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Rear AxleSingle-Reduction Carrier

Model MS-113Maintenance Manual MM-0230

Revised 08-10

Service Notes

Service NotesService Notes

About This Manual

This manual provides instructions for Meritor’s model MS-113 single-reduction rear axle.

Before You Begin

1. Read and understand all instructions and procedures before you begin to service components.

2. Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or both.

3. Follow your company’s maintenance and service, installation, and diagnostics guidelines.

4. Use special tools when required to help avoid serious personal injury and damage to components.

Hazard Alert Messages and Torque Symbols

WARNING

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

CAUTION

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

This symbol alerts you to tighten fasteners to a specified torque value.

How to Obtain Additional Maintenance and Service Information

On the Web

Visit Literature on Demand at arvinmeritor.com to access and order product, service, aftermarket, and warranty literature for ArvinMeritor’s truck, trailer and specialty vehicle components.

Literature on Demand DVD (LODonDVD)

The LODonDVD contains product, service and warranty information for ArvinMeritor components. To order the DVD, visit Literature on Demand at arvinmeritor.com and specify TP-0742.

How to Obtain Supplies Specified in This Manual

Call ArvinMeritor’s Commercial Vehicle Aftermarket at 888-725-9355 to obtain Meritor supplies.

SPX Kent-Moore, 28635 Mound Road, Warren, Michigan, 48092. Call the company’s customer service center at 800-345-2233, or visit their website at spxkentmoore.com.

T

Table of Contents

Table of ContentsExploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Section 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Section 2: Removal and Disassembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Axle Shafts from the Axle Assembly Differential Carrier from the Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Differential Case and Ring Gear from the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Drive Pinion from the Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Differential Case and Ring Gear Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Section 3: Prepare Parts for Assembly Clean Ground and Polished Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Clean Rough Parts Clean Axle Assemblies Dry Parts After Cleaning Prevent Corrosion on Cleaned Parts Inspect Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Repair or Replace Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Repair Welding on Axle Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11For Complete Welding Instructions on Meritor Drive Axle Housings Prepare the AxleDo Not Bend or Straighten a Damaged Drive Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Removing Fasteners Secured with Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Install Fasteners New Fasteners with Pre-Applied Adhesive Original or Used Fasteners Using Meritor Liquid Adhesive 2297-C-7049 or

Loctite® 680 Adhesive, or Equivalent Applying Meritor Specification 2297-T-3994, Loctite® 680 Adhesive, or Equivalent in the Bearing Bores Differential Applying Loctite® 5699 Silicone Gasket Material, or Equivalent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Gear Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Examples

Section 4: Assembly and Installation Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Drive Pinion Differential Case and Ring Gear Differential Gears Rotating Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Installation Drive Pinion into the Carrier Differential Case and Ring Gear into the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Adjust Differential Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Check Ring Gear Runout (Radial Movement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Ring Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Check the Tooth Contact Patterns (Backlash) of the Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Differential Carrier into the Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Axle Shafts in the Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Fill the Axle with Lubricant

Table of Contents

Section 5: Diagnostics Vehicle Will Not Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Differential Making Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Oil Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Contaminated Lubricant Found During Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Section 6: Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Section 7: Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Section 8: Towing Instructions Before Towing or Drive-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36After Towing or Drive-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Section 9: Special Tools Carrier Repair Stand Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38How to Make a Yoke Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Seal Driver Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Exploded View

ArvinMeritor Maintenance Manual MM-0230 Copyright 2010(Revised 08-10) ArvinMeritor, Inc. Page i

Exploded View

1 Locknut, M32 x 1.5 13 Inner Bearing Cup 25 Side Gear

2 Yoke 14 Carrier 26 Differential Pinion Shaft3 Seal 15 Differential Cap Capscrew, M14 x 2.0 27 Differential Case4 Screws, M6 x 1.0 16 Cotter Pins 28 Differential Case Capscrew, M12 x 1.75

5 Lock Plate 17 Thrust Washer 29 Carrier-to-Housing Capscrew, M12 x 1.75 x 606 Pinion Cage 18 Differential Pinion 30 Carrier-to-Housing Capscrew, M12 x 1.75 x 307 O-Ring 19 Adjusting Ring 31 Breather

8 Outer Bearing Cup 20 Bearing Cup 32 Axle Housing9 Outer Bearing Cone 21 Bearing Cone 33 Fill Plug10 Drive Pinion 22 Ring Gear 34 Drain Plug

11 Shim 23 Differential Case — Ring Gear Side 35 Axle Shaft12 Inner Bearing Cone 24 Thrust Washer

12

3

4

11

1312

14

10

5

9

76

8

272821

1920

24

16

25

15

17

18

26

17

18

25

23

24

2221

1920

3334

32

31

29

30

35

35

Section 1Introduction

ArvinMeritor Maintenance Manual MM-0230 Copyright 2010(Revised 08-10) ArvinMeritor, Inc. Page 1

Section 1IntroductionMeritor’s model MS-113 single-reduction rearaxle has a single-reduction carrier, which is front-mounted into the axle housing. Figure 1.1. The carrier has a hypoid drive pinion and ring gear set. Bevel gears are used in the differential assembly. All bearings in the carrier are tapered roller bearings.

When the carrier operates, there is normal differential action between the wheels all the time.

Figure 1.1

1 ADJUSTING RING

2 CARRIER

3 RING GEAR AND DRIVE PINION

4 TAPERED ROLLER BEARING

5 TAPERED ROLLER BEARING

6 HOUSING

7 DIFFERENTIAL PINION

8 COTTER PIN

1

2

4

3

58

7

6

Section 2Removal and Disassembly

Copyright 2010 ArvinMeritor Maintenance Manual MM-0230Page 2 ArvinMeritor, Inc. (Revised 08-10)


WARNING

To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.

Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result.

Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury.

Removal

Axle Shafts from the Axle Assembly

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

2. Raise the rear end of the vehicle so that the rear wheels are off the ground. Support the vehicle with safety stands. Figure 2.1.

3. Place a drain pan under the rear axle.

4. Remove the drain plug from the bottom of the axle housing. Drain the lubricant from the assembly. Install the drain plug and tighten it to 35-50 lb-ft (48-67 N•m).

5. Disconnect the driveline universal joint from the pinion input yoke on the carrier. Figure 2.2.

Figure 2.1

T

SAFETYSTANDS

1002983a

Figure 2.2

1 FULL ROUND BEARING CUPS

2 END YOKE

3 YOKE SADDLE

4 WELD YOKE

5 BEARING STRAP

6 CAPSCREWS

7 EASY-SERVICE BEARING CUPS

8 U-JOINT CROSS

9 SLIP YOKE

10 CAPSCREWS

11 END YOKE

12 WELD YOKE

13 SLIP YOKE

14 U-JOINT CROSS

15 CAPSCREWS

16 END YOKE

17 WELD YOKE

18 SLIP YOKE

19 U-JOINT CROSS

20 CAPSCREWS

21 END YOKE

22 SLIP YOKE

23 TUBING

24 U-JOINT CROSS

25 WELD YOKE

12

13

11

14

10

7

8

6

45

1

2

3

9

16

15

17

18

19

1002984b

EASY SERVICETM

WING SERIESPERMALUBETM

FULL-ROUND

“RPL” SERIES,PERMALUBETM

2324

22

2021

25



6. Remove the capscrews from the flanges of both axle shafts. Figure 2.3.

7. Mark each axle shaft before you remove it from the axle assembly.

Differential Carrier from the Axle Housing

1. Place a hydraulic roller jack under the carrier. Figure 2.4.

NOTE: Two capscrews in the TOP of the carrier housing secure the carrier.

2. Remove all of the capscrews that secure the carrier to the axle housing, except the two capscrews in the TOP of the carrier.

3. Loosen the two capscrews in the TOP of the carrier, but do not remove them.

4. Loosen the carrier by striking the mounting flange at several points with a dead-blow hammer. Remove the two capscrews in the TOP of the carrier that secure the carrier to the axle housing.

5. Use a hydraulic roller jack and pry bar with a round end to remove the carrier from the axle housing. Take care when you use the pry bar so that you don’t damage the carrier or housing flange.

WARNING

To avoid serious personal injury and damage to components, take care when using lifting devices during service and maintenance procedures. Inspect a lifting strap to ensure that it is not damaged. Do not subject lifting straps to shocks or drop-loading.

NOTE: A carrier stand is available from SPX Kent-Moore. Refer to the Service Notes page on the front inside cover of this manual to obtain the stand.

6. Use a lifting tool to place the carrier into a carrier stand. Figure 2.5. Refer to Section 9 to build a stand.

Figure 2.3

1 CAPSCREW

2 AXLE SHAFT FLANGE

3 AXLE SHAFT HUB

Figure 2.4

321

WOODBLOCK

ROLLERJACK 1002709c

Figure 2.5

1 DIFFERENTIAL CARRIER

2 REPAIR STAND

2

1



Differential Case and Ring Gear from the Carrier

NOTE: Before working on the differential carrier, inspect the gear set for damage. If the gear set is not damaged, it can be reused. Measure the backlash of the gear set and record the dimension. Figure 2.6. Refer to Section 4.

1. Remove the cotter pins from the side gear adjusting rings. Figure 2.7.

2. Remove the differential bearing cap capscrews and the cap. Figure 2.8.

3. Remove the differential adjusting ring and bearing cup from bolted-on bearing cap side. Figure 2.9.

4. Remove the differential assembly from the carrier and place it onto a workbench.

5. Remove the differential adjusting ring and bearing cup from integral bearing cap side.

Drive Pinion from the Carrier

1. Fasten a yoke bar onto the yoke to hold the yoke when you remove the locknut. Figure 2.10. Refer to Section 9 to build a yoke bar.

2. Remove the yoke locknut. Figure 2.11. Remove the yoke bar.

Figure 2.6

Figure 2.7

1 COTTER PIN

11

Figure 2.8

1 CAPSCREWS

2 DIFFERENTIAL CAP

Figure 2.9

1 BEARING CUP

2 ADJUSTING RING

1

2

1

2



3. Remove the yoke from the drive pinion.

� If the yoke is tight on the drive pinion: Use a puller to remove the yoke.

4. Remove the lock plate capscrews and the lock plate. Figure 2.12.

5. Use a spanner wrench to unscrew the pinion cage from the carrier.

6. Remove the pinion cage and the drive pinion from the carrier.

7. Remove the drive pinion inner bearing cup from the carrier.

Disassembly

WARNING

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

Differential Case and Ring Gear

1. Remove the capscrews from the differential case. Figure 2.13.

Figure 2.10

1 YOKE BAR

Figure 2.11

1 LOCK PLATE

2 CAPSCREW

3 PINION CAGE

4 YOKE LOCKNUT

1

3

4

1

2

Figure 2.12

1 CAPSCREW

2 LOCK PLATE

Figure 2.13

1 CAPSCREWS

2

1

1



2. Separate the differential case halves. Figure 2.14. Remove the thrust washer and side gear. Figure 2.15.

3. Remove the differential pinion shaft, differential pinions and thrust washers. Figure 2.16.

4. Remove the side gear and thrust washer. Figure 2.17. Use a brass hammer to remove the ring gear from the differential case.Figure 2.18.

Figure 2.14

Figure 2.15

1 THRUST WASHER

2 SIDE GEAR

1

2

Figure 2.16


2 THRUST WASHER

3 DIFFERENTIAL PINION SHAFT

Figure 2.17

1 SIDE GEAR

2 THRUST WASHER

Figure 2.18

1 RING GEAR

2 DIFFERENTIAL CASE

1 2

3

1

2

1 2



5. Use a bearing puller or a press to remove the bearing cones from both halves of the differential case. Figure 2.19.

Drive Pinion

1. Remove and discard the pinion cage O-ring. Figure 2.20.

2. Remove the outer bearing cup and seal from the pinion cage. Discard the seal.

3. Use a bearing puller or a press to remove the inner and outer bearing cones from the drive pinion.

4. Remove the shim from the drive pinion.

Figure 2.19

1 DIFFERENTIAL CASE

Figure 2.20

1 PINION CAGE

2 O-RING

3 OUTER BEARING CUP

4 OUTER BEARING CONE

5 DRIVE PINION

6 SHIM

7 INNER BEARING CONE

1

1

7

23 4 5

6

Section 3Prepare Parts for Assembly


Section 3 Prepare Parts for Assembly

WARNING


Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion-type cleaners and petroleum-based cleaners. To avoid serious personal injury when you use solvent cleaners, you must carefully follow the manufacturer’s product instructions and these procedures:

� Wear safe eye protection.

� Wear clothing that protects your skin.

� Work in a well-ventilated area.

� Do not use gasoline, or solvents that contain gasoline. Gasoline can explode.

� You must use hot solution tanks or alkaline solutions correctly. Follow the manufacturer’s instructions carefully.

Clean Ground and Polished Parts

1. Use a cleaning solvent to clean ground or polished parts or surfaces. Kerosene or diesel fuel oil can be used for this purpose. DO NOT USE GASOLINE.

2. Use a tool with a flat blade if required, to remove sealant material from parts. Be careful not to damage the polished or smooth surfaces.

CAUTION

Do not use hot solution tanks or water and alkaline solutions to clean ground or polished parts. Damage to parts will result.

3. Do not clean ground or polished parts with water or steam. Do not immerse ground or polished parts in a hot solution tank or use strong alkaline solutions for cleaning, or the smooth sealing surface may be damaged.

Clean Rough Parts

1. Clean rough parts with the same method as cleaning ground and polished parts.

2. Rough parts can be cleaned in hot solution tanks with a weak or diluted alkaline solution.

3. Parts must remain in hot solution tanks until heated and completely cleaned.

4. Parts must be washed with water until all traces of the alkaline solution are removed.

Clean Axle Assemblies

1. A complete axle assembly can be steam cleaned on the outside to remove dirt.

2. Before the axle is steam cleaned, close or place a cover over all openings in the axle assembly. Examples of openings are breathers or vents in air chambers.

Dry 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.

3. Except for bearings, parts can be dried with compressed air.

Prevent Corrosion on Cleaned Parts

1. Apply axle lubricant to cleaned and dried parts that are not damaged and are to be assembled.

2. To store parts, apply a special material that prevents corrosion to all surfaces. Wrap cleaned parts in a special paper that will protect the parts from moisture and prevent corrosion.



Inspect Parts

It is very important to inspect all parts carefully and completely before the axle or carrier is assembled. Check all parts for wear and replace damaged parts.

1. Inspect the cup, cone, rollers and cage of all tapered roller bearings in the assembly. If any of the following conditions exist, replace the bearing.

� The center of the large-diameter end of the rollers is worn level with or below the outer surface. Figure 3.1.

� The radius at the large-diameter end of the rollers is worn to a sharp edge. Figure 3.1.

� There is a visible roller groove in the cup or cone inner race surfaces. The groove can be seen at the small- or large-diameter end of both parts. Figure 3.2.

� There are deep cracks or breaks in the cup, cone inner race or roller surfaces.Figure 3.2.

� There are bright wear marks on the outer surface of the roller cage. Figure 3.3.

� There is damage on the rollers and on the surfaces of the cup and cone inner race that touch the rollers. Figure 3.4.

� There is damage on the cup and cone inner race surfaces that touch the rollers.Figure 3.5.

Figure 3.1

1003017b

WORN RADIUS

WORN SURFACE

Figure 3.2

Figure 3.3

Figure 3.4

1003018b

WEARGROOVES

CRACK

1003019aWEAR MARKS

1003020a

ETCHING AND PITTING



CAUTION

A drive pinion and ring gear is 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.

2. Inspect pinions and gears for wear or damage. Replace gears that are worn or damaged.

CAUTION

A thrust washer, differential side gear and pinion gear are machined as a matched set. When you replace any of these parts, you must install a new matched set. Do not mix old and new parts. Damaged to components can result.

3. Inspect the following main differential assembly parts for wear or stress. Replace parts that are damaged. Figure 3.6.

� Inside surfaces of both case halves

� Both surfaces of all thrust washers

� The differential pinion shaft

� Teeth and splines of both differential side gears

� Teeth and bore of all differential pinions

4. Inspect axle shafts for wear and cracks at the flange, shaft and splines. Replace the axle shafts, if required.

Repair or Replace Parts

NOTE: Threads must be without damage and clean so that accurate adjustments and correct torque values can be applied to fasteners and parts.

1. Replace any fastener if corners of the head are worn.

2. Replace washers if damaged.

3. Replace gaskets, oil seals or grease seals at the time of axle or carrier repair.

4. Clean parts and apply new silicone gasket material where required when the axle or carrier is assembled. Figure 3.7.

5. Remove nicks, marks and burrs from parts with machined or ground surfaces. Use a fine file, india stone, emery cloth or crocus cloth.

6. Clean and repair threads of fasteners and holes. Use a die, a tap of the correct size, ora fine file.

Figure 3.5

1003021b

SPALLING AND FLAKING

Figure 3.6

1 CASE HALVES

2 PINION AND THRUST WASHER

3 SIDE GEAR AND THRUST WASHER


1

2

2

3

4

3 1



Repair Welding on Axle Housings

For Complete Welding Instructions on Meritor Drive Axle Housings

Refer to Maintenance Manual 8, Drive Axle Housings. To obtain this publication, refer to the Service Notes page on the front inside cover of this manual.

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 manufacturers.

Axle weld locations and welding procedures must adhere to Meritor‘s standards. Welding at locations other than those authorized by Meritor will void the warranty and can reduce axle beam fatigue life. Serious personal injury and damage to components can result.

Meritor permits drive axle housing assembly repair welding in the following locations only.

� Housing-to-cover weld joints

� Snorkel welds

� Housing seam welds between the suspension attaching brackets

� Bracket welding to the drive axle housing

Prepare the Axle

WARNING

The high temperature caused by the open flame from the cutting torch can ignite the oil in the axle housing and can cause serious personal injury.

1. Remove the oil drain plug from the bottom of the axle housing and drain the lubricant from the assembly.

CAUTION

Remove the differential carrier from the axle housing before you weld onto an axle. Do not weld onto an axle with the differential carrier installed. Electrical arching and damage to components can result.

2. Remove the differential carrier from the axle housing. Refer to the correct Meritor carrier maintenance manual or the vehicle manufacturer’s instructions.

CAUTION

Remove the brake air chambers before you weld onto an axle. Do not expose a brake air chamber to more than 250°F (121°C). Damage to the air chamber can result.

3. Remove the wheel-end components and brake air chambers from the axle. Refer to the correct Meritor brake maintenance manual or the vehicle manufacturer’s instructions.

4. For housing-to-cover welds, clean the outside housing-to-cover weld area 2.00-3.00-inches (50.8-76.2 mm) past each end or side of the crack. Clean the inside area where the cover mates with the housing. Clean the area completely around the cover. Use a wire brush and a cleaning solvent that will remove dirt and grease from these areas. Figure 3.8.

Figure 3.7

1 REMOVE SILICONE GASKET FROM PARTS.

1003028b

1



5. For suspension bracket welds, clean both lower and upper suspension brackets and the areas of the axle housing around each bracket. Use a wire brush and a cleaning solvent that will remove dirt and grease from these areas. Figures 3.9 and 3.10.

WARNING

The axle housing must be 70°F (21°C) or warmer before you weld onto the axle. Do not weld onto a cold axle or weld cold parts onto an axle. Cracks in the weld area, damage to components and serious personal injury can result.

6. Ensure that the axle housing temperature measures 70°F (21°C) or warmer.

� If the axle housing temperature measures less than 70°F (21°C): Store the axle in a heated room until the housing reaches the correct temperature.

7. Heat the damaged area to approximately 300°F (149°C) before you begin welding.

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 equivalents E7018 and ER70S3, respectively).

9. For complete welding instruction, refer to Maintenance Manual 8. To obtain this publication, refer to the Service Notes page on the front inside cover of this manual.

Do Not Bend or Straighten a Damaged Drive Axle Housing

WARNING

Replace damaged or out-of-specification axle components. Do not bend, repair or recondition axle components by welding or heat-treating. A bent axle beam reduces axle strength, affects vehicle operation and voids Meritor’s warranty. Serious personal injury and damage to components can result.

Always replace a damaged drive axle housing. Do not bend or straighten a damaged housing, which can misalign or weaken it, and void Meritor’s warranty.

Figure 3.8

Figure 3.9

Figure 3.10

Clean this area.4000309a

Clean these areas.

4000310a

LOWER

BRACKET

Clean this area.

4000310a

Clean these areas.

UPPERBRACKET



Removing Fasteners Secured with Adhesive

If it’s difficult to remove fasteners secured with Dri-Loc®, Meritor specification 2297-P-3994, Loctite® 680 adhesive, or equivalent, use the following procedure.

CAUTION

When you remove fasteners secured with adhesive, slowly heat the fastener to 350°F (177°C). Do not exceed this temperature, or heat fasteners quickly. Damage to components can result.

1. Heat a fastener for three to five seconds only. Try to loosen the fastener with a wrench. Do not use an impact wrench or hit the fastener with a hammer.

2. Repeat Step 1 until you can remove the fastener.

Install Fasteners

New Fasteners with Pre-Applied Adhesive

NOTE: No drying time is required for fasteners with pre-applied adhesive.

1. Use a wire brush to clean oil and dirt from threaded holes.

2. Install new fasteners with pre-applied adhesive to assemble parts. Do not apply adhesives or sealants to fasteners with pre-applied adhesive, or to fastener holes.

3. Tighten fasteners to the required torque value for that size fastener.

Original or Used Fasteners Using Meritor Liquid Adhesive 2297-C-7049, Loctite® 680 Adhesive, or Equivalent

WARNING

Take care when you use Loctite® to avoid serious personal injury. Follow the manufacturer’s instructions to prevent irritation to the eyes and skin.

1. Use a wire brush to clean the oil, dirt and old adhesive from all threads and threaded holes.

2. Apply four or five drops of Meritor liquid adhesive, Loctite® 680 adhesive, or equivalent, inside each threaded hole or bore. Do not apply adhesive directly to fastener threads. Figure 3.11.

NOTE: There is no drying time required for Meritor specification 2297-C-7049 liquid adhesive, Loctite® 680 adhesive, or equivalent.

3. Tighten the fasteners to the required torque value for that size fastener.

Applying Meritor Specification 2297-P-3994, Loctite® 680 Adhesive, or Equivalent in the Bearing Bores Differential

NOTE: Use Meritor specification 2297-P-3994, Loctite® 680 adhesive, or equivalent for all axles. To obtain this adhesive, refer to the Service Notes page on the front inside cover of this manual.

1. Clean the oil and dirt from the outer diameters of the bearing cups and bearing bores in the carrier and bearing caps. There is no special cleaning required.

2. Apply axle lubricant to the bearing cones and the inner diameters of the bearing cups of the main differential. Do not get oil onto the outer diameter of the bearing cup and do not permit oil to drip onto the bearing bores.

Figure 3.11

1003025a

FOUR TOFIVE DROPS

ON BORETHREADS



3. Apply a single continuous bead of adhesive to the bearing bores in the carrier and bearing cap. Apply the adhesive around the circumference of the smooth, ground surfaces only. On the integral cap side, apply the adhesive near the thread end. Do not apply adhesive onto the threaded areas. Figure 3.12.

NOTE: Meritor specification 2297-P-3994, Loctite® 680 adhesive, or equivalent will dry in approximately two hours. Perform Steps 4 and 5 within two hours from the time you apply the adhesive. If two hours have passed since application, clean the adhesive from the parts and apply new adhesive.

4. Install the main differential assembly, bearing cups and bearing cap into the carrier. The bearing cup of the integral bearing cap side must be assembled from the thread side. Refer to Section 4. Remove excess adhesive after assembly.

5. Adjust the preload of the differential bearings, backlash and tooth contact patterns of the gear set as required. Refer to Section 4.

Applying Loctite® 5699 Silicone Gasket Material, or Equivalent

WARNING

When you apply some silicone gasket materials, small amounts of acid vapor are present. To prevent serious personal injury, ensure that the work area is well ventilated. If the silicone gasket material gets into your eyes, flush them with water for 15 minutes. Have your eyes checked by a physician as soon as possible.

NOTE: The following silicone gasket products or equivalent can be used for Meritor components:

� Loctite® 5699 silicone gasket material

� Loctite® 18581 Ultra Grey adhesive/sealant

� Meritor gasket material/part number 2297-F-7052. To obtain this gasket material, refer to the Service Notes page on the front inside cover of this manual.

1. Use a tool with a flat blade, if required, to remove all old gasket material from surfaces. Figure 3.13.

2. Use a cleaning solvent to clean the surfaces where you will apply silicone gasket material. Remove all oil, grease, dirt and moisture without damaging the mating surfaces.Figure 3.13.

3. Dry surfaces.

Figure 3.12

ADHESIVE BEARINGCAP

CARRIERLEG

1003026a

Figure 3.13

1003027c

sealant material.

HOUSING AND CARRIERSHOWN



CAUTION

Apply silicone gasket material in a continuous 1/8-inch (3 mm) bead. If you use more than this amount, the gasket material can break off and plug lubrication passages. Damage to components can result.

4. Apply a 1/8-inch (3 mm) diameter continuous bead of the silicone gasket material around one surface. Also apply the gasket material around the edge of all fastener holes on that surface. Figure 3.14.

5. Assemble the components immediately to permit the silicone gasket material to compress evenly between the parts. Tighten fasteners to the required torque value for that size fastener. Refer to Section 6.

6. Wait 20 minutes before filling the assembly with the correct lubricant. Refer to Section 7.

Gear Sets

Refer to the following examples for information on identifying gear sets with matched parts. Always check match numbers to verify that the gear set you will install has matched parts. Figure 3.15.

Examples

Gear Set

Gear Set Tooth Combination Number

Gear Set Match Number

NOTE: Meritor’s drive pinions and ring gears are only available as matched sets. Each gear in a set has an alpha-numeric match number.

Figure 3.14

1 0.125” (3 MM) DIAMETER SILICONE GASKET BEAD

1003028b

1

Figure 3.15

ALTERNATE LOCATIONS:1 PART NUMBER, TOOTH COMBINATION NUMBER,

GEAR SET MATCH NUMBER, PINION CONE VARIATION NUMBER

2 PART NUMBER, TOOTH COMBINATION NUMBER3 GEAR SET MATCH NUMBER, PINION CONE

VARIATION NUMBER4 PART NUMBER, TOOTH COMBINATION NUMBER,

GEAR SET MATCH NUMBER5 PART NUMBER, TOOTH COMBINATION NUMBER

GEAR SET MATCH NUMBER

Part Number Location

Conventional ring gear

36786 On the front face or outer diameter

Conventional drive pinion

36787 At the end at threads

Gear Set TeethDrive Pinion Location

Ring Gear Location

5-37 = gear set has a five-tooth drive pinion and a 37-tooth ring gear

At the end at threads

On the front face or outer diameter

Match NumberDrive Pinion Location

Ring Gear Location

M29 At the end of the gear head

On the front face or outer diameter

4

5

1

2 3

1003031a



Pinion Cone Variation 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 in the carrier. Refer to Section 4.

Pinion Cone (PC) Variation Number

Drive Pinion Location

Ring Gear Location

PC+3+2+0.01 mmPC-5–1–0.02 mm

At the end of the pinon gear head

On the outer diameter

Section 4Assembly and Installation



WARNING


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

Assembly

Drive Pinion

1. Apply Meritor specification 2297-W-4287, 2297-U-4519 or 076328-4 lubricant to the new O-ring, carrier threads, O-ring bore, pinion cage threads and the inner and outer bearings. Figure 4.1. To obtain this lubricant, refer to the Service Notes page on the front inside cover of this manual.

2. Install the new O-ring onto the pinion cage.

3. Install the shim onto the drive pinion.

4. Use a press to install the inner and outer bearing cones onto the drive pinion.

Differential Case and Ring Gear

1. Use a press to install the bearing cones onto both halves of the differential case.

CAUTION

Heat the ring gear before seating it onto the differential case. Do not press a cold ring gear onto the differential case. A cold ring gear will damage the differential case because of the tight fit.

2. Heat the ring gear. A maximum temperature of 340°F (170°C) can be applied at the gear web. The temperature at the gear teeth must not exceed 250°F (120°C). Wear safe clothing and gloves while working with the hot ring gear.

3. Position the differential case on a workbench with the bearing cone on top.

4. Place the ring gear over the differential case immediately after the gear is heated.

� If the ring gear does not fit easily on the differential case: Heat the gear again.

5. Align the ring gear and differential case capscrew holes. Rotate the ring gear as necessary.

6. Use a feeler gauge to inspect for gaps between the ring gear and the differential case.

� If the gap exceeds 0.001-inch (0.025 mm) at more than three places with an arc length greater than 1.0-inch (25.4 mm): Inspect the differential case and ring gear for wear or damage. Repair or replace parts as necessary.

7. Turn the differential case over on the workbench so that the bearing cone is on the bottom.

8. Apply Meritor specification 2297-W-4287, 2297-U-4519 or 076328-4 lubricant to the differential pinion shaft, thrust washers, differential pinions and side gears. To obtain this lubricant, refer to the Service Notes page on the front inside cover of this manual.

Figure 4.1

1 PINION CAGE

2 O-RING

3 OUTER BEARING CUP

4 OUTER BEARING CONE

5 DRIVE PINION

6 SHIM

7 INNER BEARING CONE

1

7

23 4 5

6


Copyright 2010 Arvin Meritor Maintenance Manual MM-0230Page 18 ArvinMeritor, Inc. (Revised 08-10)

9. Install the thrust washer and side gear into the differential case. Figure 4.2.

10. Slide the differential pinions and thrust washers onto the differential pinion shaft. Figure 4.3.

11. Position the differential pinion shaft in the differential case on top of the side gear. The holes in the differential pinion shaft must align with the capscrew holes in the differential case. Figure 4.4.

12. Install the side gear and thrust washer over the differential pinions. Figure 4.5.

13. Position the case half over the side gear. Figure 4.6.

Figure 4.2

1 SIDE GEAR

2 THRUST WASHER

Figure 4.3


2 THRUST WASHER


1

2

1 2

3

Figure 4.4

1 Align holes.

Figure 4.5

1 THRUST WASHER

2 SIDE GEAR

Figure 4.6

1

1

2



14. Install the capscrews through both differential case halves and into the ring gear. Use a CRISSCROSS pattern to tighten the capscrews to 105-115 lb-ft (140-155 N•m). Figure 4.7.

15. Inspect the differential gears rotating resistance. Use the following procedure.

Differential Gears Rotating Resistance

1. Make an inspection tool using an axle shaft that matches the spline size of the differential side gear. Cut the shaft to approximately 12-inches (304.8 mm). Weld a nut onto the end of the shaft. Figure 4.8.

2. Place the differential and ring gear assembly in a vise. Install soft metal covers over the vise jaws to protect the ring gear.

3. Install the tool into the differential until the spines on the tool are engaged with one side gear.

4. Place a torque wrench onto the nut onto the tool and rotate the differential gears. Read the value indicated on the torque wrench.

� If the torque value is greater than 50 lb-ft (68 N•m): Disassemble the differential case and inspect parts for wear or damage. Repair or replace parts as necessary. Reassemble the differential case and repeat Steps 2 through 4.

Installation

Drive Pinion into the Carrier

1. Install the drive pinion inner bearing cup into the carrier.

2. Apply axle lubricant onto the carrier pinion cage bore and inner bearing cup.

3. Apply axle lubricant onto the pinion inner and outer cone.

4. Install the drive pinion into the inner bearing cup in the carrier. Install the outer bearing cup into the pinion case.

5. Coat the pinion cage seal bore with GL-5 gear oil prior to installing the new seal. To obtain this lubricant, refer to the Service Notes page on the front inside cover of this manual.

6. Use a seal driver to install a new seal into the pinion cage. Refer to the tool drawing in Section 9 to fabricate the seal driver.

7. Install a new O-ring onto the pinion cage.

8. Apply axle lubricant on the pinion cage thread and pilots, O-ring and outer bearing cone.

9. Place the pinion cage onto the carrier. Use your hands to screw the pinion cage into the carrier to verify that the cage is correctly installed.

10. Install the yoke locknut onto the drive pinion shaft. Do not install the yoke at this time.

Figure 4.7

1 CAPSCREWS

Figure 4.8

T

1

1003071a

APPROXIMATELY304.8 MM (12-INCHES)

SIDE VIEWWeld nut toend of shaft.

ENDVIEW



11. Use appropriate tools to screw the pinion cage into the carrier while rotating the pinion to seat the bearings.

12. Tighten the pinion cage to adjust the drive pinion bearing preload. Check the preload by rotating the pinion by the yoke locknut with a torque wrench. Figure 4.9. The correct torque is 5-20 lb-in (5.8-23 N•m).

13. Position the pinion cage lock plate.Figure 4.10.

� If the lock plate does not match one of the four possible positions: Tighten or loosen the pinion cage while checking the preload to keep it within specification.

14. Install the capscrews and tighten them to 10-13 lb-ft (14-18 N•m). Remove the yoke locknut.

15. Install the yoke and locknut onto the drive pinion shaft.

16. Fasten a yoke bar to the yoke to hold the drive pinion in position when you tighten the locknut. Figure 4.11. Refer to Section 9 to build a yoke bar.

17. Tighten the locknut to 740-920 lb-ft (1000-1245 N•m). Remove the yoke bar.

Differential Case and Ring Gear into the Carrier

1. Install the bearing cup and adjusting ring into the bore of the integral bearing cap side of the carrier.

2. Install the differential case and ring gear assembly into the carrier.

3. Install the bearing cup and adjusting ring into the carrier on the bolted-on bearing cap side.

4. Position the differential cap onto the carrier. Install the capscrews and tighten them to 115-140 lb-ft (155-190 N•m).

5. Adjust the differential bearings preload and ring gear backlash. Check the tooth contact patterns.

Figure 4.9

Figure 4.10

1 CAPSCREW

2 LOCK PLATE

T

T

2

1

Figure 4.11

1 YOKE BAR

T

1

T



Adjust Differential Bearing Preload

Use Method 1 or Method 2 below to adjust differential bearing preload.

Specifications

Method 1

1. Attach a dial indicator onto the carrier mounting flange so that the pointer is against the ring gear’s back surface. Figure 4.12.

2. Use a T-bar wrench to loosen the bearing adjusting ring that is opposite the ring gear. Figure 4.13. The dial indicator will show a small amount of end play.

3. Use one of the following procedures to move the differential and ring gear to the LEFT and RIGHT while you read the dial indicator.

A. Insert two pry bars between the bearing adjusting rings and the ends of the differential case. Figure 4.14. The pry bars must not touch the differential bearings.

B. Insert two pry bars between the differential case, or the ring gear and the carrier at locations other than specified in Step A. Figure 4.15. The pry bars must not touch the differential bearings.

4. Tighten the bearing adjusting ring until the dial indicator reads ZERO end play. Move the differential ring to the LEFT and RIGHT as needed. If necessary, repeat Step A or B.

5. Tighten each bearing adjusting ring one notch from ZERO. Proceed to Check Ring Gear Runout (Radial Movement) in this section.

Differential bearing preload

15-35 lb-in(1.7-3.5 N•m)

Expansion between bearing caps

0.006-0.013-inch(0.15-0.33 mm)

Figure 4.12

Figure 4.13

1 T-BAR WRENCH

2 ADJUSTING RING OPPOSITE RING GEAR

1

2

Figure 4.14

1 Pry bars must not touch bearings.

Figure 4.15

1 Pry bars must not touch bearings.

1

1



Method 2

1. Hand-tighten both adjusting rings against the differential bearings.

2. Use a micrometer to measure the opposite surfaces of the bearing caps at X or Y. Figures 4.16 and 4.17. Record the measurement.

3. Tighten each bearing adjusting ring one notch.

4. Measure the opposite surfaces of the bearing caps at X or Y again. Compare the measurement with the one you obtained in Step 2.

5. Subtract the measurement you obtained in Step 2 from the measurement in Step 4. The difference is the amount the bearing caps have expanded. Refer to the following example.

� If the measurement is 0.006-0.013-inch (0.15-0.33 mm): Proceed to Check Ring Gear Runout (Radial Movement)) in this section.

� If the measurement is not within the specification above: Repeat Steps 3 and 4 as necessary.

Sample Differential Bearing Preload Calculation

Check Ring Gear Runout (Radial Movement)

1. Attach a dial indicator onto the carrier’s mounting flange. Figure 4.18.

2. Adjust the dial indicator so that the pointer is against the ring gear’s back surface. Set the dial indicator to ZERO.

Figure 4.16

Figure 4.17

1 MICROMETER

1

X or Y Measurement Before Tightening Adjusting Rings

X or Y Measurement After Tightening Adjusting Rings

Amount BearingCaps Have Expanded

13.927-inch (353.74 mm)

13.936-inch (353.97 mm)

0.009-inch(0.23 mm)

Figure 4.18



3. Rotate the differential and ring gear. Read the dial indicator. Runout must not exceed 0.008-inch (0.200 mm).

� If runout exceeds the specification above: Remove the differential and ring gear assembly from the carrier. Refer toSection 2 and Steps 4-5 below.

� If runout is within specification: Proceed to Ring Gear Backlash in this section.

4. Check the differential parts including the carrier for wear and damage. Repair or replace parts as necessary.

5. Install the differential and ring gear into the carrier. Repeat the preload adjustment of the differential bearings.

Ring Gear Backlash

Specifications

After checking the tooth contact patterns, the backlash can be adjusted within specification limits, if needed. To change the location of the pattern, use the following procedures.

1. Attach a dial indicator onto the mounting flange of the carrier. Figure 4.19.

2. Adjust the dial indicator so that the plunger or pointer is against the tooth surface.

3. Adjust the dial indicator to ZERO. Hold the drive pinion in position.

4. After reading the dial indicator, rotate the differential and ring gear a small amount in both directions against the drive pinion teeth.

� If the backlash reading is within specification: Check the tooth contact patterns.

� If the backlash reading is not within specification: Adjust backlash as necessary.

5. Loosen one bearing adjusting ring one notch, then tighten the opposite ring the same amount. Figures 4.20 and 4.21.

� To increase backlash: Move the ring gear away from the drive pinion.

� To decrease backlash: Move the ring gear toward the drive pinion.

Backlash setting range for old gear sets

0.008-0.018-inch(0.20-0.46 mm)

Backlash setting for new gear sets

0.005-0.015-inch (0.13-0.38 mm)

Figure 4.19

Figure 4.20

1 Tighten adjusting ring this side.

2 Increase backlash.

3 Loosen adjusting ring this side.

Figure 4.21

1 Loosen adjusting ring this side.

2 Decrease backlash.

3 Tighten adjusting ring this side.

1

2

3

1

2

3



NOTE: When you adjust backlash, only move the ring gear. Do not move the drive pinion.

6. Repeat Steps 2-5 until the backlash is within specifications.

Check the Tooth Contact Patterns (Backlash) of the Gear Set

In the following procedures, movement of the contact pattern in the length of the tooth is indicated as toward the heel or toe of the ring gear. Figure 4.22.

Always check tooth contact patterns on the drive side of the gear teeth. Figure 4.23.

1. Adjust the backlash of a new gear set to 0.005-0.015-inch (0.13-0.38 mm). Adjust the backlash of an old gear set to the setting that you measured before the carrier was disassembled. Refer to Ring Gear Backlash in this section.

2. Apply a marking compound onto approximately 12 gear teeth of the ring gear. Rotate the ring gear so that the 12 gear teeth are next to the drive pinion. Figure 4.24.

3. Rotate the ring gear forward and backward so that the 12 gear teeth go past the drive pinion six times to get the contact patterns. Repeat if needed to get a clearer pattern.

4. Look at the contact patterns on the ring gear teeth. Compare the patterns to Figures 4.25, 4.26 and 4.27.

� The location of good hand-rolled contact patterns for new gear sets is toward the toe of the gear tooth and in the center between the top and bottom of the tooth. Figure 4.25.

� 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 4.28.

� The location of a good hand-rolled contact pattern for an old gear 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 4.22

1 HEEL

2 TOE

Figure 4.23

1

1003090e

2

DRIVESIDE

(CONCAVE)

Figure 4.24



A high contact pattern indicates that the drive pinion was not installed deep enough into the carrier. A low contact pattern indicates that the drive pinion was installed too deep in the carrier.

� 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.

� If the contact patterns are in the center of the gear teeth: Continue by following Step 6.

5. Adjust the position of the drive pinion in the carrier to move the contact patterns between the top and bottom of the gear teeth. Use the following procedure.

A. Disassemble the yoke, pinion cage and the drive pinion. Refer to Section 2.

B. Remove the inner bearing cone from the drive pinion. Refer to Section 2.

C. Change the bearing shim.

� To correct a high contact pattern, Figure 4.26: Replace the bearing shim with a thicker shim.

� To correct a low contact pattern, Figure 4.27: Replace the bearing shim with a thinner shim.

D. Install the inner bearing cone onto the drive pinion. Install the drive pinion into the carrier. Refer to the appropriate procedures in this section.

E. Repeat Steps 2-5 until the contact patterns are in the center between the top and bottom of the gear teeth.

Figure 4.25

Figure 4.26

Figure 4.27

GOOD HAND-ROLLED PATTERN, HYPOID GENEROID GEARS

1001092c

HIGH PATTERN1001093c

1001094a

LOW PATTERN, HYPOID GENEROID GEARS

Figure 4.28

GOOD PATTERN IN OPERATION, GENEROID GEARS



6. Adjust the backlash of the ring gear within the specification range to move the contact patterns to the correct location in the length of the gear teeth. Refer to Ring Gear Backlash in this section.

A. Decrease backlash to move the contact patterns toward the toe of the ring gear teeth. Figure 4.29.

B. Increase backlash to move the contact patterns toward the heel of the ring gear teeth. Figure 4.30.

C. Repeat Steps 2-4 and 6 until the contact patterns are at the correct location in the length of the gear teeth.

7. Install the cotter pins into the adjusting rings so that the large end is between the adjusting ring lugs. Bend the tabs out flat against the outboard side of the leg caps in two places. Figure 4.31.

Figure 4.29

Figure 4.30

Move pattern toward toe,loosen adjusting ring

this side

Decrease backlash.

Tighten adjusting ring.

1003103b

Move pattern toward toe,loosen adjusting ring

this side

Decrease backlash.Loosen adjusting ring.

1003104b

Figure 4.31

1 COTTER PINS

11



Differential Carrier into the Axle Housing

WARNING

Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion-type cleaners and petroleum-based cleaners. To avoid serious personal injury when you use solvent cleaners, you must carefully follow the manufacturer’s product instructions and these procedures:

� Wear safe eye protection.

� Wear clothing that protects your skin.

� Work in a well-ventilated area.

� Do not use gasoline, or solvents that contain gasoline. Gasoline can explode.

� You must use hot solution tanks or alkaline solutions correctly. Follow the manufacturer’s instructions carefully.

When you apply some silicone gasket materials, small amounts of acid vapor are present. To prevent serious personal injury, ensure that the work area is well ventilated. If the silicone gasket material gets into your eyes, flush them with water for 15 minutes. Have your eyes checked by a physician as soon as possible.

1. Clean the inside of the axle housing and the carrier mounting surfaces. Use a cleaning solvent and rags to remove dirt. Blow dry the cleaned areas with air. Refer to Section 3.

2. Inspect the axle housing for damage. Repair or replace the axle housing. Refer to Section 3.

3. Apply Loctite® 242 threadlocker, or equivalent, into the threaded holes in the axle housing. To obtain this threadlocker, refer to the Service Notes page on the front inside cover of this manual. Refer to Section 3.

4. Apply silicone gasket material onto the carrier mounting surface of the housing. Refer to Section 3.

WARNING

To avoid serious personal injury and damage to components, take care when using lifting devices during service and maintenance procedures. Inspect a lifting strap to ensure that it is not damaged. Do not subject lifting straps to shocks or drop-loading.

5. Install the carrier into the axle housing. Use a hydraulic roller jack or a lifting tool.

6. Install capscrews in the four corner locations around the carrier and axle housing. Hand-tighten the fasteners. Figure 4.32.

7. Carefully push the carrier into position. Tighten the four capscrews two or three turns each in a CRISSCROSS pattern.

8. Repeat Step 7 until the four capscrews are tightened to 83-110 lb-ft (110-150 N•m).

9. Install the remaining capscrews and tighten them to 83-110 lb-ft (110-150 N•m).

Figure 4.32

1001105b

T

T



Axle Shafts in the Axle Assembly

1. Clean the mating surfaces of the axle shaft flange and the wheel hub.

2. Apply a 1/8-inch (3 mm) diameter bead of RTV sealant around the mating surface of the hub and around the edge of each fastener hole.

3. Install the axle shaft into the housing. The axle shaft flange must fit flat against the wheel hub. Figure 4.33.

4. Install the capscrews and tighten them to 105-115 lb-ft (140-155 N•m).

5. Connect the driveline universal joint to the pinion input yoke on the carrier.

6. Remove the safety stands. Lower the vehicle. Remove the blocks from the wheels.

Fill the Axle with Lubricant

1. Park the vehicle on a level surface.

2. Remove the fill plug from the axle housing.

3. Fill the axle housing with the correct lubricant until the lubricant level is to the bottom of the fill plug hole. Refer to Section 7.

4. Install the fill plug and tighten it to 35-50 lb-ft (48-67 N•m).

5. Road test the vehicle in an unloaded condition for one to two miles (1.6-3.2 km). Do not exceed 25 mph (40 km/h).

6. Recheck the lubricant level. Adjust the lubricant level as necessary.

Figure 4.33

1 CAPSCREW

2 AXLE SHAFT FLANGE

3 AXLE SHAFT HUB

321

T

T

Section 5Diagnostics


Section 5DiagnosticsVehicle Will Not Move

Damaged?Yes

No

Damaged?Yes

Damaged?Yes

No

Contaminated?

Determine

the source of

contamination.

Yes

No

Damaged?

No

Yes

Backlash

within spec?

When the carrier is

reassembled later, set

the backlash to spec.

Refer to Section 4.

When the carrier is

reassembled later,

set the backlash to

the recorded reading.

Yes No

Damaged?

Yes

No

Disassemble the main differential

and ring gear. Refer to Section 2.

Damaged?Yes

No

Reset the backlash.

Refer to Section 4.

Install a new

unitized seal.

Reassemble and install

the main differential.

Refer to Section 4.

Inspect the differential

case bearings for damage.

Refer to TP-0445, Parts

Failure Analysis.

Inspect the main differential bearings

for damage. Refer to TP-0445,

Parts Failure Analysis.

Install the carrier.

Refer to Section 4.

Test drive the vehicle.

Return the vehicle to service.

Visually inspect

the carrier in

the axle housing.

Remove the

carrier from the

axle housing.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 2.

Drain and inspect

the lubricant.

Refer to MM 1.

Remove the carrier

from the axle housing.

Refer to Section 2.

Visually inspect the ring

gear and pinion for

damage. Refer to

TP-0445, Parts Failure

Analysis.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.

Check the ring gear

backlash and record the

reading. Refer to Section 4.

Use the backlash reading when

you reassemble the carrier.

Remove the main

differential and

ring gear from

the carrier. Refer

to Section 2.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.

Inspect the main differential case and side

gears for damage. Refer to TP-0445,


Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.

Inspect the drive pinion and inner

drive pinion bearing for

damage. Refer to TP-0445,


Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.

Check the drive pinion end play.

Refer to Section 4. Any end play

looseness indicates possible

bearing damage.



Differential Making Noise

Damaged?Yes

No

Damaged?Yes

Inspect the differential

bearings for damage. Refer to

TP-0445, Parts Failure Analysis.

Damaged?Yes

No

Contaminated?

Determine

the source of

contamination.

Yes

No

Damaged?

No

Yes

Backlash

within spec?

When the carrier is

reassembled later, set

the backlash to spec.

Refer to Section 4.

When the carrier is

reassembled later,

set the backlash to

the recorded reading.

Yes No

Disassemble the

main differential

and ring gear.

Refer to Section 2.

Damaged?Yes

No

Damaged?

Reassemble and install the main

differential. Refer to Section 4.

Yes

No

Reset the backlash.

Refer to Section 4.

Install a new

unitized seal.

Inspect the main differential bearings

for damage. Refer to TP-0445,


Install the carrier. Refer to

Section 4. Test drive the vehicle.

Return the vehicle to service.

Visually inspect

the carrier in

the axle housing.

Remove the carrier


Repair the carrier

or install a

remanufactured

carrier.

Refer to Section 2.

Drain and inspect

the lubricant.

Refer to MM 1.

Check the drive pinion

end play. Refer to Section 4.

Any end play looseness

indicates possible

bearing damage.

Remove the carrier from the

axle housing. Refer to Section 2.

Visually inspect the ring gear

and pinion for damage. Refer to

TP-0445, Parts Failure Analysis.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.

Check the ring gear

backlash and record the

reading. Refer to Section 4.

Use the backlash reading when

you reassemble the carrier.

Remove the main

differential and

ring gear from

the carrier. Refer

to Section 2.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.

Inspect the main differential case and side

gears for damage. Refer to TP-0445, Parts

Failure Analysis.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.

Inspect the drive pinion and inner drive pinion

bearing for damage. Refer to TP-0445, Parts

Failure Analysis.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.



Oil Leak

Damaged?

Inspect the

breather.

Yes

No

Breather

clogged?

Clean or replace the

breather. A clogged

breather can cause

a seal leak.

Yes

No

Inspect the

pinion seals

for leaks.

Seal

leaking?

Replace the pinion

seal with a

unitized seal.

Replace the pinion

cage O-ring with

a new O-ring.

Yes

No

Joint

leaking?No

Yes

Inspect the

carrier-to-housing

joint for leaks.

Test drive the vehicle to

confirm that the leak is

repaired. Return the

vehicle to service.

Visually inspect

the carrier in

the axle housing.

Remove the carrier


Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 2.

Inspect the axle housing

welds for cracks or leaks.

If you find weld cracks,

contact Meritor for repair

welding procedures.

Fill the carrier with the

correct amount of the

specified lubricant.

Refer to Section 6.

Clean the seal area.

Test drive the vehicle

to confirm that the

leak is repaired.

Return the vehicle to

service.

Drain and inspect

the lubricant.

Refer to MM 1.

Remove the carrier


Refer to Section 2.

Clean and prepare the

housing and carrier

flanges. Apply the correct

gasket or silicone.

Refer to Section 3.


Refer to Section 4.

Fill the carrier with

the correct amount

of the specified lubricant.

Refer to Section 6.



Contaminated Lubricant Found During Preventive Maintenance

Visually

inspect the

lubricant.

Lubricant

color?

Milky,

Brownish

Indicates

that water

is entering

the axle.

Silvery

Inspect the

breather.

Indicates

metallic

contamination.

Clean or replace the

breather. A clogged

breather can cause

a seal leak.

Breather

clogged?

No

Inspect the

pinion seals

for leaks.

If analysis results

indicate wear or

breakdown in the carrier,

refer to the Differential

Making Noise diagnostic

flowchart in this publication.

Yes

Seal

leaking?

Yes

Inspect the

carrier-to-housing

joint for leaks.

No

Remove the

carrier from

the axle. Refer to

Section 2.

Drain and

inspect the

lubricant.

Refer to MM 1.

Replace the pinion

seal with a

unitized seal.

Replace the pinion

cage O-ring with

a new O-ring.

Joint

leaking?

No

Yes

Test drive the vehicle

to confirm that the

leak is repaired. Return

the vehicle to service.

Send out a lubrication

sample for analysis.

Advise the owner to

return for the results.

Inspect the axle housing

welds for cracks or leaks.

If you find weld cracks,

contact Meritor for

repair welding procedures.

Fill the carrier

with the correct

amount of the

specified lubricant.

Refer to Section 6.

Clean the seal area.

Test drive the

vehicle to confirm

that the leak is

repaired. Return the

vehicle to service.

Clean and prepare the

housing and carrier

flanges. Apply the correct

gasket or silicone.

Refer to Section 3.


Refer to Section 4.

Fill the carrier with

the correct amount

of the specified lubricant.

Refer to Section 6.

Section 6Torque Specifications


Section 6 Torque SpecificationsDescription Specification

Pinion Bearing Preload Rolling Torque 5-20 lb-in(5.8-23.0 N•cm)

Differential Bearing Preload 15-35 lb-in(1.7-3.5 N•m)

Expansion Between Bearing Caps 0.006-0.013-inch(0.15-0.33 mm)

Differential Gears Rotating Resistance 50 lb-ft(68 N•m)

Ring Gear Runout 0.008-inch(0.200 mm) maximum

Backlash Setting Range for Old Gear Sets 0.008-0.018-inch(0.20-0.46 mm)

Backlash Setting for New Gear Sets 0.005-0.015-inch(0.13-0.38 mm)

Fastener SizeTorque Value lb-ft (N•m)

Yoke Locknut M32 x 1.5 740-920 (1000-1245)

Adjusting Ring Lock Plate Capscrews

M6 x 1.0, Class 10.9 10-13(14-18)

Differential Case Capscrews M12 x 1.75, Class 10.9 105-115(140-155)

Differential Cap Capscrews M14 x 2.0, Class 10.9 115-140(155-190)

Carrier-to-Housing Capscrews 41 x 1467 (short)41 x 1465 (long)

83-110(110-150)

Axle Shaft Capscrews M12 x 1.75 105-115(140-155)

Fill Plug 0.75-14 35-50(48-67)

Drain Plug 0.50-14 35-50(48-67)

Section 7Lubrication


Section 7LubricationFor 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.

Lubricant Capacity

Oil Change Intervals and Specifications for All Rear Drive Axles�

� If a No-Spin differential is installed, change the oil (petroleum or synthetic) at minimum interval or 40,000 miles (64 000 km) or a maximum interval or 50,000 miles (80 000 km).

� This interval applies to approved semi-synthetic and full synthetic oils only. For 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.

MS Series

U.S. Pints Liters

14 6.8

Vocation or Vehicle Operation

Motorhome Recreational Vehicle

Commercial VanBeverage TruckStake TruckWreckerCity Delivery School Bus Fire TruckMunicipal TruckUtility Truck

Initial Oil Change No longer required as of January 1, 1993

Check Oil Level Every 25,000 miles (40 000 km), or the fleet maintenance interval (whichever comes first)

Every 10,000 miles (16 000 km), once a month, or the fleet maintenance interval (whichever comes first)

Petroleum Based Oil Change on Axle with or without Pump and Filter System

Every 100,000 miles (160 000 km) or annually, whichever comes first


Synthetic Oil Change on Axle without Pump and Filter System �



Synthetic Oil Change on Axle with Pump and Filter System �

Every 500,000 miles (800 000 km) Every 250,000 miles (400 000 km)

Filter Change on Axle with Pump and Filter System

Every 100,000 miles (160 000 km) Every 100,000 miles (160 000 km)

Section 7Lubrication


Axle Oil Specifications

Gear Oil TypeA.P.I. Specification

SAE Grade

Meritor Specification

Military/SAE Specification

Outside Temperature

No

n-E

xte

nd

ed

Dra

in

Lu

bri

can

ts

Petroleum with EP Additives

GL-5 85W/140 O-76A MIL-PRF-2105EandSAE J2360

Above +10°F (–12°C)

80W/140 O-76B Above –15°F (–26°C)

80W/90 O-76D Above –15°F (–26°C)

75W/90 O-76E Above –40°F (–40°C)

75W O-76J From –40°F (–40°C) to 35°F (2°C)

75W/140 O-76L Above –40°F (–40°C)

Ex

ten

de

d D

rain

L

ub

rican

ts

Petroleum with Extended Drain Additives

GL-5 80W/90 — MIL-PRF-2105EandSAE J2360

Above –15°F (–26°C)

Semi-Synthetic 80W/90 — Above –15°F (–26°C)

Full Synthetic 75W/140 O-76M Above –40°F (–40°C)

Full Synthetic 75W/90 O-76N Above –40°F (–40°C)

Section 8Towing Instructions



WARNING


When transporting a vehicle with the wheels of one or both drive axles on the road, it is possible to damage the axles if the wrong procedure is used before transporting begins. Meritor recommends that you use the following procedure.

Before Towing or Drive-Away

WARNING

Engage the parking brake to prevent the vehicle from moving before you begin maintenance or service procedures that require you to be under the vehicle. Serious personal injury can result.

1. Apply the vehicle parking brakes using the switch inside the cab of the vehicle.

NOTE: Remove both axle shafts from the axle(s) that will remain on the road when the vehicle is transported.

2. Remove the capscrews from the flange of the axle shafts. Figure 8.1.

3. Identify each axle shaft that is removed from the axle assembly so they can be installed in the same location after transporting or repair is completed. Example: Match mark a mating axle shaft and hub.

4. Remove the axle shaft from the axle assembly. Figure 8.1.

5. Install a cover over the open end of each hub where an axle shaft was removed. This will prevent dirt from entering the bearing cavity and loss of lubricant.

NOTE: If an air supply will be used for the brake system of the transported vehicle, continue with Steps 6 and 7, otherwise continue with Step 8.

6. Connect an auxiliary air supply to the brake system of the vehicle that is being transported. Before moving the vehicle, charge the brake system with the correct amount of air pressure to operate the brakes. Refer to the instructions supplied by the vehicle manufacturer for procedures and specifications. If an auxiliary air supply is not used, continue with Step 8.

7. When the correct amount of air pressure is in the brake system, release the parking brakes of the vehicle that is being transported. Step 8 is not required.

WARNING

When you work on a spring chamber, carefully follow the service instructions of the chamber manufacturer. Sudden release of a compressed spring can cause serious personal injury.

8. If there are spring 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.

Figure 8.1

1 CAPSCREW

2 AXLE SHAFT FLANGE

3 AXLE SHAFT HUB

321



After Towing or Drive-Away

WARNING

Engage the parking brake to prevent the vehicle from moving before you begin maintenance or service procedures that require you to be under the vehicle. Serious personal injury can result.

1. If an auxiliary air supply was used, apply the vehicle parking brakes using the switch inside the cab of the vehicle. If an auxiliary air supply was not used, begin with Step 2.

WARNING

When you work on a spring chamber, carefully follow the service instructions of the chamber manufacturer. Sudden release of a compressed spring can cause serious personal injury.

2. Apply the vehicle spring parking brakes by manually releasing each spring that was compressed before transporting started. Refer to the manufacturer’s instructions.

3. Disconnect the auxiliary air supply, if used, from the brake system of the vehicle that was transported. Connect the vehicle’s air supply to the brake system.

4. Remove the covers from the hubs.

NOTE: Continue with Steps 5-6 to install all axle shafts.

5. Install the axle shaft into the axle housing and carrier in the same location it was removed from. The flange of the axle shaft must be flat against the hub. Rotate the axle shaft or the driveline as necessary to align the splines and the holes in the flange with the studs in the hub. Figure 8.1.

6. Install the capscrews. Tighten the capscrews to 105-115 lb-ft (140-155 N•m).

7. Check the lubricant level in the axles and hubs where the axle shafts were removed. Refer to Section 7 for specifications and intervals. For additional information, 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.

T

Section 9Special Tools


Section 9Special ToolsCarrier Repair Stand Specifications

Refer to the Service Notes page on the front inside cover of this manual to obtain this repair stand.

1 Plates 8’ (2.44 mm) long x 3/4” (19.05 mm) thick x 1-1/4” (31.75 mm) wide with a tongue to fit slot in bar weld plates to bar 2 Handle 7” (177.8 mm) long with slot in one end to fit clamp screw3 Bar 2” (50.8 mm) diameter x 9” (228.6 mm) long with one end slotted to fit plate4 Weld all around after pressing plug into pipe.5 Weld6 Shape and size of holes to fit carrier7 23-1/2” (596.9 mm) center to center of pipe8 Chamfer end of pipe for welding.9 4” (101.6 mm) diameter pipe 10 Plug 4” (101.6 mm) diameter x 7” (177.8 mm) long with one end turned 3” (76.2 mm) long to fit pipe. Drill 2” (50.8 mm) hole

and mill 3/16” (4.76 mm) wide slot 2” (50.8 mm) from top.11 Screw 3-1/2” (88.9 mm) long x 5/8” (15.86 mm) diameter with flats onto end to fit handle and 2-1/2” (63.5 mm) length of

thread on other end12 Drill 3/8” (9.5 mm) hole through handle and screw.

2

1

4

3

6

5

8

7

10

9

12

11

SPX Kent-Moore

part number J-3409-D

1002990e



How to Make a Yoke Bar

1. Measure dimensions A and B of the yoke you are servicing. Figure 9.1.

8. Calculate dimensions C and D of the yoke bar by adding 0.125-0.250-inch (3.175-6.35 mm) to dimensions A and B of the yoke. Figure 9.2.

WARNING

Wear safe clothing and eye protection when you use welding equipment. Welding equipmentcan burn you and cause serious personal injury. Follow the operating instructions and safety procedures recommended by the welding equipment manufacturer.

9. To make the box section, cut and weld1.0-inch x 2.0-inch (25.4 mm x 50.8 mm) mild steel square stock according to dimensions C and D. Figure 9.2.

10. Cut a 4.0-foot x 1.25-inch (1.21 m x 31.75 mm) piece of mild steel round stock to make the yoke bar handle. Center weld this piece to the box section. Figure 9.2.

• To increase yoke bar rigidity: Weld two angle pieces onto the handle. Figure 9.2.

Figure 9.1

1 YOKE

A

B

YOKE

1003459a

Figure 9.2

C

D

YOKEBAR

1003460a



Seal Driver Tool

Figure 9.3

1

2

3

8

6

910

1112

13 14

4 5

7

4006989a

SEAL PILOTED,READY FOR

INSTALLATION

SEAL DRIVER

SEAL INSTALLED,SEATED

SEAL DRIVER MATERIALRECOMMENDATIONS

ALLOY STEEL 8620RC 45-50 HARDNESS VALUEBLACK OXIDE FINISH

25

24

15

17

18

1619

20

21

22

23

26

1 2.25" (57.15 MM) DIAMETER2 2" (50.8 MM) DIAMETER3 0.06" (1.524 MM) RADIUS4 0.03" (0.762 MM) X 45 DEGREE CHAMFER5 0.38" (9.652 MM) X 45 DEGREE CHAMFER6 STAMP TOOL AND DETAIL NUMBER7 0.25" (6.35 MM) RADIUS8 0.38" (9.652 MM) RADIUS9 0.25" (6.35 MM) X 45 DEGREE CHAMFER10 0.03" (0.762 MM) X 45 DEGREE CHAMFER11 0.06" (1.524 MM) RADIUS12 0.03" (0.762 MM) X 45 DEGREE CHAMFER (2)13 0.12" (3.048 MM) X 45 DEGREE CHAMFER14 1.5" (38.1 MM) DIAMETER

15 1.75" (44.45 MM) DIAMETER16 2.25" (57.15 MM) DIAMETER17 4.3" (109.22 MM) DIAMETER18 4.5" (114.3 MM) DIAMETER19 0.875" (22.225 MM)20 0.955" (24.257 MM)21 1.5" (38.1 MM)22 1.63" (41.402 MM)23 2.75" (69.85 MM)24 1.375" (34.925 MM)25 3.875" (98.425 MM)26 6" (152.4 MM)27 8" (203.2 MM) RADIUS

27

Meritor Heavy Vehicle Systems, LLC2135 West Maple RoadTroy, MI 48084 USA866-OnTrac1 (668-7221)arvinmeritor.com

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.

Copyright 2010 Maintenance Manual MM-0230ArvinMeritor, Inc. Revised 08-10All Rights Reserved Printed in the USA (16579)

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