Sie sind auf Seite 1von 113

Maintenance Manual MM-0970

MT-14X Series Single-Reduction Forward


Differential Carriers on Tandem Axles
Revised 07-12
Service Notes

About This Manual How to Obtain Additional Maintenance,


This manual provides service and repair procedures for Meritor Service and Product Information
MT-14X Series single-reduction forward differential carriers on Visit Literature on Demand at meritor.com to access and order
tandem axles. additional information.
Contact the OnTrac Customer Service Center at 866-668-7221
Before You Begin (United States and Canada); 001-800-889-1834 (Mexico); or email
1. Read and understand all instructions and procedures before OnTrac@meritor.com.
you begin to service components.
2. Read and observe all Warning and Caution hazard alert If Tools and Supplies are Specified in
messages in this publication. They provide information that can This Manual
help prevent serious personal injury, damage to components,
Contact Meritor’s Commercial Vehicle Aftermarket at
or both.
888-725-9355.
3. Follow your company’s maintenance and service, installation,
and diagnostics guidelines.
4. Use special tools when required to help avoid serious personal
injury and damage to components.

Hazard Alert Messages and Torque


Symbols
WARNING
A Warning alerts you to an instruction or procedure that you
must follow exactly to avoid serious personal injury and
damage to components.

CAUTION
A Caution alerts you to an instruction or procedure that you
must follow exactly to avoid damage to components.

@ This symbol alerts you to tighten fasteners to a specified torque


value.

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12)


Contents

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

MT-14X SERIES DIFFERENTIAL CARRIER


18
17
16
15
14
13
12
11

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

Meritor Maintenance Manual MM-0970 (Revised 07-12) 1


1 Exploded Views

Item Description Item Description


1 Input Shaft Locknut 36 Helical Drive Gear
2 Flat Washer 37 Thrust Bearing
3 Input Yoke 38 Needle Bearing Assembly
4 Deflector 39 Pinion Gear
5 Oil Seal 40 Bearing Cone
6 Bearing Adjusting Ring 41 Bearing Cup
7 Bearing Cup 42 Drive Pinion Shims
8 Bearing Cone 43 Drive Pinion Spacer
9 Capscrew 44 Helical Driven Gear
10 Adjusting Ring Lock Plate 45 Pinion Bearing Shim Spacer
11 Front Cover 46 Bearing Cup
12 Oil Pump Gear Assembly 47 Bearing Cone
13 Oil Pump Plate 48 Pinion Nut Washer
14 Flat Washer 49 Pinion Locknut
15 Capscrew 50 Differential Lock Switch
16 Clutch Collar 51 Carrier Housing
17 Shift Fork 52 Hardened Washer
18 Input Shaft 53 1.75-inch Capscrew
19 Pressure Relief Valve 54 Shift Spring
20 Spring 55 Shims
21 Sealing Ring Washer 56 Shift Pushrod
22 Pressure Relief Plug 57 Piston O-Ring
23 Hardened Washer 58 Piston
24 Capscrew 59 Housing O-Ring
25 Oil Screen and Plug Assembly 60 Tapered Dowel
26 Oil Dam Baffle 61 2.25-inch Capscrew
27 Hardened Washer 62 Washer
28 Capscrew 63 Nut
29 Bearing Cup 64 Stud
30 Bearing Cone 65 DCDL Assembly
31 Differential Side Gear
32 Snap Ring
33 Inter-Axle Differential Case
34 Differential Spider
35 Differential Pinion Gear

2 Meritor Maintenance Manual MM-0970 (Revised 07-12)


1 Exploded Views

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

Item Description Item Description


1 Capscrew 18 Ring Gear-to-Flange Half Capscrew
2 Lock Plate 19 Differential Case Plain Half
3 Bearing Cap Capscrew 20 Plain Half-to-Flange Half Capscrew
4 Hardened Washer 21 DCDL Shift Collar, If Equipped
5 Bearing Cap DCDL (If Equipped)
6 Bearing Adjusting Ring 1 Shims
7 Bearing Cup 2 Shift Spring
8 Bearing Cone 3 Shift Fork
9 Differential Case Flange Half 4 Shift Pushrod
10 Locknut 5 O-Ring
11 Washer 6 Piston
12 Differential Washer 7 Gasket
13 Differential Side Gear 8 DCDL Cover
14 Differential Spider 9 Plug Cup
15 Pinion Gear 10 Washer
16 Thrust Washer 11 Capscrew
17 Ring Gear

Meritor Maintenance Manual MM-0970 (Revised 07-12) 3


1 Exploded Views

Figure 1.3

AXLE HOUSING WITH THRU-SHAFT

7 8

6 9
10
11
5
12
1
13
4
3
14
2
7
15
16
17
18 19

20
21

4007391b

Item Description Item Description


1 Short Axle Shaft 12 Tapered Snap Ring
2 Thru-Shaft Cage Assembly 13 Cup Spacer
3 Hardened Washer 14 Oil Seal Assembly
4 Capscrew 15 Breather Hose
5 Thru-Shaft 16 Breather
6 Bearing Cone 17 Oil Fill Plug
7 Bearing Cup 18 Magnetic Fill Plug (Optional)
8 Output Yoke 19 Long Axle Shaft
9 Locknut 20 Magnetic Plug
10 Flat Washer 21 Housing
11 Thru-Shaft Snap Ring Spacer

4 Meritor Maintenance Manual MM-0970 (Revised 07-12)


2 Introduction

Description Optional Pressurized Lubrication System


2 Introduction

The forward axles can be equipped with an optional pressurized


Forward Tandem Axle lubrication system. This system has an oil pump driven by the input
The Meritor MT-14X Series forward tandem axles use a shaft. The pump circulates lubricant to the journals in the forward
single-reduction, thru-drive carrier. The drive gearing is a input shaft bearings and directly to the inter-axle differential.
two-helical gear train and an amboid ring gear and pinion. Bevel
gears are used in the main differential and the inter-axle differential. Optional Driver-Controlled Main Differential
Figure 2.1 and Figure 2.2. Lock (DCDL)
The inter-axle differential is located behind the helical gear on the The forward axle can be equipped with an optional driver-controlled
input shaft. The forward side gear of the inter-axle differential is part main differential lock (DCDL). The differential lock is operated by an
of the upper helical gear hub. The thru-shaft is splined to the rear air-actuated shift unit located on the forward axle carrier.
side gear of the inter-axle differential. Figure 2.1 and Figure 2.2.
앫 When the differential lock is activated, the shift collar moves
Figure 2.1
along the splines of the axle shaft toward the differential case.
DRIVE
HELICAL INTER-AXLE 앫 When the collar engages with the clutch teeth on the differential
GEAR DIFFERENTIAL case, the axle shaft and the differential assembly lock together.
INPUT
SHAFT THRU-SHAFT 앫 When the carrier operates with the DCDL in the locked position,
there is no differential action between the wheels.
앫 When the carrier is operated in the unlocked position, there is
normal differential action between the wheels at all times.
OIL
PUMP Inter-Axle Differential (IAD) Lock
RING
GEAR The Meritor inter-axle differential (IAD) lock is a driver-controlled,
DRIVEN DRIVE air-actuated traction device. The IAD allows for speed differences
HELICAL PINION
GEAR 1002702d between the forward and rear axles in a tandem while also providing
equal pulling power from each axle of the tandem. By activating the
OIL PUMP MODEL
IAD switch located in the vehicle dash, improved traction is provided
Figure 2.1 for each axle.
The inter-axle differential is also known as a power divider or third
differential.
Figure 2.2

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

Meritor Maintenance Manual MM-0970 (Revised 07-12) 5


2 Introduction

Use of Traction Chains Figure 2.4

Meritor recommends that if you are using traction chains, you


should install chains on both tires on each side of all drive axles on
the vehicle.

Identification
CARRIER PART NO.
CUSTOMER NO.

Model Number SERIAL NO.


RATIO

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

AXLE IDENTIFICATION TAG INFORMATION

Model No. . . . . . . . . . . . . . . . . . . .
Customer No. . . . . . . . . . . . . . . . .

Serial No. . . . . . . . . Plant . . . . . . . .


Ratio . . . . . . . . . . . .

IDENTIFICATION TAG

LOCATION OF THE IDENTIFICATION TAG, OR STAMP


NUMBER, FOR THE AXLES. LOCATION IS
DETERMINED FROM THE LEFT DRIVER SIDE
LOOKING TOWARD THE FRONT OF THE VEHICLE.
FRONT ENGINE DRIVE — RIGHT REAR,
NEXT TO COVER

4008141a

Figure 2.3

6 Meritor Maintenance Manual MM-0970 (Revised 07-12)


2 Introduction

Figure 2.5

Meritor MS/MT-14X Drive Axle Model Nomenclature


Housing Wall
0 = Cast
1 = TBD
2 = 0.31 in. (8 mm)
3 = 0.37/0.39 in. (9.5/10.0 mm)
GAWR 4 = 0.43 in. (11 mm)
xx = GAWR (000) Pounds or Tons 5 = 0.50/0.51 in. (12.7/13.0 mm)
(dependent on mfg. location) 6 = 0.56 in. (14.3 mm)
7 = TBD
8 = 0.63 in. (16 mm)
9 = TBD
Axle Model Type Relative Gearing
Size or Series
S= Single Rear (Solo) Carrier Variation
X= Front Drive Steer 0 = No Gearing A = Aluminum
D= Fwd Rear w/IAD 1 = 292/347 B = Aluminum/Ductile Amboid (Tandem Split)
N= Fwd Rear less IAD 2 = 337/387 C = Ductile/Ductile Amboid (Tandem Split)
P= Fwd Rear w/Pump 3 = TBD D = Ductile Rear, Hyboid
R= Rear Rear 4 = 381/432 E = Aluminum/Ductile (Tandem Split)
T= Tandem Drive 5 = 415/432 F = Ductile Amboid/Ductile Hypoid (Tandem Split)
Z= Tridem Drive 6 = 432/457 M= Ductile Rear, Amboid
C= Coach 7 = 457 N= No Carrier
H= High Entry 8 = 460/498 R = Ductile Front Drive Axle Carrier, Right Hand

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

Axle Type Ratio 1


0 = No Carrier
MFG Location
M = Meritor 1 = Single Speed
A = Australia/Asia/Africa
2 = Two Speed
E = Europe
3 = Helical Double Reduction
N = North America
4 = Salisbury
S = South America Specification Number
5 = Planetary Double Reduction
T = Telma Retarder
6 = Planetary Hub Reduction Includes: TRACK, PARKING
(U.S.A.)
7 = Portal BRAKE, OTHER.
8 = Bevel Hub Reduction
9 = Single Speed with Torque
Output Limited Engine Brake Type
B = “B” Frame Brake
Main Differential Nest Type C = Air Disc Brake
A = DCDL/Standard (Tandem Wheel End/Brake Attachment D = Wedge Brake, Dual Air Chambers
Split) A = Conventional Spindle/Conventional E = Wedge Brake, Dual Hydraulic
B = Special Differential Brake Cylinders
C = Driver Controlled Differential E = Unitized Spindle/Conventional Brake F = Wedge Brake, Single Hydraulic
Lock — DCDL J = Conventional Spindle/Integral Brake Cylinder
D = DCDL/NoSPIN® (Tandem L = Conventional L Spindle/Conventional G = DuraPark® Hydraulic Drum
Split) Brake H = Quadraulic™ Disc
E = Standard/DCDL (Tandem N = Unitized Spindle/Integral Brake K = DiscPlus™ Air Disc
Split) R = Conventional R Spindle/Conventional L = Q Plus™ Cam Brake
F = Standard Differential Brake N = None
G = Standard/NoSPIN® S = Bolt on Conventional Spindle/ P = “P” Series Cam Brake
(Tandem Split) Conventional Brake Q = “Q” Series Cam Brake
H = High Traction Differential R = Cast Plus™ Brake
J = NoSPIN®/DCDL (Tandem NOTE: The term “Tandem Split” refers to S = Wedge Brake, Single Air Chamber
Split) when there is a difference between the T = “T” Series Cam Brake
Forward axle and Rear axle of the Tandem V = Simplex Air Cam Brake
K = NoSPIN®/Standard (Tandem
or Tridem axle set when the Tandem or W = “W” Series Cam Brake
Split)
Tridem axle set part number is used. The Z = Non-Meritor Brake
L = No Differential value to the left of the “/” references the
N = NoSPIN® Forward axle, and the number to the right
of the “/” references the Rear axle. For
information related to the Middle axle of a
Tridem axle set part number, refer to the
Bills of Material.
4007403b

Figure 2.5

Meritor Maintenance Manual MM-0970 (Revised 07-12) 7


3 Removal and Disassembly

Hazard Alert Messages


3 Removal and Disassembly

Tool Part Number Manufacturer


Read and observe all Warning and Caution hazard alert messages in Axle Shaft K-1280 Kiene Diesel
this publication. They provide information that can help prevent Remover Accessories, Inc.
serious personal injury, damage to components, or both. Axle Stud Cone 7077 SPX OTC
Plier
WARNING
To prevent serious eye injury, always wear safe eye protection Brass Drift Method
when you perform vehicle maintenance or service.
WARNING
Use a brass or synthetic mallet for assembly and disassembly Do not strike the round driving lugs on the flange of an axle
procedures. Do not hit steel parts with a steel hammer. Pieces shaft. Pieces can break off and cause serious personal injury.
of a part can break off. Serious personal injury and damage to
components can result. 1. Hold a 1-1/2-inch diameter brass drift or brass hammer
against the center of the axle shaft, inside the round driving
Observe all warnings and cautions provided by the press lugs. Figure 3.1.
manufacturer to avoid damage to components and serious
personal injury. Figure 3.1

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.

8 Meritor Maintenance Manual MM-0970 (Revised 07-12)


3 Removal and Disassembly

Figure 3.2 Figure 3.3

STUD TAPERED DOWEL, ROUND HAMMER


NUT IF EQUIPPED BIT BETWEEN HUB
GASKET STUD STUDS
WASHER

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 9


3 Removal and Disassembly

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

22 3. Remove the thru-shaft nut, washer and yoke or flange. Use a


24
23 puller tool to remove the yoke or flange from the shaft.
1002984e
Figure 3.6.
1 FULL-ROUND BEARING CUPS 14 U-JOINT CROSS
2 END YOKE 15 CAPSCREWS
3 YOKE SADDLE 16 END YOKE
4 WELD YOKE 17 WELD YOKE
5 BEARING STRAP 18 SLIP YOKE
6 CAPSCREWS 19 U-JOINT CROSS
7 EASY SERVICE™ BEARING CUPS 20 CAPSCREWS
8 U-JOINT CROSS 21 END YOKE
9 SLIP YOKE 22 SLIP YOKE
10 CAPSCREWS 23 TUBING
11 END YOKE 24 U-JOINT CROSS
12 WELD YOKE 25 WELD YOKE
13 SLIP YOKE
Figure 3.4

10 Meritor Maintenance Manual MM-0970 (Revised 07-12)


3 Removal and Disassembly

Figure 3.6 Figure 3.8

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

the axle housing. If necessary, loosen the cage from the


housing with a soft mallet. Figure 3.7. 4. Remove all but the top two carrier-to-housing capscrews or
stud nuts and washers. Figure 3.8.
5. Loosen, but do not remove, the top two carrier-to-housing
Figure 3.7

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 11


3 Removal and Disassembly

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

3. Remove the snap ring from the bearing cage assembly.


4. Install the thru-shaft assembly into a press with the threaded
end DOWN and the bearing cage resting on the press. Press
down on the shaft end until the bearing cones, cup spacer and
outer bearing cup are free from the bearing cage.
1002715d
5. Use a bearing cup remover or other suitable tool to remove the
Figure 3.9 inner bearing cup from the bearing cage.
6. Install the thru-shaft in a press with the threads facing UP. Use
Disassembly a suitable tool or fixture to support the bearing cones. Press
down on the shaft until the bearing cones are free from the
Thru-Shaft and Output Bearing Cage shaft.
1. Remove and discard the oil seal.
2. Remove the thru-shaft snap ring spacer from the thru-shaft.
Figure 3.10 and 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

12 Meritor Maintenance Manual MM-0970 (Revised 07-12)


3 Removal and Disassembly

Removal Figure 3.13

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

1 OIL SEAL 11 INPUT SHAFT


6 2 BEARING ADJUSTING RING 12 NEEDLE BEARING ASSEMBLIES
3 3 BEARING CUP 13 THRUST BEARING
18 4 CAPSCREW 14 HELICAL GEAR
2 19
5 LOCK PLATE 15 BEARING CONE
1 20 6 COVER 16 REAR SIDE GEAR
21 7 OIL BAFFLE FLANGE 17 SNAP RING
12 13 22 8 WASHER 18 IAD CASE
1002732c
9 CAPSCREW 19 PINION GEAR
1 OIL SEAL 13 INPUT SHAFT 10 BEARING CONE 20 SPIDER
2 BEARING ADJUSTING RING 14 NEEDLE BEARING ASSEMBLIES NON-PUMP MODEL
3 BEARING CUP 15 THRUST BEARING
Figure 3.13
4 CAPSCREW 16 HELICAL GEAR
5 LOCK PLATE 17 BEARING CONE
6 BEARING CONE 18 REAR SIDE GEAR 1. Rotate the carrier in the stand to access the input yoke.
7 COVER 19 SNAP RING
8 OIL PUMP GEARS 20 IAD CASE
Figure 3.14.
9 OIL PUMP PLATE 21 PINION GEAR
10 WASHER 22 SPIDER Figure 3.14

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 13


3 Removal and Disassembly

Figure 3.15 Figure 3.17

ADJUSTING SEAL PRY


RING TOOL

1002725c 4008186a

Figure 3.15 Figure 3.17

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.

14 Meritor Maintenance Manual MM-0970 (Revised 07-12)


3 Removal and Disassembly

Figure 3.19 Figure 3.21

1002723d 1002723c

Figure 3.19 Figure 3.21

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

cover is free from the input shaft. Figure 3.20. Remove


the cover. Remove all gasket material from the cover. 7
1002743c
E. If necessary, remove the bearing cup and cone from the
cover. Figure 3.12. 1 HOUSING O-RING
2 PISTON
7. For non-pump models, use the following procedure to remove 3 PISTON O-RING
4 SHIFT SHAFT
the cover. 5 SHIMS
6 CLUTCH COLLAR
A. Remove the capscrews and washers that fasten the cover
7 SHIFT FORK
to the carrier housing. Remove the cover. Remove all 8 SPRING
gasket material from the cover. Figure 3.21. IAD SHIFT ASSEMBLY
Figure 3.22

Meritor Maintenance Manual MM-0970 (Revised 07-12) 15


3 Removal and Disassembly

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

TOOL PART NUMBER


A3256L1234

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

fork out with the clutch collar. Figure 3.25.


REAR SIDE
Figure 3.25 GEAR
TOOL PART NUMBER
A3256L1234

COLLAR
SPRING
COMPRESSION
TOOL

1002818c

Figure 3.27
SHIFT FORK 4008154c

Figure 3.25

16 Meritor Maintenance Manual MM-0970 (Revised 07-12)


3 Removal and Disassembly

CAUTION Figure 3.29

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

1 OIL SEAL 13 INPUT SHAFT


2 BEARING ADJUSTING RING 14 NEEDLE BEARING ASSEMBLIES
3 BEARING CUP 15 THRUST BEARING
1002731c
4 CAPSCREW 16 HELICAL GEAR
5 LOCK PLATE 17 BEARING CONE
Figure 3.28
6 BEARING CONE 18 REAR SIDE GEAR
7 COVER 19 SNAP RING
Disassembly 8
9
OIL PUMP GEARS
OIL PUMP PLATE
20
21
IAD CASE
PINION GEAR
10 WASHER 22 SPIDER
Input Shaft and Inter-Axle Differential 11 CAPSCREW
12 OIL SCREEN AND PLUG
1. Remove the snap ring that fastens the inter-axle differential ASSEMBLY
assembly to the input shaft. Remove the inter-axle differential OIL PUMP MODEL
assembly from the input shaft. Figure 3.29, Figure 3.30 and Figure 3.29
Figure 3.31.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 17


3 Removal and Disassembly

Figure 3.30 Figure 3.32

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

7 OIL BAFFLE FLANGE 17 SNAP RING


8 WASHER 18 IAD CASE PRESS
9 CAPSCREW 19 PINION GEAR
10 BEARING CONE 20 SPIDER
NON-PUMP MODEL
Figure 3.30

Figure 3.31

SNAP RING INPUT SHAFT


4008144a
INTER-AXLE
DIFFERENTIAL Figure 3.33

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.

18 Meritor Maintenance Manual MM-0970 (Revised 07-12)


3 Removal and Disassembly

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

1002722d Figure 3.35

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

앫 If the smallest of the three measurements is not


0.008-0.018-inch (0.20-0.46 mm): Replace the ring gear
and drive pinion as a set. THREADED HOLES
IN CAP
Main Differential Case and Ring Gear
1. Rotate the carrier in the stand until the ring gear is toward you.

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.

5. Use an adjusting ring tool or equivalent tool to loosen the


adjusting rings. Figure 3.37.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 19


3 Removal and Disassembly

Figure 3.37 Figure 3.39

ADJUSTING
RING TOOL

ADJUSTING
RING OPPOSITE
RING GEAR 1002747d 1002749h

Figure 3.37 Figure 3.39

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

REAR SIDE GEAR


7. Remove the bearing caps, adjusting rings and bearing cups BEARING CUP
from the differential carrier. Figure 3.38.

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.

20 Meritor Maintenance Manual MM-0970 (Revised 07-12)


3 Removal and Disassembly

Figure 3.41 Figure 3.43

THRUST
PULLER WASHER

PRESS SIDE
SPIDER, PINIONS
GEAR
AND THRUST
WASHERS

1002750c

Figure 3.41

Disassembly 1002752c

Main Differential Case and Ring Gear Figure 3.43

1. Measure and record the gear set backlash. Refer to Measure


Ring Gear Backlash in this section. Removal
2. Use a punch and hammer to mark the case halves. The marks Ring Gear from the Differential Case
will help you correctly align the case halves during assembly.
Figure 3.42. 1. For SFR gear set ratios 2.47 and 2.64, remove the bolts from
the flange side of the differential case. For all other gear set
Figure 3.42 ratios, remove the bolts, washers and nuts that fasten the ring
gear to the differential case.
MARKS ON
BOTH HALVES
OF THE
2. Use a brass hammer, dead blow hammer or press to remove
DIFFERENTIAL the ring gear from the differential case. Take care not to
ASSEMBLY damage the ring gear teeth.
CASE
3. Inspect the hypoid ring gear set for damage. If it is not
damaged, you can reuse the ring gear set at assembly.
Inspect the hypoid ring gear set for damage. If it is not damaged,
you can reuse the ring gear set at assembly. Measure and record
the gear set backlash. Refer to Measure Ring Gear Backlash in this
1002751c
section.
Figure 3.42
Drive Pinion
3. Remove the capscrews that fasten the halves of the main 1. Install a block of wood between the pinion gear teeth and the
differential together. carrier to keep the pinion from rotating. Remove the nut and
4. Remove the spider, pinions, thrust washers and side gears washer from the drive pinion. Figure 3.44.
from the separated case assembly. Figure 3.43.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 21


3 Removal and Disassembly

Figure 3.44 Figure 3.46

4 5 6

2 3
1

11
10
9
8
7
1002724c 1002755c

Figure 3.44 1 NUT 7 INNER SPACER


2 WASHER 8 SHIMS
3 OUTER BEARING CONE 9 INNER BEARING CUP
2. Remove the drive pinion from the carrier. 4 OUTER BEARING CUP 10 INNER BEARING CONE
5 OUTER SPACER 11 DRIVE PINION
A. Place the differential carrier into a press so that the 6 HELICAL DRIVEN GEAR
threaded end of the drive pinion is facing UP. Place Figure 3.46
supports under the carrier mounting flange.
B. Place a protector onto the top of the drive pinion shaft. CAUTION
Figure 3.45.
If you replace either the bearing cup or the cone, replace both
parts in a fully-matched set from the same manufacturer. Do
Figure 3.45

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

Figure 3.45 INNER


BEARING
CUP
CAUTION
The drive pinion must not fall on the floor when the drive
pinion is pressed from the carrier. If the drive pinion falls to the
floor, the gear teeth may be damaged.

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.

22 Meritor Maintenance Manual MM-0970 (Revised 07-12)


3 Removal and Disassembly

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

5. If necessary, remove the inner bearing cone from the drive


pinion. Place a bearing puller under the inner race to support
the bearing. Place a protector on top of the pinion shaft and
press the drive pinion out of the bearing cone. Figure 3.49.

Figure 3.49

PRESS

BEARING
PULLER

1002758b

Figure 3.49

Meritor Maintenance Manual MM-0970 (Revised 07-12) 23


4 Prepare Parts for Assembly

Hazard Alert Messages Clean, Dry and Inspect Parts


4 Prepare Parts for Assembly

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.

When you apply some silicone gasket materials, a small


amount of acid vapor is present. To prevent serious personal
injury, ensure that the work area is well-ventilated. Read the
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.

24 Meritor Maintenance Manual MM-0970 (Revised 07-12)


4 Prepare Parts for Assembly

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.

Yoke Seal Minimum Yoke Diameter


Dry Parts Immediately After Cleaning
Diameter at Groove (Inches)
3.000/3.005" 2.990" All Parts Except Bearings
3.250/3.255" 3.240"
Use soft, clean paper, cloth rags or compressed air to dry parts
1003390e immediately after cleaning.
A MINIMUM GROOVE DEPTH — DIAMETER Bearings
B YOKE SEAL DIAMETER
Figure 4.1
CAUTION
Use soft, clean paper or cloth rags to dry bearings immediately
Clean Ground and Polished Parts after cleaning. Do not use compressed air, which can damage
1. Use a cleaning solvent to clean ground or polished parts or the bearings when they are rotated and dried.
surfaces. Do not use gasoline.
Use soft, clean paper or cloth rags to dry bearings immediately after
2. Use a tool with a flat blade if required, to remove sealant cleaning. Do not use compressed air.
material from parts. Be careful not to damage the polished or
smooth surfaces. Prevent Corrosion on Cleaned Parts
1. Apply axle lubricant to cleaned and dried parts that are not
CAUTION
damaged and are to be assembled.
Do not use hot solution tanks or water and alkaline solutions to
clean ground or polished parts. Damage to parts can result. 2. To store parts, apply a special material that prevents corrosion
to all surfaces. Wrap cleaned parts in a special paper that will
3. Do not clean ground or polished parts with water or steam. Do protect the parts from moisture and prevent corrosion.
not immerse ground or polished parts in a hot solution tank or
use strong alkaline solutions for cleaning, or the smooth Inspect Parts
sealing surface may be damaged.
It is very important to inspect all parts carefully and completely
before the axle or carrier is assembled. Check all parts for wear and
Clean Rough Parts replace damaged parts.
1. Clean rough parts with the same method as cleaning ground
1. Inspect the cup, cone, rollers and cage of all tapered roller
and polished parts.
bearings in the assembly. If any of the following conditions
2. Rough parts can be cleaned in hot solution tanks with a weak exist, replace the bearing.
or diluted alkaline solution.
앫 The center of the large-diameter end of the rollers is worn
3. Parts must remain in hot solution tanks until heated and level with or below the outer surface. Figure 4.2.
completely cleaned.
앫 The radius at the large-diameter end of the rollers is worn
4. Parts must be washed with water until all traces of the alkaline to a sharp edge. Figure 4.2.
solution are removed.
앫 There is a visible roller groove in the cup or cone inner race
surfaces. The groove can be seen at the small- or
large-diameter end of both parts. Figure 4.3.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 25


4 Prepare Parts for Assembly

앫 There are deep cracks or breaks in the cup, cone inner race Figure 4.4

or roller surfaces. Figure 4.3.


앫 There are bright wear marks on the outer surface of the
roller cage. Figure 4.4.
앫 There is damage on the rollers and on the surfaces of the
cup and cone inner race that touch the rollers. Figure 4.5.
앫 There is damage on the cup and cone inner race surfaces
that touch the rollers. Figure 4.6.
WEAR MARKS
Figure 4.2
1003019a

WORN RADIUS Figure 4.4

Figure 4.5

ETCHING AND PITTING

WORN SURFACE 1003017b

Figure 4.2 1003020a

Figure 4.5
Figure 4.3

Figure 4.6

WEAR
CRACK
GROOVES

SPALLING AND FLAKING

1003018b 1003021b

Figure 4.3 Figure 4.6

2. Inspect the needle bearing assemblies for damage and replace


if necessary.

26 Meritor Maintenance Manual MM-0970 (Revised 07-12)


4 Prepare Parts for Assembly

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.

CAUTION C. Apply compressed air to the breather.


When you need to replace a thrust washer, differential side 앫 If compressed air does not pass through the
gear or pinion gear, you must replace all of these parts with a breather: Replace the breather.
new set. Do not mix old and new parts. Damage to
components can result. D. Install the breather into the axle housing.

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

DIFFERENTIAL Remove silicone


CASE HALVES gasket from parts.

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

Meritor Maintenance Manual MM-0970 (Revised 07-12) 27


4 Prepare Parts for Assembly

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

Do Not Bend or Straighten a Damaged Drive


Axle Housing
WARNING
Replace damaged or out-of-specification axle components. Do
not bend, repair or recondition axle components by welding or
FOUR TO
heat-treating. A bent axle beam reduces axle strength, affects FIVE DROPS
vehicle operation and voids Meritor’s warranty. Serious ON BORE
THREADS
personal injury and damage to components can result. 1003025a

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.

28 Meritor Maintenance Manual MM-0970 (Revised 07-12)


4 Prepare Parts for Assembly

Figure 4.10 Figure 4.11

Cleaning the housing face with a rotary


tool and a scour pad.

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.

8. If you reuse the carrier-to-housing capscrews, use a rotary


wire brush to remove any threadlocker material and clean the
capscrew threads. Use a clean cloth to wipe the threads.
0.25" (6 MM)
9. Use a tap to clean the internal threads in the housing.
4000623b

CAUTION Figure 4.12


Apply silicone gasket material in a continuous 0.25-inch
(6 mm) bead. If you use more than this amount, gasket 14. Install the capscrews. Use a crossing pattern to tighten the
material can break off and plug lubrication passages. Damage capscrews evenly. The capscrews must be tightened within 10
to components can result. minutes of initial application of Loctite 242 threadlocker.

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 29


4 Prepare Parts for Assembly

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.

1003031c Table D: Pinion Cone Variation Number


1 PART NUMBER, TOOTH COMBINATION NUMBER, GEAR SET MATCH Pinion Cone (PC) Drive Pinion Ring Gear
NUMBER, PINION CONE VARIATION NUMBER
2 PART NUMBER, TOOTH COMBINATION NUMBER
Variation Number Location Location
3 GEAR SET MATCH NUMBER, PINION CONE VARIATION NUMBER PC+3 At the end of the On the outer
4 PART NUMBER, TOOTH COMBINATION NUMBER, GEAR SET MATCH
NUMBER +2 pinion gear head diameter
5 PART NUMBER, TOOTH COMBINATION NUMBER, GEAR SET MATCH
NUMBER +0.01 mm
Figure 4.13 PC–5
–1
Examples –0.02 mm
Table A: Gear Set Part Numbers
Part Number Location Check for Mismatched Ratios on
Conventional ring XXXXX, XXXXXK2, On the front face Tandem Axles
gear XXXXXK3, or outer diameter For a tandem axle pair to function correctly, the forward and rear
XXXXXK4, axles must operate with axle ratios within one percent. A
XXXXXK5 mismatched tandem axle pair can cause carrier overheating, gear
Conventional drive XXXXX, XXXXXK2, At the end at set wear, metal debris to collect on the magnetic drain plug, carrier
pinion XXXXXK3, threads lubricant additive depletion, excessive inter-axle differential wear
XXXXXK4, and noise.
XXXXXK5 To determine if the tandem axle ratios operate within allowable
limits, refer to one of the following procedures. Perform the
procedure that will work best for the vehicle you are servicing.

30 Meritor Maintenance Manual MM-0970 (Revised 07-12)


4 Prepare Parts for Assembly

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.

1. Park the vehicle on a level surface.


AL NO.
RATI
O

2. Engage the inter-axle differential and shift the transmission into


NEUTRAL.
CARRIER PART NO.
1 CUSTOMER NO. 2 3. Block the wheels to prevent the vehicle from moving.
SERIAL NO.
RATIO
1003452c 4. Use a jack to raise the vehicle until all the tandem drive axle
wheels clear the ground. Support the vehicle with safety
1 FORWARD
2 REAR stands.
Figure 4.14 5. Mark the forward and rear tires at identical relative positions.
Figure 4.15.
2. Compare the axle ratios shown on the tags. To operate
correctly, the axle ratios for both axles must be within one Figure 4.15

percent of each other. To calculate the percentage difference


between the axle ratios, refer to the equation in Table E.

Table E:

Larger Ratio – Smaller


Ratio Percentage Difference
X 100 =
Between Axle Ratios
Smaller Ratio
MARKS MARKS 1003453a

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 31


4 Prepare Parts for Assembly

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

1. Park the vehicle on a level surface.


7. Note the positions of the tire marks you previously made. On a
correctly matched tandem axle gear set, both tire marks will be 2. Block the wheels to prevent the vehicle from moving.
within ± 3.6 degrees of each other. Figure 4.17.
To Identify the Gear Teeth Number on the Forward
앫 If the positions of the tire marks are more than 3.6 Axle Drive Pinion
degrees from each other: Refer to the vehicle
1. Remove the forward carrier cover. Refer to the procedure in
manufacturer for further information.
Section 3.
Figure 4.17
2. Look into the carrier housing. Identify and record the gear set
If the mark appears in teeth numbers stamped on the drive pinion end. Figure 4.18.
the shaded area, the tandem
gear set is incorrectly matched. Figure 4.18

4
10 - 7

3.6 3.6

If the mark appears in


this area, the tandem axle LARGER NUMBER
= GEAR SET RATIO
SMALLER NUMBER
gear set is correctly matched. 1003456d
1003455a
Figure 4.18
Figure 4.17

3. Calculate the gear set ratio by dividing the larger number by


8. Remove the safety stands and lower the vehicle. the smaller number. Figure 4.18.

To Identify the Gear Teeth Number on the Rear Axle


Drive Pinion
1. Remove the inter-axle drive shaft. Refer to the procedure in
Section 3.

32 Meritor Maintenance Manual MM-0970 (Revised 07-12)


4 Prepare Parts for Assembly

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

RING GEAR TEETH = ACTUAL


PINION GEAR TEETH GEAR SET RATIO
1003458e
LARGER NUMBER
= GEAR SET RATIO Figure 4.20
SMALLER NUMBER 1003457c

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.

1. Park the vehicle on a level surface. Block the wheels to prevent


the vehicle from moving.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 33


4 Prepare Parts for Assembly

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.

Tire Matching for Tandem Axles


CAUTION
Unmatched tires on tandem drive units will cause tire wear
and scuffing and possible damage to the drive units. Meritor
recommends that the tires be matched to within 0.125-inch
(3.18 mm) of the same rolling radius, 0.75-inch (19.05 mm) of
the same rolling circumference.

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.

34 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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.

WARNING Drive Pinion Shim Pack Thickness


To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. NOTE: If the original gear set and shim pack are being installed, go
to the “dry fit” drive pinion assembly procedure in this section. If the
Take care when you use Loctite adhesive to avoid serious pinion depth shims are misplaced during carrier repair, use
personal injury. Read the manufacturer’s instructions before 0.030-inch (0.76 mm) for the initial pinion position and continue to
using this product. Follow the instructions carefully to prevent the “dry fit” drive pinion assembly procedure in this section. In all
irritation to the eyes and skin. If Loctite adhesive material other cases, continue with the following procedure. Figure 5.1.
gets into your eyes, follow the manufacturer’s emergency
procedures. Have your eyes checked by a physician as soon as
possible. Figure 5.1

BEARING
Observe all warnings and cautions provided by the press CUP
manufacturer to avoid damage to components and serious
SHIMS
personal injury.

To avoid serious personal injury and damage to components,


take care when using lifting devices during service and
maintenance procedures. Inspect a lifting strap to ensure that
it is not damaged. Do not subject the lifting straps to shocks or
drop-loading.
1002767b

Installation Figure 5.1

“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

pack thickness. The carrier is then disassembled and reassembled


using the helical gear, spacers and adjusted shim pack. If the drive
pinion is correctly adjusted, perform the “final” installation steps to
complete the installation.

Installing the Drive Pinion, Adjusting Pinion


Depth and Contact Pattern
The procedure in this manual is to perform a “dry fit” installation of
the pinion, bearings and calculated shim pack into the case
WITHOUT the helical gear and two spacers. You must also install the 1002764a
ring gear and set the backlash to 0.012-inch (0.3 mm). After you
check and adjust the tooth contact patterns to determine the correct Figure 5.2

Meritor Maintenance Manual MM-0970 (Revised 07-12) 35


5 Assembly and Installation

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

1003032d Old PC Number, PC +2 + 0.002 + 0.050


Standard Shim Pack Thickness = 0.032 = 0.810
Figure 5.3
New PC Number, PC –5 + 0.005 + 0.120
3. If you can’t find the PC number or it’s unreadable, install a new New Shim Pack Thickness = 0.037 = 0.930
shim pack of the same thickness that you measured in Step 1.
4. Old Shim Pack Thickness 0.030 0.760
4. If the old pinion cone number is a plus (+), ADD the cone Old PC Number, PC –2 – 0.002 – 0.050
number to the old shim pack thickness that was measured in
Standard Shim Pack Thickness = 0.028 = 0.710
Step 1.
New PC Number, PC –5 + 0.005 + 0.120
5. If the old pinion cone number is a minus (–), SUBTRACT the
cone number from the old shim pack thickness that was New Shim Pack Thickness = 0.033 = 0.830
measured in Step 1.
6. Find the pinion cone variation number on the new drive pinion Assembly
that will be installed. Record the number.
“Dry Fit”Assembly of the Drive Pinion to
7. If the new pinion cone number is a plus (+), SUBTRACT the Verify Shim Pack
number from the standard shim pack thickness that was
calculated in Step 4 or Step 5. Use new shims to make a shim NOTE: For initial assembly to verify the shim pack, the helical driven
pack to the determined thickness. Refer to Table F. gear and the spacers are not installed. For final assembly, the
8. If the new pinion cone number is a minus (–), ADD the number spacers and preload must be established and the helical driven gear
to the standard shim pack thickness that was calculated in installed.
Step 4 or Step 5. Use new shims to make a shim pack to the
determined thickness. Refer to Table F. 1. If you are installing a new ring gear and drive pinion, the
correct thickness of the shim pack between the pinion inner
bearing cup and the carrier must be determined. Refer to the
procedure in this section before temporarily assembling and
installing the drive pinion assembly according to this
procedure.

36 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

If you are installing the original ring gear and drive pinion, Figure 5.5

temporarily install the drive pinion assembly. BEARING


CUP
2. If removed, use a press and a sleeve to install the inner bearing
cone onto the drive pinion. Place the sleeve onto the inner race SHIMS
of the bearing. Apply pressure until the bottom of the cone
touches the shoulder on the pinion. Check to ensure the sleeve
does not contact the bearing roller cage during installation.
Figure 5.4.

Figure 5.4

PRESS
1002767b
AND SLEEVE
Figure 5.5
BEARING
ROLLER
CAGE
Figure 5.6

PRESS

1002766b

Figure 5.4

3. Apply axle lubricant to the bearing cups and cones. BEARING


CUP 1002768b
4. If removed, install the shim pack and the inner bearing cup of
the drive pinion. Figure 5.6

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 37


5 Assembly and Installation

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 5.8 4008143a

Figure 5.9

38 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

Figure 5.10 앫 If the gaps exceed specification at more than three


FLANGE points: Inspect the flange case half and ring gear for the
RING
CASE GEAR problem that causes the gap. Repair or replace parts as
HALF
necessary. Reassemble the ring gear on the flange case
BOLT HEAD half. Reinspect for gaps.
INSTALLED
FROM FRONT Figure 5.12

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

Bolts on Gear Set Ratios 320 ± 20 lb-ft 30 ± 5 lb-ft


8. Use a press and the correct size sleeve to install the bearing
2.47 and 2.64 (430 ± (40 ± 5 N폷m)
cones onto both of the case halves. Ensure the sleeve contacts
30 N폷m) plus 90 degrees
the inner race of the bearing during installation and does not
Nuts on All Other Gear 185 ± 25 lb-ft ± 5 degrees
contact the bearing roller cage. Figure 5.13.
Set Ratios (255 ± angle
35 N폷m) Figure 5.13

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

9. Apply axle lubricant on the inside surfaces of both case halves,


7. Inspect for gaps between the back surface of the ring gear and
spider or cross, thrust washers, side gears and differential
the flange of the differential case. Use a 0.001-inch
pinions.
(0.025 mm) feeler gauge to inspect at four points around the
assembly. Figure 5.12.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 39


5 Assembly and Installation

10. Place the flange case half onto a bench with the ring gear teeth Figure 5.16

toward the TOP.


11. Install one thrust washer and side gear into the flange case THRUST
WASHER
half. Figure 5.14.
SIDE GEAR
Figure 5.14
PLAIN
CASE
SIDE HALF
GEAR

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

12. Install the spider or cross, differential pinions and thrust


washers into the flange case half. Figure 5.15. PLAIN
CASE
Figure 5.15
HALF

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.

40 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

Figure 5.18 Figure 5.20

CRISSCROSS TIGHTENING PATTERN


15 1
11 5
9
7
TOOL FOR
3 13 CHECKING
RESISTANCE

14 4

8
10
12
6
16 1003072i
2 4008145a

Figure 5.18 Figure 5.20

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)

SIDE Read torque


VIEW
value.

END WELD NUT


VIEW TO END
OF SHAFT 1003071c

Figure 5.19

2. Place the differential and ring gear assembly flat on a work 1003073e
bench. Figure 5.20.
Figure 5.21

Meritor Maintenance Manual MM-0970 (Revised 07-12) 41


5 Assembly and Installation

Installation Figure 5.23

“Dry Fit” Installation of the Main Differential


BEARING
Case and Ring Gear Assembly Into the CUP
Carrier BEARING
CUP
To carry out preliminary checks for drive pinion adjustments,
LEG
perform a “dry fit” installation of the differential and ring gear BORE
assembly. Do not lubricate, apply sealant or tighten the fasteners
completely. Once adjustments are made, also perform the “final”
installation steps to complete the procedure.
1002788e
1. If the bearing cones on the main differential case were
Figure 5.23
removed, install a new cone and cup in a fully-matched set
from the same manufacturer. The bearing cones are not
3. Use a lifting device to safely lift the differential and ring gear
interchangeable. Use a press and sleeve to install the cones
assembly and install it into the carrier. The bearing cups must
onto the case. Press only on the inner race of the bearing.
be flat against the bores between the carrier legs. Figure 5.23.
Figure 5.22.
4. Install the bearing adjusting rings between the carrier legs.
Figure 5.22

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.

42 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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

Adjustment of Pinion Shim Pack and


Backlash for Contact Pattern
1002790e

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

cross-threading can result.

6. Use a light leather plastic or rubber mallet to seat each bearing


cap. The caps must fit easily against the bearings, adjusting
rings and carrier. Do not force the bearing caps into position.
앫 If the bearing caps do not correctly fit into position:
Check the alignment of the match marks between the caps
and carrier. Remove the caps and repeat Step 4 through
Step 6.
7. Hand-tighten the adjusting rings against the bearing cups to 1003086e
position the ring gear to the pinion with 0.012-inch (0.3 mm) Figure 5.26
backlash. Refer to the backlash procedure in this section.
8. Install the capscrews and washers that secure the bearing 2. Adjust the dial indicator so that the plunger is against the tooth
caps to the carrier. Tighten the capscrews to 25 lb-ft (34 N폷m). surface.
@
3. Adjust the dial indicator to ZERO. Hold the drive pinion in
position.
4. After reading the dial indicator, rotate the differential and ring
gear a small amount in both directions against the drive pinion
teeth. Ensure the pinion is held in place to prevent rotation.
Refer to Table G.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 43


5 Assembly and Installation

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

Loosen adjusting Figure 5.29


ring this side.
The drive side of the 14X forward is the convex side of the ring gear.
Decrease backlash.
The drive side takes precedence over the coast side; but the coast
side should be evaluated as well. Figure 5.30.
Tighten adjusting Figure 5.30

ring this side.


1002796b TOE

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)

pinion bearing preload. 4008201a

Figure 5.30

44 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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

1003092d Figure 5.33

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 45


5 Assembly and Installation

Figure 5.35 Figure 5.38

HIGH PATTERN (BAD) SHORT AND EXTREME


TOE PATTERN (BAD)

CONVEX 4008134a CONVEX 4008137b

Figure 5.35 Figure 5.38

Figure 5.36 Figure 5.39

LOW PATTERN (BAD) SHORT AND EXTREME


HEEL PATTERN (BAD)

CONCAVE
4008135a CONVEX 4008138b

Figure 5.36 Figure 5.39

Figure 5.37 Figure 5.40

LOW PATTERN (BAD)

CONVEX SATISFACTORY PATTERN IN OPERATION


4008136a
1001095d
Figure 5.37
Figure 5.40

46 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

Figure 5.41 Figure 5.42

SATISFACTORY PATTERN IN OPERATION

CONVEX Increase shim pack.


4008139a 1002802b

Figure 5.41 Figure 5.42

4. Change the thickness of the shim pack between the pinion Figure 5.43

inner bearing cup and the differential carrier to move the


contact patterns between the top and the bottom of the gear
teeth.
A. Remove the drive pinion, inner bearing cup and shims
from the carrier. Refer to Section 3.
앫 To correct a high-contact pattern: Increase the
thickness of the shim pack. When you increase the
thickness of the shim pack, the drive pinion will move Decrease shim pack.
toward the ring gear. Figure 5.42. 1002803b
앫 To correct a low contact pattern: Decrease the
Figure 5.43
thickness of the shim pack. When you decrease the
thickness of the shim, the drive pinion will move away
NOTE: It may be necessary to repeat the pattern adjustment
from the ring gear. Figure 5.43.
procedure several times until the correct pattern is achieved.
B. Install the inner bearing cup, the shims and the drive
pinion into the carrier. Refer to the procedure in this 5. Adjust the ring gear backlash within the specification range to
section. move the contact patterns to the correct location along the
length of the gear teeth. Refer to the procedure in this section.
C. Repeat Step 1 through Step 4 until the contact patterns
are in the center between the top and bottom of the gear The toe-to-heel position of the contact pattern on a good
teeth. hand-rolled gear set is toe-center to center on the convex side
and center to center-heel on the concave side. Figure 5.32 and
Figure 5.33.
A. Decrease the backlash to move the convex pattern toward
the toe and concave pattern toward the heel. Figure 5.44.
B. Increase the backlash to move the convex pattern toward
the heel and the concave pattern toward the toe.
Figure 5.45.
C. Repeat Step 1 through Step 5 until the contact patterns
are at the correct location along the length of the gear
teeth.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 47


5 Assembly and Installation

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

Figure 5.45 OUTER


SPACER
BEARING
CONE
6. If the backlash and contact patterns are correct, mark the
position of the adjusting rings for use during the final
installation procedure. Remove the leg cap capscrews. Use an DRIVE
appropriate lifting device to remove the ring gear and PINION
SUPPORT
differential case assembly. SUPPORT

Installation 1002779e

“Final” Installation of the Drive Pinion and Figure 5.46

Bearing Preload Adjustment


1. Place the carrier into a press so that the threaded end of the
Use the shim pack and backlash established by the “dry fit” pinion is UP. Place supports under the flange of the carrier so
procedure for final assembly. that the carrier is level. Place a wood block under the head of
The preload of the bearings on the drive pinion is controlled by a the pinion. Figure 5.47.
spacer between the outer bearing cone and the helical driven gear. 2. Press the drive pinion out of the outer bearing cone. Remove
Adjust the preload by changing the size of the spacer. the cone. Figure 5.47.

앫 To decrease the preload: Use a thicker spacer.


앫 To increase the preload: Use a thinner spacer.
If the depth of the drive pinion is changed, the thickness of the
spacer must also be changed the same amount. Refer to the
following examples.

48 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 49


5 Assembly and Installation

Figure 5.50 Figure 5.51

PRESS – DO NOT SLEEVE PRESS – DO NOT


APPLY MORE THAN APPLY MORE THAN SLEEVE
TWO TONS (1814 KG) OUTER TWO TONS (1814 KG) OUTER
OF PRESSURE BEARING OF PRESSURE BEARING
CONE ROTATE/OSCILLATE CONE
HELICAL THE CARRIER SPACER
PIECES OF DRIVEN ABOUT THE PINION
GEAR AXIS AS THE CONE HELICAL
SOLDER DRIVEN
IS PRESSED ON THE
PINION GEAR
WOOD BLOCK – WOOD BLOCK – SPACER
MUST SUPPORT MUST TOUCH
HEAD OF PINION 1002775c HEAD OF
DRIVE PINION 1002776d
Figure 5.50
Figure 5.51

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.

50 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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 5.52 1002779e

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

Meritor Maintenance Manual MM-0970 (Revised 07-12) 51


5 Assembly and Installation

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

“Final” Installation of the Main Differential


Case and Ring Gear Assembly Into the
Carrier
1. Clean and dry the bearing cups and bores of the carrier legs
and bearing caps.
LEG
2. Apply axle lubricant to the bearing cones and inside surface of 1002789f
the bearing cups.
Figure 5.55

NOTE: Meritor specification 2297-P-3994 adhesive will dry in


approximately two hours. You must complete the procedure within CAUTION
two hours from the time you apply the adhesive. If two hours have Correctly install the bearing caps into their original locations
passed since application, clean the adhesive from the parts and on the carrier. Do not force the bearing caps into position,
apply new adhesive. which can damage the carrier. If the bearing caps are not
installed correctly, the bores and threads in the cap will not
3. Apply Meritor specification 2297-P-3994, Loctite 680 match the carrier. Damage to the adjusting rings by
adhesive or equivalent 360 degrees around the outside cross-threading can result.
diameter of the bearing cups. The adhesive must not contact
the adjusting ring threads. Refer to Section 4. 7. Install the bearing caps over the bearings and adjusting rings in
4. Install the bearing cups over the bearing cones in the case the correct location as marked before removal. Figure 5.56.
halves. Figure 5.54.
Figure 5.56

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.

52 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

WARNING Dial Indicator Method


Use a brass or synthetic mallet for assembly and disassembly 1. Attach a dial indicator onto the carrier mounting flange so that
procedures. Do not hit steel parts with a steel hammer. Pieces the plunger or the pointer is against the back surface of the
of a part can break off. Serious personal injury and damage to ring gear. Figure 5.57.
components can result.
Figure 5.57

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.

8. Use a light leather plastic or rubber mallet to seat each bearing


cap. The caps must fit easily against the bearings, adjusting 1003078e
rings and carrier. Do not force the bearing caps into position. Figure 5.57
앫 If the bearing caps do not correctly fit into position:
Check the alignment of the match marks between the caps
CAUTION
and carrier. Remove the caps and repeat Step 6 through
When you turn the adjusting rings, always use a tool that
Step 8.
engages two or more opposite notches in the ring. An
9. Hand-tighten the adjusting rings against the bearing cups to adjusting ring tool can be used for this purpose. If the tool does
position the ring gear to the pinion with 0.012-inch (0.3 mm) not correctly fit into the notches, damage to the lugs will occur.
backlash. Refer to the backlash setting procedure in this
section. 2. Use an adjusting ring tool to loosen the adjusting ring that is
opposite the ring gear. A small amount of end play will show on
10. Install the capscrews and washers that secure the bearing
the dial indicator. Figure 5.58.
caps to the carrier. Tighten the capscrews to 25 lb-ft (34 N폷m).
@ Figure 5.58

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 53


5 Assembly and Installation

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

B. Insert two pry bars between the differential case or the


ring gear and the carrier at locations other than described
in Step A. The pry bars must not touch the differential
bearings. Figure 5.60.

Figure 5.59

Tighten each
ring one notch.
1002794d

Figure 5.61

6. Proceed to check ring gear runout.


Bars must not Large Micrometer Method
touch bearings.
1. Hand-tighten the adjusting rings against the differential
bearings.
1003080h
2. Use a large micrometer to measure distance X and Y between
Figure 5.59 the opposite surfaces of the bearing caps. Record the
measurement. Figure 5.62 and Figure 5.63.
Figure 5.60

Figure 5.62

Bars must not


touch bearings.

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.

54 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

Figure 5.63 Table J: Expansion Between Bearing Caps


LARGE
MICROMETER
Required Deflection
Micrometer
Axle Series Size Inches Millimeters
120/125 12-13″ 0.008-0.013 0.15-0.33
140/145/ 13-14″ 0.002-0.009 0.05-0.23
14X
160/164 16-17″ 0.002-0.009 0.05-0.23
180/185 17-18″ 0.006-0.013 0.15-0.33
1003083h

Figure 5.63 Ring Gear Runout


1. Attach a dial indicator onto the carrier mounting flange.
CAUTION Figure 5.64.
When turning the adjusting rings, always use a tool that
engages two or more opposite notches in the ring. An Figure 5.64

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

4. Measure distance X and Y again. Compare the measurements


with the distances X and Y measured in Step 2. The difference
between the two distances is the amount the bearing caps
have expanded. Refer to Table I.
1003084g
Table I: Example
Figure 5.64
Distances X and Y BEFORE = 13.927-inches (353.75 mm)
tightening the adjusting rings
2. Adjust the dial indicator so that the plunger or pointer is against
Distances X and Y AFTER = 13.932-inches (353.87 mm) the back surface of the ring gear. Figure 5.64. Set the dial
tightening the adjusting rings indicator to ZERO.
13.932-inches – = 0.005-inch difference
3. Rotate the differential and ring gear. Read the dial indicator.
13.927-inches
The ring gear runout must not exceed 0.008-inch (0.200 mm).
353.87 mm – 353.75 mm = 0.12 mm difference
앫 If the ring gear runout is within the specification: Set
the backlash and contact patterns to the settings
5. If the difference is at or within the specification in Table J:
determined in the “Check Gear Set Tooth Contact Patterns”
Continue by checking the runout.
procedure in this section.
If the difference is more or less than the specification:
앫 If the ring gear runout exceeds the specification:
Repeat as needed.
Remove the differential and ring gear assembly from the
NOTE: The maximum legspread between bearing caps for the carrier. Refer to Section 3.
140/145/14X series cannot exceed 13.941-inches (354.101 mm).
A. Inspect the differential parts, including the carrier, for
wear and damage. Repair or replace parts as necessary.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 55


5 Assembly and Installation

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

5. Once the correct gap is achieved, use a suitable tool to prevent


1003105f rotation of the thrust screw and tighten the jam nut to 150 ±
Figure 5.65
50 lb-ft (200 ± 60 N폷m). @

B. Install the capscrews that hold the lock plate to the


bearing cap. New capscrews include a locking patch,
which can only be used once. If you are installing used
capscrews, apply Loctite 242 threadlocker to the
capscrew threads before you install the capscrews.
Tighten the capscrews to the correct torque value. Refer
to Section 8. Figure 5.65.

56 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

Assembly Figure 5.68

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

5 LOCK PLATE 17 BEARING CONE


6 BEARING CONE 18 REAR SIDE GEAR SNAP RING INPUT SHAFT
7 COVER 19 SNAP RING
8 OIL PUMP GEARS 20 IAD CASE INTER-AXLE
9 OIL PUMP PLATE 21 PINION GEAR DIFFERENTIAL
10 WASHER 22 SPIDER
11 CAPSCREW
12 OIL SCREEN AND PLUG HELICAL
GEAR
ASSEMBLY
OIL PUMP MODEL
Figure 5.67
1002815c

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.

6. If removed, use a press and sleeve to drive the bearing cone


onto the rear side gear until it is flat against the shoulder.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 57


5 Assembly and Installation

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.

1. Apply axle lubricant, Meritor specification 2297-U-4519, to the Figure 5.72

parts as they are being assembled. Figure 5.70.


HELICAL
Figure 5.70
GEAR

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

58 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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

correct carrier position.


1. If removed, install the bearing cup for the rear side gear into
the differential carrier. Use a press and a sleeve to install the
cup into the carrier. If a press is not available, use a sleeve or a
long, brass drift and a hammer to install the cup. The cup is
correctly installed when the bottom of the cup is seated against
the bottom of the bore. Figure 5.74.

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

both parts in a fully-matched set from the same manufacturer.

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

Meritor Maintenance Manual MM-0970 (Revised 07-12) 59


5 Assembly and Installation

B. Install the spring compression tool over the IAD bore and Figure 5.80

finger tighten the retaining screws. Tighten the tool CLUTCH


handle until it bottoms to compress the spring. COLLAR
Figure 5.78.
SHIFT
Figure 5.78 FORK
SPRING

TOOL PART NUMBER


SHIFT
A3256L1234 PISTON SHAFT
SHIMS 4007400a

Figure 5.80

D. While holding the fork in position, loosen the tool handle


to release the spring. Loosen the retaining screws and
4008683a remove the spring compression tool.
Figure 5.78 E. Insert a centering tool, screwdriver or other suitable tool
to align the fork with the case shift shaft housing bore.
C. Install the clutch collar onto the fork. Slide clutch collar Refer to Section 10 for a tool drawing.
and fork over the input shaft. Insert the end of the fork
above the compressed spring while you install the clutch F. Apply grease, Meritor specification 2297-U-4519 or
collar onto the input shaft. Figure 5.79. The machined 1199-U-1113, to the tapered surface of the shift shaft.
area of the fork shaft end must be toward the piston bore Insert the shift shaft into the housing bore through the
and the teeth of the clutch collar must face the helical shift fork and spring. Figure 5.80. If necessary, install a
gear. Ensure the spring is correctly seated within the centering tool or other suitable tool to center and seat the
raised areas of the fork. Figure 5.80. shift shaft. Refer to Section 10 for a tool drawing.
G. Install the same amount of shims as were removed.
Figure 5.79

H. Apply grease, Meritor specification 2297-U-4519 or


TOOL PART NUMBER
A3256L1234 1199-U-1113, to the O-ring and piston. Install the O-ring
onto the piston. Install the piston into the housing with the
COLLAR
stamped ’M’ or solid flat surface facing the front cover.
SPRING
COMPRESSION
Figure 5.81.
TOOL
NOTE: The current piston has an ’M’ stamped on the top
surface and is no longer solid flat.

Figure 5.81

SHIFT FORK 4008154c

Figure 5.79

1002845d

Figure 5.81

60 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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

K. Ensure the collar moves freely on the input shaft and is


not binding on the fork levers.
L. Check the clearance between the teeth of the clutch collar
and the helical gear to ensure there is a clearance of
0.020-0.040-inch (0.5-1.0 mm). If necessary, remove 1002816e
the piston and add or remove shims. Reassemble and
Figure 5.84
retest until correct clearance is achieved. Figure 5.80.
M. Remove the shop air from the shift tester. Loosen the tool 7. With the input shaft cup and cone removed, install the cover on
screws and remove the shift tester. the carrier housing and verify it is fully seated. Rotate the input
shaft and verify the pump teeth are engaged with the shaft
N. Grease the IAD front cover-to-housing O-ring and install it
splines. Install the washers and capscrews. Replace the two
onto the face of the carrier housing. Use care not to get
locating dowels with washers and capscrews. Tighten the
excess grease on the front face of the carrier.
capscrews using a crisscross pattern to 90 ± 15 lb-ft
Figure 5.83.
(125 ± 20 N폷m). You may also use an alternate method of
Figure 5.83
tightening the capscrews in a crisscross pattern to 30 ± 5 lb-ft
(40 ± 5 N폷m), then tighten the capscrews an additional
90 ± 5 degrees using a crisscross pattern. Figure 5.85. @
PISTON

The current
M
piston has an
‘M’ stamped
O-RING
on it. INSTALLED
ON HOUSING
4008192a

Figure 5.83

Meritor Maintenance Manual MM-0970 (Revised 07-12) 61


5 Assembly and Installation

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

Figure 5.85 HAMMER

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

4008160a Figure 5.88

Figure 5.86 10. Apply thread sealant, Meritor specification 2297-U-6417, to


the oil screen and plug assembly threads. Install the oil screen
Figure 5.87
and plug assembly into the cover and tighten it to a minimum
of 48 lb-ft (65 N폷m). Figure 5.89. @

Figure 5.89

YOKE
INSTALLATION
TOOL

BEARING
SLEEVE

1002817d
4008159a

Figure 5.87 Figure 5.89

62 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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

the differential carrier. Use a press and a sleeve to install the


cup into the carrier. If a press is not available, use a sleeve or a
long, brass drift and a hammer to install the cup. The cup is
correctly installed when the bottom of the cup is seated against
the bottom of the bore. Figure 5.90.

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

Meritor Maintenance Manual MM-0970 (Revised 07-12) 63


5 Assembly and Installation

B. Install the spring compression tool over the IAD bore and Figure 5.96

finger tighten the retaining screws. Tighten the tool


CLUTCH
handle until it bottoms to compress the spring. COLLAR
Figure 5.94.
SHIFT
Figure 5.94

FORK
SPRING

TOOL PART NUMBER


A3256L1234 SHIFT
PISTON SHAFT
SHIMS 4007400a

Figure 5.96

D. While holding the fork in position, loosen the tool handle


4008683a to release the spring. Loosen the retaining screws and
remove the spring compression tool.
Figure 5.94
E. Insert a centering tool, screwdriver or other suitable tool
C. Install the clutch collar onto the fork. Slide clutch collar to align the fork with the case shift shaft housing bore.
and fork over the input shaft. Insert the end of the fork Refer to Section 10 for a tool drawing.
above the compressed spring while you install the clutch F. Apply grease, Meritor specification 2297-U-4519 or
collar onto the input shaft. Figure 5.95. The machined 1199-U-1113, to the tapered surface of the shift shaft.
area of the fork shaft end must be toward the piston bore Insert the shift shaft into the housing bore through the
and the teeth of the clutch collar must face the helical shift fork and spring. Figure 5.96. If necessary, install a
gear. Ensure the spring is correctly seated within the centering tool or other suitable tool to center and seat the
raised areas of the fork. Figure 5.96. shift shaft. Refer to Section 10 for a tool drawing.

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

SHIFT FORK 4008154c

Figure 5.95

1002845d

Figure 5.97

64 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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.

7. Apply grey sealant, Meritor specification 2297-H-7054, or blue


sealant, Meritor specification 2297-D-7076, in a continuous
1/8-inch (3.175 mm) wide bead to the carrier housing face. Do
not allow the sealant to enter into the IAD piston bore. Be ready
4008155b to install the cover within 20 minutes of applying the sealant.
Figure 5.100.
Figure 5.98
Figure 5.100

J. Ensure the collar moves freely on the input shaft and is


not binding on the fork levers.
K. Check the clearance between the teeth of the clutch collar
and the helical gear to ensure there is a clearance of
0.020-0.040-inch (0.5-1.0 mm). If necessary, remove
the piston and add or remove shims. Reassemble and
retest until correct clearance is achieved. Figure 5.96.
L. Remove the shop air from the shift tester. Loosen the tool
screws and remove the shift tester.
1002816e
M. Grease the IAD front cover-to-housing O-ring and install it
Figure 5.100
onto the face of the carrier housing. Use care not to get
excess grease on the front face of the carrier.
Figure 5.99. 8. Install the cover on the carrier housing. Install the washers and
capscrews. Replace the two locating dowels with washers and
Figure 5.99
capscrews. Tighten the capscrews using a crisscross pattern
to 90 ± 15 lb-ft (125 ± 20 N폷m). You may also use an alternate
method of tightening the capscrews in a crisscross pattern to
30 ± 5 lb-ft (40 ± 5 N폷m), then tighten the capscrews an
PISTON
additional 90 ± 5 degrees using a crisscross pattern.

The current
M Figure 5.101. @
piston has an
‘M’ stamped
O-RING
on it. INSTALLED
ON HOUSING
4008192a

Figure 5.99

Meritor Maintenance Manual MM-0970 (Revised 07-12) 65


5 Assembly and Installation

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

2. Place a rag in the carrier cover opening to prevent debris from


entering the bearing area during the cleaning process. Clean
the old sealant from the axle carrier mating threads in the
cover.
4008157b

Figure 5.102 WARNING


Use surface primer in a well-ventilated area and follow the
manufacturer’s recommended instructions to prevent serious
personal injury.

3. Once all threads have been cleaned of old sealant, apply


Loctite 7090 surface primer to both threaded surfaces. Use
the surface primer in a well-ventilated area.

66 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

WARNING Figure 5.104

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.

4. Apply Loctite 565 thread sealant to the entire circumference PLATE


of the input bearing adjusting ring and the axle carrier cover
making sure to embed the Loctite 565 thread sealant into
threads.
5. Install the adjusting ring into the cover until it bottoms out and
seats the cup and bearing. Typically, this is two to three 1002576c
notches past the original position. If a reference mark was
made during removal, check the mark to determine Figure 5.104
approximate position of the adjusting ring. Rotate the input
shaft back and forth to further ensure the bearing is seated. 13. Use a pry bar and a support to push the yoke or the flange
Then, back the adjusting ring out two notches. away from the carrier. Read the dial indicator. Correct end play
is 0.002-0.008-inch (0.05-0.20 mm). Figure 5.105.
6. For the purpose of gauging end play, install a test yoke or
flange that fits loosely on the shaft. Do not install the intended Figure 5.105

service yoke or flange for this procedure. Align the splines of


the test yoke or flange with the shaft splines. Slide the yoke or
flange over the shaft splines until seated.
7. Install the nut and washer onto the input shaft.
8. Fasten a yoke or flange bar to the input yoke or flange. The bar
will hold the input shaft in position when the nut is tightened.
9. Tighten the nut on the input shaft to the correct torque value.
Refer to Section 8.
10. Remove the yoke or flange bar.
11. Rotate the input shaft in each direction and push the yoke or
flange toward the cover. This ensures that the input shaft
assembly is at the bottom of its travel. 1002577c

12. Use a dial indicator with a magnetic base or a C-clamp base to


inspect the end play of the input bearing. Verify that the pointer Figure 5.105
of the dial indicator is against the top of the input shaft. Set the
dial indicator to ZERO. Figure 5.104. 14. Use a spanner wrench to tighten or loosen the adjusting ring as
necessary and check the input shaft end play until end play is
0.002-0.008 inch (0.05-0.20 mm). Use care to avoid
overtightening the adjusting ring.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 67


5 Assembly and Installation

앫 If the adjusting ring is tightened to the point that the


end play is less than 0.002-inch (0.05 mm): Loosen the
adjusting ring and pry up on the yoke. Pull the input shaft
and bearing cup enough to gain more end play. Continue to
check the end play and adjust the ring until end play is
0.002-0.008 inch (0.05-0.20 mm).
15. Once the correct end play is achieved, remove the yoke or
flange, washer and nut. Install the lock plate and capscrew to
secure the adjusting ring. Tighten the capscrew to
specification. Install the seal and yoke or flange according to
the procedures in this section.
16. Wait two hours after final assembly before you operate the
vehicle.

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

68 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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

Meritor Maintenance Manual MM-0970 (Revised 07-12) 69


5 Assembly and Installation

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 5.108 Figure 5.110

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.

70 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

Figure 5.111 Figure 5.113

FORWARD-REAR INPUT

4004877b

4004876c Figure 5.113

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 71


5 Assembly and Installation

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.

2. If the bearing cones were removed from the thru-shaft, install


new bearing cones. Place both cones back-to-back onto the
thru-shaft. Use a press and sleeve to install both cones. Apply
pressure until the inner cone seats onto the shoulder of the
thru-shaft. Figure 5.118.

1002725c Figure 5.118

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.

72 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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. Install the snap ring or the yoke-to-cone spacer onto the


1002828b
thru-shaft until the snap ring touches the outer cone.
7. Inspect and adjust the end play of the thru-shaft bearing. Figure 5.121

Meritor Maintenance Manual MM-0970 (Revised 07-12) 73


5 Assembly and Installation

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

fastens the bearings in the cage. Install a thinner snap ring


FORWARD-REAR OUTPUT
to increase the end play. Install a thicker snap ring to
decrease the end play. Figure 5.122.
7. Remove the nut that fastens the yoke or flange to the
thru-shaft. Use the correct puller tool to remove the yoke.

Figure 5.122

OUTPUT BEARING END PLAY

SNAP
RING

4004878a

Figure 5.123

2. Use a feeler gauge to measure the gap around the complete


flange-to-cage area. The seal is correctly installed if the gap is
less than 0.010-inch (0.25 mm) around the circumference of
the seal flange. Figure 5.124.
To increase end play, install a thinner snap ring.
앫 If the gap is more than 0.010-inch (0.25 mm): Use a
To decrease end play, install a thicker snap ring.
dead-blow hammer and the appropriate driver to
1002585c
completely install the seal.
Figure 5.122
Figure 5.124

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

1. Install the multiple-lip seal (MLS). Refer to the procedure in this


section for complete instructions.

74 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

앫 Work in a well-ventilated area.


CAUTION
Use a press and a sleeve or yoke installation tool to install the 앫 Do not use gasoline or solvents that contain gasoline.
yoke. Do not use a hammer or mallet. Using a hammer or Gasoline can explode.
mallet can damage the bearings, yoke or flange.
앫 You must use hot solution tanks or alkaline solutions
correctly. Read the manufacturer’s instructions before
3. Use a press and sleeve or an installation tool to install the yoke
using hot solution tanks and alkaline solutions. Then
onto the thru-shaft. Verify that the splines inside the yoke or
carefully follow the instructions.
flange are aligned with the splines on the thru-shaft. If a press
and sleeve are used, verify that the thru-shaft is supported.
1. Use a cleaning solvent and rags to clean the inside of the axle
4. Install the nut that fastens the output yoke or flange to the housing and the carrier mounting surface. Refer to Section 4.
thru-shaft. Place a holding tool on the yoke or flange and
2. Inspect the axle housing for damage. Repair or replace the axle
tighten the nut to 600-700 lb-ft (815-950 N폷m). Figure 5.125.
housing. Refer to Section 4.
@
3. Check for loose studs, if equipped, in the mounting surface of
Figure 5.125
the housing where the carrier fastens. Remove and clean the
studs that are loose.
4. Install the studs into the axle housing. Refer to the procedure in
this section. Tighten the studs to 150-230 lb-ft
(203-312 N폷m). @

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.

WARNING 5. Apply a continuous 0.25-inch (6 mm) wide bead of Loctite


Solvent cleaners can be flammable, poisonous and cause Ultra Grey sealant, Meritor specification 2297-H-7054, to the
burns. Examples of solvent cleaners are carbon tetrachloride, mounting surface of the housing where the carrier fastens.
and emulsion-type and petroleum-base cleaners. Read the Figure 5.126.
manufacturer’s instructions before using a solvent cleaner,
then carefully follow the instructions. Also follow the
procedures below.
앫 Wear safe eye protection.
앫 Wear clothing that protects your skin.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 75


5 Assembly and Installation

Figure 5.126 Figure 5.128

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

into the axle housing. Figure 5.127. 1.75”


CAPSCREW STUDS
Figure 5.127

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.

76 Meritor Maintenance Manual MM-0970 (Revised 07-12)


5 Assembly and Installation

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.

Fill the Axle with Lubricant


TAPERED NOTE: For additional lubrication information, refer to Maintenance
DOWEL,
IF EQUIPPED Manual 1, Preventive Maintenance and Lubrication. To obtain this
publication, refer to the Service Notes page on the front inside cover
AXLE SHAFT of this manual.
SHAFT OR HUB
FLANGE AXLE 1002581c
1. Park the vehicle on a level surface. When the angle of the drive
Figure 5.130 pinion changes, the lubricant capacity of the axle will change.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 77


5 Assembly and Installation

2. Remove the fill plug from the side of the bowl cover of the axle
housing. Figure 5.131.

Figure 5.131

FILL PLUG LOCATION IN BACK


OF AXLE HOUSING BOWL

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.

78 Meritor Maintenance Manual MM-0970 (Revised 07-12)


6 Driver-Controlled Main Differential Lock (DCDL)

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

Engagement or Lockout of the DCDL

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.

Removal Park the vehicle on a level surface. Block the wheels to


prevent the vehicle from moving. Support the vehicle with
Differential Carrier from the Axle Housing safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
Before the differential carrier can be removed or installed, the damage to components can result.
differential lock must be shifted into and held in the locked or
engaged position. The locked position gives enough clearance Manual Method
between the shift collar and the axle housing to permit the removal
or installation of the carrier. Use the following manual engaging method to shift the DCDL into
the locked position.
The Axle Shafts Were Removed for Towing with the If an auxiliary air supply is not available or if the differential carrier is
Differential in the Unlocked or Disengaged Position to be stored for later use, use this manual engaging method for the
Install the left-hand axle shaft into the housing before continuing. DCDL.
Perform the following steps for reinstalling the axle shafts into the
1. Park the vehicle on a level surface. Block the wheels to prevent
axle housing.
the vehicle from moving.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 79


6 Driver-Controlled Main Differential Lock (DCDL)

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.

80 Meritor Maintenance Manual MM-0970 (Revised 07-12)


6 Driver-Controlled Main Differential Lock (DCDL)

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

3. Use a high-powered magnet or magnetic base of a dial


indicator to remove the piston. Inspect the O-ring for any
SHIFT
damage such as cracks, cuts or breaks and replace if
SHAFT necessary. Figure 6.7.
GEAR
SHIMS
TEETH Figure 6.7

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

Figure 6.5 Figure 6.8

Meritor Maintenance Manual MM-0970 (Revised 07-12) 81


6 Driver-Controlled Main Differential Lock (DCDL)

5. Remove the shims from the bore. Figure 6.11

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

TOOL PART NUMBER


A3256L1234

1002847e

Figure 6.11

10. Further disassembly of these carriers is the same as axles


4008683a without the driver-controlled main differential lock. To continue
disassembly, follow the procedures in Section 3.
Figure 6.9

7. Tighten the tool handle down until it bottoms to compress the


Installation
spring. When the spring is compressed below the fork, pull the
fork out with the shift collar. Figure 6.10.
DCDL Shift Unit

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.

82 Meritor Maintenance Manual MM-0970 (Revised 07-12)


6 Driver-Controlled Main Differential Lock (DCDL)

Figure 6.12 Figure 6.14

TOOL PART NUMBER


A3256L1234
SPRING

4008685a

1002847e Figure 6.14

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

TOOL PART NUMBER


A3256L1234
SPRING

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 83


6 Driver-Controlled Main Differential Lock (DCDL)

Figure 6.16 Figure 6.18

SPRING SHIFT FORK DIFFERENTIAL


LOCK COLLAR

SHIFT
SHAFT
GEAR
SHIMS
TEETH
ENGAGED
SHIFT PISTON 4007399c
SHAFT 1002854d
DCDL IN LOCKED POSITION
Figure 6.16
Figure 6.18

8. Install the same amount of shims as were removed.


CAUTION
9. Apply grease, Meritor specification 2297-U-4519 or
When tightening the caging bolt, do not exceed 50 lb-in
1199-U-1113, to the O-ring and piston. Install the O-ring onto
(7 N폷m). Damage to components can result.
the piston. Install the piston into the housing.
10. Apply Loctite 242 threadlocker to the capscrew holes. Install 14. Remove the shop air from the DCDL lock cover and install the
the DCDL cover plate with the gasket onto the housing. Install DCDL caging bolt. Check to see that the DCDL teeth are
the washers and capscrews. Tighten the capscrews to engaged with the main differential case teeth while engaging
50 ± 10 lb-in (6 ± 1 N폷m). Figure 6.17. @ the caging bolt. Do not exceed 50 lb-in (7 N폷m) when
tightening the caging bolt. When installing the carrier, leave the
Figure 6.17
caging bolt in until the axle shafts are installed. Also, it is
necessary to cage the DCDL when removing the carrier.
Figure 6.19.

Figure 6.19

SPRING SHIFT FORK DIFFERENTIAL


LOCK COLLAR

CAPSCREW AND
WASHER, FOUR
CORNERS COVER
SHIFT
1002850d SHAFT

Figure 6.17

PISTON CAGING BOLT 4007399b


11. Apply shop air to the DCDL assembly to engage the DCDL lock
collar into locked position. DCDL LOCKED WITH CAGING BOLT
12. Ensure the collar moves freely in the engaged position and is Figure 6.19
not binding on the fork levers.
15. Engage the DCDL so the shift collar is in the locked position
13. Check the clearance between the teeth of the clutch collar and
and install the sensor switch into its hole but do not tighten.
the main differential case to ensure there is 0.020-0.040-inch
Figure 6.20.
(0.5-1.0 mm) clearance. If necessary, remove the piston and
add or remove shims. Reassemble and retest until correct
clearance is achieved. Figure 6.18.

84 Meritor Maintenance Manual MM-0970 (Revised 07-12)


6 Driver-Controlled Main Differential Lock (DCDL)

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

The indicator light will also activate if the DCDL is partially


engaged. This vehicle is equipped with Meritor’s driver-controlled, full-locking
differential (DCDL).
20. When testing is complete, reinstall the caging bolt into its • Engage DCDL only under poor road conditions.
• Do not engage DCDL during downhill operation.
threaded hole and tighten to 7-11 lb-ft (10-15 N폷m). @ • Do not engage DCDL or operate the vehicle at speeds above 25 mph.
When DCDL is engaged, an “understeer” condition can occur when
making turns, so operate the vehicle carefully. When you disengage

Check the Differential Lock DCDL, normal steering resumes.


Refer to the vehicle manufacturer’s manual or Meritor technical
bulletin TP-9579. To obtain this bulletin, visit Literature on Demand at
meritor.com or call 866-OnTrac1 (668-7221).
1. Shift the vehicle transmission into neutral. Start the engine to TP-9579ALBL (04-06)

get the system air pressure to the normal level. 4008262a

WARNING Figure 6.21


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,
and the vehicle’s wheels are raised from the floor. The vehicle
can move and cause serious personal injury and damage to
components.

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.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 85


6 Driver-Controlled Main Differential Lock (DCDL)

Driver Instruction Information Available


to Order
Refer to the Service Notes page on the front inside cover of this
manual to obtain the following publications.
앫 DCDL Caution Alert Label/Order part number TP9579ALBL.
앫 DCDL Driver Instruction Kit/Contains a compilation of technical
bulletins covering DCDL and inter-axle differential (IAD)
operation; the DCDL Caution alert label; and instructions to
prepare an axle for towing or new vehicle drive away
(piggybacking). Order part number TP-9579.
앫 Traction Controls for Drive Axles DVD/Order part number
SP03105.

86 Meritor Maintenance Manual MM-0970 (Revised 07-12)


7 Lubrication

Specifications
7 Lubrication

Meritor recommends using a lubricant analysis program. Perform


lubricant analysis at regularly-scheduled preventive maintenance
intervals.
For complete information on lubricating drive axles and carriers,
refer to 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.
Refer to Table M, Table N and Table O for standard information on
lubricants, schedules and capacities.

Table M: Lubricant Cross Reference (Viscosity) and Temperature Chart


Meritor Lubricant Minimum Outside Maximum Outside
Specification Description Cross Reference Temperature Temperature
O-76-A Hypoid Gear Oil GL-5, S.A.E. 85W/140 +10°F (–12.2°C) *
O-76-B Hypoid Gear Oil GL-5, S.A.E. 80W/140 –15°F (–26.1°C) *
O-76-D Hypoid Gear Oil GL-5, S.A.E. 80W/90 –15°F (–26.1°C) *
O-76-E Hypoid Gear Oil GL-5, S.A.E. 75W/90 –40°F (–40°C) *
O-76-J Hypoid Gear Oil GL-5, S.A.E. 75W –40°F (–40°C) +35°F (+1.6°C)
O-76-L Hypoid Gear Oil GL-5, S.A.E. 75W/140 –40°F (–40°C) *
*There is no upper limit on these outside temperatures, but the axle sump temperature must never exceed 250°F (+121°C).

Table N: Oil Change Intervals for All Rear Drive Axles


Construction, Transit Bus,
City Delivery, School Refuse, Yard Tractor, Logging,
Vocation or Bus, Fire Truck, Heavy Haul, Mining, Oil Field,
Vehicle Operation Linehaul Intercity Coach Motorhome Rescue
Initial Oil Change Not required Not required Not required Not required
Check Oil Level Every 25,000 miles Every 25,000 miles Every 10,000 miles Every 5,000 miles (8000 km),
Add the correct type (40 000 km), or the (40 000 km), or the (16 000 km), once a once a month, or the fleet
and amount of oil as fleet maintenance fleet maintenance month, or the fleet maintenance interval, whichever
required. interval, whichever interval, whichever maintenance interval, comes first1
comes first comes first whichever comes first
Petroleum-Based Every 100,000 Every 100,000 miles Every 50,000 miles Every 25,000 miles (40 000 km)
Oil miles (160 000 km) (160 000 km) or (80 000 km) or annually, or annually, whichever comes
Change on axles or annually, annually, whichever whichever comes first first
with or without a whichever comes comes first
pump and filter first
system.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 87


7 Lubrication

Construction, Transit Bus,


City Delivery, School Refuse, Yard Tractor, Logging,
Vocation or Bus, Fire Truck, Heavy Haul, Mining, Oil Field,
Vehicle Operation Linehaul Intercity Coach Motorhome Rescue
Synthetic Oil Every 500,000 Every 250,000 miles Every 250,000 miles Every 100,000 miles
Change on axles miles (800 000 km), (400 000 km), or every (400 000 km), or every (160 000 km), or every 2 years,
with or without a or every 4 years, 4 years, whichever 3 years, whichever comes whichever comes first3
pump and filter whichever comes comes first first
system.2 first

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.)

Table O: Tandem Rear Drive Axle Oil Capacities


Oil Capacity*
Axle Model Carrier Pints Liters
MT-40-14X Forward 30 14.2
Rear 32 15.14
*The oil capacities are for standard track axles that have been measured
at various common drive pinion angles. The quantities listed include oil for
both wheel ends. The oil capacities will change if the track or the drive
pinion angle is different.

88 Meritor Maintenance Manual MM-0970 (Revised 07-12)


8 Specifications

Specifications
8 Specifications

Figure 8.1

MT-14X SERIES DIFFERENTIAL CARRIER


1
2

OPTION

5
6

7 8

12
13 10

11
14
4007405a

Figure 8.1

Meritor Maintenance Manual MM-0970 (Revised 07-12) 89


8 Specifications

Table P: Torque Specifications


Torque
Item Description Size Lb-Ft N폷m
1 Oil Baffle Capscrew M8 x 1.25-6H 70 ± 10 lb-in 8±2
Class 8.8
2 Oil Pump Cover Capscrew M8 x 1.25 5-7 7-10
3 Lock Plate Capscrew M8 x 1.25 25 ± 1 30 ± 5
Class 8.8
4 Oil Screen and Plug M26 x 1.5 48 65
5 Cover Capscrew M12 x 1.75 90 ± 15 125 ± 20
Optional Method: 30 ± 5 (40 ± 5) plus angle tighten to
90 degrees ± 5 degrees
6 Input Shaft Yoke Nut M45 x 1.5 800 ± 45 1090 ± 60
7 Carrier-to-Axle Housing Capscrew 5/8″ 225 305
8 Pinion Nut M45 x 1.5 1100 ± 200 1500 ± 250
9 DCDL Cover Bolts M6 x 1.0-6g 50 ± 10 lb-in 6±1
Class 8.8
10 DCDL Switch M16 x 1.0 25-55 35-75
11 Carrier-to-Axle Housing Capscrew 5/8″ 225 305
12 Stud Nut 225 305
13 Stud 5/8″ 225 305
14 DCDL Caging Bolt M10 x 1.25-6g 7-9 10-12
— Pressure Relief Screw M16 x 1.5 20-40 27-54
— Thrust Screw Jam Nut M22 x 1.5 150 ± 50 200 ± 60

90 Meritor Maintenance Manual MM-0970 (Revised 07-12)


8 Specifications

Figure 8.2

1 MAIN DIFFERENTIAL CASE AND


RING GEAR ASSEMBLY
2 (ALL GEAR SET RATIOS
EXCEPT 2.47-2.64)
4

1 (GEAR SET RATIOS 2.47-2.64)

3 4007406a

Figure 8.2

Meritor Maintenance Manual MM-0970 (Revised 07-12) 91


8 Specifications

Table Q: Torque Specifications


Torque
Item Description Size Lb-Ft N폷m
1 Lock Plate Capscrew M6 x 1.0-6g Class 8.8 50 ± 10 lb-in 6±1
2 Bearing Cap Capscrew* M20 x 2.5-6g Class 10.9 Torque Plus Angle Method: 150 ± 35
(200 ± 50) plus angle tighten to 90 degrees
± 5 degrees
Optional Method:
Initial torque: 20 ± 8 (25 ± 10)
Final torque: 360 ± 40 (485 ± 55)
3 Plain Half-to-Flange Half Capscrew M12 x 1.75 41x-1618 105 ± 10 140 ± 15
Flange Head Class 12.9
Optional Method: 45 ± 5 (60 ± 5) plus angle
tighten to 90 degrees ± 5 degrees
4 Ring Gear-to-Flange Half Nut (for all gear set M16 x 1.5 Class 12 std 185 ± 25 255 ± 35
ratios excluding 2.47 and 2.64) hex head
Optional Method: 30 ± 5 (40 ± 5) plus angle
tighten to 90 degrees ± 5 degrees
5 Ring Gear-to-Flange Half Capscrew (for gear set M16 x 1.5-6g Class 12.9 320 ± 20 430 ± 30
ratios 2.47 to 2.64)
Optional Method: 30 ± 5 (40 ± 5) plus angle
tighten to 90 degrees ± 5 degrees

*Change to new capscrews after two reassemblies.

92 Meritor Maintenance Manual MM-0970 (Revised 07-12)


8 Specifications

Figure 8.3

AXLE HOUSING WITH OUTPUT SHAFT

4007407a

Figure 8.3

Table R: Torque Specifications


Torque
Item Description Size Lb-Ft N폷m
1 Output Shaft Nut M39 x 1.5 650 ± 50 880 ± 65
2 Output Bearing Cage-to-Carrier Capscrew 0.38″-16 42 ± 8 55 ± 10
3 Breather 0.38″-18 25 ± 5 30 ± 7
4 Drain and Fill Plugs 0.75-14 35 Minimum 47.5 Minimum

Meritor Maintenance Manual MM-0970 (Revised 07-12) 93


9 Adjustment

Adjustment
9 Adjustment

Table S: Drive Pinion Bearings — Preload


Specification New bearings
10-50 lb-in (1.1-5.1 N폷m)
Used bearings in good condition
10-30 lb-in (1.13-3.39 N폷m)
Adjustment Preload is controlled by the thickness of the spacer between bearing cones.
To increase preload, install a thinner spacer.
To decrease preload, install a thicker spacer.

Table T: Drive Pinion — Depth in Carrier


Specification Install the correct amount of shims between the inner pinion bearing cup and the carrier. To
calculate, use the old shim pack thickness and the new and old pinion cone numbers.
Adjustment Change the thickness of the shim pack to get a good gear tooth contact pattern.

Table U: Hypoid Gear Set — Tooth Contact Patterns (Hand Rolled)


Specification Toward the toe of the gear tooth and in the center between the top and bottom of the tooth.
Adjustment Tooth contact patterns are controlled by the thickness of the shim pack between the inner bearing
cone of the drive pinion and the carrier and by ring gear backlash.
To move the contact pattern lower, increase the thickness of the shim pack between the inner
bearing cup of the drive pinion and the carrier.
To move the contact pattern higher, decrease the thickness of the shim pack between the inner
bearing cup of the drive pinion and the carrier.
To move the convex pattern toward the toe and the concave pattern toward the heel, decrease the
backlash of the ring gear.
To move the convex pattern toward the heel and the concave pattern toward the toe, increase the
backlash of the ring gear.

Table V: Main Differential Bearings — Preload


Specification 15-35 lb-in (1.7-3.9 N폷m)
or
Expansion between bearing caps
0.002-0.009-inch (0.05-0.23 mm)
Adjustment Preload is controlled by tightening both adjusting rings after zero end play is reached.

Table W: Main Differential Gears — Rotating Resistance


Specification 50 lb-ft (68 N폷m) maximum torque applied to one side gear

94 Meritor Maintenance Manual MM-0970 (Revised 07-12)


9 Adjustment

Table X: Input Shaft End Play Adjustment


End Play of the Input Shaft 0.002-0.008-inch (0.050-0.200 mm)

Table Y: Output Bearing — End Play and Preload


Specification 0.004-0.008-inch (0.10-0.20 mm) bearing end play
Adjustment End play is controlled by the size of the snap ring in the output bearing cage.
Increase end play by installing a thinner snap ring.
Decrease end play by installing a thicker snap ring.

NOTE: If the end play on the output bearing measures ZERO, a thinner snap ring is required.

Table Z: Ring Gear — Backlash


Specification Range: 0.008-0.018-inch (0.20-0.460 mm)
Backlash setting for new gear sets: 0.012-inch (0.300 mm)
Adjustment Backlash is controlled by the position of the ring gear. Change backlash within specifications to
get a good tooth contact pattern.
To increase backlash, move the ring gear away from the drive pinion.
To decrease backlash, move the ring gear toward the drive pinion.

Table AA: Ring Gear — Runout


Specification 0.008-inch (0.200 mm) maximum

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). @

Meritor Maintenance Manual MM-0970 (Revised 07-12) 95


10 Special Tools

Specifications
10 Special Tools

Carrier Repair Stand


Figure 10.1

HANDLE 7" LONG


DRILL 3/8" HOLE PLATES 8" LONG x 3/4" WITH SLOT IN
THROUGH HANDLE THICK x 1-1/4" WIDE WITH ONE END TO FIT
AND SCREW A TONGUE TO FIT SLOT IN CLAMP SCREW
BAR WELD PLATES TO BAR

SCREW 3-1/2" LONG


x 5/8" DIAMETER WITH
FLATS ON END TO FIT BAR 2" DIAMETER x 9"
HANDLE AND 2-1/2" LENGTH LONG WITH ONE END
OF THREAD ON OTHER END SLOTTED TO FIT PLATE

PLUG 4" DIAMETER x 7" LONG


WITH ONE END TURNED 3" LONG SHAPE AND SIZE
TO FIT PIPE. DRILL 2" HOLE AND OF HOLES TO FIT
MILL 3/16" WIDE SLOT 2" FROM TOP CARRIER
WELD ALL AROUND
AFTER PRESSING
PLUG IN PIPE

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.

96 Meritor Maintenance Manual MM-0970 (Revised 07-12)


10 Special Tools

How to Make a Yoke Bar


1. Measure dimensions A and B of the yoke you are servicing.
Figure 10.2.

Figure 10.2

YOKE 1003459b

Figure 10.2

2. Calculate dimensions C and D of the yoke bar by adding


0.125-0.250-inch to dimensions A and B of the yoke.
Figure 10.3.

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.

3. To make the box section, cut and weld one-inch x two-inch


mild steel square stock according to dimensions C and D.
Figure 10.3.
4. Cut a four-foot x 1.25-inch piece of mild steel round stock to
make the yoke bar handle. Center weld this piece to the box
section. Figure 10.3.
앫 To increase yoke bar rigidity: Weld two angle pieces onto
the handle. Figure 10.3.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 97


10 Special Tools

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

98 Meritor Maintenance Manual MM-0970 (Revised 07-12)


10 Special Tools

Service Tools Figure 10.8

To obtain these tools, call Meritor’s Commercial Vehicle Aftermarket


at 888-725-9355. TOOL PART NUMBER
A3256L1234
Figure 10.5

TOOL PART NUMBER


3256N1236

4008683a

IAD/DCDL SPRING COMPRESSION TOOL


Figure 10.8

4008161a
Figure 10.9

COVER REMOVAL TOOL (OIL PUMP MODELS)


Figure 10.5

Figure 10.6

TOOL PART NUMBER


MSTYT114 TOOL PART NUMBER
3256P1238
4008164a

IAD SHIFT TESTER


Figure 10.9

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.

TOOL PART NUMBER


3256M1235

4008162a

INPUT BEARING CONE INSTALLATION TOOL


Figure 10.7

Meritor Maintenance Manual MM-0970 (Revised 07-12) 99


10 Special Tools

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.

100 Meritor Maintenance Manual MM-0970 (Revised 07-12)


11 Vehicle Towing Instructions

Hazard Alert Messages When transporting a vehicle with the wheels of one or both drive
11 Vehicle Towing Instructions

axles on the road, it is possible to damage the axles if the wrong


Read and observe all Warning and Caution hazard alert messages in procedure is used before transporting begins. Meritor recommends
this publication. They provide information that can help prevent that you use the following procedure.
serious personal injury, damage to components, or both.

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.

NOTE: For complete towing information, refer to Technical Bulletin


TP-9579, Driver Instruction Kit. To obtain this publication, refer to
the Service Notes page on the front inside cover of this manual.

These instructions supersede all other instructions for the purpose


of transporting vehicles for service or new vehicle drive-away dated
before April 1995, including those contained in Meritor maintenance
manuals.

Meritor Maintenance Manual MM-0970 (Revised 07-12) 101


11 Vehicle Towing Instructions

Figure 11.1 Table AE: Shaft-to-Hub Torque Fastener Chart


DCDL SHIFT ASSEMBLY SHOWN IN THE
LOCKED OR ENGAGED POSITION Torque Value — Grade 8 Nuts lb-ft
Thread (N폷m)
Fastener Size Plain Nut Locknut
Stud Nut 0.62-18 180-230 (244-312) 150-190 (203-258)
2 or Axle 0.75-16 310-400 (420-542) 270-350 (366-475)
Shaft
1 Studs All Install the coarse thread end of the stud
3 into the hub and tighten to the last thread.

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.

1 CURBSIDE, AXLE SHAFT


12. Check the lubricant level in the axles and hubs where the axle
2 SHIFT ASSEMBLY shafts were removed. Add the correct type and amount of
3 SHIFT COLLAR lubricant if necessary. Refer to Section 7.
4 ROADSIDE, AXLE SHAFT
5 DOUBLE ROW OF SPLINES
6 SHIFT COLLAR AND DIFFERENTIAL CASE SPLINES ENGAGED OR LOCKED
7 SIDE GEAR
8 DIFFERENTIAL CASE
Figure 11.1

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.

102 Meritor Maintenance Manual MM-0970 (Revised 07-12)


12 Diagnostics

Troubleshooting
12 Diagnostics

Vehicle Will Not Move


Figure 12.1

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.

Visually inspect the ring


Check for further carrier
pinion gear set for
damage. If none is found,
damage. Refer to TP-9955, Yes replace the inter-axle
Failure Analysis for Damaged? differential components
Drive Axle Components.
and install the carrier.
Refer to Sections 3 and 5.

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

Check the ring gear backlash


If the carrier is a pump model,
and record the reading.
inspect the input shaft oil Refer to Section 4. Use the
pump for damage and the oil backlash reading when
screen for contamination. Refer you reassemble the carrier.
to TP-9955, Failure Analysis for
Drive Axle Components.

This flowchart continues


on the next page.

Figure 12.1

Meritor Maintenance Manual MM-0970 (Revised 07-12) 103


12 Diagnostics

Figure 12.2

This flowchart continues


from the previous page.

When the carrier is When the carrier is


reassembled later, reassembled later, If damaged, repair the
Yes Backlash No input shaft, inter-axle
set the backlash set the backlash
within spec? differential, side gears or
to the recorded to spec. Refer to
reading. Section 5. bearings. Install the input
shaft. Refer to Sections 3 and 5.
Remove the main
differential and
ring gear from
the carrier. Install a new
Refer to Section 3. multi-lip seal.

Inspect the main differential


bearings for damage. Refer Set the input
to TP-9955, Failure Analysis shaft end play to
for Drive Axle Components. the correct
specification.
Repair the carrier Refer to Section 5.

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.

Inspect the main


differential case, side gears
and spider for damage.
Refer to TP-9955,
Failure Analysis for Drive
Axle Components.

Repair the carrier


or install a
Yes
Damaged? remanufactured
carrier.
Refer to Sections
No 3 and 5.

Inspect the drive pinion and


inner drive pinion bearing for
damage. Refer to TP-9955,
Failure Analysis for Drive
Axle Components.

Repair the carrier


Yes or install a
Damaged? remanufactured
carrier.
Refer to Sections
No 3 and 5.

Reassemble and
install the main
differential.
Refer to Section 5.

Reset the backlash.


Refer to Section 5.

Figure 12.2

104 Meritor Maintenance Manual MM-0970 (Revised 07-12)


12 Diagnostics

Differential Making Noise


Figure 12.3

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.

Inspect the inter-axle


Check the input differential assembly for
shaft end play. damage. Refer to TP-9955,
Refer to Section 5. Failure Analysis for Drive
Axle Components.

Check for further carrier


Set the input
Inspect the damage. If none is found,
End play No shaft end
lubricant. Yes replace the damaged
within spec? play to spec.
Refer to MM 1. Damaged? inter-axle differential
Refer to Section 5.
components and install
Yes the carrier. Refer to
No Sections 3 and 5.

Drain and inspect Yes


the lubricant. Contaminated?
Refer to MM 1. Disassemble
the inter-axle
No
differential case.

Yes Fill the carrier with


Determine
Contaminated? the correct amount
the source of of the specified
contamination. lubricant. Refer to
Inspect the inter-axle
Section 7. Test drive
No differential spider, side gears
the vehicle.
and bearings.
Remove the carrier Refer to TP-9955,
from the housing. Failure Analysis for
Refer to Section 3. Yes Drive Axle Components.
Noisy?

Check for further carrier


No damage. If none is found, replace
Visually inspect the ring Yes the damaged inter-axle
gear and pinion for Return the Damaged? differential components and
damage. Refer to TP-9955, vehicle to install the carrier. Refer to
Failure Analysis for service. Sections 3 and 5.
Drive Axle Components. No

Inspect the main


differential bearings for damage.
Repair the carrier or Refer to TP-9955, Failure Analysis
Yes for Drive Axle Components.
Damaged? install a remanufactured
carrier. Refer to
Sections 3 and 5.
No Repair the carrier or
Yes install a remanufactured
Damaged?
Remove and carriet. Refer to
disassemble the input Sections 3 and 5.
shaft and inter-axle No
differential assembly.
Refer to Section 3. Check the ring gear
backlash and
record the reading.
Refer to Section 5.
Inspect the input shaft
oil pump for damage
and the oil screen for
contamination. Refer to
TP-9955, Failure This flowchart continues
on the next page.
Analysis for Drive Axle
Components.

Figure 12.3

Meritor Maintenance Manual MM-0970 (Revised 07-12) 105


12 Diagnostics

Figure 12.4

This flowchart continues


from the previous page.

When the main When the main


differential is differential is Reassemble and install
reassembled later, Yes Backlash No reassembled later, set the main differential.
set the backlash to within spec? the backlash to spec. Refer to Section 5.
the recorded reading. Refer to Section 5.

Remove the main


differential and Reset the backlash.
ring gear from Refer to Section 5.
the carrier.
Refer to Section 3.

If damaged, repair the


input shaft, inter-axle
differential, side gears
Inspect the main differential
or bearings. Install the input
bearings for damage.
shaft. Refer to Sections 3 and 5.
Refer to TP-9955, Failure
Analysis for Drive Axle
Components.

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.

Repair the carrier


Yes or install a
Damaged? remanufactured
carrier. Refer to
Sections 3 and 5.
No

Inspect the drive pinion,


inner drive pinion
bearing and spigot bearing
for damage. Refer to
TP-9955, Failure Analysis
for Drive Axle Components.

Repair the carrier


Yes or install a
Damaged? remanufactured
carrier. Refer to
Sections 3 and 5.
No

Figure 12.4

106 Meritor Maintenance Manual MM-0970 (Revised 07-12)


12 Diagnostics

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.

Clean and prepare


the housing and
carrier flanges.
Apply the correct
Replace the
Yes gasket or silicone.
Breather breather. A clogged
Refer to Section 4.
clogged? breather can cause
a seal leak.

No
Install the carrier.
Refer to Section 5.
Inspect the
input shaft seal
for leaks.

Fill the carrier with


the correct amount
of the specified lubricant.
Seal Yes Replace the input Refer to Section 7.
leaking? shaft seal with
a unitized seal.

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.

Replace the output


shaft seal with Yes Seal
a unitized seal. leaking? Test drive the vehicle
to confirm that
the leak is repaired.
No
Return the vehicle
to service.
Fill the carrier with the
correct amount of the Inspect the
specified lubricant. carrier-to-housing
Refer to Section 7. joint for leaks.
Clean the seal area.

Inspect the axle


housing welds for
Test drive the vehicle Joint No cracks or leaks. If you
to confirm that the leaking? find weld cracks, contact
leak is repaired. Return Meritor for repair
the vehicle to service. welding procedures.
Yes

Figure 12.5

Meritor Maintenance Manual MM-0970 (Revised 07-12) 107


12 Diagnostics

Contaminated Lubricant Found During Preventive Maintenance


Figure 12.6

Visually
inspect the
lubricant.

Clean and prepare the


Indicates Milky, Indicates housing and carrier
that water Brownish Silvery flanges. Apply the correct
Lubricant metallic
is entering gasket or silicone.
color? contamination.
the axle. Refer to Section 4.

Send out a lubrication


sample for analysis. Install the carrier.
Inspect the Advise the owner to Refer to Section 5.
breather. return for the results.

If analysis results Fill the carrier with


Replace the
Breather Yes indicate wear or the correct amount
breather. A clogged of the specified lubricant.
clogged? breakdown in the carrier,
breather can cause Refer to Section 7.
refer to the Differential
a seal leak.
Making Noise diagnostic
flowchart in this publication.
No

Test drive the vehicle


Inspect the
to confirm that the
carrier seals
leak is repaired. Return
for leaks.
the vehicle to service.

Seal No Inspect the


leaking? carrier-to-housing
joint for leaks.

Yes

Inspect the axle housing


Replace the leaking Joint No welds for cracks or leaks.
seal with a leaking? If you find weld cracks,
multi-lip seal. contact Meritor for
repair welding procedures.
Yes

Fill the carrier Drain and


with the correct inspect the
amount of the lubricant.
specified lubricant. Refer to MM 1.
Refer to Section 7.
Clean the seal area.

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

108 Meritor Maintenance Manual MM-0970 (Revised 07-12)


Meritor Heavy Vehicle Systems, LLC
2135 West Maple Road Printed in USA
Troy, MI 48084 USA
866-OnTrac1 (668-7221) Copyright 2012 Revised 07-12
meritor.com Meritor, Inc. Maintenance Manual MM-0970 (16579)