MAINTENANCE MANUAL. Differential Axle MS Edition october/11

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1 MAINTENANCE MANUAL Differential Axle MS Edition october/11

2 Index 1 - Notes to Technical Assistance Exploded View MS Exploded View MS-113 Plus Introduction Removal and disassembly Prepare Parts for Assembly Assembly and Installation Torque Specifications Lubrication Towing Instructions Special Tools Failures and Causes MAINTENANCE MANUAL

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4 Notes about Technical Assistance Before you Begin Hazard Alert Messages and Torque Symbols CAUTION This manual includes the models MS-113 AND MS-113 Plus. This manual provides instructions for Meritor s model MS-113 and MS-113 Plus single-reduction rear axle. 1. Read and understand all instructions and procedures before you begin to service components. 2. Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or both. 3. Follow your company s maintenance and service, installation, and diagnostics guidelines. 4. Use special tools when required to help avoid serious personal injury and damage to components. WARNING CAUTION TORQUE OBSERVATION A Warning alerts you to an instruction or procedure that you must follow exactly to avoid serious personal injury and damage to components. A Caution alerts you to an instruction or procedure that you must follow exactly to avoid damage to components. This symbol alerts you to tighten fasteners to a specified torque value. An OBSERVATION supply informations and suggestions that will help you to provide propper technical assistance to a componente. MAINTENANCE MANUAL 3

5 Exploded View MS Locknut, M32 x Inner Bearing Cap 25- Side Gear 2- Fork 14-Differential Case 26- Differential Pinion Shaft 3- Seals 4- Screws, M5 x 1,0 16- Cotter Pins 15- Differential Cap Capscrew, M14 x Lock Plate 17- Thrust Washer 27- Differential Halve 28- Differential Case Capscrew, M14 x Differential-to-Housing Capscrew, M12 x 1.75 x Pinion Case 18- Thrust Washer 30- Differential-to-Housing Capscrew, M12 x 1.75 x O-Ring 19- Adjusting Ring 31- Breather 8- Outer Bearing Cap 20- Bearing Cap 32- Axle Housing 9- Outer Bearing Cone 21- Bearing Cone 33- Fill Plug 10- Drive Pinion 22- Ring Gear 34- Drain Plug 11- Shim 23- Differential Halve Ring Gear Side 12- Inner Bearing Cone 24- Thrust Washer 35- Axle Shaft 4 MAINTENANCE MANUAL

6 Exploded View MS-113 Plus 1- Locknut, M32 x 1,5 13- Inner Bearing Cone 25- Side Gear 2- Fork 14- Differential Cage 26- Differential Pinion Shaft 3- Seals 4- Screws, M5 x 1,0 16- Cotter Pins 15- Differential Cap Capscrew, M14 x Lock Plate 17- Thrust Washer 27- Differential Halve 28- Differential Case Capscrew, M14 x Differential-to-Housing Capscrew, M12 x 1.75 x Lock Plate 18- Thrust Washer 30- Differential-to-Housing Capscrew, M12 x 1.75 x O-Ring 19- Adjusting Ring 31- Breather 8- Outer Bearing cap 20 -Bearing cap 32- Axle Housing 9- Outer Bearing Cone 21- Bearing Cone 33- Fill Plug 10- Drive Pinion 22- Ring Gear 34- Drain Plug 11- Shim 23- Differential Halve Ring Gear Side 12- Inner Bearing Cone 24- Thrust Washer 35- Axle Shaft MAINTENANCE MANUAL 5

7 Introduction Meritor s model MS-113 and MS-113 Plus single-reduction rear axle have a single-reduction differential, which is front-mounted into the axle housing. Figure 1.1. The differential has a hypoid drive pinion and ring gear set. Bevel gears are used in the differential assembly. All bearings in the differential are tapered roller bearings. When the differential operates, there is normal differential action between the wheels all the time. WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result. Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury. 1 - ADJUSTING RING 2 - DIFFERENTIAL 3 - RING GEAR AND DRIVE PINION 4 - TAPERED ROLLER BEARING 5 - TAPERED ROLLER BEARING 6 - HOUSING 7 - SIDE GEAR 8 - COTTER PIN Figure 1.1 Removal Axle Shafts from the Axle Assembly 1. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. 2. Raise the rear end of the vehicle so that the rear wheels are off the ground. Support the vehicle with safety stands. Figure Place a drain pan under the rear axle. 4. Remove the drain plug from the bottom of the axle housing. Drain the lubricant from the assembly. Install the drain plug and tighten it to 35 lbs.ft minimum. 5. Disconnect the driveline universal joint from the pinion input Fork on the differential. Figure SAFETY STANDS Figure MAINTENANCE MANUAL

8 Removal and disassembly EASY SERVICE 6. Remove the capscrews from the flanges of both axle shafts. Figure Mark each axle shaft before you remove it from the axle assembly. SERIE WING PERMALUBE 1 - CAPSCREW 2 - AXLE SHAFT FLANGE 3 - AXLE SHAFT HUB Figure 2.3 Differential from the Axle Housing 1. Place a hydraulic roller jack under the differential.figure 2.4. SERIE RPL PERMALUBE 1 - FULL ROUND Bearing caps 2 - END FORK 3 - FORK SADDLE 4 - WELD FORK 5 - BEARING STRAP 6 - CAPSCREWS 7 - EASY-SERVICE Bearing caps 8 - SPIDER 9 - SLIP FORK 10 - CAPSCREWS 11 - END FORK 12 - WELD FORK 13 - SLIP FORK Figure SPIDER 15 - CAPSCREWS 16 - END FORK 17 - WELD FORK 18 - SLIP FORK 19 - SPIDER 20 - CAPSCREWS 21 - END FORK 20 - LIP FORK 23 - TUBING 24 - SPIDER 25 - WELD FORK 1 - WOOD BLOCK 2 - ROLLER JACK Figure 2.4 NOTE: Two capscrews in the TOP of the differential housing secure. 2. Remove all of the capscrews that secure the carrier to the axle housing, except the two capscrews in the TOP. 3. Loosen the two capscrews in the TOP of the differential, but do not remove them. MAINTENANCE MANUAL 7

9 Removal and disassembly 4. Loosen the differential by striking the mounting flange at several points with a dead-blow hammer. Remove the two capscrews in the TOP of the differential that secure to the axle housing. 5. Use a hydraulic roller jack and lever with a round end to remove the carrier from the axle housing. Take care when you use the lever so that you don t damage the carrier or housing flange. Differential Case and Ring Gear NOTE: Before working on the differential, inspect the gear set for damage. If the gear set is not damaged, it can be reused. Measure the backlash of the gear set and record the dimension. Figure 2.6. See the Section Remove the cotter pins from the side gear adjusting rings. Figure 2.7. 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. 6. Use a lifting tool to place the differential into a carrier stand. Figure 2.5. See the Section 9 to build a stand. Figure DIFFERENTIAL 2 - REPAIR STAND Figure COtter pin Figure Remove the differential bearing cap capscrews and the cap. Figure Remove the differential adjusting ring and Bearing cap from bolted-on bearing cap side. Figure MAINTENANCE MANUAL

10 Removal and disassembly 1 - CAPSCREWS 2 - DIFFERENTIAL CAP Figure FORK BAR Figure LOCK PLATE 2 - CAPSCREW 3 - PINION CAGE 1 - Bearing cap 2 - ADJUSTING RING 4 - FORK LOCKNUT Figure 2.11 Figure Remove the differential assembly and place it onto a workbench. 5. Remove the differential adjusting ring and Bearing cap from integral bearing cap side. Drive pinion cage 1. Fasten a Fork bar onto the Fork to hold the Fork when you remove the locknut. Figure See the Section 9 to build a Fork bar. 2. Remove the Fork locknut. Figure Remove the Fork bar. 3. Remove the Fork from the drive pinion. If the Fork is tight on the drive pinion: Use a puller to remove the Fork. 4. Remove the lock plate capscrews and the lock plate. Figure Use a spanner wrench to unscrew the pinion cage from the carrier. 6. Remove the pinion cage and the drive pinion from the differential. 7. Remove the drive pinion inner Bearing cap from the differential. MAINTENANCE MANUAL 9

11 Removal and disassembly 4. Remove the side gear and thrust washer.figure Use a brass hammer to remove the ring gear from the differential case. Figure CAPSCREW 2 - LOCK PLATE Disassembly Figure 2.12 Figure 2.14 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 MS Remove the capscrews from the differential case. Figure THRUST WASHER 2 - SIDE GEAR Figure CAPSCREWS Figure Separate the differential case halves. Figure Remove the thrust washer and side gear. Figure Remove the differential pinion shaft, differential pinions and thrust washers. Figure DIFFERENTIAL PINION 2 - THRUST WASHER 3 - DIFFERENTIAL PINION SHAFT Figure MAINTENANCE MANUAL

12 Removal and disassembly Differential Case and Rear Ring Gear MS- 113 Plus 1. Remove the ring gear capscrews. Figure Side Gear 2 - Thrust Washer Figure CAPSCREW Figure RING GEAR 2 - DIFFERENTIAL CASE Figure Separate the case halves. Figure Remove the thrust washer and the pinion. Figure Remove the differential pinion shaft, the side gears and the thrust washers. Figure Remove the side gear and thrust washer. Figure Use a brass hammer to remove the differential case. Figure Use a bearing puller or a press to remove the bearing cones from both halves of the differential case. Figure Figure DIFFERENTIAL CASE Figure 2.19 MAINTENANCE MANUAL 11

13 Removal and disassembly 1 - THRUST WASHER 2 - SIDE GEAR 1 - RING GEAR 2 - DIFFERENTIAL CASE Figure 2.25 Figure Use a bearing puller or press to remove the bearing cones of the two halves of the differential case. Figure SIDE GEAR 2 - THRUST WASHER 3 - DIFERENTIAL PINION SHAFT Figure DIFFERENTIAL CASE Figure 2.26 Drive Pinion 1. Remove and discard the pinion cage O-ring. Figure SIDE GEAR 2 - THRUST WASHER Figure PINION CAGE 2 - O-RING 3 - OUTER Bearing cap 4 - OUTER BEARING CONE 5 - DRIVE PINION 6 - SHIM 7 - INNER BEARING CONE Figure MAINTENANCE MANUAL

14 Prepare Parts for Assembly 2. Remove the outer Bearing cap 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. 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 3. Do not clean ground or polished parts with water or steam. Do not immerse ground or polished parts in a hot solution tank or use strong alkaline solutions for cleaning, or the smooth sealing surface may be damaged. Clean Rough Parts 1. Clean rough parts with the same method as cleaning ground and polished parts. 2. Rough parts can be cleaned in hot solution tanks with a weak or diluted alkaline solution. 3. Parts must remain in hot solution tanks until heated and completely cleaned. 4. Parts must be washed with water until all traces of the alkaline solution are removed. Clean Axle Assemblies 1. A complete axle assembly can be steam cleaned on the outside to remove dirt. 2. Before the axle is steam cleaned, close or place a cover over all openings in the axle assembly. Examples of openings are breathers or vents in air chambers. Dry Parts After Cleaning 1. Parts must be dried immediately after cleaning and washing. 2. Dry the parts using soft, clean paper or cloth rags. 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 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. CAUTION Do not use hot solution tanks or water and alkaline solutions to clean ground or polished parts. Damage to parts will result. MAINTENANCE MANUAL 13

15 Prepare Parts for Assembly Prevent Corrosion on Cleaned Parts 1. Apply axle lubricant to cleaned and dried parts that are not damaged and are tobe assembled. 2. To store parts, apply a special material that prevents corrosion to all surfaces. Wrap cleaned parts in a special paper that will protect the parts from moisture and prevent corrosion. Inspect Parts It is very important to inspect all parts carefully and completely before the axle or differential be assembled. Check all parts for wear and replace damaged parts. 1. Inspect the cup, cone, rollers and cage of all tapered roller bearings in the assembly. If any of the following conditions exist, replace the bearing. The center of the large-diameter end of the rollers is worn level with or below the outer surface. Figure 3.1. The radius at the large-diameter end of the rollers are worn to a sharp edge. Figure 3.1. There is a visible roller groove in the cup or cone inner race surfaces. The groove can be seen at the small or large-diameter end of both parts. Figure 3.2. There are deep cracks or breaks in the cup, cone inner race or roller surfaces. Figure 3.2. There are bright wear marks on the outer surface of the roller cage. Figure 3.3. There is damage on the rollers and on the surfaces of the cup and cone inner race that touch the rollers. Figure 3.4. There is damage on the cup and cone inner race surfaces that touch the rollers. Figure worn radius 2 - worn surface 1 - crack 2 - wear groves Figure 3.1 Figure WEAR MARKS Figure marks and chemical attack by corrosion cavity Figure MAINTENANCE MANUAL

16 Prepare Parts for Assembly DIFFERENTIAL PINION SHAFT Figure 3.7. Teeth and splines of both differential side gears Teeth and bore of all differential pinions 1 - SPALLING AND FLAKING Figure 3.5 CAUTION drive pinion and ring gear ARE machined as a matched set. When you replace either a drive pinion or a ring gear, you must replace both parts as a matched set. Do not mix old and new parts. Damage to components can result. 1 - CASE HALVES 2 - PINION AND THRUST WASHER 3 - SIDE GEAR AND THRUST WASHER 4 - DIFFERENTIAL PINION SHAFT Figure 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. 1 - CASE HALVES 2 - PINION AND THRUST WASHER 3 - SIDE GEAR AND THRUST WASHER 4 - DIFFERENTIAL PINION SHAFT 3. Inspect the following main differential assembly parts for wear or stress. Replace parts that are damaged. Figure 3.6 and 3.7. Inside surfaces of both case halves Both surfaces of all thrust washers The differential pinion shaft Figure Inspect axle shafts for wear and cracks at the flange, shaft and splines. Replace the axle shafts, if required. MAINTENANCE MANUAL 15

17 Prepare Parts for Assembly 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 differential repair. 4. Clean parts and apply new silicone gasket material where required when the axle or differential 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. WARNING Wear safe clothing and eye protection when you use welding equipment. Welding equipment can burn you and cause serious personal injury. Follow the operating instructions and safety procedures recommended by the welding equipment manufacturers. Axle weld locations and welding procedures must adhere to Meritor s standards. Welding at locations other than those authorized by Meritor will void the warranty and can reduce axle beam fatigue life. Serious personal injury and damage to components can result. Meritor permits drive axle housing assembly repair welding in the following locations only. Housing-to-cover weld joints Snorkel welds Housing seam welds between the suspension attaching brackets Bracket welding to the drive axle housing Prepare the Axle WARNING The high temperature caused by the open flame from the cutting torch can ignite the oil in the axle housing and can cause serious personal injury. 1. Remove the oil drain plug from the bottom of the axle housing and drain the lubricant from the assembly. 1 - REMOVE SILICONE GASKET FROM PARTS Figure 3.8 Repair Welding on Axle Housings For Complete Welding Instructions on Meritor Drive Axle Housings See the Maintenance Manual 8, Drive Axle Housings. To obtain this publication, see the Service Notes page on the front inside cover of this manual. CAUTION Remove the differential from the axle housing before you weld onto an axle. Do not weld onto an axle with the differential installed. Electrical arching and damage to components can result. 16 MAINTENANCE MANUAL

18 Prepare Parts for Assembly 2. Remove the differential from the axle housing. See the correct Meritor differential maintenance manual or the vehicle manufacturer s instructions. CAUTION Remove the brake air chambers before you weld onto an axle. Do not expose a brake air chamber to more than 250 F (121 C). Damage to the air chamber can result. 3. Remove the wheel-end components and brake air chambers from the axle. See 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 WARNING The axle housing must be 70 F (21 C) or warmer before you weld onto the axle. Do not weld onto a cold axle or weld cold parts onto an axle. Cracks in the weld area, damage to components and serious personal injury can result. 6. Ensure that the axle housing temperature measures 70 F (21 C) or warmer. If the axle housing temperature measures less than 70 F (21 C): Store the axle in a heated room until the housing reaches the correct temperature. 7. Heat the damaged area to approximately 300 F (149 C) before you begin welding. 8. Use suitable weld wire electrodes when you weld. Suitable weld wire electrodes include either BS EN 499 E 42 2 B 32 H5 or BS EN 440 G 42 2 M GSi (American Welding Society equivalents E7018 and ER70S3, respectively). 9. For complete welding instruction, see the Maintenance Manual 8. To obtain this publication, see the Service Notes page on the front inside cover of this manual. Do Not Bend or Straighten a Damaged Drive Axle Housing 1 - Clean this area Figure 3.9 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. 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. 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. MAINTENANCE MANUAL 17

19 Prepare Parts for Assembly Removing Fasteners Secured with Adhesive If it s difficult to remove fasteners secured with Dri-Loc, Meritor specification 2297-T-4180, Loctite 277 adhesive, or equivalent, use the following procedure. 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. CAUTION When you remove fasteners secured with adhesive, slowly heat the fastener to 350 F (177 C). Do not exceed this temperature, or heat fasteners quickly. Damage to components can result. 1. Heat a fastener for three to five seconds only. Try to loosen the fastener with a wrench. Do not use an impact wrench or hit the fastenerwith a hammer. 2. Repeat Step 1 until you can remove the fastener. 1. Use a wire brush to clean the oil, dirt and old adhesive from all threads and threaded holes. 2. Apply four or five drops of Meritor Liquid adhesive Loctite 680 or equivalent inside each threaded hole or bore. Do not apply adhesive directly to fastener threads. Figure Install Fasteners New Fasteners with Pre-Applied Adhesive NOTE: No drying time is required for fasteners with pre-applied adhesive. 1. Use a wire brush to clean oil and dirt from threaded holes. 2. Install new fasteners with pre-applied adhesive to assemble parts. Do not apply adhesives or sealants to fasteners with pre-applied adhesive, or to fastener holes. 3. Tighten fasteners to the required torque value for that size fastener. Componentes de Fijación Originales o utilizando Adhesivo Líquido Meritor 2297-C-7049 o Adhesivo Loctite 680, o equivalente. 1-4 TO 5 DROPS ON BORE THREADS Figure 3.10 NOTE: There is no drying time required for Meritor specification for Meritor 2297-C-7049 liquid adhesive, Loctite 680 adhesive or equivalent. 3.Tighten the fasteners to the required torque value for that size fastener.aplicar el Adhesivo en los Agujeros para Cojinete del Diferencial NOTE: Use Loctite 638 adhesive, or equivalent for all axles. 1. Clean the oil and dirt from the outer diameters of the bearing caps and bearing bores in the differential and bearing caps. There is no special cleaning required. 2. Apply axle lubricant to the bearing cones and the inner diameters of the Bearing caps of the main differential. Do not get oil onto the outer diameter of the Bearing cap and do not permit oil to drip onto the bearing bores. 18 MAINTENANCE MANUAL

20 Prepare Parts for Assembly 3. Apply a single continuous bead of adhesive to the bearing bores in the differential 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 ADHESIVE 2 - BEARING CAP 3 - DIFFERENTIAL CASE Figure 3.11 NOTE: Loctite 638 adhesive, or equivalent will dry in approximately two hours. Perform Steps 4 and 5 within two hours from the time you apply the adhesive. If two hours have passed since application, clean the adhesive from the parts and apply new adhesive. 4. Install the main differential assembly, Bearing caps and bearing cap into the differential. The Bearing cap of the integral bearing cap side must be assembled from the thread side. See the 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. See the Section 4. Applying Three Bond 1216 Silicone Gasket Material or Equivalent WARNING When you apply some silicone gasket materials, small amounts of acid vapor are present. To prevent serious personal injury, ensure that the work area is well ventilated. If the silicone gasket material gets into your eyes, flush them with water for 15 minutes. Have your eyes checked by a physician as soon as possible. NOTE: The following silicone gasket products or equivalent can be used for Meritor components: Silicone Gasket material Three Bond number TB 1216 (Grey) or equivalent. Loctite Ultra grey Adhesive/Sealant number Meritor gasket material/part number 2297-F To obtain this gasket material, see 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 Remove the old seal material Differential Carrier Presentation Figure 3.12 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. 3. Apply a 1/8-inch (3 mm) diameter continuous bead of the silicone gasket material around one surface. Also apply the gasket material around the edge of all fastener holes on that surface. Figure MAINTENANCE MANUAL 19

21 Prepare Parts for Assembly 4. 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. See the Section Wait 20 minutes before filling the assembly with the correct lubricant. See the Section 7. Alternate Locations 1 - PART NUMBER, TOOTH COMBINATION NUM- BER, GEAR SET MATCH NUMBER, PINION CONE VA- RIATION NUMBER 2 - PART NUMBER, TOOTH COMBINATION NUMBER 3 - GEAR SET MATCH NUMBER, PINION CONE VARIA- TION NUMBER 4 - PART NUMBER, TOOTH COMBINATION NUM- BER, GEAR SET MATCH NUMBER 5 - PART NUMBER, TOOTH COMBINATION NUM- BER GEAR SET MATCH NUMBER Figure diameter silicone gasket bead Figure 3.13 GEAR SETS See 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 had matched parts. Figure Examples Ring Gear and Drive Pinion Set PART NUMBER LOCATION Conventional Ring Gear Conventional Drive Pinion On the front face or outer diameter At the end at threads Gear set tooth combination number Gear set teeth Drive Pinion location Ring gear location 5-37 = gear set has a five-tooth drive pinion and a 37-tooth ring gear At the ed at threads On the front face or outer diameter Gear set match numbers 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. 20 MAINTENANCE MANUAL

22 Assembly and Installation Location number M29 Drive pinion location At the end of the gear head Ring gear location On the front face or outer diameter 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 differential. See the Section Pinion Cage 2 - O-Ring 3 - Outer Bearing cap 4 - Outer bearing cone 5 - DRIVE PINION 6 - LOCTITE SHIM 8 - INTERNAL BEARING CONE Figure 4.1 Pinion Cone (PC) Variation number PC ,01 mm PC ,02 mm Drive Pinion location At the end of the pinion gear head Ring gear location Ubicación de la Corona On the outer diameter 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. 2. Install the new O-ring in the Pinion housing. 3. Install the shim (6) in the drive pinion. 4. Use a press to install the pinion bearing s internal and external cone. Assembly of the Pinion Seal into the Pinion Case 1. Apply axel lubricant onto the pinion and differential case nuts and in the seal housing before assembly (if the seal is not rubberized externally). Figure 4.2. Assembly OIL Drive Pinion 1. Apply lubricant to the new O-ring, differential threads, O-ring bore, pinion cage threads and the inner and outer bearings Figure 4.1. To obtain this lubricant, see the Service Notes page on the front inside cover of this manual. Figure 4.2 MAINTENANCE MANUAL 21

23 Assembly and Installation 2.Support the differential case, position the pinion seal, and using a proper tool and a press, position and assembly into its housing. See Figure Check the maximum clearance of 1,0 mm between the seal and the pinion case surface. See Figure 4.3. Important: The maximum variation must be 0,5 mm along the seal perimeter. Apply in the bearing perimeter a string of about 1 mm in diameter - or equivalent Figure 4.4 1,0 max. Figure 4.3 NOTE: Make sure that the bearing cones are free of burrs; Make sure that during the pressing, the housing material is not being pulled; Make sure that the cones are completely touching their respective. Differential Case and Rear Ring Gear MS Use a press to install the bearing cones onto both halves of the differential case. Assembly of the Bearing Cones onto Both Halves of the Differential Case 1. Install the bearing cones onto both halves of the differential case using a proper tool and a press. See Figure 4.4. CAUTION Heat the ring gear before seating it onto the differential case. Do not press a cold ring gear onto the differential case. A cold ring gear will damage the differential case because of the tight fit. 2. Heat the ring gear. A maximum temperature of 340 F (170 C) can be applied at the gear web. The temperature at the gear teeth must not exceed 250 F (120 C). Wear safe clothing and gloves while working with the hot ring gear. 3. Position the differential case on a workbench with the bearing cone on top. 4. Place the ring gear over the differential case immediately after the gear is heated. 22 MAINTENANCE MANUAL

24 Assembly and Installation 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 inch (0.025 mm) at more than three places with an arc length greater than 1.0-inch (25.4 mm): Inspect the differential case and ring gear for wear or damage. Repair or replace parts as necessary. 7. Turn the differential case over on the workbench so that the bearing cone is on the bottom. 8. Apply lubricant to the differential pinion shaft, thrust washers, differential pinions and side gears. To obtain this lubricant, see the Service Notes page on the front inside cover of this manual. 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 DIFFERENTIAL PINION 2 - THRUST WASHER 3 - DIFFERENTIAL PINION SHAFT 1 - ALIGN HOLES Figure 4.6 Figure thrust washer 2 - side gear Figure SIDE GEAR 2 - THRUST WASHER Figure 4.5 Figure 4.9 MAINTENANCE MANUAL 23

25 Assembly and Installation 14. IInstall the capscrews through both differential case halves and into the ring gear. Use a CRISSCROSS pattern to tighten the capscrews like specification below: For M14 screws, apply toque at an angle of /-0 Lb. foot ( /-0 N.m + 60º + 5º / -0º) 15. Inspect the differential gears rotating resistance. Use the following procedure. NOTE: Make sure that the bearing cones are free of burrs; Make sure that during the pressing, the housing material is not being pulled; Make sure that the cones are completely touching their respective. 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. 1 - capscrews Figure 4.10 Assembly of the Bearing Cones onto Both Halves of the Differential Case 1. Use a press to install the bearing cones onto both halves of the differential case Assembly of the Bearing Cones onto Both Halves of the Differential Case 1. Install the bearing cones onto both halves of the differential case using a proper tool and a press. See Figure Heat the ring gear. A maximum temperature of 340 F (170 C) can be applied at the gear web. The temperature at the gear teeth must not exceed 250 F (120 C). Wear safe clothing and gloves while working with the hot ring gear. 3. Position the differential case on a workbench with the bearing cone on top. 4. Place the ring gear over the differential case immediately after the gear is heated. If the ring gear does not fit easily on the differential case: Heat the gear again. 5. Align the ring gear and differential case capscrew holes. Rotate the ring gear as necessary. 6. Use a feeler gauge to inspect for gaps between the ring gear and the differential case. If the gap exceeds inch (0.025 mm) at more than three places with an arc length greater than 1.0-inch (25.4 mm): Inspect the differential case and ring gear for wear or damage. Repair or replace parts as necessary. Check the differential case and ring gear for wear or damage. Fix or replace the parts as necessary. 7. Turn the differential case over on the workbench so that the bearing cone is on the bottom. Figure MAINTENANCE MANUAL

26 8. Apply lubricant to the differential pinion shaft, thrust washers, differential pinions and side gears. To obtain this lubricant, see the Service Notes page on the front inside cover of this manual. 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. Figure Install the side gear and thrust washer over the differential pinions. Figure Position the case half over the side gear. Figure CROSS HEAD Assembly and Installation Figure SIDE GEAR 2 - THRUST WASHER Figure SIDE GEAR 2 - THRUST WASHER Figure 4,12 Figure DIFFERENTIAL PINION 2 - THRUST WASHER 3 - DIFFERENTIAL PINION SHAFT Figure 4.13 MAINTENANCE MANUAL 25

27 Assembly and Installation 14. Install the capscrews through both differential case halves and into the ring gear. Use a CRISSCROSS pattern to tighten the capscrews shown below: 1. For screws M12, apply toque angle of /-0 Lb. ( /-0 N.m + 60º + 10º / -0º) 2. For screws M14, apply toque angle of /-0 Lb. ( /-0 N.m + 60º + 5º / -0º) 15. Inspect the differential gears rotating resistance. Use the following procedure 2. Place the differential and ring gear assembly in a vise. Install soft metal covers over the vise jaws to protect the ring gear. 3. Install the tool into the differential until the spines on the tool are engaged with one side gear. 4. Place a torque wrench onto the nut onto the tool and rotate the differential gears. Read the value indicated on the torque wrench. If the torque value is greater than 50 lb-ft (68 N.m): Disassemble the differential case and inspect parts for wear or damage. Repair or replace parts as necessary. Reassemble the differential case and repeat Steps 2 through 4. Installation Pinion Cage onto the Differential 1 - CAPSCREWS Figure 4.17 Differential Gears Rotating Resistance 1. Make an inspection tool using an axle shaft that matches the spline size of the differential side gear. Cut the shaft to approximately 12-inches (304.8 mm). Weld a nut onto the end of the shaft. Figure Place the pinion cage onto the differential. Use your hands to screw the pinion cage into the differential to verify that the cage is correctly installed. 2. Install the Fork locknut onto the drive pinion shaft. Do not install the Fork at this time. 3. Use appropriate tools to screw the pinion cage into the differential while rotating the pinion to seat the bearings. 4. Tighten the pinion cage to adjust the drive pinion bearing preload. Check the preload by rotating the pinion by the Fork locknut with a torque wrench. Figure The correct torque is 5-20 lb.-in ( N.m). 5. Position the pinion cage lock plate. Figure If the lock plate does not match one of the four possible positions: Tighten the pinion cage while checking the preload to keep it within specification. 6. Install the capscrews and tighten them to lb-ft (14-18 N m). Remove the Fork locknut. 1 - APROXIMATELY 12 (305 mm) 2 - SIDE VIEW 3 - WELD NUT TO END OF SHAFT 4 - END VIEW Figure MAINTENANCE MANUAL

28 Assembly and Installation Figure 4.19 Differential Case and Ring Gear 1. Install the Bearing cap and adjusting ring into the bore of the integral bearing cap side of the differential. 2. Install the differential case and ring gear assembly into the differential. 3. Install the Bearing cap and adjusting ring into the differential on the bolted-on bearing cap side. 4. Position the cap onto the differential. Install the capscrews and tighten them to lb-ft ( N.m). 5. Adjust the differential bearings preload and ring gear backlash. Check the tooth contact patterns. Adjust Differential Bearing Preload Use Method 1 or Method 2 below to adjust differential bearing preload. 1 - CAPSCREWS 2 - LOCK PLATE Figure 4.20 Specifications 7. Install the Fork and locknut onto the drive pinion shaft. 8. Fasten a Fork bar to the Fork to hold the drive pinion in position when you tighten the locknut. Figure See the Section 9 to build a Fork bar. 9. Tighten the locknut to lb-ft ( N m). Remove the Fork bar. Differential bearing pre-load Expansion between Bearing caps 5-20 lb-pol (5,8-23,0 N.m) 0,006-0,013 pol. (0,15-0,33 mm) 450 lbs.pé Method 1 1. Attach a dial indicator onto the differential mounting flange so that the pointer is against the ring gear s back surface. 2. Use a T-bar wrench to loosen the bearing adjusting ring that is opposite the ring gear. Figure The dial indicator will show a small amount of endplay. 1 - SPECIAL TOOL Figure 4.21 MAINTENANCE MANUAL 27

29 Assembly and Installation Figure 4.25 Figure LEVER must not touch bearings. 4. Tighten the bearing adjusting ring until the dial indicator reads ZERO endplay. 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. 1 - lever Wrench 2 - Adjusting Ring Opposite Ring Gear Figure 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 lever between the bearing adjusting rings and the ends of the differential case. Figure The lever must not touch the differential bearings. B. Insert two lever between the differential case, or the ring gear and the carrier at locations other than specified in Step A. Figure The lever must not touch the differential bearings. Method 2 1. Hand-tighten both adjusting rings against the differential bearings. 2. Use a micrometer to measure the opposite surfaces of the bearing caps at X or Y. Figures 4.26 e Record the measurement 3. Tighten each bearing adjusting ring one notch. 4. Measure the opposite surfaces of the bearing caps at X or Y again. Compare the measurement with the one you obtained in Step 2. Figure LEVER must not touch bearings. Figure MAINTENANCE MANUAL

30 Assembly and Installation 1 - MICROMETER Figure 4.27 Figure Subtract the measurement you obtained in Step 2 from the measurement in Step 4. The difference is the amount the bearing caps have expanded. See 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 specifications above: Repeat Steps 3 and 4 as necessary Sample Differential Bearing Preload Calculation 3. Rotate the differential and ring gear. Read the dial indicator. Runout must not exceed inch (0.200 mm). If runout exceeds the specification above: Remove the differential and ring gear assembly from the differential. See the Section 2 and Steps 4-5 below. If runout is within specification: Proceed to Ring Gear Backlash in this section. 4. Check the differential parts including the case for wear and damage. Repair or replace parts as necessary. 5. Install the differential and ring gear into the case. Repeat the preload adjustment of the differential bearings. X or Y Measurement Before Tightening Adjusting Rings X or Y Measurement After Tightening Adjusting Rings Amount Bearing Caps Have Expanded Ring Gear Backlash Specifications 13,927 inch. 13,936 inch. 0,009 inch. 353,74 mm 353,97 mm 0,23 mm Check Ring Gear Run Out (Radial Movement) Backlash setting range for old gear sets 0,008-0,018 inch. (0,20-0,46 mm) 1. Attach a dial indicator onto the differential 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. Backlash setting for new gear sets 0,005-0,015 inch. (0,13-0,25 mm) 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. MAINTENANCE MANUAL 29

31 Assembly and Installation 1. Attach a dial indicator onto the mounting flange of the differential. Figure Adjust the dial indicator so that the plunger or pointer is against the tooth surface. 1 - Tighten adjusting ring this side 2 - Increase backlash 3 - Loosen adjusting ring this side Figure 4.31 Figure 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 4.30 e To increase backlash: Move the ring gear away from the drive pinion. To decrease backlash: Move the ring gear toward the drive pinion. NOTE: When you adjust backlash, only move the ring gear. Do not move the drive pinion. 6. Repeat Steps 2-5 until the backlash is within specifications. Check the Tooth Contact Patterns (Backlash) of the Gear Set In the following procedures, movement of the contact pattern in the length of the tooth is indicated as toward the heel or toe of the ring gear. Figure Always check tooth contact patterns on the drive side of the gear teeth. Figure Tighten adjusting ring this side. 2 - Increase backlash. 3 - Loosen adjusting ring this side. 1 - TOE 2 - HEEL Figure 4.32 Figure MAINTENANCE MANUAL

32 Assembly and Installation 1. 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 differential was disassembled. See the Ring Gear Backlash in this section. 2. Apply a marking compound onto approximately 12 gear teeth of the ring gear. Rotate the ring gear so that the 12 gear teeth are next to the drive pinion. Figure Figure GOOD HAND-ROLLED PATTERN Figure Rotate the ring gear forward and backward so that the 12 gear teeth go past the drive pinion six times to get the contact patterns. Repeat if needed to get a clearer pattern. Figure Look at the contact patterns on the ring gear teeth. Compare the patterns to Figures 4.35, 4.36 and 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 When the differential 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 The location of a good hand-rolled contact pattern for an old gear set must match the wear pattern in the ring gear. The new contact pattern will be smaller in area than the old wear pattern. Figure High Pattern Figure Low Pattern MAINTENANCE MANUAL 31

33 Assembly and Installation 1 - Good Pattern in Operation Figure 4.38 A high contact pattern indicates that the drive pinion was not installed deep enough into the differential. A low contact pattern indicates that the drive pinion was installed too deep in the differential. 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 differential to move the contact patterns between the top and bottom of the gear teeth. Use the following procedure. A. Disassemble the Fork, pinion cage and the drive pinion. See the Section 2. B. Remove the inner bearing cone from the drive pinion. See the Section 2. C. Change the bearing shim. To correct a high contact pattern, Figure 4.36: Replace the bearing shim with a thicker shim. To correct a low contact pattern, Figure 4.37: Replace the bearing shim with a thinner shim. D. Install the inner bearing cone onto the drive pinion. Install the drive pinion into the differential. See the appropriate procedures in this section. E. Repeat Steps 2-5 until the contact patterns are in the center between the top and bottom of the gear teeth. Figure 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. See the Ring Gear Backlash in this section. 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 C. Repeat Steps 2-4 and 6 until the contact patterns are at the correct location in the length of the gear teeth. 1 - Move pattern toward toe, loosen adjusting ring this side 2 - Decrease Backlash 3 - Tighten Adjusting Ring 1 - Move pattern toward toe, loosen adjusting ring this side 2 - Decrease Backlash 3 - Loosen adjusting ring Figure 4.39 Figure MAINTENANCE MANUAL

34 Assembly and Installation 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 Cotter Pins Differential into the Axle Housing Figure 4.41 WARNING Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion- -type cleaners and petroleum-based cleaners. To avoid serious personal injury when you use solvent cleaners, you must carefully follow the manufacturer s product instructions and these procedures: Wear safe eye protection. Wear clothing that protects your skin. Work in a well-ventilated area. Do not use gasoline, or solvents that contain gasoline. Gasoline can explode. You must use hot solution tanks or alkaline solutions correctly. Follow the manufacturer s instructions carefully. When you apply some silicone gasket materials, small amounts of acid vapor are present. To prevent serious personal injury, ensure that the work area is well ventilated. If the silicone gasket material gets into your eyes, flush them with water for 15 minutes. Have your eyes checked by a physician as soon as possible. 1. Clean the inside of the axle housing and the differential mounting surfaces. Use a cleaning solvent and rags to remove dirt. Blow dry the cleaned areas with air. See the Section Inspect the axle housing for damage. Repair or replace the axle housing. See the Section Apply liquid adhesive Meritor specification 2297-T-4180, or equivalent, into the threaded holes in the axle housing. To obtain this threadlocker, see the Service Notes page on the front inside cover of this manual. See the Section Apply silicone gasket material onto the differential mounting surface of the housing. See the Section. 4 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 differential into the axle housing. Use a hydraulic roller jack or a lifting tool. 6. Install capscrews in the four corner locations around the differential and axle housing. Hand-tighten the fasteners. Figure 4.42 Figure 4.42 MAINTENANCE MANUAL 33

35 Assembly and Installation 7. Carefully push the differential 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 lb-ft ( N.m). 9. Install the remaining capscrews and tighten them to lb-ft ( N.m). Axle Shafts in the Axle Assembly 1. Clean the mating surfaces of the axle shaft flange and the wheel hub. 2. Apply a 1/8-inch (3 mm) diameter bead of RTV sealant around the mating surface of the hub and around the edge of each fastener hole. 3. Install the axle shaft into the housing. The axle shaft flange must fit flat against the wheel hub. Fill the Axle with Lubricant 1. Park the vehicle on a level surface. 2. Remove the fill plug from the axle housing. 3. Fill the axle housing with the correct lubricant until the lubricant level is to the bottom of the fill plug hole. See the Section Install the fill plug and tighten it to 35 lb-pé minimum. 5. Road test the vehicle in an unloaded condition for one to two miles ( km). Do not exceed 25 mph (40 km/h). 6. Recheck the lubricant level. Adjust the lubricant level as necessary. 1 - CAPSCREW 2 - AXLE SHAFT FLANGE 3 - AXLE SHAFT HUB Figure Install the capscrews and tighten them to lb-ft ( N.m). 5. Connect the driveline universal joint to the pinion input Fork on the differential. 6. Remove the safety stands. Lower the vehicle. Remove the blocks from the wheels. 34 MAINTENANCE MANUAL

36 Torque Specifications Fastener Dimensions Torque lb.-foot (N.m) 1- Fork Locknut M32 x 1, ( ) 2- Adjusting Ring Lock Plate Capscrews 3- Differential Case Capscrews 4- Differential Cap Capscrews M6 x 1,0, Class (14-18) M12 x 1,75, Class 10.9 (MS- 113) M14 x 1,75, Class 10.9 (MS-113 Plus) /-0 Lb.ft (50+10/-0 N.m + 60º + 10º /-0º /-0 Lb.ft (85+5/-0 N.m + 60º + 5º /-0º M14 x 2,0, Class ( ) 5 e 6- Differential Case Capscrew 41 x 1467 (short) 41 x 1465 (long) ( ) 7- Axle Shaft capscrews M12 x 1, ( ) 8- Fill plug 0, minimum 9- Drain plug 0, minimum 10- Breather plug 297U lb.inch MAINTENANCE MANUAL 35

37 Lubrication Description Pinion Bearing Preload Rolling Torque Differential Bearing Preload Expansion between Bearing cap Differential Gears Rotating Resistance Ring Gear Runout Backlash Setting Range for Old Gear Sets Backlash Setting Range for Old Gear Sets Specification 5-20 lb-inch. (5,8 23,0 N.m) 5-20 lb-inch. (5,8 23,0 N.m) 0,006 0,013 inch. (0,15 0,33 mm) 50 lb-inch (68 N.m) 0,008 inch. (0,200 mm) maximum 0,008 0,018 inch (0,20 0,46 mm) 0,005 0,015 inch (0,13 0,25 mm) Lubrication Capacity MS Series Liters 6,8 Oil Change Intervals and Specifications for all tractive rear axles (1) Ocupación o Operación del Vehículo Recreational Vehicle Trailer Commercial Vans Beverage Truck Rescue Truck Urban Delivery School bus Firefighters Truck Utilitarian Municipal Truck Initial Oil Change No longer required since January 1st 1993 Oil level check Petroleum based oil change in the axle with or without pump and filter. Synthetic Oil change in the axle without pump or filter (2) Every miles ( km) or fleet maintenance interval (whichever comes first) Every miles ( km) Or annually, whichever comes first Every miles ( km) Or annually, whichever comes first Every miles ( km), once a month, or fleet maintenance interval (whichever comes first) Every miles ( km) or annually, whichever comes first Every miles ( km) or annually, whichever comes first Synthetic Oil change in the axle with pump and filter system Every miles ( km) Every miles ( km) Filter Exchange in the axle Every miles ( km) with pump system and filter Every miles ( km) (1) If a No-Spin differential (non-slip) is installed, change the oil (petroleum based or synthetic) in intervals of 40,000 miles (64,000 km) or maximum range of 50,000 miles (80,000 km). (2) This interval only applies to semi-synthetic oils and fully approved synthetic. Approved lubricants for Tractive Rear Axle relative to the approved list of oil for axle with extended drain period. To obtain this publication, see the sheet for Comments on Technical Assistance on the inside cover of this manual. (3) The first oil change (mineral type) should be between 2000 and 5000 km. 36 MAINTENANCE MANUAL

38 Lubrication Oil Specification for Axles Oil Specification for Axles Specifica- A.P.I tion SAE Class Meritor Specification Military/SAE Specification External Temperature Lubrificantes de Dreno Não Prolongado Lubrificantes de Dreno Prolongado Petroleum Additives EP with Petroleum Additives with Extended Drain GL-5 GL-5 85W/140 O-76A 80W/140 O-76B 80W/90 O-76D 75W/90 O76-E 75W O-76J 75W/140 O-76L 80W/90 Semi Synthetic 80W/90 Pure Synthetic 75W/140 O-76M Pure Synthetic 75W/90 O-76N MIL-PRF-2105E e SAE J2360 MIL-PRF-2105E e SAE J2360 Over +10 F (-12 C) Over -15 F (-26 C) Over -15 F (-26 C) Over -40 F (-40 C) From -40 F (-40 C) to 35 F (2 C) Over -40 F (-40 C) Over -15 F (-26 C) Over -15 F (-26 C) Over -40 F (-40 C) Over -40 F (-40 C) MAINTENANCE MANUAL 37

39 Towing Instructions WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. When transporting a vehicle with the wheels of one or both drive axles on the road, it is possible to damage the axles if the wrong procedure is used before transporting begins. Meritor recommends that you use the following procedure. 3. Identify each axle shaft that is removed from the axle assembly so they can be installed in the same location after transporting or repair is completed. Example: Match mark a mating axle shaft and hub. 4. Remove the axle shaft from the axle assembly. Figure Install a cover over the open end of each hub where an axle shaft was removed. This will prevent dirt from entering the bearing cavity and loss of lubricant. Before Towing or Drive-Away WARNING Engage the parking brake to prevent the vehicle from moving before you begin maintenance or service procedures that require you to be under the vehicle. Serious personal injury can result. 1. Apply the vehicle parking brakes using the switch inside the cab of the vehicle. NOTE: Remove both axle shafts from the axle(s) that will remain on the road when the vehicle is transported. 2. Remove the capscrews from the flange of the axle shafts. Figure 7.1. NOTE: If an air supply will be used for the brake system of the transported vehicle, continue with Steps 6 and 7, otherwise continue with Step Connect an auxiliary air supply to the brake system of the vehicle that is being transported. Before moving the vehicle, charge the brake system with the correct amount of air pressure to operate the brakes. See the instructions supplied by the vehicle manufacturer for procedures and specifications. If an auxiliary air supply is not used, continue with Step When the correct amount of air pressure is in the brake system, release the parking brakes of the vehicle that is being transported. Step 8 is not required. WARNING When you work on a spring chamber, carefully follow the service instructions of the chamber manufacturer. Sudden release of a compressed spring can cause serious personal injury. 8. If there are spring parking brakes on the axle(s) that will remain on the road when the vehicle is transported, and they cannot be released by air pressure, manually compress and lock each spring so that the brakes are released. See the manufacturer s instructions. 1 - CAPSCREW 2 - AXLE SHAFT FLANGE 3 - AXLE SHAFT HUB Figure MAINTENANCE MANUAL

40 Towing Instructions After Towing or Drive-Away WARNING Engage the parking brake to prevent the vehicle from moving before you begin maintenance or service procedures that require you to be under the vehicle. Serious personal injury can result 7. Check the lubricant level in the axles and hubs where the axle shafts were removed. See the Section 7 for specifications and intervals. For Manual 1, Preventive Maintenance and Lubrication. To obtain this publication, see the Service Notes page on the front inside cover of this manual. 1. If an auxiliary air supply was used, apply the vehicle parking brakes using the switch inside the cab of the vehicle. If an auxiliary air supply was not used, begin with Step 2. WARNING When you work on a spring chamber, carefully follow the service instructions of the chamber manufacturer. Sudden release of a compressed spring can cause serious personal injury. 2. Apply the vehicle spring parking brakes by manually releasing each spring that was compressed before transporting started. See the manufacturer s instructions. 3. Disconnect the auxiliary air supply, if used, from the brake system of the vehicle that was transported. Connect the vehicle s air supply to the brake system. 4. Remove the covers from the hubs. NOTE: Continue with Steps 5-6 to install all axle shafts. 5. Install the axle shaft into the axle housing and differential in the same location it was removed from. The flange of the axle shaft must be flat against the hub. Rotate the axle shaft or the driveline as necessary to align the splines and the holes in the flange with the studs in the hub. Figure Install the capscrews. Tighten the capscrews to lb-ft ( N.m). MAINTENANCE MANUAL 39

41 Special Tools Differential Repair Stand Specifications SPX Kent-Moore número de la pieza J-3409-D 1 - Plates 8 (2.44 mm) long x 3/4 (19.05 mm) thick x 1-1/4 (31.75 mm) wide with a tongue to fit slot in bar weld plates to bar 2 - Handle 7 (177.8 mm) long with slot in one end to fit clamp screw 3 - Bar 2 (50.8 mm) diameter x 9 (228.6 mm) long with one end slotted to fit plate 4 - Weld all around after pressing plug into pipe. 5 - Weld 6 - Shape and size of holes to fit differential /2 (596.9 mm) center to center of pipe 8 - Chamfer end of pipe for welding. 9-4 (101.6 mm) diameter pipe 10 - Plug 4 (101.6 mm) diameter x 7 (177.8 mm) long with one end turned 3 (76.2 mm) long to fit pipe. Drill 2 (50.8 mm) hole and mill 3/16 (4.76 mm) wide slot 2 (50.8 mm) from top Screw 3-1/2 (88.9 mm) long x 5/8 (15.86 mm) diameter with flats onto end to fit handle and 2-1/2 (63.5 mm) length of thread on other end 12 - Drill 3/8 (9.5 mm) hole through handle and screw. See the Service Notes page on the front inside cover of this manual to obtain this repair stand. 40 MAINTENANCE MANUAL

42 Failures and Causes How to make a Fork Bar 1. Measure dimensions A and B of the Fork you are servicing. Figure Special Tool Figure Fork Figure Calculate dimensions C and D of the Fork bar by adding inch ( mm) to dimensions A and B of the Fork. Figure 8.2. WARNING Wear safe clothing and eye protection when you use welding equipment. Welding equipment can burn you and cause serious personal injury. Follow the operating instructions and safety procedures recommended by the welding equipment manufacturer. Overview of Damaged Components 1. Flexing overload: One look at the drive pinion shows the entire breakage as rough and crystalline. Broken parts showing surfaces like this clearly indicate that the damages were instantaneous and caused by shock. Figure To make the box section, cut and weld 1.0- inch x 2.0-inch (25.4 mm x 50.8 mm) mild steel square stock according to dimensions C and D. Figure Cut a 4.0-foot x 1.25-inch (1.21 m x mm) piece of mild steel round stock to make the Fork bar handle. Center weld this piece to the box section. Figure 8.2. To increase Fork bar rigidity: Weld two angle pieces onto the handle. Figure 9.1 MAINTENANCE MANUAL 41

43 Failures and Causes 2. Flexing Fatigue: Flexion fatigues at the root are originated by shock and / or repetitive overload, causing cracks found in the roots of the teeth of the gear. As the mileage increases, the initial cracks increases and the gear teeth will progressively weaken until the break occurs. Flexion fatigue in the root of the drive pinion teeth is characterized by the same type of beach marks left on the axles that has flexion fatigue failure caused by rotation. When only two or three teeth breaks, this indicates that the cause may have been an instantaneous shock load. Fatigue-induced by shock loads will also show origins that are also in line. If all the remaining teeth are broken, the likely cause was a severe shock load with continuous application of voltage or overload of the vehicle. The beach marks causes flexion fatigue cracks at the root, starting at the root of all affected teeth and progress to the hardened surface of the drive pinion and ring gear set teeth. Figure Fatigue Initiated by Shock: Shock loads are often severe enough to break the gear s teeth at the root, parting axles in two and causing other failures as well. Often, shock loads do not produce instantaneous failure, but leave the component weakened or with a crack. Depending on the severity of the shock, the definite failure may occur only after many kilometers. Figure 9.3. Figure Flank Cracking Flank cracking usually causes the peeling of a metal surface very similar to what is a failure by chipping (spalling). However, a gear with cracks in the sides will develop first longitudinal breaks along the surface of the gear tooth. Once these cracks appear, the failure occurs quickly. Many times, just one tooth gives a sign of decay while the other teeth are intact. But when breaks appear, soon the metal between them begins to flake off the teeth. Figure 9.4. Figure MAINTENANCE MANUAL

44 Failures and Causes Figure 9.4 Figure 9.5 Lubrication 5. Exhausted Additive Damage: Meritor axles requires lubricants that meet the specifications EP (Extreme Pressure) with additives base of sulfur / phosphorus. To function, the required oil is GL-5, as specified L- -PRF-2105E. Inappropriate grade lubricant with additives depleted or in situations of low oil level (or no oil) can take the ring gear and drive pinion to provide a lubrication failure characterized by contact wear pattern, which is known as crow s foot. Such patterns are described as lines or grooves in the teeth of the gear. Figure 9.5. and Figure 9.6. Meritor transmissions require that the lubricants are for heavy-duty engine (straight grade) or GL-1 petroleum with corrosion and oxidation inhibitor (mineral or synthetic). Lubricants for tractive axles MUST NOT be used in transmissions, as well as lubricants for transmissions MUST NOT be used in tractive axes. The mixture of the two lubricants accelerates deterioration and premature wear of parts in the assembly. For more information see the lubrication Maintenance Manual No. 1, Lubrication. Figure 9.6 MAINTENANCE MANUAL 43

45 Failures and Causes The drive pinion teeth deteriorate until it assumes the form of a knife blade due to inadequate lubrication or the use of exhausted lubricant (old). Figure 9.7 Figure MAINTENANCE MANUAL

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