Rear Axle Single-Reduction Carrier

Transcription

1 Revised 08-0 Rear Axle Single-Reduction Carrier Model MS-3 Maintenance Manual MM-030

2 Service Notes Service Notes Notes About This Manual This manual provides instructions for Meritor s model MS-3 single-reduction rear axle. Before You Begin. Read and understand all instructions and procedures before you begin to service components.. Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or both. 3. Follow your company s maintenance and service, installation, and diagnostics guidelines. 4. Use special tools when required to help avoid serious personal injury and damage to components. Literature on Demand DVD (LODonDVD) The LODonDVD contains product, service and warranty information for ArvinMeritor components. To order the DVD, visit Literature on Demand at arvinmeritor.com and specify TP-074. How to Obtain Supplies Specified in This Manual Call ArvinMeritor s Commercial Vehicle Aftermarket at to obtain Meritor supplies. SPX Kent-Moore, 8635 Mound Road, Warren, Michigan, Call the company s customer service center at , or visit their website at spxkentmoore.com. Hazard Alert Messages and Torque Symbols WARNING A Warning alerts you to an instruction or procedure that you must follow exactly to avoid serious personal injury and damage to components. CAUTION A Caution alerts you to an instruction or procedure that you must follow exactly to avoid damage to components. T This symbol alerts you to tighten fasteners to a specified torque value. How to Obtain Additional Maintenance and Service Information On the Web Visit Literature on Demand at arvinmeritor.com to access and order product, service, aftermarket, and warranty literature for ArvinMeritor s truck, trailer and specialty vehicle components.

3 Table of Contents Table of Contents Exploded View i Section : Introduction Section : Removal and Disassembly Removal Axle Shafts from the Axle Assembly Differential Carrier from the Axle Housing Differential Case and Ring Gear from the Carrier Drive Pinion from the Carrier Disassembly Differential Case and Ring Gear Drive Pinion Section 3: Prepare Parts for Assembly Clean Ground and Polished Parts Clean Rough Parts Clean Axle Assemblies Dry Parts After Cleaning Prevent Corrosion on Cleaned Parts Inspect Parts Repair or Replace Parts Repair Welding on Axle Housings For Complete Welding Instructions on Meritor Drive Axle Housings Prepare the Axle Do Not Bend or Straighten a Damaged Drive Axle Housing Removing Fasteners Secured with Adhesive Install Fasteners New Fasteners with Pre-Applied Adhesive Original or Used Fasteners Using Meritor Liquid Adhesive 97-C-7049 or Loctite 680 Adhesive, or Equivalent Applying Meritor Specification 97-T-3994, Loctite 680 Adhesive, or Equivalent in the Bearing Bores Differential Applying Loctite 5699 Silicone Gasket Material, or Equivalent Gear Sets Examples Section 4: Assembly and Installation Assembly Drive Pinion Differential Case and Ring Gear Differential Gears Rotating Resistance Installation Drive Pinion into the Carrier Differential Case and Ring Gear into the Carrier Adjust Differential Bearing Preload Check Ring Gear Runout (Radial Movement) Ring Gear Backlash Check the Tooth Contact Patterns (Backlash) of the Gear Set Differential Carrier into the Axle Housing Axle Shafts in the Axle Assembly Fill the Axle with Lubricant

4 Table of Contents Section 5: Diagnostics Vehicle Will Not Move Differential Making Noise Oil Leak Contaminated Lubricant Found During Preventive Maintenance Section 6: Torque Specifications Section 7: Lubrication Section 8: Towing Instructions Before Towing or Drive-Away After Towing or Drive-Away Section 9: Special Tools Carrier Repair Stand Specifications How to Make a Yoke Bar Seal Driver Tool

5 Exploded View Exploded View Locknut, M3 x.5 3 Inner Bearing Cup 5 Side Gear Yoke 4 Carrier 6 Differential Pinion Shaft 3 Seal 5 Differential Cap Capscrew, M4 x.0 7 Differential Case 4 Screws, M6 x.0 6 Cotter Pins 8 Differential Case Capscrew, M x.75 5 Lock Plate 7 Thrust Washer 9 Carrier-to-Housing Capscrew, M x.75 x 60 6 Pinion Cage 8 Differential Pinion 30 Carrier-to-Housing Capscrew, M x.75 x 30 7 O-Ring 9 Adjusting Ring 3 Breather 8 Outer Bearing Cup 0 Bearing Cup 3 Axle Housing 9 Outer Bearing Cone Bearing Cone 33 Fill Plug 0 Drive Pinion Ring Gear 34 Drain Plug Shim 3 Differential Case Ring Gear Side 35 Axle Shaft Inner Bearing Cone 4 Thrust Washer ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page i

6 Section Introduction Section Introduction Meritor s model MS-3 single-reduction rear axle has a single-reduction carrier, which is front-mounted into the axle housing. Figure.. The carrier has a hypoid drive pinion and ring gear set. Bevel gears are used in the differential assembly. All bearings in the carrier are tapered roller bearings. When the carrier operates, there is normal differential action between the wheels all the time. Figure ADJUSTING RING CARRIER 3 RING GEAR AND DRIVE PINION 4 TAPERED ROLLER BEARING 5 TAPERED ROLLER BEARING 6 HOUSING 7 DIFFERENTIAL PINION 8 COTTER PIN ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page

7 Section Removal and Disassembly Section Removal and Disassembly WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Figure. EASY SERVICE TM 9 Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury. Removal WING SERIES PERMALUBE TM Axle Shafts from the Axle Assembly. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. 5 FULL-ROUND. Raise the rear end of the vehicle so that the rear wheels are off the ground. Support the vehicle with safety stands. Figure Place a drain pan under the rear axle. 4. Remove the drain plug from the bottom of the axle housing. Drain the lubricant from the assembly. Install the drain plug and tighten it to lb-ft (48-67 N m). T 5. Disconnect the driveline universal joint from the pinion input yoke on the carrier. Figure RPL SERIES, PERMALUBE TM Figure. SAFETY STANDS 00983a 4 3 FULL ROUND BEARING CUPS END YOKE 3 YOKE SADDLE 4 WELD YOKE 5 BEARING STRAP 6 CAPSCREWS 7 EASY-SERVICE BEARING CUPS 8 U-JOINT CROSS 9 SLIP YOKE 0 CAPSCREWS END YOKE WELD YOKE 00984b 3 SLIP YOKE 4 U-JOINT CROSS 5 CAPSCREWS 6 END YOKE 7 WELD YOKE 8 SLIP YOKE 9 U-JOINT CROSS 0 CAPSCREWS END YOKE SLIP YOKE 3 TUBING 4 U-JOINT CROSS 5 WELD YOKE Copyright 00 ArvinMeritor Maintenance Manual MM-030 Page ArvinMeritor, Inc. (Revised 08-0)

8 Section Removal and Disassembly 6. Remove the capscrews from the flanges of both axle shafts. Figure Mark each axle shaft before you remove it from the axle assembly. Figure.3 3. Loosen the two capscrews in the TOP of the carrier, but do not remove them. 4. Loosen the carrier by striking the mounting flange at several points with a dead-blow hammer. Remove the two capscrews in the TOP of the carrier that secure the carrier to the axle housing. 5. Use a hydraulic roller jack and pry bar with a round end to remove the carrier from the axle housing. Take care when you use the pry bar so that you don t damage the carrier or housing flange. CAPSCREW AXLE SHAFT FLANGE 3 AXLE SHAFT HUB 3 WARNING To avoid serious personal injury and damage to components, take care when using lifting devices during service and maintenance procedures. Inspect a lifting strap to ensure that it is not damaged. Do not subject lifting straps to shocks or drop-loading. Differential Carrier from the Axle Housing. Place a hydraulic roller jack under the carrier. Figure.4. Figure.4 NOTE: A carrier stand is available from SPX Kent-Moore. Refer to the Service Notes page on the front inside cover of this manual to obtain the stand. 6. Use a lifting tool to place the carrier into a carrier stand. Figure.5. Refer to Section 9 to build a stand. Figure.5 WOOD BLOCK ROLLER JACK 00709c NOTE: Two capscrews in the TOP of the carrier housing secure the carrier.. Remove all of the capscrews that secure the carrier to the axle housing, except the two capscrews in the TOP of the carrier. DIFFERENTIAL CARRIER REPAIR STAND ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page 3

9 Section Removal and Disassembly Differential Case and Ring Gear from the Carrier NOTE: Before working on the differential carrier, inspect the gear set for damage. If the gear set is not damaged, it can be reused. Measure the backlash of the gear set and record the dimension. Figure.6. Refer to Section 4.. Remove the cotter pins from the side gear adjusting rings. Figure.7. Figure.6 Figure.8 CAPSCREWS DIFFERENTIAL CAP Figure.9 Figure.7 BEARING CUP ADJUSTING RING 4. Remove the differential assembly from the carrier and place it onto a workbench. 5. Remove the differential adjusting ring and bearing cup from integral bearing cap side. COTTER PIN. Remove the differential bearing cap capscrews and the cap. Figure Remove the differential adjusting ring and bearing cup from bolted-on bearing cap side. Figure.9. Drive Pinion from the Carrier. Fasten a yoke bar onto the yoke to hold the yoke when you remove the locknut. Figure.0. Refer to Section 9 to build a yoke bar.. Remove the yoke locknut. Figure.. Remove the yoke bar. Copyright 00 ArvinMeritor Maintenance Manual MM-030 Page 4 ArvinMeritor, Inc. (Revised 08-0)

10 Section Removal and Disassembly Figure.0 Figure. YOKE BAR CAPSCREW LOCK PLATE Figure. 4 3 Disassembly WARNING Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury. Differential Case and Ring Gear. Remove the capscrews from the differential case. Figure.3. LOCK PLATE CAPSCREW 3 PINION CAGE 4 YOKE LOCKNUT Figure.3 3. Remove the yoke from the drive pinion. If the yoke is tight on the drive pinion: Use a puller to remove the yoke. 4. Remove the lock plate capscrews and the lock plate. Figure.. 5. Use a spanner wrench to unscrew the pinion cage from the carrier. 6. Remove the pinion cage and the drive pinion from the carrier. 7. Remove the drive pinion inner bearing cup from the carrier. CAPSCREWS ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page 5

11 Section Removal and Disassembly. Separate the differential case halves. Figure.4. Remove the thrust washer and side gear. Figure Remove the differential pinion shaft, differential pinions and thrust washers. Figure.6. Figure Remove the side gear and thrust washer. Figure.7. Use a brass hammer to remove the ring gear from the differential case. Figure.8. Figure.4 DIFFERENTIAL PINION THRUST WASHER 3 DIFFERENTIAL PINION SHAFT Figure.7 Figure.5 SIDE GEAR THRUST WASHER Figure.8 THRUST WASHER SIDE GEAR RING GEAR DIFFERENTIAL CASE Copyright 00 ArvinMeritor Maintenance Manual MM-030 Page 6 ArvinMeritor, Inc. (Revised 08-0)

12 Section Removal and Disassembly 5. Use a bearing puller or a press to remove the bearing cones from both halves of the differential case. Figure.9. Figure.9 DIFFERENTIAL CASE Drive Pinion. Remove and discard the pinion cage O-ring. Figure.0. Figure PINION CAGE O-RING 3 OUTER BEARING CUP 4 OUTER BEARING CONE 5 DRIVE PINION 6 SHIM 7 INNER BEARING CONE. Remove the outer bearing cup and seal from the pinion cage. Discard the seal. 3. Use a bearing puller or a press to remove the inner and outer bearing cones from the drive pinion. 4. Remove the shim from the drive pinion. ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page 7

13 Section 3 Prepare Parts for Assembly Section Prepare 3 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. Work in a well-ventilated area. Do not use gasoline, or solvents that contain gasoline. Gasoline can explode. You must use hot solution tanks or alkaline solutions correctly. Follow the manufacturer s instructions carefully. Clean Ground and Polished Parts. 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.. 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. Clean rough parts with the same method as cleaning ground and polished parts.. 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. A complete axle assembly can be steam cleaned on the outside to remove dirt.. 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. Parts must be dried immediately after cleaning and washing.. Dry the parts using soft, clean paper or cloth rags. CAUTION Damage to bearings can result when they are rotated and dried with compressed air. 3. Except for bearings, parts can be dried with compressed air. Prevent Corrosion on Cleaned Parts. Apply axle lubricant to cleaned and dried parts that are not damaged and are to be assembled.. 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. Copyright 00 ArvinMeritor Maintenance Manual MM-030 Page 8 ArvinMeritor, Inc. (Revised 08-0)

14 Section 3 Prepare Parts for Assembly Inspect Parts It is very important to inspect all parts carefully and completely before the axle or carrier is assembled. Check all parts for wear and replace damaged parts.. Inspect the cup, cone, rollers and cage of all tapered roller bearings in the assembly. If any of the following conditions exist, replace the bearing. The center of the large-diameter end of the rollers is worn level with or below the outer surface. Figure 3.. The radius at the large-diameter end of the rollers is worn to a sharp edge. Figure 3.. There is a visible roller groove in the cup or cone inner race surfaces. The groove can be seen at the small- or large-diameter end of both parts. Figure 3.. There are deep cracks or breaks in the cup, cone inner race or roller surfaces. Figure 3.. There are bright wear marks on the outer surface of the roller cage. Figure 3.3. There is damage on the rollers and on the surfaces of the cup and cone inner race that touch the rollers. Figure 3.4. There is damage on the cup and cone inner race surfaces that touch the rollers. Figure 3.5. Figure 3. WORN RADIUS Figure 3. CRACK Figure 3.3 Figure 3.4 WEAR MARKS WEAR GROOVES 00308b 00309a ETCHING AND PITTING WORN SURFACE 00307b 00300a ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page 9

15 Section 3 Prepare Parts for Assembly Figure 3.5 Figure SPALLING AND FLAKING 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.. Inspect pinions and gears for wear or damage. Replace gears that are worn or damaged. CAUTION 0030b A thrust washer, differential side gear and pinion gear are machined as a matched set. When you replace any of these parts, you must install a new matched set. Do not mix old and new parts. Damaged to components can result. 3. Inspect the following main differential assembly parts for wear or stress. Replace parts that are damaged. Figure 3.6. Inside surfaces of both case halves Both surfaces of all thrust washers The differential pinion shaft Teeth and splines of both differential side gears Teeth and bore of all differential pinions 4. Inspect axle shafts for wear and cracks at the flange, shaft and splines. Replace the axle shafts, if required. CASE HALVES PINION AND THRUST WASHER 3 SIDE GEAR AND THRUST WASHER 4 DIFFERENTIAL PINION SHAFT 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.. Replace any fastener if corners of the head are worn.. 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. 6. Clean and repair threads of fasteners and holes. Use a die, a tap of the correct size, or a fine file. Copyright 00 ArvinMeritor Maintenance Manual MM-030 Page 0 ArvinMeritor, Inc. (Revised 08-0)

16 Section 3 Prepare Parts for Assembly Figure 3.7 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. REMOVE SILICONE GASKET FROM PARTS. Repair Welding on Axle Housings For Complete Welding Instructions on Meritor Drive Axle Housings Refer to Maintenance Manual 8, Drive Axle Housings. To obtain this publication, refer to the Service Notes page on the front inside cover of this manual. WARNING 00308b 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. 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.. 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 50 F ( C). Damage to the air chamber can result. 3. Remove the wheel-end components and brake air chambers from the axle. Refer to the correct Meritor brake maintenance manual or the vehicle manufacturer s instructions. 4. For housing-to-cover welds, clean the outside housing-to-cover weld area inches ( mm) past each end or side of the crack. Clean the inside area where the cover mates with the housing. Clean the area completely around the cover. Use a wire brush and a cleaning solvent that will remove dirt and grease from these areas. Figure 3.8. ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page

17 Section 3 Prepare Parts for Assembly Figure 3.8 Clean this area. 5. For suspension bracket welds, clean both lower and upper suspension brackets and the areas of the axle housing around each bracket. Use a wire brush and a cleaning solvent that will remove dirt and grease from these areas. Figures 3.9 and 3.0. Figure 3.9 LOWER BRACKET Clean these areas a WARNING The axle housing must be 70 F ( C) or warmer before you weld onto the axle. Do not weld onto a cold axle or weld cold parts onto an axle. Cracks in the weld area, damage to components and serious personal injury can result. 6. Ensure that the axle housing temperature measures 70 F ( C) or warmer. If the axle housing temperature measures less than 70 F ( C): Store the axle in a heated room until the housing reaches the correct temperature. 7. Heat the damaged area to approximately 300 F (49 C) before you begin welding. 8. Use suitable weld wire electrodes when you weld. Suitable weld wire electrodes include either BS EN 499 E 4 B 3 H5 or BS EN 440 G 4 M GSi (American Welding Society equivalents E708 and ER70S3, respectively). 9. For complete welding instruction, refer to Maintenance Manual 8. To obtain this publication, refer to the Service Notes page on the front inside cover of this manual. Do Not Bend or Straighten a Damaged Drive Axle Housing Figure a Clean this area. WARNING Replace damaged or out-of-specification axle components. Do not bend, repair or recondition axle components by welding or heat-treating. A bent axle beam reduces axle strength, affects vehicle operation and voids Meritor s warranty. Serious personal injury and damage to components can result. Always replace a damaged drive axle housing. Do not bend or straighten a damaged housing, which can misalign or weaken it, and void Meritor s warranty. UPPER BRACKET Clean these areas a Copyright 00 ArvinMeritor Maintenance Manual MM-030 Page ArvinMeritor, Inc. (Revised 08-0)

18 Section 3 Prepare Parts for Assembly Removing Fasteners Secured with Adhesive If it s difficult to remove fasteners secured with Dri-Loc, Meritor specification 97-P-3994, Loctite 680 adhesive, or equivalent, use the following procedure. CAUTION When you remove fasteners secured with adhesive, slowly heat the fastener to 350 F (77 C). Do not exceed this temperature, or heat fasteners quickly. Damage to components can result.. Heat a fastener for three to five seconds only. Try to loosen the fastener with a wrench. Do not use an impact wrench or hit the fastener with a hammer.. Repeat Step until you can remove the fastener. Install Fasteners New Fasteners with Pre-Applied Adhesive NOTE: No drying time is required for fasteners with pre-applied adhesive.. Use a wire brush to clean oil and dirt from threaded holes.. Install new fasteners with pre-applied adhesive to assemble parts. Do not apply adhesives or sealants to fasteners with pre-applied adhesive, or to fastener holes. 3. Tighten fasteners to the required torque value for that size fastener. Original or Used Fasteners Using Meritor Liquid Adhesive 97-C-7049, Loctite 680 Adhesive, or Equivalent WARNING Take care when you use Loctite to avoid serious personal injury. Follow the manufacturer s instructions to prevent irritation to the eyes and skin.. Apply four or five drops of Meritor liquid adhesive, Loctite 680 adhesive, or equivalent, inside each threaded hole or bore. Do not apply adhesive directly to fastener threads. Figure 3.. Figure 3. FOUR TO FIVE DROPS ON BORE THREADS 00305a NOTE: There is no drying time required for Meritor specification 97-C-7049 liquid adhesive, Loctite 680 adhesive, or equivalent. 3. Tighten the fasteners to the required torque value for that size fastener. Applying Meritor Specification 97-P-3994, Loctite 680 Adhesive, or Equivalent in the Bearing Bores Differential NOTE: Use Meritor specification 97-P-3994, Loctite 680 adhesive, or equivalent for all axles. To obtain this adhesive, refer to the Service Notes page on the front inside cover of this manual.. Clean the oil and dirt from the outer diameters of the bearing cups and bearing bores in the carrier and bearing caps. There is no special cleaning required.. Apply axle lubricant to the bearing cones and the inner diameters of the bearing cups of the main differential. Do not get oil onto the outer diameter of the bearing cup and do not permit oil to drip onto the bearing bores.. Use a wire brush to clean the oil, dirt and old adhesive from all threads and threaded holes. ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page 3

19 Section 3 Prepare Parts for Assembly 3. Apply a single continuous bead of adhesive to the bearing bores in the carrier and bearing cap. Apply the adhesive around the circumference of the smooth, ground surfaces only. On the integral cap side, apply the adhesive near the thread end. Do not apply adhesive onto the threaded areas. Figure 3.. Figure 3. ADHESIVE BEARING CAP CARRIER LEG 00306a NOTE: Meritor specification 97-P-3994, Loctite 680 adhesive, or equivalent will dry in approximately two hours. Perform Steps 4 and 5 within two hours from the time you apply the adhesive. If two hours have passed since application, clean the adhesive from the parts and apply new adhesive. Applying Loctite 5699 Silicone Gasket Material, or Equivalent WARNING When you apply some silicone gasket materials, small amounts of acid vapor are present. To prevent serious personal injury, ensure that the work area is well ventilated. If the silicone gasket material gets into your eyes, flush them with water for 5 minutes. Have your eyes checked by a physician as soon as possible. NOTE: The following silicone gasket products or equivalent can be used for Meritor components: Loctite 5699 silicone gasket material Loctite 858 Ultra Grey adhesive/sealant Meritor gasket material/part number 97-F-705. To obtain this gasket material, refer to the Service Notes page on the front inside cover of this manual.. 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 surfaces. 4. Install the main differential assembly, bearing cups and bearing cap into the carrier. The bearing cup of the integral bearing cap side must be assembled from the thread side. Refer to Section 4. Remove excess adhesive after assembly. 5. Adjust the preload of the differential bearings, backlash and tooth contact patterns of the gear set as required. Refer to Section 4. Figure 3.3 sealant material. HOUSING AND CARRIER SHOWN 00307c Copyright 00 ArvinMeritor Maintenance Manual MM-030 Page 4 ArvinMeritor, Inc. (Revised 08-0)

20 Section 3 Prepare Parts for Assembly CAUTION Apply silicone gasket material in a continuous /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 /8-inch (3 mm) diameter continuous bead of the silicone gasket material around one surface. Also apply the gasket material around the edge of all fastener holes on that surface. Figure 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 0 minutes before filling the assembly with the correct lubricant. Refer to Section 7. Figure 3.4 Figure 3.5 ALTERNATE LOCATIONS: PART NUMBER, TOOTH COMBINATION NUMBER, GEAR SET MATCH NUMBER, PINION CONE VARIATION NUMBER PART NUMBER, TOOTH COMBINATION NUMBER 3 GEAR SET MATCH NUMBER, PINION CONE VARIATION NUMBER 4 PART NUMBER, TOOTH COMBINATION NUMBER, GEAR SET MATCH NUMBER 5 PART NUMBER, TOOTH COMBINATION NUMBER GEAR SET MATCH NUMBER Examples a Gear Set Part Number Location Conventional ring gear Conventional drive pinion On the front face or outer diameter At the end at threads 00308b 0.5 (3 MM) DIAMETER SILICONE GASKET BEAD Gear Sets Refer to the following examples for information on identifying gear sets with matched parts. Always check match numbers to verify that the gear set you will install has matched parts. Figure 3.5. Gear Set Tooth Combination Number Gear Set Teeth 5-37 = gear set has a five-tooth drive pinion and a 37-tooth ring gear Drive Pinion Location At the end at threads Gear Set Match Number Ring Gear Location On the front face or outer diameter NOTE: Meritor s drive pinions and ring gears are only available as matched sets. Each gear in a set has an alpha-numeric match number. Match Number M9 Drive Pinion Location At the end of the gear head Ring Gear Location On the front face or outer diameter ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page 5

21 Section 3 Prepare Parts for Assembly Pinion Cone Variation Number NOTE: Don t use the pinion cone variation number when you check for a matched gear set. Use this number when you adjust the pinion depth in the carrier. Refer to Section 4. Pinion Cone (PC) Variation Number PC mm PC mm Drive Pinion Location At the end of the pinon gear head Ring Gear Location On the outer diameter Copyright 00 ArvinMeritor Maintenance Manual MM-030 Page 6 ArvinMeritor, Inc. (Revised 08-0)

22 Section 4 Assembly and Installation Section Assembly 4 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. Assembly Drive Pinion. Apply Meritor specification 97-W-487, 97-U-459 or lubricant to the new O-ring, carrier threads, O-ring bore, pinion cage threads and the inner and outer bearings. Figure 4.. To obtain this lubricant, refer to the Service Notes page on the front inside cover of this manual. Figure 4. PINION CAGE O-RING 3 OUTER BEARING CUP 4 OUTER BEARING CONE Install the new O-ring onto the pinion cage. 3. Install the shim onto the drive pinion. 4. Use a press to install the inner and outer bearing cones onto the drive pinion. 6 5 DRIVE PINION 6 SHIM 7 INNER BEARING CONE 7 Differential Case and Ring Gear. Use a press to install the bearing cones onto both halves of the differential case. CAUTION Heat the ring gear before seating it onto the differential case. Do not press a cold ring gear onto the differential case. A cold ring gear will damage the differential case because of the tight fit.. Heat the ring gear. A maximum temperature of 340 F (70 C) can be applied at the gear web. The temperature at the gear teeth must not exceed 50 F (0 C). Wear safe clothing and gloves while working with the hot ring gear. 3. Position the differential case on a workbench with the bearing cone on top. 4. Place the ring gear over the differential case immediately after the gear is heated. If the ring gear does not fit easily on the differential case: Heat the gear again. 5. Align the ring gear and differential case capscrew holes. Rotate the ring gear as necessary. 6. Use a feeler gauge to inspect for gaps between the ring gear and the differential case. If the gap exceeds 0.00-inch (0.05 mm) at more than three places with an arc length greater than.0-inch (5.4 mm): Inspect the differential case and ring gear for wear or damage. Repair or replace parts as necessary. 7. Turn the differential case over on the workbench so that the bearing cone is on the bottom. 8. Apply Meritor specification 97-W-487, 97-U-459 or lubricant to the differential pinion shaft, thrust washers, differential pinions and side gears. To obtain this lubricant, refer to the Service Notes page on the front inside cover of this manual. ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page 7

23 Section 4 Assembly and Installation 9. Install the thrust washer and side gear into the differential case. Figure Slide the differential pinions and thrust washers onto the differential pinion shaft. Figure Position the differential pinion shaft in the differential case on top of the side gear. The holes in the differential pinion shaft must align with the capscrew holes in the differential case. Figure Install the side gear and thrust washer over the differential pinions. Figure Position the case half over the side gear. Figure 4.6. Figure 4. Figure 4.4 Align holes. Figure 4.5 SIDE GEAR THRUST WASHER THRUST WASHER SIDE GEAR Figure 4.3 Figure DIFFERENTIAL PINION THRUST WASHER 3 DIFFERENTIAL PINION SHAFT Copyright 00 Arvin Meritor Maintenance Manual MM-030 Page 8 ArvinMeritor, Inc. (Revised 08-0)

24 Section 4 Assembly and Installation 4. Install the capscrews through both differential case halves and into the ring gear. Use a CRISSCROSS pattern to tighten the capscrews to 05-5 lb-ft (40-55 N m). Figure 4.7. T 5. Inspect the differential gears rotating resistance. Use the following procedure. Figure 4.7. Place the differential and ring gear assembly in a vise. Install soft metal covers over the vise jaws to protect the ring gear. 3. Install the tool into the differential until the spines on the tool are engaged with one side gear. 4. Place a torque wrench onto the nut onto the tool and rotate the differential gears. Read the value indicated on the torque wrench. If the torque value is greater than 50 lb-ft (68 N m): Disassemble the differential case and inspect parts for wear or damage. Repair or replace parts as necessary. Reassemble the differential case and repeat Steps through 4. Installation CAPSCREWS Differential Gears Rotating Resistance. Make an inspection tool using an axle shaft that matches the spline size of the differential side gear. Cut the shaft to approximately -inches (304.8 mm). Weld a nut onto the end of the shaft. Figure 4.8. Figure 4.8 SIDE VIEW APPROXIMATELY MM (-INCHES) END VIEW Weld nut to end of shaft a Drive Pinion into the Carrier. Install the drive pinion inner bearing cup into the carrier.. Apply axle lubricant onto the carrier pinion cage bore and inner bearing cup. 3. Apply axle lubricant onto the pinion inner and outer cone. 4. Install the drive pinion into the inner bearing cup in the carrier. Install the outer bearing cup into the pinion case. 5. Coat the pinion cage seal bore with GL-5 gear oil prior to installing the new seal. To obtain this lubricant, refer to the Service Notes page on the front inside cover of this manual. 6. Use a seal driver to install a new seal into the pinion cage. Refer to the tool drawing in Section 9 to fabricate the seal driver. 7. Install a new O-ring onto the pinion cage. 8. Apply axle lubricant on the pinion cage thread and pilots, O-ring and outer bearing cone. 9. Place the pinion cage onto the carrier. Use your hands to screw the pinion cage into the carrier to verify that the cage is correctly installed. 0. Install the yoke locknut onto the drive pinion shaft. Do not install the yoke at this time. ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page 9

25 Section 4 Assembly and Installation. Use appropriate tools to screw the pinion cage into the carrier while rotating the pinion to seat the bearings.. Tighten the pinion cage to adjust the drive pinion bearing preload. Check the preload by rotating the pinion by the yoke locknut with a torque wrench. Figure 4.9. The correct torque is 5-0 lb-in (5.8-3 N m). 3. Position the pinion cage lock plate. Figure 4.0. If the lock plate does not match one of the four possible positions: Tighten or loosen the pinion cage while checking the preload to keep it within specification. 4. Install the capscrews and tighten them to 0-3 lb-ft (4-8 N m). Remove the yoke locknut. T T 5. Install the yoke and locknut onto the drive pinion shaft. 6. Fasten a yoke bar to the yoke to hold the drive pinion in position when you tighten the locknut. Figure 4.. Refer to Section 9 to build a yoke bar. 7. Tighten the locknut to lb-ft ( N m). Remove the yoke bar. Figure 4. T Figure 4.9 YOKE BAR Figure 4.0 Differential Case and Ring Gear into the Carrier. Install the bearing cup and adjusting ring into the bore of the integral bearing cap side of the carrier.. Install the differential case and ring gear assembly into the carrier. 3. Install the bearing cup and adjusting ring into the carrier on the bolted-on bearing cap side. 4. Position the differential cap onto the carrier. Install the capscrews and tighten them to 5-40 lb-ft (55-90 N m). 5. Adjust the differential bearings preload and ring gear backlash. Check the tooth contact patterns. T CAPSCREW LOCK PLATE Copyright 00 Arvin Meritor Maintenance Manual MM-030 Page 0 ArvinMeritor, Inc. (Revised 08-0)

26 Section 4 Assembly and Installation Adjust Differential Bearing Preload Use Method or Method below to adjust differential bearing preload. Specifications Differential bearing preload Expansion between bearing caps 5-35 lb-in ( N m) inch ( mm) Method. Attach a dial indicator onto the carrier mounting flange so that the pointer is against the ring gear s back surface. Figure 4... Use a T-bar wrench to loosen the bearing adjusting ring that is opposite the ring gear. Figure 4.3. The dial indicator will show a small amount of end play. 3. Use one of the following procedures to move the differential and ring gear to the LEFT and RIGHT while you read the dial indicator. A. Insert two pry bars between the bearing adjusting rings and the ends of the differential case. Figure 4.4. The pry bars must not touch the differential bearings. B. Insert two pry bars between the differential case, or the ring gear and the carrier at locations other than specified in Step A. Figure 4.5. The pry bars must not touch the differential bearings. Figure 4.4 Figure 4. Pry bars must not touch bearings. Figure 4.5 Figure 4.3 Pry bars must not touch bearings. T-BAR WRENCH ADJUSTING RING OPPOSITE RING GEAR 4. Tighten the bearing adjusting ring until the dial indicator reads ZERO end play. Move the differential ring to the LEFT and RIGHT as needed. If necessary, repeat Step A or B. 5. Tighten each bearing adjusting ring one notch from ZERO. Proceed to Check Ring Gear Runout (Radial Movement) in this section. ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page

27 Section 4 Assembly and Installation Method. Hand-tighten both adjusting rings against the differential bearings.. Use a micrometer to measure the opposite surfaces of the bearing caps at X or Y. Figures 4.6 and 4.7. Record the measurement. 3. Tighten each bearing adjusting ring one notch. 4. Measure the opposite surfaces of the bearing caps at X or Y again. Compare the measurement with the one you obtained in Step. Figure Subtract the measurement you obtained in Step from the measurement in Step 4. The difference is the amount the bearing caps have expanded. Refer to the following example. If the measurement is inch ( mm): Proceed to Check Ring Gear Runout (Radial Movement)) in this section. If the measurement is not within the specification above: Repeat Steps 3 and 4 as necessary. Sample Differential Bearing Preload Calculation X or Y Measurement Before Tightening Adjusting Rings 3.97-inch ( mm) X or Y Measurement After Tightening Adjusting Rings inch ( mm) Amount Bearing Caps Have Expanded inch (0.3 mm) Figure 4.7 Check Ring Gear Runout (Radial Movement). Attach a dial indicator onto the carrier s mounting flange. Figure Adjust the dial indicator so that the pointer is against the ring gear s back surface. Set the dial indicator to ZERO. Figure 4.8 MICROMETER Copyright 00 Arvin Meritor Maintenance Manual MM-030 Page ArvinMeritor, Inc. (Revised 08-0)

28 Section 4 Assembly and Installation 3. Rotate the differential and ring gear. Read the dial indicator. Runout must not exceed inch (0.00 mm). If runout exceeds the specification above: Remove the differential and ring gear assembly from the carrier. Refer to Section and Steps 4-5 below. If runout is within specification: Proceed to Ring Gear Backlash in this section. 4. Check the differential parts including the carrier for wear and damage. Repair or replace parts as necessary. 5. Install the differential and ring gear into the carrier. Repeat the preload adjustment of the differential bearings. Ring Gear Backlash Specifications Backlash setting range for old gear sets Backlash setting for new gear sets inch ( mm) inch ( mm) 3. Adjust the dial indicator to ZERO. Hold the drive pinion in position. 4. After reading the dial indicator, rotate the differential and ring gear a small amount in both directions against the drive pinion teeth. If the backlash reading is within specification: Check the tooth contact patterns. If the backlash reading is not within specification: Adjust backlash as necessary. 5. Loosen one bearing adjusting ring one notch, then tighten the opposite ring the same amount. Figures 4.0 and 4.. To increase backlash: Move the ring gear away from the drive pinion. To decrease backlash: Move the ring gear toward the drive pinion. Figure 4.0 After checking the tooth contact patterns, the backlash can be adjusted within specification limits, if needed. To change the location of the pattern, use the following procedures.. Attach a dial indicator onto the mounting flange of the carrier. Figure Adjust the dial indicator so that the plunger or pointer is against the tooth surface. Tighten adjusting ring this side. Increase backlash. 3 Loosen adjusting ring this side. 3 Figure 4.9 Figure 4. Loosen adjusting ring this side. Decrease backlash. 3 Tighten adjusting ring this side. 3 ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page 3

29 Section 4 Assembly and Installation NOTE: When you adjust backlash, only move the ring gear. Do not move the drive pinion. 6. Repeat Steps -5 until the backlash is within specifications. Check the Tooth Contact Patterns (Backlash) of the Gear Set In the following procedures, movement of the contact pattern in the length of the tooth is indicated as toward the heel or toe of the ring gear. Figure 4.. Always check tooth contact patterns on the drive side of the gear teeth. Figure Adjust the backlash of a new gear set to inch ( mm). Adjust the backlash of an old gear set to the setting that you measured before the carrier was disassembled. Refer to Ring Gear Backlash in this section.. Apply a marking compound onto approximately gear teeth of the ring gear. Rotate the ring gear so that the gear teeth are next to the drive pinion. Figure 4.4. Figure 4.4 Figure 4. HEEL TOE Figure 4.3 DRIVE SIDE (CONCAVE) e 3. Rotate the ring gear forward and backward so that the gear teeth go past the drive pinion six times to get the contact patterns. Repeat if needed to get a clearer pattern. 4. Look at the contact patterns on the ring gear teeth. Compare the patterns to Figures 4.5, 4.6 and 4.7. The location of good hand-rolled contact patterns for new gear sets is toward the toe of the gear tooth and in the center between the top and bottom of the tooth. Figure 4.5. When the carrier is operated, a good pattern will extend approximately the full length of the gear tooth. The top of the pattern will be near the top of the gear tooth. Figure 4.8. The location of a good hand-rolled contact pattern for an old gear set must match the wear pattern in the ring gear. The new contact pattern will be smaller in area than the old wear pattern. Copyright 00 Arvin Meritor Maintenance Manual MM-030 Page 4 ArvinMeritor, Inc. (Revised 08-0)

30 Section 4 Assembly and Installation Figure 4.5 GOOD HAND-ROLLED PATTERN, HYPOID GENEROID GEARS Figure 4.8 GOOD PATTERN IN OPERATION, GENEROID GEARS 0009c Figure 4.6 HIGH PATTERN 00093c Figure 4.7 LOW PATTERN, HYPOID GENEROID GEARS 00094a A high contact pattern indicates that the drive pinion was not installed deep enough into the carrier. A low contact pattern indicates that the drive pinion was installed too deep in the carrier. If the contact patterns require adjustment: Continue by following Step 5 to move the contact patterns between the top and bottom of the gear teeth. If the contact patterns are in the center of the gear teeth: Continue by following Step Adjust the position of the drive pinion in the carrier to move the contact patterns between the top and bottom of the gear teeth. Use the following procedure. A. Disassemble the yoke, pinion cage and the drive pinion. Refer to Section. B. Remove the inner bearing cone from the drive pinion. Refer to Section. C. Change the bearing shim. To correct a high contact pattern, Figure 4.6: Replace the bearing shim with a thicker shim. To correct a low contact pattern, Figure 4.7: Replace the bearing shim with a thinner shim. D. Install the inner bearing cone onto the drive pinion. Install the drive pinion into the carrier. Refer to the appropriate procedures in this section. E. Repeat Steps -5 until the contact patterns are in the center between the top and bottom of the gear teeth. ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page 5

31 Section 4 Assembly and Installation 6. Adjust the backlash of the ring gear within the specification range to move the contact patterns to the correct location in the length of the gear teeth. Refer to Ring Gear Backlash in this section. A. Decrease backlash to move the contact patterns toward the toe of the ring gear teeth. Figure 4.9. B. Increase backlash to move the contact patterns toward the heel of the ring gear teeth. Figure C. Repeat Steps -4 and 6 until the contact patterns are at the correct location in the length of the gear teeth. 7. Install the cotter pins into the adjusting rings so that the large end is between the adjusting ring lugs. Bend the tabs out flat against the outboard side of the leg caps in two places. Figure 4.3. Figure 4.3 Figure 4.9 Move pattern toward toe, loosen adjusting ring this side Decrease backlash. COTTER PINS Tighten adjusting ring b Figure 4.30 Move pattern toward toe, loosen adjusting ring this side Decrease backlash. Loosen adjusting ring b Copyright 00 Arvin Meritor Maintenance Manual MM-030 Page 6 ArvinMeritor, Inc. (Revised 08-0)

32 Section 4 Assembly and Installation Differential Carrier into the Axle Housing WARNING Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion-type cleaners and petroleum-based cleaners. To avoid serious personal injury when you use solvent cleaners, you must carefully follow the manufacturer s product instructions and these procedures: Wear safe eye protection. Wear clothing that protects your skin. Work in a well-ventilated area. Do not use gasoline, or solvents that contain gasoline. Gasoline can explode. You must use hot solution tanks or alkaline solutions correctly. Follow the manufacturer s instructions carefully. When you apply some silicone gasket materials, small amounts of acid vapor are present. To prevent serious personal injury, ensure that the work area is well ventilated. If the silicone gasket material gets into your eyes, flush them with water for 5 minutes. Have your eyes checked by a physician as soon as possible.. Clean the inside of the axle housing and the carrier mounting surfaces. Use a cleaning solvent and rags to remove dirt. Blow dry the cleaned areas with air. Refer to Section 3.. Inspect the axle housing for damage. Repair or replace the axle housing. Refer to Section Apply Loctite 4 threadlocker, or equivalent, into the threaded holes in the axle housing. To obtain this threadlocker, refer to the Service Notes page on the front inside cover of this manual. Refer to Section Apply silicone gasket material onto the carrier mounting surface of the housing. Refer to Section 3. WARNING To avoid serious personal injury and damage to components, take care when using lifting devices during service and maintenance procedures. Inspect a lifting strap to ensure that it is not damaged. Do not subject lifting straps to shocks or drop-loading. 5. Install the carrier into the axle housing. Use a hydraulic roller jack or a lifting tool. 6. Install capscrews in the four corner locations around the carrier and axle housing. Hand-tighten the fasteners. Figure 4.3. Figure b 7. Carefully push the carrier into position. Tighten the four capscrews two or three turns each in a CRISSCROSS pattern. 8. Repeat Step 7 until the four capscrews are tightened to 83-0 lb-ft (0-50 N m). 9. Install the remaining capscrews and tighten them to 83-0 lb-ft (0-50 N m). T T ArvinMeritor Maintenance Manual MM-030 Copyright 00 (Revised 08-0) ArvinMeritor, Inc. Page 7