Maintenance Manual MM-0220 Single Reduction Differential Forward Carrier MD15. Issue November 2017

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1 Maintenance Manual MM-0220 Single Reduction Differential Forward Carrier MD15 Issue November 2017

2 Service Notes Before You Begin This publication provides installation and maintenance procedures for the Single Reduction Differential Forward Carrier MD15 produced by MERITOR HVS. Access Information on Meritor's Web Site Additional maintenance and service information for Meritor's commercial vehicle systems component lineup is also available at visiting the Literature on Demand page. The information contained in this publication was current at the time of printing and is subject to revision without notice or liability. You must understand all procedures and instructions before you begin maintenance and service procedures. You must follow your company's maintenance and service guidelines. You must use special tools, when required, to avoid serious personal injury and damage to components. Meritor uses the following notations to alert the user of possible safety issues and to provide information that will help to prevent damage to equipment and components. WARNING A WARNING indicates a procedure that you must follow exactly to avoid serious personal injury. All rights reserved. No part of this publication may be reproduced in any form or by any means or granted to any third parties without thewritten permission of MERITOR. MERITOR reserves the right to publish revisions at any time for technical or commercial purposes. Therefore all material contained in this manual is based on the latest information available at time of publication approval. Copyright 2007 by MERITOR HVS Document No. MM-0220 Issue: October2017 CAUTION A CAUTION indicates a procedure that you must follow exactly to avoid damaging equipment or components. Serious personal injury can also occur. NOTE: A note indicates an operational, procedure or instruction that is important for proper service. A NOTE can also supply information that will help to make service quicker and easier. This symbol indicates that you must tighten fasteners to a specific torque. 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 Commercial Vehicle Systems reserves the right to revise the information presented to discontinue the production of parts described at any time. 2 Meritor Forward Carrier MD15

3 Terms used in this manual Manufacturer: MERITOR Manual: Maintenance manual no. MM-0220 Device: Single Reduction Differential Forward Carrier MD15 Technician: Qualified personnel working on the carrier maintenance and servicing. Maintenance and servicing: Maintenance and servicing refer to periodical checks and/or replacement of the Single Reduction Differential Forward Carrier parts or components. It also refers to the determining of the cause of a malfunction in order to restore the initial operating conditions. Operator: Any person who will use the Single Reduction Differential Forward Carrier as part of a more complex device. Warranty Warranty applies to the Single Reduction Differential Forward Carrier installed on vehicles for which it was designed. Warranty is void in the following cases: Improper use of the vehicle on which the single reduction carrier is installed (usage conditions, overloading etc.) Tampering with vehicle components that may affect the carrier performance. Use of non-original spare parts. Improper installation, adjustment, repair or modification. Poor or improper maintenance (including consumables other than those specified). Further information on warranty conditions may be obtained directly from the manufacturer or by referring to the Meritor web site Meritor Forward Carrier MD15 3

4 Contents pg. 05 Section 1: Introduction 06 Exploded view 07 Parts list 08 Exploded view 09 Parts list 10 Exploded view 11 Description 12 Inter-Axle Main Differential (IAD) 12 Driver-Controlled Main Differential Lock (DCDL) 12 Identification Tag 15 Section 2: Removal and Disassembly 16 Differential Carrier Removal 17 Thru-Shaft Removal 19 Inspect Ring Gear Backlash 19 Driver-Controlled Main Differential Lock (DCDL) Removal 21 Remove the Main Differential Case and Ring Gear from the Carrier 22 Main Differential and Ring Gear Disassembly 23 Input Shaft and Inter-Axle Differential (IAD) Removal 26 Pinion Gear Disassembly 29 Section 3: Prepare Parts for Assembly 30 Clean Ground and Polished Parts 30 Clean Rough Parts - Clean Axle Assemblies 30 Dry Parts After Cleaning 30 Prevent Corrosion on Cleaned Parts 31 Inspect Parts 33 Repair or Replace Parts 34 Prepare the Axle 35 Applying Three Bond 1216, or Equivalent, Silicone Gasket Material 36 Install a Unitized Seal on the Output Shaft 37 Install an Oil Seal and V-Ring Seal on the Input Shaft 38 Clean, Inspect and Install the Yoke 38 Check for Mismatched Ratios on Tandem Axles 39 Check the Hypoid Gear Set Ratios Listed on the Identification Tags 39 Rotate the Forward Driveshaft to Check the Hypoid Gear Set Ratio 40 Check the Hypoid Gear Set Teeth Numbers Stamped on the Forward and Rear Axle Drive Pinions 41 Verify the Actual Hypoid Gear Set Ratios 42 Torque Plus Angle Recommendations 42 Tire Matching for Tandem Axles pg. 43 Section 4: Assembly and Installation 44 Shim Pack calculation 44 Gear set replacement only (when PC value is marked on the pinion) 45 Calculate Shim Pack Thickness 46 Assemble and Install the Drive Pinion Assembly 48 Adjust the Drive Pinion Bearing Preload 51 Inspect Drive Pinion Bearing Preload 51 Torque Wrench Method 52 Spring Scale Method - Replace the Spacer 53 Install the Pinion Cover 53 Main Differential and Ring Gear Assembly 56 Check the Differential Assembly Rotating Resistance 56 Install the Main Differential Case and Ring Gear Assembly Into the Carrier 58 Adjust Differential Bearings Preload 61 Inspect Ring Gear Runout - Adjust Ring Gear Backlash 63 Inspect the Gear Set Tooth Contact Patterns (Backlash) 63 Tooth Contact Patterns 66 Install and Adjust the Thrust Screw 67 Install the Inter-Axle Differential (IAD) and Lock Shift 68 IAD Lock Shift Shaft Stop Adjustment 68 Install the Input Shaft Assembly 69 Install the Yoke on the Input Shaft 69 Inspect and Adjust the Input Bearing End Play 71 Install the Driver-Controlled Differential Lock (DCDL) 72 Install the Output Bearings and Thru-Shaft 73 Inspect and Adjust Output Bearing End Play 74 Install the Differential Carrier 75 Check the Differential Lock 77 Section 5: Lubrication 78 Fill the Axle With Lubricant 79 Section 6 Torque Specifications 81 Torque Plus Angle Recommendations 83 Section 7: Special Tools 84 Carrier Repair Stand Specifications 85 How to Build: a Yoke Bar - a T-Bar Wrench 86 How to Build a Companion Flange Retainer Tool 87 MST Seal removal tool 88 MST Inner Deflector 89 MST Inner Ring 91 Section 8: Vehicle Towing Instructions 95 Section 9: Diagnostic Flowcharts 4 Meritor Forward Carrier MD15

5 Introduction 1 pg. 06 Single Reduction Differential Forward Carrier MD15 Exploded view 07 Single Reduction Differential Forward Carrier MD15 Parts list 08 Single Reduction Differential Forward Carrier MD15 Exploded view 09 Single Reduction Differential Forward Carrier MD15 Parts list 10 Single Reduction Differential Forward Carrier MD15 Exploded view 11 Description 12 Inter-Axle Main Differential (IAD) 12 Driver-Controlled Main Differential Lock (DCDL) 12 Identification Tag Meritor Forward Carrier MD15 5

6 Exploded view Single Reduction Differential Forward Carrier MD15 6 Meritor Forward Carrier MD15

7 Parts list Single Reduction Differential Forward Carrier MD15 Ref. Description 1 Carrier 2 Bearing Cap L.H. 3 Bearing Cap R.H. 4 Bearing Cap Washer 5 Bearing Cap Capscrew 6 Spiral Pin 7 Cotter Pin 8 Identification Plate 9 Thrust Screw 10 Thrust Screw Nut 11 Clutch Collar 12 Adjusting Ring 13 Retaining Ring 14 Spacer 15 Fixed Collar 16 Differential Bearing Cup R.H. 17 Differential Bearing Cone R.H. 18 Differential Case Capscrew 19 Ring Gear Capscrew 20 Flange Half Differential Case 21 Ring Gear 22 Side Gear Thrust Washer 23 Differential Side Gear 24 Differential Spider Ref. Description 25 Differential Pinion 26 Differential Pinion Thrust Washer 27 Plain Half Differential Case 28 Differential Bearing Cone L.H. 29 Differential Bearing Cup L.H. 30 Shift Shaft Spring 31 Shift Fork 32 Shift Fork Pin 33 Shift Shaft 34 Piston 35 Piston O-Ring 36 Cylinder Cover Gasket 37 Plug 38 Cylinder End Cover 39 Cover Capscrew 40 Cover Capscrew Washer 41 Sensor Switch Lock Nut 42 Sensor Switch 43 Lock Nut 44 Companion Flange 45 Shield 46 V-Ring Seal 47 Seal - Oil 48 Input Cage Capscrew Meritor Forward Carrier MD15 7

8 Exploded view Single Reduction Differential Forward Carrier MD15 8 Meritor Forward Carrier MD15

9 Parts list Single Reduction Differential Forward Carrier MD15 Ref. Description 49 Input Bearing Cage 50 Shim 51 Input Bearing Cup 52 Input Bearing Cone 53 Inter-Axle Differential Clutch Collar 54 Inter-Axle Differential Shift Fork 55 Input Shaft 56 Helical Drive Gear Thrust Needle Bearing 57 Helical Drive Gear 58 Inter-Axle Differential Pinion 59 Differential Pinion Thrust Washer 60 Inter-Axle Differential Spider 61 Inter-Axle Differential Carrier 62 Inter-Axle Differential Side Gear 63 Rear Side Gear Bearing Cone 64 Rear Side Gear Bearing Cup 65 Pinion Cover Capscrew 66 Pinion Cover Capscrew Washer 67 Pinion Cover 68 Pinion Nut 69 Pinion Nut Washer Ref. Description 70 Outer Pinion Bearing Cone 71 Outer Pinion Bearing Cup 72 Spacer Sleeve 73 Helical Driven Gear 74 Spacer Sleeve 75 Shim 76 Inner Pinion Bearing Cup 77 Inner Pinion Bearing Cone 78 Pinion 79 Cover Capscrew 80 Inter-Axle Differential Lock Cover 81 Inter-Axle Differential Lock Diaphragm 82 Inter-Axle Differential Lock Piston 83 Diaphragm Seat 84 Inter-Axle Differential Lock Spring 85 Needle Bearing Plate 86 Needle Bearings 87 Needle Bearing Retainer Ring 88 Caged Needle Bearing Assembly 89 Spacer Meritor Forward Carrier MD15 9

10 Exploded view Single Reduction Differential Forward Carrier MD15 Ref. Description 1 Nut - Companion Flange 2 Companion Flange 3 Output Oil Seal 4 Snap Ring Spacer 5 Output Bearing Cone 6 Output Bearing Cup 7 Output Thru Shaft 8 Axle Housing 10 Meritor Forward Carrier MD15

11 1 Introduction Description Meritor s MD-150-E is a single-reduction, thru-drive carrier. The drive gearing consists of a two-helical gear train and a hypoid ring gear and pinion. Bevel gears are used in the main differential and the inter-axle differential. Figures 1.1, 1.2 and 1.3. The inter-axle differential is located behind the helical gear on the input shaft. The forward side gear of the inter-axle differential is part of the upper helical gear hub. The thru-shaft is splined to the rear side gear of the inter-axle differential. The 418 mm (16.46-inch) ring gear uses capscrews to fasten the gear to the differential case. Fig. 1.1 Fig. 1.2 Fig. 1.3 Meritor Forward Carrier MD15 11

12 1 Introduction Inter-Axle Main Differential (IAD) Meritor s inter-axle differential (IAD) is a driver-controlled, airactuated traction device. The IAD allows for speed differences between the forward and rear axles in a tandem while also providing equal pulling power from each axle of the tandem. By activating the IAD lock switch located in the vehicle instrument panel, improved traction is provided for each axle. IAD is also known as a power divider or third differential. Axle Identification Tag Information Driver-Controlled Main Differential Lock (DCDL) The forward axles are equipped with a driver-controlled main differential lock. This device, also known as the DCDL, is operated by an air-actuated shift unit located on the forward unit of the tandem axle carrier. When the differential lock is activated, the shift collar moves along the splines of the axle shaft toward the differential case. The collar splines engage with the splines on the differential case and the axle shaft and the differential assembly lock together. In the locked position, there is no differential action between the wheels of the axle. In the unlocked position, there is normal differential action between the wheels of each axle at all times. Identification Tag An identification tag is located on the axle housing or on the differential carrier. Refer to Figures 1.4 and 1.5. Use the model number and the ratio number marked on the identification tag and the number on the carrier to order replacement parts.refer to Figure 1.6 for an explanation of the model number. Fig Meritor Forward Carrier MD15

13 1 Introduction Carrier Model Tag Location Fig. 1.5 Carrier Model Tag Number Information Meritor (Rockwell) Nominal Axle Load Rating (GAWR): in thousands of pounds. Individual forward and rear axles of a tandem set (D, N, P) are rated as single axles. A tandem set (T) is rated as the combination of the two axles. Axle Type S = Single Rear (Solo) R = Rear-Rear Axle of a Drive Tandem T = Tandem Drive Axle Set Gearing Type 1 = Single Speed Manufacturing Location: N = N.A. S = S.A. E = Europe A = Australia/Asia Axle Design Variation: Indicates axle design level or variation (Housing Wall e.g.: 0 = Cast 5 = mm) Carrier Type Carrier size. Large numbers indicate a higher GCW rated Carrier; i.e., larger ring gear, etc. Fig. 1.6 Meritor Forward Carrier MD15 13

14 14 Meritor Forward Carrier MD15

15 Removal and Disassembly 2 pg. 16 Differential Carrier Removal 17 Thru-Shaft Removal 19 Inspect Ring Gear Backlash 19 Driver-Controlled Main Differential Lock (DCDL) Removal 21 Remove the Main Differential Case and Ring Gear from the Carrier 22 Main Differential and Ring Gear Disassembly 23 Input Shaft and Inter-Axle Differential (IAD) Removal 26 Pinion Gear Disassembly Meritor Forward Carrier MD15 15

16 2 Removal and Disassembly WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury. Differential Carrier Removal WARNING 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.injury and damage to components can result. 1. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Set the parking brake. WARNING Do not attempt to lift the axle by placing a jack directly under the axle carrier bowl. The axle housing may be damaged or the vehicle could shift off of the jack. Serious personal injury and damage to components can result. 2. Lift the axle with jacks placed under the spring mounting pads or the axle housing tubes. The jacks must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. 3. After lifting the axle, support the vehicle with safety stands located under the spring mounting pads or the axle housing tubes. Figure Remove the oil drain plug from bottom of the axle housing and drain the axle lubricant from the housing assembly. 5. Disconnect the vehicle air line from theinter-axle differential and main differential lock actuator assemblies. Fig Disconnect the driveline universal joint from the pinion input yoke or flange on the carrier. For driveline and U-joint disassembly and service, refer to the manufacturer s instructions. 7. Remove the capscrews and washers or stud nuts and washers, if equipped, from the flanges of both axle shafts. 8. Loosen the tapered dowels, if equipped, in the axle flanges of both axle shafts. 9. Remove the axle shafts per the vehicle manufacturer s recommended procedures. 10. Place a hydraulic roller jack under the differential carrier to support the assembly. Figure Remove all but the top two carrier-to-housing fasteners, or stud nuts and washers. Figure Loosen, but do not remove, the top two carrier-to-housing fasteners. The fasteners secure the carrier in the housing. 13. Loosen the differential carrier in the axle housing. Remove the top two fasteners that secure the assembly in the axle housing. 14. Carefully remove the carrier from the axle housing using the hydraulic roller jack. Use a pry bar that has a round end to help remove the carrier from the housing. 15. Release the air pressure and disconnect the air hose from the shift unit. 16 Meritor Forward Carrier MD15

17 2 Removal and Disassembly Thru-Shaft Removal 1. Disconnect the forward and rear drive shafts. CAUTION Always use a flange or yoke bar during removal and installation of the flange yoke nut to prevent damage to the gearing. 2. Attach a flange bar to the flange or place a yoke bar over the input or output yoke. Figure 2.4. To build a yoke bar, refer to Section 7. Fig. 2.2 NOTE: A carrier stand is available from SPX Kent-Moore. To obtain this tool, refer to the Service Notes page on the front inside cover of this manual. You can also build a carrier stand. Refer to Section Use a lifting tool to lift the differential carrier by the input yoke or flange. Place the assembly in a carrier stand. Figure 2.3. Fig Disconnect the air lines at the inter-axle differential shift unit. 4. Use a suitable tool to release the two stakes on the perimeter of the companion flange lock nut. You must remove the staking or damage to the flange face and recesses may result. Fig. 2.3 Meritor Forward Carrier MD15 17

18 2 Removal and Disassembly 5. Remove the thru-shaft nut, and yoke or flange. Use a puller tool to remove the yoke or flange from the shaft. Figure Remove and discard the original oil seal. Figure 2.6. NOTE: If either the bearing cup or the cone need replacement, both parts must be replaced in a fully-matched set from the same manufacturer. 7. Remove the external snap ring from the thru-shaft. NOTE: When the thru-shaft is pulled from the axle housing, the inner cup remains in the cage. The outer cup is removed with the thru-shaft and the cones. 8. Use a slide hammer to pull the thru-shaft out of the housing. 9. Use a press or a bearing puller to remove the bearing cones from the thru-shaft. Refer to the following procedures under Bearing Cone Removal. Bearing Cone Removal Press Method 1. Place a used bearing cup on the inner bearing cone. 2. Place the thru-shaft in a press. Figure 2.7. The used bearing cup supports the thru-shaft. Fig Press the thru-shaft through the bearing cones. Discard the bearing cones. 4. If the carrier is still assembled on the axle, use a bearing puller to remove the inner cup. Refer Bearing Puller Method in this section. Fig. 2.6 Fig Meritor Forward Carrier MD15

19 2 Removal and Disassembly Bearing Puller Method 1. Place a used bearing cup on the inner bearing cone. 2. Install a bearing puller tool on the thru-shaft. Figure 2.8. The bearing cup supports the thru-shaft. Fig Install a dial indicator on the flange of the carrier. Place the tip of the indicator against the drive side of a ring gear tooth. Adjust the dial indicator to ZERO. Figure 2.9. Fig. 2.8 WARNING 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. 3. Pull the bearing cones off the thru-shaft. Discard the bearing cones. - If the carrier is removed: Use a brass drift and a hammer to carefully tap the inner cup from the housing. Discard the cup. 3. Slightly rotate the ring gear in both directions. Do not move the drive pinion. Record the reading on the dial indicator. 4. Rotate the gear 120 degrees and repeat the measurement. Take a total of three measurements to obtain an average. Driver-Controlled Main Differential Lock (DCDL) Removal 1. Remove the position sensor and lock nut from the DCDL casting. Figure If the carrier is still assembled on the axle: Pull the inner cup out using a bearing puller. Inspect Ring Gear Backlash NOTE: The backlash of the ring gear must be inspected and the measurements recorded before the carrier is disassembled. Backlash readings are necessary for correct reassembly of the ring gear and drive pinion. 1. Rotate the carrier in the repair stand until the ring gear is at the top of the assembly. Fig Meritor Forward Carrier MD15 19

20 2 Removal and Disassembly 2. Remove the four capscrews from the cylinder end cover. Remove the cover and the cylinder cover gasket. Figure Remove the piston. Figure Inspect the piston O-ring for cracks, cuts or breaks. - If the O-ring is damaged: Replace it with a new O-ring when you assemble the components. 4. Remove the shift shaft from the fork and out through the carrier. Figure Turn over the housing in the stand. Push the roll pins on the shift fork. 6. Remove the clutch collar from the shift fork. Figure Compress and remove the shift shaft spring. Remove the shift fork. Figure Fig Fig Fig Fig Fig Meritor Forward Carrier MD15

21 2 Removal and Disassembly 8. Remove the retaining ring and spacer on the end of the flange half. Figure Remove the fixed collar. 9. Clean and inspect all shift assembly parts. Figure Remove the Main Differential Case and Ring Gear from the Carrier 1. Move the carrier so that the ring gear is TOWARD you. 2. Use a punch and hammer to mark the position of each bearing cap on the legs of the differential carrier. The marks will correctly match the plain half and the flange half during reassembly operations. Figure Remove the lock pins and cotter pins from the bearing caps. Figure CAUTION Do not hit the adjusting ring with a hammer. Do not use a hammer and a drift to loosen the adjusting rings. Damage to the adjusting rings will result. 4. Use a T-bar wrench or equivalent tool to loosen the adjusting rings. Do not remove the adjusting rings. For T-bar wrench specifications, refer to Section 7. Figure Remove the capscrews and the washers that fasten the bearing caps to the differential carrier. Fig Fig Fig Fig Meritor Forward Carrier MD15 21

22 2 Removal and Disassembly 6. Remove the bearing caps, the adjusting rings and the bearing cups from the differential carrier. Each bearing cap must be installed on the same carrier leg from which it was removed. Figure Use a lifting sling to remove the main differential case and ring gear assembly from the carrier. Figure If the bearing cones on the main differential case need to be replaced, use a bearing puller to remove the cones. The bearing cones are not interchangeable. - If either the bearing cup or the cone needs replacement: Replace both parts in a fully-matched set from the same manufacturer. Main Differential and Ring Gear Disassembly 1. Remove the 16 capscrews around the outside perimeter of the flange half of the differential case. WARNING 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. 2. Press the ring gear off the case half. If necessary, use a brass or leather mallet to loosen the ring gear. Figure Mark both case halves and the spider for correct positioning at reassembly. 4. Remove the 12 capscrews around the inside perimeter of the flange half of the differential case. Figure Fig Fig Fig Fig Meritor Forward Carrier MD15

23 2 Removal and Disassembly 5. Remove the plain half of the differential case. Remove the differential side gear. Figure Remove the differential spider, pinions and thrust washers. Figure Check the pinions for wear or damage. 8. Remove the bearing cones from the differential halves. A. Place the assembly half in a press and support it appropriately. Ensure parts do not fall to the floor when loosened. B. Install a bearing puller under the bearing cone. Place a sleeve on the differential case end. C. Press DOWN on the sleeve until the differential case is free of the bearing cone. Figure Clean and inspect the parts for damage. Replace as necessary. Fig Input Shaft and Inter-Axle Differential (IAD) Removal 1. Use a suitable tool to release the two staked indentations on the flange of the companion flange lock nut. You must remove the staking or damage to the flange face and recesses may result. 2. Use a companion flange retainer tool CT03 to hold the companion flange in a stationary position. To obtain this tool, refer to the Service Notes page on the inside front cover of this manual. Refer to Section 7 to build the tool. 3. Remove and discard the lock nut. Figure Fig Fig Fig Meritor Forward Carrier MD15 23

24 2 Removal and Disassembly 4. Remove the companion flange, shield and V-ring seal from the input shaft. 5. Remove the 12 capscrews that secure the input bearing cage. Figure Use two pry bars to remove the cover. Figure Remove the shims. 8. If necessary, install a bearing puller and remove the input bearing cup from the cover. Figure Remove the four capscrews on the inter-axle lock cover. Figure Fig Remove the inter-axle lock cover and diaphragm. Remove the IAD lock piston, diaphragm seat and IAD spring. Figure Fig Fig Fig Fig Meritor Forward Carrier MD15

25 2 Removal and Disassembly 11. Carefully remove the input shaft from the carrier. If necessary, tap or rotate the input shaft to help loosen the assembly. Place the input shaft assembly onto a bench. Figure Remove the thrust needle bearing from the helical drive gear. Install a bearing puller and remove the input bearing cone. 13. Remove the IAD shift fork and clutch collar. Figure Paint alignment marks on the gears for correct positioning during reassembly. Lift the helical drive gear out of the housing. Figure Remove the two caged needle bearing assemblies and the spacer from the helical drive gear. Remove the IAD gear assembly. Figure 2.36 Fig Fig Fig Remove the spider assembly from the IAD housing by rotating the spider and removing the two pinions. 16. Rotate the spider and remove the two remaining pinions. Fig Meritor Forward Carrier MD15 25

26 2 Removal and Disassembly NOTE: Needle bearings are not caged and may fall out on disassembly. 17. Remove the needle bearings from the pinions. Remove the rear side gear and rear side gear bearing cone. Figure Fig Pinion Gear Disassembly 1. Remove the drive pinion from the carrier. Fig Remove the two caged needle bearing assemblies from the rear side gear. 19. If necessary, use a press, sleeve and bearing puller to remove the bearing cone from the side gear. 20. With the other end of the housing facing UP, use a brass drift and hammer to remove the rear side gear bearing cup from the carrier. A. Place the differential carrier in a heavy truck press so that the threaded end of the drive pinion is facing UP. Place the supports under the mounting flange of the carrier. B. Place a protector on the top of the drive pinion shaft. Figure C. Support the pinion gear underneath as it is pressed from the carrier. Press the pinion through the outer bearing cone and the helical driven gear. Remove the drive pinion from the bottom of the carrier. D. Remove the outer bearing cone, the outer bearing spacer and the helical driven gear from the carrier. Remove the inner spacer from the drive pinion. Drive Pinion Removal 1. Remove the five capscrews on the pinion cover. Use a pry bar to loosen and remove the pinion cover. Figure Use the correct tool to hold the helical driven gear in a stationary position. Remove the pinion nut and discard. Fig Meritor Forward Carrier MD15

27 2 Removal and Disassembly 2. If a new ring gear and drive pinion are being installed, the inner bearing cup must be removed to change the shim pack between the cup and the carrier. A. If necessary, use a hammer and drift to remove the inner and outer bearing cups from the carrier. Replace any shims that are damaged. Measure and record the thickness of the shim pack for use during assembly. Figure B. If necessary, remove the inner bearing cone from the drive pinion. Place a bearing puller under the inner race to support the bearing. Place a protector on top of the pinion shaft and press the drive pinion out of the bearing cone. Figure If either the bearing cup or the cone needs replacement: Both parts must be replaced in a fully-matched set from the same manufacturer. Fig Fig Meritor Forward Carrier MD15 27

28 28 Meritor Forward Carrier MD15

29 Prepare Parts for Assembly 3 pg. 30 Clean Ground and Polished Parts 30 Clean Rough Parts 30 Clean Axle Assemblies 30 Dry Parts After Cleaning 30 Prevent Corrosion on Cleaned Parts 31 Inspect Parts 33 Repair or Replace Parts 34 Prepare the Axle 35 Applying Three Bond 1216, or Equivalent, Silicone Gasket Material 36 Install a Unitized Seal on the Output Shaft 37 Install an Oil Seal and V-Ring Seal on the Input Shaft 38 Clean, Inspect and Install the Yoke 38 Check for Mismatched Ratios on Tandem Axles 39 Check the Hypoid Gear Set Ratios Listed on the Identification Tags 39 Rotate the Forward Driveshaft to Check the Hypoid Gear Set Ratio 40 Check the Hypoid Gear Set Teeth Numbers Stamped on the Forward and Rear Axle Drive Pinions 41 Verify the Actual Hypoid Gear Set Ratios 42 Torque Plus Angle Recommendations 42 Tire Matching for Tandem Axles Meritor Forward Carrier MD15 29

30 3 Prepare Parts for Assembly WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. 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. O Work in a wellventilated 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. CAUTION Damage to bearings can result when they are rotated and dried with compressed air. 2. Dry the parts using soft, clean paper or cloth rags. 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. 30 Meritor Forward Carrier MD15

31 3 Prepare Parts for Assembly Inspect Parts It is very important to inspect all parts carefully andcompletely 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 alltapered roller bearings in the assembly. If anyof the following conditions exist, replace thebearing. - The center of the large-diameter end of therollers is worn level with or below the outersurface. Figure The radius at the large-diameter end of therollers is worn to a sharp edge. Figure There is a visible roller groove in the cup orcone inner race surfaces. The groove can beseen at the small- or largediameter end ofboth parts. Figure There are deep cracks or breaks in the cup,cone inner race or roller surfaces.figure 3.2. Fig There are bright wear marks on the outersurface of the roller cage. Figure There is damage on the rollers and on thesurfaces of the cup and cone inner race thattouch the rollers. Figure There is damage on the cup and cone innerrace surfaces that touch the rollers.figure 3.5. Fig. 3.3 Fig. 3.1 Fig. 3.4 Meritor Forward Carrier MD15 31

32 3 Prepare Parts for Assembly Fig. 3.5 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 Inside surfaces of both case halves - Both surfaces of all thrust washers - The four trunnion ends of the spider - 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. Fig Inspect the following IAD assembly parts for wear or stress. Replace parts that are damaged. Figure Both surfaces of all thrust washers - The four trunnion ends of the spider - Teeth and splines of both differential side gears - Teeth and bore of all differential pinions - Pinion needle bearings 6. Inspect the breather. A. Remove the breather from the axle housing. B. Clean the breather. If the breather remains dirty after cleaning, replace the breather. C. Apply compressed air to the breather. If compressed air does not pass through the breather, replace the breather. D. Install the breather in the axle housing. 32 Meritor Forward Carrier MD15

33 3 Prepare Parts for Assembly Fig. 3.8 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. Fig. 3.7 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 Remove nicks, marks and burrs from parts with machined or ground surfaces. Use a fine file, india stone, emery cloth or crocus cloth. 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 6. Clean and repair threads of fasteners and holes. Use a die, a tap of the correct size, ora fine file. Meritor Forward Carrier MD15 33

34 3 Prepare Parts for Assembly 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. Fig 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 121 C (250 F). 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-tocover weld area mm ( inches) 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 3.9. Fig 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 3.10 and Fig Meritor Forward Carrier MD15

35 3 Prepare Parts for Assembly WARNING The axle housing must be 21 C (70 F) 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 21 C (70 F) or warmer. - If the axle housing temperature measures less than 21 C (70 F): Store the axle in a heated room until the housing reaches the correct temperature. 7. Heat the damaged area to approximately 149 C (300 F) 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 instructions, 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. Applying Three Bond 1216, or Equivalent, Silicone Gasket Material 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: - Three Bond Liquid Gasket number TB 1216 (Grey) - Loctite Ultra Grey Adhesive/Sealant number Meritor part number 2297-F-7052 gasket material. 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 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 Dry both surfaces. 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. Fig Meritor Forward Carrier MD15 35

36 3 Prepare Parts for Assembly 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 3 mm (1/8-inch) 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 Remove the unitized pinion seal A-1205-N-2588 from the package. Place the seal on Meritor s seal driver R To obtain Kit 4454, refer to the Service Notes page on the front inside cover of this manual. Figure Position the driver and seal. The driver tool outer spokes must fit between the bearing cage bolts. The reference mark on the driver tool must be in the 12 o clock or the 6 o clock positions when you install the new seal.figure Fig Fig 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 Wait 20 minutes before filling the assembly with the correct lubricant. Refer to Section 5. Install a Unitized Seal on the Output Shaft 1. Remove the old seal. Do not damage the bearing cage seal surface area. Do not touch or allow dirt or grease to contaminate the sealing surface areas or the adjacent bearings. 2. Inspect the bearing cage seal area for damage that could cause lubricant leaks after the seal is installed. Use emery paper or equivalent to remove scratches, nicks or burrs. 3. Inspect the axle breather. If the axle breather is restricted by a build-up of purged axle lubrication, accumulated oil, road debris or dirt, remove the axle breather and clean the inside and outside with a safe cleaning solvent. Fig Meritor Forward Carrier MD15

37 3 Prepare Parts for Assembly CAUTION Use a rubber mallet to install seal. Do not use a steel, brass or plastic hammer, which can damage the seal and driver tool. 6. Use a rubber mallet to drive the seal into or against the bearing cage. Figure Use a feeler gauge to measure the gap around the complete flange-to-cage area. A gap of mm ( inch) can exist between the flange and the cage. The gap is a normal condition from the flexible coating on the flange of the seal. - If the gap varies more than 0.25 mm (0.01-inch) between the highest and lowest measurement: Remove and reinstall the seal. 2. Install the new oil seal using the following procedure. A. Apply axle lubricant to the inner bore of the input bearing cage or the outer diameter of the new oil seal. B. Place the oil seal in the bearing cage so the seal flange is parallel with the top of the cage. C. Use a press and a flat metal plate, or mallet and seal driver to press the seal into the input bearing cage. Figure D. Use a feeler gauge to measure the gap between the complete flange-to-cage area. A gap of mm ( inch) can exist between the flange and the cage. The gap is a normal condition because of the flexible coating on the flange of the seal. - If the gap varies more than mm (0.010-inch) between the highest and lowest measurement: Remove and reseat the seal. Figure Fig Fig Install an Oil Seal and V-Ring Seal on the Input Shaft 1. Remove the old oil seal and V-ring seal. Do not damage components or contaminate mounting surfaces. WARNING Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury. Fig Meritor Forward Carrier MD15 37

38 3 Prepare Parts for Assembly 3. Install the input bearing cage onto the carrier. Tighten the capscrews to specifications. 4. Install the shield and V-ring seal onto the companion flange journal. Install the companion flange on the input shaft. 5. Lightly oil the threads and contact surface of the flange nut with GL 5 or Meritor Specification number Tighten the companion flange nut to N m ( lb-ft). 7. Stake the companion flange nut on opposite sides of the nut. Stake indentations should be approximately 3 mm (0.12-inch) deep. 8. Rotate the nut one complete turn after assembly to ensure correct torque and seal seating. Clean, Inspect and Install the Yoke 1. Clean the ground and polished surface of the yoke journal using a clean shop towel and a safe cleaning solvent. Do not use gasoline, abrasive cleaners, towels, or scrubbers to clean the yoke. Do not polish the yoke. 2. Inspect both the input and output yoke seal surfaces for grooves. CAUTION 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 can cause the seal to leak. 3. Before installing the yoke, lightly lubricate or coat the yoke seal journal with axle oil. 4. Align the yoke splines with the shaft splines. Slide the yoke over the shaft spline. Check for Mismatched Ratios on Tandem Axles For a tandem axle pair to function correctly, the forward and rear axles must operate with axle ratios within one percent. A mismatched tandem axle pair can cause carrier overheating, hypoid gear set wear, metal debris to collect on the magnetic drain plug, carrier lubricant additive depletion, excessive interaxle wear and noise. To determine if the tandem axle ratios operate within allowable limits, refer to one of the following procedures. Perform the procedure that will work best for the vehicle you are servicing. A. If you find any grooves on the input yoke seal surface, replace it. B. If you find grooves on the output yoke UPS seal, use calipers to measure the groove diameters. If any groove diameter measures less than the dimension shown in Figure 3.19, replace the yoke. Fig Meritor Forward Carrier MD15

39 3 Prepare Parts for Assembly Check the Hypoid Gear Set Ratios Listed on the Identification Tags 1. Locate the identification tags riveted to the forward and rear axle differential carriers. Figure Rotate the Forward Driveshaft to Check the Hypoid Gear Set Ratio WARNING Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result. 1. Park the vehicle on a level surface. 2. Engage the power divider and shift the transmission into NEUTRAL. 3. Block the wheels to prevent the vehicle from moving. 4. Use a jack to raise the vehicle until all tandem drive axle wheels clear the ground. Support the vehicle with safety stands. 5. Mark the forward and rear tires. Figure Fig Compare the axle ratios shown on both tags. To operate correctly, the axle ratios for both axles must be within one percent of each other. To calculate the percentage difference between the axle ratios, refer to the equation below. If the axle ratios shown on the identification tags are not within one percent of each other: Refer to the vehicle manufacturer for further information. Fig Meritor Forward Carrier MD15 39

40 3 Prepare Parts for Assembly 6. Turn the forward driveshaft in one direction by hand until the forward tire completes two rotations. Figure Verify that the forward tire rotates only two times. - If the forward tire rotates more or less than two rotations: The angle measurements in Step 7 will be inaccurate. Check the Hypoid Gear Set Teeth Numbers Stamped on the Forward and Rear Axle Drive Pinions When the interaxle driveline or differential carrier are removed for service, you can check the hypoid gear set teeth numbers stamped on the forward and rear axle drive pinions. WARNING Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result. 1. Park the vehicle on a level surface. 2. Block the wheels to prevent the vehicle from moving. Fig Note the positions of the tire marks made previously. On a correctly matched tandem axle gear set, both tire marks will be within ± 3.6 degrees of each other. Figure If the positions of the tire marks are more than 3.6 degrees from each other: Refer to the vehicle manufacturer for further information. 8. Remove the safety stands and lower the vehicle. 3. Identify the gear teeth number on the forward axle drive pinion. A. Remove the forward carrier pinion cover. Refer to the vehicle manufacturer s procedures. B. Look into the carrier housing. Identify and record the gear set teeth numbers stamped on the drive pinion end. Figure C. Calculate the hypoid gear set ratio by dividing the larger number by the smaller number. Figure Fig Fig Meritor Forward Carrier MD15

41 3 Prepare Parts for Assembly 4. Identify the gear teeth number on the rear axle drive pinion. A. Remove the interaxle driveshaft. Refer to the vehicle manufacturer s procedures. B. Identify and record the gear set teeth numbers stamped on the end of the rear axle drive pinion. Figure C. Calculate the hypoid gear set ratio by dividing the larger number by the smaller number. Figure Verify the Actual Hypoid Gear Set Ratios You can check the actual hypoid gear set ratios when you remove the differential carriers from the axle housings for service or repair. Refer to the following procedure to calculate the actual gear set ratios. 1. Count the number of ring gear teeth and pinion gear teeth. Figure Divide the number of ring gear teeth by the number of pinion gear teeth to determine the actual hypoid gear set ratio for each axle. Figure Calculate the percentage difference between the hypoid gear set ratios using the equation below. All ratios must match within one percent. - If the actual hypoid gear set ratios are not within one percent of each other: Refer to the vehicle manufacturer for further information. Fig Compare both hypoid gear set ratios. Both ratios must be within one percent of each other. To calculate the percentage difference between the axle ratios refer to the equation below. - If the axle ratios shown on the identification tags are not within one percent of each other: Refer to the vehicle manufacturer for further information. 6. Install the interaxle driveshaft. Refer to the vehicle manufacturer s procedures. 7. Install the pinion cover. Refer to the vehicle manufacturer s procedures. 8. Remove the safety stands and lower the vehicle. Fig Fig. 5.15b Meritor Forward Carrier MD15 41

42 3 Prepare Parts for Assembly Torque Plus Angle Recommendations When tightening ring gear capscrews, housing nuts and capscrews, tighten to the correct specifications using the standard torque method or the torque plus angle method. Torque Plus Angle Method 1. Tighten the ring gear capscrews in a criss-cross sequence. A. Use a torque wrench to tighten the capscrews to 100 N m (73.75 lb-ft). B. Tighten the capscrews an additional degrees. 2. Tighten the plain half differential case capscrews in a crisscross sequence. A. Use a torque wrench to tighten the capscrews to 100 N m (73.75 lb-ft). B. Tighten the capscrews an additional degrees. 3. Nuts for studs and capscrews on the housing: A. Use a torque wrench to tighten the nuts and capscrews to 100 N m (73.75 lb-ft). B. Tighten the nuts and capscrews an additional degrees. Park the vehicle on a level surface. The vehicle must carry a correctly distributed rated capacity load. All the tires must be the same size. Measure new tires to verify that they will be correctly matched. 1. Inflate all tires to the same pressure. 2. Carefully measure the rolling circumference of each tire with a steel tape. 3. Mark the size on each tire with chalk and arrange the tires in order of size, largest to smallest. 4. Mount the two largest tires on one side of one axle. Mount the two smallest on the opposite side of the same axle. 5. Mount the four other tires on the other axle in the same manner. 6. Test run the vehicle to gather accurate rear axle lubricant temperature readings on the two axle lubricant temperature gauges. 7. Vary tire air pressure within the tire manufacturer s recommended range so the lubricant temperature of both axles is within 1 C (30 F) of each other and not in excess of 93 C (200 F). This helps to ensure uniform tire loading and optimum tire life. Tire Matching for Tandem Axles CAUTION Unmatched tires on tandem drive units will cause tire wear and scuffing and possible damage to the drive units. Meritor recommends that the tires be matched to within 3.18 mm (1/8-inch) of the same rolling radius, mm (3/4-inch) of the same rolling circumference to prevent damage to components. For optimum tire life, Meritor recommends matching the tires to within 3.18 mm (1/8-inch) of the same rolling radius and mm (3/4-inch) of the same rolling circumference. In addition, the total tire circumferences of both driving axles should be matched to each other as nearly as possible. This will help to ensure optimum life of both tires and axles. 42 Meritor Forward Carrier MD15

43 Assembly and Installation 4 pg. 44 Shim Pack calculation 44 Gear set replacement only (when PC value is marked on the pinion) 45 Calculate Shim Pack Thickness 46 Assemble and Install the Drive Pinion Assembly 48 Adjust the Drive Pinion Bearing Preload 51 Inspect Drive Pinion Bearing Preload 51 Torque Wrench Method 52 Spring Scale Method - Replace the Spacer 53 Install the Pinion Cover 53 Main Differential and Ring Gear Assembly 56 Check the Differential Assembly Rotating Resistance 56 Install the Main Differential Case and Ring Gear Assembly Into the Carrier 58 Adjust Differential Bearings Preload 61 Inspect Ring Gear Runout - Adjust Ring Gear Backlash 63 Inspect the Gear Set Tooth Contact Patterns (Backlash) 63 Tooth Contact Patterns 66 Install and Adjust the Thrust Screw 67 Install the Inter-Axle Differential (IAD) and Lock Shift 68 IAD Lock Shift Shaft Stop Adjustment 68 Install the Input Shaft Assembly 69 Install the Yoke on the Input Shaft 69 Inspect and Adjust the Input Bearing End Play 71 Install the Driver-Controlled Differential Lock (DCDL) 72 Install the Output Bearings and Thru-Shaft 73 Inspect and Adjust Output Bearing End Play 74 Install the Differential Carrier 75 Check the Differential Lock Meritor Forward Carrier MD15 43

44 4 Assembly and Installation WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury. Shim Pack calculation Gear set replacement only (when PC value is marked on the pinion) If the original ring gear and drive pinion are being installed, refer to Assemble and Install the Drive Pinion Assembly. Use the value obtained in Example 2 in Table A to calculate the thickness of the shim pack to install between the bearing cup and the differential carrier.shims between the differential carrier and inner bearing cup are available in thicknesses of 0.125/0.200/0.500 mm (0.005-/0.008-/0.020-inch).Use this procedure if you ll install a new drive pinion or ring gear set, or if you have to adjust the depth of the original drive pinion. 1. Use a micrometer or a gauge to measure the thickness of the shim pack that you removed from under the inner bearing cup. Record the measurement. Figure 4.2. If a new ring gear and drive pinion are installed, the correct thickness of the shim pack between the inner bearing cup and the carrier must be determined. Figure 4.1. Refer to the following procedure. Fig Find the pinion cone (H) variation number on the drive pinion you ll replace. Figures 4.3A, 4.3B and 4.4. Fig. 4.1 The Pinion Cone variation (H value) indicates the nominal assembly distance. This indication is present for each drive produced before If any indication is not present, see next section. Use this number to calculate the thickness of the shim pack between the pinion bearing cage and differential carrier. This variation number is stamped on outer face of the drive gear; for example, H mm or H 0.1 mm. 1 - Part number 2 - Tooth combination number 3 - Pinion Drive Gear pair set number 4 - Variation number Fig Pinion Drive Gear set manufacturing and testing date, month/year 6 - Pinion Drive Gear set nominal backlash value 44 Meritor Forward Carrier MD15 Fig. 4.3A Fig. 4.3B

45 4 Assembly and Installation 3. If the new H number for a forward tandem carrier is plus (+): SUBTRACT the number from the standard shim pack thickness that you calculated in Step 1 or 2. Use new shims to make a shim pack to the correct thickness. Refer to Table A 4. If the new H number for a forward tandem carrier is minus ( ): ADD the number from the standard shim pack thickness that you calculated in Step 1 or 2. Use new shims to make a shim pack to the correct thickness. Refer to Table A. Fig. 4.4 NOTE: The new component could be delivered with a different marking as shown in the above mentioned pictures. Record the number for later use. The H number can be one of the following values. Refer to Calculate Shim Pack Thickness inch (a thousandth of an inch) H +3 = mm (0.003-inch) H 3 = mm (0.003-inch) 3. If you can t find the H number or it s unreadable, re-install the same shim that you measured in Step 1. In case the shim pack used is not available it is possible to use the average of Manufacturer s Adjusted Shim Pack value which is 1,4 mm for the MD15 carrier. Check tooth contact pattern and adjust the shim pack thickness as necessary to achieve the correct contact pattern 4. Inspect the gear tooth contact pattern. Refer to Inspect the Gear Set Tooth Contact Patterns (Backlash) in this section. 5. Find the H variation on the new drive pinion you ll install. Record the number. Refer to Calculate Shim Pack Thickness in this section. Calculate Shim Pack Thickness 1. If the old H number for a forward tandem carrier is plus (+): ADD the PC number to the thickness of the old shim pack that you measured in Step If the old H number for a forward tandem carrier is minus ( ): SUBTRACT the PC number from the thickness of the old shim pack that you measured in Step 1. TABLE A Example mm Inches 1. Old Shim Pack Thickness Old H number, H Resulting Value New H Number, H New Shim Pack Thickness Old Shim Pack Thickness Old H number, H Resulting Value New H Number, H New Shim Pack Thickness Old Shim Pack Thickness Old H number, H Resulting Value New H Number, H New Shim Pack Thickness Old Shim Pack Thickness Old H number, H Resulting Value New H Number, H New Shim Pack Thickness Meritor Forward Carrier MD15 45

46 4 Assembly and Installation Assemble and Install the Drive Pinion Assembly The depth of the drive pinion and ring gear contact is determined by shim pack thickness. Figure Increase shim pack thickness to increase the depth of the drive pinion contact. - Decrease shim pack thickness to decrease the depth of the drive pinion pattern. Drive pinion bearing preload is determined by a spacer between the outer bearing cone and the helical driven gear. Adjust the preload by changing the size of the spacer. - Use a thicker spacer to decrease the preload. - Use a thinner spacer to increase the preload. The helical driven gear and the spacers are installed when the bearing preload on the drive pinion is inspected and adjusted. - If a new ring gear and drive pinion are being installed: The correct thickness of the shim pack between the pinion inner bearing cup and the carrier must be determined. Refer to Adjust Shim Pack Thickness for a New Drive Pinion (Depth of Pinion) in this section before temporarily assembling and installing the drive pinion assembly. - If the original ring gear and drive pinion are being installed: Temporarily install the drive pinion assembly. 1. If removed, use a press and a sleeve to install the inner bearing cone on the drive pinion. Place the sleeve on the inner race of the bearing. Apply pressure until the bottom of the cone touches the pinion shoulder. Figure 4.6. Fig. 4.6 Fig. 4.5 If the depth of the drive pinion changes, the thickness of the spacer must change the same amount. Refer to the following examples. - If a shim is added to the shim pack to increase the depth of the drive pinion, then a larger spacer must be installed to keep the preload on the bearings. - If a shim is removed from the shim pack to decrease the depth of the drive pinion, then a smaller spacer must be installed to keep the preload on the bearings. 46 Meritor Forward Carrier MD15 2. Apply axle lubricant to the bearing cups and cones. 3. If removed, install the shim pack and the inner bearing cup of the drive pinion. A. Place the carrier on a press with the legs of the carrier toward the top of the press. B. Install the correct amount of shims in the bore for the inner bearing cup of the drive pinion. Figure 4.7. C. Place the cup in the bore. Figure 4.7. Place supports under the differential carrier so that the carrier is level. D. Place a sleeve or a bearing driver tool on the cup. Press the cup into the bore until the bottom of the cup touches the shims. - If a press is not available: Use a sleeve, a brass drift, or a bearing driver tool and a hammer to install the cup. Figure 4.8.

47 4 Assembly and Installation 4. If removed, install the outer bearing cup for the drive pinion. A. Place the carrier in a press with the legs of the carrier toward the bottom of the press. Place supports under the carrier so that the carrier is level. B. Place the outer bearing cup for the drive pinion in the bore of the carrier. C. Use a sleeve or a bearing driver tool and a press to install the cup. Press the cup into the carrier until the bottom of the cup touches the bottom of the bore. - If a press is not available: Use a sleeve, a brass drift or a bearing driver tool and a hammer to install the cup. Figure 4.9. Fig Install the drive pinion into the carrier. Figure A. Place the drive pinion into the carrier with the pinion through the inner and the outer bearing cups. B. Place the carrier in a press with the legs of the carrier toward the bottom of the press. Place supports under the carrier so that the carrier is level. Place a support under the head of the drive pinion. The inner bearing cone on the pinion shaft must touch the inner bearing cup in the carrier. C. Place the outer bearing cone onto the pinion shaft. D. Use a press and a sleeve to install the bearing cone onto the pinion. Apply no more than 1814 kg (two tons) of force. Fig. 4.9 Fig. 4.7 Fig Meritor Forward Carrier MD15 47

48 4 Assembly and Installation Adjust the Drive Pinion Bearing Preload Specification If the depth of the drive pinion was changed, then the amount of the change must be added or subtracted to thickness of the spacer between the outer bearing cup and the helical driven gear. After the gear tooth contact pattern and the thickness of shim pack are correct, you must adjust the drive pinion bearing preload. The preload is controlled by the thickness of the spacer between the helical driven gear and the outer bearing cone. Figure Fig Place the helical driven gear over the pinion bore in the carrier with the splines inside the gear toward the front of the carrier. 5. Place the large spacer on top of the helical driven gear with the spacer toward the inner bearing cup. Figure Fig Place the carrier in a press with the threaded end of the pinion facing up. Place supports under the flange of the carrier so that the carrier is level. Place a wood block under the head of the pinion. Figure Press the drive pinion out of the outer bearing cone. Remove the cone. Figure Install the drive pinion in the helical driven gear. Verify that the splines on the pinion engage the splines inside the gear. Figure Place a protector onto the head of the drive pinion. Use a press to install the pinion into the carrier so that the inner bearing cone touches the bearing cup. The helical driven gear will not be completely installed onto the drive pinion. Figure Turn the carrier over so that the legs of the carrier are facing up. Place supports under the carrier so that the carrier is level. 48 Meritor Forward Carrier MD15

49 4 Assembly and Installation Fig Fig Place the carrier in a press with the threaded end of the pinion toward the top of the press. Place supports under the flange of the carrier so that the carrier is level. Place a wood block under the head of the drive pinion so the inner pinion bearing cone touches the inner bearing cup. Figure Use a press and a sleeve to completely install the helical driven gear onto the drive pinion. Use a sleeve on the hub of the gear that fits inside the pinion bore in the carrier. Press the gear on the drive pinion until the gear touches the spacer. Figure Cut two pieces of solder or lead approximately 14 mm ( inch) long and 16 mm (0.625-inch) wide. Use the two pieces of solder to determine the correct thickness of the spacer between the helical driven gear and the outer bearing. 11. Place the two pieces of solder opposite each other on top of the helical driven gear. 12. Place the outer bearing cone into the cup. Meritor Forward Carrier MD15 49

50 4 Assembly and Installation 13. Remove the support from the flange of the carrier. Place a sleeve on top of the outer bearing cone. Use a press to apply a maximum of 1814 kg (two tons) of force to the outer bearing cone. The force of the press compresses the solder pieces to the correct size. Figure Use a micrometer to measure the thicknesses of the compressed pieces of solder. A. Add the measurements of the two pieces and divide by two to determine the average size of the pieces. B. Add mm (0.004-inch) to the average size. Use this dimension to determine the size of the spacer to install between the helical driven gear and the outer bearing. Example mm Inches Thickness of piece No (0.504) Thickness of piece No (0.506) Total thickness (1.010) Divide by two to get average thickness (0.505) Add mm (0.004-inch) to get thickness of spacer (0.509) 18. Place a wood block under the head of the drive pinion so that the inner bearing cone on the pinion touches the inner bearing cup in the carrier. 19. Remove the supports from the carrier. Figure Fig Release the pressure. Remove the wood block from under the drive pinion. 15. Use a press and a sleeve to press the shaft of the drive pinion out of the outer bearing cone. Do not press the shaft of the drive pinion out of the helical driven gear. 16. Remove the outer bearing cone and the two pieces of solder from the outer bearing cone. 20. Use a press and a sleeve to completely install the helical driven gear onto the drive pinion. Use a sleeve on the hub of the gear that fits inside the pinion bore in the carrier. Press the gear on the drive pinion until the gear touches the spacer. Do not remove the wood block at this time. Figure Install the correct size spacer on the shaft of the pinion in front of the helical driven gear. 22. Verify that the wood block is still under the drive pinion. The inner bearing cone on the pinion must touch the cup in the carrier. 50 Meritor Forward Carrier MD15

51 4 Assembly and Installation 23. Install the outer bearing cone onto the shaft of the drive pinion. Figure A. Place the outer bearing cone on the shaft of the drive pinion. B. Place a sleeve onto the inner race of the outer bearing cone. C. Use a press to apply 1814 kg (two tons) of force on the bearing cone to install the cone on the shaft of the drive pinion. While the cone is being installed, rotate the carrier in both directions, so that the carrier pivots on the drive pinion. 24. Release the pressure and remove the carrier from the press and place the carrier in a repair stand. 25. Install the washer and the nut on the drive pinion. 26. Use a fixture to hold the teeth of the helical driven gear or place wood blocks between the head of the pinion and the carrier wall. 27. Tighten the nut to the specified torque. Refer to Section 6. Remove the holding fixture or the wood blocks. 28. Use a Newton-meter (inch-pound) torque wrench or a spring scale to inspect the drive pinion bearing preload. Refer to the following procedures under Inspect Drive Pinion Bearing Preload. Inspect Drive Pinion Bearing Preload Specification Torque Wrench Method 1. Place a Newton-meter (inch-pound) torque wrench and the correct socket on the nut of the drive pinion. Figure Fig Fig Meritor Forward Carrier MD15 51

52 4 Assembly and Installation 2. Use the torque wrench to rotate the drive pinion assembly. Inspect and record the torque level while rotating the assembly. Example - If preload is not within specification: Remove and replace the spacer between the outer bearing cone and the helical driven gear. Refer to Replace the Spacer. - If preload is within specification: Proceed to Install the Pinion Cover. Spring Scale Method 1. Wind a cord around the washer under the drive pinion nut. Attach a spring scale to the end of the cord. 2. Pull the spring scale and cord in a horizontal direction while checking the reading on the spring scale. Figure Measure the outer diameter of the washer under the drive pinion. 4. Divide the outer diameter of the washer by two. Replace the Spacer 1. Prevent the drive pinion assembly from rotating by using a fixture to hold the teeth of the helical driven gear or place hard wood blocks between the head of the pinion and the carrier wall. 2. Remove the nut and the washer from the shaft of the drive pinion. Figure Multiply by the reading on the spring scale to get the preload on the pinion bearings. - If preload is not within specification: Remove and replace the spacer between the outer bearing cone and the helical driven gear. Refer to Replace the Spacer. - If preload is within specification: Proceed to Install the Pinion Cover. Fig Fig Meritor Forward Carrier MD15

53 4 Assembly and Installation 3. Place the carrier in a press with the threaded end of the pinion toward the top of the press. 4. Place supports under the flange of the carrier so that the carrier is level. 5. Place a wood block under the head of the pinion. Ensure that the wood block does not touch the head of the drive pinion. 6. Press the drive pinion out of the bearing cone. Remove the outer bearing cone from the differential carrier. 7. Install the correct size spacer on the shaft of the pinion over the helical driven gear. A. Install a thicker spacer to decrease the preload. B. Install a thinner spacer to increase the preload. 8. Repeat Steps of Adjust the Drive Pinion Bearing Preload. Install the Pinion Cover 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. Main Differential and Ring Gear Assembly CAUTION Heat the ring gear before seating it onto the flange case half. Do not press a cold ring gear on the flange case half. A cold ring gear will damage the case half because of the tight fit. 1. Expand the ring gear by heating the gear in a tank of water to a temperature of C ( F) for 10 to 15 minutes. WARNING Wear protective clothing and gloves to avoid injury when working with the hot ring gear. 2. Use a lifting tool to safely lift the ring gear from the tank of water. 3. Install the ring gear on the flange case half immediately after the gear is heated. If the ring gear does not fit easily on the case half, heat the gear again. Repeat Step Align the fastener holes of the ring gear and flange case half. Rotate the ring gear as needed. Install two capscrews opposite each other. Do not tighten the capscrews. Let the assembly cool. 5. Install the new capscrews that hold the ring gear to the flange case half. Figure Figure Apply a 3.0 mm (0.12-inch) continuous bead of silicone gasket material, Meritor specification 2297-H-7054, around the pinion cover. Assemble the pinion cover within 20 minutes of application. 2. Install the capscrews and torque to specification. Fig Meritor Forward Carrier MD15 53

54 4 Assembly and Installation 6. Tighten the capscrews in a criss-cross sequence to the correct specification. Refer to the following table and Section 6. Figure A. After the bolts are installed, inspect for gaps between the back surface of the ring gear and the case flange. Use an mm (0.003-inch) feeler gauge and inspect at four points around the assembly. Figure B. Inspect the flange case half and ring gear for the problem that causes the gap. Repair or replace parts as necessary. C. After the parts are repaired or replaced, assemble the ring gear on the flange case half. Repeat the previous procedure and Steps A-C. Fig Fig Install the bearing cones on both of the case halves. Use a press and sleeve of the correct size. Figure Fig Apply axle lubricant on the inside surfaces of both case halves, spider, thrust washers, side gears and differential pinions. 9. Place the flange case half on a bench, ring gear teeth toward top. 10. Install one thrust washer and side gear into the flange case half. 54 Meritor Forward Carrier MD15

55 4 Assembly and Installation 11. Align the spider match marks. Install the spider, differential pinions and thrust washers into the flange case half. Figure Install the second side gear and thrust washer over the spider and differential pinions. Figure Place the plain half of the differential case over the flange half and gears. Rotate the plain half as needed to align the match marks. Figures 4.25 and Install the fasteners into the case halves. Figure Tighten the fasteners to the correct torque value. Refer to the following table and Section 6. Fig Inspect the rotating resistance of the differential gears. Verify that the differential assembly freely rotates. Fig Fig Fig Meritor Forward Carrier MD15 55

56 4 Assembly and Installation Check the Differential Assembly Rotating Resistance 1. Make a tool to check the rotating resistance of the differential gears. The tool can be made from an axle shaft that matches the spline size of the differential side gear. Figure Fig Attach a wrench to the nut of the tool and rotate the differential gears. The differential assembly must freely rotate. Figure Fig Place the differential and ring gear assembly on a workbench. 3. Install the tool into the differential until the splines of the tool and one side gear are engaged. Figure If the differential assembly does not rotate freely, disassemble the differential gears from the case halves. 6. Check the case halves, spider, gears and thrust washers for the cause of the rotation resistance. Repair or replace parts as necessary. 7. After the parts are repaired or replaced, reassemble the differential cage assembly parts and repeat Steps 2-6. Install the Main Differential Case and Ring Gear Assembly Into the Carrier NOTE: The bearing cones are not interchangeable. 1. If the bearing cones on the main differential case were removed, install a new cone and cup in a fully-matched set from the same manufacturer. Use a press and a sleeve to install the cones on the case. Press only on the inner race of the bearing. Figure Fig Fig Meritor Forward Carrier MD15

57 4 Assembly and Installation 2. Remove the bearing caps. Clean and dry the bearing cups and bores of the carrier legs and bearing caps. Figure Lubricate the bearing cups and cones with the same axle lubricant used in the axle housing. Fig Install the bearing cups over the bearing cones assembled in the case halves. Figure Safely lift the differential and ring gear assembly and install it into the carrier. The bearing cups must be flat against the bores between the carrier legs. Figure Fig Install both of the bearing adjusting rings into position between the carrier legs. Turn each adjusting ring hand-tight against the bearing cup. Figure CAUTION The bearing caps must be correctly installed or the adjusting rings will be damaged by cross-threading. Forcing the caps into position can damage the caps and the carrier housing. Fig Meritor Forward Carrier MD15 57

58 4 Assembly and Installation 7. Install the bearing caps over the bearings and adjusting rings in the correct location. Figure WARNING 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 brake off and cause serious personal injury. 8. Use a leather, plastic or rubber mallet to seat each bearing cap. The caps must fit easily against the bearings, adjusting rings and carrier. Do not force the bearing caps into position. CAUTION If bearing caps are not installed correctly in the original carrier locations, the bores and threads in the caps will not match the carrier. Forcing the bearing caps into the wrong original position will result in damage to the carrier. 9. If the bearing caps do not correctly fit into position, check the alignment of the match marks, performed at disassembly, between the caps and the carrier. Remove the caps and repeat Steps Install the capscrews and washers that secure the bearing caps to the carrier. Tighten the capscrews by hand four to six turn. Then tighten the capscrews to N m ( lb-ft). 11. Do not install the cotter keys or pins that hold the bearing adjusting rings in position at this time. Proceed to Adjust Differential Bearings Preload. Fig Adjust Differential Bearings Preload Use either dial indicator method one or two, or the large micrometer method, to inspect and adjust the main differential side bearing preload. NOTE: Install the adjusting roll pins after you check the tooth contact pattern. Dial Indicator Method One 1. Attach a dial indicator onto the carrier mounting flange. 2. Adjust the dial indicator so that the pointer is against the back surface of the ring gear. Figure Fig Meritor Forward Carrier MD15

59 4 Assembly and Installation Fig Fig Use a T-bar wrench to loosen the adjusting ring that is opposite the ring gear so that a small amount of end play shows on the dial indicator. Figure Use one of the following procedures to move the differential and the ring gear to the LEFT and RIGHT while you read the dial indicator. Use Step A or B. A. Insert two pry bars between the bearing adjusting rings and the ends of the differential case. The pry bars must not touch the differential bearings. Figure B. Insert two pry bars between the differential case or the ring gear and the carrier at locations other than those described in Step A. The pry bars must not touch the differential bearings. Figure Fig Tighten the same bearing adjusting ring so that no end play shows on the dial indicator. Move the differential to the LEFT and RIGHT as needed. Repeat Step A or B. 6. Tighten each bearing adjusting ring one notch from the zero end play measured in Step 5. The differential side bearings should now have a preload of N m (15-35 lb-in). Figure Proceed to Inspect Ring Gear Runout in this section. Fig Meritor Forward Carrier MD15 59

60 4 Assembly and Installation Method Two 1. Place two dial indicators in central and crossways positions onto the outer machined faces of the caps. Figure Use a wrench to tighten bearing adjusting rings until pinionto-drive gear end play and backlash readings are ZERO. Check that the drive gear is not tight against the pinion. 3. When backlash and end play are ZERO, continue tightening both adjusting rings until the cap expansion reading is between mm ( inch). This measurement is the sum of readings on both dial gauges. Rotate for three noches. Method Three 1. Place two dial indicators in central and crossways positions onto the outer machined faces of the caps. Figure Fig Use a wrench to tighten bearing adjusting rings until pinionto-drive gear end play and backlash readings are ZERO. Check that the drive gear is not tight against the pinion. 3. Mark adjusting ring position using cotter pin hole on cap as reference 4. From the reference point continue tightening the adjusting ring by three space notches and this will preload bearings Large Micrometer Method 1. Hand-tighten both adjusting rings against the differential bearings. Fig Use a large micrometer to measure the distances X and Y between opposite surfaces of the bearing caps. Figures 4.42 and 4.43 Fig Meritor Forward Carrier MD15

61 4 Assembly and Installation 3. Use a T-bar wrench to tighten each bearing adjusting ring one notch. Figure Measure the distances X and Y again. Compare the dimensions with the distances X and Y measured in Step 2. The difference between the two dimensions is the amount the bearing caps have expanded. - If the dimension is within specifications: Inspect runout. - If the dimension is not within specification: Repeat Steps 3 and 4 as needed. Example Fig Inspect Ring Gear Runout 1. Attach a dial indicator on the mounting flange of the carrier. Figure Position the dial indicator so that the plunger is against the back surface of the ring gear. Figure Adjust the dial indicator to ZERO. 3. Rotate the differential and ring gear and read the dial indicator. Ring gear runout must not exceed mm (0.008-inch). - If the runout specification: Remove the differential and ring gear assembly from the carrier. Refer to Remove the Main Differential Case and Ring Gear from the Carrier in Section Inspect the differential parts and carrier for wear or damage. Repair or replace parts as necessary. 5. After the parts are repaired or replaced, install the main differential case and ring gear assembly into the carrier. Refer to Main Differential and Ring Gear Assembly in this section. 6. Repeat the procedure for preload adjustment of the differential side bearings. Adjust Ring Gear Backlash After inspecting the tooth contact patterns, the backlash can be adjusted within specification limits, if needed, to change the location of the pattern. - If the old gear set is installed: Adjust the backlash to the setting that was measured before the carrier was disassembled, mm ( inch). - If a new gear set is installed: Adjust the ring gear backlash to 0.30 mm (0.012-inch). Meritor Forward Carrier MD15 61

62 4 Assembly and Installation 1. Attach a dial indicator onto the carrier mounting flange. Figure Position the dial indicator so that the plunger is against a tooth surface. Adjust the dial indicator to ZERO. Hold the drive pinion in position. 3. 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: Continue inspecting tooth contact patterns. - If the backlash reading is not within specification: Adjust backlash as needed. 4. Loosen one bearing adjusting ring one notch, then tighten the opposite ring the same amount. Refer to Figures 4.46 and Fig Backlash is increased by moving the ring gear away from the drive pinion. Figure Backlash is decreased by moving the ring gear toward the drive pinion. Figure NOTE: When adjusting the backlash, only move the ring gear. Do not move the drive pinion to adjust the backlash. 5. Repeat Steps 2-4 until the backlash is within specifications. Record the setting for use when you adjust the preload of the pinion bearing. Fig Fig Meritor Forward Carrier MD15

63 4 Assembly and Installation Inspect the Gear Set Tooth Contact Patterns (Backlash) Meritor carriers can have a conventional or a generoid hypoid gear set. The tooth contact patterns for each gear set are different. Inspect the part numbers to determine which gear set is in the carrier. Refer to Figure 4.48 for the location of the part number. Fig Fig Examples Table B Fig Tooth Contact Patterns 1. Adjust the backlash of the gear set. Refer to Adjust Ring Gear Backlash in this section. In the following procedures, movement of the contact pattern along the length of the tooth is indicated as toward the heel or toe of the ring gear. Figure Always inspect the tooth contact patterns on the drive side of the gear teeth. Figure Adjust a new gear set to either mm (0.012-inch) or mm (0.015-inch) depending on the size of the ring gear. - Adjust an old gear set to the setting that was measured before the carrier was disassembled. Meritor Forward Carrier MD15 63

64 4 Assembly and Installation 2. Apply a marking compound to 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 Fig Fig Rotate the ring gear forward and backward so that the 12 gear teeth go past the drive pinion six times to get the contact pattern. Repeat, if needed, to get a more clear pattern. 4. Look at the contact patterns on the ring gear teeth. Compare the patterns to Figures 4.52, 4.53 and Fig The location of a good hand-rolled contact pattern for a new gear set is toward the toe of the gear tooth and in the center, between the top and the bottom of the tooth. When the carrier is operated under load, the pattern will extend approximately the full length of the tooth. The top of the pattern will be near the top of the gear tooth. Figure Fig Fig Meritor Forward Carrier MD15

65 4 Assembly and Installation The location of a good hand-rolled pattern for a used gear set must match the wear pattern in the ring gear. The contact pattern will be smaller in area than the wear pattern. If the contact pattern requires adjustment, continue by following Step 5 to move the contact patterns to a deeper or shallower position on the gear teeth. If the contact patterns are in the center of the gear teeth, continue by following Step 6. A high-contact pattern indicates that the drive pinion was not installed deep enough into the carrier. A deep-contact pattern indicates that the drive pinion was installed too far in the carrier. 5. Change the thickness of the shim pack between the pinion inner bearing cup and the differential carrier to move the contact patterns between the top and the bottom of the gear teeth. Use the following procedure. Fig A. Remove the drive pinion, the inner bearing cup and the shims from the carrier. Refer to Drive Pinion Removal in Section 2. - To correct a high-contact pattern: Increase the thickness of the shim pack. When you increase the thickness of the shim pack, the drive pinion will move toward the ring gear. Figure To correct a deep pattern: Decrease the thickness of the shim pack. When you decrease the thickness of the shim, the drive pinion will move away from the ring gear. Figure B. Install the inner bearing cup, the shims and the drive pinion into the carrier. Refer to Assemble and Install the Drive Pinion Assembly in this section. C. Repeat Steps 2-6 until the contact patterns are in the center between the top and bottom of the gear teeth. 6. Adjust the backlash of the ring gear within the specification range to move the contact patterns to the correct location along the length of the gear teeth. Refer to the procedure in Tooth Contact Patterns in this section. Fig C. Repeat Steps 2-4 and 6 until the contact patterns are at the correct location along the length of the gear teeth. 7. After all the adjustments are finally completed, install the roll pin on the bearing cap with the pin between the lugs of the adjusting ring. A. Decrease backlash to move the contact patterns toward the toe of the ring gear teeth. Figure B. Increase backlash to move the contact patterns toward the heel of the ring gear teeth. Figure Meritor Forward Carrier MD15 65

66 4 Assembly and Installation 4. Loosen the thrust screw 1/2 turn or 180 degrees. Figure Tighten the jam nut to N m ( lb-ft). Refer to Section 6. Figure Fig Fig Fig Install and Adjust the Thrust Screw If removed, apply Meritor specification number 2297-D-7076 sealant in a continuous 1.5 mm (0.06-inch) wide bead around the circumference of the inner thrust screw threads. To obtain this sealant, refer to the Service Notes page on the front inside cover of this manual. 1. Rotate the carrier in the repair stand until the back surface of the ring gear is toward the top. Fig Install the thrust screw. Clearance between the thrust screw and ring gear should be mm ( inch). 3. Install the jam nut on the thrust screw, one half the distance between both ends. Figure Meritor Forward Carrier MD15

67 4 Assembly and Installation Fig Install the Inter-Axle Differential (IAD) and Lock Shift Assembly 1. If removed, use a hammer and brass drift to install the rear side gear bearing cup. Strike the cup evenly until it is fully seated in the bore. NOTE: If a new rear bearing cone is required, a new matching bearing cup must be installed at the same time. 2. If removed, use a press to install the rear side bearing cone on the rear side gear. 3. Apply Meritor specification 2297-W-4287 lubricant to the IAD spider legs, pinion teeth, side gear teeth, bearing cones, forward and rear side gear journals, and thrust washer surfaces as they are being assembled. Figure To obtain this lubricant, refer to the Service Notes page on the front inside cover of this manual. 4. If removed, install the bearing cup into the input bearing cage. Use a press and a sleeve to install the cup in the cage. The cup is correctly installed when the bottom of the cup is fully seated in the cage bore. 5. Install the two caged needle bearing assemblies into the rear side gear. Install the rear side gear into the carrier. Fig Lubricate with light grease and assemble the needle bearings into the pinions. 7. Install the inter-axle differential spider, pinions and thrust washers into the IAD carrier. Install the IAD assembly into the carrier housing. 8. Install the helical drive gear in its original position using the previously painted marks. 9. Install the helical drive gear spacer, thrust needle bearing and two caged needle bearing assemblies. 10. Insert the IAD lock spring into the IAD opening. 11. Install the IAD clutch collar and shift fork with the fork boss facing outwards. 12. Insert the diaphragm seat. 13. Apply Meritor specification 2297-E-4295 sealant to the IAD piston threads. To obtain this sealant, refer to the Service Notes page on the front inside cover of this manual. Install the piston into the shift fork and tighten to N m ( lb-ft). Meritor Forward Carrier MD15 67

68 4 Assembly and Installation 14. Place the IAD lock diaphragm and cover in position over the opening. 15. Install the cover capscrews and tighten to N m (11-18 lb-ft). IAD Lock Shift Shaft Stop Adjustment 1. Apply sealant around the circumference of the adjusting screw threads. 2. Install the adjusting screw and jam nut. 3. Loosen the jam nut and adjusting screw until the screw does not touch the end of the shift shaft. Figure Install the Input Shaft Assembly 1. Apply axle lubricant to the parts as they are being assembled. NOTE: Bearing cones and cups are matched as sets. If a new input bearing cone is installed, the matching cup must also be installed at the same time. 2. If necessary, install the bearing cone on the input shaft. A. Place the shaft in a press. B. Place a sleeve over the bearing cone. C. Press the bearing cone onto the input shaft until it bottoms on the shoulder of the shaft. 3. Install the input shaft into the carrier. If necessary, rotate the IAD to align the gear teeth. Figure Fig Fig Apply and hold 800 kpa (116 psi) of air pressure to the IAD lock cover valve, so that the shift collar engages the splines on the drive gear. 5. Tighten the adjusting screw until the tip of the screw touches the end of the IAD lock piston. Tighten the screw one additional turn. Tighten the jam nut to N m (40-55 lb-ft). 6. Check that the clutch collar moves freely and is not clamped to the drive gear. Release the air pressure. 4. Install the input bearing cup on the input bearing cage. 5. Place the required shims on the lip of the input cage. 6. If necessary, use a seal driver and mallet to install a new seal in the input bearing cage cover. 7. Install the input bearing cage cover on the housing. 8. Install the cage capscrews and tighten them to the correct specification. 9. Install the V-ring seal and shield on the input companion flange. 10. Install the companion flange on the input shaft. 11. Install the lock nut on the input shaft and tighten it to the correct specification. Replace the lock nut with a new one if it was damaged during removal. 68 Meritor Forward Carrier MD Use a suitable pointed instrument and a hammer to stake the lock nut on the companion flange.

69 4 Assembly and Installation Install the Yoke on the Input Shaft 1. Inspect the flange seal journal for damage or grooving. Replace the flange if damage is found. CAUTION Use a press and a sleeve or yoke installation tool to install the yoke. Do not use a hammer or mallet to install the yoke. Using a hammer or mallet can damage the bearings, yoke or flange. 2. Use a press and a sleeve or an installation tool to install the yoke or the flange on the input shaft. If a press and a sleeve are used, make sure that the input shaft is well supported. 3. Rotate the yoke at least one full turn after the yoke nut is tightened to correct torque specification. This ensures correct seating of the seal. CAUTION Do not use the nut to draw the yoke onto the input shaft. Possible thread damage and probable incorrect yoke seating will result. 4. Install the nut that fastens the yoke or the flange to the input shaft. Tighten the nut by hand. Do not tighten the nut to the specified torque until the bearing cage and pump assembly is installed in the housing. Inspect and Adjust the Input Bearing End Play 1. Install capscrews, but not the washers, that fasten the input bearing cage to the carrier. Rotate the input shaft in each direction to make sure the bearings are correctly installed while hand tightening the capscrews. Do not torque the capscrews. Figure Fig Use a feeler gauge to measure the gap between the input bearing cage and the differential carrier. Inspect the gap at four equally-spaced places on the cage. Figure Add up the four measurements and determine the average gap between the cage and the carrier. Add 0.05 mm ( inch) to the average gap measurement to determine the size of the shim pack between the cage and the carrier. 4. Use at least three shims when building a shim pack, always place the thickest shims in the middle of the shim pack. 5. Remove the capscrews that fasten the input bearing cage to the carrier. Fig Meritor Forward Carrier MD15 69

70 4 Assembly and Installation Fig Fig Install the shim pack. A. Connect a lifting device to the input yoke. Lift the input shaft assembly until there is a distance of 6-12 mm (1/4-1/2-inch) between the cage and carrier mounting surface. B. Install the shim pack under the bearing cage. The hole pattern of the shim pack must match the hole pattern of the cage. Figure C. Install the capscrews and the washers that fasten the cage to the carrier. The capscrews must be aligned with the holes in the shim pack. Tighten the capscrews so that the threads engage in the holes of the carrier. D. Lower the input shaft assembly so that the cage and the shim pack are installed against the carrier. Remove the lifting device from the yoke or flange. E. Tighten the capscrews from N m (75-95 lb-ft) while rotating the input shaft in each direction to ensure that the bearings are correctly installed. 9. Inspect the end play of the input shaft. A. Rotate the input shaft in each direction and push the yoke or flange toward the bearing cage. This verifies that the input shaft assembly is at the bottom of its travel. B. Use a dial indicator with a magnetic base or a C-clamp base to inspect the end play of the input bearing. Verify that the pointer of the dial indicator is against the top of the input shaft. Set the dial indicator to ZERO. Figure C. Use a pry bar and a support to push the yoke or the flange away from the carrier. Read the dial indicator. The reading must be in the mm ( inch) range. Figure If the end play of the input bearing is not within the mm ( inch) range: Add or remove shims from the shim pack. Repeat Steps 5-9 of this procedure. Place the shield for the oil filter in position on the bearing cage. 7. Place a holding tool on the input yoke or flange and tighten the nut to the specified torque. Refer to Section Rotate the yoke at least one full turn after you tighten the yoke nut to the correct torque specification to verify that the seal seats correctly. 70 Meritor Forward Carrier MD15 Fig. 4.70

71 4 Assembly and Installation Install the Driver-Controlled Differential Lock (DCDL) Assembly 1. Install the adapter on the differential case and secure it with a spacer and snap ring. 2. Apply grease 2297-M-4303 on the tapered surface of the shift fork before assembly. 3. Insert the shift fork and spring into the DCDL opening. Figure Compress the spring behind the shift fork until it is fully seated between the fork and casting. 5. Insert the shift shaft in the housing, through the shift fork and spring. Fig Apply Meritor specification 2297-W-4287 lubricant to the shift collar splines and groove. 7. Install the clutch collar on the shift fork. Figure Push in the roll pins securing the clutch collar within the shift fork. Figure If the O-ring was removed, lubricate the O-ring with 2297-X and reinstall it into the piston bore. 10. Install the piston so the shaft is fully seated. 11. Position the cover and gasket over the DCDL provision. Fig Install the washers and capscrews on the cover. Torque to the correct specifications. Figure Apply Meritor specification 2297-X-6628 or Loctite 573 sealant to the sensor switch on the outside threads about 5 mm (0.20-inch). 14. Install the sensor switch. Tighten the lock nut. Figure Fig Meritor Forward Carrier MD15 71

72 4 Assembly and Installation 15. Apply air pressure of 800 kpa (116 psi) to the DCDL cover valve to engage the differential lock fork. 16. Connect the test unit to the switch terminals and adjust the switch until contact is made with the shift fork. Screw in the switch one complete turn and tighten the lock nut to specifications. 17. Remove air pressure, then reapply air again to check correct operation of switch. Install the Output Bearings and Thru-Shaft 1. Lubricate the bearing cups and the cones with axle lubricant. Figure NOTE: If either the bearing cup or the cone need replacement, both parts must be replaced in a fully-matched set from the same manufacturer. Fig If the bearing cones were removed from the thru-shaft, install new bearing cones. Place both cones back-to-back on the thru-shaft. Use a press and a sleeve to install both cones. Apply pressure until the inner cone seats on the shoulder of the thru-shaft. Figure Use a press and a sleeve to install the inner bearing cup in the cage. Place the thru-shaft and bearing assembly in the cage. 4. Use a brass drift, bearing driver tool and a sleeve to install the outer bearing cup into the housing over the thru-shaft. Figure Fig Install the snap ring that fastens the outer cup in the cage. The snap ring controls the end play of the output bearing. 6. Inspect and adjust the end play of the thru-shaft bearing. Refer to the following procedure. Fig Meritor Forward Carrier MD15

73 4 Assembly and Installation Inspect and Adjust Output Bearing End Play The end play of the output bearing is controlled by the size of the snap ring that holds the bearings in the output cage. The snap rings are available in increments of mm (0.003-inch). Install the snap ring which results in an end play of mm ( inch). 1. Use an installation tool to install the yoke or flange on the thru-shaft. Do not use the nut to draw the yoke onto the shaft. Do not install the oil seal at this time. 2. Install the nut that fastens the yoke or flange to the thrushaft. Place a holding tool on the yoke or flange and tighten the nut to the specified torque. Refer to Section Push the yoke or flange toward the axle housing and rotate the shaft in each direction to verify that the bearings are correctly installed. Fig Install a dial indicator so that the base of the indicator is on the axle housing. The pointer of the indicator must touch the yoke or flange end of the thru-shaft. Adjust the dial indicator to the ZERO setting. Figure Place pry bars under the yoke or flange and push the yoke or flange away from the axle housing. Record the reading on the dial indicator. The reading must be mm ( inch). The reading is the measurement of the end play on the output bearing. 6. If the end play reading is not within the mm ( inch) specification, remove and replace the snap ring that fastens the bearings in the cage. Install a thinner snap ring to increase end play. Install a thicker snap ring to decrease end play. Figure Remove the nut that fastens the yoke or flange to the thrushaft. Use the correct puller tool to remove the yoke. 8. Install the seal using a seal driver and mallet. Refer to Install a Unitized Seal on the Output Shaft in Section Assemble the yoke and nut, then place the holding tool on the yoke or flange. Tighten the nut to specifications. 10. Using a punch or suitable tool, stake the nut on the flange in two places. Fig Meritor Forward Carrier MD15 73

74 4 Assembly and Installation Install the Differential Carrier 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: 5. Apply RTV silicone gasket material to the mounting surface of the housing where the carrier fastens. Figure Wear safe eye protection. - Wear clothing that protects your skin. O Work in a wellventilated area. - Do not use gasoline, or solvents that contain gasoline. Gasoline can explode. Fig You must use hot solution tanks or alkaline solutions correctly. Follow the manufacturer s instructions carefully. 1. Clean the inside of the axle housing and the mounting surface where the carrier fastens. Use a cleaning solvent and rags to remove dirt. Blow dry the cleaned areas with air. Refer to Clean Ground and Polished Parts in Section Inspect the axle housing for damage. Repair or replace the axle housing. Refer to Repair or Replace Parts in Section Inspect for loose studs in the mounting surface of the housing where the carrier fastens. Remove and clean the studs that are loose. 4. Reinstall the studs in the axle housing. Install the axle shafts. Refer to the vehicle manufacturer s recommended procedures. Tighten the studs from N m ( lb-ft). WARNING When you apply some silicone gasket materials, small amounts of acid vapor are present. To prevent possible serious personal injury, the work area must be well ventilated. If the silicone gasket material gets in your eyes, flush them with water for 15 minutes. Have your eyes checked by a doctor as soon as possible. Fig On axles that use a main differential lock, the lock MUST be shifted into and held in the locked, or engaged position. The locked position provides clearance between the shift collar and the axle housing to permit the installation of the carrier. 7. Using a hydraulic roller jack or a lifting tool, install the carrier into the axle housing. Figure CAUTION Do not use a hammer or a mallet to install the carrier. A hammer or a mallet will damage the mounting flange of the carrier and cause oil leaks. 74 Meritor Forward Carrier MD15

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