Meritor Preventative Maintenance and Lubrication Mm1
Meritor Preventative Maintenance and Lubrication Mm1
Meritor Preventative Maintenance and Lubrication Mm1
00
Maintenance Manual 1
Preventive Maintenance and Lubrication
Revised 07-10
Service Notes
CAUTION
A Caution alerts you to an instruction or procedure that you
must follow exactly to avoid damage to components.
Information contained in this publication was in effect at the time the publication was
approved for printing and is subject to change without notice or liability. Meritor Heavy
Vehicle Systems, LLC, reserves the right to revise the information presented or to
discontinue the production of parts described at any time.
Figure 0.1
Overview Viscosity
1 Introduction
앫 Always use the specified oil or grease lubricant from a Oil viscosity grades and classifications are provided by the Society
manufacturer that provides quality products and complete of Automotive Engineers (SAE) and the American Petroleum Institute
application instructions. (API).
To obtain additional maintenance and service information for 앫 Use multigrade oils when vehicles operate in both cold and warm
components included in this manual, refer to the Service Notes page weather between oil changes.
on the front inside cover of this manual. 앫 Use low viscosity single grade oils only in cold climates. Single
grade 75W oils are not approved for use in drive axles where
Regularly-Scheduled Maintenance ambient or outside temperatures exceed 40°F (4°C).
Internal components can shed fine metal wear particles at a 앫 Use multigrade oil for drive axles only. The hypoid gearing
steady rate, especially during the break-in period. If wear requires a GL-5 oil with Extreme Pressure (EP) additives to
particles, moisture and other contaminants are allowed to circulate provide adequate lubricant film protection that prevents gear
in the lubricant, the components will wear at a faster rate than failure.
normal.
Regularly-scheduled maintenance using the specified lubricants
Oil Change Schedules
will help to ensure maximum component performance and life. To determine an oil change schedule, take an oil sample at a
specified interval or mileage recommendation. Analyze the sample
Oil Lubricants to establish a schedule.
There are three types of oil lubricants: petroleum, full-synthetic and However, service duty will often dictate when to change the oil,
semi-synthetic. Both full-synthetic and semi-synthetic oils retain regardless of mileage or a previously-established schedule.
their lubrication properties longer than petroleum oil.
앫 Petroleum oil is derived from crude oil. Crude petroleum oil also Oil Drain Conditions
yields combustible fuels and a wide range of petroleum
chemicals.
Differential Oil (Hypoid Gear Oils)
Drain and replace used differential oil that does not meet the
앫 Full-synthetic oil uses a man-made-base oil with predictable
physical properties. Full-synthetic oil contains no refined following used-oil analyses. Replace the drained oil with the oil
petroleum-base fluids. specified for hypoid drive axle use.
앫 Semi-synthetic oil contains a mixture of petroleum-base and Meritor recommends that you perform a lubricant analysis at
synthetic fluids that can help extend service intervals, improve every regularly-scheduled preventive maintenance interval.
cold weather properties and reduce volatility.
Table A: Used-Oil Analyses (ppm = parts per million) Do not mix different types of grease. Incompatible greases may
Iron (Fe) If the level is 1000-1500 ppm, resample the reduce the lubricating ability of the greases.
oil. If resampling indicates that the iron level is An important property of a grease is its dropping point, the
above 1000 ppm, drain and replace the oil. temperature where grease changes from a semi-solid state to a
If the level is above 1500 ppm, drain and liquid state. However, the operating temperature of a specific grease
replace the oil. is not determined solely by the dropping point. Other properties such
Silicon (Si) If the level is greater than 100 ppm, drain and as resistance to change in consistency and chemical deterioration at
replace the oil. high temperatures must be considered.
If the level is greater than 0.3%, drain and
Water (H2O)
replace the oil. National Lubricating Grease Institute (NLGI)
Phosphorus (P) If the level is less than 900 ppm, it is possible Standards
that the oil is not a GL-5 gear oil. Contact the The National Lubricating Grease Institute (NLGI) classifies and
lubricant manufacturer or Meritor Materials grades grease lubricants according to consistency and the
Engineering to determine the expected application for which it is used.
phosphorus level of a new oil sample. Only
GL-5 type gear oils are approved for use in The NLGI also issues licensed labels that identify approved grease
Meritor differentials. lubricant applications.
Toluene If the level is greater than 0.100 wt.%, drain
Insolubles and replace the oil. Extreme Pressure (EP) Lubricants
CAUTION
Manual Transmission Oils Do not use multi-viscosity or Extreme Pressure (EP) GL-5 gear
If used transmission oil analyses indicate that any one of these oils in a manual transmission or transfer case. Damage to the
criteria is not met, drain the used oil and replace it with an oil that is transmission will result.
recommended for manual transmissions.
Extreme Pressure lubricants are often identified by the abbreviation
Table B: Used-Oil Analyses (ppm = parts per million) EP. Extreme Pressure lubricants contain additives that provide extra
Iron (Fe) If the level is greater than 500 ppm, drain anti-wear protection to heavily-loaded parts. EP greases or EP oils
and replace the oil. are required in various applications. Figure 1.1.
Silicon (Si) If the level is greater than 100 ppm, drain Approved hypoid gear oils contain EP additives that protect against
and replace the oil. tooth scoring and surface fatigue.
If the level is greater than 0.3%, drain and
Water (H2O)
replace the oil.
Grease Lubricants
Grease lubricants contain three substances: oil, thickener base and
additives. The oil lubricates. The thickener or base holds the oil in
place and releases it to provide the necessary lubrication. The
thickener may be a simple or complex soap (lithium, calcium,
aluminum, etc.), organic (polyurea) or inorganic (clay). The additives
enhance the characteristics of the oil and thickener. Extreme
Pressure (EP) additives help prevent scoring, galling and welding
of moving parts.
Figure 1.1
Figure 1.1
Read and observe all Warning and Caution hazard alert messages in Meritor provides a wide selection of components to the transit bus
this publication. They provide information that can help prevent and coach industry suited to the latest vehicle designs as well as for
serious personal injury, damage to components, or both. traditional applications. These include:
앫 Front non-drive steer axles — 17100, 17101, 17111, FH 941,
WARNING
FH 945 and FH 946
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. 앫 Rear drive axles — 59000 Series, 61000 Series, 71000 Series
and RC-23-160
Park the vehicle on a level surface. Block the wheels to
앫 Center non-drive axles — 61000 Series, 71000 Series and
prevent the vehicle from moving. Support the vehicle with
RC-26-700
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and 앫 Inverted portal drive axles — RC-26-720 and RC-27-720
damage to components can result. 앫 Planetary drive axle — RC-26-633
앫 Stopmaster® wedge brakes — RDC Series
Technical Publications
앫 Cam brakes — Q Series, Q Plus™, Cast Plus™ and W Series
How to Obtain Additional Maintenance and 앫 Disc brakes — DiscPlus™ DX195 and DX225
Service Information
앫 Parking brake — T Series
Refer to the publications in Table C. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
Front Axles
manual.
Seven Meritor front non-drive steer axle models are available for
Table C: Publications buses and coaches. Models 17110 and 17111 have an I-beam
construction. Models 17100 and 17101 have a rectangular beam in
Model Manual
the center. Figure 2.1. Models FH 941, FH 945 and FH 946 have an
Bus and Coach Front Axles Maintenance Manual 23 I-beam construction. Figure 2.2 and Figure 2.3.
Bus and Coach Rear Axles Maintenance Manual 23A
Figure 2.1
Figure 2.2
2
Figure 2.3
61000 Series
The Meritor 61000 Series drive axles have the following features.
Figure 2.5.
앫 The single-reduction carrier is combined with a hypoid drive
pinion and a ring gear.
4003475a
앫 Optional double-reduction carriers are also available.
Figure 2.3 앫 The housing is designed with replaceable axle tubes at the wheel
spindles.
Rear Axles 앫 The housing has weld-on torque rod brackets.
The Meritor bus and coach rear drive axles are available in the
59000, 61000 and 71000 Series and RC-23-160. Figure 2.5
59000 Series
The Meritor 59000 Series drive axles have the following features.
Figure 2.4.
앫 Spiral bevel gearing is used in an angle drive carrier. The pinion
is at a 63-degree angle to the axis of the axle shafts.
앫 Optional conventional single-reduction and double-reduction 4001372a
carriers with hypoid gearing are also available.
Figure 2.5
앫 A driveline parking brake is installed on the flange of some angle
drive carriers. 71000 Series
앫 The housing is designed with replaceable axle tubes at the wheel The Meritor 71000 Series drive axles have the following features.
spindles. Figure 2.6.
Figure 2.4
앫 The single-reduction carrier is combined with a hypoid drive
pinion and a ring gear.
앫 The housing is designed with replaceable axle tubes at the wheel
spindles.
앫 The housing has bolt-on torque rod brackets.
앫 The axles are equipped with either S-cam or DiscPlus™ brakes.
Figure 2.6
4001371a
Figure 2.4
4001364a
Figure 2.6
models are the suspension bracketry configuration and the Figure 2.8
mounting of the brake chambers and automatic slack adjusters.
Both axles feature spiral bevel and helical forged gearing with
Planetary Drive Axle
industry-standard wheel ends. All gears are ground to minimize the
potential for gear noise. Figure 2.7. The Meritor RC-26-633 is a double-reduction axle. The first
reduction is in the carrier and the second reduction is in the wheel
Figure 2.7 end. This allows for a smaller carrier ring gear and a lower bus floor.
Special ground gearing in both the carrier and wheel end produces
quieter operation. Figure 2.9.
Figure 2.9
4000884a
Figure 2.9
The axles feature a modular design that consists of five separate
units:
The axle is equipped with Meritor Cast Plus™ cam brakes with a
앫 One center housing 16.5-inch diameter and 8.62-inch wide heavy-duty cast shoes. The
앫 Two helical gear housings axle also is equipped with the anti-lock braking system sensor and
tooth ring.
앫 Two wheel ends
This modular design allows each module to be assembled and
serviced independently for easier maintenance. Figure 2.8.
2
Center Axles Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
The Meritor bus and coach center axles are available in the 61000 prior to returning the vehicle into service.
and 71000 Series and RC-26-700.
In the event that a manual adjustment must be made (although not a
61000 and 71000 Series common practice), a service appointment and full foundation brake,
The 61000 and 71000 Series center axles have the following ASA, and other system component inspection should be conducted
features. as soon as possible to ensure integrity of the overall brake system.
앫 Center axles are identical to the 61000 and 71000 Series drive For Meritor brake adjustment, refer to the brake adjustment tables
axles except without carriers or axle shafts. in Section 7. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
앫 The spindle ends are capped so only the wheel end is filled with
lubricant. Cam Brakes
앫 A hubcap is used to keep lubricant in the wheel end instead of Meritor cam brakes are air-actuated, cam-operated, double shoe
an axle shaft. Figure 2.10. brakes with each shoe mounted on a separate anchor pin. The
brakes are available with automatic or manual adjustment and can
Figure 2.10
앫 Tubular deep-drop axles are designed for low floor applications. Q AND Q-PLUS™ SERIES
Figure 2.11.
Figure 2.11
4001365a 4001453a
Important Information Q Series brakes are available in 16.5-inch diameter with a 10-inch
width and 0.75-inch tapered brake lining. A 15-inch diameter is
Meritor automatic slack adjusters (ASAs) should not need to be
available for front non-drive applications.
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be Q Plus™ brakes are available in 16.5-inch (419 mm) diameter with
an indication that a problem exists with the foundation brake, ASA, 5-, 6-, 7- and 8.625-inch (127, 152, 178 and 219 mm) widths.
brake actuator or other system components. The tapered brake linings are 0.75-inch (19.05 mm) thick.
DiscPlus™ Brakes
DiscPlus™ DX195 and DX225 air disc brakes are optional on FF
and FG bus and coach front steer axles. Brakes feature sealed
calipers lubricated to protect components that actuate the brake.
4001454a The brake is comprised of a lightweight single-piece cast caliper
supported on twin fully seated slide pins fixed to a mounting saddle.
Figure 2.14 Figure 2.15.
2
Figure 2.15
Identification
Model Nomenclature
Front Axles
The axle model identification plate is located on the axle center. Use
the model number to obtain the correct parts from Meritor.
Figure 2.17 and Figure 2.18.
Figure 2.17
Identification
4002891a
Number
Figure 2.15
17101 WX-69
T Series Parking Brake Front Axle Specification
Indentification Number Variation
The 59000 Series parking brake is a Meritor T Series brake installed
on the drive pinion bearing cage in the differential carrier. Brake Usage
Brake Usage
SLACK
ADJUSTER
4002889a
JAM
NUT Figure 2.18
CAGING
SLEEVE PUSH
ROD
ADJUSTING
BOLT
PARKING CLEVIS
BRAKE
4001373a
Figure 2.16
Axle Identification
An identification tag is located on the axle housing or the differential
Number
carrier. Use the model number and the ratio number marked on the 61000 SERIES
tag to obtain replacement parts. Figure 2.19. 71000 SERIES
61142 RDC 123
Figure 2.19
Figure 2.21
Figure 2.20 and Figure 2.21 explain the model number designation
for the 59000, 61000 and 71000 Series axles.
Figure 2.20
Axle Identification
59000 SERIES Number Assembly
59722W 123
Series and Capacity Type Brakes
25,000 lb. (11 340 kg)
Overall
Gearing Type 2 — 96"
7 — Single Reduction 3 — 102"
8 — Double Reduction
0 — No Reduction
Housing
2 — Std. Angle Drive 63˚
3 — New Generation Angle Drive
4 — Housing Altered to Accommodate
“R” Series Carriers
5 — Large Housing Box Size
4001442a
Figure 2.20
2
The RC-23-160 coach rear axle, RC-26-720 and RC-27-720
inverted portal axles and RC-26-633 planetary drive axle are
identified by a letter and number system that provides information
about the specific axle model. Figure 2.22. The first seven positions
of the designation identify a basic axle model. The second group of
letters and numbers identify complete axle specifications.
Figure 2.22
RC-23-160 SERIES
4001444a
Figure 2.22
Figure 2.23
17010-WX-69 59733-RDC-18
BRAKE BRAKE
IDENTIFICATION
IDENTIFICATION
NUMBER
NUMBER 4002873a
Figure 2.23
When using replacement parts, verify that the correct parts are
used. Part numbers are found on the brake spider and the brake
When parts are replaced, the correct parts must be used. Part
shoes.
numbers are found on the top of the camshaft, on the brake spider,
on the brake shoes and on the air chamber bracket.
Inspection
Wedge Brakes
Meritor Stopmaster® brakes are identified by a three-letter code on Front Axles
the axle identification plate. Figure 2.24 and Figure 2.25. Inspect components during regularly scheduled maintenance
intervals to ensure correct operation and maximize the life of the
Figure 2.24
parts.
RDC WARNING
Replace damaged or out-of-specification axle components. Do
C = COACH
not bend, repair or recondition axle components by welding or
heat-treating. A bent axle beam reduces axle strength, affects
vehicle operation and voids Meritor’s warranty. Serious
D = DOUBLE
ACTUATED personal injury and damage to components can result.
Fasteners
MERITOR
STOPMASTER® Verify that all fasteners are tightened to the specified torque. Use a
WEDGE BRAKE
torque wrench to check the torque in a tightening direction. As soon
4002872a
as the fastener starts to move, record the torque. Correct if
Figure 2.24 necessary. Replace any worn or damaged fasteners.
2
Pivot Points Figure 2.27
Verify that looseness does not exist at the pivot points. Verify that TOP
GREASE
the pivot points are lubricated. FITTING
Operation
Verify that all the parts move freely through the complete turning
radius.
NEW NEW
King Pin Bushings GREASE GREASE
Figure 2.26
4006842a
Figure 2.28
6. Apply lubricant into the bottom grease fitting until new grease
appears from under the lower lip of the bearing deflector.
Figure 2.29.
Figure 2.29
4006840a THRUST
BEARING
Figure 2.26
BEARING
3. Clean all grease fittings before you lubricate the king pins. DEFLECTOR
4. Lubricate the king pins through the top and bottom grease
fittings. Figure 2.27. NEW
GREASE
4006843a
Figure 2.29
Tie Rod 7. Install the inner and outer bearing cones into the cups in the
hubs. The bearing cups must be pressed tight against the
1. Park the vehicle on a level surface. Block the wheels to prevent shoulder in the hubs.
the vehicle from moving. Set the parking brake.
8. Install new wheel seals into the hubs.
2. Verify that the tires touch the ground. Do not raise the vehicle.
9. Install the hub and the wheel and tire assembly. Install the
3. Clean and remove the oil grease fittings prior to lubrication. outer wheel bearing cone into the hub. Install the adjusting nut.
4. Apply lubricant at each grease fitting until new lubricant flows 10. Adjust the wheel bearings.
from the boot.
Oil-Lubricated Wheel Bearings
Grease-Lubricated Wheel Bearings
1. Park the vehicle on a level surface. Block the wheels to prevent NOTE: If you cannot observe the oil level because the sightglass is
the vehicle from moving. stained, remove the fill plug, check the oil level with your finger and
follow the procedures for Step 3 below. Replace the stained
2. Raise the vehicle so that the wheels are off the ground.
sightglass as soon as possible.
Support the vehicle with safety stands.
3. Remove the tire and wheel assembly. Remove and 1. Park the vehicle on a level surface. Block the wheels to prevent
disassemble the hub. the vehicle from moving.
4. Use the correct cleaning solvent to remove the old grease from 2. Check the oil level on the cap.
all parts. Discard the seals. Inspect the wheel bearings for 3. If the oil level is more than 0.25-inch (6 mm) below the
wear or damage. Replace worn or damaged bearings. specified level on the cap, remove the fill plug.
5. Before installing the wheel bearings, lubricate the bearing 4. Add the specified oil to the specified level. Figure 2.31.
journals on the spindle with the grease that is used for the
bearings. Figure 2.30. Figure 2.31
LUBE
1003338a
Figure 2.31
1003337a
6. Use a pressure packer to force the specified grease from the Rear Axles
large end of the cones into the cavities between the rollers and
cage. Pack the hub between the bearing cups with grease to Inspection
the level of the smallest diameter of the cups. Inspect components during regularly scheduled maintenance
intervals to ensure correct operation and maximize the life of the
앫 If a pressure packer is not available: Grease the
bearings by hand. parts.
2
Drain and Replace the Oil 2. Place a drain pan under the axle. Remove and drain the oil
from the two drain plugs on the lower side of the helical gear
1. Park the vehicle on a level surface. Block the wheels to prevent
housing and the plug below the carrier in the center housing.
the vehicle from moving. The axle lubricant capacity changes
Install the drain plugs and tighten them to 35 lb-ft (47 N폷m).
when the drive pinion angle changes.
Figure 2.32. @
2. Place a drain pan under the axle. Remove the drain plug from
the bottom of the axle housing. Drain the lubricant. Install the Figure 2.32
앫 If the axle shafts or hubs are equipped with oil fill HELICAL
HELICAL
plugs: Rotate the hub until the fill plugs are at the top. GEAR CASE GEAR CASE
DRAIN PLUG DRAIN PLUG
Remove the oil fill plugs. Fill each hub cavity with 2 pints
(1 L) of rear axle lubricant. Install and tighten the fill plugs to CENTER HOUSING
DRAIN PLUG,
10 lb-ft (13.8 N폷m) minimum. @ NOT SHOWN 4000890a
앫 If the axle shafts and hubs are not equipped with oil fill Figure 2.32
plugs: Slowly drive each side of the vehicle over a 6-inch
(152.4 mm) raised surface so that the oil can flow out to 3. Remove the fill plug from the helical gear case that is closest to
the hubs. Check the oil level in the housing and refill to the the differential. Figure 2.32.
bottom of the fill plug.
4. Fill the helical gear case with approximately 1.6 gallons
6. Road test the vehicle in an unloaded condition for 1-2 miles (6 liters) of lubricant until the lubricant level is even with the
(1.6-3.2 km) at speeds not more than 25 mph (40 km/h). bottom of the fill hole. Install the fill plug. Tighten the plug to
Recheck the lubricant levels and all of the fasteners. Adjust as 35 lb-ft (47 N폷m). @
necessary.
5. Remove the fill plug from the side of the axle housing bowl
cover. Figure 2.32.
Inverted Portal Drive Axle
6. Fill the axle housing with approximately 5 gallons (19 liters) of
Inspect Magnets lubricant until the lubricant is level with the bottom of the fill hole.
Inspect and clean the magnets located on the drain plug of each
7. Wait five minutes. Add lubricant to the axle center housing until
helical gear case and on the axle center housing drain plug.
the lubricant is level with the bottom of the fill hole. Repeat this
앫 If excessive debris is found on a magnet: Inspect all step until the oil level in the axle center housing does not drop.
components for the source of the debris.
8. Install the fill plug. Tighten the plug to 35 lb-ft (47 N폷m). When
Drain and Replace the Oil correctly installed, one complete thread of the fill plug is visible
between the housing and the plug head. @
1. Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. The axle lubricant capacity changes 9. Road test the vehicle in an unloaded condition for 1-2 miles
when the drive pinion angle changes. (1.6-3.2 km) at speeds not more than 25 mph (40 km/h).
Recheck the lubricant levels and all of the fasteners. Adjust as
necessary.
Inverted Portal Drive Axle Wheel Ends 3. Inspect the thrust washer on the end of the spindle for wear or
damage, especially around the flange area.
NOTE: If the axle shafts or hubs are equipped with oil fill plugs, fill
the wheel ends with oil using the following procedure. 앫 If the thrust washer is worn, grooved or shows signs of
galling: Replace the thrust washer.
1. Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Drain and Replace the Oil
2. Use a jack to raise the vehicle so that the wheels to be serviced NOTE: The RC-26-633 axle has a common oil level between the
are off the ground. Support the vehicle with safety stands. carrier and the wheel ends. Three locations must be filled. The
3. Rotate the hub until the fill plugs are at the top. vehicle must be on a level surface when filling. Fill to the bottom of
each fill plug hole, same as the axle horizontal center line.
4. Remove the oil fill plugs. Fill each hub cavity with 2 pints
(0.95 liters) of the recommended rear hub axle lubricant. 1. Park the vehicle on a level surface. Block the wheels to prevent
5. Install and tighten the fill plugs to 10 lb-ft (14 N폷m). @ the vehicle from moving.
2. Use a jack to raise the vehicle so that the wheels to be serviced
Planetary Drive Axles are off the ground. Support the vehicle with safety stands.
Inspect the Thrust Button, Thrust Screw and 3. Remove the wheel nuts, and tire and rim assemblies from both
Coupling wheel ends.
NOTE: As a preventive maintenance procedure, you must inspect 4. Rotate the wheel ends so the drain plug in the spider is at the
the internal components of the wheel ends every 24,000 miles BOTTOM. Place a drain pan under the wheel ends. Remove the
(39 000 km) or at every brake reline, whichever comes first. plug and drain the lubricant from both wheel ends. Install the
plug and tighten it to 18-25 lb-ft (24-34 N폷m). @
NOTE: Thrust surfaces can wear a combined total of 0.08-inch
(2 mm) from their original position. If the wear is greater than 5. Place a drain pan under the axle housing. Remove the plug
0.08-inch (2 mm), you must disassemble the wheel end and inspect from the bottom of the axle housing. Drain the lubricant from
the internal parts for wear. the carrier center section. Install the plug.
6. Fill the wheel ends and the carrier center section with a
1. Inspect the thrust button and thrust screw.
multigrade API GL-5 gear oil approved under MIL-PRF-2105E
앫 If a groove or recess is worn into the thrust button specification.
face, from contact with the thrust screw: Replace the
앫 The carrier fill plug is located in the axle housing bowl.
thrust button.
Figure 2.33.
앫 If the slotted end of the thrust screw is worn or shows
앫 Original design wheel ends: Rotate the wheel ends so the
signs of mushrooming or galling: Replace the thrust
fill plug gives a level the same as the axle horizontal center
screw.
line. Figure 2.34.
NOTE: Slide the coupling back on the shaft for inspection. Do not 앫 Revised design wheel ends: Rotate the wheel end until
remove it. the fill hole is at the TOP. Remove the oil level capscrew and
copper washer located in the center of the thrust screw. Do
2. Inspect the coupling on the axle shaft for wear. The thickness not remove the thrust screw and lock nut. Fill until oil
of a new coupling is 0.24-inch (6 mm), with an allowable comes out of the level hole in the center of the wheel end.
surface wear of 0.039-inch (1 mm) along any groove. Measure Install the copper washer and oil level capscrew. Tighten
the thickness of the coupling along the thinnest part of the the capscrew to 8 lb-ft (11 N폷m). Figure 2.35. @
groove. If any measurement is 0.20-inch (5 mm) or less,
replace the coupling.
앫 If the coupling thickness is less than the limits above:
Replace the coupling.
2
Figure 2.33
Cam Brakes
WARNING
During lubrication procedures, if grease flows from the seal
near the camshaft head, replace the seal. Remove all grease
or oil from the camshaft head, rollers and brake linings.
Always replace linings contaminated with grease or oil, which
FILL PLUG FOR CARRIER can increase stopping distances. Serious personal injury and
4002876a
damage to components can result.
Figure 2.33
For lubrication information, refer to Table M and Figure 2.36,
Figure 2.34
Figure 2.37 or Figure 2.38.
Rotate plug so
Figure 2.36
oil level is
same as axle Q AND Q-PLUS™ BRAKE LUBRICATION AREAS
horizontal
center line. ANCHOR PINS — CAMSHAFT
FILL PLUG
Lubricate where — SPLINES:
LEVEL PLUG pins touch Apply lubricant
brake shoes. directly.
— BUSHING:
Apply lubricant
through
grease fitting.
OIL LEVEL
(HORIZONTAL
CENTER LINE)
4002877a
Figure 2.34
Figure 2.35
FILL HOLE
LEVEL
CONTROL
HOLE SHOE ROLLERS —
Lubricate where
pins touch
brake shoes. 4001492c
OIL LEVEL
Figure 2.36
LEVEL
Do not touch CONTROL
thrust screw SCREW
and nut.
4002878a
Figure 2.35
Figure 2.37
CAMSHAFT
Camshaft Bushings
— SPLINES:
Apply lubricant directly. WARNING
During lubrication procedures, if grease flows from the seal
— BUSHING:
SHOE ROLLERS — Apply lubricant through near the camshaft head, replace the seal. Remove all grease
Lubricate where grease fitting. or oil from the camshaft head, rollers and brake linings.
pins touch brake shoes.
Always replace linings contaminated with grease or oil, which
can increase stopping distances. Serious personal injury and
damage to components can result.
Figure 2.38
T-SERIES PARKING BRAKE ANCHOR PINS
W SERIES BRAKE LUBRICATION AREAS Lubricate where
pins touch
CAMSHAFT shoe assemblies.
ANCHOR PINS — Lubricate splines
Apply lubricant and bushings
through through fittings
grease fitting. in carrier.
SHOE ROLLERS
Lubricate where
rollers touch
shoe assemblies. 4001375c
4001494c
Figure 2.38
2
Anchor Pins
Lubricate the anchor pins when necessary or when the brake is
disassembled. Apply the lubricant to the anchor pins where the pins
touch the brake shoes. Figure 2.39.
Shoe Rollers
Lubricate the shoe rollers when necessary or when the brake is
disassembled. Apply the lubricant to the roller pins where the pins
touch the brake shoes. Do not apply lubricant on the part of the
roller that touches the cam head. Figure 2.39.
Stopmaster® Brakes
Lubricant Areas
Lubricate the following areas of the brake.
앫 The outer diameter, the ramp and the slot of the anchor plungers
앫 The outer diameter, the inner diameter, the ramp and the slot of
the adjusting plungers
앫 The teeth on the outer diameter and the threads on the inner
diameter of the actuators
앫 The teeth and the outer diameter of the adjusting pawls
앫 The rollers and the head of the wedge assemblies
앫 The plunger bores and the bore for the pawl in the plunger
housing
* Applies to ball studs on Easy Steer Plus™ axles. Sealed axles require inspection of the boot on the ball stud every 100,000 miles
(160 000 km) for wear and damage. Service as necessary.
2
Table F: Rear Axle Lubricant Cross Reference (Viscosity and Temperature)
Meritor Lubricant Minimum Outside Maximum Outside
Specification Description Cross Reference Temperature Temperature
O-76-A Hypoid Gear Oil GL-5, SAE 85W/140 +10°F (–12°C) *
O-76-B Hypoid Gear Oil GL-5, SAE 80W/140 –15°F (–26°C) *
O-76-D Hypoid Gear Oil GL-5, SAE 80W/90 –15°F (–26°C) *
O-76-E Hypoid Gear Oil GL-5, SAE 75W/80 –40°F (–40°C) *
O-76-J Hypoid Gear Oil GL-5, SAE 75W –40°F (–40°C) +35°F (+2°C)
O-76-L Hypoid Gear Oil GL-5, SAE 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).
59752 30.5 14.4 35.5 pints (16.7 liters) 7.0 pints (3.3 liters)
2
WARNING
During lubrication procedures, if grease flows from the seal near the camshaft head, replace the seal. Remove all grease or oil from
the camshaft head, rollers and brake linings. Always replace linings contaminated with grease or oil, which can increase stopping
distances. Serious personal injury and damage to components can result.
For lubrication information, refer to Table M and Figure 2.36, Figure 2.37 or Figure 2.38.
4001206a
Technical Publications
Figure 3.2
How to Obtain Additional Maintenance and
Service Information Figure 3.3
Table O: Publications
Model Manual
Clutches Maintenance Manual 25A
Clutch Failure Analysis TP-9494 4001207a
Figure 3.3
Description
Meritor clutches are primarily used on Class 6 to Class 8 series
vehicles. The clutches are available in 14-inch manual adjust,
15-1/2-inch manual adjust and 15-1/2-inch AutoJust™ models.
The clutches are available in an eight-hole installation pattern.
Figure 3.1, Figure 3.2 and Figure 3.3.
Figure 3.1
4001205a
Figure 3.1
Identification
To identify a clutch, refer to the identification and serial numbers
located on the front of the clutch cover. Refer to these numbers when
you replace parts. Use only the specified parts.
앫 For clutch models manufactured on or before May 1999: 앫 For clutch models manufactured on or after May 1999:
Refer to the identification tag and serial number tag attached to Refer to the identification and serial numbers etched on the
the clutch cover. Figure 3.4. clutch housing. Figure 3.5.
Figure 3.4 Figure 3.5
CO.
M E R I TO R C L U T C H
28
S P E C HC14C2200N
00
R E P L . N O . R1401 FOR
A DJUST
53NT PS
0022051CH CE R
P
0 4151R L / S
SERIAL 27 5 4 9 4 N
NUMBER
TAG
IDENTIFICATION 4001209b
TAG 4001208c
Model Nomenclature
Refer to Figure 3.6 for an explanation of the original clutch
specification number. Refer to Figure 3.7 for an explanation of the
replacement clutch assembly part number.
Figure 3.6
Figure 3.6
Figure 3.7
R 15 1 4 0 6
Clutch Type
0 — 8 Spring Standard or 7 Spring Standard LTD
1 — 14" 8 Spring Lite Pedal
3
Meritor
Designation Unique 5 — “Super 8” 8 Spring or 7 Spring LTD Lite Pedal*
Identification 6 — “Super 8” 8 Spring Lite Pedal or LTD 6-Paddle*
Number 8 — AutojustTM (4-Paddle)*
9 — AutojustTM (6-Paddle)*
Size
14 — 14" Facing Type
15 — 15-1/2" 0 — Ceramic Disc
2 — Flat Flywheel (No longer available)/Dual grease fitting
3 — Hi Torque Dual Grease Fitting
5 — Molded Organic Disc (except Hi Torque LTD clutches which are ceramic)
Options
1 — 8 Spring Single-Stage Dampened Disc
4 — 8 Spring Two-Stage Dampened Disc
5 — Single Plate
6 — Standard LTD 7 Spring Dampened Disc (available as ceramic disc only)*
7 — Lite Pedal LTD 7 Spring Dampened Disc (available as ceramic disc only)*
8 — Two-Stage (Free Travel LTD) (available as ceramic disc only)*
Figure 3.7
Inspection 1. The operation of the linkage. Push down on the clutch pedal
and have another person check the release fork for movement.
When to Inspect the Clutch The smallest movement of the clutch pedal must cause
Inspect the clutch when any of the following occurs. movement at the release fork.
앫 As required by the maintenance schedule of the vehicle 앫 If the release fork does not move when the clutch
manufacturer pedal moves: Find and service the cause of the free play
앫 When any part of the clutch system is serviced condition.
앫 When the clutch pedal free travel is less than 1/2-inch (13 mm) 2. The condition of the linkage operation. The linkage must
or more than 1-1/2-inches (38 mm)
move if the pedal is actuated. The linkage must not be
obstructed. Every pivot point operates freely. The linkage must
Clutch Linkage not be loose at any point.
The clutch linkage must be inspected carefully. The clutch will not
앫 If the linkage does not operate freely: Find and service
operate correctly if the linkage is worn or damaged. Inspect the
the cause of the condition.
linkage according to the following procedures. Figure 3.8.
Figure 3.8
3. The condition of all parts of the linkage. Inspect the clutch
linkage. The pedal, springs, brackets, bushings, shafts, clevis
CLUTCH pins, levers, cables and rods must not be worn or damaged.
PEDAL
If a hydraulic system is used, verify that the system is not
leaking and that the reservoir is filled to the specified level.
LINKAGE Replace any parts that are missing or damaged. Do not
RELEASE straighten any damaged parts.
FORK
4. Lubrication. Every pivot point in the linkage must be
lubricated. Use the lubricant specified by the vehicle
4001296a manufacturer. Refer to the lubricant specifications listed in
this section.
Figure 3.8
Figure 3.9
RELEASE
BEARING 1/2"
GAUGE
0.500-0.560" TOOL
(12.7-14.2 MM)
CLEARANCE
CLUTCH
BRAKE 4001297a
Figure 3.9
Figure 3.10
RELEASE
BEARING 1/2" TELESCOPING
0.500-0.560"
(12.7-14.2 MM) GAUGE TOOL
CLEARANCE
CLUTCH
BRAKE 4002689a
Figure 3.10
Figure 3.11
RELEASE FORK
1/8" (3 MM)
CLEARANCE
1/8" GAUGE
TOOL
3
Figure 3.11
4. The AutoJust™ sensor bolt clearance between the bolt head 5. If the release bearing is equipped with a lube tube, grease
and flange should be 0.55-inch (14 mm) minimum. must be coming out of the bearing housing, which ensures that
lubricant is reaching the bearing. Verify that the lube tube is
5. Release Fork Condition. Remove and replace the release fork
secure and not damaged.
if the tips are worn or damaged.
6. Release Bearing Condition. Replace the complete clutch 6. Use the same procedure for extended lubrication clutches, at
assembly if the bearing is worn or damaged. The bearing must the same specified interval.
be lubricated. 7. Install the inspection cover. Figure 3.12.
7. Transmission Input Shaft Condition. If the splines are worn
or damaged, replace the input shaft. Figure 3.12
Lubrication
Release Bearing
GREASE
CAUTION FITTING 1003314a
The inspection cover on the clutch housing must be used. If an
inspection cover is not used, dirt and contaminants will enter Figure 3.12
the clutch housing and damage the clutch.
LUBRICATE
LUBRICATE
1003315a
Figure 3.13
1003316a
Figure 3.14
Lubricant Recommendation
Clutch Bearing Grease Exxon Unirex N Grade 3 (NLGI 3
Grade 3, Lithium Complex)
Troubleshooting
Before troubleshooting the clutch, verify the following. Once these conditions are verified,
refer to Table R, Table S and Table T to troubleshoot the clutch.
1. The engine is operating correctly.
2. The engine mounts are in good condition.
3. The driveline angles of the engine, transmission, driveshaft and rear axle are correct.
4. The inspection cover is installed on the clutch housing.
Operating Conditions
Table R: Operating Conditions Diagnostic Table
Condition Possible Cause Correction
Clutch does not Release bearing clearance needs adjustment. Adjust release bearing clearance.
release or does Clutch linkage needs adjustment. Adjust clutch linkage.
not release Worn or damaged linkage. Lubricate linkage. Verify that the linkage is not loose.
completely.
If condition still exists, replace linkage.
Worn or damaged release bearing. Lubricate release bearing. If condition still exists, replace
release bearing.
Worn or damaged splines on input shaft. Replace input shaft.
Bell housing loose. Tighten fasteners to specified torque. If necessary, replace
fasteners.
Center plate binding. 14-inch clutch: Inspect drive pins in flywheel housing and
slots in center plate. 15-1/2-inch clutch: Inspect tabs on
center plate and slots in cover. Service as necessary.
Damaged hub in clutch discs. Replace discs.
Damaged pilot bearing. Replace pilot bearing.
Clutch pedal is Excessively worn contact pads on release bearing. Replace clutch assembly. Verify that the clutch is correctly
hard to operate. adjusted.
Tight or stiff pivots in clutch linkage. Lubricate linkage. If condition still exists, replace linkage.
Worn or damaged clutch components. Replace clutch assembly.
Worn or damaged pedal shaft or cross shaft Repair or replace as necessary.
bushings.
Components
Table S: Components Diagnostic Table
Condition Possible Cause Correction
Broken tabs on Release bearing clearance needs adjustment. Adjust release bearing clearance.
3
clutch brake Clutch linkage needs adjustment. Adjust clutch linkage.
Driver engages clutch brake incorrectly while vehicle is Use correct driving procedures.
moving.
Worn or damaged Driver keeps foot on clutch pedal. Use correct vehicle operating procedures.
release bearing Free travel not adjusted correctly. Adjust free travel correctly.
housing
Worn bosses on Damaged or out-of-adjustment linkage. Lubricate and adjust linkage. Inspect linkage for wear or
release bearing damage.
housing Release fork binding. Lubricate shaft of release fork. If fork does not move freely,
replace shaft and fork assembly.
Free travel out-of-adjustment. Adjust free travel to specification.
Worn or damaged Transmission not aligned. Verify that driveline angles are correct.
input shaft splines Incorrect transmission installation procedures. Install transmission correctly.
Damaged hubs in clutch discs. Replace clutch assembly.
Worn or damaged pilot bearing. Replace pilot bearing.
Pressure plate Driver engages clutch while vehicle is coasting to Use correct vehicle operating procedures.
cracked or create shock load.
damaged by heat Driver uses clutch as a brake to hold vehicle on a grade. Use correct vehicle operating procedures.
Free travel not adjusted correctly. Adjust free travel to specification.
Oil or grease on facings. Replace clutch assembly.
Driver slips clutch excessively during engagement. Use correct vehicle operating procedures.
Adjusting ring Too much dirt in bell housing. Remove dirt from bell housing. Service as necessary. Verify
does not move that inspection cover is installed.
Worn or damaged adjusting ring. Replace clutch assembly.
Warped hub in Incorrect transmission installation procedures. Replace clutch assembly. Install transmission correctly.
clutch disc
Hub separates Incorrect transmission installation procedures. Install transmission correctly.
from disc Clutch housing loose. Tighten clutch housing to specified torque. If necessary,
replace fasteners.
Shock loading. Use correct vehicle operating procedures.
Co-axial springs Shock loading. Use correct vehicle operating procedures.
separate from
disc
Heat damage on Driver keeps foot on clutch pedal or slips clutch. Use correct vehicle operating procedures.
disc Clutch does not engage or disengage completely. Refer to Table R.
Free travel not adjusted correctly. Adjust free travel correctly.
Worn or damaged diaphragm spring. Replace clutch assembly.
Grease or oil on facings. Replace clutch assembly.
Linings separate Facings worn past specified dimension. Replace clutch assembly.
from discs
Cracked or Driver does not start vehicle in correct gear. Use correct vehicle operating procedures.
damaged center Driver uses clutch as a brake to hold vehicle on a Use correct vehicle operating procedures.
plate grade.
Driver slips clutch excessively during engagement. Use correct vehicle operating procedures.
WARNING
Operate the vehicle according to the vehicle manufacturer’s
procedure. Do not coast downhill with the transmission in gear
and the clutch released. If the vehicle coasts downhill with the
transmission in gear and the clutch released, the facings can
separate from the disc and cause serious personal injury and
damage.
Special Tools
NOTE: To obtain these tools, refer to the Service Notes page on the front inside cover of this manual.
Read and observe all Warning and Caution hazard alert messages in The Meritor Wing-Style Permalube™ driveline requires lubrication
this publication. They provide information that can help prevent of the slip yoke splines only. Figure 4.2.
serious personal injury, damage to components, or both.
Figure 4.2
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. 4
Technical Publications
How to Obtain Additional Maintenance and WING-STYLE PERMALUBETM
Service Information 4001790a
Refer to the publications in Table V. To obtain these publications, Figure 4.2
refer to the Service Notes page on the front inside cover of this
manual. Full-Round, Easy Service™, Wing-Style and
Table V: Publications 155R Series (Greaseable)
Model Manual Full-Round, Easy Service™, Wing-Style and 155R Series
greaseable drivelines require periodic lubrication of the universal
Drivelines Maintenance Manual MM-0998, joints and slip yoke splines. Figure 4.3, Figure 4.4 and Figure 4.5.
MM-96147
Driveline I.D. Gauge Kit SP-87101B Figure 4.3
Description
RPL Series Permalube™ (Non-Greaseable)
The Meritor RPL Series Permalube™ non-greaseable driveline is
permanently lubricated and sealed at the factory and does not
FULL-ROUND 4001788a
require lubricants. Arrows on the wing bushings help you to
correctly install the universal joint. Figure 4.1. Figure 4.3
Figure 4.1
Figure 4.4
Figure 4.5
Inspection
Driveline
WARNING
Check end yoke retaining nuts and bolts for looseness. Tighten
loose fasteners to specification. Check the input and output
shaft splines for wear and damage. Replace worn or damaged
splines. Check for loose, missing or damaged driveline
155R SERIES fasteners and parts. Tighten loose fasteners, and replace
damaged and missing parts. Loose, damaged or missing parts
4001789b can cause the driveline to separate from the vehicle. Serious
personal injury and damage to components can result.
Figure 4.5
Meritor genuine driveline components are identified by the following Park the vehicle on a level surface. Block the wheels to
markings on the component. prevent the vehicle from moving. Support the vehicle with
앫 Logo stamped on the part safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
앫 Balance bosses damage to components can result.
앫 Forging part number which identifies the driveline series
1. Park the vehicle on a level surface. Block the wheels to keep
the vehicle from moving. Raise the vehicle so that the area you
Table W: Drivelines
will service is off the ground.
Meritor Driveline Series
2. Inspect the driveline at regular intervals. Loose end yokes,
155R 58WB excessive radial movement, slip spline radial movement, bent
16N 62N driveline tubing or missing plugs in the slip yoke can damage
universal joints and bearings.
17N 72N
176N 82N 3. Check the output and input end yokes on both the transmission
and axle for axial looseness. Refer to the axle or transmission
18N 85WB
manufacturer’s service instructions.
25W* 92N
앫 If the output and input end yokes are loose: Disconnect
20W* the driveline. Tighten the end yoke retaining nut to the
correct specification. Refer to the axle or transmission
* RPL25 and RPL20 do not follow the above convention and utilize their
manufacturer’s service instructions.
own unique numbering system.
4. Inspect for worn universal joints. Apply vertical force of about
50 pounds (22.7 kg) to the driveline near the universal joints.
앫 If movement is greater than 0.006-inch (0.152 mm):
Replace the universal joint.
5. Use a dial indicator to examine the slip yoke spline for Figure 4.6
Perform the following procedures before you lubricate universal Figure 4.6
joints or slip yokes. If you lubricate these components before you
inspect them, lubricant can cover wear, damage and looseness. 3. Inspect for worn, damaged, missing and loose parts. Replace
1. Do not lubricate components. Inspect all input and output end as required.
yoke retaining nuts and bolts for gaps between mating
surfaces. WARNING
Use a fine-tooth file or an emery cloth to remove raised metal
앫 If gaps are present: Refer to the transmission, axle or or fretting from yoke cross hole surfaces. Take care not to
transfer case manufacturer’s service instructions. remove an excessive amount of metal. These conditions can
2. Check the output and input end yokes on both the axle and damage the cross and bearing and cause the driveline to
transmission for axial looseness using the following procedure. separate from the vehicle. Serious personal injury and damage
Also refer to the axle or transmission manufacturer’s service to components can result.
instructions.
4. Inspect all end yoke cross hole surfaces and bolt hole threads
A. Hold the end yoke with both hands. for damage. Remove raised metal or fretting with a fine-tooth
B. Move the end yoke UP-AND-DOWN and SIDE-TO-SIDE. file or emery cloth. Figure 4.7.
There shouldn’t be any movement where the yoke 앫 If bolt hole threads are damaged: Replace the yoke.
connects to the input and output shafts. Figure 4.6.
Figure 4.7
WARNING
Excessive looseness across the ends of universal joint bearing
cup assemblies can cause imbalance or vibration in the
driveline assembly. Imbalance or vibration can cause
component wear, which can result in separation of the
driveline from the vehicle. Serious personal injury and
damage to components can result.
4001802a
1. Use the following procedure to check for looseness across the
ends of the universal joint bearing cup assemblies and Figure 4.9
trunnions.
A. Hold the INBOARD yoke on the driveline with both hands. Center Bearings
B. Try to move the yoke UP-AND-DOWN and SIDE-TO-SIDE 1. Inspect all center bearing and end yoke midship nuts for gaps
by applying at least 50 lb-ft (222.5 N폷m) of force to the between the mating surfaces. Figure 4.10.
driveline near the universal joints. Figure 4.8. @ 앫 If you can see gaps between the mating surfaces:
앫 If movement is greater than 0.006-inch Disconnect the driveline. Tighten the coupling yoke
(0.152 mm): Replace the universal joint. retaining nut to 450-600 lb-ft (612-816 N폷m). @
2. Inspect all universal joint kits in the driveline assembly. Figure 4.10
Figure 4.8
4001797a
Figure 4.10
4001794a
Figure 4.8 2. Inspect the center bearing bracket bolts for looseness.
Figure 4.11.
Greaseable Universal Joints 앫 If the bolts are loose: Verify that the bracket is aligned
correctly before you tighten the bolts. Tighten the center
1. Check that all grease fittings are installed. Replace missing
bearing bracket bolts. Refer to the vehicle manufacturer’s
or damaged fittings. Tighten them to 6 lb-ft (8 N폷m).
procedures for the correct torque specification.
Figure 4.9. @
2. Check for loose grease fittings. Tighten them to 6 lb-ft
(8 N폷m). @
Figure 4.11
Slip Yoke
NOTE: Check a slip yoke for movement with the driveline installed
and the vehicle on a level surface with its wheels on the ground.
4001880a
yoke barrel next to the dust seal. Figure 4.13. You don’t want 4
the dial indicator to move when you check the slip yoke for
Figure 4.11
looseness, or the measurement will not be correct.
3. Extend the dial indicator arm from the base, so that it contacts
3. Inspect the center bearing rubber cushion for damage. the neck of the spline plug within 3/4-inch (19.05 mm) from
If equipped, check that the deflectors are not rubbing against the dust seal. Figure 4.13.
the rubber cushion. Verify that the rubber cushion is correctly
Figure 4.13
Figure 4.12
CENTER
BEARING
4001951a
4001793a
Figure 4.12
Figure 4.14
5. Inspect the driveline for damage or bent tubing. Wing-Style Permalube™ Drivelines
앫 If the driveline is damaged or bent: Replace the driveline. 1. Check that both capscrews and lock washers are installed on
all universal joint positions. RPL Series Permalube™
6. If necessary, carefully remove mud or road debris from the
capscrews and Wing-Style Permalube™ capscrews are
driveline. not interchangeable.
7. Inspect the slip yoke spline seal for grease leakage or seal 앫 If the capscrews and lock washers are missing:
damage. Check for damage to the universal joint and yoke.
8. Inspect for missing balance weights, damaged tubing or a Replace damaged parts and capscrews and lock washers.
missing welch plug at the slip yoke. 앫 If the capscrews are loose: Remove and discard the loose
capscrews. Replace them with new capscrews and lock
Universal Joint Capscrews washers.
2. Use a torque wrench to verify that capscrews are tightened to
WARNING the correct specification.
Inspect RPL Series Permalube™ and Wing-Style Permalube™
drivelines for loose or missing capscrews and lock washers. Check End Play
Loose or missing fasteners can allow the driveline to separate 1. Check the universal joint for end play. Apply force in an
from the vehicle. Serious personal injury and damage to UP-AND-DOWN and SIDE-TO-SIDE motion. The universal joint
components can result. If fasteners are loose or missing: must not move in either direction. Figure 4.15. There should be
앫 RPL Series Permalube™ drivelines: Install new capscrews less than 0.006-inch (0.152 mm) BACK-AND-FORTH motion of
with Dri-Loc® patches. the universal joint. Figure 4.16.
앫 Wing-Style Permalube™ drivelines: Install new capscrews 앫 If movement is greater than 0.006-inch (0.152 mm):
with Dri-Loc® patches and secure the capscrews with lock Replace the universal joint.
washers.
Figure 4.15
missing capscrews.
앫 If the capscrews are loose: Remove and discard loose
capscrews. Replace them with new capscrews.
2. Use a torque wrench to verify that capscrews are tightened to
115-135 lb-ft (155-183 N폷m). @
4001806a
Figure 4.16
Figure 4.18
Xtended Lube MXL™ 17N, 176N and 18N
Series Drivelines (Full Round) 1. Move the assembly UP-AND-DOWN or SIDE-TO-SIDE while you
The Meritor Xtended Lube MXL™ 17N, 176N and 18N Series apply grease gun pressure. Figure 4.19.
drivelines have extended lubrication intervals for both the slip
sections and universal joints at 100,000 miles (160 000 km) for Figure 4.2
linehaul applications.
Figure 4.17
4001844a
MXL
STAMP 앫 If you cannot determine the problem: Replace the
4007586a
universal joint.
Meritor Xtended Lube MXL™ Series
3. Tighten the capscrews. @
Figure 4.17
Figure 4.3
Standard/Conventional Driveline Universal
Joint
1. Check the driveline for looseness. If loose, service the driveline
as necessary. Figure 4.22.
Figure 4.5
BEARING
The amount of grease will vary with the driveline series. To avoid STRAP
EASY SERVICETM U-JOINT
purging excess grease through the slip yoke welch plug when the BEARING CROSS CAPSCREWS
assembly is fully collapsed, follow the recommendations in Table X. CUPS 1003317a
Figure 4.22
Table X
Driveline Number of 2. Clean all grease fittings prior to lubrication.
Series Grease Volume Pumps
3. Apply the specified grease at the grease fitting on the universal
17N 0.7 oz (20 grams) 4-6 joint. Apply grease until new grease purges from all four seals.
176N 0.7 oz (20 grams) 4-6 앫 If new grease does not purge at all the seals: Loosen
18N 1.1 oz (30 grams) 6-8 the problem bearing cap bolts and regrease until all four
cups purge.
RPL Series Permalube™ Driveline Universal 앫 If new grease still does not purge: Replace the
Joint, Slip Yoke and Splines universal joint.
The universal joint, slip yoke and splines are permanently lubricated
and sealed and do not require regular lubrication. Figure 4.21. Standard/Conventional Driveline Slip Yoke
and Splines
Figure 4.4
RPL SERIES PERMALUBETM 1. Check the driveline for looseness. If loose, service the driveline
as necessary. Figure 4.22.
2. Cover the vent hole in the welch plug with a finger.
END 3. Apply the specified grease at the grease fitting on the slip yoke
CAPSCREWS
YOKE until the grease purges from the deflector. Six to eight pumps
WELD or approximately one ounce (28 grams) is sufficient to lube
YOKE SLIP YOKE
the splines.
U-JOINT
CROSS
TUBING
1003318a
Wing-Style Permalube™ Driveline Universal
Figure 4.21
Joint
The universal joint is permanently lubricated and does not require
regular maintenance. Figure 4.23.
Figure 4.6
WING-STYLE PERMALUBETM
CAPSCREWS
END
YOKE
WELD YOKE
U-JOINT GREASE TO
CROSS PURGE AT SEAL 4
SLIP
YOKE 1003319a
Figure 4.23
Intervals
Inspection and Maintenance
Table Y: RPL Series Permalube™ and Wing-Style Permalube™ Driveline Inspection Intervals and Procedures
Mileage Intervals Procedures
At initial inspection, Verify that all bolts are tightened to 115-135 lb-ft (155-183 N폷m). @
or no more than
2,000 miles (3200 km)
Every 25,000 miles If you observe any of the following conditions, remove and replace components as needed.
(40 000 km) 1. Inspect all universal joints for grease leakage.
앫 If a universal joint shows normal grease leakage: Do not replace the universal joint.
앫 If a universal joint shows excessive grease leakage: Replace the universal joint.
2. Check for excessive looseness across the ends of the universal joint bearing cup assemblies and trunnions.
앫 Grip the driveline near the INBOARD yoke with both hands.
앫 Try to move the yoke VERTICALLY and HORIZONTALLY. Movement in the universal joint relative to the
INBOARD or OUTBOARD yokes must not exceed 0.006-inch (0.152 mm). Figure 4.24.
3. Inspect the slip yoke spline seal for grease leakage or seal damage.
4. Inspect for missing balance weights, damaged tubing or a missing welch plug at the slip yoke.
Every 150,000 miles In addition to the 25,000-mile (40 000 km) requirements:
(240 000 km) 앫 Use a dial indicator to inspect the slip splines for wear (backlash). Radial looseness between the slip yoke and
the tube shaft must not exceed 0.017-inch (0.432 mm). Figure 4.25.
Figure 4.7
18T
155R 1/2 Round
Wing-Style 92N Wing-Style
Greaseable
Wing-Style 92N Wing-Style Splines Only
Permalube™
RPL Series RPL 25 Combination None
3/4" (Meritor Wing and
(19.05 MM) RPL 20
MAXIMUM 4001870a
Permalube™) Full-Round
Figure 4.25
Troubleshooting
WARNING
To prevent serious eye injury, always wear safe eye
protection when you perform vehicle maintenance or service.
4001860a
Needle rollers brinelled into bearing Excessive continuous running load Replace with a higher capacity universal joint and
cup and cross trunnion driveline.
Continuous operation at high angle/high Replace with a higher capacity universal joint and
UNIVERSAL speed driveline. Check the universal joint operating
JOINT angles. Reduce the angles if necessary.
TRUNNION
Insufficient operating angles Increase the operating angles to a minimum
4001861a
of 2°.
Broken cross and bearing Excessive torque load for universal joint and Replace with a higher capacity universal joint and
assemblies driveline size driveline.
TYPICAL SHOCK
FAILURE —
CROSS DAMAGE
4001862a
4001863a
Tube circle weld fracture Balance weight located in apex of weld yoke lug Replace the tubing and rebalance.
area
Balance weight too close to circle weld Replace the tubing and rebalance.
Incorrect circle weld Replace the tubing and rebalance.
Read and observe all Warning and Caution hazard alert messages in Model Maintenance Manual
this publication. They provide information that can help prevent MX Series Medium-Duty Maintenance Manual MM-0170
serious personal injury, damage to components, or both. Front Drive Steer Axles
Heavy-Duty Front Drive Maintenance Manual 12
WARNING Steer Axles
To prevent serious eye injury, always wear safe eye protection
Single Reduction Maintenance Manual 5
when you perform vehicle maintenance or service.
Differential Carriers
Park the vehicle on a level surface. Block the wheels to Front Drive Axles Failure Analysis Manual TP-0445
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
Description 5
damage to components can result.
Front Drive Steer Axles
Meritor produces a complete line of medium-duty and heavy-duty
Technical Publications front drive steer axles with single axle capacities of 10,000 lbs
(3732 kg) to 23,000 lbs (10 432 kg). Figure 5.1. Axle models are
How to Obtain Additional Maintenance and
available with:
Service Information
앫 Single-reduction carriers
Refer to the publications in Table AI. To obtain these publications,
refer to the Service Notes page on the front inside cover of this 앫 Q Plus™ S-cam brakes
manual. 앫 Standard or wide track
앫 Driver-controlled main differential lock for increased traction
Figure 5.1
4000719a
Figure 5.1
Identification
The axle build information and assembly date for Meritor front drive
steer axles are on the axle identification tag. Figure 5.2.
Figure 5.2
MODEL AND
SPECIFICATION CUSTOMER
NUMBER NUMBER
MODEL MFS-12-143A-N
CUSTOMER NO 01X21A62
ASSY PLANT & SERIAL NO AVF 9521109
DATE 01327
AXLE ASSEMBLY
AXLE
PLANT AND SERIAL
ASSEMBLY TAG
NUMBER
DATE EXAMPLE
1000319f
Figure 5.2
HSG Wall
0 = Cast
GAWR
1 = TBD
xx = GAWR (000) Pounds or Tonnes 2 = 0.31 in. (8 mm)
(dependent on mfg. location) 3 = 0.37/0.39 in. (9.5/10.0 mm)
4 = 0.43 in. (11 mm)
Axle Model Type Relative Gearing 5 = 0.50/0.51 in. (12.7/13.0 mm)
S= Single Rear (Solo) Size or Series 6 = 0.56 in. (14.3 mm)
X= Front Drive Steer 7 = TBD
0 = No Gearing
D= Fwd Rear w/IAD 8 = 0.63 in. (16 mm)
1 = 292/347
N= Fwd Rear less IAD 9 = TBD
2 = 337/387
P= Fwd Rear w/Pump 3 = TBD
R= Rear Rear 4 = 381/432 Carrier Variation
T= Tandem Drive 5 = 415/432
Z= Tridem Drive A= Aluminum
C= Coach
6
7
=
=
432/457
457
D=
M=
Ductile
Ductile Rear, Amboid
5
H= High Entry 8 = 460/498 N= No Carrier
R= Ductile Front Drive Axle
Carrier, Right Hand
T = Ductile Telma Ratio 1 Ratio 2
M X - xx - 1 2 0 x N - x - N 1 2 3 - xxxx - xxxx
M = Meritor
Carrier Type
MFG Location
0 = No Carrier
1 = Single Speed N= North America
2 = Two Speed S= South America
3 = Helical Double Reduction E= Europe
4 = Salisbury A= Australia/Asia/Africa Specification Number
5 = Planetary Double Reduction Includes: TRACK,
6 = Hub Reduction PARKING BRAKE, TELMA,
7 = Portal OTHER
9 = Single Speed With
Torque Output
Limited Engine
Brake Type
Wheel End/Brake Attachment/Differential
B = “B” Frame Brake
A = Conventional Spindle/Conventional Brake/Standard Differential
C = Air Disc Brake
B = Conventional Spindle/Conventional Brake/DCDL
D = Wedge Brake, Dual Air Chambers
C = Conventional Spindle/Conventional Brake/NoSPIN®
E = Wedge Brake, Dual Hydraulic Cylinders
D = Conventional Spindle/Conventional Brake/Other Differential
F = Wedge Brake, Single Hydraulic Cylinder
E = Unitized Spindle/Conventional Brake/Standard Differential G = DuraPark Hydraulic Drum
F = Unitized Spindle/Conventional Brake/DCDL H = Qualdraulic Disc
G = Unitized Spindle/Conventional Brake/NoSPIN® K = Disc PlusTM Air Disc
H = Unitized Spindle/Conventional Brake/Other Differential L = Q Plus Cam Brake
J = Conventional Spindle/Integral Brake/Standard Differential N = None
K = Conventional Spindle/Integral Brake/DCDL P = P Series Cam Brake
L = Conventional Spindle/Integral Brake/NoSPIN® Q = Q Series Cam Brake
M = Conventional Spindle/Integral Brake/Other Differential R = Cast PlusTM Brake
N = Unitized Spindle/Integral Brake/Standard Differential S = Wedge Brake, Single Air Chamber
P = Unitized Spindle/Integral Brake/DCDL T = T Series Cam Brake
Q = Unitized Spindle/Integral Brake/NoSPIN® W = W Series Cam Brake
R = Unitized Spindle/Integral Brake/Other Differential
S = Bolt on Conventional Spindle/Conventional Brake/No Differential
4002706a
Front Drive Steer Axles, Prior Models As an example, a 16,000 lb (7258 kg) front drive steer axle with a
single-reduction 145 model carrier is identified by the following:
Front drive steer axle models manufactured from 1989 to 2002 are
identified by a letter and number system. The letters and numbers
give important information about the specific axle model.
The first seven positions of the designations identify a basic axle
model. The second group of letters and numbers identify particular
specifications.
Manufacturing Location
B — Brazil
E — Europe (CVC) Main Differential Nest Type
M — Europe (Maudslay) B — Special Differential
N — U.S.A. C — Driver -Controlled
Differential Lock
F — Standard Differential
H — High Traction Differential
N — NoSpin® Differential
Meritor heavy-duty front drive steer axle models manufactured Meritor makes a complete line of FDS series front drive axles with
before 1989 were identified as shown in Figure 5.3. For example, single axle capacities of 7,500 lb (3400 kg) to 23,000 lbs
an 18,000 lb (8165 kg) front drive steer axle with a (10 500 kg).
double-reduction 255 carrier model was identified as
FDS series front drive axle model designations show the capacity,
FDS-1805-SAX-60 10.59.
carrier model and design modifications of each model. The letters
Figure 5.3
and numbers of the model designation correspond with information
listed in Table AJ.
FDS-1805-SAX-60 10.59
Carrier Ratio
Customer Specification
Number
Brake Type 5
Basic Capacity
Front Drive Steer Axle
4002692a
Figure 5.3
DIAL
Steering-Related Components INDICATOR
Fasteners
Verify that all fasteners are tightened to the specified torque. Use a
torque wrench to check the torque in a tightening direction. As soon
as the fastener starts to move, record the torque. Correct if
necessary. Replace any worn or damaged fasteners.
5. Move the top of the tire side-to-side TOWARD and AWAY from Figure 5.6
the vehicle.
앫 If the dial indicator moves a total of 0.010-inch
(0.254 mm): The upper bushing is worn or damaged.
Replace both bushings in the knuckle. Refer to the
appropriate maintenance manual for complete service
information. Figure 5.5.
Figure 5.5
DRIVER SIDE
1000008d
Figure 5.6
Figure 5.7
Figure 5.7
CAUTION BALL/STUD
Check the tie rod end play by hand. Do not use a pry bar which
can affect the accuracy of the dial indicator reading. Damage
to components can result.
6. Move the tie rod end cross tube assembly UP and DOWN by
hand. Record the dial indicator reading.
앫 If the dial indicates a reading of more than 0.060-inch
(1.52 mm): Replace the tie rod end. NATURAL
PIVOT WEAR
7. Place the dial indicator on the tie rod end assembly at the
BALL/STUD
opposite side of the vehicle.
1. Drive the vehicle onto ramps. Follow the ramp manufacturer’s Figure 5.8
instructions.
2. Inspect and lubricate the tie rod ends.
Figure 5.9
1003403b
Figure 5.10
1003402a
Figure 5.9 7. Check that the tie rod end is threaded correctly into the cross
tube and installed deeper than the end of the cross tube slot.
The tie rod end must be visible the entire length of the cross
tube slot. Figure 5.11.
Figure 5.11
8. Check that the grease fittings are installed. Replace a damaged Figure 5.13
grease fitting.
앫 If the tie rod ends are non-greaseable: Do not install a
grease fitting if the tie rod end is the non-greaseable type.
Figure 5.12.
Figure 5.12
ALTERNATE
GREASE
FITTING
LOCATIONS
Figure 5.13
1003408a CAUTION
Figure 5.12 Replace bent or damaged cross tubes with original equipment
parts of the same length, diameter and threads. Do not
9. By hand or using a pipe wrench with jaw protectors to avoid attempt to straighten a bent cross tube. Damage to
gouging the cross tube, rotate the cross tube toward the components can result.
FRONT of the vehicle and then toward the REAR.
12. Inspect the cross tube and clamps for damage. Figure 5.14.
앫 After rotating, center the cross tube.
앫 If the cross tube is bent or cracked: Replace it. Use
앫 If the cross tube will not rotate in either direction: original equipment parts of the same length, diameter and
Replace both tie rod ends. threads.
10. Position yourself directly underneath the ball stud socket. 앫 If the clamps are damaged: Replace them.
Grasp the end of the tie rod assembly with both hands as close
앫 If either clamp has become welded to the cross tube:
as possible to the socket. Your hands should be within
Replace the entire cross tube assembly. Use original
6-inches (152.4 mm) of the socket.
equipment parts of the same length, diameter and threads.
Figure 5.14
NOTE: As the truck hub unit warms up during operation, some
CROSS TUBE small amounts of grease will purge out the outboard dust seal as
CLAMP pressure is released from inside the truck hub unit. The grease
purge is permissible if it does not exceed two grams or about
one-half teaspoon. Do not replace the truck hub unit if the grease
purge does not exceed two grams.
Baffle-type breathers help keep the axles free from external 3. Clean, install and tighten the drain plug to 35-50 Ib-ft
moisture and dirt, which can cause premature oil and component (48-67 N폷m). @
failure. 4. Remove the fill plug from the axle.
Seals 5. Fill the axle to the bottom of the fill plug hole with the specified
oil. Allow enough time for the oil to circulate through the axle
CAUTION assembly.
Always use the correct tools and procedures when replacing 6. Install and tighten the fill plug to 35-50 Ib-ft (48-67 N폷m). @
the seals to prevent incorrect installation and help prevent the
seals from leaking.
Lubrication
Seals keep the lubricant in and the dirt out of a component. When
they are worn or damaged, seals leak and produce low lubricant King Pin Bushings
levels which may damage components. 1. Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Set the parking brake.
Durable triple-lip seals, standard in Meritor axles, protect the quality
and levels of the lubricant and provide superior performance. 2. Verify that the tires touch the ground. Do not raise the vehicle.
The full weight of the vehicle must be on the axle assembly.
Temperature Indicators Figure 5.15.
Many Meritor axles have a tapped hole in the housing for the
installation of a lubricant temperature indicator that will help reduce
the failure of axle parts from overheated oil.
Figure 5.16
Camshaft Retainer Bushing and Cam Bushing
TOP Pump grease until it purges through the seals. Figure 5.19.
GREASE
FITTING
Figure 5.19
GREASE
PURGE
BOTTOM LOCATIONS
GREASE
FITTING
4006841a
Figure 5.16
GREASE 5
FITTINGS
5. Apply lubricant into the top grease fitting until new grease
purges from the upper shim pack. Figure 5.17.
Figure 5.17
NEW NEW
GREASE GREASE
GREASE
FITTINGS
UPPER
SHIM PACK GREASE
PURGE
LOCATIONS
4006842a 4000066a
Figure 5.19
Figure 5.17
6. Apply lubricant into the bottom grease fitting until new grease Cross Tube End Assembly
appears from under the lower lip of the bearing deflector. 1. Check the cross tube for looseness of more than 0.060-inch
Figure 5.18. (1.52 mm). Figure 5.20.
Figure 5.18
앫 If the cross tube is loose: Service as necessary.
Figure 5.20
BEARING
DEFLECTOR
NEW
GREASE
4006843a
CROSS TUBE
Figure 5.18
GREASE FITTING 4000067b
Figure 5.20
2. Apply the specified grease at the grease fitting on the cross Knuckle Bushing
tube until new grease purges from all the seals.
1. Check the knuckle for looseness. The correct end play is
앫 If new grease does not purge at the seals: Move the 0.001-0.065-inch (0.025-1.65 mm) for new axles or
cross tube while applying grease at the fittings until new 0.001-0.075-inch (0.025-1.9 mm) for in-service axles. If
grease purges from all the seals. loose, service as necessary.
앫 If new grease still does not purge: Disassemble the 2. Clean all grease fittings prior to lubrication.
cross tube. Inspect the grease and the components.
3. Apply the specified grease at the grease fitting on the knuckle.
Service as necessary.
Apply grease until new grease purges from all the seals.
Grease the lower pin cap with the vehicle weight on the wheel
Drive Axle Shaft Universal Joints
end to ensure that the thrust bearing is completely greased.
1. Permanently-lubricated Permalube™ joints do not have a
앫 If new grease does not purge at the seals: Move the
grease fitting provided. Periodic greasing is not required for
knuckle while applying grease at the fittings until new
these parts. For serviceable universal joints with grease
grease purges at the seals.
fittings, follow Step 2 and Step 3.
앫 If new grease still does not purge: Disassemble the
2. Clean all grease fittings prior to lubrication.
knuckle. Inspect the grease and the components. Service
3. Apply the specified grease at the grease fitting on the universal as necessary.
joint. Apply grease until new grease purges from all the seals.
앫 If new grease does not purge at every seal: Move the Wheel Bearings
driveline while applying grease at the fittings until new
grease purges at every seal. WARNING
Park the vehicle on a level surface. Block the wheels to
앫 If new grease still does not purge: Disassemble the prevent the vehicle from moving. Support the vehicle with
universal joint. Inspect the grease and the components. safety stands. Do not work under a vehicle supported only by
Service as necessary. jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
Axle Shaft Spline and Thrust Washer
On axles with greaseable drive flanges, pump grease through the 1. Park the vehicle on a level surface. Place blocks under the
grease fitting until it purges at the axle shaft seal. Figure 5.21. wheels not being serviced to prevent the vehicle from moving.
2. Raise the vehicle so that the wheels to be serviced are off the
Figure 5.21
O & S — LUBE 5
PURGES FROM THREE
HOLES TOP OF BOOT
TRW — LUBE
PURGES FROM
BOOT BASE IN EVEN,
SMALL STREAMS
Point wheels straight ahead. 1003405a
Figure 5.22
O & S — NON-GREASEABLE
1003424c
Figure 5.23
4. If the tie rod end is designed for lube service and does not
accept grease, perform the following procedure.
A. Remove the grease fitting.
B. Inspect the threaded grease fitting hole in the tie rod end
and remove any obstructions.
C. Install a new grease fitting.
D. Continue the lubrication procedure.
5. Apply grease until all the old grease is purged from the boot.
4. Force lubricant into the upper and lower knuckle sockets until
the lubricant flows out between the axle housing sockets and
the steering knuckle.
Meritor °F °C
Specification Oil Oil 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 GL-5, SAE 75W –40 35 –40 2
O-76L Gear Oil GL-5, SAE 75W/140 –40 None –40 None
O-76M Full-Synthetic Oil GL-5, SAE 75W/140 –40 None –40 None
5
O-76N Full-Synthetic Oil GL-5, SAE 75W/90 –40 None –40 None
Military Specification Approval for all oils is ML-L-2105D or MIL-PRF-2105-E.
* 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.
Troubleshooting
Table AP: Front Drive Steer Axle Troubleshooting
Condition Cause Correction
Tires wear out quickly or Tires have incorrect air pressure Adjust the air pressure in the tires.
have uneven tire tread Tires out-of-balance Balance or replace the tires.
wear.
Incorrect tandem axle alignment Align the tandem axles.
Incorrect toe-in setting Adjust the toe-in specified setting.
Incorrect steering arm geometry Service the steering system as necessary.
Excessive wheel end play Readjust the wheel bearings.
Vehicle is hard to steer. Power steering system pressure low Repair the power steering system.
Steering gear linkage not assembled correctly Assemble the steering gear correctly.
Steering linkage needs lubrication Lubricate the steering linkage.
King pins binding Replace the king pins.
Incorrect steering arm geometry Service the steering system as necessary.
Caster out-of-adjustment Adjust the caster as necessary.
Tie rod ends hard to move Replace the tie rod ends.
Worn thrust bearing Replace the thrust bearing.
Tie rod ends are worn and Tie rod ends require lubrication Lubricate the cross tube ends. Verify that the lubrication
require replacement. schedule is followed.
Severe operating conditions Increase the frequency of the inspection and lubrication
intervals.
Damaged boot on the tie rod end Replace the boot.
Bent or broken cross tube, Too much pressure in the power steering Adjust the power steering system to the specified
tie rod end ball stud, system; pressure exceeds vehicle pressure.
steering arm or tie rod end. manufacturer’s specification
Component requires Power steering system cut-off pressure, Adjust the power steering system to the specified
replacement. out-of-adjustment pressure.
Vehicle operated under severe conditions Verify that the vehicle is operated correctly.
Add-on type of power steering system not Correctly install the add-on power steering system.
installed correctly
Steering gear overtravel poppets incorrectly set Check for correct operation or adjust the overtravel of
or malfunctioning the poppets to the vehicle manufacturer’s
specifications.
Axle stops incorrectly set Set the axle stops to the vehicle manufacturer’s
specification.
Figure 6.1
DRIVER SIDE
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
STEERING
WARNING ARM CURBSIDE
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
KNUCKLE
refer to the Service Notes page on the front inside cover of this DRIVER SIDE
manual.
Description KNUCKLE
Figure 6.2
In the following example, 01 is the year 2001 and 327 refers to CUSTOMER NO 01X21A62
Model Nomenclature
Refer to Figure 6.4 for an explanation of non-MFS front non-drive model numbers. For an explanation of MFS model numbers, refer to Figure 6.5.
Figure 6.4
Meritor Identification
Basic Capacity
A 5,000 lbs
B 6,000 lbs
C 7,000-8,000 lbs
D 9,000 lbs Basic Series
E 10,000 lbs.
F 12,000-13,200 lbs Brake Usage
Front Axle G 14,600 lbs
L 16,000-20,000 lbs
LX 30,000 lbs Specification Number
U 28,000-30,000 lbs
F F - 9 8 1 - L X - 122
Figure 6.4
Figure 6.5
Figure 6.5
Inspect the tires for wear patterns that indicate suspension damage
or misalignment. Correct if necessary.
PRY BAR
1000004b
Figure 6.8
Steering Knuckle Vertical End Play
5. Set the dial indicator on ZERO.
Axles with Conventional Wheel Ends
6. Use the pry bar to push the knuckle UPWARD. Record the
1. Park the vehicle on a level surface. Block the wheels to prevent reading on the dial indicator.
the vehicle from moving.
앫 If the reading is ZERO: Remove the knuckle. Remove the
2. Use a jack to raise the vehicle until the front wheels are off the shims from the shim pack. Refer to Maintenance Manual 2,
ground. Support the front axle with safety stands. Front Non-Drive Steer Axles, for more information.
3. Install a dial indicator with the base on the I-beam and the tip 앫 If the reading is more than the correct end play
on the top knuckle cap. Figure 6.7. specifications shown in the table below: Remove the
knuckle. Add shims to the shim pack. Refer to Maintenance
Manual 2, Front Non-Drive Steer Axles, for more information.
Axles with Unitized Wheel Ends D. Place the dial indicator tip onto the exposed king pin top.
Set the dial indicator to ZERO.
1. Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Set the parking brake. E. Move the jack up. Measure and record the dial indicator
reading. Lower the jack.
2. Use a jack to raise the vehicle until the front wheels are off the
ground. Support the front axle with safety stands. Alternate Method to Measure End Play
3. Install a dial indicator for each side of the axle beam. A. As an alternative method to measure end play, turn the
wheels to the RIGHT for a curbside knuckle or LEFT for a
Curbside Knuckle
driver-side knuckle measurement.
A. Turn the wheels STRAIGHT ahead. Install the dial base
B. Place a pry bar between the tie rod arm and the axle
onto the axle beam.
beam. Figure 6.10.
B. Place the dial indicator tip onto the upper king pin cap.
C. Set the dial indicator to ZERO.
C. Place a jack and a wood block, with a hole that allows
D. Lift the knuckle UPWARD using a pry bar. Record the
clearance for the lower king pin grease fitting, under the
reading on the dial indicator.
lower king pin cap area. Figure 6.9.
4. Compare the reading you obtained with the end play
Figure 6.9
specifications below.
CURBSIDE
앫 If the reading is ZERO: Remove the knuckle. Remove
shims from the shim pack. Refer to Maintenance Manual 2,
Front Non-Drive Steer Axles, for more information.
앫 If the reading is more than the correct end play
specifications: Remove the knuckle. Add shims to the
shim pack. Refer to Maintenance Manual 2, Front
Non-Drive Steer Axles, for more information.
WOOD
BLOCK 1000005c Table AS: End Play Specifications
Figure 6.9 New or Rebuilt 0.001-0.010-inch (0.025-0.254 mm)
In-Service Axles 0.001-0.030-inch (0.025-0.762 mm)
D. Set the dial indicator to ZERO.
E. Raise the jack until you start to lift the axle beam off the
safety stands. Measure and record the dial indicator Figure 6.10
NOTE: The wood block should have a hole that allows clearance for
TIE ROD
the lower king pin grease fitting. ARM 1000006c
C. Place a jack and a wood block under the lower king pin Figure 6.10
cap area.
Upper and Lower King Pin Bushings 4. Set the dial indicator to ZERO.
Wheel-to-Hub Mounting 5. Move the top of the tire side-to-side TOWARD and AWAY from
the vehicle.
To help determine the cause of movement and looseness, first
check the wheel-to-hub mounting. 앫 If the indicator moves a total of 0.010-inch (0.254 mm):
The upper bushing is worn or damaged. Replace both
1. Verify that the wheel is mounted correctly and all wheel-end
bushings in the knuckle. Refer to Maintenance Manual 2,
fasteners and hardware are secure.
Front Non-Drive Steer Axles, for more information.
2. Apply the service brake to lock the hub and spindle assembly Figure 6.11 and Figure 6.12.
together.
6. Check the lower king pin bushing. Install a dial indicator so that
앫 If movement is detected: The king pin or king pin the base is on the I-beam and that the tip is against the side of
bushings are most likely worn. the bottom of the knuckle. Figure 6.13 and Figure 6.14.
앫 If applying the service brake eliminates the movement:
Proceed to Detailed Inspection to determine the unitized Figure 6.13
Figure 6.11
Figure 6.14
CONVENTIONAL WHEEL END — DRIVER SIDE UNITIZED WHEEL END — FRONT VIEW CURBSIDE
1000323d
1000008e
Figure 6.11
Figure 6.14
Figure 6.12
Unitized Wheel End 4. Grasp the tire and wheel-end assembly at the 9 and 3 o’clock
positions. Check for vertical and horizontal movement. With
The unitized wheel end is sealed and greased for life and does not your hands, apply approximately 50 lb (23 kg) of force to the
require lubrication. If you disassemble, or attempt to repair or lubricate assembly. You should not feel or see any looseness or
a unitized wheel-end assembly, you will void Meritor’s warranty. The
movement.
basic and detailed inspection procedures provided in this manual do
not instruct you to disassemble the unitized wheel end. 앫 If you feel or see any movement or looseness in the
tire and wheel-end assembly: Perform a detailed
Wheel-to-Hub Mounting inspection to determine the cause of the movement, such
To help determine the cause of movement and looseness, first as worn king pin bushings or pins; wheel-to-hub-mounting
check the wheel-to-hub mounting. end play; unitized wheel-end hub end play; or a
combination of them all. To determine unitized wheel-end
1. Verify that the wheel is mounted correctly and all wheel-end hub end play, refer to the detailed inspection procedure in
fasteners and hardware are tightened to the correct this section.
specification.
If other front axle components, such as king pin bushings,
2. Apply the service brake to lock the hub and spindle assembly require inspection or service, refer to the appropriate
together. procedures in this manual.
앫 If you detect movement or looseness: The king pin or
king pin bushings are most likely worn.
Detailed Inspection
Perform detailed inspections after the initial 200,000 miles
앫 If applying the service brake eliminates the movement:
(321 800 km) of operation and after every additional 200,000 miles
Proceed to the detailed inspection procedure in this section
(321 800 km) of operation thereafter.
to determine the unitized wheel-end hub end play.
1. Park the vehicle on a level surface. Block the wheels to prevent
Basic Inspection the vehicle from moving.
After the initial 200,000-mile (321 800 km) detailed inspection, 2. Remove the hubcap. The outboard and inboard seals may
perform a basic inspection at each scheduled preventive purge small amounts of grease that are visible during
maintenance interval, not to exceed 50,000-mile (80 467 km) inspection. Figure 6.15. This is a normal occurrence.
intervals.
If the Vehicle is Equipped with ABS on the Steer Axle
Figure 6.15
2. Raise the vehicle so that the front wheels are off the ground.
Support the vehicle with safety stands. Do not use a jack to
support the vehicle.
3. Visually inspect the unitized wheel end as you rotate the tire
and unitized wheel-end assembly. Verify that it rotates
smoothly and without noise. While rotating the wheel, grasp
the brake chamber to feel for unitized wheel-end hub vibration.
앫 If the tire and unitized wheel-end assembly does not 4000299b
rotate smoothly, or you hear noise or feel wheel-end
hub vibration during rotation: Replace the unitized Figure 6.15
wheel-end hub. Refer to Maintenance Manual 2, Front
Non-Drive Steer Axles, for the procedures. 3. Raise the vehicle so that the front wheels are off the ground.
Support the vehicle with safety stands. Do not use a jack to
앫 If the wheel end rotates smoothly: Proceed to Step 4. support the vehicle.
4. Verify that the unitized wheel end rotates smoothly and without NOTE: The inner wheel bearing nut and the outer wheel bearing nut
noise. While rotating the wheel, grasp the brake chamber to are identical, but the torque values are different.
feel for unitized wheel-end hub vibration.
8. Install the tabbed washer and outer wheel bearing nut onto the
앫 If the tire and unitized wheel-end assembly does not
spindle.
rotate smoothly, or you hear noise or feel wheel-end
hub vibration during rotation: Replace the unitized 앫 For 1-1/8-inch (28.6 mm) wheel bearing nuts used on
wheel-end hub. MFS-06, MFS-07 and MFS-08 Series axles: Tighten to
150-225 lb-ft (203-305 N폷m). @
앫 If the wheel end rotates smoothly: Proceed to Step 5.
앫 For other series axles: Tighten the outer wheel bearing nut
5. Remove the wheel and drum. Attach the magnetic base of a
to 200-300 lb-ft (272-408 N폷m). @
dial indicator onto the end of the spindle. Figure 6.16. Touch
the indicator stem perpendicular against the unitized wheel 9. Reattach the dial indicator. Set the dial indicator to ZERO. Do
end’s mounting face. not rotate the wheel end. Place your hands at the 9 and
3 o’clock positions.
Figure 6.16
10. Push the unitized wheel end straight IN. Note the reading. Pull
the unitized wheel end straight OUT. Note the reading.
앫 If the total movement of the dial indicator is greater
6
than 0.003-inch (0.08 mm), but less than 0.006-inch
(0.15 mm): Record the measurement in a maintenance
log, and perform a basic inspection at the next
DIAL regularly-scheduled maintenance interval, or not to exceed
INDICATOR
50,000 miles (80 467 km), whichever comes first.
After you’ve taken the measurement, bend the parts of the
tabbed washer that protrude over the flats of the outer
4000308a wheel bearing nut and the inner wheel bearing nut. Bend
Figure 6.16 the washer a minimum of one flat edge to each nut.
Inspection is complete. Return the vehicle to service.
6. Set the dial indicator to ZERO. Do not rotate the wheel end. 앫 If the total movement of the dial indicator is 0.006-inch
Place your hands at the 9 and 3 o’clock positions. (0.15 mm) or greater: Replace the unitized wheel-end
7. Push the unitized wheel end straight IN. Note the reading. Pull hub.
the unitized wheel end straight OUT. Note the reading.
Tie Rod and Cross Tube Assembly
앫 If the total movement of the dial indicator is less than
0.003-inch (0.08 mm): Inspection is complete. Return the NOTE: Do not grease the tie rod assembly before you perform the
vehicle to service. inspection.
앫 If the total movement of the dial indicator is 0.003-inch
(0.08 mm) or greater: Remove the outer bearing nut and You may not be able to detect loose or worn tie rod ends during
tabbed washer. Tighten the inner wheel bearing nut to operation. Under normal operating conditions, wear occurs over
500-700 lb-ft (679-949 N폷m) while rotating the unitized time. The preload bearings inside each tie rod end provide less
wheel end a minimum of five rotations. @ resistance, which can affect steering control, front tire wear, and
other axle components.
Regularly-scheduled inspection and maintenance helps to minimize
the effects of tie rod end wear on the vehicle. Refer to Table AT and
Table AU in this section for inspection intervals. Figure 6.17.
Figure 6.17 4. Check the tie rod boot for cracks, tears or other damage. Also
check the boot seals for damage. Replace the entire tie rod end
BALL/STUD
if the boot is damaged or missing. Figure 6.19.
BALL/STUD
Figure 6.19
4000283b
5. Check that the tie rod nut is installed and secured with a
cotter pin.
앫 If the cotter pin is missing: Tighten the tie rod end nut to
the correct specification. Install a new cotter pin. Always
tighten the tie rod nut to the specified torque when setting
the cotter pin. Do not back-off the nut to insert the cotter
pin. Figure 6.20.
Figure 6.20
TIE
TIE CROSS
ROD Missing cotter pin
ROD TUBE
END indicates unsafe
ARM 1000325b condition and requires
immediate replacement.
Figure 6.18
2. Raise the vehicle so that the front wheels are off the ground.
Support the vehicle with safety stands. Do not use a jack to
support the vehicle.
3. With the engine off, turn the wheels from full left to full right.
Return to the straight-ahead position. This step will require
more force for vehicles with the power steering off. STEERING
KNUCKLE 4000284a
Figure 6.20
6. Check that the tie rod end is threaded correctly into the cross 9. Position yourself directly below the ball stud socket. Using both
tube and installed deeper than the end of the cross tube slot. hands, grasp the assembly end as close to the socket as
The tie rod end must be visible the entire length of the cross possible, no more than 6-inches (152.4 mm) from the end.
tube slot. Figure 6.21.
CAUTION
Figure 6.21
Figure 6.21
CAUTION
Replace bent or damaged cross tubes with original equipment
parts of the same length, diameter and threads. Do not
4000289a
attempt to straighten a bent cross tube. Damage to
components can result.
Figure 6.22
11. Inspect the cross tube and clamps for damage. Figure 6.24.
8. By hand or using a pipe wrench with jaw protectors to avoid 앫 If the cross tube is bent or cracked: Replace it. Use
gouging the cross tube, rotate the cross tube toward the front original equipment parts of the same length, diameter and
of the vehicle and then toward the rear. After rotating, center threads.
the cross tube between the stop positions.
앫 If the clamps are damaged: Replace them.
앫 If the cross tube will not rotate in either direction:
Replace both tie rod ends. 앫 If either clamp has become welded to the cross tube:
Replace the entire cross tube assembly. Use original
equipment parts of the same length, diameter and threads.
Figure 6.25
Figure 6.24
CROSS
TUBE
CLAMP
CRACK
DAMAGE 4000288a
Point wheels straight ahead. 1003405a
Figure 6.24
Figure 6.25
Department of Transportation Roadside Tie 3. Wipe the grease fitting, seal and boot clean with shop towels.
Rod Assembly Replacement Criteria Figure 6.26.
When the roadside check indicates tie rod movement of 0.125-inch Figure 6.26
(3 mm) or more, immediately remove the vehicle from service to Always clean off grease
fittings prior to applying lube.
replace the tie rod. Figure 6.23.
앫 If the roadside check is less than 0.125-inch (3 mm) tie rod
end movement: The vehicle does not need to be immediately
removed from a service run. Schedule a major out-of-service
inspection and maintenance as soon as possible.
Lubrication GREASE
FITTING
ALTERNATE
Tie Rod End LOCATION
1003422b
Figure 6.26
WARNING
Park the vehicle on a level surface. Block the wheels to
4. Attach either a hand or air pressure grease gun to the grease
prevent the vehicle from moving. Support the vehicle with
fitting. Figure 6.27. If using air pressure, do not exceed 150 psi
safety stands. Do not work under a vehicle supported only by
(1035 kPa).
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result. Figure 6.27
This procedure refers to all tie rod ends on Meritor non-drive steer
axles.
1. Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Set the parking brake.
2. Turn the vehicle wheels to the STRAIGHT position. Figure 6.25.
5. Apply grease into the grease fitting. Discolored old grease 6. If the tie rod end is designed for lube service and it does not
should come out of the purge holes near the boot crimp or accept grease, perform the following procedure.
bellows area, typically three or more places. Figure 6.28.
A. Remove the grease fitting.
Figure 6.28 B. Inspect the threaded grease fitting hole in the tie rod end
and remove any obstructions.
SLIDING SEAL TIE
ROD ENDS C. Install a new grease fitting.
D. Continue the lubrication procedure.
7. Apply grease until all old grease is purged from the boot.
TRW — LUBE PURGES
EVENLY FROM BASE OF BOOT
King Pin Bushings
NON-REMOVABLE AND ALL-WEATHER Axles with Conventional Wheel Ends
BOOT SEAL TIE ROD ENDS 1. Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Set the parking brake.
O & S — LUBE 2. Verify that the tires touch the ground. Do not raise the vehicle. 6
PURGES FROM THREE The full weight of the vehicle must be on the axle assembly.
HOLES TOP OF BOOT
Figure 6.29.
Figure 6.29
TRW — LUBE
PURGES FROM
BOOT BASE IN EVEN,
SMALL STREAMS
O & S — LUBE
3. Clean all grease fittings before you lubricate the king pins.
PURGES FROM THREE
HOLES TOP OF BOOT 4. Lubricate the king pins through the top and bottom grease
fittings. Figure 6.30.
Figure 6.30
TOP
O & S — NON-GREASEABLE GREASE
FITTING
1003424c
Figure 6.28
BOTTOM
GREASE
FITTING
4006841a
Figure 6.30
5. Apply lubricant into the top grease fitting until new grease Figure 6.33
purges from the upper shim pack. Figure 6.31. Lube must
GREASE come from here.
Figure 6.31
FITTING
NEW NEW
GREASE GREASE
GREASE
UPPER FITTING 1000011b
SHIM PACK
Figure 6.33
4006842a
5. Force lubricant into the upper and lower king pin grease fitting
Figure 6.31 caps until new lubricant flows from between the upper axle
beam end and the knuckle, and the lower axle beam end and
6. Apply lubricant into the bottom grease fitting until new grease the knuckle. Figure 6.33.
appears from under the lower lip of the bearing deflector.
Figure 6.32. Ball Studs on the Steering Arm and the Tie
Figure 6.32
Rod Arm Ends
Axles with Conventional and Unitized Wheel Ends
THRUST
BEARING 1. Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Set the parking brake.
BEARING 2. Verify that the tires touch the ground. DO NOT RAISE THE
DEFLECTOR VEHICLE.
3. Clean off all grease fittings prior to lubrication.
NEW
GREASE 4. Apply lubricant until new lubricant comes from the boot.
4006843a Figure 6.34 and Figure 6.35.
Figure 6.32 Figure 6.34
4. Lubricate the king pins through the grease fittings on the top GREASE
and bottom king pin caps. Figure 6.33. FITTING
1000329a
Figure 6.34
Figure 6.35
5. Install the inner and outer bearing cones into the cups in the
UNITIZED
hubs. The bearing cups must be pressed tight against the
shoulder in the hubs.
6. Install new wheel seals into the hubs.
7. Install the hub and the wheel and tire assembly. Install the
Lube must come
outer wheel bearing cone into the hub. Install the adjusting nut.
from here. 8. Adjust the wheel bearings.
GREASE
FITTING
1000012b
Oil-Lubricated Wheel Bearings
Figure 6.35
Axles with Conventional Wheel Ends
Grease-Lubricated Wheel Bearings
NOTE: This procedure applies to hubs with oil-lubricated wheel
Axles with Conventional Wheel Ends bearings.
NOTE: This procedure applies to hubs with grease-lubricated wheel 1. Check the level on the cap. If the oil level is not at the specified
bearings. level on the cap, remove the fill plug. 6
1. Park the vehicle on a level surface. Block the wheels to keep 2. Add the specified oil until the oil is at the specified level.
the vehicle from moving. Set the parking brake. Figure 6.37.
2. Remove the tire and wheel assembly. Remove and Figure 6.37
LUBE
1000330b
Figure 6.36
Steering Arm Bolts Axles with Conventional and Unitized Wheel Ends
NOTE: This procedure applies to all except 901, 903 and 970
WARNING Series axles. These axles do not use a draw key. Refer to the
Take care when you use Loctite® adhesive to avoid serious identification tag on the front of the axle beam.
personal injury. Read the manufacturer’s instructions before
using this product. Follow the instructions carefully to prevent Tighten the nuts on the side of the knuckle that hold the draw keys
irritation to the eyes and skin. If Loctite® adhesive material to 30-45 lb-ft (41-61 N폷m) at the following times. Figure 6.38 and
gets into your eyes, follow the manufacturer’s emergency Figure 6.39. @
procedures. Have your eyes checked by a physician as soon as
possible. 앫 After the first 6,000 miles (10 000 km) of new vehicle operation
앫 Every 36,000 miles (58 000 km) of operation
1. Check the steering arm bolts for minimum torque. Refer to the
table below. Figure 6.38
above. UNITIZED
1000013c
Figure 6.39
Lubricant
Table AV: Front Non-Drive Axle Greasing Specifications
Grease* Meritor Specification NLGI Grade Grease Classification Outside Temperature
Multi-Purpose Grease* O-617-A 1 6% Lithium 12-Hydroxyl Refer to the grease
Stearate manufacturer’s
O-617-B 2 8% Lithium 12-Hydroxyl specifications for the
Stearate temperature service
limits.
* Meritor recognizes that industry trends are moving toward increased selection and usage of synthetic grease in vehicle maintenance.
However, some seals are known to expand when in contact with synthetic grease. Consult your local Meritor representative for synthetic
grease application references BEFORE using any synthetic grease when performing axle service and maintenance.
Troubleshooting
Table AW: Front Non-Drive Steer Axle Diagnostic Table
Figure 7.1
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
non-asbestos materials.
Cam Brakes
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Refer to the publications in Table AX. To obtain these publications,
4000319n
refer to the Service Notes page on the front inside cover of this
manual. Cast Plus™
Figure 7.2
Table AX: Publications
Model Manual Figure 7.3
Description
4000321n
Q Plus™ and Cast Plus™; and Q, P and T Series
P Series
Meritor cam brakes are air-actuated, cam-operated, two-shoe
Figure 7.3
brakes with each shoe mounted on a separate anchor pin. The
brakes are available with automatic slack adjusters and can be
assembled with air chambers. Q, Q Plus™ and P Series brakes are
available with brake lining wear sensors. Figure 7.1, Figure 7.2,
Figure 7.3 and Figure 7.4.
Figure 7.4
Identification
Cam brakes are identified as follows.
앫 A model number tag for the brake assembly is located on the
camshaft tube.
앫 An example of a part number format for a 16.5 Q Plus™ brake
is QP1 1657 1234.
In addition to the model number tag on the cam tube, a brake shoe
4000322n label is attached to the brake shoe web. This label provides
T Series information on brake type, lining material and service parts
replacement number. Figure 7.5.
Figure 7.4
Figure 7.5
The brake shoe lining also contains identification. Figure 7.6. The Figure 7.6
information that exists on the edge code of the lining is listed in the
following order. EXAMPLE: MERITOR MA212 FF
4707 ANC 6133 D-159 53076
앫 Meritor stamped logo
앫 Lining mix designation
앫 Friction code
앫 Friction Material Standards Institute (FMSI) number, four to eight
4002661b
spaces
앫 Block type
Figure 7.6
앫 Meritor part number, last four digits
앫 Word drawing engineering change letter
앫 Julian date, four or five characters
Model Nomenclature
Refer to Figure 7.7 for an explanation of brake model numbers.
Figure 7.7
Figure 7.7
Figure 7.8
Cam Brakes, All Models
TANDEM AXLES FRONT AXLE
WARNING
Before you service a spring chamber, carefully follow the
manufacturer’s instructions to compress and lock the spring to
completely release the brake. Verify that no air pressure
remains in the service chamber before you proceed. Sudden
release of compressed air can cause serious personal injury
and damage to components.
Both wheel ends of each axle must
have identical drums and lining.
When you perform preventive maintenance procedures on an
4000376a in-service brake, check both the free stroke and adjusted chamber
stroke.
Figure 7.8
Free stroke sets the clearance between the linings and drum. The
6. Always follow the specifications supplied by the vehicle in-service free stroke may be slightly longer than 0.5-0.625-inch
manufacturer for the correct lining to be used. Vehicle brake (12.7-15.9 mm) specified in this procedure. This is not a concern if
systems must have the correct friction material and these the adjusted chamber stroke is within the limits shown in Table AY
requirements can change from vehicle to vehicle. and Table AZ.
7. The return springs must retract the shoes completely when the Measure Free Stroke
brakes are released. Replace the return springs each time the
brakes are relined. The spring brakes must retract completely Before taking measurements, verify that the brakes are fully
when they are released. released. Cage the spring brake chambers if equipped.
8. The air chamber area multiplied by the length of the automatic 1. Measure the distance from the center of the large clevis pin to
slack adjuster is called the AL factor. This number must be the bottom of the air chamber while the brake is released. The
equal for both ends of a single axle and all four ends of a measurement you obtain is X in Figure 7.10.
tandem axle. Figure 7.9.
Figure 7.10
Figure 7.9 2. Use a pry bar to move the slack adjuster and position the
linings against the drum with brakes applied. Measure the
9. Measure the brake free stroke and adjust the chamber stroke. same distance again while the brakes are applied. The
measurement you obtain is Y in Figure 7.10.
10. Lubricate the brake system components.
Figure 7.12
Table AZ: Long-Stroke Clamp-Type Brake Chamber Data*
Step 1 Mark push rod here
to measure stroke. Outside Diameter Brake Adjustment
Type (inches) Limit (inches)
16 6-3/8 2.0
• Spring brakes 20 6-25/32 2.0
released
24 7-7/32 2.0
• Service brakes Step 2
not applied 24 7-7/32 2.5
30 8-3/32 2.5
Step 3 STROKE
*For 3" maximum stroke type 24 chambers.
90-100 psi (620-690 kPa)
in air tank — engine OFF Alternate Method to Measure Push Rod Travel
(Adjusted Chamber Stroke)
• Spring brakes Use the CVSA procedure, except in Steps 3-4, measure the distance
released
from the bottom of the air chamber to the center of the large clevis
• Service brakes pin on each of the brakes.
applied 4000374b
Figure 7.12 CVSA North American Out-of-Service Criteria
Reference Tables
4. Measure the push rod travel or adjusted chamber stroke from
Information contained in Table AY and Table AZ is for reference only.
where the push rod exits the brake chamber to your mark on
Consult the CVSA’s Out-of-Service Criteria Handbook for North
the push rod. Measure and record the distance. Figure 7.12.
American Standards, Appendix A. Visit their website at
5. Subtract the measurement you recorded in Step 3 from the http://64.35.82.7/ to obtain the handbook.
measurement you recorded in Step 4. The difference is the
push rod travel or adjusted chamber stroke. Cam Brake Lubrication Intervals and
6. Refer to Table AY or Table AZ to verify that the stroke length is Procedures
correct for the size and type of air chambers on the vehicle.
Before you perform lubrication procedures, release the brakes to
앫 If the push rod travel or adjusted chamber stroke is ensure the camshaft bushings and automatic slack adjusters will be
greater than the maximum stroke shown in Table AY or sufficiently lubricated. If the brake has a spring brake, compress and
Table AZ: Refer to Diagnostic Charts, Table BO, in this lock the spring to completely release the brake. No air pressure
section. must remain in the service half of the air chamber.
Table AY: Standard-Stroke Clamp-Type Brake Chamber Data Brake Inspections Before the Recommended
Outside Diameter Brake Adjustment Lubrication Interval
Type (inches) Limit (inches)
NOTE: You do not have to replace Q Plus™ LX500 and MX500
6 4-1/2 1-1/4 brake camshaft bushings and seals when you reline the brake prior
9 5-1/4 1-3/8 to the recommended service interval.
12 5-4/16 1-3/8
1. Periodically inspect brake shoe linings. If the lining thickness is
16 6-3/8 1-3/4
0.25-inch (6.35 mm) at the thinnest point, reline the brakes.
20 6-25/32 1-3/4 Refer to Maintenance Manual MM-96173, Q Plus™ LX500
24 7-7/32 1-3/4 and MX500 Cam Brakes, for more information. To obtain this
30 8-3/32 2 publication, refer to the Service Notes page on the front inside
cover of this manual.
36 9 2-1/4
2. Periodically inspect the brakes for correct clearance between Figure 7.14
the lining and drum. If you must manually adjust the brakes Q, Q PLUS™ AND P SERIES
because of excessive air chamber stroke, correct the problem. Lubricate Lubricate
Refer to Maintenance Manual MM-96173, Q Plus™ LX500 here only. entirely.
and MX500 Cam Brakes, for more information. To obtain this
publication, refer to the Service Notes page on the front inside
cover of this manual.
Table BA: Q Plus™ LX500 and MX500 Cam Brake Lubrication Do not CAM
Intervals lubricate here. ANCHOR PIN
CAM
Q Plus™ LX500 Cam Brake ROLLER PIN
4000365b
On-Highway Linehaul 3 years/500,000 miles (805 000 km)
All Other Applications 1 year, regardless of mileage Figure 7.14
Q Plus™ LX500 and MX500 Cam Brakes and 1. Park the vehicle on a level surface. Block the wheels to prevent
Automatic Slack Adjusters After the the vehicle from moving. Release the brakes to ensure the
Specified Time or Mileage Intervals camshaft bushings and automatic slack adjusters will be
sufficiently lubricated.
Brakes Without a Pressure Relief Valve Built Prior to
July 2000 2. Remove the identification tag from the chamber bracket.
WARNING 3. Remove the grease plugs from both the chamber bracket and
the automatic slack adjuster.
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. 4. Remove the automatic slack adjuster. Remove the O-ring from
Park the vehicle on a level surface. Block the wheels to the splined gear. Discard the O-ring. Install the automatic slack
prevent the vehicle from moving. Support the vehicle with adjuster onto the camshaft.
safety stands. Do not work under a vehicle supported only with 5. Install new grease fittings. Use Meritor-approved O-701
jacks. Jacks can slip and fall over. Serious personal injury and
calcium-base NLGI Grade 2 synthetic grease to lubricate the
damage to components can result.
brake assembly through the grease fitting in the bracket until
1. Park the vehicle on a level surface. Block the wheels to prevent new grease flows from the pressure relief valve in the bracket.
the vehicle from moving. Release the brakes to ensure the
camshaft bushings and automatic slack adjusters will be 6. Use Meritor-approved O-701 calcium-base NLGI Grade 2
sufficiently lubricated. synthetic grease to lubricate the automatic slack adjuster
through the grease fitting until new grease purges from the pull
2. Remove the identification tag from the chamber bracket.
pawl, or the boot begins to expand.
3. Remove the grease plugs from both the chamber bracket and
the automatic slack adjuster. 7. After the first lubrication, follow the manufacturer’s chassis
lubrication schedule and your regular preventive maintenance
4. Remove the automatic slack adjuster. Remove the O-ring from
the splined gear. Discard the O-ring. Install the automatic slack schedule. You should also continue to perform periodic
adjuster onto the camshaft. inspections of the brakes.
5. Install new grease fittings. Use Meritor-approved O-701
calcium-base NLGI Grade 2 synthetic grease to lubricate the Cam Brake Tips
brake assembly through the grease fitting in the bracket until
new grease flows from the inboard, slack end, seal.
Air Chambers
6. Use Meritor-approved O-701 calcium-base NLGI Grade 2 To ensure correct brake balance, all brake chambers on the same
synthetic grease to lubricate the automatic slack adjuster axle must be the same size and type to help ensure a balanced
through the grease fitting until new grease purges from the pull brake system for maximum lining wear and drum life.
pawl, or the boot begins to expand.
Brake Kits
7. After the first lubrication, follow the manufacturer’s chassis
lubrication schedule and your regular preventive maintenance Meritor brake shoes, rollers, camshafts and shoe return springs are
schedule. You should also continue to perform periodic designed to perform as a system. Always install original equipment
inspections of the brakes. manufacturer’s components during maintenance or when you
Brakes with a Pressure Relief Valve Built After July upgrade from standard to long-life brakes to help ensure correct
2000 brake performance and maximum lining life.
A cast drum and a centrifuse drum each absorbs and dissipates Trailer Cam Brakes
heat differently. When drum types and weights are mixed, different Long-life bushings require correct lubrication for maximum
rates of heat absorption and dissipation occur that can affect the performance and bushing life. Although you do not have to replace
brake system. spider cam bushings on trailer axles as frequently, Meritor
recommends that you lubricate the bushings at least four times
Hardware during the life of your brake lining.
When you service cam brakes, replace all the springs, anchor pins,
bushings and rollers — not just the shoe return springs — to help Automatic Slack Adjusters
ensure maximum braking performance. Automatic doesn’t mean maintenance-free. Correctly-installed and
lubricated automatic slack adjusters help to ensure maximum brake
Linings system performance. 7
Insist on the same brand of quality friction lining material Never mix automatic slack adjusters on the same axle. When you
recommended by the component equipment manufacturer to help replace automatic slack adjusters, always use the replacement parts
ensure fewer relines and compatibility with your present system. that were originally designed for the brake system to help ensure
even brake wear, balanced braking and maximum brake
performance.
Approved Lubricants
Table BB: Cam Brake Grease Specifications
Components Meritor Specification NLGI Grade Grease Type Outside Temperature
Retainer Clips O-616-A 1 Clay-Base Down to −40°F (−40°C)
Anchor Pins O-617-A 1 Lithium 12-Hydroxy Refer to the grease
O-617-B 2 Stearate or Lithium manufacturer’s
Rollers, Journals Only
Complex specifications for the
Camshaft Bushings temperature service
limits.
O-645 2 Synthetic Oil, Clay-Base Down to −65°F (−54°C)
O-692 1 and 2 Lithium-Base Down to −40°F (−40°C)
Camshaft Splines Any of Above Refer to Above Refer to Above Refer to Above
O-637* 1-1/2 Calcium-Base Refer to the grease
O-641 — Anti-Seize manufacturer’s
specifications for the
temperature service
limits.
*Do not mix Meritor grease specification O-637, part number 2297-U-4571, a calcium-base, rust-preventive grease, with other greases.
Important Information
Meritor automatic slack adjusters (ASAs) should not need to be In the event that a manual adjustment must be made (although not a
manually adjusted in service. ASAs should not have to be adjusted common practice), a service appointment and full foundation brake,
to correct excessive pushrod stroke. The excessive stroke may be ASA, and other system component inspection should be conducted
an indication that a problem exists with the foundation brake, ASA, as soon as possible to ensure integrity of the overall brake system.
brake actuator or other system components.
For Meritor brake adjustment, refer to the brake adjustment tables
Meritor recommends troubleshooting the problem, replacing in this section. For non-Meritor brake adjusters, refer to the brake
suspect components and then confirming proper brake operation manufacturer’s service procedures.
prior to returning the vehicle into service.
DISC, ROTOR —
CALIPER
VENTED TYPE
Technical Publications
AUTOMATIC
How to Obtain Additional Maintenance and Service SLACK
Information ADJUSTER
Model Nomenclature
Refer to Figure 7.17 and Figure 7.18 for an explanation of model
numbers.
4002891a
Figure 7.16
7
Figure 7.17
4002716b
Figure 7.17
Figure 7.18
4002716d
Figure 7.18
Air Disc Brake Inspection Intervals and Slide Pins and Bushings: Air Disc Brake Model
ADB 1560
Procedures
1. Check for contamination on the slide pins. If necessary, remove
Inspection Schedules and clean the slide pins and caliper bushings.
2. Use a pin gauge J-34064-54, to check the slide pin bushings
Use the schedule below that gives the most frequent inspection.
for wear. If you can fit the gauge between the slide pin and the
앫 Fleet chassis lubrication schedule bushing, the bushing or slide pin is worn. Replace worn
bushings and slide pins. To obtain the pin gauge, contact SPX
앫 Chassis manufacturer lubrication schedule
Kent-Moore at 800-328-6657.
앫 At least four times during the lining life
Rotors
앫 At tire replacement
Inspect the rotor for cracks, deep scores or other damage. Replace
Minor Inspections the rotor when necessary.
The maintenance schedules shown in this manual are for normal Air Chamber
operating conditions. Refer below for other operating conditions. Move the air chamber from side-to-side to check that the caliper
moves freely on the slide pins. When the caliper does not move
앫 Operation under severe conditions can require shorter periods
freely, inspect the slide pins, slide pin bushings and slide pin
between maintenance.
retainers for wear or damage. Replace components when
앫 Operation over long distances with few stops can permit longer necessary.
periods between maintenance.
Linings
A maintenance schedule for each vehicle can be set after the brakes When the linings wear, the caliper slides in along the slide pins. To
are inspected several times. check for lining wear, check the position of the caliper inboard
bosses on the slide pins. Figure 7.19. If the bosses are within
Major Inspections
0.25-inch (6.4 mm) of the ends of the pins, remove the wheels and
Inspect and lubricate the brake and automatic slack adjuster tires and inspect the linings. If the bosses are within 0.125-inch
according to one of the following schedules. Use the schedule that (3.2 mm) of the ends of the pins, replace the linings.
provides the most frequent inspection and lubrication.
Figure 7.19
Air System
앫 A vehicle equipped with a combination of air disc and drum
brakes requires special attention to obtain maximum brake
performance.
UNWORN
앫 Replace the air system valves with valves of identical
WORN
performance characteristics.
앫 A correctly maintained air system and correct air pressure to
each brake can help to ensure maximum brake performance and
reduced lining wear.
LINING WEAR INDICATOR
Automatic Slack Adjusters 4001655a
Major Inspections 2. Verify that pressure is 100 psi (689 kPa) in the air tanks.
Determine the size and type of brake chambers on the vehicle.
When you reline the brakes, or at least one time a year, perform the
following inspection. 3. With the brakes released, mark the push rod where it exits the
chamber. Measure and record the distance. Have another
1. Inspect the automatic slack adjuster and brakes as previously
person apply and hold the brakes on full application.
described in Minor Inspections. Perform minor inspections
Figure 7.20. Hold the ruler parallel to the push rod and
before you do any other maintenance or reline procedures.
measure as carefully as possible. A measurement error can
2. Perform all the procedures, inspections and measurements. affect CVSA re-adjustment limits. CVSA states that “any brake
3. Lubricate the automatic slack adjuster and the caliper. 1/4-inch or more past the re-adjustment limit, or any two
brakes less than 1/4-inch beyond the re-adjustment limit, will
4. Adjust the brakes.
be cause for rejection.”
Meritor automatic slack adjusters (ASAs) should not need to be Step 1 Mark push rod here
manually adjusted in service. ASAs should not have to be adjusted to measure stroke.
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
• Spring brakes
Meritor recommends troubleshooting the problem, replacing released
suspect components and then confirming proper brake operation • Service brakes Step 2
prior to returning the vehicle into service. not applied 7
In the event that a manual adjustment must be made (although not a
Step 3 STROKE
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted 90-100 psi (620-690 kPa)
as soon as possible to ensure integrity of the overall brake system. in air tank — engine OFF
Reference Tables
Information contained in Table BG and Table BH is for reference only.
Consult the CVSA’s Out-of-Service Criteria Handbook for North
American Standards, Appendix A. Visit their website at
http://64.35.82.7/ to obtain the handbook.
Measure
this
distance.
4002890a
Figure 7.21
4. Have another person apply and hold the brakes on full Disc and Rotor
application.
5. Measure the distance from the bottom of the air chamber to
CAUTION
the center of the clevis pin while the brakes are applied. Always replace a cracked disc to avoid serious personal injury
and damage to components.
6. To determine push rod travel, adjusted chamber stroke:
Subtract the measurement you obtained in Step 2 from the Inspect both sides of the disc, rotor, for the following conditions.
measurement you obtained in Step 5. The difference is the Replace the disc, rotor, if necessary.
push rod travel, adjusted chamber stroke. 앫 When a crack extends through a section of the disc, rotor,
A. Push rod travel, adjusted chamber stroke, must not be replace the disc, rotor.
greater than two-inches (50.8 mm) for the type 16 and 앫 Heat checks are short, thin, sometimes numerous radial
20 long-stroke chambers used on these axles. interruptions of the braking surfaces of the rotor. They are a
B. If push rod travel, adjusted chamber stroke, is greater normal phenomena of the disc brake function. They are the
than the maximum stroke, refer to Condition 1 in Table BK result of the heating and cooling that occurs as brakes are
for more information. applied time after time. Heat checks will frequently wear away
and reform or they may progress into braking surface cracks,
depending on such factors as the lining/rotor wear rate, brake
DiscPlus™ DX195 and DX225 Air Disc Brake
balance and how hard the brakes are used. There are two kinds
Components of heat checking: light and heavy.
Lining Thickness 앫 Cracks on the surface of the disc, rotor, that result from light
Lining material thickness must not be less than 0.200-inch heat checking are small and fine and do not require disc, rotor, 7
(5.1 mm). Replace the linings before the lining material thickness replacement.
reaches this specification. 앫 Heavy heat checking is surface cracks that have width and
depth. If you find heavy heat checking, replace the disc, rotor.
Anti-Rattle Springs 앫 Inspect both sides of the disc, rotor. If you find deep grooves or
1. Anti-rattle springs are attached to the linings. Inspect for bent, scores, replace the disc, rotor. If the grooves or scores are not
cracked or broken springs. too deep, you can continue to use the disc.
2. If you find damaged springs, replace the springs. 앫 Blue marks or bands indicate that the disc, rotor, was very hot.
Refer to Conditions 2, 3 and 4 in Table BK to determine the
Seals cause and correct the condition.
Replace the caliper if you find cracked, torn or otherwise damaged 앫 Measure the thickness of the disc, rotor, when you reline the
seals. brakes. The disc, rotor, must be at least 1.626-inches
(41.3 mm). Figure 7.22. If the thickness of a disc, rotor, is less
Caliper than the specification, replace the disc, rotor.
The caliper should slide freely on the slide pins. Slide the caliper Figure 7.22
back and forth to check for clearance between the disc, rotor, and
1.626" (41.3 MM)
pad. MINIMUM THICKNESS
VENTED DISC
4002908a
Figure 7.22
Anti-Seize Compound
Meritor lubricant specification O-637, part number 2297-U-4571, is
a corrosion-control grease. Do not mix this grease with other 4001651a
greases. This compound is also available from the Southwest
Petro-Chemical Division of Witco Chemical Corporation, 1400 South Figure 7.24
Harrison, Olathe, KS 66061, as Corrosion Control, part number SA
8249496. Figure 7.25
앫 Use anti-seize compound on the clevis pins of all slack adjusters. MANUFACTURED AFTER 1991
Also use anti-seize compound on the automatic slack adjuster GREASE FITTING
and cam splines if the slack adjuster gear has no grease groove
and holes around its inner diameter.
CAUTION
Only use Meritor specification O-616-A or O-645 grease inside RELIEF
VALVE 4001652a
the disc brake caliper. Do not use lithium-base grease, which
can melt from high temperatures inside the caliper. Damage to Figure 7.25
components can result.
Lubricate brake-actuating components inside the caliper two to four NOTE: For calipers with grease fittings in the caliper and the
times during the life of the lining, or every six months. camshaft cap, first apply grease to the caliper fitting, then apply
grease to the camshaft cap fitting.
1. Turn the adjusting nut on the automatic slack adjuster to move
the inboard lining against the rotor. Figure 7.26.
3. Apply grease through the grease fitting in the caliper until
Figure 7.26
grease flows out of the seal at the camshaft cap.
CAUTION
You must force excess grease from the caliper. Brakes can
drag due to excessive grease in the caliper, which will reduce
brake lining life.
4. Remove the pressure relief valve from the caliper. Turn the
slack adjuster adjusting nut in the opposite direction to fully
STEP 1 retract the caliper piston and force the excess grease through
the pressure relief hole.
5. Clean the excess grease from the outside of the caliper with a
rag.
STEP 2 4001653a 6. Install the pressure relief valve.
7. Adjust the brake.
Figure 7.26
7
2. Plug the pressure relief valve by holding a finger over the
poppet.
Approved Lubricants
Table BI: Air Disc Brake Model ADB 1560 Grease Specifications
Meritor
Component Specification NLGI Grade Grease Description Outside Temperature
Caliper1 O-616-A 1 Clay Base Down to −40°F (−40°C)
O-645 2 Synthetic Oil, Clay Down to −65°F (−54°C)
Base
Slide Pin Retainers O-6372 1-1/2 Calcium Base Refer to the grease
O-641 — Anti-Seize manufacturer’s specifications for
the temperature service limits.
Powershaft Splines Any of Above Refer to Above Refer to Above Refer to Above
1
The grease used inside the caliper must be non-melting and also allow correct brake function at cold temperatures listed.
2
Do not mix O-637 calcium-base, corrosion-control grease with other greases.
Important Information
Meritor automatic slack adjusters (ASAs) should not need to be In the event that a manual adjustment must be made (although not a
manually adjusted in service. ASAs should not have to be adjusted common practice), a service appointment and full foundation brake,
to correct excessive pushrod stroke. The excessive stroke may be ASA, and other system component inspection should be conducted
an indication that a problem exists with the foundation brake, ASA, as soon as possible to ensure integrity of the overall brake system.
brake actuator or other system components.
For Meritor brake adjustment, refer to the brake adjustment tables
Meritor recommends troubleshooting the problem, replacing in this section. For non-Meritor brake adjusters, refer to the brake
suspect components and then confirming proper brake operation manufacturer’s service procedures.
prior to returning the vehicle into service.
앫 Rapid lining wear Vehicle air system Correct operation of the quick release Repair or replace parts as required.
malfunction valve and relay valve
앫 Heavy blueing or
Spring brake not releasing Vehicle air system leakage Find the source of the leak and repair
discoloration of disc
as required.
or rotor braking
surface Spring brake chamber malfunction Repair or replace the spring brake
chamber as required.
앫 Torn or charred
Slow build-up of trailer emergency air Wait for full build-up before driving.
piston or caliper boot
pressure
seal
Incorrect air pressure range at Set the compressor or governor to the
compressor or governor correct pressure range.
Excessive grease pressure Incorrect lubrication procedures Follow the lubrication 7
in the caliper recommendations.
Internal corrosion of caliper Piston boot and caliper seals Replace the seals as required. Inspect
assembly and overhaul the caliper assembly as
required.
Short outboard lining Caliper seized on slide pins Excessive paint or other foreign Remove both pins. Clean, inspect and
life build-up on the caliper slide pins or replace the pins and bushings as
앫 Brake drag bushings required.
Misalignment of slide pins Caliper should move back and forth Remove the pads. Clean, inspect and
with hand effort, 20-30 lb-ft replace the slide pins and bushings as
(27-41 N폷m) necessary. Install the caliper and slide
pins without the pads. Tighten the
retainer nuts. Check that the caliper
slides freely on the slide pins. If the
problem continues, check the axle
mounting flange for nicks, burrs or
gouges. Repair as necessary. Install
the torque plate and caliper and check
again for free movement. If the flange
is acceptable but the problem
continues, contact your Meritor
representative for information.
Important Information
Meritor automatic brake adjusters (ABAs) should not need to be In the event that a manual adjustment must be made (although not a
manually adjusted in service. ABAs should not have to be adjusted common practice), a service appointment and full foundation brake,
to correct excessive pushrod stroke. The excessive stroke may be ABA, and other system component inspection should be conducted
an indication that a problem exists with the foundation brake, ABA, as soon as possible to ensure integrity of the overall brake system.
brake actuator or other system components.
For Meritor brake adjustment, refer to the brake adjustment tables
Meritor recommends troubleshooting the problem, replacing in this section. For non-Meritor brake adjusters, refer to the brake
suspect components and then confirming proper brake operation manufacturer’s service procedures.
prior to returning the vehicle into service.
Vehicle air system Correct operation of quick Repair or replace the parts as required.
malfunction release valve
3 — Short outboard brake Caliper seized or sticking Damaged slide-pin seals. Repair the caliper/saddle assembly.
pad lining life on slide pins Caliper should move
back-and-forth by hand
with linings removed.
4 — Short lining life Refer to conditions 2 and Refer to conditions 2 and Refer to conditions 2 and 3.
3. 3.
Rotor surface Cracks or heavy heat Refer to conditions 3 and 4 for disc, rotor,
checking. Refer to inspection.
condition 3.
Vehicle overload Refer to GAWR limitations Observe the vehicle manufacturer’s load
on vehicle I.D. plate. recommendations.
Companion brakes not Inspect companion Adjust or repair as required.
working correctly. vehicle brakes and air
system.
5 — Brake smoking High brake temperature Refer to conditions 2, 3 Refer to conditions 2, 3 and 4.
and 4.
Contamination on linings Grease, oil, etc., on Inspect the hub seal. Replace as required. Clean
linings the rotor and caliper assembly. Replace linings.
앫 High brake pressures Vehicle overload Refer to GAWR limitations Observe the vehicle manufacturer’s load
on vehicle I.D. plate. recommendations.
앫 Lack of normal
response Contamination on linings Grease, oil, etc., on Observe the vehicle manufacturer’s load
linings recommendations.
앫 Vehicle pulls to one
side Companion brakes not Inspect companion Adjust or repair as required.
working correctly vehicle brakes and air
system.
7 — Shimmy or brake pull Refer to conditions 1, 2 Refer to conditions 1, 2 Refer to conditions 1, 2 and 6.
and 6. and 6.
Rotor runout and Replace the hub and rotor assembly.
thickness variation
Identification WARNING
The part number is located on the side of the slack adjuster. Before you service a spring chamber, carefully follow the
manufacturer’s instructions to compress and lock the spring to
Meritor uses either black, red, yellow, green or blue to color-code
completely release the brake. Verify that no air pressure
the automatic slack adjuster internal actuator piston according to
remains in the service chamber before you proceed. Sudden
brake type and air chamber size.
release of compressed air can cause serious personal injury
A mylar tag is attached to the current-design slack adjuster with a and damage to components.
press-in boot. The color of the actuator piston is printed on the
mylar tag. Figure 7.27. 2. If the vehicle has spring brakes, manually compress and lock the
springs to release the brakes. You must check to ensure that no
On previous-design slack adjusters, a color-coded tie wrap attaches air pressure remains in the service halves of the air chambers.
the boot to the slack adjuster body. The color of the tie wrap
matches the color of the actuator piston. Figure 7.27. Slack Adjusters Manufactured in 1993
1. Use the correct slack adjuster template to ensure that the
Figure 7.27
Approved Lubricants
Table BM: Automatic Slack Adjuster Grease Specifications
Components Meritor Specification NLGI Grade Grease Type Outside Temperature
Automatic Slack Adjuster O-616-A 1 Clay Base Down to –40°F (–40°C)
O-645 2 Synthetic Oil, Clay Base Down to –65°F (–54°C)
O-692 1 and 2 Lithium Base Down to –40°F (–40°C)
Clevis Pins Any of Above Refer to Above Refer to Above Refer to Above
O-637* 1-1/2 Calcium Base Refer to the grease
O-641 — Anti-Seize manufacturer’s
specifications for the
temperature service limits.
*Do not mix Meritor grease specification O-637, part number 2297-U-4571, a calcium-base, rust-preventive grease, with other greases.
Anti-Seize Compound
Meritor lubricant specification O-637, part number 2297-U-4571, is
a corrosion-control grease. Do not mix this grease with other
greases. This compound is also available from the Southwest
Petro-Chemical Division of Witco Chemical Corporation, 1400 South
Harrison, Olathe, KS 66061, as Corrosion Control, part number SA
8249496.
앫 Use anti-seize compound on the clevis pins of all slack adjusters.
앫 Also use anti-seize compound on the automatic slack adjuster
and cam splines if the slack adjuster gear has no grease groove
and holes around its inner diameter.
Important Information
Meritor automatic slack adjusters (ASAs) should not need to be In the event that a manual adjustment must be made (although not a
manually adjusted in service. ASAs should not have to be adjusted common practice), a service appointment and full foundation brake,
to correct excessive pushrod stroke. The excessive stroke may be ASA, and other system component inspection should be conducted
an indication that a problem exists with the foundation brake, ASA, as soon as possible to ensure integrity of the overall brake system.
brake actuator or other system components. For Meritor brake adjustment, refer to the brake adjustment tables
Meritor recommends troubleshooting the problem, replacing in this section. For non-Meritor brake adjusters, refer to the brake
suspect components and then confirming proper brake operation manufacturer’s service procedures.
prior to returning the vehicle into service.
Wedge Brakes For complete maintenance and service information for Meritor
wedge brakes, refer to Maintenance Manual 4R, Wedge Brakes. To
Technical Publications obtain this publication, refer to the Service Notes page on the front
inside cover of this manual.
How to Obtain Additional Maintenance and Service
Information Identification
Refer to the publications in Table BP. To obtain these publications, Wedge brakes are identified as follows.
refer to the Service Notes page on the front inside cover of this
앫 A model number tag is typically attached to the wedge tube or
manual.
dust shield of the brake assembly.
Table BP: Publications 앫 An example of a part number format for a 15-inch brake is RSA
Model Manual 1540 1234.
Wedge Brakes Maintenance Manual 4R Model Nomenclature
®
Stopmaster Wedge Brake Maintenance Manual MM-0153
Refer to Figure 7.29 for an explanation of brake model numbers.
Description
Meritor Stopmaster® wedge brakes for on-highway vehicles are
air-actuated and are available as single-actuated (RSA) and
dual-actuated (RDA). Both models can be specified with 12-, 14- or
16-degree wedge angles. Figure 7.28.
Figure 7.28
4002631a
Figure 7.28
Figure 7.29
S = Single Actuation
D = Dual Actuation Drum I.D. (Inches) Specification Number
Speci cation Number
Meritor —
Blank = No Chamber or Cylinder Shoe Width (Inches)
Wedge Design
A = With Air Chamber
H = With Hydraulic Chamber 4002716c
Figure 7.29
Important Information 3. Remove the plugs from the adjustment and inspection slots on
the dust shield.
Meritor automatic brake adjusters (ABAs) should not need to be
manually adjusted in service. ABAs should not have to be adjusted 4. While you rotate the drum, use an adjusting spoon to turn the
to correct excessive pushrod stroke. The excessive stroke may be adjusting bolt until the linings drag heavily on the drum. Turn
an indication that a problem exists with the foundation brake, ABA, the adjusting bolt 10-20 teeth in the opposite direction until the
brake actuator or other system components. lining-to-drum clearance is 0.020-0.040-inch
(0.51-1.02 mm). Operate the brakes. Use a ruler to measure
Meritor recommends troubleshooting the problem, replacing
movement at the center of the shoe to determine the
suspect components and then confirming proper brake operation lining-to-drum clearance.
prior to returning the vehicle into service.
5. Repeat Step 4 for the other adjuster on the brake.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake, 6. If the brake has a spring chamber, release the spring.
ABA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system. NOTE: Meritor KIT 1184 includes an adjusting spoon plus a seal
driver and a brake spring tool. The kit or the individual tools are
For Meritor brake adjustment, refer to the brake adjustment tables available from Meritor Aftermarket Parts and Services, 7975 Dixie
in this section. For non-Meritor brake adjusters, refer to the brake Highway, Florence, KY 41042. Adjusting spoons available from tool
manufacturer’s service procedures. manufacturers include Kent-Moore J-34061, Proto 2006 and
Snap-on® S-9523.
Brake Adjustment Procedure
Inspection Procedure 7
WARNING
You must manually adjust the brake after you perform WARNING
maintenance or service. Do not depend on the automatic
Park the vehicle on a level surface. Block the wheels to
adjusters to remove the excessive clearance created when you
prevent the vehicle from moving. Support the vehicle with
back off the brake during service. The automatic adjusters are
safety stands. Do not work under a vehicle supported only by
designed to compensate for normal lining wear. Damage to
jacks. Jacks can slip and fall over. Serious personal injury and
components and serious personal injury can occur.
damage to components can result.
2. If the brake has a spring chamber, cage the spring. Rotate the
drum to verify that the brake is completely released.
Figure 7.30 3. While someone operates the service and parking brake
GROOVED systems, check each brake to verify that it operates correctly.
Use a ruler to measure the movement at the center of each
shoe to determine the lining-to-drum clearance. Clearance of a
shoe must not exceed 0.090-inch (2.3 mm). Total clearance of
the two shoes must not exceed 0.120-inch (3.05 mm). When
clearance exceeds these limits, the automatic adjusters are not
SCALLOPED
working correctly. Refer to the troubleshooting tables in this
section to correct the problem before you adjust the brake.
Lubrication
Lubricate the components shown in Figure 7.32 every
100,000 miles (160 000 km), or once a year, or when any of the
4002660a following occur.
the leading shoe. When the plunger housing is in front of the ADJUSTING BOLT
SHOE SLOT INSIDE OF SEAL
axle, the bottom shoe is the leading shoe. Figure 7.31.
AND THREADS
ENTIRE
Figure 7.31
ACTUATOR
PAWL TEETH
LEFT-HAND BRAKES RIGHT-HAND BRAKES ENTIRE
ADJUSTING
WHEEL ROTATION WHEEL ROTATION
PLUNGER
ALL PLUNGER
HOUSING BORES
WEDGE HEAD
AND ROLLERS
LEADING SHOE
ENTIRE PLUNGER
BELOW SEAL
GROOVE AND
AREAS OF SPIDER
ANCHOR PLUNGER
AND HARDWARE THAT
SHOE SLOT
CONTACT SHOES
INSIDE
OF SEAL 4002659a
Figure 7.31
Approved Lubricants
Table BQ: Wedge Brake Grease Specifications
Meritor
Component Specification NLGI Grade Grease Description Outside Temperature
All Actuating O-616-A 1 Clay Base Down to –40°F (–40°C)
Components O-645 2 Synthetic Oil, Clay Down to –65°F (–54°C)
All Areas Where Shoes Base
Contact Spider
Anchor Plungers
Adjusting Bolts or
Retainer Hardware
Important Information
Meritor automatic brake adjusters (ABAs) should not need to be In the event that a manual adjustment must be made (although not a
manually adjusted in service. ABAs should not have to be adjusted common practice), a service appointment and full foundation brake,
to correct excessive pushrod stroke. The excessive stroke may be ABA, and other system component inspection should be conducted
an indication that a problem exists with the foundation brake, ABA, as soon as possible to ensure integrity of the overall brake system.
brake actuator or other system components. For Meritor brake adjustment, refer to the brake adjustment tables
Meritor recommends troubleshooting the problem, replacing in this section. For non-Meritor brake adjusters, refer to the brake 7
suspect components and then confirming proper brake operation manufacturer’s service procedures.
prior to returning the vehicle into service.
refer to the Service Notes page on the front inside cover of this
manual.
caliper design for use on both front and rear drive axles. An
installation includes four major components — the caliper
assembly, support assembly, hub/rotor assembly and the attaching
hardware.
The inboard pistons apply the inboard pads and the outboard
pistons apply the outboard pads. Two sizes of calipers are used,
2.520-inch (64 mm) and 2.756-inch (70 mm).
Features of the caliper include the following.
PREVIOUS STYLE CURRENT STYLE
앫 Designed for hydraulic brake systems 4003785b
앫 Hard-mounted to the anchor plate to eliminate caliper and
Figure 7.34
anchor plate replacement
앫 Designed with hardened stainless steel mounting surfaces, high
temperature piston boot compound, sealed bleeder screws and Current Style Previous Style
full-coverage zinc plating Metric caliper bolts SAE caliper bolts
앫 Compatible with anti-lock braking systems (ABS) and existing Caliper housing halves held Caliper housing halves held
hydraulic systems together by bolts in blind holes together by bolts and nuts in
앫 Helps to increase lining life in the bridge area. the bridge area.
Integral piston/heat shield Separate piston and heat
앫 Can be adapted to fit most vehicles with a hydraulic system that
shield
supplies to 1,800 psi (12 402 kPa)
Phenolic piston Metal piston
앫 Available in 33,000 lbs maximum GVWR (4 x 70 mm) and
maximum 24,000 lbs GVWR (4 x 64 mm). brake pads, two
stainless steel lining rail covers installed with button head bolts,
a pad retainer spring and bolt, bleeder screw and crossover tube
Four-Piston Quadraulic Disc Brake 2. Use a wire brush to clean the caliper mounting area.
Inspection 3. Inspect the mounting plate for cracks or elongated bolt holes.
CAUTION
Use a crocus cloth to remove minor stains and corrosion from
the caliper bore. Do not use abrasives, including an every
cloth. If you cannot remove minor stains and corrosion,
replace the caliper bore to avoid damage to components.
ADJUSTER PISTON
Technical Publications AND MANUAL
OVERRIDE WHEEL
How to Obtain Additional Maintenance and Service
Information
CURRENT
Refer to Maintenance Manual MM-99101, DuraPark® Type A2LS
Heavy-Duty Drum Brake Assembly. To obtain this publication, refer
to the Service Notes page on the front inside cover of this manual. 4002882a
Figure 7.35
Figure 7.36
ADJUSTER PISTON
AND MANUAL
OVERRIDE WHEEL Permatex® Apply Permatex®
is not required. to this area.
PREVIOUS 4002883a
Figure 7.38
4002881a
Figure 7.36
Figure 7.39
Adjustment Procedures
PISTON DESIGN
Measuring Shoe-to-Drum Clearance
PREVIOUS
NOTE: The clearance between the drum and lining may vary from
top to bottom and from left to right sides of the vehicle. This is
normal and does not indicate that service is required. In the past
design, the top shoe clearance was adjusted during reverse stops,
PARK CYLINDER PARK CYLINDER ADJUSTER
HANDBRAKE EXPANDER CYLINDER and the bottom shoe clearance was adjusted during forward stops.
PISTON PISTON PISTON However, with the newer design shoe return springs, both top and
bottom shoes are allowed to adjust during stops in either direction.
CURRENT
NOTE: Correct and full adjustment will only occur with the drum
rotating. Pumping the brake pedal with the vehicle stationary will not
achieve correct adjustment.
4002884a
1. Block the front wheels to prevent the vehicle from moving
Figure 7.39
before any service work is started.
Figure 7.40
2. Manually cage the parking brake chambers per the vehicle
manufacturer’s recommendations.
SHOE RETURN SPRINGS
LH BRAKE RH BRAKE 3. Center the shoes in the drum by making two slow, hard
applications and releases of the service brakes. 7
4. Remove the plugs from the lining inspection holes. Insert feeler
gauges between the lining and the drum approximately half
way across the width of the lining. The feeler gauges must be
on the lining surfaces and not in the area between the two
linings blocks.
The normal shoe-to-drum clearance range is
FRONT OF FRONT OF 0.020-0.050-inch (0.508-1.27 mm). In some circumstances,
VEHICLE VEHICLE larger clearances may be seen. In these cases, it is necessary
CURRENT 4002885a
to add the top shoe clearance and the bottom shoe clearance.
Figure 7.40 The normal sum of the top and bottom shoe clearance is
0.040-0.100-inch (1.016-2.54 mm). Do not attempt to adjust
Figure 7.41 the clearances if they meet either of the above requirements.
PISTON SEALS Figure 7.42 and Figure 7.43.
Figure 7.42
FEELER GAUGE
LINING
INSPECTION
HOLE
PREVIOUS CURRENT
4002886a
Figure 7.41
4002879a
Figure 7.42
Figure 7.43
NOTE: Extra caution should be taken if linings have not yet been
ADJUSTMENT
LINING SLOT burnished.
INSPECTION
HOLE
ADJUSTER 14. Road test.
SIGHT
HOLE
Brake Drums and Rotors
LINING
INSPECTION ADJUSTER
SIGHT
Technical Publications
HOLE
HOLE
ADJUSTMENT
How to Obtain Additional Maintenance and Service
SLOT Information
4002880a
Refer to the publications in Table BU. To obtain these publications,
Figure 7.43
refer to the Service Notes page on the front inside cover of this
manual.
Manual Brake Adjustment
1. Block the front wheels to prevent the vehicle from moving Table BU: Publications
before any service is started. Model Manual
2. Release the parking brake system via a button, lever or switch Wheel Equipment (Disc Wheel Maintenance Manual
in the cab. This action pressurizes the spring chamber and Hubs and Brake Drum Failure MM-99100
compresses the parking brake spring. Analysis)
3. Cage the parking brake spring in accordance with your vehicle Parts Failure Analysis Manual TP-87123
or spring chamber manufacturer’s recommendations.
4. Jack up the rear wheels and install safety stands.
Brake Drum Inspection and Failure Analysis
Warnings appear before maintenance procedures to alert you to
5. Center the shoes in the drum by making two slow, hard
stud and nut conditions that can affect your safety and the integrity
applications and release of the service brakes.
of the vehicle and its components.
6. Manually adjust the shoes by pushing or pulling the adjusting
Carefully read all of the warnings before you perform the
tool (OTC part number D9OT-2588-AR) in the direction shown.
procedures.
Adjust burnished shoes to 0.020-inch (0.508 mm). Adjust new
shoes to 0.030-inch (0.762 mm). The Brake Drum section provides information on brake drum wear
conditions, conditions that can affect brake drum wear, a
7. Run the engine to ensure that the park brake system is
troubleshooting table, maintenance procedures, replacing a brake
pressurized. The cab mounted park brake button, lever or
drum and preventive maintenance tips.
switch should still be in the released position.
This information is also available in VHS format. To obtain a copy of
8. Uncage the park brake spring in accordance with your vehicle
the video, Brake Drum Failure Analysis, call ArvinMeritor’s Customer
or spring chamber manufacturer’s recommended procedure.
Service Center at 800-535-5560 and request item number
9. Rotate each wheel by hand to ensure that the hydraulic system T99105V.
has fully released the park brakes.
10. Apply the park brake and check that the wheels cannot be
rotated by hand.
11. Remove the safety stands and blocks.
12. Run the engine and release the park brake.
13. Drive the vehicle slowly while checking the service and park
brakes.
4001717a
Figure 7.44
6. Check the following areas for wear, which can be caused by a Use the following procedure to clean the drums during maintenance
wheel that runs loose on the hub. and service, and after machining.
앫 The pilot on a hub-piloted assembly 1. Clean the brake drum with a cloth dampened with water or a
앫 The mounting surfaces of all hub types water-base solution.
앫 Outboard drum mounting surfaces 2. If a drum has been exposed to leaking oil or grease, perform
Step 1. Then clean the drum with a non-oil base solvent.
NOTE: Use a calibrated torque wrench with right- and left-hand
capabilities to tighten the ball seat mounts. Replace a Brake Drum
8. If wheels have run loose on the hub, the pilot on hub-piloted NOTE: Before you remove the wheel and brake drum, it may be
assemblies and the mounting faces of all types of hubs, or necessary to de-adjust the slack adjuster to provide clearance
outboard brake drum mounting faces, will show wear. between the brake linings and drum.
A. Replace the entire hub assembly, including the nuts. A
3. Remove the wheel lug nuts. Remove the wheel assembly.
worn pilot or brake drum mounting surface will cause
fatigue damage to the studs, and the hub or outboard 4. Loosen the drum from the hub mounting bolts. Remove the
brake drum mounting surface will not provide a flat drum.
support for the disc wheels.
앫 If the drum is rusted or corroded: Treat the bolts. Apply
B. Replace the disc wheels. pressure to one side of the drum. Pull the drum from the
hub.
5. Clean the brake drum surfaces to remove dirt and
contaminants.
6. Measure the replacement drum in several places to ensure that Brake Drum Wear Conditions
dimensions are correct.
Most of the following wear conditions that affect a brake drum
7. Clean the debris from the drum. require that you replace the drum. Refer to the brake drum
diagnostic charts in this section for possible causes of, and
NOTE: At installation, take care that wheel bearing grease does not corrective actions for, the following wear conditions.
contaminate the drum.
What is Normal Wear?
8. Clean the drum and hub pilots with a wire brush.
Brake drums wear evenly under normal operating conditions. Use
9. Align the drum with the hub bolts. Install the drum onto the hub. fleet history, if available, to determine the approximate wear rate of
Ensure that the drum seats flat against the face of the hub. tractor drums. Normal wear is the most common reason to remove a
brake drum from service.
10. Install the locknuts onto the bolts. Tighten to the correct torque
specification. Refer to Table BW. What is Deep or Excessive Wear?
Table BW: Torque Specifications It is important to inspect a brake drum for the following excessive
wear conditions, which require you to replace the drum.
Drum Locknut Sizes Torque
Drum Replacements: Deep, Uniform Wear
5/8" diameter 95-130 lb-ft (129.2-176.8 N폷m) Deep, uniform wear at the edge of the drum where the lining rub
3/4" diameter 200-250 lb-ft (272-340 N폷m) path starts can result from brake drag, brake imbalance and dirt
embedded in the brake lining. Figure 7.46 and Figure 7.47.
Blind Tapped Holes: 7
5/8" diameter 153-207 lb-ft (208.1-281.5 N폷m) Figure 7.46
4001702a 4001704a
Figure 7.49
Figure 7.47
Deep Wear on One Side of the Drum Only Heat Checking Only on One Side of the Drum
Deep wear only on one side of the drum indicates that the drum is Heat checking that appears only on one side of the drum results
not concentric with the bearing center line of the hub. No evidence when a drum is not concentric to the linings. Hot spotting may or
of hot spotting may be evident. Figure 7.48. may not be evident. However, you may also notice deep wear on the
same side of the drum. Replace the drum. Figure 7.50.
Figure 7.48
Figure 7.50
4001703a
4001705a
Figure 7.48
Figure 7.50
Hot Spotting (Black Spots) In Three Equally Distant Places. Figure 7.53.
Hot spotting is black spots on a drum’s surface that can appear in Replace the brake drum.
the following ways.
Figure 7.53
Figure 7.51
HOT
SPOTS REPLACE DRUM
4001708a
Figure 7.53
4001706a
Polished or Glazed Drum
Figure 7.51 7
A polished or glazed drum has a mirror-like finish on the friction
On One Side Only. Figure 7.52. surface. This condition occurs with some non-asbestos linings.
Figure 7.54.
Figure 7.52
Figure 7.54
4001707a
4001709a
Figure 7.52
Figure 7.54
Figure 7.57
4001710a
Figure 7.55
“Blue” Drum
The inside of the brake drum has a blue tint, and components can
be damaged or deformed. These conditions indicate that extremely
high temperatures occurred during operation. Replace the drum. 4001712a
4001711a
Figure 7.56
4001713a
Figure 7.58
cause the entire cross-section of the drum to crack, if the drum was
forced onto the pilot while interference is present.
Figure 7.59
4001716a
Figure 7.61
7
4001714a 1. Oil and grease spots have penetrated the drum’s surface.
Figure 7.59
2. The brake drum is discolored.
Worn Brake Drum Bolt Holes 3. Oil and grease spots are evident on the components, which
The brake drum bolt holes are worn, usually because the bolts were resulted from the wheel or hub oil seals that leaked.
not tightened to the correct torque specification. The drum pilots 4. Replace the drum.
may also be worn, and runout in the brake drum may have
occurred. The mating hub or wheel pilots may be extensively Conditions That Can Affect Brake Drum Wear
damaged. Replace both the hub and drum. Figure 7.60.
Brake Drag
앫 Worn camshaft bushings
Figure 7.60
CAUTION
You must always replace a damaged rotor or disc. SOLID DISC
When you inspect the brakes, inspect both sides and the outer
diameter of the rotor or disc for the following conditions. Refer to 1.626" (41.3 MM)
MINIMUM THICKNESS
Brake Drum Wear Conditions in this section for photographs that
illustrate these conditions.
앫 Cracks VENTED DISC
4001603a
앫 Heat checking
앫 Grooves or scores Figure 7.62
Read and observe all Warning and Caution hazard alert messages in Meritor produces medium- and heavy-duty rear drive axles to suit a
this publication. They provide information that can help prevent wide range of vocations. Models are available in a variety of ratios to
serious personal injury, damage to components, or both. meet many performance requirements.
WARNING Single rear axles are front mounted into the axle housing and have a
To prevent serious eye injury, always wear safe eye protection hypoid bevel drive pinion and ring gear set with straight bevel gears
when you perform vehicle maintenance or service. in the differential assembly.
Park the vehicle on a level surface. Block the wheels to A tridem is a series of three driving axles configured as follows.
prevent the vehicle from moving. Support the vehicle with 앫 1 axle is the forward axle of a normal tandem axle set.
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and 앫 2 and 3 axles are a normal tandem set.
damage to components can result.
Identification
Technical Publications To identify the axle, carrier and housing models, refer to the three
identification tags located on the main axle housing. Figure 8.1.
How to Obtain Additional Maintenance and
Specify the information stamped on these tags when you obtain
Service Information replacement parts.
Refer to the publications in Table BY. To obtain these publications,
refer to the Service Notes page on the front inside cover of this Figure 8.1
manual.
Differential Carriers Mo me
Cu
sto .
.
l No .
de r No
l No
Pla
Da
nt
te
ria
Se
Drive Units
*Tandem Axle Forward Rear Maintenance Manual 5C
Drive Units
*Tandem Axle Forward Maintenance Manual 5E Model No.
Customer No.
Serial No. Plant
CARRIER PART NO.
CUSTOMER NO.
SERIAL NO.
Model Nomenclature
Axle Model Numbers and Designations
Refer to Figure 8.2 and Figure 8.3 for an explanation of rear axle model numbers.
Figure 8.2
Figure 8.2
Figure 8.3
BRAKE TYPE
GEARING TYPE B = Reaction Beam Disc Brake (B-Frame)
1 = Single Speed C = Air Disc Brake
2 = Two Speed MAIN DIFFERENTIAL NEST TYPE D = Wedge Brake (Dual Air Chambers)
3 = Helical Double-Reduction B= Special Differential E = Wedge Brake (Dual Hydraulic Cylinders)
4 = Salisbury Single Speed C= Driver Controlled Differential Lock F = Wedge Brake (Single Hydraulic Cylinder)
5 = Planetary Double-Reduction F= Standard Differential G= DuraPark Hydraulic Drum
6 = Hub Reduction H= High Traction® Differential H = Quadraulic Disc
N= No-SPIN® K = Disc Plus Air Disc
L = Q Plus™ Cam Brake
N = None
P = “P” Series Cam Brake
Q= “Q” Series Cam Brake
NOMINAL AXLE LOAD R = Cast Plus™ Brake
RATING (GAWR) MANUFACTURING
LOCATION S = Wedge Brake (Single Air Chamber)
In thousands of pounds. Individual T = “T” Series Cam Brake
forward and rear axles of a tandem A= Australia W= “W” Series Cam Brake
set (D, N, P, R) are rated as single B= Brazil (Braseixos)
axles. A tandem set (T) is rated as C= India
the combination of the two axles D= Mexico (Dirona) AXLE SPECIFICATION NUMBER
and a tridem set (Z) as the E= Europe (C.V.C.)
combination of the three axles. Identifies specific customer axle
M= Europe (Maudslay) configurations (variations from the
N= U.S.A. original axle design). For information
about the variation, refer to the Bill of
Materials for that specific axle model.
Meritor
RR 20 1 4 5 N C Q F* 123
HUB TYPE
A = Aluminum
C = Cast Spoke Wheel
F = Ferrous
N = None
AXLE TYPE *NOTE: This position will be used to designate hub only
until more than three digits are required to designate
C = Single Rear Drive Axle, Coach axle specification.
D = Forward-Rear Axle of a Drive Tandem
with Inter-Axle Differential
F = Front Drive Axle AXLE DESIGN VARIATION
N = Forward-Rear Axle of a Drive Tandem or Indicates axle design level or variation, (e.g., RS 23 161
Tridem without Inter-Axle Differential has a thicker wall housing than the RS 23 160). For
P = Forward-Rear Axle of a Drive Tandem CARRIER TYPE information, refer to the Bill of Materials for that speci c axle
with Inter-Axle Differential and Pump Carrier size. Larger numbers model. (Also refer to Tridem Axle Note 2 below.)
R = Rear-Rear Axle of a Drive Tandem indicate a higher GCW rated
S = Single Rear Drive Axle carrier; i.e., larger ring gear, etc. NOTE 1:
T = Tandem Drive Axle Set (Also refer to Tridem Axle Note 2 If a complete axle designation is not required, use the rst se ven
below) positions of the model designation to identify the basic axle model.
Z = Tridem Drive Axle Set
RS 17 145 = Single Rear Drive, 17,000 lbs., Single Speed, 15"
Ring Gear, 145 Carrier Model.
RT 52 380 = Tandem Drive Axle Set, 52,000 lbs., Helical
NOTE 2, FOR TRIDEM AXLES ONLY: Double-Reduction, 19.62" Ring Gear, 380 Carrier
For a Tridem Drive Axle Set (RZ), the number Model.
in the sixth position designates the carrier in RZ 60 164 = Tridem Drive Axle Set, 60,000 lbs., Single Speed,
the rst axle . The number in the seventh Includes a 160 Series Forward Rear or First Axle
position designates the carriers in the second and a 145 Series Tandem Axle Set as the Second
and third axles. and Third Axles.
4002694a
Figure 8.3
Inspection Breather
Carrier CAUTION
Cover the breather when steam cleaning the housing to
Check magnets and magnetic drain plugs, breathers, seals and prevent water from entering the housing and contaminating
temperature indicators during regularly-scheduled oil checks and the oil. Damage to components can result.
changes.
Baffle-type breathers release pressure and vacuum condensation to
CAUTION minimize premature oil and component failure.
Fill axles with specified lubricants only. Filling an axle with
non-approved lubricants will void Meritor’s warranty. Damage Temperature Indicators
to axle components also can result.
CAUTION
To avoid axle component damage, fill axles with approved lubricants Axles can operate above 190°F (88°C) without damage.
only. Using non-approved lubricants also will void Meritor’s warranty. However, if the oil temperature reaches 250°F (121°C), stop
the vehicle immediately and check for the cause of
NOTE: For information on lubricant suppliers, refer to technical overheating. Damage to components can result.
bulletin TP-9539, Approved Rear Drive Axle Lubricants. To obtain
this publication, refer to the Service Notes page on the front inside Some axles may have a tapped hole in the housing to install a
cover of this manual. temperature indicator. A temperature indicator monitors oil
temperature and helps to maximize component life, which can be
Magnets and Magnetic Drain Plugs shortened by high oil temperatures that result from severe operating
conditions, or unequally inflated and mismatched tires.
NOTE: Inspect the magnetic drain plug each time the oil is
changed. Use the correct part. Pipe plugs will leak if used as a Oil Seals
drain plug.
CAUTION
8
Although axles are normally equipped with magnetic plugs having Always use the correct tools and procedures when replacing
a minimum pick-up capacity of 1.5 lbs (0.7 kg) of low carbon seals to prevent incorrect installation, leaking seals and
steel, Advanced Lube axles have stronger magnetic cleansing damage to components.
features.
These axles are equipped with strong 5-lb (2.2 kg) pull magnets, Seals keep lubricant in and dirt out of a component. When they are
and high-grade magnetic fill and drain plugs that collect damaging worn or damaged, seals leak and produce damaging low lubricant
particles at the bottom of the axle housing. levels.
Tandem axles have four magnets in each housing and high-grade Durable triple-lip pinion seals protect the quality and levels of the
magnetic fill and drain plugs. Single axles have six magnets in each lubricant and provide superior performance. Advanced Lube axles
housing and high-grade magnetic drain and fill plugs. have triple-lip seals designed to work with current and future
lubricants.
Check the drain plug for metal particles every 100,000 miles
(160 000 kilometers). A magnetic drain plug can be used if the plug
has a minimum pick-up capacity of 1.5 lbs (0.7 kg) of low carbon
steel after cleaning.
1. Thoroughly clean and dry the area around the entire seal
retainer casting, especially at the top.
2. Drive the vehicle for 15-20 minutes at highway speeds.
3. Check for wetness or moisture on or around the seal. Also
check for oil dripping from the seal. If you notice either of these
conditions, replace the seal.
Prevention
Follow Meritor’s recommended maintenance practices and service
procedures. 4005124a
Figure 8.5
4005120a
Figure 8.7
Figure 8.8
Lubrication
Advanced Lube Axles
Advanced Lube axles require different drain intervals than other
axles. Refer to Table BZ.
The vehicle manufacturer may attach a tag at the axle fill hole or on
the inside of the door to identify an Advanced Lube axle. The tag
specifies that the axle is filled with semi-synthetic or full-synthetic
gear oil.
Figure 8.9
NOTE: Limited slip friction modifiers usually deteriorate more
quickly than Extreme Pressure (EP) additives. Shorten the lubricant
change schedule when using a friction modifier.
4005125a
Figure 8.9
Figure 8.13
FILL PLUG
TEMPERATURE INDICATOR Figure 8.14
HYPOID GEARING
2. If the drive pin angle is 7 degrees or less, use the fill plug in the WITH INTER-AXLE
DIFFERENTIAL
differential carrier. Figure 8.11 and Figure 8.16.
DRAIN PLUG
3. If the drive pin angle is more than 7 degrees, use the fill plug in
the axle housing bowl. Figure 8.13 through Figure 8.17. FILL PLUG (NOT SHOWN)
DRAIN PLUG
Figure 8.11
1003328a
FILL PLUG LOCATION IN BACK OF
AXLE HOUSING BOWL FILL PLUG Figure 8.14
8
Figure 8.15
FRONT-MOUNTED SINGLE-REDUCTION
TANDEM AXLES
FILL PLUG (NOT SHOWN)
Figure 8.12
DRAIN PLUG
1003326a
Figure 8.12
Figure 8.16
Drain and Replace the Oil
FRONT-MOUNTED DOUBLE-REDUCTION
AND TWO-SPEED AXLES
NOTE: Drain the oil when it is warm. Remove and replace the oil
filters each time the oil is drained.
FILL HOLE
IN CARRIER 1. Refer to Fill Plug Locations in this section.
2. Park the vehicle on a level surface. Place blocks under the
front wheels to prevent the vehicle from moving. Place a large
FILL PLUG container under the axle.
DRAIN PLUG
1003330a
3. Install the drain plug. Tighten the plug to 35-50 lb-ft
Figure 8.16 (48-67 N폷m). @
앫 If an oil pump is used: Remove and replace the oil filters.
Figure 8.17
FRONT-MOUNTED DOUBLE-REDUCTION 앫 For Advanced Lube axles: Replace the oil filter every
AND TWO-SPEED AXLES 100,000 miles (160 000 km).
4. Clean the area around the fill plug. Remove the fill plug from
FILL HOLE IN the differential carrier of the axle housing bowl, depending on
AXLE HOUSING the axle. Do not remove the temperature indicator plug.
5. Add the specified oil until the oil is even with the bottom of the
fill plug hole. Wait to allow the oil to flow through the axle.
FILL PLUG
DRAIN PLUG 앫 If the inter-axle differential has a top fill plug hole: Add
1003331a an additional two pints (0.946 liters) of the same oil into the
inter-axle differential housing.
Figure 8.17
6. Check the oil level again. If necessary, continue to add oil until
Check and Adjust the Oil Level it is even with the bottom of the fill plug hole.
Check the oil level when the axle is at room temperature. When hot, 7. Install the fill plug. Tighten the plug to 35-50 lb-ft (48-67 N폷m).
@
the oil temperature may be 190°F (88°C) or more and can cause
burns. A correct level is not obtained when the axle is warm or hot.
Serious personal injury and damage to components can result. Inter-Axle Assemblies with Separate
Housings
1. Park the vehicle on a level surface. Place blocks under the
front wheels to prevent the vehicle from moving. The axle must SLHD, SQHD, STDD and SFDD forward-rear tandem axle carrier
be cold or near room temperature. models include separate housings for inter-axle differential
assemblies.
2. Clean the area around the fill plug. Remove the fill plug from
the differential carrier or the axle housing bowl, depending on The baffles and dams used in these housings hold a reservoir of oil
the axle. Do not remove the temperature indicator plug. that can also trap wear particles and debris. Always purge the oil
Figure 8.11 through Figure 8.17. from these reservoirs when changing the axle oil.
3. Check the oil level. The level must be even with the bottom of These carriers have separate drain and fill holes in either the
the fill plug hole. Figure 8.10. inter-axle differential cover or housing.
4. Install the fill plug. Tighten the plug to 35-50 lb-ft (48-67 N폷m).
@
Table BZ: Oil Change Intervals for All Rear Drive Axles
Construction, Transit Bus,
City Delivery, School Refuse, Yard Tractor, Logging,
Vocation or Vehicle Bus, Fire Truck, Heavy Haul, Mining, Oil Field,
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 fleet (16 000 km), once a once a month, or the fleet
and amount of oil as fleet maintenance maintenance interval, month, or the fleet maintenance interval, whichever
required. interval, whichever whichever comes first maintenance interval, comes first1
comes first whichever comes first
Petroleum-Based Oil Every 100,000 miles Every 100,000 miles Every 50,000 miles Every 25,000 miles (40 000 km)
Change on axles (160 000 km) or (160 000 km) or (80 000 km) or annually, or annually, whichever comes
with or without a annually, whichever annually, whichever whichever comes first first
pump and filter comes first comes first
system.
Synthetic Oil Every 500,000 miles Every 250,000 miles Every 250,000 miles Every 100,000 miles
Change on axles (800 000 km), or (400 000 km), or every (400 000 km), or every (160 000 km), or every 2 years, 8
with or without a 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 miles Every 100,000 miles Every 100,000 miles Every 100,000 miles
Change on axles (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 Section 1.
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 CA: Single Rear Drive Axle Oil Capacities Oil Capacity*
Oil Capacity* Axle Model Pints Liters
Axle Model Pints Liters RS-15-120 18.4 8.7
A-150 5.5 2.6 RS-15-210 14.3 6.8
B-100 10.0 4.7 RS-15-220 30.0 14.0
B-140 12.0 5.7 RS-17-140 28.6 13.5
B-150 3.5 1.7 RS-17-144 32.0 15.0
C-100 12.5 5.9 RS-17-145 33.6 15.9
D-100 12.5 5.9 RS-17-220 30.7 14.5
D-140 12.5 5.9 RS-17-224 29.0 13.0
E-100 15.0 7.1 RS-19-144 32.0 15.0
E-105 12.5 5.9 RS-19-145 33.2 15.7
E-150 9.0 4.3 RS-19-220 30.0 14.0
F-100 13.0 6.2 RS-19-224 29.0 13.0
F-106 13.0 6.2 RS-21-145 32.3 15.3
F-120 15.0 7.1 RS-21-160 39.0 18.0
F-121 15.0 7.1 RS-21-230 38.9 18.4
F-140 14.0 6.6 RS-23-160 39.5 18.7
G-161 21.0 9.9 RS-23-161 37.2 17.6
H-100 20.0 9.5 RS-23-180 47.3 22.4
H-140 21.0 9.9 RS-23-186 47.3 22.4
H-150 11.0 5.2 RS-23-240 37.4 17.7
H-162 20.0 9.5 RS-23-380 63.6 30.1
H-170 27.0 12.8 RS-25-160 37.0 17.0
H-172 27.0 12.8 RS-26-160 47.5 22.5
L-100 23.0 10.9 RS-26-180 46.6 22.0
L-140 24.0 11.4 RS-26-185 46.0 22.0
L-155 24.0 11.4 RS-26-380 58.2 27.5
L-172 27.0 12.8 RS-30-180 46.6 22.0
M-172 27.0 12.8 RS-30-185 46.0 22.0
Q-100 31.0 14.7 RS-30-380 58.2 27.5
Q-145 24.0 11.4 RS-38-380 53.1 25.1
QT-140 24.0 11.4 S-170 43.0 20.3
R-100 30.0 14.2 U-140 24.0 11.4
R-140 28.0 13.3 U-170 43.0 20.3
R-155 28.0 13.3 U-270 55.0 26.0
R-160 28.0 13.3 W-170 43.0 20.3
R-163 34.0 16.1 W-270 55.0 26.0
R-170 43.0 20.3 59722 30.5 14.4
R-270 55.0 26.0 59723 30.5 14.4
RL-170 48.0 22.7 59732 30.5 14.4
RC-22-145 32.3 15.3 59733 30.5 14.4
RC-23-160 41.0 19.4 59843 30.5 14.4
RC-25-160 39.5 18.7 61142 42.0 19.8
RS-13-120 18.4 8.7 61143 41.0 19.3
* 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.
Table CB: Tandem Rear Drive Axle Oil Capacities Oil Capacity1
Oil Capacity1 Axle Model Carrier Pints Liters
Axle Model Carrier Pints Liters SQHP Forward Rear 40.0 36.0 18.9 17.0
MT-40-143MA-N Forward Rear 30.2 25.8 14.3 12.2 SR-170 Forward Rear 55.0 43.0 26.0 20.3
RT-34-140 Forward Rear 26.0 35.0 12.3 16.6 SRHD Forward Rear 39.0 36.0 18.5 17.0
RT-34-144 Forward Rear 30.0 25.0 14.0 12.0 SSHD Forward Rear 34.0 28.0 16.0 13.2
RT-34-145 Forward Rear 29.6 25.4 14.0 12.0 ST-170 Forward Rear 55.0 43.0 26.0 20.3
RT-34-145P Forward Rear 25.7 23.4 12.1 11.1 STHD Forward Rear 34.0 28.0 16.0 13.2
RT-40-140 Forward Rear 30.2 22.8 14.3 10.8 SU-170 Forward Rear 55.0 43.0 26.0 20.3
RT-40-145 Forward Rear 30.2 25.8 14.3 12.2 SUHD Forward Rear 34.0 28.0 16.0 13.2
RT-40-149 Forward Rear 30.0 25.0 14.0 12.0 SW-170 Forward Rear 55.0 43.0 26.0 20.3
RT-40-160 Forward Rear 39.1 34.4 18.5 16.3 1
Oil capacities are not for standard track axles that have been measured
RT-40-169 Forward Rear 39.0 34.0 18.0 16.0 at various common drive pinion angles. The quantities listed include
enough oil for both wheel ends. These oil capacities will change if the
RT-44-145 Forward Rear 29.3 25.1 13.9 11.9
track or the drive pinion angle is different.
RT-46-16HEH/HP Forward Rear 38.0 33.0 18.0 15.0 2
Forward carrier with oil pump system
RT-46-160 Forward Rear 39.1 34.4 18.5 16.3
RT-46-164 Forward Rear 39.1 34.4 18.5 16.3 Table CC: Oil Quantities for R-170 Axles with and without
RT-46-164EH/P Forward Rear 38.0 33.0 18.0 15.0 Traction Equalizer®
RT-46-169 Forward Rear 39.0 34.0 18.0 16.0 Without Traction
®
With Traction Equalizer Equalizer®
RT-48-1802 Forward Rear 61.1 36.8 28.9 17.4 8
40 pints oil (18.9 liters) + 3 pints 43 pints oil (20.3 liters)
RT-48-3802 Forward Rear 61.1 63.6 28.9 30.1
additive (1.4 liters)
RT-50-160 Forward Rear 38.0 33.0 18.0 15.0
RT-52-160 Forward Rear 44.1 41.2 20.9 19.5
2
RT-52-180 Forward Rear 56.1 36.1 26.5 17.1
RT-52-185 Forward Rear 56.1 36.1 26.5 17.1
RT-52-380 2 Forward Rear 56.1 58.2 26.5 27.5
2
RT-58-180 Forward Rear 56.1 36.1 26.5 17.1
RT-58-185 Forward Rear 56.1 36.1 26.5 17.1
2
RT-58-380 Forward Rear 56.1 58.2 26.5 27.5
RT-70-380 2 Forward Rear 54.4 53.1 25.7 25.1
SFHD Forward Rear 17.0 16.5 8.0 7.8
SL-100 Forward Rear 39.6 37.7 18.7 17.8
SLHD Forward Rear 32.5 32.0 15.3 15.1
SQ-100 Forward Rear 39.6 37.7 18.7 17.8
SQ-100A Forward Rear 39.3 37.6 18.6 17.8
SQHD Forward Rear 34.0 31.0 16.0 14.7
Oil Capacity*
Axle Model Carrier Pints Liters
RZ-166 Axle 1 Axle 2 Axle 3 39.1 39.1 34.4 18.5 18.5 16.3
RZ-186 Axle 1 Axle 2 Axle 3 56.1 39.1 34.4 26.5 18.5 16.3
RZ-188 Axle 1 Axle 2 Axle 3 56.1 56.1 36.1 26.5 26.5 17.1
* Oil capacities are not 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.
* For all GL-5 oils, petroleum oil or synthetic, add one of the specified
limited slip friction modifiers.
Troubleshooting
All Rear Axles
Contaminated Lubricant Found During Preventive Maintenance
Figure 8.18
Visually
inspect the
lubricant.
8
Seal No Inspect the
leaking? carrier-to-housing
joint for leaks.
Yes
Remove the
carrier from
Test drive the
the axle.
vehicle to confirm
that the leak is
repaired. Return the
vehicle to service.
4000515g
Figure 8.18
Figure 9.1
CURBSIDE AIR
Read and observe all Warning and Caution hazard alert messages in SPRING
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
FRAME
BRACKET
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Technical Publications
SHOCK
How to Obtain Additional Maintenance and ABSORBER
Service Information
Refer to the publications in Table CG. To obtain these publications,
refer to the Service Notes page on the front inside cover of this LOWER AXLE SHOWN WITH
CONTROL OPTIONAL X-30
manual. ARM BRAKE DRUMS
AXLE
Table CG: Publications ROADSIDE ASSEMBLY 4003726c
control arms are parallel to each other. The air springs mount
ID TAG directly over the axle. Figure 9.4.
LOCATION
Figure 9.4
SLIDER
ASSEMBLY
0000000a
FOR SUSPENSION NOMINAL RIDE HEIGHT
(NRH), REFER TO THE NRH VALUE INDICATED
ON THIS LABEL. FOR THE ACTUAL RIDE
HEIGHT VALUE, REFER TO THE VEHICLE/
TRAILER MANUFACTURER'S SPECIFICATION.
SUSP. CAP. LB. NRH IN.
A B
C D
MODEL SERIAL NO.
The model number on the identification tag provides suspension and Figure 9.4
axle information. Figure 9.3.
Components
9
Figure 9.3
Figure 9.3
앫 A compact 37,600 lb (17 055 kg) capacity tandem trailer air Model Number Example
suspension and slider system designed for sliding tandems.
RHP11 TN 1805
앫 A nominal ride height of 16.5-18.5-inches (41.9-47.0 cm) with
eight-inches (20.3 cm) of total travel, three-inches (7.6 cm) Sequence Number: Can
be cross referenced
jounce and five-inches (12.7 cm) of rebound. to the Bill of Material.
앫 A mounting height of 24.5-26.5-inches (62.2-67.3 cm). Axle Model
앫 An air system option is available when transporting the trailer by Suspension Model
4002671b
rail car.
7. Inspect the shock absorbers for worn bushings, oil leaks and
dents. Check that the mounting holes have not enlarged.
8. After normal operation, check the shock absorbers for heat. 9
앫 Warm shock absorbers most likely indicate that the shock
absorbers are operating correctly. UPPER
CONTROL
앫 Cold shock absorbers can indicate that the shock absorbers ARM
are not operating correctly and must be replaced. Replace
FRAME
the shock absorbers as necessary. BRACKET
9. Inspect the structure of the suspension. Figure 9.7 and LOWER
Figure 9.8. Inspect the following items. CONTROL
LOWER
ARMS
AXLE SEAT
앫 Upper axle seats
ROADSIDE 4002673a
앫 Upper control arms
SLIDING TANDEM TRAILER SUSPENSION
앫 Lower axle seats
Figure 9.8
앫 Lower control arms
앫 Axle welds
앫 Brake interference, cam or chamber
앫 Frame brackets
앫 Shock absorber brackets
Upper Control Arm Bushing Periodic 5. Inspect the upper control arm and bushing for the following
Inspection Guidelines: All RideStar™ conditions.
RHP Series Trailer Air Suspension Systems A. The bushing flanges are intact on both sides of the
bushing tube, and everything is centered within the frame
Meritor recommends conducting a visual inspection of the
bracket or axle seat, which is the correct position for the
RideStar™ RHP Series air suspension system whenever routine
upper control arm and bushing. Figure 9.9.
maintenance is performed. The purpose of the inspection is to
determine the condition of the two-piece urethane bushings located If the position is correct, insert a two-foot (0.61 m) pry bar
within the upper control arm bushing tubes. Being aware of certain between the upper control arm and the bottom of the axle
wear trends of this part will ensure that excessive wear to the upper seat to measure the free play gap.
control arm, frame bracket and axle seat does not occur causing the
앫 If the bushing free play gap exceeds 1/16-inch
component to be replaced.
(1.588 mm) at either the axle seat or the frame
Follow these instructions to inspect the upper control arm bushings bracket: Replace the bushings. Note: Even if the free
without performing disassembly procedures underneath the trailer. play gap exceeds the specification for one bushing,
you must replace all eight bushings at the next
WARNING available opportunity.
To prevent serious eye injury, always wear safe eye protection 앫 If the bushing free play gap is less than 1/16-inch
when you perform trailer maintenance or service. (1.588 mm) for all the bushings: The bushings are
not worn. Do not replace the bushings.
Park the trailer on a level surface. Block the wheels to prevent
the trailer from moving, which can cause serious personal B. The upper control arm and bushing have shifted slightly to
injury and damage to components. one side. The bushing flange is worn, torn or missing. You
don’t find significant wear between the upper control arm
1. Wear safe eye protection. and the frame bracket or axle seat. The free play gap is
less on one side than the other side. Figure 9.10.
2. Park the trailer on a level surface. Block the wheels to prevent
the trailer from moving. 앫 If you find these conditions: Replace the bushing at
the next available opportunity.
3. You do not need to lift the tires off the ground. Do not remove
the tires. C. The upper control arm and bushing have shifted and
clamped to one side. The bushing flange is missing on
4. Use a flashlight to visually inspect all eight upper control arm
one side. The upper control arm is pinned against the
bushings to determine bushing condition.
frame bracket. Significant wear exists between the upper
control arm and the frame bracket or axle seat. There is
no free play gap on one side, and a large gap on the other
side. Figure 9.11.
앫 If you find these conditions: Replace the bushing
immediately to prevent damage to components.
Figure 9.9
Slider on Sliding Tandem Suspension
The gap on both sides System
should be equal.
1. Inspect for loose, broken or missing fasteners. Repair or
UPPER CONTROL replace as needed.
ARM BUSHING
TUBE 2. Check the slider locking pins, slider pull-bar mechanism and
slider wear pads for signs of excessive wear or binding.
URETHANE Figure 9.12. Repair or replace as needed.
BUSHING
FLANGES
3. Inspect the structure of the slider box and crossmembers for
FRAME damage. Repair as needed.
BRACKET 4005368a
4. Inspect the front and rear hold down clips to ensure that they
Figure 9.9 are secured correctly around the body rails.
Figure 9.12
Figure 9.10
URETHANE
The urethane BUSHING FLANGE WEAR WEAR
bushing flange PAD PAD
is worn, torn
or missing. UPPER
CONTROL ARM
BUSHING
TUBE
PIN CLIP
The urethane bushing flange is missing
4002672c
on one side and the upper control arm
is pinned against the frame bracket.
9
Figure 9.12
URETHANE
BUSHING
FLANGE
UPPER
CONTROL ARM
BUSHING
TUBE
Figure 9.11
Figure 9.15
Figure 9.13 Operating a vehicle with ride height higher than specified by the
application can cause the trailer to be over the legal height limit,
depending on the type of trailer and payload.
Model Nomenclature
An identification tag is located on the rear of the roadside trailing To obtain the correct ride-height specification, check the
arm. To obtain replacement parts, refer to the Service Notes page at suspension’s identification tag located on the rear of the ROADSIDE
the beginning of this manual and specify the model number on the trailing arm. Also refer to Model Nomenclature.
tag. Figure 9.14.
How to Determine the Correct Ride Height
Consider the following factors when you determine the correct
Figure 9.14
Figure 9.14
UNLOADED
You must measure the distance from the bottom of the trailer frame TRAILER
FRAME
to the ground at each suspension location. Figure 9.16. This
measurement determines the required trailer deck height.
DECK
HEIGHT
Figure 9.16
FRAME-TO-GROUND FRAME-TO-GROUND
LOADED UNLOADED
4000949a
Figure 9.18
FRAME-TO-GROUND
Auxiliary Air Suspension Lift Axles (Loaded
4000947a
Frame-to-Ground)
Figure 9.16 You must determine the loaded frame-to-ground measurement of
auxiliary air suspension lift axles at each suspension location.
Figure 9.19. A leaf-spring suspension’s ride height changes under
Trailer Deck Height
various loads and the auxiliary lift axles must be spec’d to meet the
To calculate the required suspension ride height, subtract the tire’s ride height of the loaded leaf-spring suspension for correct operation.
static loaded radius from the loaded frame-to-ground dimension.
Figure 9.15. Figure 9.19
4000947c
Figure 9.17
Figure 9.19
AUXILIARY "LIFT" SUSPENSION
9
Jounce and Rebound
DECK
HEIGHT Jounce is the amount of upward axle travel from the suspension’s
designed ride-height position. Figure 9.20.
LOADED LOADED RIDE Rebound is the amount of downward axle travel from the
FRAME-TO-GROUND HEIGHT
suspension’s designed ride-height position. Figure 9.20.
4000947c
Figure 9.20
Figure 9.17
JOUNCE
Trailer Frame Deflection RIDE
HEIGHT
When the suspension was installed, ride height was determined
CENTERLINE
without a load on the trailer. Trailer frame deflection can occur when OF
the trailer is loaded and will change ride height. Be sure to allow for AXLE
frame deflection when you determine the correct ride height at each REBOUND
4000948b
suspension. Figure 9.18.
Figure 9.20
2" MINIMUM
Meritor air suspensions require a 1.5-inch (38 mm) minimum tire LATERAL TIRE
clearance between the top of the tire and the bottom of the trailer CLEARANCE
REQUIRED
frame structure above the tire when the suspension is at full jounce.
Figure 9.21.
Figure 9.21
TIRE TRAILER
FRAME
TIRE
CLEARANCE
RIDE 4000950a
HEIGHT
Figure 9.22
TIRE Maintenance
4000948c
Inspect air suspension components, the height control valve and
Figure 9.21 axle at regular intervals during normal operation and each time the
trailer is serviced.
How to Determine Tire Clearance Before each trip, visually inspect the suspension system and listen
Determine tire clearance by adding the specified tire clearance to for any air leaks.
the suspension jounce. This sum is the distance required between
Replace damaged fasteners to maintain correct torque value
the top of the tire and the bottom of the trailer frame when the
specifications and comply with warranty requirements.
suspension is at its designed ride height.
Perform the following inspections after the first 1,000 miles
Example
(1600 km) of operation and annually thereafter.
앫 Jounce = 3-inches (76 mm)
1. Check fastener torque values, tighten loose fasteners and
앫 Tire Clearance = 1.5-inches (38 mm) replace damaged or missing fasteners.
Calculation 2. Visually inspect all nuts and bolts for looseness and movement.
Figure 9.23. Tighten loose fasteners to the correct torque
3-inches (76 mm) + 1.5-inches (38 mm) = 4.5-inches (114 mm) = values. Thereafter, inspect the suspension components each
Space required above the tire at ride height time the trailer is serviced.
A two-inch (51 mm) clearance is required between the inside of the
3. Check for loose pivot bolts.
tire and the trailer frame on each side. This clearance allows for
both lateral movement of the suspension and tire deflection. 앫 If the bolts are loose: Align the axles before tightening
Figure 9.22. the bolts.
Figure 9.23 1. Inspect for broken and missing fasteners. Repair or replace as
needed.
TOP VIEW
2. Inspect welds for cracks at the trailing arm and axle
1
subassembly and hanger assemblies.
3. Inspect the flexmember of the air springs for any cuts and
abrasions. Replace the air spring immediately if it is cut or
2
3 damaged.
4 4. Check for obstructions and interference at the air springs that
5
may cause scuffing and abrasions. Relocate and secure items
such as air hoses that can contact any part of the air spring.
5. Check for leaks in the air lines, at the air spring upper bead
6 plate, piston and mounting studs. Figure 9.24. Replace leaking
air lines, fittings or air springs.
7 8 Figure 9.24
Figure 9.24
10 10
Figure 9.25
What to Look for and Actions Required
HANGER TRAILING ARM
ASSEMBLY AND AXLE What to Look for Actions Required
SUBASSEMBLY
Washers ARE NOT installed at Install new washers (Meritor
the upper and lower shock part number 1229-M-4979).
absorber pivot connections,
PIVOT and bushing migration IS NOT
CONNECTION
evident.
SHOCK Washers ARE NOT installed at Install a replacement shock
ABSORBER AXLE-TO-TRAILER the upper and lower shock absorber (Meritor part number
MOUNTINGS ARM CONNECTION absorber pivot connections, A-7805-L-1026) with new
4000953b
and bushing migration IS washers (Meritor part number
Figure 9.25 evident. 1229-M-4979).
SHOCK ABSORBER Park the vehicle on a level surface. Block the wheels to
TOP MOUNTING 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.
Verify that all personnel are clear of the trailer before you
inflate or deflate the air springs. The air suspension system
has various pinch points that can cause serious personal
injury.
Discard this
washer.
Retain the
nut and
washer.
Retain this
washer.
Retain
the nut.
Discard the
EXISTING UPPER MOUNT washer.
4000958b EXISTING LOWER MOUNT
4000959b
Figure 9.27
Figure 9.29
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle service or maintenance.
manual.
Drop center beams, such as the TQD and TRD models. Figure 10.3. TB Series Trailer Axles with Unitized
Figure 10.3
Wheel-End Assemblies
CAUTION
TB series trailer axles with unitized wheel-end assemblies use
conventional brakes and automatic slack adjusters, as well as
conventional tire and wheel assemblies. Service these
components as you would under normal operating conditions
4002697a to avoid damage to components.
Figure 10.4
AXLE SPINDLE
Figure 10.4
On a conventional wheel end, you install the hub, seal, lubricant and How to Find the Model Number, Serial
bearings onto the axle spindle as separate components.
Figure 10.5. Number and Date of Manufacture
Effective July 2004, Meritor now engraves the axle model number,
Figure 10.5
serial number and date of manufacture onto the center of the trailer
INNER axle beam. Figure 10.6. Previously Meritor affixed an aluminum tag
BEARING CUP LUBRICANT
OUTER to the center of the axle beam that includes this information.
BEARING CUP INNER
BEARING CONE Figure 10.7.
Figure 10.6
OUTER OIL
BEARING CONE HUB SEAL AXLE
SPINDLE
1003333a MERITOR
TQ 4671Q 9115 P/N TN4671Q636Q
S/N FRA04161115
Figure 10.5 FRA04161115 DATE 06/15/04
06/14/03
CURRENT NEW ENGRAVED
How to Identify Trailer Axles with Unitized ALUMINUM TAG IDENTIFICATION
Figure 10.6
Removal of long-life bearings, seals or lubricant from the Meritor TB
series trailer axle hub will void the warranty. Refer to Maintenance
Manual MM-0420, Trailer Axles with Unitized Wheel Ends, or call Figure 10.7
앫 The hubs contain non-serviceable bearings, seals and lubricant. SERIAL NO. KNA 38050685
DATE 27693
앫 The hubcaps screw onto the axle spindle and have no provisions KENTON, OHIO 43326
4002698a
for adding lubricant.
앫 The axle spindle retention hardware features a thicker inner nut Figure 10.7
10
and a bendable tab lock washer.
앫 Warranty information is stamped on each unitized wheel-end
hubcap.
Serial Number
The serial number is a Meritor internal control number; for example,
KNA 38050685.
Date of Manufacture
The date of manufacture is a Julian date; for example, 27693.
앫 The first three digits (276) indicate the 276th day of the year:
October 3.
앫 The last two digits (93) indicate the year: 1993.
Model Nomenclature
Current Production Model Numbers
Model numbers for Meritor trailer axles are composed of letters and
digits; for example, TQD 4670 Q 52. These letters and digits
indicate the weight capacity and type of components installed on the
axle. For a more comprehensive list of Meritor current production
trailer axle models, refer to publication TP-8301, Trailer Axle
Specifications.
Meritor aftermarket model numbers differ from the current
production model numbers detailed in Figure 10.8. Refer to parts
catalog PB-8857, Brake, Trailer Axle and Wheel-Attaching Parts, for
a chart detailing these numbers. To obtain these publications, refer
to the Service Notes page on the front inside cover of this manual.
Figure 10.8
Sequential number
specifying unique
model/axle information,
such as camshaft length,
spider model, lining
material, track, etc.
Beam Type
T = Tubular T N -4 6 7 O Q 2020
Axle Components
P = Cam
Q = Cam-Quick
Change
QH = Q with hub
installed
QW = Q with wheel
installed
L = Q Plus™
cam brake
LH = Q Plus™ with
Beam Capacity➀ Modification Brake Width hub installed
1 = Single wheel 1 = 10" (25 cm) LW = Q Plus™ with
lbs kg
wheel installed
N = 22,500 (10,206) 2 = Intermodal 6 = 6" (15 cm)➂
RDA = Stopmaster ®
P = 22,500/ (10,206/ 3 = Bolted on brakes 7 = 7" or 7.5" (18-19 cm)➃
4 = Manual bearing wedge
25,000/ 11,340/ 8 = 8" or 8.625" (22 cm)
adjustment D = Air disc
30,000 13,608) 9 = 8" (20 cm)
6 = Positive bearing DH = Air disc with
Q = 25,000/ (11,340/ 0 = No brakes
adjustment hub installed
30,000 (13,608)
8 = 0.625" nominal DW = Air disc with
R = 22,500/ (10,206/
25,000 11,340) wall axles
9 = 0.75" nominal wall
wheel installed
10
B = 22,500/ (10,206/
axles
25,000 11,340) ➀ Crank or drop axle beam capacity is 20,000 lbs. (9072 kg).
Disregard rating indicated by second letter of model number.
➁ Denotes either brake drum or brake rotor diameter.
➂ Denotes either brake shoe width or disc brake pad size
(60 square inches)
➃ Denotes either 7" on 16.5" diameter brakes or 7.5" on 12.25"
diameter brakes
4002699a
Figure 10.8
Read and observe all Warning and Caution hazard alert messages in Meritor offers a variety of transfer cases constructed to meet a wide
this publication. They provide information that can help prevent range of output shaft requirements. Design features include 4x4 or
serious personal injury, damage to components, or both. 6x6 capability, selected gear ratios, declutch, proportional
differential, auxiliary drive, parking brake, and two-, three- or
WARNING four-shaft designs.
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. Identification
Park the vehicle on a level surface. Block the wheels to An identification tag is located on the front cover. Figure 11.1.
prevent the vehicle from moving. Support the vehicle with
Figure 11.1
Technical Publications
How to Obtain Additional Maintenance and
Service Information
Refer to the publications in Table CI. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
Model Nomenclature
Figure 11.2
Figure 11.2
Figure 11.3
Housing
Number Material Specification
Transfer Case of Speeds G= Grey Iron Number Low Ratio
1 = Single Speed D = Ductile Iron
2 = Two Speed A = Aluminum
Figure 11.3
Some Meritor transfer cases use unitized seals, and some transfer 2. Clean the area around the fill plug. Remove the fill plug from
cases use single seals or two-piece seals. You must install the the transfer case. Figure 11.4. The oil level must be even with
correct seal when you service a transfer case. Otherwise, you can the bottom of the fill plug hole.
damage the seal and cause it to leak. Refer to the appropriate 앫 If oil flows from the hole when you loosen the plug: The
transfer case parts catalog for the correct seal part number before oil level is high. Drain the oil to the bottom of the fill hole.
you install a seal.
앫 If the oil level is below the bottom of the fill plug hole
or stand pipe: Add the specified oil into the transfer case
until the oil is even with the bottom of the fill hole.
3. Install and tighten the fill plug to 35-50 lb-ft (47-68 N폷m). @
11
4. Test drive the vehicle for at least one mile (1.6 km). Allow the
oil to settle for five minutes and recheck the fluid level. Top off
the oil level by adding oil to the fill opening. Reinstall and
tighten the fill plug to 35-50 lb-ft (47-68 N폷m). @
Figure 11.4
Intervals
T-2111 SHOWN
(TYPICAL) Operation Frequency
TOP Inspect for oil leaks Daily
SHAFT
Check oil level 1,000 miles (1609 km), 100 hours
or every month, whichever occurs
FILL DRAIN PLUG first
PLUG OR CAP
Check oil level Before and after extended time
FILL high speed road trips
STAND PIPE 1003335a
Initial oil change 2,500 miles (4000 km) or
Figure 11.4 125 hours, whichever occurs first
Synthetic oil change Every 25,000 miles (40 000 km),
Drain and Replace the Oil 1,250 hours or every 12 months,
whichever occurs first
Transfer Case Oil
Towing Procedures
CAUTION
Only use new lubricant when changing or adjusting the oil in CAUTION
the transfer case. Do not reuse lubricants which can contain Follow towing procedures recommended by Meritor to prevent
metallic particles and other contaminants. Damage to internal damage to the transfer case.
components can result.
Meritor recommends that you use one of the two methods below
1. Park the vehicle on a level surface. Block the wheels to prevent when towing a vehicle equipped with an MTC-4208, -4210 or
the vehicle from moving. Place a large container under the -4213 transfer case to prevent damage to the transfer case.
transfer case.
For complete towing information and instructions on shaft removal,
2. Remove the magnetic drain plug from the bottom of the refer to Technical Bulletin TP-9579.
transfer case. Drain and discard the oil correctly. Clean the
plug. Method 1
3. Install and tighten the drain plug to 35-50 lb-ft (47-69 N폷m). Remove both axle shafts from the axles that will remain on the road
Clean the area around the fill plug. Remove the fill plug from when the vehicle is transported.
the transfer case. @
Method 2
4. Add the specified oil into the transfer case until the oil level is
Remove the drive shafts from axles that contact the ground.
even with the bottom of the fill plug hole. Install and tighten the
fill plug to 35-50 lb-ft (47-68 N폷m). @
5. Test drive the vehicle for 1/4 mile (0.4 km). Allow the oil to
settle for five minutes and recheck the fluid level. Top off the oil
level by adding oil to the fill opening. Reinstall and tighten the
fill plug to 35-50 lb-ft (47-68 N폷m). @
Specifications
Table CJ: Transfer Case Oil Specifications*
Meritor A.P.I. Military
Oil Description Specification Specification Specification SAE Grade Outside Temperature
Petroleum GL-1 Oil with Rust — A.P.I. GL-1 — 90W 80W Above 10°F (–12°C)
and Oxidation Inhibitor1 Above –15°F (–26°C)
1 2
Heavy-Duty Engine Oil — A.P.I.-CD, CE, SF or SG — 50W 40W 30W Above 10°F (–12°C)
Above –12°F (–26°C)
3
Full-Synthetic Oil O81 — — 50W Above –40°F (–40°C)
4
A.P.I. GL-5 (Axle Lube) DO NOT USE IN TRANSFER CASES
1
90W GL-1 or 50W motor oil is the same viscosity and commonly used above 10°F (–12°C).
2
Current designations are acceptable.
3
Meritor-approved full-synthetic oil for manual Meritor transmissions is also approved for Meritor transfer cases. Use synthetic oil only if the transfer case was
initially filled with synthetic oil.
4
Do not use multi-viscosity (i.e., 80/90W) GL-5 gear oil, axle lube.
* Do not use multi-viscosity (i.e., 80/90W) GL-5 gear oil, axle lube. Do not mix or switch oil types. Use the same oil that initially filled the transfer
case. Do not use multi-viscosity oils.
Capacities
Table CK: Transfer Case Oil Capacities Oil Capacity
Transfer Case
Transfer Case Oil Capacity Model Approved Oils Pints*1,2 Liters*
1,2
Model Approved Oils Pints* Liters* TG-2213 50W Synthetic 6.5 3.10
T-32 Petroleum or 2.0 0.95 T-2119 Only 7.0 3.30
T-136 50W Synthetic 14.0 6.62 MTC-4208 9.0 4.30
T-215 3.0 1.42 MTC-4210 9.0 4.30
T-221 4.0 1.89 MTC-4213 9.0 4.30
T-223 5.0 2.37 1
Due to the varied transfer case configurations, these fill quantities are for
T-226 6.5 3.07 reference only.
2
T-228 21.0 9.93 Oil Cooler equipped vehicles will use additional oil to compensate for the
cooler and cooler lines.
T-232 6.2 2.93
T-1138 13.5 6.38
Refer to bulletin TP-90114, Transmission Lubricant Specifications,
T-2111 3.0 1.42 for a list of approved distributors of synthetic oil. To obtain this 11
T-2111-HD 5.0 2.37 publication, refer to the Service Notes page on the front inside cover
T-2111-HT 5.0 2.37 of this manual.
T-2111-PD 10.0 4.73
T-2111-SD 5.0 2.37
T-2120 4.0 1.89
T-2120-RS 6.5 3.10
T-600 6.2 2.93
Troubleshooting
Figure 11.5
Clean transfer
case and operate
vehicle.
Does oil
No blow-out from
the breather?
Yes
4001525b
Figure 11.5
Figure 11.6
Continued from
previous page.
No
4001526b
Figure 11.6
Figure 11.7
Yes
Replace broken
brackets and/or Loose
tighten all Yes fasteners or No
fasteners to broken
specified torque. bracket?
Return the
vehicle to service.
4001527a
Figure 11.7
Figure 11.8
Replace faulty
Light or Yes indicator light or
sensor sensor, then try to
faulty? shift PTO.
No
Yes
No
Verify that the PTO engages and
Remove the PTO from the transfer case. disengages correctly.
Disassemble the PTO and inspect the
bearings, shift collar, shift fork declutch
bore and return spring for damage. Repair
Check the PTO for leaks.
all damaged components.
11
Reassemble and install the PTO on the
transfer case. Road test the vehicle to
confirm the problem is corrected.
4001528b
Figure 11.8
Figure 11.9
FRONT AXLE DECLUTCH DOES NOT Turn wheels left and right several
ENGAGE/DISENGAGE DIAGNOSTICS times, then try to shift declutch.
Replace faulty
Light or Yes indicator light or
sensor sensor, then try to
faulty? shift declutch.
No
Yes
Figure 11.9
Figure 11.10
No
Correct system
air pressure.
Air Refer to the Return the
pressure 65 psi No vehicle vehicle to
(4.48 bar) or manufacturer’s service.
more? instructions.
Yes
Reinstall transfer
Problem
fixed?
Yes
case in vehicle and
Disassemble transfer case and inspect shift shaft, shift fork,
shift collar and shift bore. Repair any damaged components.
11
return vehicle to service. Reassemble and check that the transfer case shifts correctly.
No
4001530b
Figure 11.10
Model Manual
Read and observe all Warning and Caution hazard alert messages in 9- and 10-Speed Publication TP-8989
this publication. They provide information that can help prevent Transmissions Operator Manual
serious personal injury, damage to components, or both. 13-Speed Manual Transmission Publication TP-90192
Operator Manual
WARNING
Air Shift Systems/9-Speed Maintenance Manual 26B
To prevent serious eye injury, always wear safe eye protection
Manual Transmissions
when you perform vehicle maintenance or service.
Air Shift Systems/13-Speed Maintenance Manual 26D
Manual Transmissions
Technical Publications
Electric Over Air (EOA) Range Maintenance and Diagnostics
How to Obtain Additional Maintenance and Shift System: All Meritor 9- and Manual MM-99140
Service Information 10-Speed Transmissions
Engine Synchro Shift™ Maintenance and Diagnostics
Refer to the publications in Table CL. To obtain these publications,
(ESS™) Transmission with Manual MM-9850
refer to the Service Notes page on the front inside cover of this
Meritor’s Transmission Control
manual.
Unit (TCU)
Table CL: Publications Engine Syncro Shift™ (ESS™) Maintenance and Diagnostics
Model Manual Transmission with Detroit Diesel Manual MM-96152
Corporation’s Electronic Control
ZF-FreedomLine Transmissions Maintenance and Diagnostics Module (ECM)
Manual MM-0150
Engine Synchro Shift™ Publication TP-95130
ZF-FreedomLine Transmission Publication TP-01110 (ESS™) Operator Manual
Wiring Diagram and Fault Code
Diagnostics Transmissions Failure Analysis Manual
TP-0445
SureShift™ Transmission Maintenance and Diagnostics
Manual MM-9970
Description
SureShift™ Transmission Publication TP-98114
Wiring Diagram and Fault Code Meritor offers both manual and automated transmissions for the
Diagnostics heavy-duty trucking industry. Manual transmissions are available in
9, 10 and 13 speeds. Automated SureShift™ transmissions are
SureShift™ Transmission Publication TP-99146 available in 9 and 10 speeds. Fully automated ZF-FreedomLine
Operator Manual transmissions are available in 12 and 16 speeds.
Platform “G” 9- and 10-Speed Maintenance Manual
Transmissions MM-99106
9-, 10- and 13-Speed Maintenance Manual 26A
Transmissions
9- and 10-Speed Publication TP-8989
Transmissions Operator Manual
13-Speed Manual Transmission Publication TP-90192
Operator Manual
Air Shift Systems/9-Speed Maintenance Manual 26B
Manual Transmissions
SureShift™ Transmission
The SureShift™ option is an electronic shift system that significantly
reduces the effort required to safely and accurately shift a constant
mesh manual transmission. With the SureShift™ interface, gear
shifts are accomplished by simply tapping the joystick on the shift
module. The SureShift™ system allows the driver complete control
over which gear the vehicle is in at any given time. The clutch pedal
is only used for starting and stopping. The SureShift™ system is
available with 9- or 10-speed transmissions.
ZF-FreedomLine Transmission
The ZF-FreedomLine is a two-pedal automated transmission that
eliminates the clutch pedal for shifting, starting and stopping. The
system allows the driver to select automatic mode or manual
operation. A self-adjusting clutch is part of the ZF-FreedomLine
system. This eliminates the need for clutch or linkage adjustments.
The ZF-FreedomLine system is available with 12- or 16-speed
transmissions. Figure 12.1.
12
Model Nomenclature
Refer to Figure 12.2, Figure 12.3 and Figure 12.4 for an explanation of the model identification number and the identification plate.
Figure 12.2
ZF-FREEDOMLINE
MERITOR TRANSMISSION MODEL NUMBER
VEHICLE
MANUFACTURER
TRANSMISSION
PART NUMBER
TRANSMISSION MANUFACTURING
SERIAL NUMBER DATE
Vehicle Manufacturer
Meritor Torque Specification
Rating Highest Torque in
O = Overdrive (lb-ft) Transmission (lb-ft)
No letter = Ratio
13 = 1350 13 = 1350
Direct Drive A
14 = 1450 14 = 1450
15 = 1550 15 = 1550
16 = 1650 12 = 12-Speed 16 = 1650
16 = 16-Speed A = Fully Automated
Z = ZF-FreedomLine
4002704c
Figure 12.2
Figure 12.3
Vehicle Manufacturer
Meritor Torque Specification
Rating Ratio Highest Torque in
O = Overdrive (lb-ft) A Transmission (lb-ft)
No letter = 11 = 1150 B 11 = 1150 15 = 1550
Direct Drive 12 = 1250 C 12 = 1250 16 = 1650
13 = 1350 13 = 1350 18 = 1850
14 = 1450 9 = 9-Speed A = Fully Automated 14 = 1450
15 = 1550 10 = 10-Speed D = ESS — DDC ECM
16 = 1650 12 = 12-Speed E = ESS — Meritor TCU
16 = 16-Speed M = Manual
Design Platform S = SureShiftTM
Progressive torque is an engine feature that requires a Torq-2 transmission. In models not featuring progressive
torque, this number will be the same as the torque rating.
Detroit Diesel Corporation 4002704d
Figure 12.3
Figure 12.4
Vehicle Manufacturer
Meritor Speed Specification
Type Progressive
Forward Ratio Shift Bar Housing Position
A = Automated F = Forward
E = Electric/Air Speeds
S = Standard
M = Manual
S = Engine Synchro x 10 = Design Level
ShiftTM Nominal 1 = Serial Numbers
W = Shift by Wire Input LB93001999
Torque and Below
Shift Pattern
No letter = Direct Drive 2 = Serial Numbers
Standard H Pattern LB93002000
X = Overdrive Standard and Above
H Pattern
O = Overdrive 9-speed
Non-Standard Pattern
OR
Overdrive 13-speed
Standard H Pattern 4002705b
Figure 12.4
Inspection Recommended
Oil coolers are recommended on:
Oil Drain Conditions
앫 All 9-, 10- and 13-speed transmissions behind an engine rated
NOTE: For a list of synthetic oil suppliers, refer to Transmission at 350-398 hp
Technical Bulletins, TP-2053. To obtain this publication, refer to the 앫 Some aerodynamic vehicles which restrict air flow over the
Service Notes page on the front inside cover of this manual. transmission causing excessive transmission operating
temperatures
Manual Transmission Oils
If used transmission oil analyses indicate that any one of these Temperature Indicator
criteria is not met, drain the used oil and replace it with an oil that is The temperature indicator is optional. The temperature sending unit
recommended for manual transmissions. is on the bottom right side of the main case. The normal operating
temperature range is less than 225°F (107°C).
Table CN: Used-Oil Analyses (ppm = parts per million)
Use the temperature indicator gauge to check transmission
Iron (Fe) If level is greater than 500 ppm, drain and
operation as described in the following example.
replace the oil.
Silicon (Si) If level is greater than 100 ppm, drain and 앫 If the temperature suddenly rises to 275°F (135°C) or more:
replace the oil. Check the transmission for the cause of the increase.
Water (H2O) If level is greater than 0.3%, drain and 앫 When operating a vehicle on a mountain grade, if the
replace the oil. temperature increases 50-75°F (10-24°C) but returns to the
normal operating temperature: This indicates a normal
Magnets and Magnetic Drain Plugs operating condition. If the temperature does not return to the
normal range, check the transmission.
All transmissions, except for the ZF-FreedomLine, have magnetic
drain plugs and four magnets in the bottom of the main case. The
ZF-FreedomLine has magnetic drain plugs only. The magnets and Check and Adjust the Oil Level
magnetic plugs have a minimum pick-up capacity of 1.5 lbs (0.7 kg)
of low carbon steel. WARNING
Park the vehicle on a level surface. Block the wheels to
NOTE: Inspect the magnetic drain plug each time the oil is prevent the vehicle from moving. Support the vehicle with
changed. Use the correct part. Pipe plugs will leak if used as a drain safety stands. Do not work under a vehicle supported only by
plug. jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
The magnetic drain plug can be reused if, after cleaning, the plug has
a minimum pick-up capacity of 1.5 lbs (0.7 kg) of low carbon steel. Before Checking the Oil Level
1. The oil must be at room temperature.
Transmission Oil Coolers
2. The vehicle must be parked for at least 10 minutes.
Required
Oil coolers are required on: Check and Adjust the Oil Level Every 10,000 Miles
(16 000 km)
앫 All ZF-FreedomLine 12- and 16-speed transmissions
1. Park the vehicle on a level surface. Place blocks under the
앫 All 9-, 10- and 13-speed transmissions behind an engine rated wheels to prevent the vehicle from moving.
at 399 hp or above
2. Inspect the transmission for oil leaks. If a transmission oil leak
앫 All 9-, 10- and 13-speed transmissions with continuous is present, refer to the Troubleshooting section in the
operating temperatures above 225°F (107°C) or intermittent appropriate Transmission Maintenance Manual for procedures.
operating temperatures reaching 275°F (135°C)
NOTE: If foam appears when you remove the fill plug, the oil is too 5. Install the oil fill plug and tighten to 35-50 lb-ft (48-67 N폷m). @
hot to check. Install the oil plug and allow the oil to cool. If oil flows
6. Operate the vehicle for five minutes. Check for transmission oil
from the fill plug hole when you remove the plug, the oil level is too
leaks and correct operation.
high. Drain the oil to the correct level.
7. Recheck the oil level.
3. Clean the area by the fill plug. Remove the fill plug from the
side of the transmission. Inspection
4. Check the transmission oil level. Verify that it is even with the
bottom of the fill plug. If the oil level is below the bottom of the Breather Vent Condition
oil fill plug, add the specified oil. Refer to Figure 12.5 for 9-, Verify that the breather vent is not damaged. Remove all dirt and oil
10- and 13-speed transmissions. Refer to Figure 12.6 for from the screen in the breather vent. On the ZF-FreedomLine, the
12- and 16-speed ZF-FreedomLine transmissions. breather vent condition can only be checked when the transmission
is removed from the vehicle. Figure 12.7.
Figure 12.5
FILL PLUG
DRAIN PLUG 1003336a
Figure 12.5
1000472a
Figure 12.6
Figure 12.7
Fastener Torque
Check the torque on the following fasteners.
앫 Clutch housing to engine flywheel
앫 Top cover housing to main case
앫 All electrical switches on the top cover housing
앫 Drain and fill plugs
SIDE OIL FILL PLUG 앫 PTO covers to main case
Oil level must be AND PORT
even with bottom DRAIN 앫 Auxiliary case to main case
PLUG
of fill plug hole. 4003606a 앫 Output bearing retainer to auxiliary case
Figure 12.6 앫 Piston housing cover to auxiliary case
앫 Auxiliary countershaft cover to auxiliary case 12
앫 Transmission to frame brackets
앫 Output yoke to output shaft
앫 Shift cover housing to top cover housing
Inspecting the Transmission for Leaks and 4. Inspect the screen on top of the container for metal particles
Damage and damaged parts.
5. If the transmission is disassembled or replaced and a
CAUTION transmission oil cooler is used, remove the cooler.
Repair all leaks to prevent damage to the transmission.
A. Remove the oil from the oil cooler and the oil lines. Follow
EPA guidelines to recycle used oil.
Inspect the following transmission parts for cracks, leaks and
damage. Verify that the leaks are transmission oil. Repair all leaks. B. Install the oil cooler and the oil lines. Tighten the fittings to
the vehicle manufacturer’s specifications.
앫 Output yoke and the oil seal in the output bearing retainer on the
auxiliary case, non-ZF-FreedomLine models 6. Install the drain plug and tighten to 35-50 lb-ft (48-67 N폷m).
@
앫 PTO covers on the main case
7. Clean the air by the fill plug. Remove the fill plug from the side
앫 Auxiliary case to main case, non-ZF-FreedomLine models
of the transmission.
앫 Main case and the clutch housing, non-ZF-FreedomLine models
앫 Clutch housing to flywheel housing CAUTION
Only use the specified oil. Do not use multi-viscosity engine
앫 Auxiliary countershaft covers, non-ZF-FreedomLine models oils or Extreme Pressure (EP) GL-5 gear oils. Damage to
앫 Slave valve to the main case, non-ZF-FreedomLine models components can result. The use of unapproved oils will void
Meritor’s warranty.
앫 Shift lever and tower assembly to the top cover,
non-ZF-FreedomLine models 8. Add the specified transmission oil through the fill plug hole.
앫 Top cover to the main case, non-ZF-FreedomLine models Add the oil until the oil level is even with the bottom of the fill
plug hole.
앫 Fill and drain plugs
9. Install and tighten the fill plug to 35-50 lb-ft (48-67 N폷m). @
앫 Output bearing retainer to the auxiliary case
10. Operate the vehicle for five minutes. Check for oil leaks and
앫 Input bearing retainer to the main case
correct operation.
앫 Speedometer bore or electronic speed pick-up in the output
11. Recheck the oil level.
bearing retainer
앫 Middle housing to rear housing on ZF-FreedomLine models Adjustment
Drain and Replace the Oil Linkage for the Remote Control Assembly
Cab-Over-Engine (COE) vehicles use a remote control assembly on
Transmission Oil top of the transmission. The linkage connects the inner shift lever to
a shift lever in the cab of the vehicle.
NOTE: Drain the oil when the transmission is hot.
The linkage must be adjusted for correct operation. See the vehicle
1. Park the vehicle on a level surface. Place blocks under the manufacturer’s procedure.
wheels to prevent the vehicle from moving.
2. Place a large container under the transmission. Place a screen
on top of the container.
3. Remove the drain plugs from the bottom of the transmission.
Drain the oil. Follow U.S. Environmental Protection Agency
(EPA) guidelines to recycle used oil.
The following oils have been approved for use in all 12- and 16-speed ZF-FreedomLine transmissions. The oil change interval shown is for
linehaul applications. All other applications must use oil analysis to determine oil change intervals.
Troubleshooting Vibration
On Manual Transmissions When checking a noise or a vibration, find out when the problem
occurs.
When checking a problem with the manual transmission, the first
thing to do is to verify the service condition. Talk to the driver, the 앫 When the transmission is in NEUTRAL or in gear
mechanic or the service manager. If possible, take the vehicle for a 앫 During upshifts or downshifts
road test.
앫 In all gears or specific gears
There are three types of problems.
앫 In the HI range or the LO range
앫 Leaks
앫 In the DIR range or the OD range (13-speed transmission only)
앫 Noise and/or vibration
앫 During coast or acceleration
앫 Operating conditions
앫 With the vehicle loaded or unloaded
Noise Also, find out what the transmission does during the problem
If a noise is the problem, find out the sound of the noise. 앫 Does not stay in the selected gear
앫 Squealing 앫 Overheats
앫 In the HI range or the LO range 3. Verify that the fluid is transmission oil.
앫 In the DIR range or the OD range (13-speed transmission only) 4. The transmission housings are not cracked or broken.
Troubleshooting Vibrations
Before troubleshooting a leak condition, verify the following:
1. The engine idle speed is within the specified range.
2. The engine is operating correctly.
3. The U-joints, yokes and driveshaft are in good condition. Check
the driveline angles. Correct as necessary.
4. The U-joints, yokes and driveshafts are correctly aligned and/or
balanced. Correct as necessary.
5. Check the air bag height. Correct as necessary.
* If the transmission does not shift correctly into the selected range, broken or loose synchronizer pins are the result of the vibration condition.
Troubleshooting Noises
For all noise conditions, check the following before disassembling the transmission:
1. Check that the oil level is even with the bottom of the fill plug hole.
2. Verify that the correct oil is used.
3. Verify that the driveline angles of the transmission are correct.
4. Verify that the transmission is correctly installed.
5. Remove the drain plug. Check for any metal shavings, gasket material or any other material in the oil.
In some noise conditions, there are additional repairs to perform. These repairs will be explained in the following charts. See the following
charts to troubleshoot the clutch.
12
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent Description
serious personal injury, damage to components, or both. Conventional wheel ends have the hub, seal, lubricant and bearings
installed onto the axle spindle as separate components.
WARNING Figure 13.1. The bearings and seals require periodic inspections
To prevent serious eye injury, always wear safe eye protection and lubrication to maintain performance.
when you perform vehicle maintenance or service.
Trailer axles with conventional wheel ends can be identified by the
following features.
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with 앫 The TN/TQ Series axles use the most common wheel bearings in
safety stands. Do not work under a vehicle only supported by the trailer industry.
jacks. Jacks can slip or fall over. Serious personal injury and
앫 The TR Series axles use wheel bearings compatible with drive
damage to components can result.
axles.
Technical Publications 앫 The TP Series axles use bearings compatible with Freuhauf
axles.
How to Obtain Additional Maintenance and Figure 13.1
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 201
13 Wheel Bearings and Wheel Ends
Model Nomenclature
Refer to Figure 13.2 and Figure 13.3 for an explanation of axle model numbers.
Figure 13.2
Figure 13.2
Figure 13.3
HSG Wall
0 = Cast
GAWR
1 = TBD
xx = GAWR (000) Pounds or Tonnes 2 = 0.31 in. (8 mm)
(dependent on mfg. location) 3 = 0.37/0.39 in. (9.5/10.0 mm)
4 = 0.43 in. (11 mm)
Axle Model Type Relative Gearing 5 = 0.50/0.51 in. (12.7/13.0 mm)
S= Single Rear (Solo) Size or Series 6 = 0.56 in. (14.3 mm)
X= Front Drive Steer 7 = TBD
0 = No Gearing
D= Fwd Rear w/IAD 8 = 0.63 in. (16 mm)
1 = 292/347
N= Fwd Rear less IAD 9 = TBD
2 = 337/387
P= Fwd Rear w/Pump 3 = TBD
R= Rear Rear 4 = 381/432 Carrier Variation
T= Tandem Drive 5 = 415/432
Z= Tridem Drive A= Aluminum
6 = 432/457 D= Ductile
C= Coach 7 = 457
H= High Entry M= Ductile Rear, Amboid
8 = 460/498 N= No Carrier
R= Ductile Front Drive Axle
Carrier, Right Hand
T = Ductile Telma Ratio 1 Ratio 2
M X - xx - 1 2 0 x N - x - N 1 2 3 - xxxx - xxxx
M = Meritor
Carrier Type
MFG Location
0 = No Carrier
1 = Single Speed N= North America
2 = Two Speed S= South America
3 = Helical Double Reduction E= Europe
4 = Salisbury A= Australia/Asia/Africa Specification Number
5 = Planetary Double Reduction Includes: TRACK,
6 = Hub Reduction PARKING BRAKE, TELMA,
7 = Portal OTHER
9 = Single Speed With
Torque Output
Limited Engine
Brake Type
Wheel End/Brake Attachment/Differential
B = “B” Frame Brake
A = Conventional Spindle/Conventional Brake/Standard Differential
C = Air Disc Brake
B = Conventional Spindle/Conventional Brake/DCDL
D = Wedge Brake, Dual Air Chambers
C = Conventional Spindle/Conventional Brake/NoSPIN®
E = Wedge Brake, Dual Hydraulic Cylinders
D = Conventional Spindle/Conventional Brake/Other Differential
F = Wedge Brake, Single Hydraulic Cylinder
E = Unitized Spindle/Conventional Brake/Standard Differential G = DuraPark Hydraulic Drum
F = Unitized Spindle/Conventional Brake/DCDL H = Qualdraulic Disc
G = Unitized Spindle/Conventional Brake/NoSPIN® K = Disc PlusTM Air Disc
H = Unitized Spindle/Conventional Brake/Other Differential L = Q Plus Cam Brake
J = Conventional Spindle/Integral Brake/Standard Differential N = None
K = Conventional Spindle/Integral Brake/DCDL P = P Series Cam Brake
L = Conventional Spindle/Integral Brake/NoSPIN® Q = Q Series Cam Brake
M = Conventional Spindle/Integral Brake/Other Differential R = Cast PlusTM Brake
N = Unitized Spindle/Integral Brake/Standard Differential S = Wedge Brake, Single Air Chamber
P = Unitized Spindle/Integral Brake/DCDL T = T Series Cam Brake
Q = Unitized Spindle/Integral Brake/NoSPIN® W = W Series Cam Brake
R = Unitized Spindle/Integral Brake/Other Differential
S = Bolt on Conventional Spindle/Conventional Brake/No Differential
4002706a
Figure 13.3
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 203
13 Wheel Bearings and Wheel Ends
Figure 13.4
LUBE
Fill the wheel end with an approved gear oil to the hubcap fill line.
5. Install the fill plug.
Note that the oil must be given sufficient time to settle prior to the
Drive Axle Hubs Without Fill Holes final check of the oil level. This is especially important in cold
conditions. Figure 13.6.
1. Add the specified amount of lubricant through the carrier or
housing bowl oil fill hole. Figure 13.6
2. Tilt the axle to the right and to the left to let the oil flow into the
hub cavities. Keep the axle tilted for one minute in each
position.
3. With the axle in the level position, add the specified oil so that
the level is even with the bottom of the fill plug hole.
4. Install and tighten the fill plug.
Shading indicates
correct amount
of oil.
4002700a
Figure 13.6
Meritor °F °C
Specifications Military/SAE Specifications Oil Description Min. Max. Min. Max.
O-76-A Gear Oil MIL-PRF-2105-E and GL-5, SAE 85W/140 –10 None –12 None
O-76-D Gear Oil SAE J2360 GL-5, SAE 80W/90 –15 None –26 None
O-76-E Gear Oil GL-5, SAE 75W/90 –40 None –40 None
O-76-J Gear Oil GL-5, SAE 75 –40 35 –40 2
O-76-M GL-5, SAE 75W/140 –40 None –40 None
Full-Synthetic Oil
O-76-N GL-5, SAE 75W/90 –40 None –40 None
Full-Synthetic Oil
Heavy-Duty MIL-L-2104 E or F A.P.I. -CD, -CE, -SG, -SH or –10 None –12 None
Engine Oil -SJ SAE 40 or 501
Heavy-Duty MIL-L-210 E or F A.P.I. -CD, -CE, -SG, -SH or –15 None –26 None
Engine Oil -SJ SAE 30 1,2
1
Current designations are acceptable. Multi-grade engine oils are acceptable if the SAE rating ends in 40 or 50.
2
Current designations are acceptable. Multi-grade engine oils are acceptable if the SAE rating ends in 30.
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 205
13 Wheel Bearings and Wheel Ends
Table CY: TP and TN Series Trailer Axles Equipped with Conventional Hub Assemblies or PreSet® by Meritor1 Hub Assemblies
Trailer Axle Series, Hub Assembly Type, Lubricant Volume per Wheel End
and Hub Part Number2 API-GL5 Oil NLGI 00 Semi-Fluid Grease3 NLGI 1 or 2 Grease3
TP Series Hubcap Fill Line 35.00 fl. oz. (63.16 cu. in.) NOT RECOMMENDED
PreSet® hub assembly Approx. 24.55 fl. oz.
Hub part number 16040 (44.31 cu. in.)
TP Series Hubcap Fill Line 33.47 fl. oz. (60.41 cu. in.) 23.37 fl. oz. (42.17 cu. in.)
Conventional hub assembly Approx. 24.55 fl. oz.
Hub part number 15968 (44.31 cu. in.)
TN Series Hubcap Fill Line 31.00 fl. oz. (55.95 cu. in.) NOT RECOMMENDED
PreSet® hub assembly Approx. 15.17 fl. oz.
Hub part number 16048 (27.37 cu. in.)
TN Series Hubcap Fill Line 25.57 fl. oz. (46.15 cu. in.) 21.22 fl. oz. (38.29 cu. in.)
Conventional hub assembly Approx. 15.17 fl. oz.
Hub part number 15984 (27.37 cu. in.)
1
The PreSet® by Meritor hub assembly is equipped with pre-installed bearings, cups and cones, and oil seals and studs. A precision tubular spacer between
the bearings eliminates manual bearing adjustments. The hub subassembly also includes an integral tooth wheel for vehicles equipped with an anti-lock
braking system (ABS).
2
The hub part number is cast into the inboard side of the wheel mounting flange.
3
Volume includes the lubricant volume of the bearing cones. PreSet® bearings are not greased prior to installation.
Table CZ: Conventional Trailer Axle Wheel-End Oil Change Intervals and Specifications
Outside Temperature
* 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 ArvinMeritor’s Customer Service Center at 800-535-5560.
Grease-Lubricated Wheel Bearings 6. Use a pressure packer to force the specified grease from the
large end of the cones into the cavities between the rollers and
Inspection and Maintenance cage. Pack the hub between the bearing cups with grease to
1. Park the vehicle on a level surface. Place blocks under the the level of the smallest diameter of the cups.
wheels to prevent the vehicle from moving. 앫 If a pressure packer is not available: Grease the
2. Raise the vehicle so that the wheels are off the ground. bearings by hand.
Support the vehicle with safety stands. 7. Install the inner and outer bearing cones into the cups in the
3. Remove the tire and wheel assembly. Remove and dissemble hubs. The bearing cups must be pressed tight against the
the hub. shoulder in the hubs.
4. Use the correct cleaning solvent to remove the old grease from 8. Install new wheel seals into the hubs.
all parts. Discard the seals. Inspect the wheel bearings for 9. Install the hub and the wheel and tire assembly. Install the
wear or damage. Replace worn or damaged bearings. outer wheel bearing cone into the hub. Install the adjusting nut.
5. Before installing the wheel bearings, lubricate the bearing 10. Adjust the wheel bearings.
journals on the spindle with the grease that is used for the
bearings.
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ArvinMeritor Maintenance Manual 1 (Revised 07-10) 207
13 Wheel Bearings and Wheel Ends
WARNING
Do not use gasoline to clean parts. Gasoline can explode or
burn and cause serious personal injury.
CAUTION
It is important to not overfill the wheel-end cavity with
lubricant. Do not extend the grease level indicated below. Also,
verify that the excess grease is wiped away since it can
contaminate the brake linings and cause poor brake
performance. Damage to components can result.
Figure 13.8
B
Shading indicates
correct amount of grease. 4002703a
Figure 13.8
A unitized hub may also be referred to as a truck hub unit, Easy When you apply some silicone gasket materials, a small
Steer Plus™ or a unitized hub. However, if a hubcap is embossed amount of acid vapor is present. To prevent serious personal
with “half moons,” it’s a unitized hub. injury, ensure that the work area is well-ventilated. Read the
manufacturer’s instructions before using a silicone gasket
Meritor Axles Equipped with Unitized Hubs material, then carefully follow the instructions. If a silicone
gasket material gets into your eyes, follow the manufacturer’s
Table DC: Model Numbers
emergency procedures. Have your eyes checked by a
MFS-10-143D-N MFS-12-144D-N FF-983 physician as soon as possible.
MFS-10-144D-N MFS-13-144D-N FF-984
MFS-12-122D-N FF-981 FF-986
Inspection Intervals
MFS-12-143D-N FF-982 FF-987 Refer to these inspection and maintenance procedures for Meritor
axles equipped with unitized wheel ends on front non-drive steer
axles. You must perform detailed and basic inspections at the
Model Nomenclature following intervals.
Refer to Figure 13.2 and Figure 13.3 for an explanation of axle
model numbers. Detailed Inspections
Refer to the procedure in this section.
Inspection Procedure
앫 After the initial 200,000 miles (321 800 km) of operation
WARNING 앫 After every additional 200,000 miles (321 800 km) of operation
YOU MUST FOLLOW THE UNITIZED WHEEL-END MAINTENANCE thereafter
AND INSPECTION PROCEDURES PROVIDED IN THIS MANUAL TO
PREVENT SERIOUS PERSONAL INJURY AND DAMAGE TO Basic Inspections
COMPONENTS. After the initial 200,000-mile (321 800 km) detailed inspection,
앫 UNITIZED WHEEL ENDS ARE NOT ADJUSTABLE. perform a basic inspection at each scheduled preventive
maintenance interval, not to exceed 50,000-mile (80 467 km)
앫 DO NOT ATTEMPT TO SET OR ADJUST END PLAY. intervals. Refer to the procedure in this section.
To prevent serious eye injury, always wear safe eye protection If the Vehicle is Equipped with ABS on the Steer Axle
when you perform vehicle maintenance or service.
In addition to the scheduled preventive maintenance, if the driver
reports indicate the ABS light has been coming on, and ABS
Park the vehicle on a level surface. Block the wheels to
diagnostics indicate the sensor gap is out-of-adjustment, check for
prevent the vehicle from moving. Support the vehicle with
possible wheel-end looseness as the cause.
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.
Tools Required
Basic Inspection
Take care when you use Loctite® adhesive to avoid serious
personal injury. Read the manufacturer’s instructions before A jack, wheel blocks and safety stands
using this product. Follow the instructions carefully to prevent
irritation to the eyes and skin. If Loctite® adhesive material
Detailed Inspection
gets into your eyes, follow the manufacturer’s emergency A dial indicator and a torque wrench with 700 lb-ft (949 N폷m)
procedures. Have your eyes checked by a physician as soon as capability
possible
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 211
13 Wheel Bearings and Wheel Ends
4. Grasp the tire and wheel-end assembly at the nine and three 2. Remove the hubcap.
o’clock positions. Check for vertical and horizontal movement. 3. Raise the vehicle so that the front wheels are off the ground.
With your hands, apply approximately 50 lb (23 kg) of force to Support the vehicle with safety stands. Do not use a jack to
the assembly. You should not feel or see any looseness or support the vehicle.
movement.
앫 If you feel or see any movement or looseness in the NOTE: The outboard and inboard seals may purge small amounts
tire and wheel-end assembly: Perform a detailed of grease that are visible during inspection. Figure 13.11. This is a
inspection to determine the cause of the movement, such normal occurrence.
as worn king pin bushings or pins; wheel-to-hub-mounting
end play; unitized wheel-end hub end play; or a 4. Remove the wheel and drum. Attach the magnetic base of a
combination of them all. To determine unitized wheel-end dial indicator to the end of the spindle. Figure 13.12. Touch the
hub end play, refer to the procedure in this section. indicator stem perpendicular against the unitized wheel end’s
mounting face.
If other front axle components, such as king pin bushings,
require inspection or service, refer to Maintenance Manual
2, Front Non-Drive Steer Axles. To obtain this publication,
refer to the Service Notes page on the front inside cover of
this manual.
Figure 13.11
Figure 13.13
PROTECTIVE UNITIZED
HUBCAP WHEEL END
INNER
OUTER WHEEL
GREASE WHEEL BEARING
BEARING NUT
NUT
O-RING
INNER “D”
TABBED WASHER
WASHER 1000063e
Figure 13.13
NOTE: The inner wheel bearing nut and the outer wheel bearing nut
are identical, but the torque values are different.
7. Install the tabbed washer and outer wheel bearing nut onto the
spindle.
4000876c
Figure 13.11 앫 For 1-1/8-inch (28.6 mm) wheel bearing nuts used on
MFS-06, MFS-07 and MFS-08 Series axles: Tighten to
Figure 13.12 150-225 lb-ft (203-305 N폷m). @
DIAL INDICATOR
앫 For other series axles: Tighten the outer wheel bearing nut
to 200-300 lb-ft (272-408 N폷m). @
8. Reattach the dial indicator. Set the dial indicator to ZERO. Do
not rotate the wheel end. Place your hands at the nine and
three o’clock positions.
9. Push the unitized wheel end straight IN. Note the reading. Pull
the unitized wheel end straight OUT. Note the reading.
4001329a 앫 If the total movement of the dial indicator is greater
Figure 13.12 than 0.003-inch (0.08 mm), but less than 0.006-inch
(0.15 mm): Record the measurement in a maintenance
5. Set the dial indicator to ZERO. Do not rotate the wheel end. log, and perform a basic inspection at the next
Place your hands at the nine and three o’clock positions. regularly-scheduled maintenance interval, or not to exceed
50,000 miles (80 467 km), whichever comes first.
6. Push the unitized wheel end straight IN. Note the reading. Pull
the unitized wheel end straight OUT. Note the reading. 앫 If the total movement of the dial indicator is 0.006-inch
(0.015 mm) or greater: Replace the unitized wheel-end
앫 If the total movement of the dial indicator is less than
hub. You must inspect a replacement hub before you install
0.003-inch (0.08 mm): Inspection is complete. No
it. Refer to the procedure in this section.
adjustment is required.
10. After you’ve taken the measurement, bend the parts of the
앫 If the total movement of the dial indicator is 0.003-inch
tabbed washer that protrude over the flats of the outer wheel
(0.08 mm) or greater: Remove the outer bearing nut and
bearing nut and the inner wheel bearing nut. Bend the washer
tabbed washer. Tighten the inner wheel bearing nut to
a minimum of one flat edge to each nut.
500-700 lb-ft (679-949 N폷m) while rotating the unitized
wheel end a minimum of five rotations. Figure 13.13. @
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 213
13 Wheel Bearings and Wheel Ends
NOTE: If a ticking sound is detected during rotation, this does not 3. Examine the exterior of the hub to verify the following.
indicate a hub problem. It is a normal occurrence.
A. There is no visible damage to the inboard or outboard
seals and the bearings have not become unseated.
11. Verify that the unitized wheel end rotates smoothly and without
Figure 13.15 and Figure 13.16.
noise. While rotating the wheel, grasp the brake chamber to
feel for unitized wheel-end hub vibration. B. The tone ring teeth are not damaged and there are no
broken or missing teeth on the tone ring. Figure 13.16.
앫 If the unitized wheel-end assembly does not rotate
smoothly, or you hear noise (such as wheel bearing Figure 13.15
Figure 13.14
INBOARD
SEAL
A
TONE
INNER RING
BEARING C
SET
CLIP 4001198a
RING
B Figure 13.16
OUTER
BEARING
SET Install the Spindle O-Rings and Hubcaps
Refer to Maintenance Manual 2, Front Non-Drive Steer Axles, for
procedures to install the spindle O-rings and hubcaps.
A AND B MUST BE EQUAL
C MUST NOT EXCEED 0.25" (6 MM) 4001196a
Figure 13.14
Unitized Wheel Ends on Bus and Coach FH Series Front and Tag Axles, and MC
Series Rear Drive Axles
Certain Meritor bus and coach FH Series front and tag axle, and MC nut pack and PRO-TORQ™ nut. They are different and not
Series rear drive axle models are equipped with unitized wheel ends. interchangeable. Figure 13.17, Figure 13.18 and Figure 13.19.
Unitized wheel-end components include a wheel adapter, rotor and Wheel ends with unitized hub bearings are sealed and greased for
unitized hub bearing mounted to a knuckle or spindle. There are two life and do not require lubrication. These unitized wheel ends require
different spindle nut designs used on unitized wheel ends, double periodic inspections to maintain performance.
Figure 13.17
THICK
WASHER
ROTOR
KEEPER
WHEEL
ADAPTER
WHEEL TORQUE
STUD PLATE
TORQUE PLATE-TO-
SPINDLE CAPSCREW
UNITIZED HUB
BEARING
PRO-TORQ™
SPINDLE NUT
INSPECTION
PLUG
WHEEL
ADAPTER
CAPSCREW 4006158c
Figure 13.17
FLAT
ADJUSTING
NUT
KEEPER
JAM NUT ARMS
PRO-TORQ™ NUT
DOUBLE NUT PACK 4005542a
4005543a
Figure 13.19
Figure 13.18
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 215
13 Wheel Bearings and Wheel Ends
Inspection
WARNING
The unitized wheel end is sealed and greased for life and does
not require lubrication. If you disassemble, or attempt to repair
or lubricate a unitized wheel-end assembly, you will void the
Meritor warranty.
앫 Unitized wheel ends are not adjustable.
앫 Do not attempt to set or adjust the end play.
Basic Inspections
앫 Perform a basic inspection between every two detailed
inspections but not to exceed 50,000 miles (80 467 km) or six
months of operation, whichever comes first.
Basic Inspection
1. Park the vehicle on a level surface. Block the rear wheels to
prevent the vehicle from moving.
2. Raise the vehicle so that the inspected axle is off the ground.
Support the vehicle with safety stands. Do not use a jack to
support the vehicle.
3. Back off the brake caliper until the rotor is clear from the pad
linings about 1/16-inch (1.588 mm) gap or more. Refer to
Maintenance Manual MM-0467, DiscPlus™ EX225 Air Disc
Brake, for more information about EX225 disc brake inspection
and adjustment. To obtain this publication, refer to the Service
Notes page on the front inside cover of this manual.
4. Visually inspect the unitized wheel end as you rotate the tire. Wheel-to-Hub Mounting
Verify that it rotates smoothly and without noise.
Before proceeding with the detailed inspection, first check the
If a clicking sound is detected during rotation, this does not wheel-to-hub mounting.
indicate a hub problem. It is a normal occurrence.
1. Verify that the wheel is mounted correctly and all wheel-end
While rotating the wheel, grasp the brake chamber to feel for fasteners and hardware are tightened to the correct
unitized wheel-end hub vibration. specification. Figure 13.20.
앫 If the tire and unitized wheel-end assembly does not
rotate smoothly, or you hear noise such as wheel
bearing grind or feel wheel-end hub vibration during
rotation: Replace the unitized wheel-end hub.
앫 If the wheel end rotates smoothly: Proceed to Step 5.
5. Grasp the tire and wheel-end assembly at the nine and three
o’clock positions. Check for vertical and horizontal movement.
With your hands, apply approximately 50 lb (23 kg) of force to
the assembly. You should not feel or see any looseness or
movement.
앫 If you feel or see any movement or looseness in the
tire and wheel-end assembly: Perform more inspections
to determine the cause of the movement. Check for worn
king pin bushings or pins; wheel-to-hub-mounting end
play; unitized hub bearing end play; or a combination of
them all. To determine unitized hub bearing end play, refer
to the detailed inspection procedure in this section.
Figure 13.20
THICK
WASHER
ROTOR
KEEPER
WHEEL
ADAPTER
WHEEL TORQUE
STUD PLATE
TORQUE PLATE-TO-
SPINDLE CAPSCREW
UNITIZED HUB
BEARING
PRO-TORQ™
SPINDLE NUT
INSPECTION
PLUG
WHEEL
ADAPTER
CAPSCREW 4006158c
Figure 13.20 13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 217
13 Wheel Bearings and Wheel Ends
2. Grasp the tire and wheel-end assembly at the nine and three 6. Attach the dial indicator. Loosen the locking set screw and
o’clock positions. Check for vertical and horizontal movement. slowly slide the dial indicator through the fitting hole. Position
With your hands, apply approximately 50 lb (23 kg) of force to the dial indicator against the hub face and tighten the locking
the assembly. You should not feel or see any looseness or set screw as the needle starts moving. Set the dial indicator to
movement. ZERO. Do not rotate the wheel end. Figure 13.21.
앫 If you detect movement or looseness on a tag axle: Figure 13.21
Detailed Inspection
7. Place your hands on the wheel hub at the nine and three
1. Park the vehicle on a level surface. Block the rear wheels to o’clock positions. Push the wheel end straight IN. Note the
prevent the vehicle from moving. reading. Then pull the wheel end straight OUT. Note the
2. Raise the vehicle so that the inspected axle is off the ground. reading. The difference between the first and second readings
Support the vehicle with safety stands. Do not use a jack to is the total bearing end play.
support the vehicle.
Take at least two readings to obtain a correct end play
3. Back off the brake caliper until the rotor is clear from the pad measurement.
linings about 1/16-inch (1.588 mm) gap or more. Refer to
Maintenance Manual MM-0467, DiscPlus ™ EX225 Air Disc 앫 If the total movement of the dial indicator is
Brake, for more information about EX225 disc brake inspection 0-0.002-inch (0.05 mm): The inspection is complete.
and adjustment. To obtain this publication, refer to the Service Go to Step 8.
Notes page on the front inside cover of this manual. 앫 If the total movement of the dial indicator is greater
4. Verify that the unitized wheel end rotates smoothly and without than 0.002-inch (0.05 mm) but less than 0.004-inch
noise. (0.1 mm): Check and retighten the spindle nut to
specifications. Set the dial indicator to ZERO and measure
If a clicking sound is detected during rotation, this does not
the end play again. Take at least two readings and record
indicate a hub problem. It is a normal occurrence.
the measurement in a maintenance log. Perform another
While rotating the wheel, grasp the brake chamber to feel for detailed inspection at the next regularly-scheduled
unitized wheel-end hub vibration. maintenance interval, or up to 50,000 miles (80 467 km),
앫 If the tire and unitized wheel-end assembly does not whichever comes first.
rotate smoothly, or you hear noise such as wheel
앫 If the total movement of the dial indicator is equal to or
bearing grind or feel wheel-end hub vibration during
greater than 0.004-inch (0.1 mm): Replace the unitized
rotation: Replace the unitized hub bearing. Inspect the
hub bearing as soon as possible. The unitized hub bearing
unitized hub bearing before installing it. Refer to the new
may not be safe to operate.
hub inspection procedure in this section.
앫 If the wheel end rotates smoothly: Proceed to Step 5. 8. Remove the dial indicator and adapter fitting.
5. Use a 5/16-inch drive tool to remove the pipe plug at the 9. Apply a thin coat of sealant to the pipe plug threads. Install it
center of the wheel adapter. Install and tighten the adapter into the wheel adapter and tighten it to a minimum of 15 lb-ft
fitting into the hole. (20.34 N폷m). @
Disassemble the Unitized Wheel End Models with a Double Nut Pack
1. Park the vehicle on a level surface. Block the rear wheels to
WARNING prevent the vehicle from moving.
You must follow the unitized wheel-end maintenance and
inspection procedures provided in this manual to prevent 2. Raise the vehicle so that the axle is off the ground. Support the
serious personal injury and damage to components. vehicle with safety stands. Do not use a jack to support the
vehicle.
The unitized wheel end is sealed and greased for life and does 3. Remove the brake caliper assembly. Refer to Maintenance
not require lubrication. If you disassemble, or attempt to repair Manual MM-0467, DiscPlus™ EX225 Air Disc Brake. To
or lubricate a unitized wheel-end assembly, you will void the obtain this publication, refer to the Service Notes page on the
Meritor warranty. front inside cover of this manual.
4. Remove the wheel adapter and rotor. Inspect the rotor for
CAUTION cracks and signs of wear. Replace the rotor if necessary.
There are two different spindle nut designs used on unitized Figure 13.22.
wheel ends, double nut pack and PRO-TORQ™ nut. They are
different and not interchangeable. You must replace
components with the same type and follow the correct
tightening procedure for the nut system used to prevent
damage to components.
Figure 13.22
TORQUE PLATE-TO-BRAKE
DiscPlus™ CALIPER CAPSCREW
BRAKE
ASSEMBLY SPINDLE
UNITIZED
HUB
BEARING
ROTOR
LOCK
WASHER
TORQUE
INSPECTION TORQUE PLATE
PLUG PLATE-TO-
THICK SPINDLE
WASHER CAPSCREW
SPINDLE
NUTS
WHEEL
STUD
4006159c
WHEEL WHEEL
ADAPTER ADAPTER
CAPSCREW
Figure 13.22
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 219
13 Wheel Bearings and Wheel Ends
5. Use a 3.5-inch (89 mm) socket wrench to remove the jam nut, Models with a PRO-TORQ™ Nut
“D” lock washer and adjusting nut. Figure 13.23.
1. Park the vehicle on a level surface. Block the rear wheels to
Figure 13.23
prevent the vehicle from moving.
“D” LOCK
2. Raise the vehicle so that the axle is off the ground. Support the
WASHER vehicle with safety stands. Do not use a jack to support the
vehicle.
3. Remove the brake caliper assembly. Refer to Maintenance
Manual MM-0467, DiscPlus™ EX225 Air Disc Brake. To
obtain this publication, refer to the Service Notes page on the
ADJUSTING front inside cover of this manual.
NUT
4. Remove the wheel adapter and rotor. Inspect the rotor for
JAM NUT cracks and signs of wear. Replace the rotor if necessary.
DOUBLE NUT PACK Figure 13.24.
4005543a
Figure 13.23
Figure 13.24
THICK
WASHER
ROTOR
KEEPER
WHEEL
ADAPTER
WHEEL TORQUE
STUD PLATE
TORQUE PLATE-TO-
SPINDLE CAPSCREW
UNITIZED HUB
BEARING
PRO-TORQ™
SPINDLE NUT
INSPECTION
PLUG
WHEEL
ADAPTER
CAPSCREW 4006158c
Figure 13.24
Figure 13.26
CAUTION
AXLE SPINDLE
Remove the keeper from the PRO-TORQ™ nut before you
attach the nut to the axle spindle, or tighten and loosen the
nut, to prevent damage to the nut and axle spindle.
FLAT
KEEPER
ARMS
PRO-TORQ™ NUT
4005542a
Figure 13.25
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 221
13 Wheel Bearings and Wheel Ends
Model Nomenclature
Refer to Figure 13.27 for an explanation of axle model numbers.
Figure 13.27
Sequential number
specifying unique
model/axle information,
such as camshaft length,
spider model, lining
material, track, etc.
Beam Type
T = Tubular T N -4 6 7 O Q 2020
Axle Components
P = Cam
Q = Cam-Quick
Change
QH = Q with hub
installed
QW = Q with wheel
installed
L = Q Plus™
cam brake
LH = Q Plus™ with
Beam Capacity➀ Modification Brake Width hub installed
1 = Single wheel 1 = 10" (25 cm) LW = Q Plus™ with
lbs kg
wheel installed
N = 22,500 (10,206) 2 = Intermodal 6 = 6" (15 cm)➂
RDA = Stopmaster ®
P = 22,500/ (10,206/ 3 = Bolted on brakes 7 = 7" or 7.5" (18-19 cm)➃
4 = Manual bearing wedge
25,000/ 11,340/ 8 = 8" or 8.625" (22 cm)
adjustment D = Air disc
30,000 13,608) 9 = 8" (20 cm)
6 = Positive bearing DH = Air disc with
Q = 25,000/ (11,340/ 0 = No brakes
adjustment hub installed
30,000 (13,608)
8 = 0.625" nominal DW = Air disc with
R = 22,500/ (10,206/
wall axles wheel installed
25,000 11,340)
B* = 22,500/ (10,206/ 9 = 0.75" nominal wall
axles
25,000 11,340) ➀ Crank or drop axle beam capacity is 20,000 lbs. (9072 kg).
L** = 20,000 (9072) Disregard rating indicated by second letter of model number.
➁ Denotes either brake drum or brake rotor diameter.
*B = Unitized Bearing Hub ➂ Denotes either brake shoe width or disc brake pad size
**L = Packaged Bearing Hub (60 square inches)
➃ Denotes either 7" on 16.5" diameter brakes or 7.5" on 12.25"
diameter brakes
4002699b
Figure 13.27
Assemblies DIAL
INDICATOR
TB Series trailer axles with unitized hub assemblies can be identified
STEM
by the following features.
앫 The model number designation for the TB Series is prefixed with
TB; for example, TB-4670 or TB-8670.
앫 The axle spindles are shorter with a single journal.
앫 The hubs contain non-serviceable bearings, seals and lubricant. MAGNETIC
BASE
앫 The hubcaps screw onto the axle spindle and have no provisions
4001742a
for adding lubricant.
Figure 13.28
앫 The axle spindle retention hardware features a thicker inner nut
and a bendable tab lock washer.
2. Push the hub INWARD until the dial indicator does not change.
앫 Warranty information is stamped on each unitized wheel-end Set the dial indicator to ZERO. Figure 13.29.
hubcap.
Figure 13.29
1. Inspect the unitized hub for smooth rotation at each brake 4001743a
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 223
13 Wheel Bearings and Wheel Ends
Figure 13.30
Small amounts of grease may be visible at the hub’s outer seal. This
is a normal occurrence and does not indicate a seal leak. However, if
PULL a large amount of grease is visible, the seal is leaking. Replace the
hub. Figure 13.33.
Figure 13.33
NORMAL
GREASE OUTER
CONDITION SEAL
4001744a
Figure 13.30
Seal Leaks
Check the back of the hub for a seal leak. The hub incorporates a
grease seal. A leak of this seal will appear like that in a conventional
wheel end. Figure 13.31.
4001725a
Figure 13.31
Figure 13.33
4001746a
Figure 13.32
Inspect the packaged bearing hub assembly for smooth rotation at Inspect the Inner and Outer Grease Seals for Leaks
each brake reline. Rotate the hub in both directions. If the bearing
When the hub assembly is installed, a small amount of grease may
feels rough or sounds noisy, replace the hub. If a large amount of
appear at the spindle backup collar-to-hub joint. This is a normal
grease is visible at the hub’s outer seal, replace the hub.
occurrence and does not indicate that a seal is leaking.
Inspect the packaged bearing hub assembly for smooth rotation and
1. Inspect the hub assembly’s inner grease seal for leakage. A
movement if driver reports indicate that the anti-lock braking system
leaking seal will stain the back of the hub with lubricant, a
(ABS) warning lamp comes on during operation, and ABS
condition similar with a conventional hub.
diagnostics indicate a gap exists between the wheel speed sensor
and tooth wheel (sensor out-of-adjustment). 앫 If the seal is leaking: Replace the hub assembly.
2. Inspect the hub assembly’s outer grease seal for leakage. A
Inspection Procedure
small amount of grease around the perimeter of the seal is a
WARNING normal occurrence and doesn’t indicate that the seal is
leaking.
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with 앫 If you find a large amount of grease on the entire
safety stands. Do not work under a vehicle supported only by surface of the seal and surrounding hub surfaces:
jacks. Jacks can slip and fall over. Serious personal injury and Replace the hub assembly.
damage to components can result.
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 225
13 Wheel Bearings and Wheel Ends
TRIAD™ Trailer Axle Wheel-End System 2. Install the adjusting nut against the hardened washer. Tighten
the nut to 150-200 lb-ft (204-272 N폷m) while rotating the
Installing Spindle Nuts on Trailer Axle Models TN, TQ wheel-end assembly. @
and TP
3. Completely loosen the adjusting nut. Tighten the nut to 25 lb-ft
Use the following procedure to install spindle nuts on trailer axle (34 N폷m) while rotating the wheel-end assembly. @
models TN, TQ and TP equipped with TRIAD™ trailer axle wheel
ends. 4. Install the tabbed washer against the adjusting nut.
Removal of the bearings, seals or lubricant from the hub voids the 5. Install the retainer nut against the tabbed washer. Tighten the
nut to 25 lb-ft (34 N폷m). @
warranty.
Align the tab with a flat surface of the retainer nut. If necessary,
1. Install the hardened washer against the outer bearing.
Figure 13.34. turn the nut COUNTERCLOCKWISE to align the closest flat with
the tab.
Figure 13.34
6. Bend the washer tab OUTWARD over the flat surface of the
retainer nut.
7. Apply 200-275 lb-ft (272-374 N폷m) of torque to rotate the
adjusting nut in a COUNTERCLOCKWISE direction and jam it
against the tabbed washer and retainer nut. @
SPINDLE
HARDENED
WASHER
Wheel-End Equipment Checks
ADJUSTING
TABBED NUT Studs and Nuts
RETAINER
NUT WASHER The following warnings are to alert you to stud and nut conditions
4005450a
and maintenance procedures that can affect your safety and the
Figure 13.34 integrity of the vehicle and its components.
Carefully read the warnings before you install disc wheels.
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 227
13 Wheel Bearings and Wheel Ends
C. Serrated studs do not usually interchange with those in 3. Check for R and L stamped in the end of the stud.
various hub part numbers. Check the application. Call Figure 13.38. Install right-hand studs onto the right side of the
ArvinMeritor’s Customer Service Center at vehicle, and left-hand studs onto the left side of the vehicle.
800-535-5560 for more information.
Figure 13.38
Figure 13.35
R L
4001691a
Figure 13.38
4001690a 4001692a
Figure 13.37
Figure 13.39
Figure 13.40 8. Install nuts with the correct thread size onto the studs. A
INCORRECT: STEEL WHEEL NUT correct thread size enables the nut to turn freely on the stud.
ON ALUMINUM WHEEL An incorrect nut will fit very loosely on the stud thread, which
can cause the thread to strip.
9. Check the extension of the stud through the nut after you
tighten the nut to the specified torque.
앫 If less than two threads extend through the nut, or
more than 3/8-inch (9.5 mm) of the stud extends
through the nut: Check all parts to verify that they are
4001693a
correct for the wheel system you will install on the vehicle.
10. Ensure that the nut and wheel mate correctly. Ensure that you
Figure 13.40
install the correct components onto the wheel systems.
Figure 13.43 and Figure 13.44.
7. Install steel wheel nuts onto steel wheels. Do not install
aluminum wheel nuts. The extension of the aluminum wheel 앫 If the wheel has a ball seat bolt hole pattern: The nut
nut can bottom against the hub flange or brake drum before must have a spherical surface that seats in the ball seat.
the disc is clamped correctly. Figure 13.41 and Figure 13.42.
앫 If the wheel has a cylindrical bolt hole pattern: The nut
Figure 13.41
must have a flat surface that seats against the wheel.
ON STEEL WHEEL
4001694a
CORRECT: BALL SEAT WHEEL ON BALL SEAT HUB
Figure 13.41
Figure 13.42
Figure 13.43
4001695a
Figure 13.42
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 229
13 Wheel Bearings and Wheel Ends
Figure 13.44 12. Add two drops of oil between the nut flange and the hex portion
of the swivel area at each installation if you reinstall the
two-piece flange nuts that have been in service. Do not oil the
stud or nut threads.
13. Retighten all wheel nuts on all systems at 50-100 miles
(80-160 km) to the correct torque specifications.
14. Use the correct installation tools.
15. Ensure that the gross weight does not exceed gross vehicle
weight (GVW). Ensure that the axle loads do not exceed gross
CORRECT: HUB-PILOTED WHEELS ON HUB-PILOTED HUB axle weight ratings (GAWR).
Figure 13.45 1. Tighten the inner 3/4-16 nuts to 100 lb-ft (136 N폷m) to seat
the wheel studs. Figure 13.46. @
2. Tighten the outer M22 x 1.5 nuts to 390-450 lb-ft
(529-610 N폷m) to install the hub-piloted wheels. @
Figure 13.46
HUB 3/4-16
M22X1.5
THREAD THREAD
ROTOR
4005394a
Figure 13.46
13
ArvinMeritor Maintenance Manual 1 (Revised 07-10) 231
14 Specifications
Grease Lubricants
Table DE: Grease Lubricants*
Meritor NLGI Outside
Specification Grease Typical Application Grade Grease Description Temperature
1
O-616 Brake Grease Cam Brake Anchor Pins, Mechanical 2 Clay Base
Brake Anchor Pins
O-616-A Brake Grease Air Disc Brake Caliper, Automatic 1 Clay Base Down to –40°F (–
Slack Adjuster, Wedge Brake 40°C)
Components
1
O-617-A or Multi-Purpose Cam Brake Chamber Brackets, Cam 1 or 2 Lithium 12-Hydroxy
O-617-B Grease Brake Hold Down Clips, Cross Tube Stearate or Lithium
Ends, Drag Link, Wheel Bearings, Complex
King Pins and Bushings, Knuckle
Bushings, 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
1
O-634-B Universal Joint Driveshaft Slip Yokes, Driveshaft 2 Lithium 12-Hydroxy
Grease Splines, Driveshaft Universal Joints Stearate with
Molybdenum Disulfide
O-6372 Special Air Disc Brake Slide Pin, Splines and 1-1/2 Calcium 1
* 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 an ArvinMeritor service representative.
Oil Lubricants
Table DF: Oil Lubricants
Outside Temperature
Meritor Military/SAE °F °C
Specification Oil Typical Application Specifications Oil 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 Drive Axle, Front Drive Axle Wheel MIL-PRF-2105-E GL-5 SAE –10 None –12 None
Bearings, Non-Drive Axle Wheel and SAE J2360 85W/140
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
O-76D Gear Oil Front Drive Axle, Front Drive Axle Wheel GL-5 SAE –15 None –26 None
Bearings, Non-Drive Axle Wheel 80W/90
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
O76E Gear Oil Front Drive Axle, Front Drive Axle Wheel GL-5 SAE –40 None –40 None
Bearings, Non-Drive Axle Wheel 75W/90
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
O-76J Gear Oil Front Drive Axle, Front Drive Axle Wheel GL-5 SAE –40 35 –40 2
Bearings, Non-Drive Axle Wheel 75W
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
O-76L Gear Oil Front Drive Axle, Front Drive Axle Wheel GL-5 SAE –40 None –40 None
Bearings, Non-Drive Axle Wheel 75W/140
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
O-76M Full Front Drive Axle, Front Drive Axle Wheel GL-5 SAE –40 None –40 None
Synthetic Bearings, Non-Drive Axle Wheel 75W/140
Oil Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
O-76N Full Front Drive Axle, Front Drive Axle Wheel GL-5 SAE –40 None –40 None
Synthetic Bearings, Non-Drive Axle Wheel 75W/90
Oil Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
O-81 Full Transmission — SAE 50 –40 None –40 None
Synthetic
Oil
14
14 Specifications