Maintenance Manual
Maintenance Manual
Maintenance Manual
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 1.1
1
2 3
3A
73 4
8
5 9
6
7
72
71
74
70
69 29
68 33
67
66 30
64 31
65
34
62 32
63 59
58
60 57
61 56
1002980c
Figure 1.2
20 A
19
18 A
18 B
15 17
16
20
14
13 21
12 22
64
78 11 24 23 A
28 26 25 L
77 23 CD
76 A LD 41
TION 42
75
OP
10 40
27
28 36 39
38
36
37
43
35
39
45 44
46
54 36
55
36
53
47 37 NO-SPIN
ASSEMBLY
48
49
52
50
51
1002980e
Figure 2.1
앫 When the carrier is operated in the unlocked position, there is
normal differential action between the wheels at all times.
Figure 2.2
1
1
8
2
7 2
3
6
5 1000982c
1002981c
1 BOLT-IN STYLE
2 SCREW-IN OR THREADED STYLE
1 TAPERED ROLLER BEARINGS STANDARD CARRIER WITH DIFFERENTIAL LOCK (DCDL)
2 CARRIER
Figure 2.2
3 STRAIGHT ROLLER BEARING
4 TAPERED ROLLER BEARING
5 BEVEL DIFFERENTIAL GEARS
6 HOUSING
7 TAPERED ROLLER BEARING
8 HYPOID DRIVE PINION AND RING GEAR
Figure 2.1
Axle Models Covered in This Manual Table D: Front Drive Steer Axles
Table A, Table B, Table C and Table D list the axle models covered in MX-10-120 RF-7-120 RF-21-160
this manual. For other models (non-MX, RS, RT and RF Series), refer MX-12-120 RF-9-120 RF-21-185
to Maintenance Manual 5, Single-Reduction Differential Carriers. To
MX-14-120 RF-12-120 RF-21-355
obtain this publication, refer to the Service Notes page on the front
inside cover of this manual. MX-16-120 RF-12-125 RF-22-166
MX-21-160 RF-16-145 RF-23-180
Table A: RS Series Single Drive Axles
MX-21-160R RF-21-155 RF-23-185
RS-13-120 RS-17-145 RS-21-160 RS-23-186
MX-23-160 RF-21-156
RS-15-120 RS-17-145A RS-21-160A RS-25-160
MX-23-160R
RS-16-140 RS-19-144 RS-23-160 RS-25-160A
RS-16-141 RS-19-144A RS-23-160A RS-26-160 Stall-Testing Can Damage a Drive Axle
RS-16-145 RS-19-145 RS-23-161 RS-26-180 Stall-testing is a procedure used to troubleshoot transmissions,
RS-17-140 RS-19-145A RS-23-161A RS-26-185 evaluate vehicle performance, and test the service and park brakes.
RS-17-141 RS-21-145 RS-23-180 RS-30-180 During stall-testing, or any similar procedure, the drive axle input
RS-17-144 RS-21-145A RS-23-185 RS-30-185 receives multiplied torque, which can exceed the specified torque
rating. Excessive torque can damage a drive axle, which will affect
RS-17-144A
axle performance and component life. A drive axle damaged by
stall-testing will void Meritor’s warranty.
Table B: Bus and Coach Application Single Drive Axles
Call ArvinMeritor’s Customer Service Center at 800-535-5560 if
59722 59753 61052 61152 you have questions regarding stall-testing.
59723 59842 61053 61153
59732 59843 61063 61163 Use of Traction Chains
59733 61042 61142 RC-23-160 Meritor recommends that if you are using traction chains, you
59752 61043 61143 should install chains on both tires on each side of all drive axles
on the vehicle.
Table C: Rear Axle of Tandem Axles
RT-34-140 RT-40-146 RT-44-145P RT-46-169A
RT-34-144 RT-40-149 RT-44-149 RT-46-169P
RT-34-144A RT-40-149A RT-46-16HEH RT-48-180
RT-34-144P RT-40-149P RT-46-16HP RT-48-185
RT-34-145 RT-40-160 RT-46-160 RT-50-160
RT-34-145P RT-40-160A RT-46-160A RT-50-160P
RT-34-146 RT-40-160P RT-46-160P RT-52-180
RT-40-140 RT-40-169 RT-46-164 RT-52-185
RT-40-145 RT-40-169A RT-46-164EH RT-58-180
RT-40-145A RT-40-169P RT-46-164P RT-58-185
RT-40-145P RT-44-145 RT-46-169
personal injury.
2. Strike the end of the drift with a large hammer, five to six
pounds, and the axle shaft and tapered dowels will loosen.
Removal
3. Mark each axle shaft before it is removed from the axle
Axle Shaft Removal Methods assembly.
Use Special Tools Recommended by Meritor 4. Remove the tapered dowels and separate the axle shafts from
the main axle hub assembly. Figure 3.2.
To help prevent serious personal injury and damage to components
when you remove the axle shaft from the housing, Meritor Figure 3.2
recommends that you use the following tools in the table below. STUD TAPERED
Refer to the Service Notes page at the front inside cover of this NUT DOWEL
GASKET STUD
manual for information on how to contact the manufacturers to WASHER
obtain the tools.
앫 If the tools are not available when you remove the axle
shaft: Follow procedures for using the Brass Drift Method or the
Air Vibration Method.
5. Install a cover over the open end of each axle assembly hub
where an axle shaft was removed.
Air Hammer Vibration Method Axle Shafts from the Axle Housing
WARNING NOTE: If the vehicle is equipped with a driver-controlled main
Wear safe eye protection when using an air hammer. When differential lock, the DCDL collar must be engaged before removing
using power tools, axle components can loosen and break off the axle shafts. Refer to Section 6.
causing serious personal injury.
1. Park the vehicle on a level surface. Block the wheels to prevent
CAUTION the vehicle from moving. Figure 3.1.
Do not use a chisel or wedge to loosen the axle shaft and Figure 3.1
EASY SERVICETM 1
1. Place a hydraulic roller jack under the differential carrier to
2 support the assembly. Figure 3.3.
9
Figure 3.3
8 4
5
6
7
10 WOOD
WING SERIES BLOCK
11
PERMALUBETM
12
14 ROLLER
13 JACK
1002709c
Figure 3.3
15
FULL-ROUND
2. Remove all but the top two carrier-to-housing capscrews or
16
stud nuts and washers.
3. Loosen the top two carrier-to-housing fasteners and leave
19 17 attached to the assembly. The fasteners will hold the carrier in
18 the housing.
4. Loosen the differential carrier in the axle housing. Use a leather
20
25 mallet to hit the mounting flange of the carrier at several
“RPL” SERIES 21
PERMALUBETM points.
24 22
23
5. After the carrier is loosened, remove the top two fasteners.
1002984d
CAUTION
1 FULL-ROUND 8 U-JOINT CROSS 17 WELD YOKE
BEARING CUPS 9 SLIP YOKE 18 SLIP YOKE When you use a pry bar, be careful not to damage the carrier
2 END YOKE 10 CAPSCREWS 19 U-JOINT CROSS or housing flange. Damage to these surfaces will cause
3 YOKE SADDLE 11 END YOKE 20 CAPSCREWS oil leaks.
4 WELD YOKE 12 WELD YOKE 21 END YOKE
5 BEARING STRAP 13 SLIP YOKE 22 SLIP YOKE
6 CAPSCREWS 14 U-JOINT CROSS 23 TUBING 6. Use the hydraulic roller jack to remove the carrier from the axle
7 EASY SERVICE™ 15 CAPSCREWS 24 U-JOINT CROSS housing. Use a pry bar that has a round end to help remove the
BEARING CUPS 16 END YOKE 25 WELD YOKE carrier from the housing.
Figure 3.2
NOTE: A carrier stand is available from SPX Kent-Moore. Refer to
6. Remove the capscrews and washers or stud nuts and washers, the Service Notes page on the front inside cover of this manual to
if equipped, from the flanges of both axle shafts. obtain the stand.
7. Loosen the tapered dowels, if equipped, in the axle flanges of
7. Use a lifting tool to lift the differential carrier by the input yoke
both axle shafts using one of the following methods. Refer to
or flange and place the assembly in a repair stand. Figure 3.4.
the procedures in this section.
Do not lift by hand. A carrier stand can be built by referring to
Figure 3.5.
Figure 3.4
DIFFERENTIAL
CARRIER
REPAIR
STAND
1002710e
Figure 3.4
Figure 3.5
1 2
12
11
3
10
4
9 5
SPX Kent-Moore
8
part number J-3409-D
1002990f
1 PLATES 8’ LONG x 3/4” THICK x 1-1/4” WIDE WITH A TONGUE TO FIT SLOT IN BAR WELD PLATES TO BAR
2 HANDLE 7” LONG WITH SLOT IN ONE END TO FIT CLAMP SCREW
3 BAR 2” DIAMETER x 9” LONG WITH ONE END SLOTTED TO FIT PLATE
4 WELD ALL AROUND AFTER PRESSING PLUG IN PIPE
5 WELD
6 SHAPE AND SIZE OF HOLES TO FIT CARRIER
7 23-1/2” CENTER TO CENTER OF PIPE
8 CHAMFER END OF PIPE FOR WELDING
9 4” DIAMETER PIPE
10 PLUG 4” DIAMETER x 7” LONG WITH ONE END TURNED 3” LONG TO FIT PIPE. DRILL 2” HOLE AND MILL 3/16” WIDE SLOT 2” FROM TOP
11 SCREW 3-1/2” LONG x 5/8” DIAMETER WITH FLATS ON END TO FIT HANDLE AND 2-1/2” LENGTH OF THREAD ON OTHER END
12 DRILL 3/8” HOLE THROUGH HANDLE AND SCREW
CARRIER STAND
Figure 3.5
Meritor Maintenance Manual 5A (Revised 08-06) 9
3 Removal and Disassembly
INDICATOR
THRUST SCREW
AND JAM NUT
1002722c
1002993e
Figure 3.6
Figure 3.8
3. Read the dial indicator while you slightly rotate the ring gear in
both directions. When you rotate the ring gear to measure the 3. Rotate the differential carrier in the repair stand until the ring
backlash, the drive pinion must not move. Record the reading gear is at the top of the assembly.
on the dial indicator. 4. Mark one carrier leg and bearing cap to correctly match the
4. Repeat the procedure at two more locations on the ring gear. parts during carrier assembly. Mark the parts using a center
punch and hammer. Figure 3.9.
앫 If the smallest of the three measurements is not
0.008-0.018-inch (0.20-0.46 mm) for ring gears with a Figure 3.9
Figure 3.9
5. Remove the capscrews, cotter pins, roll pins or lock plates, if 8. Safely lift the main differential and ring gear assembly from the
equipped, that hold the bearing adjusting rings in position. Use carrier. Place the assembly on a workbench. Figure 3.13.
a small drift and hammer to remove the pins. Each lock plate is
Figure 3.13
REMOVING REMOVING
COTTER PIN LOCK
PLATE
1002998a
Figure 3.14
BEARING MATCH
CAP MARKS
MATCH
MATCH MARKS
1002996b MARKS
Figure 3.11
7. Remove the bearing caps and bearing adjusting rings from the 1002999d
carrier. Figure 3.12.
Figure 3.14
Figure 3.12
1002997b
Figure 3.12
4. Remove the differential spider or cross, four pinion gears, two Figure 3.16
side gears and six thrust washers from inside the case halves.
Figure 3.15.
Figure 3.15
SPIDER, PINIONS
AND THRUST
THRUST WASHERS
WASHER CORRECT DRILLING WRONG CHISELING
RIVETS FROM HEAD RIVETS FROM HEAD
SIDE 1003001d
GEAR
Figure 3.16
7. Use a press to separate the case half and ring gear. Support
1003000b
the assembly under the ring gear with metal or wood blocks.
Press the case half through the gear. Figure 3.17.
Figure 3.15
Figure 3.17
5. If the ring gear needs to be replaced, remove the bolts, nuts PRESS
and washers, if equipped, that hold the gear to the flange case CASE HALF PLATE
half.
CAUTION
Do not remove the rivets or rivet heads with a chisel and
hammer. Using a flat edge tool can cause damage to the flange
case. SUPPORTS
1003002b
6. If rivets hold the ring gear to the flange case half, remove the
rivets as follows. Figure 3.17
A. Carefully center punch each rivet head in the center, on 8. If the differential bearings need to be replaced, use a bearing
the ring gear side of the assembly. Do not use a chisel puller or press to remove the bearing cones from the case
and hammer. Figure 3.16. halves. Figure 3.18.
B. Drill each rivet head on the ring gear side of the assembly
to a depth equal to the thickness of one rivet head. Use a Figure 3.18
1002750b
Figure 3.18
YOKE PULLER
Figure 3.19
FLANGE PULLER
FLANGE
YOKE
1003348c
Figure 3.20
1003347b
BEARING
CAGE
Figure 3.19
2. Remove the nut and washer, if equipped, from the drive pinion.
Figure 3.19.
3. Remove the yoke or flange bar. CARRIER
CAUTION
1003350a
Do not use a hammer or mallet to loosen and remove the yoke
or flange. A hammer or mallet can damage the parts and cause Figure 3.21
driveline runout or driveline imbalance.
4. Remove the yoke or flange from the drive pinion. Do not use a
hammer or mallet.
앫 If the yoke or flange is tight on the pinion: Use a puller
for removal. Figure 3.20.
Do not use a pry bar to remove the bearing cage from the PRESS
DRIVE PINION
carrier. A pry bar can damage the bearing case, shims and OIL SEAL
carrier.
BEARING CAGE
6. Remove the drive pinion, bearing cage and shims from the
carrier. Do not use a pry bar. SUPPORT
앫 If the bearing cage is tight in the carrier: Hit the bearing SUPPORT SPIGOT
cage at several points around the flange area with a leather, BEARING
CAUTION
Be careful when you remove the seal. Do not damage the wall
of the bore. Damage to the bore wall can result in oil leaks.
1003349a
4. Use a press and a sleeve to remove the triple-lip or unitized oil
seal from the bearing cage.
Figure 3.22
앫 If a press is not available: Place a tool with a flat blade
7. If the shims are in good condition, keep the shims together to under the flange to remove the oil seal from the cage.
use when the carrier is assembled. Figure 3.24.
8. If shims are to be discarded because of damage, first measure Figure 3.24
Disassembly
Drive Pinion and Bearing Cage
1. Place the drive pinion and bearing cage in a press. The pinion
shaft must be toward the top of the assembly. Figure 3.23.
2. Support the bearing cage under the flange area with metal or
wood blocks. Figure 3.23.
1002437a
Figure 3.24
5. If the pinion bearings need to be replaced, remove the inner Figure 3.27
and outer bearing cups from the inside of the cage. PRESS
Figure 3.25. Use a press and sleeve, bearing puller or a small DRIVE
drift hammer. The type of tool used depends on the design of PINION
INNER
the bearing cage. Figure 3.26. BEARING
CONE BEARING
When a press is used, support the bearing cage under the PULLER
flange area with metal or wood blocks.
Figure 3.25
Figure 3.27
BEARING
SPACER 7. If the spigot bearing needs to be replaced, place the drive
pinion in a vise. Install a soft metal cover over each vise jaw to
INNER BEARING, protect the drive pinion.
CUP AND CONE
SPIGOT
8. Remove the snap ring, if equipped, from the end of the drive
SNAP
RING BEARING pinion with snap ring pliers that expand. Figure 3.28.
1003008c
Figure 3.28
Figure 3.25
SPIGOT
BEARING
Figure 3.26
SNAP
RING
BEARING
DRIVER
BEARING
PULLER
1003013c
Figure 3.28
1003011f
Figure 3.26
9. Remove the spigot bearing from the drive pinion with a bearing
puller. Figure 3.29. Some spigot bearings are fastened to the
drive pinion with a special peening tool. Figure 3.30.
Figure 3.29
BEARING
PULLER
SPIGOT
BEARING
1003015c
Figure 3.29
Figure 3.30
PEENING
POINTS
1003014c
Figure 3.30
Figure 3.31
Remove inner
race from pinion. 1003016C
Figure 3.31
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent Clean and Inspect Yokes
serious personal injury, damage to components, or both.
CAUTION
Do not install a press-on shaft excluder or POSE™ seal after
WARNING
you install a unitized pinion seal. The use of a POSE™ seal will
To prevent serious eye injury, always wear safe eye protection
prevent correct seating of the unitized pinion seal on the yoke
when you perform vehicle maintenance or service.
and will result in lubricant leakage at the seal. POSE™ seal
installation is recommended only for triple-lip and other
Solvent cleaners can be flammable, poisonous and cause
previous design seals.
burns. Examples of solvent cleaners are carbon tetrachloride,
and emulsion-type and petroleum-base cleaners. Read the Do not use thin metal wear sleeves to refresh the yoke surface.
manufacturer’s instructions before using a solvent cleaner, Wear sleeves pressed onto the yoke will prevent correct
then carefully follow the instructions. Also follow the seating of the pinion seal and damage the pinion seal
procedures below. assembly. Wear sleeve usage will cause the seal to leak.
앫 Wear safe eye protection.
1. Clean the ground and polished surface of the yoke journal
앫 Wear clothing that protects your skin. using a clean shop towel and a safe cleaning solvent. Do not
앫 Work in a well-ventilated area. use abrasive cleaners, towels or scrubbers to clean the yoke or
flange surface. Do not use gasoline.
앫 Do not use gasoline, or solvents that contain gasoline.
Gasoline can explode. NOTE: The unitized seal features a rubber inner sleeve that is
designed to seal and rotate with the yoke. This feature allows you to
앫 You must use hot solution tanks or alkaline solutions
reuse a yoke with minor grooves.
correctly. Read the manufacturer’s instructions before
using hot solution tanks and alkaline solutions. Then 2. Inspect the yoke seal surface for grooves.
carefully follow the instructions.
앫 If you find grooves on yoke hubs used with single or
Take care when you use Loctite‚ adhesive to avoid serious triple-lip seals: Replace the yokes.
personal injury. Read the manufacturer’s instructions before 앫 If you find grooves on the yoke: Use calipers to measure
using this product. Follow the instructions carefully to prevent the groove diameters. If any groove diameter measures less
irritation to the eyes and skin. If Loctite® adhesive material than the dimensions shown in Figure 4.1, replace the yoke.
gets into your eyes, follow the manufacturer’s emergency
Figure 4.1
1003390e
A MINIMUM GROOVE DEPTH — DIAMETER
B YOKE SEAL DIAMETER
Figure 4.1
Clean Rough Parts 앫 The center of the large-diameter end of the rollers is worn
level with or below the outer surface. Figure 4.2.
1. Clean rough parts with the same method as cleaning ground
and polished parts. 앫 The radius at the large-diameter end of the rollers is worn
to a sharp edge. Figure 4.2.
2. Rough parts can be cleaned in hot solution tanks with a weak
or diluted alkaline solution. 앫 There is a visible roller groove in the cup or cone inner race
surfaces. The groove can be seen at the small- or
3. Parts must remain in hot solution tanks until heated and large-diameter end of both parts. Figure 4.3.
completely cleaned.
앫 There are deep cracks or breaks in the cup, cone inner race
4. Parts must be washed with water until all traces of the alkaline or roller surfaces. Figure 4.3.
solution are removed.
앫 There are bright wear marks on the outer surface of the
Clean Axle Assemblies roller cage. Figure 4.4.
1. A complete axle assembly can be steam cleaned on the 앫 There is damage on the rollers and on the surfaces of the
outside to remove dirt. cup and cone inner race that touch the rollers. Figure 4.5.
2. Before the axle is steam cleaned, close or place a cover over all 앫 There is damage on the cup and cone inner race surfaces
openings in the axle assembly. Examples of openings are that touch the rollers. Figure 4.6.
breathers or vents in air chambers.
Figure 4.2
WORN RADIUS
Drying Parts After Cleaning
1. Parts must be dried immediately after cleaning and washing.
2. Dry the parts using soft, clean paper or cloth rags.
CAUTION
Damage to bearings can result when they are rotated and
dried with compressed air.
WORN SURFACE 1003017b
3. Except for bearings, parts can be dried with compressed air.
Figure 4.2
WEAR
CRACK
GROOVES
SPALLING AND FLAKING
1003021b
Figure 4.3
CAUTION
Figure 4.4
A drive pinion and ring gear are machined as a matched set.
When you replace either a drive pinion or a ring gear, you must
replace both parts as a matched set. Do not mix old and new
parts. Damage to components can result.
CAUTION
WEAR MARKS A thrust washer, differential side gear and pinion gear are
1003019a machined as a matched set. When you replace any of these
Figure 4.4
parts, you must install a new matched set. Do not mix old and
new parts. Damage to components can result.
Figure 4.5
Figure 4.5
Figure 4.7 4. Clean the parts and apply new silicone gasket material where
Inspect required when the axle or carrier is assembled. Figure 4.8.
inside
surfaces.
Figure 4.8
SIDE GEAR
PINION AND AND THRUST
THRUST WASHER
Inspect.
WASHER
1003023a
Figure 4.8
Inspect.
5. Remove nicks, mars and burrs from parts with machined or
DIFFERENTIAL
GEAR NEST ground surfaces. Use a fine file, india stone, emery cloth or
ASSEMBLY crocus cloth.
SPIDER OR
Inspect. CROSS 6. Clean and repair the threads of fasteners and holes. Use a die
1003022f
or tap of the correct size or a fine file.
Figure 4.7
Prepare the Axle 5. For suspension bracket welds, clean both lower and upper
suspension brackets and the areas of the axle housing around
WARNING each bracket. Use a wire brush and a cleaning solvent that will
The high temperature caused by the open flame from the remove dirt and grease from these areas. Figure 4.10 and
cutting torch can ignite the oil in the axle housing and can Figure 4.11.
cause serious personal injury.
Figure 4.10
1. Remove the oil drain plug from the bottom of the axle housing Clean these areas.
and drain the lubricant from the assembly.
CAUTION
LOWER
Remove the differential carrier from the axle housing before
BRACKET
you weld onto an axle. Do not weld onto an axle with the
differential carrier installed. Electrical arcing and damage to
components can result.
4000310a
2. Remove the differential carrier from the axle housing. Refer to
the correct Meritor carrier maintenance manual or the vehicle Figure 4.10
manufacturer’s instructions.
Figure 4.11
Figure 4.9
7. Heat the damaged area to approximately 300° F (149° C) 3. Tighten the fasteners to the required torque value for that size
before you begin welding. fastener. No drying time is required for fasteners with
pre-applied adhesive.
8. Use suitable weld wire electrodes when you weld. Suitable weld
wire electrodes include either BS EN 499 – E 42 2 B 32 H5 or
BS EN 440 – G 42 2 M GSi (American Welding Society
Original or Used Fasteners
equivalents E7018 and ER70S3, respectively). 1. Use a wire brush to clean the oil, dirt and old adhesive from all
threads and threaded holes.
9. For complete welding instructions, refer to Maintenance
Manual 8, Drive Axle Housings. To obtain this publication, refer 2. Apply four or five drops of Meritor liquid adhesive
to the Service Notes page on the front inside cover of this 2297-C-7049, Loctite® 638 or 680 liquid adhesive or
manual. equivalent inside each threaded hole or bore. Do not apply
adhesive directly to the fastener threads. Figure 4.12.
Do Not Bend or Straighten a Damaged Drive
Axle Housing Figure 4.12
WARNING
Replace damaged or out-of-specification axle components.
Do 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 FOUR TO
FIVE DROPS
personal injury and damage to components can result. ON BORE
THREADS
1003025a
Always replace a damaged drive axle housing. Do not bend or
straighten a damaged housing, which can misalign or weaken it,
Figure 4.12
and void Meritor’s warranty.
3. Tighten the fasteners to the required torque value for that size
Removing Fasteners Secured with Adhesive fastener. There is no drying time required for Meritor liquid
If it is difficult to remove fasteners secured with Dri-Loc®, Meritor adhesive 2297-C-7049, Loctite® 638 or 680 liquid adhesive
adhesive or Loctite® 277 adhesive, use the following procedure. or equivalent.
When you remove fasteners secured with adhesive, slowly heat the
fastener to 350° F (177° C). Do not exceed this temperature, or heat Meritor Specification 2297-T-4180 Adhesive
fasteners quickly. Damage to components can result. in the Differential Bearing Bores
1. Heat the fastener for three to five seconds. Try to loosen the NOTE: Use Meritor specification 2297-T-4180 adhesive for all
fastener with a wrench. Do not use an impact wrench or hit the axles.
fastener with a hammer.
2. Repeat Step 1 until you can remove the fastener. 1. Clean the oil and dirt from the outer diameters of the bearing
cups and bearing bores in the carrier and bearing caps. There
New Fasteners with Pre-Applied Adhesive is no special cleaning required.
1. Use a wire brush to clean the oil and dirt from threaded holes. 2. Apply axle lubricant to the bearing cones and the inner
diameters of the bearing cups of the main differential. Do not
2. Install new fasteners with pre-applied adhesive to assemble get oil on the outer diameter of the bearing cup and do not
parts. Do not apply adhesives or sealants to fasteners with permit oil to drip onto the bearing bores.
pre-applied adhesive, or to fastener holes.
approximately two hours. You must complete the procedure within Cleaning the housing face with a rotary
two hours from the time you apply the adhesive. If two hours have tool and a scour pad.
passed since application, clean the adhesive from the parts and
apply new adhesive.
Figure 4.13
ADHESIVE BEARING
CAP
4000621a
Figure 4.14
CARRIER
LEG
4. Remove metal filings from the magnets inside the housing.
5. Use solvent to clean the inside of the housing.
6. Use Loctite® ODC Free cleaner or brake cleaner to clean the
housing and carrier faces.
7. Dry the housing and carrier faces.
1003026a
CAUTION
Figure 4.13 New capscrew kits have blue Dri-Loc® STS threadlocker, an
equivalent to Loctite® 242 threadlocker, applied to the
4. Install the main differential assembly, bearing cups and bearing capscrews. Do not remove the blue Dri-Loc® STS threadlocker
caps into the carrier. Refer to Section 5. from the capscrews. Damage to components can result.
5. Adjust the preload of the differential bearings, backlash and
8. If you reuse the carrier-to-housing capscrews, use a rotary
tooth contact patterns of the gear set as required. Refer to
wire brush to remove any threadlocker material and clean the
Section 5.
capscrew threads. Use a clean cloth to wipe the threads.
Carrier-to-Housing Joint Sealing Procedure 9. Use a tap to clean the internal threads in the housing.
1. Remove the carrier from the housing. Refer to Section 3.
2. Remove all debris from inside the housing.
3. Use a rotary tool with a scour pad to clean all silicone residue
from the housing and carrier faces. Figure 4.14. Surfaces must
be clean, dry and free of foreign matter. The surfaces must not
be oily to the touch.
Install the end yoke hub capscrews by hand after seating the U-joint.
Tighten the capscrews according to the manufacturer’s torque
specifications.
Identification
Gear Sets
0.25" (6 MM) Refer to Table E, Table F, Table G and Table H for information on
DIAMETER SILICONE identifying gear sets with matched parts. Always check match
4004435a
GASKET BEAD
numbers to verify that the gear set you will install has matched
Figure 4.15 parts. Figure 4.17.
11. Install two long studs in the carrier to guide the carrier into the Figure 4.17
0.25" (6 MM)
4000623b
Figure 4.16
Examples
Table E: Gear Set Part Numbers
Part Number Location
Conventional ring 36786 On the front face
gear or outer diameter
Conventional drive 36787 At the end at
pinion threads
Generoid ring gear 36786 K or 36786 K2 On the front face
or outer diameter
Generoid drive pinion 36787 K or 36787 K2 At the end at
threads
NOTE: Meritor drive pinions and ring gears are only available as
matched sets. Each gear in a set has an alphanumeric match
number.
NOTE: Don’t use the pinion cone variation number when you check
for a matched gear set. Use this number when you adjust the pinion
depth of the carrier. Refer to Section 5.
+0.01 mm
PC–5
–1
–0.02 mm
Figure 5.1
Read and observe all Warning and Caution hazard alert messages in PRESS SLEEVE
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both. BEARING
CAGE CUP
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
When you apply some silicone gasket materials, a small SUPPORTS 1003033b
amount of acid vapor is present. To prevent serious personal
injury, ensure that the work area is well-ventilated. Read the Figure 5.1
manufacturer’s instructions before using a silicone gasket
material, then carefully follow the instructions. If a silicone 4. Place the drive pinion in a press with the gear head or teeth
gasket material gets into your eyes, follow the manufacturer’s toward the bottom. Figure 5.2.
emergency procedures. Have your eyes checked by a
physician as soon as possible. Figure 5.2
Take care when you use Loctite® adhesive to avoid serious SLEEVE
personal injury. Read the manufacturer’s instructions before
using this product. Follow the instructions carefully to prevent
irritation to the eyes and skin. If Loctite® adhesive material
gets into your eyes, follow the manufacturer’s emergency INNER
BEARING
procedures. Have your eyes checked by a physician as soon CONE
as possible.
1003120b
Use a brass or synthetic mallet for assembly and disassembly
procedures. Do not hit steel parts with a steel hammer. Pieces Figure 5.2
of a part can break off. Serious personal injury and damage to
components can result. 5. Press the inner bearing cone on the shaft of the drive pinion
until the cone is flat against the gear head. Use a sleeve of the
Observe all warnings and cautions provided by the press correct size against the bearing inner race.
manufacturer to avoid damage to components and serious
personal injury. NOTE: Spigot bearings are usually fastened to the drive pinion with
a snap ring. Some are fastened with a peening tool, and some are a
Assembly two-piece bearing assembly with the inner race pressed on the nose
of the pinion and the outer race pressed into its bore in the carrier.
Drive Pinion, Bearings and Bearing Cage
6. Install the spigot bearing using one of the following three
1. Place the bearing cage in a press. Figure 5.1. procedures.
2. Support the bearing cage with metal or wood blocks.
3. Press the bearing cup into the bore of the bearing cage until
the cup is flat against the bottom of the bore. Use a sleeve of
the correct size to install the bearing cup. Use the same
procedure for both bearing cups. Figure 5.1.
1. Place the drive pinion in a press with the gear head or the teeth
toward the top. Figure 5.3.
PUNCH
Figure 5.3
PRESS TUBE
SLEEVE
SPIGOT
BEARING 1003037b
Figure 5.5
1. Place the drive pinion and the tube of the staking tool into a
press with the spigot bearing toward the top. Figure 5.6.
Figure 5.6
1003034b
Figure 5.6
SPIGOT
BEARING
2. When you use a staking tool and press, apply 6,614 lb
(3 000 kg) force on a 0.375-inch (10 mm) ball. Calculate the
force required on the tool as follows.
3. Place the punch of the staking tool over the end of the pinion Figure 5.8
2. Place the heat shield over the pinion stem so that you can see
the temperature indicating liquid through the hole in the shield.
Figure 5.9.
Figure 5.9
1003036b
Figure 5.7
NOTE: To hold the races in place, use a staking tool, not the old
CAUTION
race, to start the new race on the stem. The old race can be used to
Do not overheat the pinion stem or you will weaken the metal.
completely seat the new race.
Damage to components can result.
7. Place the staking tool over the bearing race. Cut a one-inch
NOTE: Correct heating will take approximately 25-35 seconds,
(25 mm) piece from the green plastigage strip and place in
depending on how hot the torch is.
between the punch and the staking tool. You do not need to
use the plastigage for every stake. Use the plastigage until you
4. Light and adjust the torch until the white part of the flame is
are sure that you are hitting the punch with the correct amount
approximately 0.25-inch (6 mm) long. Keep the white part of
of force. Figure 5.11.
the flame approximately 0.125-inch (3 mm) from the top of the
stem. Figure 5.10. Move the flame around the outer diameter
Figure 5.11
0.25"
(6 MM)
WHITE PART
OF FLAME 0.125"
VIEW A VIEW B
(3 MM)
1003042b
HEAT
SHIELD Figure 5.11
PINION
1003041b
8. Strike the punch with a two-three pound (0.9-1.4 kg) brass
Figure 5.10 hammer to upset the end of the pinion stem. Remove the strip
and measure its thickness against the gauge on the strip’s
5. Remove the flame and the heat shield from the pinion. Let the wrapper. The strip must not be less than 0.003-inch
pinion air cool for 10 minutes. Use a razor blade to remove the (0.0762 mm) thick. This thickness indicates that you are using
temperature indicating liquid. enough force when you hit the punch. If the strip is too thin,
then you must hit the punch harder so the stake will hold the
CAUTION race in place. Rotate the tool and repeat this procedure until
Do not press or directly strike the new inner race. Damage to there are six evenly spaced stake marks around the stem.
the bearing will result. Figure 5.11.
9. With a press or a soft mallet and sleeve, install the outer race
6. Use a press, if available, or a brass hammer to install the new
and roller assembly into its bore in the carrier. Use a sleeve that
inner race. Use the old inner race as a sleeve. The face is
is the same size as the outer race. Press the bearing until it is
completely seated when you cannot fit a 0.002-inch
squarely seated against the shoulder in the bottom of its bore.
(0.0508 mm) feeler gauge between the race and the
pinion shoulder.
Drive Pinion 2. Install a sleeve of the correct size against the inner race of the
outer bearing. Figure 5.13.
1. Apply axle lubricant to the bearing cups and to the bearing
cones in the cage. Figure 5.13
Figure 5.12
OUTER
BEARING CONE
1003044b
Table I
DRIVE INNER
PINION BEARING CONE Press Pressure Needed Torque Value Needed on
Thread on Bearings for Correct Pinion Nut for Correct
Size of Preload Bearing Preload
1003043a
Pinion pounds/ kg/metric
Figure 5.12
Shaft tons tons lb-ft N폷m
4. Install the outer bearing cone onto the pinion shaft against the 7/8″ -20 22,000/1 9979/10 200-275 271-373
spacer. Do not install the pinion seal into the bearing cage. 1″ -20 30,000/15 13 608/13.6 300-400 407-542
Figure 5.12. 1-1/4″ -12 54,000/27 24 494/24.5 700-900 949-1220
1-1/4″ -18 54,000/27 24 494/24.5 700-900 949-1220
Adjustment
1-1/2″ -12 54,000/27 24 494/24.5 800-1100 1085-1491
Pinion Bearing Preload 1-1/2″ -18 54,000/27 24 494/24.5 800-1100 1085-1491
Press Method 1-3/4″ -12 50,000/25 22 680/22.7 900-1200 1220-1627
If a press is not available, or the press does not have a pressure 2″ -12 50,000/25 22 680/22.7 1200-1500 1627-2034
gauge, use the yoke or flange method to adjust the pinion bearing
preload. 4. While pressure is held against the assembly, wind a cord
around the bearing cage several times.
NOTE: Do not read the starting torque. Read only the torque value
5. Attach a spring scale to the end of the cord.
after the cage starts to rotate. The starting torque will give an
incorrect reading. 6. Pull the cord on a horizontal line. As the bearing cage rotates,
read the value indicated on the scale. Record the reading.
1. Place the drive pinion and cage assembly into a press with the Figure 5.13.
gear head or teeth toward the bottom.
7. Measure the diameter of the bearing cage where the cord was Yoke or Flange Method
wound. Measure in inches or centimeters. Figure 5.14.
CAUTION
Figure 5.14
1. Use a press to install the input yoke or flange, nut and washer,
if equipped, onto the drive pinion. The yoke or flange must be
seated against the outer bearing. Figure 5.15.
Figure 5.15
앫 Reading from spring scale = 7.5 pounds (3.4 kg) Figure 5.16
4. Fasten a yoke or flange bar to the input yoke or flange. The bar 9. After adjusting the pinion bearing preload, remove the drive
will hold the drive pinion in position when the nut is tightened. pinion and bearing cage from the carrier. Refer to Section 3.
Figure 5.17.
Shim Pack Thickness for a New Drive Pinion
Figure 5.17
Use this procedure if you’ll install a new drive pinion and ring gear
set, or if you have to adjust the depth of the drive pinion. If the pinion
depth shims are misplaced during carrier repair, use 0.045-inch
(1.14 mm) for the initial pinion position. Figure 5.19.
Figure 5.19
SHIM PACK
FLANGE CONTROLS DEPTH
BAR BEARING CAGE
OF PINION
SHOWN
1003352b
Figure 5.17
Figure 5.20
Read
torque
value.
1001049b
Figure 5.18
1003055a
8. If the pinion bearing preload or torque is not within 5-45 lb-in
Figure 5.20
(0.56-5.08 N폷m) for new pinion bearings or 10-30 lb-in
(1.13-3.39 N폷m) for used pinion bearings in good condition,
remove the pinion and cage assembly from the carrier. Adjust
the spacer and repeat Step 1 through Step 7. @
앫 To increase preload: Install a thinner bearing spacer.
앫 To decrease preload: Install a thicker bearing spacer.
2. Find the pinion cone (PC) variation number on the drive pinion Table J
you’ll replace. Figure 5.21. Record the number. The pinion
Examples Inches mm
cone number can be one of the following values.
1. Old Shim Pack Thickness. 0.030 – 0.002 0.760 – 0.050
앫 PC +3, PC –3, +3 or –3 = 0.003-inch Old PC Number, PC = 0.028 = 0.710
앫 PC +0.03, PC 0.03 mm, +0.03 mm or –0.03 = 0.03 mm +2-inches (+0.05 mm) + 0.005 + 0.130
Standard Shim Pack = 0.033 = 0.840
Figure 5.21
Thickness. New PC
Number, PC +5-inches
(+0.13 mm)
PINION CONE
VARIATION New Shim Pack Thickness
NUMBER
2. Old Shim Pack Thickness. 0.030 + 0.002 0.760 + 0.050
Old PC Number, PC = 0.032 = 0.810
–2-inches (–0.05 mm) + 0.005 + 0.130
Standard Shim Pack = 0.037 = 0.940
Thickness. New PC
1003056b Number, PC +5-inches
(+0.13 mm)
Figure 5.21
New Shim Pack Thickness
3. If you can’t find the PC number or it’s unreadable, install a new 3. Old Shim Pack Thickness. 0.030 – 0.002 0.760 – 0.050
shim pack of the same thickness that you measured in Step 1. Old PC Number, PC = 0.028 = 0.710
4. If the old pinion cone number is a plus (+) number, subtract the +2-inches (+0.05 mm) – 0.005 – 0.130
number from the old shim pack thickness that was measured Standard Shim Pack = 0.023 = 0.580
in Step 2. Thickness. New PC
Number, PC –5-inches
5. If the old pinion cone number is a minus (–) number, add the
(–0.13 mm)
number to the old shim pack thickness that was measured in
Step 2. New Shim Pack Thickness
6. Find the pinion cone (PC) variation number on the new drive 4. Old Shim Pack Thickness. 0.030 + 0.002 0.760 + 0.050
pinion that will be installed. Record the number. Old PC Number, PC = 0.032 = 0.810
–2-inches (–0.05 mm) – 0.005 – 0.130
7. If the new pinion cone number is a plus (+) number, add the = 0.027 = 0.680
Standard Shim Pack
number to the standard shim pack thickness that was
Thickness. New PC
calculated in Step 4 or Step 5. Use new shims to make a shim
Number, PC –5-inches
pack to the correct thickness. Refer to Table J.
(–0.13 mm)
New Shim Pack Thickness
DRIVE PINION
AND BEARING CAGE
Drive Pinion, Bearing Cage and Shim Pack
into the Carrier
NOTE: If a new drive pinion and ring gear set is installed, or if the
SHIMS
depth of the drive pinion has to be adjusted, calculate the thickness
CARRIER
of the shim pack. Refer to the procedure in this section.
1. Select the correct shim pack and install it between the bearing
cage and carrier. Figure 5.22.
1003355c
Figure 5.22
Figure 5.23
GUIDE STUDS
Figure 5.24
CARRIER
1003354b
Figure 5.22
1001059a
2. Apply Loctite® 518 Gasket Eliminator to the carrier face.
Figure 5.24
3. Align the oil slots in the shims with the oil slots in the bearing
cage and carrier. Use guide studs to help align the shims.
Figure 5.22. Tight Fit Yokes and POSE™ Seal
4. Apply Loctite® 518 Gasket Eliminator to the top of the shim CAUTION
pack. Do not use a hammer or mallet to install tight fit yokes onto
5. Install the drive pinion and bearing cage into the carrier. If shafts. A hammer or mallet can damage the yoke.
necessary, use a rubber, plastic or leather mallet to hit the
assembly into position. Figure 5.23. The seal lips must be clean. Dirt and particles may cause a
leak between the yoke and the POSE™ seal.
NOTE: Do not install a POSE™ seal all the way against the yoke
shoulder. This seal is designed to position itself as the yoke is
installed.
Lubricate triple-lip
or main seal. C. Press the seal into the bearing cage. The seal flange must
be flat against the top of the bearing cage. Use a sleeve or
seal driver of the correct size that fits against the metal
INPUT SHAFT
OR PINION seal flange. The diameter of the sleeve or driver must be
larger than the flange diameter. Figure 5.28.
POSETM SEAL, 앫 If a press is not available: Use a mallet and the
0.25-0.50" (6.4-12.7 MM)
Inspect ONTO HUB
sleeve or driver to install the seal. Figure 5.29.
yoke hub.
1003360a D. After the triple-lip seal is installed, a gap of approximately
0.015-0.030-inch (0.38-0.76 mm) between the flange
Figure 5.25
and bearing cage is normal. Figure 5.30.
4. Slide the yoke over the input shaft pinion. Align the yoke E. Check the gap with a feeler gauge at several points
splines with the shaft splines. around the seal. The gap must be within
0.015-0.030-inch (0.38-0.76 mm). The difference
CAUTION between the largest and smallest gap measurement must
Do not use a hammer or mallet to install the yoke to the input not exceed 0.010-inch (0.0254 mm).
pinion shaft. A hammer or mallet can damage the yoke or
flange. Figure 5.27
Apply lubricant
5. Install the input yoke flange onto the drive pinion shaft. The to seal bore.
Apply grease.
yoke or flange must be fully seated against the outer
differential bearing before the nut is tightened to specifications.
6. Install the drive pinion nut and washer onto the input pinion
shaft and against the yoke collar. Tighten the nut against yoke
collar to torque specifications. Figure 5.26. Refer to Section 8.
BEARING
Figure 5.26
CAGE TRIPLE-LIP,
MAIN SEAL
DRIVE
PINION
1003050b
Figure 5.27
Use flange
or yoke bar.
1003062a
Figure 5.26
Figure 5.28
Any Type Yoke with a Unitized Pinion Seal
(UPS)
PRESS
SLEEVE 1. Remove the replacement unitized seal from the package.
SLEEVE SEAL Figure 5.31.
Figure 5.31
BEARING
DRIVE CAGE UNITIZED
PINION SEAL
SUPPORTS
1003051b
Figure 5.28
CAUTION
If a yoke is removed after it has been partially or fully installed,
the unitized pinion seal will be damaged. Remove and discard
the original unitized pinion seal and replace it with a new one.
1003052b If a yoke has been installed into the unitized pinion seal and
then removed, the inner sleeve of the seal will be damaged.
Figure 5.29
Install a new seal.
Figure 5.30
2. Select the correct seal driver from Table K. Each seal driver
is designed to correctly install a specific diameter seal.
0.015-0.030" To determine the yoke seal diameter, measure the yoke journal.
(0.38-0.76 MM) To obtain the Meritor seal driver KIT 4454, refer to the Service
SHOWN WITHOUT Notes page on the front inside cover of this manual.
BEARINGS AND
PINION 3. Position the seal on the driver.
CAUTION
Use a rubber mallet to install the seal. Do not use a steel, brass
or plastic hammer. Using a steel, brass or plastic hammer can
1003053b damage the seal and driver tool.
Figure 5.30
4. Use a rubber mallet to drive the seal into or against the bearing
cage. The seal must fully seat into or against the bearing cage.
Figure 5.32.
Figure 5.32
RUBBER REFERENCE
MALLET MARK
Figure 5.32
RS-25-160 /A RT-40-169 /A /P A-1205-N-2588 Tandem and Single Rear Input — R4422401 3.000
145 models 3.005
RS-23-186 RT-46-160 /A /P
RS-26-185 RT-46-169 /A /P A-1205-Q-2591 Tandem and Single Rear Input — R4422402 3.250
160/164/185 models 3.255
RS-30-185 RT-46-164EH /P
RT-46-16HEH /P
RT-50-160 /P
RT-52-185*
RT-58-185*
Clean, Inspect and Install the Yoke After 4. Align the yoke splines with the shaft splines. Slide the yoke
Installing a Unitized Pinion Seal over the shaft spline.
1. Use a clean shop towel and a safe cleaning solvent to clean the CAUTION
ground and polished surface of the yoke journal. Do not use Do not use a hammer or mallet to install the yoke to the input
gasoline, abrasive cleaners, towels or scrubbers to clean the pinion shaft. A hammer or mallet can damage the yoke or
yoke. Do not attempt to polish the yoke. flange.
NOTE: The unitized seal features a rubber inner sleeve that is 5. Install the input yoke flange onto the drive pinion shaft. The
designed to seal and rotate with the yoke. This feature allows you to yoke or flange must be fully seated against the outer
reuse a yoke with minor grooves. differential bearing before the nut is torqued to specifications.
2. Inspect the yoke seal surface for grooves. 6. Apply a single bead of Loctite® 277 adhesive (part number
1199Y3795) or Loctite® 270 adhesive (part number
앫 If you find grooves on the yoke: Use calipers to measure 2297M5213) at the top of the input shaft threads from inboard
the groove diameters. If any groove diameter measures less to outboard. The bead should be 0.120-inch wide.
than the dimensions shown in Figure 5.33, replace the yoke.
7. Install the drive pinion nut, and washer if required, onto the
Figure 5.33
input pinion shaft and against the yoke collar. Tighten the nut
UNITIZED PINION SEAL (UPS)
against the yoke collar to torque specifications. Figure 5.34.
Refer to Section 8.
B
Figure 5.34
Do not use thin metal wear sleeves to refresh the yoke surface.
Wear sleeves pressed onto the yoke can prevent correct
seating of the pinion seal, damage the pinion seal assembly
and cause the seal to leak.
3. Before you install the yoke, lightly lubricate or coat the yoke
seal journal with axle oil.
4005523a
Figure 5.35
If a yoke is removed after it has been partially or fully installed, REAR-REAR INPUT
the multiple lip seal will be damaged. Remove and discard the
original multiple lip seal and replace it with a new one.
If a yoke has been installed into the multiple lip seal and then
removed, the inner sleeve of the seal will be damaged. Install
a new seal.
2. Select the correct seal driver from Table L. Each seal driver is 4004879a
designed to correctly install a specific diameter seal. To
Figure 5.36
determine the yoke seal diameter, measure the yoke journal. To
obtain the Meritor seal driver KIT 4454, refer to the Service
Notes page on the front inside cover of this manual. 5. Use a feeler gauge to check the seal gap at all three axle
positions. The seal is correctly installed if the gap is less than
3. Position the seal on the driver. 0.005-inch (0.127 mm) around the circumference of the seal
4. Install the rear-rear axle input seal. Hold the seal only on the flange.
outer diameter. Position the seal into the seal driver and align it 앫 If the gap is more than 0.005-inch (0.127 mm): Use a
with the rear-rear axle input bearing cage. Use a dead-blow dead-blow hammer and the appropriate driver to
hammer and the appropriate driver to install the seal into the completely install the seal.
bearing cage. Figure 5.36.
Forward input and output seals must be serviced with the seal and sleeve. The service part number provides both when required.
5. Install the bolts, nuts and washers that hold the ring gear to
the flange case half. Install the bolts from the gear side of the
assembly. The bolt heads must be against the ring gear.
Figure 5.38.
앫 If rivets were used to hold the ring gear to the flange
case half: Replace them with bolts, nuts and washers.
or yoke bar.
RING GEAR
FLANGE
1003062a
CASE
HALF
Figure 5.37
BOLT HEAD
AGAINST GEAR
1003063a
Figure 5.38
6. Tighten the bolts and nuts to the correct torque value. Refer to 9. Apply axle lubricant on the inside surfaces of both case halves,
Section 8. spider or cross, thrust washers, side gears and differential
pinions.
앫 For 59000 Series carriers: Apply four to six drops of red
Loctite® 277 threadlocker to the threaded holes in the ring 10. Place the flange case half on a bench with the ring gear teeth
gear. Install the capscrews. Tighten the capscrews to toward the top.
360-470 lb-ft (490-639 N폷m). @
11. Install one thrust washer and side gear into the flange case
7. Use a 0.003-inch (0.08 mm) feeler gauge to check for gaps half. Figure 5.41.
between the back surface of the ring gear and the case flange.
Check for gaps at four points around the assembly. Figure 5.41
Figure 5.39
1003066a
Figure 5.41
CAUTION
Check for 0.003" The side gears in some carrier models have hubs of different
(0.08 mm) gap at lengths. Install the correct length side gear into the flange
four locations. case half. Damage to components can result.
1003056b
12. Install the spider or cross, differential pinions and thrust
Figure 5.39
washers into the flange case half. Figure 5.42.
8. Use a press and the correct size sleeve to install the bearing Figure 5.42
PRESS
SLEEVE
BEARING
CONE
CASE
HALF
1003067a
Figure 5.42
SUPPORT SUPPORT
1003065a
Figure 5.40
13. Install the second side gear and thrust washer over the spider Figure 5.45
Figure 5.45
1003068b
Inspection
Figure 5.43
Differential Gears Rotating Resistance
14. Place the plain half of the differential case over the flange half 1. Make an inspection tool using an axle shaft that matches the
and gears. Rotate the plain half to align the match marks. spline size of the differential side gear. Cut the shaft to
Figure 5.43 and Figure 5.44. approximately 12-inches (304.8 mm). Weld a nut onto the end
of the shaft. Figure 5.46.
Figure 5.44
CASE APPROXIMATELY
HALF 12" (304.8 MM)
MATCH
MARKS
Figure 5.47
3. Install the tool into the differential until the splines of the tool Figure 5.49
are engaged with one side gear. Figure 5.47. ADHESIVE BEARING CAP
4. Place a torque wrench onto the nut of the tool and rotate the
differential gears. As the differential gears rotate, read the CARRIER LEG
value indicated on the torque wrench. Figure 5.48.
앫 If the torque value exceeds 50 lb-ft (67.8 N폷m):
Disassemble the differential gears from the case halves.
Inspect the case halves, spider, gears and thrust washers.
Repair or replace parts. Assemble the parts and repeat
Step 2 through Step 4. 1003026d
Figure 5.48
Figure 5.49
4. Install the bearing cups over the bearing cones that are
assembled on the case halves. Figure 5.50.
Figure 5.50
BEARING
Read torque value. CUP
BEARING
1003073d CUP
LEG
Figure 5.48 BORE
Installation
1002788d
Differential and Ring Gear Assembly
Figure 5.50
1. Clean and dry the bearing cups and bores of the carrier legs
and bearing caps. 5. Safely lift the differential and ring gear assembly and install it
2. Apply axle lubricant on the inner diameter of the bearing cups into the carrier. The bearing cups must be flat against the
and on both bearing cones that are assembled on the case bores between the carrier legs. Figure 5.50.
halves. 6. Install both of the bearing adjusting rings into position between
® the carrier legs. Turn each adjusting ring hand-tight against the
3. Apply green Loctite 635 or 680 adhesive into the bearing
bores of the carrier legs and bearing caps so that the Loctite® bearing cup. Figure 5.51.
adhesive is spread out 360 degrees. Adhesive must not 앫 For 59000 Series carriers: Apply green Loctite® 635 or
contact the adjusting ring threads. Refer to Section 6. 680 adhesive to the adjusting ring threads on the carrier
Figure 5.49. legs and bearing caps so that the Loctite® adhesive is
spread out 360 degrees. Do not apply Loctite® adhesive
between the bearing cup and adjusting ring. You must
adjust the preload within the “set-time” of the Loctite®
adhesive used. Refer to the manufacturer’s instructions for
these set-times. Also, during and after setting the bearings,
verify that no Loctite® adhesive gets into the interface
between the bearing cup and the adjusting ring.
Figure 5.51 9. Install the capscrews and washers that hold the bearing caps
ADJUSTING to the carrier. Hand-tighten the capscrews four to six turns.
RING Tighten the capscrews to the correct torque value. Refer to
Section 8.
Do not install the capscrews, cotter pins, roll pins or lock
plates, if equipped, that hold the bearing adjusting rings in
position.
10. Adjust the differential bearing preload and hypoid gear
backlash. Check the tooth contact patterns.
LEG
1002789d
Adjustment
Figure 5.51
Differential Bearing Preload
7. Install the bearing caps over the bearings and adjusting rings.
Align the match marks you made when you removed the caps. Method 1
Figure 5.52. 1. Attach a dial indicator onto the carrier mounting flange so that
the plunger or pointer is against the ring gear back surface.
Figure 5.52
Figure 5.53.
Figure 5.53
BEARING DIAL
CAP INDICATOR
MATCH
MARKS
1002790c
Figure 5.52
1003078d
"T" BAR
WRENCH
ADJUSTING
RING
OPPOSITE
RING GEAR
1003081g
1003079b
3. Use one of the following methods to move the differential and 4. Tighten the bearing adjusting ring until the dial indicator reads
ring gear to the left and right while you read the dial indicator. ZERO end play. Move the differential and ring gear to the left
and right as needed. If necessary, repeat Step A or Step B.
A. Insert two pry bars between the bearing adjusting rings
and ends of the differential case. The pry bars must not 5. Tighten each bearing adjusting ring one notch from ZERO.
touch the differential bearings. Figure 5.55. 6. Proceed to check ring gear runout.
B. Insert two pry bars between the differential case or ring
gear and the carrier at locations other than described in Method 2
Step A. The pry bars must not touch the differential 1. Hand-tighten both adjusting rings against the differential
bearings. Figure 5.56. bearings.
Figure 5.55
2. Use a micrometer to measure distance X or Y between the
opposite surfaces of the bearing caps. Figure 5.57 and
Figure 5.58. Record the measurement.
Figure 5.57
1003080f
Figure 5.55
1003082d
Figure 5.57
Figure 5.58
Ring Gear Runout
MICROMETER 1. Attach a dial indicator onto the carrier mounting flange.
Figure 5.59.
Figure 5.59
DIAL
INDICATOR
1003083d
Figure 5.58
Distance X or Y before tightening the adjusting rings = 앫 If the ring gear runout exceeds the specification:
13.927-inches (353.74 mm) Remove the differential and ring gear assembly from the
carrier. Refer to Section 3.
Distance X or Y after tightening the adjusting rings =
13.936-inches (353.97 mm) A. Inspect the differential parts, including the carrier, for
13.936-inches – 13.927-inches = 0.009-inch (0.23 mm) wear and damage. Repair or replace parts as necessary.
difference B. Install the main differential case and ring gear assembly
into the carrier. Refer to the procedure in this section.
Table N: Specification
C. Repeat the procedure for preload adjustment of the
Differential differential side bearings.
Bearing Preload Expansion Between Bearing Caps
15-35 lb-in RS-140, RS-145 RS-120 and all
(1.7-3.9 N폷m) and RS-160 other carrier
carrier models models
0.002-0.009-inch 0.006-0.013-inch
(0.05-0.229 mm) (0.15-0.33 mm)
Table O: Specifications
Ring Gear Pitch Range of Backlash Setting
Diameter Backlash Setting for New Gear Sets
Less than 17-inches 0.008-0.018-inch 0.012-inch
(431.8 mm) (0.20-0.46 mm) (0.30 mm)
Greater than 0.010-0.020-inch 0.015-inch
17-inches (0.25-0.51 mm) (0.38 mm)
(431.8 mm) 1003086d
Figure 5.61
Measure the outer diameter of the ring gear for the approximate
pitch diameter. Figure 5.60.
5. Loosen one bearing adjusting ring one notch. Tighten the
앫 If the old gear set is installed: Adjust the backlash to the opposite ring by the same amount.
setting that was measured before the carrier was disassembled.
앫 To increase the backlash: Move the ring gear away from
앫 If a new gear set is installed: Adjust the backlash to the correct the drive pinion. Figure 5.62.
specification for new gear sets.
앫 To decrease the backlash: Move the ring gear toward the
Figure 5.60 drive pinion. Figure 5.63.
Figure 5.62
Tighten adjusting
ring this side.
Measure outer
diameter for
approximate
pitch diameter. Loosen adjusting
Increase backlash. ring this side.
1003090k
Figure 5.60 1002795b
Figure 5.62
After checking the tooth contact patterns, the backlash can be
adjusted within the specification limits, if needed. To change the Figure 5.63
6. Repeat Step 2 through Step 5 until the backlash is within Figure 5.66
specification. Record the setting for use when you adjust the
pinion bearing preload.
Figure 5.65
1001091a
Figure 5.67
TOE
3. Rotate the ring gear forward and backward so that the 12 gear
HEEL teeth go past the drive pinion six times to get the contact
patterns. Repeat if needed to get a clearer pattern.
1003090l
Figure 5.65
Always check the tooth contact patterns on the drive side of the gear
teeth. Figure 5.66.
4. Look at the contact patterns on the ring gear teeth. Compare Figure 5.70
the patterns to Figure 5.68, Figure 5.69 and Figure 5.70. LOW PATTERN, HYPOID GENEROID GEARS
The location of good hand-rolled contact patterns for new
conventional and generoid gear sets is toward the toe of the
gear tooth and in the center between the top and bottom of the
tooth. Figure 5.68.
When the carrier is operated, a good pattern will extend
approximately the full length of the gear tooth. The top of the
pattern will be near the top of the gear tooth. Figure 5.71.
1001094a
The location of a good hand-rolled contact pattern for an old gear
Figure 5.70
set must match the wear pattern in the ring gear. The new
contact pattern will be smaller in area than the old wear pattern.
Figure 5.71
A high contact pattern indicates that the drive pinion was not GOOD PATTERN IN OPERATION, GENEROID GEARS
installed deep enough into the carrier. A low contact pattern
indicates that the drive pinion was installed too deep in the
carrier.
앫 If the contact patterns require adjustment: Continue by
following Step 5 to move the contact patterns between the
top and bottom of the gear teeth.
앫 If the contact patterns are in the center of the gear
teeth: Continue by following Step 6.
Figure 5.68 1001095a
GOOD HAND-ROLLED PATTERN,
HYPOID GENEROID GEARS Figure 5.71
1001092c
Figure 5.68
Figure 5.69
1001093a
Figure 5.69
5. Change the thickness of the shim pack under the bearing cage 6. Adjust the backlash of the ring gear within the specification
to move the contact patterns between the top and bottom of range to move the contact patterns to the correct location in
the gear teeth. Use the following procedure. the length of the gear teeth. Refer to the procedure in this
A. Remove the drive pinion and bearing cage from the section.
carrier. Refer to Section 3. A. Decrease the backlash to move the contact patterns
앫 To correct a high contact pattern: Decrease the toward the toe of the ring gear teeth. Figure 5.74.
thickness of the shim pack under the bearing cage. B. Increase the backlash to move the contact patterns
When decreasing the thickness of the shim pack, the toward the heel of the ring gear teeth. Figure 5.75.
drive pinion will move toward the ring gear.
Figure 5.72. C. Repeat Step 2 through Step 4 and Step 6 until the contact
patterns are at the correct location in the length of the
앫 To correct a low contact pattern: Increase the
gear teeth.
thickness of the shim pack under the bearing cage.
When increasing the thickness of the shim pack, the Figure 5.74
Figure 5.74
Figure 5.75
1003102b
Figure 5.72
Loosen adjusting ring.
Decrease backlash.
Figure 5.73 1003104b
Figure 5.75
1003101b
Figure 5.73
CAUTION Installation
If the carrier has cotter pins or capscrews, lock the adjusting
rings only with cotter pins or capscrews. If the carrier has roll Thrust Screw (If Equipped)
pins, reuse the roll pins. Do not force a roll pin into a cotter pin 1. Rotate the carrier in the repair stand until the back surface of
hole. Damage to components can result. the ring gear is toward the TOP.
7. Install the capscrews, cotter pins, roll pins or lock plates, if 2. Install the jam nut onto the thrust screw. Thread the jam nut to
equipped, that hold the two bearing adjusting rings in position. the middle of the thrust screw. Figure 5.77.
Use the following procedures.
Figure 5.77
tab threaded holes. Apply Loctite® 277 threadlocker REAR CARRIER EXAMPLE
even if the capscrews have a locking patch.
Loosen thrust screw
Figure 5.76
1/2 turn.
CAPSCREW COTTER PIN ROLL PIN
LOCK
PLATE
1003105e
Figure 5.76
5. Tighten the jam nut, if equipped, to the correct torque value 1. Use a cleaning solvent and rags to clean the inside of the axle
against the carrier. Refer to Section 8. Figure 5.79. housing and the carrier mounting surface.
To complete the assembly of axles equipped with 2. Inspect the axle housing for damage. Repair or replace the axle
driver-controlled main differential locks, refer to Section 6. housing.
Figure 5.79
3. Check for loose studs, if equipped, in the mounting surface of
the housing where the carrier fastens. Remove and clean the
REAR CARRIER EXAMPLE
studs that are loose.
Hold thrust screw Tighten jam nut to
in position. correct torque value. 4. Apply liquid adhesive to the threaded holes. Install the studs
into the axle housing. Tighten the studs to the correct torque
value. Refer to Section 8. @
CAUTION
Apply silicone gasket material in a continuous 0.25-inch
(6 mm) bead. If you use more than this amount, gasket
1002808c material can break off and plug lubrication passages. Damage
Figure 5.79 to components can result.
앫 Do not use gasoline, or solvents that contain gasoline. 6. Use a hydraulic roller jack or a lifting tool to install the carrier
Gasoline can explode. into the axle housing.
앫 You must use hot solution tanks or alkaline solutions 7. Install nuts and washers or capscrews and washers, if
correctly. Read the manufacturer’s instructions before equipped, into the four corner locations around the carrier and
using hot solution tanks and alkaline solutions. Then axle housing. Hand-tighten the fasteners. Figure 5.81.
carefully follow the instructions.
Figure 5.81
Straight Holes, Nuts and Hardened Washers
1. Clean the mating surfaces of the axle shaft and the wheel hub.
2. If silicone gasket material is used, apply a 0.125-inch (3 mm)
diameter bead of the gasket material around the mating
surface of the hub and around the edge of each fastener hole.
3. Install the gasket and the axle shaft into the housing. The
gasket and the flange of the axle shaft must fit flat against the
wheel hub. Figure 5.82.
1001105c
4. Install the Grade 8 nuts and hardened washers onto the stud.
Figure 5.81 Lock washers are an acceptable alternative. Tighten the stud
nuts to the torque specified in Table P.
8. Carefully push the carrier into position. Tighten the four
fasteners two or three turns each in a pattern opposite each Table P: Shaft-to-Hub Torque Fastener Chart — Non-Tapered
other. Figure 5.81. Dowel Applications
Torque Value —
9. Repeat Step 8 until the four fasteners are tightened to the
Grade 8 Nuts lb-ft (N폷m)
correct torque value. Refer to Section 8.
Fastener Thread Size Plain Nut Locknut
10. Install the other fasteners and washers that hold the carrier in
the axle housing. Tighten fasteners to the correct torque value. Stud Nut, 0.62-18 150-230 130-190
Refer to Section 8. Axle Shaft (244-312) (203-258)
0.75-16 310-400 270-350
11. Connect the driveline universal joint to the pinion input yoke or
(420-542) (366-475)
flange on the carrier.
Studs All Install the coarse thread end of
12. Install the gaskets and axle shafts into the axle housing and the stud into the hub and
carrier. The gasket and flange of the axle shafts must fit flat tighten to the last thread.
against the wheel hub. Figure 5.82.
Figure 5.82
Tapered Dowel, Hardened Washer and Hardened Nut
TAPERED DOWEL RETENTION 1. Clean the mating surfaces of the axle shaft and the wheel hub.
STUD
STUD WASHER 2. If silicone gasket material is used, apply a 0.125-inch (3 mm)
NUT GASKET
TAPERED diameter bead of the gasket material around the mating
DOWEL
surface of the hub and around the edge of each fastener hole.
3. Install the gasket and the axle shaft into the housing. The
gasket and the flange of the axle shaft must fit flat against the
wheel hub. Figure 5.82.
WASHER 4. Install solid tapered dowels over each stud and into the flange
CAPSCREW AXLE SHAFT of the axle shaft. Use a punch or a drift and hammer, if
SHAFT OR HUB
NON-TAPERED FLANGE AXLE necessary.
DOWEL RETENTION 1002581b
Figure 5.82
5. Install the Grade 8 nuts and hardened washers onto the stud.
Lock washers are an acceptable alternative. Tighten the stud
nuts to the torque specified in Table Q.
Figure 6.1
11
9 10
6 8
7 12
5
4 13
1 2 3
15 14
16
22 20 18 17
19
21
22
1001107a
Hazard Alert Messages 2. Install the axle shafts after the vehicle is towed. Refer to
Section 11.
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent 3. If the differential carrier must be removed from the axle
serious personal injury, damage to components, or both. housing, use the following procedures.
WARNING Removal
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. Differential Carrier from the Axle Housing
When you apply some silicone gasket materials, a small Before the differential carrier can be removed or installed, the
amount of acid vapor is present. To prevent serious personal differential lock must be shifted into and held in the locked or
injury, ensure that the work area is well-ventilated. Read the engaged position. The locked position gives enough clearance
manufacturer’s instructions before using a silicone gasket between the shift collar and the axle housing to permit the removal
material, then carefully follow the instructions. If a silicone or installation of the carrier.
gasket material gets into your eyes, follow the manufacturer’s
emergency procedures. Have your eyes checked by a NOTE: If the axle shafts were removed for towing with the
physician as soon as possible. differential in the unlocked or disengaged position, install the
right-hand axle shaft into the housing before removing the
Take care when you use Loctite® adhesive to avoid serious differential carrier. Refer to Section 11.
personal injury. Read the manufacturer’s instructions before
using this product. Follow the instructions carefully to prevent To shift into the locked position, refer to the procedure in this
irritation to the eyes and skin. If Loctite® adhesive material section.
gets into your eyes, follow the manufacturer’s emergency
procedures. Have your eyes checked by a physician as soon Axle Setup for DCDL Disassembly
as possible.
WARNING
Description Park the vehicle on a level surface. Block the wheels to
Some Meritor drive axle models have a driver-controlled main prevent the vehicle from moving. Support the vehicle with
differential lock (DCDL). This differential lock is operated by a safety stands. Do not work under a vehicle supported only by
carrier-mounted, air-actuated shift unit. When activated, the shift jacks. Jacks can slip and fall over. Serious personal injury and
unit moves a sliding collar that is installed on the splines of the axle damage to components can result.
shaft. When engaged, the collar locks the axle shafts together with a
second set of splines on the differential case. When the DCDL is 1. Park the vehicle on a level surface. Block the wheels to prevent
engaged, there is no differential action. Figure 6.1. the vehicle from moving.
NOTE: The Meritor carrier models with driver-controlled differential 2. Remove the drain plug from the bottom of the housing and
lock equipment are manufactured in metric dimensions and sizes. drain the lubricant.
When these carriers are serviced, it is important to use the correct
metric size tools on the fasteners. Refer to Section 8. WARNING
During DCDL disassembly, when the DCDL is in the locked or
Vehicle Towing engaged position and the vehicle’s wheels are raised from the
floor, do not start the engine and engage the transmission. The
CAUTION vehicle can move and cause serious personal injury. Damage
If the vehicle must be towed to a service facility with the drive to components can result.
axle wheels on the ground, remove the axle shafts before the
vehicle is towed. Damage to components can result. 3. Use a jack to raise the vehicle so that the wheels to be serviced
are off the ground. Place safety stands under the spring seats
1. Remove the axle shafts before the vehicle is towed. Refer to to hold the vehicle in the raised position.
Section 11.
Figure 6.3
3. Remove the air line and fitting. Install the manual engaging A. Bolt-on style differential lock cylinder: Remove the
capscrew into the threaded hole in the center of the cylinder sensor switch and locknut.
cover.
B. Remove the four capscrews and washers that hold the
4. Turn the manual adjusting capscrew to the right until the head cylinder cover to the carrier. Remove the cylinder cover
is approximately 0.25-inch (6 mm) from the cylinder cover. Do and copper gasket. Figure 6.5.
not turn the capscrew beyond its normal stop. The capscrew is
C. Remove the shift unit cylinder and piston. Remove the
now in the service position and the main differential lock is
O-ring from the piston.
completely engaged.
D. Remove the shift shaft from the shift fork. The shaft may
5. Remove the carrier from the axle housing. Refer to Section 3.
be secured with liquid adhesive or pre-applied adhesive
material.
Differential and Gear Assembly
E. Remove the shift shaft spring and flat washer. Some
Differential Lock Sliding Collar models use silastic seal instead of the flat washer.
1. For carriers with roll pins, tap out the two retainer roll pins, if F. Remove the shift fork.
equipped, until they are level with the inner face of the shift
fork. Release the differential lock if it is manually engaged.
A. Screw-in style differential lock cylinder: Remove the
Figure 6.4.
sensor switch.
Figure 6.4
2. For carriers without roll pins, snap out the collar from the fork.
3. If required, remove the DCDL assembly at this time.
5. Mark one bearing cap and one carrier leg so that these parts Figure 6.7
will be assembled in the correct positions. Remove the bearing BOLT-ON DCDL
cap capscrews and washers, the bearing caps and the
adjusting rings. 2 3
1
6. Lift the differential and gear assembly from the carrier. Tilt the 5 4
assembly as required to permit the ring gear to clear the
support for the pinion spigot bearing. Figure 6.6. 6
13
11
12
1002860b
SHIFT
Figure 6.6 FORK
ROLL PIN
Installation
DCDL Assembly into the Carrier
INNER
Bolt-On Style Differential Lock Assembly YOKE FACES
until they are level with the inner yoke face. Figure 6.8. Do not
install the pins completely at this time.
2. On models without roll pins, snap the fork into position.
3. Apply Loctite® 222 threadlocker, Meritor part number
2297-B-6112, to the threads of the shift shaft.
4. Install the shift fork into its correct position in the carrier case.
Figure 6.9.
1002862b
Figure 6.9
5. Hold the shift fork in position. Install the shift shaft spring into 9. Install the cylinder into the housing bore. Verify that the pilot
the shift shaft opening in the carrier, through the shift fork bore journal on the piston is against its bore on the shift shaft.
and into the bore for the shift shaft spring. Figure 6.10. Figure 6.12.
SHIFT SHAFT
SHIFT
SHAFT
1002865b
1002863a
Figure 6.12
Figure 6.10
10. Install the copper gasket into its bore on the inside of the
6. Slide the shift shaft over the spring. Install the shaft into the cylinder cover. Place the cover in position over the cylinder so
shift fork. Tighten to 20-25 lb-ft (27-34 N폷m). @ that the air intake port will point UP when the carrier is installed
7. Install the flat washer, when used, or apply silastic sealant, into the housing. Install the cover with the four attaching
Meritor part number 1199-Q-2981, to the bottom of the capscrews and washers. Tighten the capscrews to
cylinder bore. Figure 6.11. 7.4-8.9 lb-ft (10-12 N폷m). Figure 6.7 and Figure 6.13. @
Figure 6.13
Figure 6.11
SHIFT
SHAFT
11. Slide the shift collar into the fork. Engage the shift collar
8. Install the O-ring into its groove on the piston. Lubricate the
splines with the splines of the differential case. Use the manual
O-ring with axle lubricant. Install the piston into the air cylinder.
actuation capscrew to move the shift collar splines into the
Figure 6.11.
differential case splines. Refer to the procedure in this section.
12. Hold the shift collar in the locked or engaged position. If 1. Install the shift spring and fork into the correct position in the
employed, tap the two roll pins into the shift fork ends until they carrier case. Compress the spring slightly while installing
are level with the outer yoke faces. Figure 6.14. the fork.
Figure 6.14 2. Install the shift shaft into the shaft bore of the carrier. Slide the
BOLT-ON STYLE shaft through the shift fork bore and shift spring inside
MANUAL diameter.
SHIFT ACTUATION
COLLAR CAPSCREW
3. Inspect the piston O-ring. Replace the O-ring if there is any
SHIFT evidence of cuts, cracks, abrasion or wear.
FORK
4. Lightly lubricate the O-ring and DCDL cylinder bore with the
same lubricant used in the axle housing.
5. Install the piston and O-ring assembly into the DCDL cylinder.
Slide the piston to the port end of the cylinder.
6. Apply a continuous 0.06-inch (1.5 mm) bead of Loctite® flange
1002867b
sealant, Meritor part number 2297-D-7076, around the DCDL
Figure 6.14
cylinder threads.
13. While the shift collar is still in the locked position, place the 7. Screw the DCDL cylinder in place. Tighten the cylinder to
sensor switch, with the jam nut loosely attached into its hole. 80-100 lb-ft (109-136 N폷m). Figure 6.16. @
14. Connect a volt-ohm meter to the sensor switch. Select ohms Figure 6.16
on the meter. Rotate the switch CLOCKWISE until the meter MANUAL
SCREW-IN STYLE
reading changes from infinity to less than one ohm. Turn the ACTUATION
switch one additional revolution. Tighten the jam nut to CAPSCREW
SHIFT
FORK
4005499b
Figure 6.15
10. Connect a volt-ohm meter to the sensor switch. Select ohms 3. Inspect the bonded lip seal piston. Replace the piston if there is
on the meter. With the DCDL engaged, the circuit should be any evidence of cuts, cracks, abrasion or wear.
closed, showing less than one ohm resistance.
4. Lightly lubricate the bonded lip seal piston and DCDL cylinder
앫 If the resistance value is over one ohm: Check the bore with the same lubricant used in the axle housing.
sensor.
5. Install the bonded lip seal piston assembly into the DCDL
A. Verify that the fork is aligned with the sensor switch when cylinder. Slide the piston to the port end of the cylinder.
it is in the engaged position.
6. Apply a continuous 0.06-inch (1.5 mm) bead of Loctite® flange
B. Check for a loose wiring connection. The connector must sealant, Meritor part number 2297-D-7076, around the DCDL
be tightly seated. cylinder threads.
C. Verify that the sensor switch is fully seated against the 7. Screw the DCDL cylinder in place. Tighten the cylinder to
carrier. 80-100 lb-ft (109-136 N폷m). Figure 6.18. @
앫 If the resistance is greater than one ohm after Figure 6.18
Figure 6.17
SHIFT SHAFT
AND SPRING 1001121a
Figure 6.17 A. Verify that the fork is aligned with the sensor switch when
it is in the engaged position.
1. Install the shift spring and fork into the correct position in the B. Check for a loose wiring connection. The connector must
carrier case. Compress the spring slightly while installing the be tightly seated.
fork. C. Verify that the sensor switch is fully seated against the
2. Install the shift shaft into the shaft bore of the carrier. Slide the carrier.
shaft through the shift fork bore and shift spring inside 앫 If the resistance is greater than one ohm after
diameter. these checks: Replace the sensor switch.
TOP STORAGE HOLE FOR Solvent cleaners can be flammable, poisonous and cause
MANUAL ENGAGING burns. Examples of solvent cleaners are carbon tetrachloride,
CAPSCREW BOLT-ON DCDL
SHIFT ASSEMBLY and emulsion-type and petroleum-base cleaners. Read the
MANUAL manufacturer’s instructions before using a solvent cleaner,
ENGAGING AIR then carefully follow the instructions. Also follow the
CAPSCREW LINE
procedures below.
PLUG
AND CYLINDER 앫 Wear safe eye protection.
GASKET COVER
앫 Wear clothing that protects your skin.
There will be a small amount of spring resistance when you SCREW-IN DCDL SHIFT ASSEMBLY
turn in the manual engaging capscrew. If a high resistance is
STORAGE
felt before reaching the locked or engaged position, stop HOLE
turning the capscrew. Damage to components can result.
CYLINDER
3. Turn the manual adjusting capscrew to the right until the
distance from the head of the capscrew is approximately
0.25-0.50-inch (6-13 mm) from the cylinder cover. Do not turn
the capscrew beyond its normal stop. When the capscrew head
is in the service position 0.25-0.50-inch (6-13 mm) from the top MANUAL
AIR ENGAGING
of the DCDL, the main differential lock is manually engaged. HOSE CAPSCREW 1002870a
A high resistance on the capscrew indicates that the splines of
Figure 6.21
the shift collar and the differential case half are not aligned or
engaged.
10. Tighten the plug, if equipped, to 44-55 lb-ft (60-75 N폷m).
Lift the shift collar as required and rotate to align the splines of Tighten the manual engaging capscrew to 22-28 lb-ft
collar and case half while turning the manual engaging (30-38 N폷m) for bolt-on style cylinders and to 7-11 lb-ft
capscrew inward. When the normal amount of spring (10-15 N폷m) for screw-in type reverse shifters. @
resistance is again felt on the capscrew, the splines are
engaged. Continue to turn in the manual engaging capscrew 11. Connect the vehicle air line to the differential lock actuator
until the 0.25-0.50-inch (6-13 mm) service position is assembly.
achieved.
12. Install the electrical connection on the sensor switch located in
4. Clean both the DCDL actuator and the housing mounting the carrier, below the actuator assembly.
surfaces.
13. Install the right- and left-hand axle shafts. Refer to Section 11.
5. Apply silicone gasket material to the cleaned housing surface
for the DCDL actuator. 14. Remove the safety stands from under the drive axle. Lower the
vehicle to the floor.
6. Remove the short plug and gasket from the storage hole of the
DCDL. 15. Proceed to Check the Differential Lock.
7. Remove the long manual engaging capscrew from the service
position in the center of the DCDL to disengage the main Check the Differential Lock
differential lock. 1. Shift the vehicle transmission into neutral. Start the engine to
8. Clean the plug, gasket, cylinder cover and threaded service get the system air pressure to the normal level.
position hole in the center of the DCDL cylinder cover.
9. Install the manual engaging capscrew into the DCDL storage WARNING
hole in the bolt-on or the screw-in DCDL assembly. Figure 6.19 During DCDL disassembly, when the DCDL is in the locked or
and Figure 6.21. The sealing gasket must be under the head of engaged position and one of the vehicle’s wheels is raised
the capscrew. from the floor, do not start the engine and engage the
transmission. The vehicle can move and cause serious
A. On a bolt-on DCDL shift assembly, remove the short plug personal injury and damage to components.
and gasket from the storage hole of the DCDL.
Install the short plug and gasket into the service position 2. Place the differential lock switch in the cab of the vehicle in the
hole in the center of the DCDL. Figure 6.19. unlocked or disengaged position.
B. On a screw-in DCDL shift assembly, install the short 3. Drive the vehicle at 5-10 mph (8-16 km/h) and check the
screw or plug into the storage hole located in the top of differential lock indicator light. The light must be off when the
the screw-in DCDL shift assembly. Figure 6.21. switch is in the unlocked or disengaged position.
Figure 6.22
CAUTION
This vehicle is equipped with Meritor's Driver-Controlled Full
Locking Differential (DCDL).
1003395b
Figure 6.22
Technical Publications
To obtain these items, refer to the Service Notes page on the front
inside cover of this manual.
앫 DCDL driver caution label, TP-86101
앫 DCDL Driver Instruction Kit (includes DCDL label and technical
bulletin), TP-9579
앫 Traction-Control Video package, T-95125V
Capacities
7 Lubrication
Meritor recommends using a lubricant analysis program. Perform lubricant analysis at regularly-scheduled preventive maintenance intervals.
For complete information on lubricating drive axles and carriers, refer to Maintenance Manual 1, Preventive Maintenance and Lubrication.
To obtain this publication, refer to the Service Notes page on the front inside cover of this manual.
Refer to Table R, Table S, Table T and Table U for standard information on lubricants, schedules and capacities.
* There is no upper limit on these outside temperatures, but the axle sump temperature must never exceed 250° F (121° C).
Table S: Oil Change Intervals and Specifications for All Front Drive and Rear Drive Axles
Construction
Transit Bus
Refuse
Yard Tractor
Logging
City Delivery Heavy Haul
School Bus Mining
Linehaul Fire Truck Oil Field
Vocation or Vehicle Operation Intercity Coach Motorhome Rescue
Initial Oil Change No longer required as of January 1, 1993
Check Oil Level and Breather Every 25,000 miles Every 10,000 miles Every 5,000 miles
(40 000 km) or the fleet (16 000 km), once a month or (8000 km), once a month or
maintenance interval, the fleet maintenance interval, the fleet maintenance interval,
whichever comes first whichever comes first whichever comes first1
Petroleum-based oil change on Every 100,000 miles Every 50,000 miles Every 25,000 miles
axle with or without pump and (160 000 km) or annually, (80 000 km) or annually, (40 000 km) or annually,
filter system whichever comes first whichever comes first whichever comes first
Synthetic oil change on axle with Every 500,000 miles Every 100,000 miles Every 50,000 miles
or without pump and filter system2 (800 000 km) (160 000 km) or annually, (80 000 km) or annually,
whichever comes first whichever comes first
Filter change on axle with pump Every 100,000 miles Every 100,000 miles Every 100,000 miles
and filter system (160 000 km) (160 000 km) (160 000 km)
1
For continuous heavy-duty operation, check the oil level every 1,000 miles (1600 km). Add the correct type and amount of oil as required.
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.
Use the lubricant capacities in Table T and Table U as a guide only. Table T: Single Drive Axles
The capacities are measured with the drive pinion in the horizontal
Capacity*
position. When the angle of the drive pinion changes, the lubricant
Axle Model Pints Liters
capacity of the axle will change.
RS-23-180 39.0 18.6
Table T: Single Drive Axles RS-23-185 39.0 18.6
Capacity* RS-23-186 39.0 18.6
Axle Model Pints Liters RS-25-160 39.0 18.6
MX-10-120 16.0 7.6 RS-25-160A 37.2 17.6
MX-12-120 16.0 7.6 RS-26-160 51.0 24.2
MX-14-120 16.0 7.6 RS-26-180 38.0 18.3
MX-16-120 16.0 7.6 RS-26-185 38.0 18.3
MX-21-160/160R 43.0 20.0 RS-30-180 38.0 18.3
MX-23-160/160R 43.0 20.0 RS-30-185 38.0 18.3
RF-7-120 15.3 7.2
* Includes one pint (0.97 liter) for each wheel end and with a drive pinion
RF-9-120 15.3 7.2
angle at three degrees.
RF-12-120 15.3 7.2
RF-12-125 15.3 7.2 Table U: Rear Axle of Tandems
RF-16-145 36.4 17.2 Capacity
RF-21-155 27.9 13.2 Axle Model Pints Liters
RF-21-156 27.9 13.2 RT-34-140 (RR-17-140) 35.0 16.9
RF-21-160 43.7 20.7 RT-34-144 25.8 12.2
RF-21-185 39.3 18.6 RT-34-145 (RR-17-145 rear) 25.4 12.0
RF-21-355 28.0 13.2 RT-34-145P 25.4 12.0
RF-22-166 43.7 20.7 RT-34-146 25.4 12.0
RF-23-180 39.3 18.6 RT-40-140 (RR-20-140) 25.8 12.2
RF-23-185 39.3 18.6 RT-40-145/149 (RR-20-145 rear) 25.8 12.2
RS-13-120 15.0 7.2 RT-40-145P 25.8 12.2
RS-15-120 15.0 7.2 RT-40-146 25.8 12.2
RS-16-140 33.6 15.9 RT-40-160 34.4 16.3
RS-16-141 33.6 15.9 RT-40-169 34.4 16.3
RS-16-145 33.6 15.9 RT-44-145 (RR-22-145 rear) 25.1 11.9
RS-17-140 32.0 15.4 RT-44-145P 25.1 11.9
RS-17-141 33.6 15.9 RT-46-160/169 (RR-23-160 rear) 34.4 16.3
RS-17-144 32.3 15.3 RT-46-160A/160P 34.4 16.3
RS-17-145 33.6 15.9 RT-46-164 33.2 15.7
RS-19-144 32.3 15.3 RT-46-164EH/16HEH 33.2 15.7
RS-19-145 36.0 17.3 RT-48-180 (RR-24-180 rear) 36.8 17.5
RS-21-145 35.0 16.9 RT-50-160/160P 33.2 15.7
RS-21-160 39.5 18.7 RT-52-160 (RR-26-160 rear) 41.2 19.5
RS-23-160 43/41 20.7/19.5 RT-52-180/185 (RR-26-180 rear) 36.1 17.1
RS-23-160A 39.5 18.7 RT-58-180/185 (RR-29-180 rear) 36.1 17.1
RS-23-161/161A 37.2 17.6
The torque values in Table V are for fasteners that have a light 1. Measure the diameter of the threads in millimeters (mm),
application of oil on the threads. dimension X. Figure 8.2.
앫 If the fasteners are dry: Increase the torque values by Figure 8.2
10 percent.
PITCH
앫 If the fasteners have a heavy application of oil on the
threads: Decrease the torque values by 10 percent.
If you do not know the size of the fastener that is being installed,
measure the fastener. Use the following procedure.
Compare the size of the fastener measured to the list of fasteners X
in Table V to find the correct torque value.
Y
X DIMENSION = EXAMPLE M8 OR 8 MM
American Standard Fasteners Y DIMENSION = DISTANCE OF 10 THREADS
1003114b
1. Measure the diameter of the threads in inches, dimension X.
Figure 8.1. Figure 8.2
Figure 8.1
2. Measure the distance of 10 threads, point to point in
AMOUNT millimeters (mm), dimension Y. Make a note of dimension Y.
OF THREADS
IN 1" Figure 8.2.
1"
3. Divide dimension Y by 10. The result will be the distance
between two threads or pitch.
X
Example
Metric size fastener is M8 x 1.25.
X DIMENSION = EXAMPLE 1/2" 1003113a
앫 M8 is the diameter of the fastener in millimeters (mm) or
Figure 8.1 dimension X.
앫 1.25 is the distance between two threads or pitch.
2. Count the amount of threads in one-inch. Figure 8.1.
Example
American Standard size fastener is 0.50-13.
앫 0.50 is the diameter of the fastener in inches or dimension X.
앫 13 is the amount of threads in one-inch.
Torque Specifications
Figure 8.3
5
4
26
1
14 19
6 25
27 20 22
12 23
24
21
7
16
21
17
15
10
11
18
13
10
9 4000262b
Specifications
10 Special Tools
1 2
12
11
3
10
4
9 5
SPX Kent-Moore
8
part number J-3409-D
1002990f
1 PLATES 8′ LONG x 3/4″ THICK x 1-1/4″ WIDE WITH A TONGUE TO FIT SLOT IN BAR WELD PLATES TO BAR
2 HANDLE 7″ LONG WITH SLOT IN ONE END TO FIT CLAMP SCREW
3 BAR 2″ DIAMETER x 9″ LONG WITH ONE END SLOTTED TO FIT PLATE
4 WELD ALL AROUND AFTER PRESSING PLUG IN PIPE
5 WELD
6 SHAPE AND SIZE OF HOLES TO FIT CARRIER
7 23-1/2″ CENTER TO CENTER OF PIPE
8 CHAMFER END OF PIPE FOR WELDING
9 4″ DIAMETER PIPE
10 PLUG 4″ DIAMETER x 7″ LONG WITH ONE END TURNED 3″ LONG TO FIT PIPE. DRILL 2″ HOLE AND MILL 3/16″ WIDE SLOT 2″ FROM TOP
11 SCREW 3-1/2″ LONG x 5/8″ DIAMETER WITH FLATS ON END TO FIT HANDLE AND 2-1/2″ LENGTH OF THREAD ON OTHER END
12 DRILL 3/8″ HOLE THROUGH HANDLE AND SCREW
Figure 10.1
To obtain a repair stand, refer to the Service Notes page on the front
inside cover of this manual.
How to Make a Yoke Bar 4. Cut a four-foot x 1.25-inch piece of mild steel round stock to
make the yoke bar handle. Center weld this piece to the box
1. Measure dimensions A and B of the yoke you are servicing.
section. Figure 10.3.
Figure 10.2.
앫 To increase yoke bar rigidity: Weld two angle pieces onto
Figure 10.2 the handle. Figure 10.3.
A
Unitized Pinion Seals and Seal Drivers
Refer to Table AG and Figure 10.4 for information on unitized pinion
B
seals and seal drivers. To obtain Meritor seal driver KIT 4454, refer
to the Service Notes page on the front inside cover of this manual.
Figure 10.4
YOKE 1003459b
Position the seal
driver to prevent the
Figure 10.2
driver spokes from
hitting the fastener
2. Calculate dimensions C and D of the yoke bar by adding SEAL heads on the
DRIVER forward tandem
0.125-0.250-inch to dimensions A and B of the yoke.
output seals.
Figure 10.3.
SEAL DRIVER
Figure 10.3
R4422401
FASTENER
YOKE BAR HEADS 1003388c
Figure 10.4
C
1003460b
Figure 10.3
WARNING
Wear safe clothing and eye protection when you use welding
equipment. Welding equipment can burn you and cause
serious personal injury. Follow the operating instructions and
safety procedures recommended by the welding equipment
manufacturer.
Forward input and output seals must be serviced with the seal and sleeve. The service part number provides both when required.
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent Single Axle with DCDL — Screw-In
serious personal injury, damage to components, or both. (Threaded) Shift Assembly, or Tandem Axle
with DCDL — Screw-In (Threaded) Shift
WARNING Assembly and with Inter-Axle Differential (IAD)
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. Before Towing or Drive-Away
Park the vehicle on a level surface. Block the wheels to 1. Park the vehicle on a level surface. Block the wheels to prevent
prevent the vehicle from moving. Support the vehicle with the vehicle from moving.
safety stands. Do not work under a vehicle supported only by 2. Apply the vehicle parking brakes using the switch inside the
jacks. Jacks can slip and fall over. Serious personal injury and cab of the vehicle.
damage to components can result.
3. Shift the transmission into neutral and start the vehicle’s
Before you service a spring chamber, carefully follow the engine.
manufacturer’s instructions to compress and lock the spring to
4. Shift the DCDL and the IAD to the unlocked or disengaged
completely release the brake. Verify that no air pressure
positions using the switches inside the cab of the vehicle.
remains in the service chamber before you proceed. Sudden
The indicator lights in the cab will go off.
release of compressed air can cause serious personal injury
and damage to components. 5. Stop the engine.
Engage the parking brake to prevent the vehicle from moving NOTE: Remove only the axle shaft(s), shown in Table AI at this time,
before you begin maintenance or service procedures that from the axle(s) that will remain on the road when the vehicle is
require you to be under the vehicle. Serious personal injury transported.
can result.
6. Remove the stud nuts or capscrews and washers from the
CAUTION flange of the axle shaft. Figure 11.1.
If the vehicle is equipped with a front drive axle, tow the
vehicle from the front, with the front wheels off the ground. Table AI
If this is not possible, you must remove the front drive shaft Single Axles
before towing. Damage to components can result.
Remove the left-hand, road side, axle shaft
Do not use a chisel or wedge to loosen the axle shaft and Tandem Axles
tapered dowels. A chisel or wedge can result in damage to the
Forward Axle
axle shaft, the gasket and seal, and the axle hub.
Remove the right-hand, curbside, axle shaft
NOTE: For complete towing information, refer to Technical Bulletin Rear Axle
TP-9579, Driver Instruction Kit. To obtain this publication, refer to
the Service Notes page on the front inside cover of this manual. Remove the left-hand, roadside, axle shaft
These instructions supersede all other instructions for the purpose 7. Loosen the tapered dowels, if used, in the flange of the axle
of transporting vehicles for service or new vehicle drive-away dated shaft. Refer to Section 3 for the recommended tools and
before April 1995, including those contained in Meritor maintenance removal procedures.
manuals.
8. Install a cover over the open end of each hub where an axle
When transporting a vehicle with the wheels of one or both drive shaft was removed. This will prevent dirt from entering the
axles on the road, it is possible to damage the axles if the wrong bearing cavity and loss of lubricant.
procedure is used before transporting begins. Meritor recommends
that you use the following procedure.
NOTE: If an air supply will be used for the brake system of the Table AJ
transported vehicle, continue with Step 9 and Step 10, otherwise
Single Axles
continue with Step 11.
Install the right-hand, curbside, axle shaft
9. Connect an auxiliary air supply to the brake system of the Tandem Axles
vehicle that is being transported. Before moving the vehicle,
charge the brake system with the correct amount of air Forward Axle
pressure to operate the brakes. Refer to the instructions Install the left-hand, roadside, axle shaft
supplied by the manufacturer of the vehicle for procedures and Rear Axle
specifications. If an auxiliary air supply is not used, continue
with Step 11. Install the right-hand, curbside, axle shaft
10. When the correct amount of air pressure is in the brake Figure 11.1
system, release the parking brakes of the vehicle that is being SINGLE AXLE OR REAR AXLE OF TANDEM SHOWN
transported. Step 11 is not required. WITH SCREW-IN DCDL SHIFT ASSEMBLY AND
SHOWN IN THE LOCKED OR ENGAGED POSITION
11. If there are spring or parking brakes on the axle(s) that will
remain on the road when the vehicle is transported, and they
cannot be released by air pressure, manually compress and
lock each spring so that the brakes are released. Refer to the
manufacturer’s instructions.
6. Install the dowels, if used, over each stud and into the tapered Single Axle with DCDL — Bolt-On Shift
holes of the flange. Assembly, or Tandem Axle with DCDL —
7. Install the washers and capscrews or stud nuts. Determine the Bolt-On Shift Assembly and with Inter-Axle
size of the fasteners and tighten the capscrews or nuts to the Differential (IAD)
corresponding torque value shown in Table AK.
Before Towing or Drive-Away
Table AK
1. Park the vehicle on a level surface. Block the wheels to prevent
Fastener Thread Size Torque Value lb-ft (N폷m) the vehicle from moving.
Capscrews 0.31"-24 18-24 (24-33) 2. Apply the vehicle parking brakes using the switch inside the
0.50"-13 85-115 (115-156) cab of the vehicle.
Stud Nuts 0.44"-20 50-75 (68-102) 3. Shift the transmission into neutral and start the vehicle’s
Plain Nut 0.50"-20 75-115 (102-156) engine.
0.56"-18 110-165 (149-224) 4. Shift the DCDL and the IAD to the unlocked or disengaged
positions using the switches inside the cab of the vehicle. The
0.62"-18 150-230 (203-312)
indicator lights in the cab will go off.
0.75"-16 310-400 (420-542)
5. Stop the engine.
Locknut 0.44"-20 40-65 (54-88)
0.50"-20 65-100 (88-136) NOTE: Remove only the axle shaft(s), shown in Table AL at this
0.56"-18 100-145 (136-197) time, from the axle(s) that will remain on the road when the vehicle
is transported.
0.62"-18 130-190 (176-258)
0.75"-16 270-350 (366-475) 6. Remove the stud nuts or capscrews and washers from the
flange of the axle shaft. Figure 11.2.
8. Unlock or disengage the DCDL by removing the manual
engaging capscrew from the shift assembly. Table AL
9. Install the manual engaging capscrew into the storage hole. Single Axles
The storage hole of threaded shift assemblies is located in the Remove the left-hand, roadside, axle shaft
shift tower of the carrier next to the cylinder. Tighten the
Tandem Axles
capscrew to 15-25 lb-ft (20-35 N폷m). Figure 11.2. @
Forward Axle
10. Connect the air hose to the shift cylinder. Tighten the air hose
Remove the right-hand, curbside, axle shaft
to 22-30 lb-ft (30-40 N폷m). @
Rear Axle
11. Install the remaining axle shaft into the axle housing and
carrier. Remove the left-hand, roadside, axle shaft
12. Check the lubricant level in the axles and hubs where the axle
shafts were removed. Add the correct type and amount of
lubricant if necessary. Refer to Section 7.
Figure 11.2 11. Remove the plug and gasket from the center of the shift
TAPERED DOWEL RETENTION cylinder cover. Install the plug and gasket into the bottom side
STUD storage hole of the shift cylinder cover, on the opposite end of
STUD WASHER
NUT GASKET the storage hole for the manual engaging capscrew. Tighten
TAPERED
DOWEL the plug to 15-25 lb-ft (20-35 N폷m). Figure 11.3. @
12. Lock or engage the main differential using one of the two
following methods: Air Pressure Method or Manual Engaging
Method.
13. Lock or engage the main differential using the air pressure
WASHER
CAPSCREW method.
AXLE SHAFT
SHAFT OR HUB
FLANGE AXLE
A. Install the manual engaging capscrew into the threaded
NON-TAPERED
DOWEL RETENTION 1002581b hole in the center of the cylinder cover. Turn the capscrew
to the right three to five turns. Figure 11.4.
Figure 11.2
B. Shift the transmission into neutral and start the vehicle’s
7. Loosen the tapered dowels, if used, in the flange of the axle engine. Let the engine idle to increase the pressure in the
shaft. Figure 11.2. air system. Do not release the parking brake.
8. Identify each axle shaft that is removed from the axle assembly C. Shift the main differential to the locked or engaged
so they can be installed in the same location after transporting position using the switch inside the cab of the vehicle.
or repair is completed. When the differential is locked, the indicator light in the
cab will go on.
9. Remove the tapered dowels, gasket, if used, and the axle shaft
from the axle assembly. Figure 11.2. 앫 If the light does not go on: Rotate the main driveline
or the IAD by hand until the main differential is locked
10. Remove the manual engaging capscrew from the storage hole. and the indicator light goes on.
The storage hole of the bolted-on shift assemblies is located in
the top side of the shift cylinder cover. Figure 11.3. NOTE: When the shift collar is completely engaged with the splines
of the main differential case, the differential is locked and the
Figure 11.3
Figure 11.3
Figure 11.4 A. Install the manual engaging capscrew into the threaded
BOLT-ON SHIFT ASSEMBLY hole in the center of the cylinder cover. Figure 11.4.
MANUAL
ENGAGING CAUTION
CAPSCREW When you turn the manual engaging capscrew and you feel a
high resistance, stop turning the capscrew. A high resistance
against the capscrew indicates that the splines of the shift
collar and differential case are not aligned. Damage to the
threads of the cylinder cover and capscrew will result.
8
1002616b
15. Remove the remaining axle shaft(s) from the axle(s) that will NOTE: Install only the axle shaft(s) shown in Table AM at this time.
remain on the road when the vehicle is transported. These axle shafts have a double row of splines that engage with the
splines of the side gear and shift collar in the main differential.
16. Install a cover over the open end of each hub where an axle
Figure 11.5.
shaft was removed. This will prevent dirt from entering the
bearing cavity and loss of lubricant.
5. Install the gasket, if used, and axle shaft into the axle housing
and carrier in the same location. The gasket and flange of the
NOTE: If an air supply will be used for the brake system of the
axle shaft must be flat against the hub. Rotate the axle shaft or
transported vehicle, continue with Step 17 and Step 18. Otherwise,
the driveline as necessary to align the splines and the holes in
continue with Step 19.
the flange with the studs in the hub. Figure 11.2.
17. Connect an auxiliary air supply to the brake system of the
Table AM
vehicle that is being transported. Before moving the vehicle,
charge the brake system with the correct amount of air Single Axles
pressure to operate the brakes. Refer to the instructions Install the right-hand, curbside, axle shaft
supplied by the manufacturer of the vehicle for procedures and
Tandem Axles
specifications. If an auxiliary air supply is not used, continue
with Step 19. Forward Axle
Install the left-hand, roadside, axle shaft
18. When the correct amount of air pressure is in the brake
system, release the parking brakes of the vehicle that is being Rear Axle
transported. Step 19 is not required. Install the right-hand, curbside, axle shaft
19. If there are spring or parking brakes on the axle(s) that will
remain on the road when the vehicle is transported, and they 6. Install the dowels, if used, over each stud and into the tapered
cannot be released by air pressure, manually compress and holes of the flange.
lock each spring so that the brakes are released. Refer to the 7. Install the washers and capscrews or stud nuts. Determine the
manufacturer’s instructions. size of the fasteners and tighten the capscrews or nuts to the
torque value shown in Table AN.
After Towing or Drive-Away
1. If an auxiliary air supply was used, apply the vehicle parking Table AN
brakes using the switch inside the cab of the vehicle. If an
Fastener Thread Size Torque Value lb-ft (N폷m)
auxiliary air supply was not used, begin with Step 2.
Capscrews 0.31"-24 18-24 (24-33)
2. Apply the vehicle spring or parking brakes by manually
0.50"-13 85-115 (115-156)
releasing each spring that was compressed before transporting
started. Refer to the manufacturer’s instructions. Stud Nuts 0.44"-20 50-75 (68-102)
3. Disconnect the auxiliary air supply, if used, from the brake Plain Nut 0.50"-20 75-115 (102-156)
system of the vehicle that was transported. Connect the 0.56"-18 110-165 (149-224)
vehicle’s air supply to the brake system. 0.62"-18 150-230 (203-312)
4. Remove the covers from the hubs. 0.75"-16 310-400 (420-542)
Locknut 0.44"-20 40-65 (54-88)
0.50"-20 65-100 (88-136)
0.56"-18 100-145 (136-197)
0.62"-18 130-190 (176-258)
0.75"-16 270-350 (366-475)
1. Park the vehicle on a level surface. Block the wheels to prevent 10. Install a cover over the open end of each hub where an axle
the vehicle from moving. shaft was removed. This will prevent dirt from entering the
bearing cavity and loss of lubricant.
2. Apply the vehicle parking brakes using the switch inside the
cab of the vehicle. NOTE: If an air supply will be used for the brake system of the
transported vehicle, continue with Step 11 and Step 12, otherwise
NOTE: For a single axle, continue with Step 6. For a tandem axle, continue with Step 13.
continue with Step 3.
11. Connect an auxiliary air supply to the brake system of the
3. Shift the transmission into neutral and start the vehicle’s vehicle that is being transported. Before moving the vehicle,
engine. charge the brake system with the correct amount of air
4. Shift the IAD to the unlocked or disengaged position using the pressure to operate the brakes. Refer to the instructions
switch inside the cab of the vehicle. The indicator light in the supplied by the manufacturer of the vehicle for procedures and
cab will go off. specifications. If an auxiliary air supply is not used, continue
with Step 13.
5. Stop the engine.
12. When the correct amount of air pressure is in the brake
NOTE: Remove both axle shafts from the axle(s) that will remain on system, release the parking brakes of the vehicle that is being
the road when the vehicle is transported. transported. Step 13 is not required.
13. If there are spring or parking brakes on the axle(s) that will
6. Remove the stud nuts or capscrews and washers from the
remain on the road when the vehicle is transported and they
flange of the axle shaft. Figure 11.7.
cannot be released by air pressure, manually compress and
7. Loosen the tapered dowels, if used, in the flange of the axle lock each spring so that the brakes are released. Refer to the
shaft. Figure 11.7. manufacturer’s instructions.
Table AO
Fastener Thread Size Torque Value lb-ft (N폷m)
Capscrews 0.31"-24 18-24 (24-33)
0.50"-13 85-115 (115-156)
Stud Nuts 0.44"-20 50-75 (68-102)
Plain Nut 0.50"-20 75-115 (102-156)
0.56"-18 110-165 (149-224)
0.62"-18 150-230 (203-312)
0.75"-16 310-400 (420-542)
Locknut 0.44"-20 40-65 (54-88)
0.50"-20 65-100 (88-136)
0.56"-18 100-145 (136-197)
0.62"-18 130-190 (176-258)
0.75"-16 270-350 (366-475)
8. Check the lubricant level in the axles and hubs where the axle
shafts were removed. Add the correct type and amount of
lubricant if necessary. Refer to Section 7.
Troubleshooting
12 Diagnostics
Visually inspect
the carrier in
the axle housing.
When the carrier is When the carrier is
reassembled later, Yes Backlash No reassembled later, set
Remove the within spec?
set the backlash to the backlash to spec.
carrier from the
the recorded reading. Refer to Section 4.
axle housing.
Yes Repair the carrier
Damaged?
or install a Remove the main
remanufactured differential and
carrier. Refer ring gear from
No to Section 2. the carrier. Refer
to Section 2.
Drain and inspect
the lubricant.
Refer to MM 1. Inspect the main differential bearings
for damage. Refer to TP-9955, Failure
Analysis for Drive Axle Components.
Yes Determine
Contaminated? the source of Repair the carrier
contamination. Yes or install a
Damaged? remanufactured
carrier. Refer
No
to Section 4.
No
Check the drive pinion end play.
Refer to Section 4. Any end play Disassemble the main differential
looseness indicates possible and ring gear. Refer to Section 2.
bearing damage.
Visually inspect
the carrier in
the axle housing.
When the carrier is When the carrier is
reassembled later, Yes Backlash No reassembled later, set
Remove the carrier set the backlash to within spec? the backlash to spec.
from the axle housing. the recorded reading. Refer to Section 4.
Repair the carrier
Yes
Damaged? or install a Remove the main
remanufactured differential and
carrier. ring gear from
No Refer to Section 2. the carrier. Refer
to Section 2.
Oil Leak
Figure 12.3
Visually inspect
the carrier in
the axle housing.
Clean and prepare the
housing and carrier
flanges. Apply the correct
Remove the carrier
gasket or silicone.
Yes from the axle housing.
Refer to Section 4.
Damaged? Repair the carrier
or install a
remanufactured
No carrier.
Install the carrier.
Refer to Section 5.
Inspect the
breather.
No
Visually
inspect the
lubricant.
Yes
Remove the
carrier from
Test drive the the axle. Refer to
vehicle to confirm Section 3.
that the leak is
repaired. Return the
vehicle to service.