle. If an
auxiliary air supply was not used, begin with Step 2.
Park the vehicle on a level surface. Block the wheels to
2. Apply the vehicle spring or parking brakes by manually
prevent the vehicle from moving. Support the vehicle with
releasing each spring that was compressed before transporting
safety stands. Do not work under a vehicle supported only by
started. Refer to the manufacturer’s instructions.
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result. 3. Disconnect the auxiliary air supply, if used, from the brake
system of the vehicle that was transported. Connect the
Before you service a spring chamber, carefully follow the vehicle’s air supply to the brake system.
manufacturer’s instructions to compress and lock the spring to
4. Remove the covers from the hubs.
completely release the brake. Verify that no air pressure
remains in the service chamber before you proceed. Sudden NOTE: Install only the axle shaft(s) shown in Table AD at this time.
release of compressed air can cause serious personal injury These axle shafts have a double row of splines that engage with
and damage to components. splines of the side gear and shift collar in the main differential.
Figure 11.1.
Engage the parking brake to prevent the vehicle from moving
before you begin maintenance or service procedures that 5. Install the gasket, if used, and axle shaft into the axle housing
require you to be under the vehicle. Serious personal injury and carrier in the same location. The gasket and flange of the
can result. axle shaft must be flat against the hub. Rotate the axle shaft or
the driveline as necessary to align the splines and the holes in
CAUTION the flange with the studs in the hub. Figure 11.1.
If the vehicle is equipped with a front drive axle, tow the
앫 If a gasket is not available: Apply a 0.125-inch (3 mm)
vehicle from the front, with the front wheels off the ground. If
diameter bead of grey sealant, Meritor specification
this is not possible, you must remove the front drive shaft
2297-H-2054, around the mating surface of the hub and
before towing. Damage to components can result.
around the edge of each fastener hole. Install the axle shaft
into the axle housing and carrier.
Do not use a chisel or wedge to loosen the axle shaft and
tapered dowels. A chisel or wedge can result in damage to the
axle shaft, the gasket and seal, and the axle hub.
4
8. Unlock or disengage the DCDL by removing the manual
engaging capscrew from the shift assembly.
9. Install the manual engaging capscrew into the storage hole.
The storage hole is located in the carrier next to the cylinder.
5
Tighten the capscrew to 40-50 lb-in (5-7 N폷m). @
10. Connect the air hose to the shift cylinder. Tighten the air hose
6
to 22-30 lb-ft (30-40 N폷m). @
7 11. Install the remaining axle shaft into the axle housing and
8
1002609c
carrier.
Table AD:
Tandem Axles
Forward Axle
Install the roadside, axle shaft
6. Install the dowels, if used, over each stud and into the tapered
holes of the flange.
7. Install the washers and stud nuts. Determine the size of the
fasteners and tighten the nuts to the corresponding torque
value shown in Table AE.
Troubleshooting
12 Diagnostics
Visually inspect
the carrier
Check for further carrier
in the axle
damage. If none is found,
housing.
Damaged or Yes repair or replace the oil
contaminated? pump, clean or replace
Remove the the oil screen and install
carrier from the the carrier. Refer to
Yes axle housing. Sections 3 and 5.
Damaged? Repair the carrier No
or install a
remanufactured Inspect the inter-axle differential
No carrier. assembly for damage. Refer to
TP-9955, Failure Analysis for
Drive Axle Components.
Drain and inspect
the lubricant. Check for further carrier
Refer to MM 1. damage. If none is found,
replace the damaged
Yes
Damaged? inter-axle differential
components and install the
carrier. Refer to Sections
No 3 and 5.
Yes Determine the
Contaminated? source of
contamination. Disassemble the
inter-axle
differential case.
No
Remove the
carrier from the Inspect the inter-axle differential
housing. Refer to spider, side gears and bearings.
Section 3. Refer to TP-9955,
Failure Analysis for Drive
Axle Components.
No
Repair the carrier
or install a
Yes remanufactured
Damaged? Inspect the main differential
carrier. bearings for damage.
Refer to Sections Refer to TP-9955,
3 and 5. Failure Analysis for
No
Drive Axle Components.
Remove and
disassemble the input Repair the carrier
shaft and inter-axle differential Yes or install a
assembly. Refer to Section 3. Damaged? remanufactured
carrier. Refer to
Sections 3 and 5.
No
Figure 12.1
Figure 12.2
Yes or install a
Damaged? remanufactured
carrier.
Refer to Sections
No 3 and 5. Install the carrier.
Refer to Section 5.
Test drive the vehicle.
Disassemble the Return the vehicle to service.
main differential.
Refer to Section 3.
Reassemble and
install the main
differential.
Refer to Section 5.
Figure 12.2
Visually inspect
the carrier in
the axle housing.
Check for further carrier
damage. If none is found,
Remove the Damaged or Yes repair or replace the
carrier from the contaminated? oil pump, clean or replace
Yes axle housing. the oil screen and install
Damaged? Repair the carrier the carrier. Refer to
or install a Sections 3 and 5.
remanufactured No
No carrier.
Figure 12.3
Figure 12.4
Install a new
multi-lip seal.
Repair the carrier
Yes or install a
Damaged? remanufactured
carrier. Refer to
Sections 3 and 5. Set the input shaft
No end play to the
correct specification.
Refer to Section 5.
Disassemble the
main differential.
Refer to Section 3.
Install the carrier.
Refer to Section 5.
Test drive the vehicle.
Return the vehicle to service.
Inspect the main
differential case, side
gears and spider for
damage. Refer to TP-9955,
Failure Analysis for Drive
Axle Components.
Figure 12.4
Oil Leak
Figure 12.5
Visually inspect
the carrier in the
axle housing.
Drain and inspect
Remove the carrier the lubricant.
from the axle housing. Refer to MM 1.
Yes Repair the carrier or
Damaged? install a
remanufactured
carrier. Refer to
No Sections 3 and 5. Remove the carrier
from the axle housing.
Refer to Section 3.
Inspect the
breather.
No
Install the carrier.
Refer to Section 5.
Inspect the
input shaft seal
for leaks.
No
Test drive the vehicle
Fill the carrier with to confirm that the
the correct amount leak is repaired. Return
Inspect the ouput
of the specified the vehicle to service.
shaft seal for
lubricant.
leakage.
Refer to Section 7.
Clean the seal area.
Figure 12.5
Visually
inspect the
lubricant.
Yes
Remove the
carrier from
Test drive the the axle. Refer to
vehicle to confirm Section 3.
that the leak is
repaired. Return the
vehicle to service.
Figure 12.6