Lubrication Meritor
Lubrication Meritor
Lubrication Meritor
50
Lubrication
Maintenance Manual No. 1
Revised 3-99
Service Notes
This manual contains Meritor’s grease and oil lubricant specifications, lubrication procedures and intervals, and
product capacities. The information contained in this manual was current at the time of publication and is subject
to change without notice or liability.
You must follow company procedures and understand all procedures and instructions before you begin to service
or repair a unit. Some procedures require the use of special tools for safe and correct service. Failure to use
special tools when required can cause serious personal injury to service personnel, as well as damage equipment
and components.
Meritor uses the following notations to warn the user of possible safety issues and to provide information that will
prevent damage to equipment and components.
CAUTION
A CAUTION indicates that you must follow
a procedure exactly. Otherwise, damage to This symbol indicates that you must
equipment or components can occur. tighten fasteners to a specific torque
Serious personal injury can also result, in value.
addition to damaged or malfunctioning
equipment or components.
Video
Lubrication
T-99398V. $20.
How to Order
Call Meritor’s Customer Service Center at
800–535–5560.
Table of Contents
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Section 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 2
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 3
Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 4
Front Driving Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 5
Front Non-Driving Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Easy-Steer Plus Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 6
On-Highway Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LX500/MX500 Cam Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Section 7
Planetary Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section 8
Rear Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Section 9
Trailer Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TB Series Trailer Axles with Unitized Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Section 10
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Section 11
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Section 12
Wheel Bearings and Wheel End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Section 13
List of Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
i
References
For more complete service information on Meritor components, consult the publications below. To order technical
literature, refer to the Service Notes page on the inside cover of this manual.
ii
Section 1
Introduction
Introduction Viscosity
In this manual, Meritor recommends specific grease Select the proper viscosity oil for a specific Meritor
and oil lubricants, lubrication procedures and intervals, component from the charts in each section of this
and product capacities that will enable you to correctly manual. When more than one lubricant is listed,
lubricate and maintain Meritor components. choose an oil viscosity that is suitable for the expected
outside temperature.
To help reduce friction, prevent dirt and wear particles
from affecting moving parts of components, protect Use multigrade oils when vehicles operate in both
components from damage and help to ensure cold and warm weather between oil changes.
maximum life for Meritor components: Use low viscosity single grade oils only in cold
Use a specified lubricant or grease from a climates. Single grade 75W oils are not
manufacturer that provides quality products and approved for use in drive axles where ambient
complete application instructions. temperatures exceed 40°F (4°C).
Follow recommended lubrication intervals and Use multigrade oil for drive axles only. The hypoid
procedures. gearing requires a GL-5 oil with Extreme Pressure
(EP) additives to provide adequate lubricant film
protection that prevents gear failure.
Oil Lubricants
There are three categories of oil lubricants: Petroleum
oil, Full Synthetic oil and Semi-Synthetic oil. Both full CAUTION
synthetic and semi-synthetic oils retain their lubrication Do not use thinning agents such as kerosene,
properties longer than petroleum oil. gasoline or any other diluents to lower the
viscosity of recommended lubricants. Thinning
Petroleum Oil is derived from crude oil. Crude agents damage the lubricant and can be a safety
petroleum oil also yields combustible fuels and a hazard.
wide range of petroleum chemicals.
NOTE: Oil viscosity grades and classifications are
Full Synthetic Oil uses a man-made-base oil with
provided by the SAE (Society of Automotive
predictable physical properties. Full synthetic oil
Engineers) and the API (American Petroleum
contains no refined petroleum-based fluids.
Institute).
Semi-Synthetic Oil contains a mixture of
petroleum-based and synthetic fluids that can help
extend service intervals, improve cold weather Oil Changes
properties and reduce volatility.
Determine the oil change interval by analyzing oil
samples taken at specified intervals or mileage.
However, the final recommended scheduled interval
may be due to service duty, regardless of vehicle
mileage or established change schedule.
Page 1
Section 1
Introduction
Page 2
Section 1
Introduction
Page 3
Section 2
Clutch
CAUTION
Make sure the inspection cover on the clutch
housing is used. If an inspection cover is not
used, dirt and contaminants enter the clutch GREASE
housing and damage the clutch. FITTING
Page 4
Section 2
Clutch
① Use the interval specified by the vehicle manufacturer or the fleet, but make sure the release bearing is
greased once per month.
② Use the grease specified by the vehicle manufacturer.
Approved Lubricants
Lubricant Recommendation
Clutch Bearing Exxon Unirex N Grade 3
Grease (NLGI Grade No. 3, Lithium
Complex)
Page 5
Section 3
Driveline
Industry WARNING
Name/ Lubrication To prevent serious eye injury, always wear safe
Description Series Type Requirements eye protection when you perform vehicle
Standard or 16N Full Round Splines and maintenance or service.
Conventional 17N Easy Universal Joints
Driveline 176N Service or
1. Check the driveline for looseness. If loose, service
18N 1/2 Round the driveline as necessary.
16T
17T
2. Clean all grease fittings prior to lubrication.
176T 3. Apply the specified grease at the grease fitting on
18T
the universal joint. Apply grease until new grease
92N 92N Wing Style Splines Only purges from all four seals.
Permalube
RPL Series RPL 25 Combination None
4. If new grease does not purge at all the seals,
(Meritor RPL 20 Wing and loosen the problem bearing cap bolts and
Permalube) Full Round regrease until all four cups purge. If new grease
still does not purge, replace the universal joint.
Standard/Conventional
Driveline Slip Yoke and Splines
1. Check the driveline for looseness. If loose, service
the driveline as necessary.
2. Cover the vent hole in the welch plug with a finger.
3. Apply the specified grease at the grease fitting on
the slip yoke until the grease purges from the dust
seal.
BEARING STRAP
EASY-SERVICE
BEARING CUPS CAPSCREWS
Page 6
Section 3
Driveline
Page 7
Section 3
Driveline
WELD YOKE
U-JOINT GREASE TO
CROSS PURGE AT SEAL
SLIP YOKE
Page 8
Section 3
Driveline
① The greasing interval depends on the individual operating conditions, speed and loads. To determine the
interval, inspect for the presence of grease at all positions until an interval can be determined. Grease the
assembly as necessary.
② Refer to the grease manufacturer’s specifications for the temperature service limits.
Approved Lubricants
Lubricant Recommendation
Universal Joint Must meet Meritor Specification O-634-B (NLGI Grade No. 2, Lithium 12-Hydroxy Stearate
Grease with Molybdenum Disulfide)
Amalie All purpose Grease with Moly-L1-2M
Exxon 5160
Shell Super Duty Special FF
Marathon Maralube Molycode 529
Phillips Petroleum Philube MW-EP2 Grease
Page 9
Section 4
Front Driving Axle
Page 10
Section 4
Front Driving Axle
Page 11
Section 4
Front Driving Axle
Outside Temperature
Military
Meritor Specification Oil F_ C_
Specifications Approval Description Min. Max. Min. Max.
O-76A, Gear Oil GL-5, SAE 85W/140 10 None -12 None
O-76D, Gear Oil GL-5, SAE 80W/90 -15 None -26 None
MIL-L-2105D
O-76E, Gear Oil or GL-5, SAE 75W/90 -40 None -40 None
O-76J, Gear Oil MIL-PRF-2105-E
MIL PRF 2105 E GL-5, SAE 75W -40 35 -40 2
O-76L, Gear Oil GL-5, SAE 75W/140 -40 None -40 None
➀ If the front drive axle is the only axle on the vehicle, change the oil every 15,000 miles (24,000 km) or 1,000
hours of operation, whichever comes first.
Page 12
Section 4
Front Driving Axle
➀ Oil capacities are for standard track axles that have been measured at various common drive pinion angles.
The quantities listed include enough oil for both wheel ends. These oil capacities will change if the track or the
drive pinion angle is different.
Page 13
Section 5
Front Non-Driving Axle
Page 14
Section 5
Front Non-Driving Axle
CAUTION
A unitized hub is permanently sealed and
lubricated as an assembly. Do not attempt to
remove the hub bearings, seals and lubricant. You
can not service or reinstall these components into GREASE
a unitized hub assembly. Damage to components FITTING
can result.
WARNING
To prevent serious eye injury, always wear safe
eye protection when you perform vehicle
maintenance or service.
NOTE: On Easy Steer Plus front axles, the grease
fittings are located on the top and bottom king pin
caps.
1. Be certain that the tires touch the ground. Do not
raise the vehicle.
2. Clean all grease fittings prior to lubrication.
3. Lubricate the king pins through the grease fittings
on the top and bottom of the knuckle. Figure 5.3.
4. Force lubricant into upper and lower king pin
grease fitting caps until new lubricant flows from
between the following two areas:
a. Upper axle beam end and the knuckle.
Figure 5.3.
b. Lower axle beam end and the knuckle.
Figure 5.3.
Page 15
Section 5
Front Non-Driving Axle
➀ Applies to ball studs on conventional and Easy Steer front axles. For sealed axles, inspect the boot on the
ball stud every 96,000 miles (154,000 km) for wear and damage. Service as necessary.
➀ Applies to ball studs on conventional and Easy Steer axles. For sealed axles, inspect the boot on the ball stud
every 96,000 miles (154,000 km) for wear and damage. Service as necessary.
Page 16
Section 5
Front Non-Driving Axle
➀ Applies to ball studs on conventional and Easy Steer axles. For sealed axles, inspect the boot on the ball stud
every 96,000 miles (154,000 km) for wear and damage. Service as necessary.
Page 17
Section 5
Front Non-Driving Axle
Page 18
Section 6
On-Highway Brakes
➀ The grease used inside the caliper must be non-melting and also allow proper brake function at the cold
temperatures listed.
*Do not mix 0-637 calcium-base, corrosion-control grease with other greases.
Page 19
Section 6
On-Highway Brakes
*Do not mix 0-637 calcium-base, corrosion-control grease with other greases.
*Do not mix 0-637 calcium-base, corrosion-control grease with other greases.
Page 20
Section 6
On-Highway Brakes
and All Other Applications You can identify Q Plust LX500 and MX500 cam
brakes by checking the identification tags affixed to
NOTE: You must continue to observe all other brake the brake.
preventive maintenance schedules and procedures for 1. A brake shoe tag identifies the brakes as
Q Plust LX500 and MX500 cam brakes with Q Plustbrakes.
factory-installed Meritor automatic slack adjusters.
Refer to Maintenance Manual No. MM-96173, Q 2. An additional identification tag imprinted with
Plust LX500 Cam Brakes; and Maintenance Manual “SEE MERITOR MAINTENANCE MANUAL
No. 4B, Automatic Slack Adjuster. MM-96173 FOR LUBE INFO,” which is affixed to
the brake chamber bracket over the top of the
Meritor’s new Q Plust LX500 Cam Brake package plugged grease hole, identifies the brake as a
with the Extended Lube feature is available for Q Plust LX500 or MX500 brake.
on-highway linehaul and all other applications and
includes: 3. Q Plust LX500 and MX500 brakes and automatic
slack adjusters do not have grease fittings.
D Q Plust LX500 cam brakes.
D Meritor factory-installed automatic slack adjusters.
D Extended Lube Feature: For on-highway linehaul
Lubricating the Q Plust LX500
applications, the Q Plust LX500 camshaft and and MX500 Cam Brakes and
slack adjusters do not require lubrication Automatic Slack Adjusters
for 3 years or 500,000 miles (800,000 km),
whichever comes first. For all other applications, After Specified Mileage or Time
the lubrication interval is one year, regardless of Intervals
mileage.
1. Remove the identification tag from the chamber
bracket housing.
Q Plus MX500 Extended
2. Remove grease plugs from both the chamber
Maintenance Package Option bracket and the automatic slack adjuster.
Available for On-Highway Linehaul 3. Install grease fittings and lubricate the brake
Applications Only assembly through the grease fitting in the bracket
with Meritor-approved synthetic grease, O-695,
Meritor’s new Q Plust MX500 cam brake is available until new grease flows from the inboard seal.
for on-highway linehaul applications only and includes: 4. Lubricate the automatic slack adjuster through the
D Extended Maintenance Package: Proprietary grease fitting until new grease flows out of the pull
friction material on 5-inch wider shoes for front pawl or camshaft seal.
axles and 8-inch wider shoes for rear axles for 5. Replace the fittings with new grease plugs and
more wearable volume than Q Plust LX500 cover the bracket plug with a new identification
brakes. tag.
D Extended Lube Feature: The Q Plust MX500
camshaft and slack adjusters do not require Camshaft Bushings
lubrication and reline for 3 years or 500,000 miles
(800,000 km), whichever comes first. CAUTION
D Meritor factory-installed automatic slack adjusters. When grease flows from the seal near the cam
head, replace the seal. Remove any grease from
the cam head, rollers and linings. Grease on the
linings can increase stopping distances.
Page 21
Section 6
On-Highway Brakes
Approved Greases
Lubricant Recommendation Lubricant Recommendation
O-616-A Shell Darina Grease No. 1 O-645 Mobilgrease 28 (Military)
Texaco Thermatex EP-1 Mobiltemp SHC 32 (Industrial)
Texaco Hytherm EP-1 Aerospace Lubricants Inc. Tribolube
Aralub 3837 12-Grade1
O-617-A Multi-Purpose Lithium Chassis Grease O-692 Amoco Super Permalube #2
O-617-B Citgo Premium Lithium EP-2 #2
O-637* Witco Chemical Corp. SA-824946 Exxon Ronex MP-2 #2
Kendall L-427 Super Blu #2
O-641 Never-Seez Anti-Seize Mobilith AW-1 #1
Sohio Factran EP-2 #2
* Do not mix 0-637 calcium-base, corrosion-control
grease with other greases. O-695 EVO-LUBE TEK-615
Page 22
Section 7
Planetary Drive Axle
WARNING
Breather To prevent serious eye injury, always wear safe
eye protection when you perform vehicle
CAUTION maintenance or service.
Cover the breather when steam cleaning the NOTE: Fill and drain plugs are located in the axle
housing. If the breather is not covered, water can housing bowl and the wheel ends. Most axles have a
enter the housing and contaminate the oil. common oil level. All steering axles and some rigid
Breathers release pressure and vacuum condensation axles have separate oil levels in each wheel end and
to minimize premature oil and component failure. the axle housing bowl.
1. Make sure the vehicle is on a level surface.
NOTE: For axles with a common oil level that have
drain and fill plugs only in the axle assembly, go to
step 3.
2. Rotate the wheels so that the “oil level lines” on
the wheel ends are parallel to the ground.
Page 23
Section 7
Planetary Drive Axle
3. Clean the area around the fill/level plug. Remove Drain and Replace Oil
the fill/level plug from the wheel ends and the axle
housing bowl. Figure 7.1. NOTE: Fill and drain plugs are located in the axle
housing bowl and the wheel ends. Most axles have a
common oil level. All steering axles and some rigid
Figure 7.1 axles have separate oil levels in each wheel end and
the axle housing bowl.
WARNING
Support the vehicle with safety stands. Do not
work under a vehicle only supported by jacks.
Jacks can slip or fall over and cause serious
personal injury.
1. Make sure the vehicle is on a level surface. Put
large containers under the axle and wheel ends.
2. Raise the vehicle so that the wheels are off the
FILL/LEVEL
ground. Support the vehicle with safety stands.
PLUG
3. Rotate the wheels so that the “fill/level” plugs in
the wheel ends are toward the ground.
4. The oil level must be even with the bottom of the 4. Remove the drain plugs from the wheel ends and
hole of the fill/level plug. axle housing bowl. Drain and discard the oil
If oil flows from the hole when the plug is properly. Clean the plug.
loosened, the oil level is high. Let the oil drain to 5. Install and tighten the drain plug in the axle
the correct level. housing bowl and the wheel ends to 35-50 lb-ft
If the oil level is below the bottom of the hole of (48-67 N•m).
the fill/level plug, add the specified oil. See the
6. Rotate the wheels so that the “oil level lines” on
following:
the wheel ends are parallel to the ground. Lower
a. For axles with separate oil levels in the wheel the vehicle.
ends and the axle housing bowl, fill each area
7. Clean the area around the fill/level plug. Remove
to the bottom of the fill plug hole with the
the fill/level plug from the wheel ends and the axle
specified oil.
housing bowl.
NOTE: Do not fill only through the axle housing bowl.
8. Add the specified oil until the oil level is even with
b. For axles with a common oil level, fill the axle the bottom of the fill/level hole. See the following:
at each wheel end and the axle housing bowl
a. For axles with separate oil levels in the wheel
to the bottom of the fill plug hole with the
ends and the axle housing bowl, fill each area
specified oil. Wait and allow the oil to flow
to the bottom of the fill/level plug hole with the
through the axle. Check the oil level again and
specified oil.
fill to the specified level if necessary.
5. Install and tighten the fill/level plugs to the correct
torque specification. NOTE: Do not fill only through the axle housing bowl.
b. For axles with a common oil level, fill the axle
at each wheel end and the axle housing bowl
to the bottom of the fill/level plug hole with the
specified oil. Wait and allow the oil to flow
through the axle. Check the oil level again
and fill the specified level if necessary.
9. Install and tighten the fill/level plugs to the correct
torque specification.
Page 24
Section 7
Planetary Drive Axle
Outside Temperature
Military
Meritor Specification Oil F C
Specifications Approval Description Min. Max. Min. Max.
O-76A, Gear Oil GL-5, SAE 85W/140 10 None -12 None
MIL-L-2105D
MIL L 2105D
O-76D, Gear Oil or GL-5, SAE 80W/90 -15 None -26 None
O-76E, Gear Oil MIL-PRF-2105-E GL-5, SAE 75W/90 -40 None -40 None
O-76L, Gear Oil GL-5, SAE 75W/140 -40 None -40 None
O-76M, Gear Oil GL-5, SAE 75W/140 -40 None -40 None
O-76N, Gear Oil GL-5, SAE 75W/140 -40 None -40 None
➀ The interval depends on the individual operating conditions, speeds and loads. Severe operating conditions
may require more frequent intervals.
* Due to varied planetary drive axle specifications, these fill quantities are for reference only.
Page 25
Section 7
Planetary Drive Axle
* Due to varied planetary drive axle specifications, these fill quantities are for reference only.
Page 26
Section 8
Rear Drive Axle
Page 27
Section 8
Rear Drive Axle
Page 28
Section 8
Rear Drive Axle
Check and Adjust the Oil D For “Advanced Lube Axles”: Replace the oil filter
every 100,000 miles (160,000 km).
5. Clean the area around the fill plug. Remove the fill
CAUTION plug from the differential carrier of the
Check the oil level when the axle is at room axle-housing bowl (depending on the axle).
temperature. When hot, the oil temperature may
be 190_ F (88_ C) or more and can cause burns. 6. Add the specified oil until the oil is even with the
Also, a correct level is not obtained when the axle bottom of the fill plug hole. Wait to allow the oil to
is warm or hot. flow through the axle.
1. Park the vehicle on a level surface. The axle must 7. Check oil level again. If necessary, continue to
be “cold” or near room temperature. add oil until it is even with the bottom of the fill
plug hole.
2. Clean the area around the fill plug. Remove the fill
plug from the differential carrier or the 8. Install the fill plug. Tighten the plug to 35-50 lb-ft
axle-housing bowl (depending on the axle). (48-67 N•m).
Figure 8.2 - 8.8.
9. If the inter-axle differential has a top fill plug
3. Check the oil level. The level must be even with hole: Add an additional two pints (0.946 liters) of
the bottom of the fill plug hole. Figure 8.1. the same oil into the inter-axle differential housing.
4. Install the fill plug. Tighten the plug to 35-50 lb-ft D Refer to the section below for information on
(48-67 N•m). inter-axle differential assemblies with separate
housings.
Inter-Axle Assemblies with Separate
Figure 8.1 Oil level must be even with Housings
bottom of fill plug hole.
Meritor’s SLHD, SQHD, STDD and SFDD
forward-rear tandem axle carrier models include
separate housings for inter-axle differential
assemblies.
D The baffles and dams used in these housings hold a
reservoir of oil that can also trap wear particles and
debris. Always purge the oil from these reservoirs
when you change axle oil.
FILL PLUG D These carriers have separate drain and fill holes in
either the inter-axle differential cover or housing.
TEMPERATURE INDICATOR PLUG-
DO NOT REMOVE Figure 8.2 FILL PLUG LOCATION IN BACK
OF AXLE HOUSING BOWL
Drain and Replace the Oil
FILL PLUG
NOTE: Drain the oil when it is warm.
1. Refer to “Fill Plug Locations” in this section.
2. Park the vehicle on a level surface. Put a large
container under the axle.
3. Install the drain plug. Tighten the plug to 35-50
lb-ft (48-67 N•m).
Page 29
Section 8
Rear Drive Axle
Figure 8.3 FRONT MOUNTED SINGLE Figure 8.6 FRONT MOUNTED SINGLE
REDUCTION AXLES REDUCTION TANDEM AXLES
CARRIER FILL PLUG (NOT SHOWN)
FILL PLUG
DRAIN PLUG
DRAIN PLUG HYPOID GEARING WITH INTER-AXLE
DRIVE PINION ANGLE 7° OR LESS DIFFERENTIAL AND PUMP
USE CARRIER FILL PLUG FORCED LUBRICATION
DRAIN PLUG
FILL PLUG
DRIVE PINION ANGLE MORE THAN 7°
USE AXLE HOUSING FILL PLUG DRAIN PLUG
FILL HOLE IN CARRIER
DRAIN
PLUG
FILL PLUG
(NOT SHOWN)
DRAIN PLUG FILL PLUG DRAIN PLUG
HYPOID GEARING WITH
INTER-AXLE DIFFERENTIAL FILL HOLE IN AXLE HOUSING
Page 30
Section 8
Rear Drive Axle
* Consult Meritor or your Meritor representative for application information and updating.
Outside Temperature
Military
Meritor Specification Oil F C
Specifications Approval Description Min. Max. Min. Max.
O-76A, Gear Oil GL-5, SAE 85W/140 10 None -12 None
O-76D, Gear Oil GL-5, SAE 80W/90 -15 None -26 None
O-76E, Gear Oil GL-5, SAE 75W/90 -40 None -40 None
O-76J, Gear Oil MIL-L-2105D GL-5, SAE 75W -40 35 -40 2
O-76L, Gear Oil or GL-5, SAE 75W/140 -40 None -40 None
MIL-PRF-2105-E
O-76M, GL-5, SAE 75W/140 -40 None -40 None
Full Synthetic Gear Oil
O-76N, GL-5, SAE 75W/90 -40 None -40 None
Full Synthetic Gear Oil
Page 31
Section 8
Rear Drive Axle
Outside Temperature
Military
Meritor Specification Oil _F _C
Specifications Approval Description Min. Max. Min. Max.
O-76A, Gear Oil GL-5, SAE 85W/140 10 None -12 None
O-76D, Gear Oil GL-5, SAE 80W/90 -15 None -26 None
O-76E, Gear Oil GL-5, SAE 75W/90 -40 None -40 None
O-76J, Gear Oil MIL-L-2105D GL-5, SAE 75W -40 35 -40 2
O-76L, Gear Oil or GL-5, SAE 75W/140 -40 None -40 None
MIL-PRF-2105-E
O-76M, GL-5, SAE 75W/140 -40 None -40 None
Full Synthetic Gear Oil
O-76N, GL-5, SAE 75W/90 -40 None -40 None
Full Synthetic Gear Oil
➀ If a No-Spint differential is installed, oil (petroleum or synthetic) must be changed at minimum of 40,000 miles
(64,000 km) or a maximum interval of 50,000 miles (80,000 km).
➁ Applies to heavy-duty on-highway and on/off-highway applications. Does not apply to off-highway applications.
➂ For extended-drain petroleum based oils, use “Synthetic Oil Change” interval.
➃ Applies to approved semi-synthetic and full synthetic oils. For list of approved extended-drain oils, refer to
Meritor’s Bulletin TP-9539, “Approved Rear Drive Axle Lubricants.” Call 800-535-5560 to obtain a copy of this
publication.
Page 32
Section 8
Rear Drive Axle
Outside Temperature
Military
Meritor Specification Oil F C
Specifications Approval Description Min. Max. Min. Max.
O-76A, Gear Oil GL-5, SAE 85W/140 10 None -12 None
O-76D, Gear Oil GL-5, SAE 80W/90 -15 None -26 None
O-76E, Gear Oil GL-5, SAE 75W/90 -40 None -40 None
O-76J, Gear Oil MIL-L-2105D GL-5, SAE 75W -40 35 -40 2
O-76L, Gear Oil or GL-5, SAE 75W/140 -40 None -40 None
MIL-PRF-2105-E
O-76M, GL-5, SAE 75W/140 -40 None -40 None
Full Synthetic Gear Oil
O-76N, GL-5, SAE 75W/90 -40 None -40 None
Full Synthetic Gear Oil
➀ If oil pump and filter is used, change filter every 100,000 miles (160,000 km). Check oil level. Add correct oil as
required.
➁ Includes heavy-duty on-highway and on/off-highway applications.
➂ For continuous heavy-duty operation, check oil level every 1,000 miles (1,600 kilometers).
➃ Applies to approved semi-synthetic and full synthetic oils. For list of approved extended-drain oils, refer to
Meritor’s Bulletin TP-9539, “Approved Rear Drive Axle Lubricants.” Call 800-535-5560 to obtain a copy of this
publication.
Page 33
Section 8
Rear Drive Axle
Tandem “Advanced Lube” Rear Drive Axle without Oil Pump and Filter Oil
Change Intervals and Specifications ①
Applies to tandem rear axles manufactured after January 1, 1993, equipped with
advanced material triple lip seals.
Operation On-Highway Off-Highway②
Check Oil Level 3,000 miles (4,800 km), once a month or 3,000 miles (4,800 km) or 200 hours of
the fleet maintenance interval (whichever operation (whichever comes first)⑤
comes first)
Petroleum Oil 100,000 miles (160,000 km) 40,000 miles (64,000 km)
Change③
Synthetic Oil Change④ 250,000 miles (400,000 km) 80,000 miles (128,000 km)
Outside Temperature
Military
Meritor Specification Oil _F _C
Specifications Approval Description Min. Max. Min. Max.
O-76A, Gear Oil GL-5, SAE 85W/140 10 None -12 None
O-76D, Gear Oil GL-5, SAE 80W/90 -15 None -26 None
O-76E, Gear Oil GL-5, SAE 75W/90 -40 None -40 None
O-76J, Gear Oil MIL-L-2105D GL-5, SAE 75W -40 35 -40 2
O-76L, Gear Oil or GL-5, SAE 75W/140 -40 None -40 None
MIL-PRF-2105-E
O-76M, GL-5, SAE 75W/140 -40 None -40 None
Full Synthetic Gear Oil
O-76N, GL-5, SAE 75W/90 -40 None -40 None
Full Synthetic Gear Oil
➀ If a No-Spint differential is installed, oil (petroleum or synthetic) must be changed at minimum interval of
40,000 miles (64,000 km) or a maximum interval of 50,000 miles (80,000 km).
➁ Also applies to heavy-duty on-highway applications. Does not apply to off-highway applications.
➂ For extended-drain petroleum based oils, use the “Synthetic Oil Change” interval.
➃ Applies to approved semi-synthetic and full synthetic oils. For list of approved extended-drain oils, refer to
Meritor’s Bulletin TP-9539, “Approved Rear Drive Axle Lubricants.” Call 800-535-5560 to obtain a copy of this
publication.
➄ For continuous heavy-duty operation, check the oil level every 1,000 miles (1,600 km). Add the correct oil as
required.
Page 34
Section 8
Rear Drive Axle
Tandem “Advanced Lube” Rear Drive Axle with Oil Pump and Filter Oil
Change Intervals and Specifications ① ②
Applies to tandem rear axles manufactured after January 1, 1993, equipped with
Membrane type breathers and advanced material triple lip seals:
RT-34-145P, RT-40-145P, RT-44-145P, RT-46-160P, AND SQ-100P (Aluminum).
Operation On-Highway Off-Highway③
Check Oil Level 3,000 miles (4,800 km), once a month or the 3,000 miles (4,800 km) or 200 hours of
fleet maintenance interval (whichever comes operation (whichever comes first)⑥
first)
Petroleum Oil 100,000 miles (160,000 km) 50,000 miles (80,000 km)
Change④
Synthetic Oil Change⑤ 500,000 miles (800,000 km) 100,000 miles (160,000 km)
Outside Temperature
Military
Meritor Specification Oil _F _C
Specifications Approval Description Min. Max. Min. Max.
O-76A, Gear Oil GL-5, SAE 85W/140 10 None -12 None
O-76D, Gear Oil GL-5, SAE 80W/90 -15 None -26 None
O-76E, Gear Oil GL-5, SAE 75W/90 -40 None -40 None
O-76J, Gear Oil MIL-L-2105D GL-5, SAE 75W -40 35 -40 2
O-76L, Gear Oil or GL-5, SAE 75W/140 -40 None -40 None
MIL-PRF-2105-E
O-76M, GL-5, SAE 75W/140 -40 None -40 None
Full Synthetic Gear Oil
O-76N, GL-5, SAE 75W/90 -40 None -40 None
Full Synthetic Gear Oil
➀ Replace oil filter every 100,000 miles (160,000 km). Check oil level. Add specified oil as required.
➁ If No-Spint differential is installed, oil (petroleum or synthetic) must be changed at minimum interval of 40,000
miles (64,000 km) or a maximum interval of 50,000 miles (80,000 km).
➂ Applies to heavy-duty on-highway applications and to on/off highway applications. Does not apply to
off-highway applications.
➃ For extended-drain petroleum based oils, use the “Synthetic Oil Change” interval.
➄ Applies to approved semi-synthetic and full synthetic oils. For list of approved extended-drain oils, refer to
Meritor’s Bulletin TP-9539, “Approved Rear Drive Axle Lubricants.” Call 800-535-5560 to obtain a copy of this
publication.
➅ For continuous heavy-duty operation, check oil level every 1,000 miles (1,600 km). Add the correct oil as
required.
Page 35
Section 8
Rear Drive Axle
➀ Oil capacities are for standard track axles that have been measured at various common drive pinion angles.
The quantities listed include enough oil for both wheel ends. These oil capacities will change if the track or the
drive pinion angle is different.
Page 36
Section 8
Rear Drive Axle
➀ Oil capacities are for standard track axles that have been measured at various common drive pinion angles.
The quantities listed include enough oil for both wheel ends. These oil capacities will change if the track or the
drive pinion angle is different.
➁ Forward carrier with oil pump system.
Page 37
Section 9
Trailer Axle
Page 38
Section 9
Trailer Axle
Removal of long-life bearings, seals or GREASE
lubricant from the Meritor TB series FITTING
trailer axle hub will void the warranty.
Refer to Technical Bulletin TP-96175 or
call 800-535-5560 for information.
TP-9700
Page 39
Section 9
Trailer Axle
➀ Applies to standard-duty on-highway service. Lubricate more frequently for heavy-duty applications. Determine
intervals by inspecting lubricant every two weeks for a four month period. Look for hard, contaminated or
missing grease. Choose an interval based on the inspection.
➀ The recommended oil change interval is based on operating conditions, speeds and loads. Limited service
applications may allow the recommended interval to be increased. Severe service applications may require the
recommended interval to be reduced. For more information, contact Meritor’s Customer Service Center at
800–535–5560.
Page 40
Section 9
Trailer Axle
➀ The recommended greasing interval is based on operating conditions, speeds and loads. Limited service
applications may allow the recommended interval to be increased. Severe service applications may require the
recommended interval to be reduced. For more information, contact a Meritor service representative.
Page 41
Section 10
Transfer Case
CAUTION 3. The oil level must be even with the bottom of the
fill plug hole or the top of the stand pipe.
Cover the breather when steam cleaning the
housing. If the breather is not covered, water a. If oil flows from the fill plug hole when the plug
enters the housing and contaminates the oil. is loosened, the oil level is high. Let the oil
drain to the correct level.
Breathers release pressure that builds up inside the
transfer case during vehicle operation. b. If the oil level is below the bottom of the fill
plug hole or stand pipe, add the specified oil.
Page 42
Section 10
Transfer Case
7. Run the vehicle for 1/4 mile (0.4 km), then “top off” FILL
the oil level by adding oil to the fill opening. STAND
PIPE
8. Reinstall and tighten the fill plug to 35-50 lb-ft
(47-68 N•m).
Page 43
Section 10
Transfer Case
➀ Do Not use multi-viscosity (I.E. 80/90W) GL-5 Gear Oil (axle lube).
➁ 90W GL-1 or 50W motor oil is same viscosity and commonly used above 10°F (-12°C).
➂ Meritor Appoved full synthetic oil for manual Meritor Transmissions are also approved for Meritor transfer
cases. Use synthetic oil only if the T-case was initially filled with synthetic oil.
➃ Do not mix or switch oil types––stay with oil that initially filled T-case.
➄ Do not use multi-viscosity oils.
➀ Due to the varied transfer case configurations, these fill quantities are for reference only. The fill procedure for
all transfer cases is as follows:
1. Fill to the top of the stand pipe or fill hole.
2. Run the vehicle for 1/4 mile (0.4 km).
3. Then “top off” the oil level.
The sump temperature should not exceed 225°F (107°C).
Page 44
Section 11
Transmission
Page 45
Section 11
Transmission
Oil Level 6. Install and tighten the fill plug to 35-50 lb-ft
(48-67 N•m).
Check and Adjust Oil
7. Operate the vehicle for 5 minutes. Check for leaks
and correct operation.
WARNING
To prevent serious eye injury, always wear safe
eye protection when you perform vehicle Drain and Replace Oil
maintenance or service.
1. Make sure of the following before checking the oil CAUTION
level. Figure 11.1. Adhere to the following lubrication guidelines to
prevent damage to the transmission.
a. The oil is at room temperature.
Use only the specified oil. Do not use
b. Wait ten minutes after the vehicle is parked
multi-viscosity engine oils or Extreme Pressure
before checking the level.
(EP) GL-5 gear oils.
2. Make sure the vehicle is parked on a level
Use the same oil that is in the transmission. Do
surface.
not mix oils.
3. Clean the area by the fill plug. Remove the fill plug Check for low oil. The oil level must be even with
from the side of the transmission.
the bottom of the fill plug for the oil to completely
4. Check for and correct any oil leaks. lubricate the transmission.
NOTE: Drain the oil when the transmission is hot.
Figure 11.1 1. Make sure the vehicle is parked on a level
Oil level must be even with surface. Put a large container under the
bottom of fill plug hole. transmission. Put a screen on top of the container.
2. Remove the drain plugs from the bottom of the
transmission. Drain and discard the oil properly.
3. Inspect the screen on the top of the drain
container for metal particles and damaged parts.
Service the transmission as necessary.
If the transmission is disassembled or replaced
and an oil cooler is used, remove the cooler.
Remove and discard the oil from the cooler and
the oil lines.
Page 46
Section 11
Transmission
CAUTION
Use only the specified oil. Do not use
multi-viscosity engine oils or Extreme Pressure
(EP) GL-5 gear oils. Damage to components can
result. The use of multi-viscosity or EP oils will
void Meritor’s warranty.
6. Add the specified transmission oil through the fill
plug hole. Add the oil until the oil level is even with
the bottom of the fill plug hole.
7. Install and tighten the fill plug to 35-50 lb-ft
(48-67 N•m).
Page 47
Section 11
Transmission
① Oil capacities are approximate. Fill the transmission to the bottom of the fill plug hole. On transmissions
equipped with an oil pump and/or oil cooler, operate the engine for five minutes after the initial fill and check the
oil level again.
➁ Weights are approximate, less clutch housing, shift controls, output yoke and lubricant.
➂ Available with Meritor’s Engine Synchro ShiftTM (ESS) System. For ESS transmission models, replace the “M”
in the above model numbers with an “S”.
Page 48
Section 12
Wheel Bearings and Wheel Ends
Greasing Wheel Bearings 6. Install the inner and outer bearing cones into the
cups in the hubs. The bearing cups must be
pressed tight against the shoulder in the hubs.
CAUTION
7. Install new wheel seals in the hubs.
To prevent serious eye injury, always wear safe
eye protection when you perform vehicle 8. Install the hub and the wheel and tire assembly.
maintenance or service. Install the outer wheel bearing cone in the hub.
Install the adjusting nut.
WARNING 9. Adjust the wheel bearings.
Support the vehicle with safety stands. Do not
work under a vehicle only supported by jacks.
Jacks can slip or fall over and cause serious Figure 12.1
personal injury. TYPICAL GREASE LUBRICATED
WHEEL BEARINGS
NOTE: For specific service information refer to the
LUBE
correct maintenance manual listed in the “References”
chart at the front of this manual.
1. Raise the vehicle so that the wheels are off the
ground. Support the vehicle with safety stands.
2. Remove the tire and wheel assembly. Remove
and disassemble the hub.
3. Use the correct cleaning solvent to remove the old
grease from all parts. Discard the seals. Inspect
the wheel bearings for wear or damage. Replace
worn or damaged bearings.
4. Before installing the wheel bearings, lubricate the
bearing journals on the spindle with the grease
that is used for the bearings. Figure 12.1.
5. Use a pressure packer to force the specified
grease from the large end of the cones into the
cavities between the rollers and cage. Pack the
hub between the bearing cups with grease to the
level of the smallest diameter of the cups. If a
pressure packer is not available, grease the
bearings by hand.
Page 49
Section 12
Wheel Bearings and Wheel Ends
Checking the Oil Level Drive Axle Hubs Without Fill Holes
on Wheel Bearings 1. Pour the specified amount of lubricant through the
NOTE: If you cannot observe the oil level because the carrier or housing bowl oil fill hole.
sightglass is stained, remove the fill plug, check the oil 2. Tilt the axle to the right and to the left to let the oil
level with your finger and follow the procedures for flow into the hub cavities. Keep the axle tilted for
Step 2, below. Replace the stained sightglass at your one minute in each position.
earliest maintenance opportunity.
3. With the axle in the level position, add the
1. Check the oil level on the cap. specified oil so that the level is even with the
2. If the oil level is more than 1/4-inch (6mm) below bottom of the fill plug hole.
the specified level on the cap, remove the fill plug. 4. Install and tighten the fill plug.
3. Add the specified oil to the specified level.
Figure 12.2.
4. Install the fill plug.
Figure 12.2
TYPICAL OIL
LUBRICATED
WHEEL BEARINGS
LUBE
Page 50
Section 12
Wheel Bearings and Wheel Ends
Outside Temperature
Military
Meritor Specifications Oil F C
Specifications Approval Description Min. Max. Min. Max.
O-76A, Gear Oil GL-5, SAE 85W/140 10 None -12 None
MIL-L-2105D
MIL L 2105D
O-76D, Gear Oil or GL-5, SAE 80W/90 -15 None -26 None
O-76E, Gear Oil MIL-PRF-2105-E GL-5, SAE 75W/90 -40 None -40 None
O-76J, Gear Oil GL-5, SAE 75 -40 35 -40 2
Heavy-Duty MIL-L-2104D, E, or F A.P.I. -CD, -CE, -SF, or -SG, 10 None -12 None
Engine Oil SAE, SAE 40 or 50 ①
Heavy-Duty MIL-L-2104D, E, or F A.P.I. -CD, -CE, -SF, or -SG, -15 None -26 None
Engine Oil SAE 30 ②
➀ Current designations are acceptable. Multi-weight engine oils are acceptable if the SAE rating ends in a 40 or
50.
➁ Current designations are acceptable. Multi-weight engine oils are acceptable if the SAE rating ends in a 30.
Page 51
Section 13
List of Lubricants
Grease Lubricants ①
Meritor NLGI Grease Outside
Specification Grease Typical Application Grade Description Temperature
O-616 Brake Grease Cam Brake Anchor Pins, 2 Clay Base ②
Mechanical Brake Anchor Pins
O-616-A Brake Grease Air Disc Brake Caliper, Automatic 1 Clay Base Down to -40F
Slack Adjuster, Wedge Brake (-40C)
Components
O-617-A Multi-Purpose Cam Brake Chamber Brackets, 1 Lithium ②
or Grease Cam Brake Hold Down Clips, or 12-Hydroxy
O-617-B Cross Tube Ends, Drag Link, 2 Stearate or
Wheel Bearings, King Pins and Lithium
Bushings, Knuckle Bushings, Complex
Manual Slack Adjuster, Steering
Arm, Ball Studs, Tie Rod End Ball
Studs, Trailer Axle Wheel
Bearings, Wedge Brake Hold-
Down Clips, Wedge Brake Shoe
Contacts at Anchors.
O-634-B Universal Driveshaft Slip Yokes, Driveshaft 2 Lithium ②
Joint Grease Splines, Driveshaft Universal 12-Hydroxy
Joints Stearate with
Molybdenum
Disulfide
O-637* Special Rust- Air Disc Brake Slide Pin, Splines 1 1/2 Calcium ②
Preventing and Clevis Pins, Cam Brake
Brake Grease Camshaft Splines
O-645 Low- Air Disc Brake Caliper, Automatic 2 Synthetic Down to -65F
Temperature Slack Adjuster, Wedge Brake (-54C)
Brake Grease Components
O-647 Trailer Axle Trailer Axle Wheel Bearings 00 Synthetic ②
Bearing
Grease
O-661 High- Clutch Release Bearing 3 Lithium ②
Temperature Complex
Multi-Purpose
Wheel
Bearing
Grease
O-692 Automatic Automatic Slack Adjuster 1&2 Lithium Base Down to -40F
Slack Adjuster (-40C)
Grease
➀ Grease recommendations are based on commercial products that have given satisfactory results in normal
operation. However, there are many proprietary grease products on the market which will perform satisfactorily
and may be preferable because of supply problems, common usage for other truck components, etc. When
such products are recommended by reputable suppliers for the specific lubrication of our components, Meritor
has no objections, provided that these substitute products are equal to or better than Meritor recommendations
in lubrication properties, water resistance, corrosion protection, high and low temperature characteristics,
oxidation stability, shear stability, etc. All substitute products are subject to Meritor approval. For more
information, contact a Meritor service representative.
➁ Refer to the manufacturer’s specifications for the temperature service limits.
*Do not mix 0-637 calcium-base, corrosion-control grease with other greases.
Page 52
Section 13
List of Lubricants
Oil Lubricants
Outside Temperature
Military F C
Meritor Typical
yp Specification Oil
Specification Oil Application Approval Description Min. Max. Min. Max.
O-62 Petroleum Transfer Case ----- SAE 90 10 None -12 None
Oil
O-63 Petroleum Transfer Case ----- SAE 140 40 None 4 None
Oil
O-76A Gear Oil Front Driving Axle, GL-5, SAE 10 None -12 None
Front Driving Axle 85W/140
Wheel Bearings,
Non-Driving Axle
Wheel Bearings,
Planetary Axle,
Rear Driving Axle,
Trailer Axle Wheel
Bearings
O-76D Gear Oil Front Driving Axle, GL-5, SAE -15 None -26 None
Front Driving Axle 80W/90
Wheel Bearings, MIL-L-2105D
Non-Driving Axle or
Wheel Bearings, MIL-PRF-2105-E
Planetary Axle,
Rear Driving Axle,
Trailer Axle Wheel
Bearings
O-76E Gear Oil Front Driving Axle, GL-5, SAE -40 None -40 None
Front Driving Axle 75W/90
Wheel Bearings,
Non-Driving Axle
Wheel Bearings,
Planetary Axle,
Rear Driving Axle,
Trailer Axle Wheel
Bearings
Page 53
Section 13
List of Lubricants
Outside Temperature
Military F C
Meritor Typical
yp Specification Oil
Specification Oil Application Approval Description Min. Max. Min. Max.
O-76J Gear Oil Front Driving Axle, GL-5, SAE -40 35 -40 2
Front Driving Axle 75W
Wheel Bearings,
Non-Driving Axle
Wheel Bearings,
Planetary Axle,
Rear Driving Axle,
Trailer Axle Wheel
Bearings
O-76L Gear Oil Front Driving Axle, GL-5, SAE -40 None -40 None
Front Driving Axle 75W/140
Wheel Bearings, MIL-L-2105D
Non-Driving Axle or
Wheel Bearings, MIL-PRF-2105-E
Planetary Axle,
Rear Driving Axle,
Trailer Axle Wheel
Bearings
O-76M Full Rear Driving Axle, GL-5, SAE -40 None -40 None
Synthetic Trailer Axle Wheel 75W/140
Oil Bearings
O-76N Full Rear Driving Axle, GL-5, SAE -40 None -40 None
Synthetic Trailer Axle Wheel 75W/90
Oil Bearings
O-81 Full Transmission ----- SAE 50 -40 None -40 None
Synthetic
Oil
----- Heavy Transmission A.P.1. -CD, 10 None -12 None
Duty -CE, -SF,
Engine Oil -SG or -SH
SAE 50
----- Heavy Transmission A.P.1. -CD, 10 None -12 None
Duty -CE, -SF,
Engine Oil -SG or -SH
SAE 40
MIL-L-2104
MIL L 2104
----- Heavy Transmission -D, -E, or -F A.P.1. -CD, -15 10 -26 -12
Duty -CE, -SF,
Engine Oil -SG or -SH
SAE 30
----- Petroleum Transmission A.P.I.-GL-1 10 None -12 None
Gear SAE90
----- Petroleum Transmission A.P.I.-GL-1 -15 None -26 None
Gear SAE80
Page 54
Meritor Heavy Vehicle Systems, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is subject
2135 West Maple Road to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the information
Troy, MI 48084 USA presented or discontinue the production of parts described at any time.
800-535-5560
http://www.meritorauto.com Copyright 1999 Maintenance Manual No. 1
Meritor Automotive, Inc. Printed in the U.S.A. Revised 3/99
All Rights Reserved Please Recycle VFTIS/Meritor