Maintenance Manual 5L

Single-Reduction Forward Differential

Carriers on Tandem and Tridem Axles
Revised 02-18
Service Notes

About This Manual Contact the Meritor OnTrac™ Customer Call Center at
866-668-7221 (United States and Canada); 001-800-889-1834
This manual provides maintenance and service information for the (Mexico); or email OnTrac@meritor.com.
Meritor forward tandem drive axles, including the RT-140; -144;
-145; -149; -160; -169; RZ-166; -186 and -188 Series models.
If Tools and Supplies are Specified in
Before You Begin This Manual
Contact Meritor’s Commercial Vehicle Aftermarket at
1. Read and understand all instructions and procedures before
888-725-9355 to obtain Meritor tools and supplies.
you begin to service components.
SPX Kent-Moore, 28635 Mound Road, Warren, Michigan, 48092.
2. Read and observe all Warning and Caution hazard alert
Call the company’s customer service center at 800-345-2233, or
messages in this publication. They provide information that can
visit their website at spxkentmoore.com.
help prevent serious personal injury, damage to components,
or both. Kiene Diesel Accessories, Inc., 325 S. Fairbanks Street, Addison, IL
60101. Call the company’s customer service center at
3. Follow your company’s maintenance and service, installation,
800-264-5950, or visit their website at kienediesel.com.
and diagnostics guidelines.
SPX/OTC Service Solutions, 655 Eisenhower Drive, Owatonna, MN
4. Use special tools when required to help avoid serious personal
55060. Call the company’s customer service center at
injury and damage to components.
800-533-6128, or visit their website at otctools.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.

@ This symbol alerts you to tighten fasteners to a specified torque

value.

How to Obtain Additional Maintenance,

Service and Product Information
Visit Literature on Demand at meritor.com to access and order
additional information.

Information contained in this publication was in effect at the time the publication was
approved for printing and is subject to change without notice or liability. Meritor Heavy
Vehicle Systems, LLC, reserves the right to revise the information presented or to
discontinue the production of parts described at any time.

Meritor Maintenance Manual 5L (Revised 02-18)

 Contents

pg. 1 Section 1: Exploded Views pg. 26 Drying Parts After Cleaning

Single-Reduction Forward Differential Carrier Prevent Corrosion on Cleaned Parts
Inspect Parts
4 Section 2: Introduction
29 Repair or Replace Parts
Description
Welding on Axle Housings
Forward Tandem Axle
30 Do Not Bend or Straighten a Damaged Drive Axle Housing
Axle Models Covered in This Manual
Removing Fasteners Secured with Adhesive
Optional Pressurized Lubrication System
New Fasteners with Pre-Applied Adhesive
Optional Driver-Controlled Main Differential Lock (DCDL)
Original or Used Fasteners
5 Inter-Axle Main Differential (IAD)
Meritor Specification 2297-T-4180 Adhesive in the
Stall-Testing Can Damage a Drive Axle
Differential Bearing Bores
Use of Traction Chains
31 Carrier-to-Housing Joint Sealing Procedure
Identification
32 General Yoke and U-Joint Reassembly
Model Number
Identification
7 Section 3: Removal and Disassembly Gear Sets
Removal 33 Check for Mismatched Ratios on Tandem Axles
Axle Shafts Hypoid Gear Set Ratios Listed on the Identification Tags
Axle Shaft Removal Methods 34 Rotate the Forward Drive Shaft to Check the Hypoid Gear
9 Axle Shafts from the Axle Housing Set Ratio
10 Thru-Shaft 35 Hypoid Gear Set Teeth Numbers Stamped on the Forward
11 Differential Carrier from the Axle Housing and Rear Axle Drive Pinions
12 Disassembly Verify the Actual Hypoid Gear Set Ratios
Thru-Shaft and Output Bearing Cage Assembly 36 Inspection
13 Removal Yoke
Bearing Cone from the Thru-Shaft 37 Tire Matching for Tandem and Tridem Axles
Measure Ring Gear Backlash
38 Section 5: Assembly and Installation
14 Input Shaft and Inter-Axle Differential Assembly
Installation
16 Disassembly
Installing the Drive Pinion and Adjusting Pinion Depth and
Input Shaft, Bearing Cage, Oil Pump and Inter-Axle
Preload
Differential
Adjustment
19 Removal
Shim Pack Thickness for a New Drive Pinion
Inter-Axle Differential Lock IAD Shift Unit
39 Assembly
20 Driver-Controlled Main Differential Lock (DCDL)
Drive Pinion Assembly
Main Differential Case and Ring Gear Assembly
41 Installation
21 Disassembly
Drive Pinion Assembly
Main Differential Case and Ring Gear
42 Adjustment
22 Removal
Drive Pinion Bearing Preload
Ring Gear from the Differential Case
46 Assembly
23 Drive Pinion Assembly
Main Differential and Ring Gear
Before You Work on a Differential Carrier
48 Check the Rotating Resistance of the Differential Assembly
Assembly Procedures
49 Installation
25 Section 4: Prepare Parts for Assembly Main Differential Case and Ring Gear Assembly Into the
Clean, Dry and Inspect Parts Carrier
Clean and Inspect Yokes 51 Adjustment
26 Clean Ground and Polished Parts Differential Bearings Preload
Clean Rough Parts 53 Ring Gear Runout
Clean Axle Assemblies Ring Gear Backlash
Contents

pg. 54 Gear Set Tooth Contact Patterns, Backlash pg. 108 Section 10: Special Tools
58 Installation Specifications
Thrust Screw (If Equipped) Carrier Repair Stand
Air Shift Unit for the Inter-Axle Differential Lock 109 How to Make a Yoke Bar
60 Assembly How to Make a Drive Flange Retainer Tool
Input Shaft, Bearing Cage, Oil Pump and Inter-Axle 110 Unitized Pinion Seals and Seal Drivers
Differential
112 Section 11: Vehicle Towing Instructions
64 Installation
Type of Axle
Input Shaft Assembly
Forward Tandem Axle, with Driver-Controlled Main
65 Inspection
Differential Lock (DCDL — Screw-In DCDL Shift
Adjust the Input Bearing End Play
Assembly) and with Inter-Axle Differential (IAD)
68 Installation
116 Forward Tandem Axle, with Driver-Controlled Main
Driver-Controlled Main Differential Lock
Differential Lock (DCDL — Bolt-On DCDL Shift
Output Bearings and Thru-Shaft
Assembly) and with Inter-Axle Differential (IAD)
69 Inspection
120 Forward Tandem Axle, without Driver-Controlled Main
Adjust the Output Bearing End Play
Differential Lock (DCDL), with Inter-Axle Differential
Installation
(IAD)
Unitized Pinion Seal
72 Installing a Multiple-Lip Seal (MLS) 122 Section 12: Diagnostics
76 Clean and Inspect the Yoke After Installing a Unitized Troubleshooting
Pinion Seal Vehicle Will Not Move
77 Tight Fit Yokes and POSE™ Seal 124 Differential Making Noise
Output Yoke or Flange and Oil Seal for the Output Bearing 126 Oil Leak
Cage 127 Contaminated Lubricant Found During Preventive
79 Differential Carrier into the Axle Housing Maintenance
82 Axle Shaft
83 Fill the Axle with Lubricant
85 Section 6: Driver-Controlled Main
Differential Lock
Description
Removal
Differential Carrier from the Axle Housing
Engagement or Lockout of the DCDL
87 Differential and Gear Assembly and Main Differential Lock
90 Installation
Differential Shift Assembly
95 Differential Lock Assembly Cover Plates
Differential Carrier Into the Forward Axle Housing
97 Check the Differential Lock
DCDL Driver Caution Alert Label
98 Driver Instruction Information Available
99 Section 7: Lubrication
Specifications
101 Section 8: Specifications
106 Section 9: Adjustment
 1 Exploded Views

Single-Reduction Forward Differential Carrier

1 Exploded Views

Item Description Item Description Item Description

1 Nut — Input Yoke 38 Shims 71A Piston — Main Differential Lock —
1A Washer — Input Yoke 39 Inner Spacer Current Design
2 Input Yoke 40 Helical Driven Gear 72 O-Ring — Piston
3 Deflector 41 Outer Spacer 72A O-Ring — Piston — Current Design
4 Capscrew — Cage-to-Carrier 42 Outer Bearing Cup — Drive Pinion 73 DCDL Cylinder — Shift Shaft
5 Washer — Cage-to-Carrier 43 Outer Bearing Cone — Drive Pinion 73A DCDL Cylinder — Shift Shaft —
Current Screw-In DCDL Design
6 Oil Seal — Triple-Lip (Main) Seal 44 Washer — Drive Pinion
74 Copper Gasket — Cover (160 Series)
6A POSE™ Seal 45 Nut — Drive Pinion
75 Capscrew — Manual Engaging
7 Input Bearing Cage 46 Cover — Drive Pinion
75A Capscrew — Manual Engaging —
8 Shims 47 Washer — Drive Pinion Cover
Current Design
9 O-Ring — Input Bearing Cage 48 Capscrew — Drive Pinion Cover
76 Cover — Main Differential Lock (Early
10 Bearing Cup — Input Shaft 49 Bearing Adjusting Ring Design)
11 Bearing Cone — Input Shaft 50 Cup — Main Differential Bearing 77 Plug — Manual Engaging (Early
12 Oil Baffle (Units Without Oil Pump) 51 Cone — Main Differential Bearing Design)
13 Washer — Oil Baffle 52 Capscrew — Main Differential Case 78 Washer — Manual Engaging
14 Capscrew — Oil Baffle Halves Capscrew
15 Input Shaft 53 Washer — Main Differential Case 79 Capscrew — Cover (Early Design)
Halves 80 Washer — Cover (Early Design)
16 Thrust Washer — Helical Drive Gear
54 Main Differential Case Assembly 81 Shift Collar — Main Differential Lock
17 Helical Drive Gear
55 Bolt — Ring Gear (145 and 160 82 Shift Fork — Main Differential Lock
18 Inter-Axle Differential Case Assembly
Series)
19 Snap Ring — Inter-Axle Differential 82A Shift Fork — Main Differential Lock
56 Washer — Differential Bearing Cap — Current Design
Case
57 Capscrew — Differential Bearing Cap 83 Roll Pin — Shift Fork (Early Design)
20 Clutch Collar — Inter-Axle Differential
Case 58 Roll Pin, Cotter Pin or Capscrew — 84 Oil Filter Shield
Differential Bearing Cap
21 Rear Side Gear 85 Plug — Oil Pressure Relief Valve
59 Thrust Washer — Main Differential
22 Shift Fork 86 Washer — Oil Pressure Relief Valve
Side Gear
23 Bearing Cone — Rear Side Gear 87 Spring — Oil Pressure Relief Valve
60 Side Gear — Main Differential
24 Bearing Cup — Rear Side Gear 88 Oil Pressure Relief Valve
61 Spider — Main Differential
25 Adjusting Screw — Shift Shaft 89 Dowel — Input Cage to Oil Pump
62 Pinion Gear — Main Differential
26 Jam Nut — Adjusting Screw (Early Design)
63 Thrust Washer — Main Differential
27 Spring — Shift Shaft 90 O-Ring — Oil Pump
63A NoSPIN Main Differential1
28 Shift Shaft and Piston 91 Oil Pump
64 Washer — Ring Gear (145 and 160
28A “E” Clip (Reverse Shift IAD Only) 92 Washer — Oil Pump
Series)
29 Air Shift Chamber Assembly — 93 Capscrew — Oil Pump
65 Nut — Ring Gear (145 and 160
Bolt-On IAD Series) 94 Oil Filter
29A Air Shift Chamber Assembly — 66 Sensor Switch — Main Differential 95 Adapter — Oil Filter
Screw-In IAD Lock 96 Oil Screen and Plug Assembly
30 Capscrew — Air Shift Chamber 67 Locknut — Main Differential Lock
Assembly
1
NoSPIN is a registered trademark of Tractech,
Sensor Switch (Early Design)
31 Differential Carrier and Caps a division of Dyneer Corp.
68 Spring — Main Differential Lock
32 Washer — Differential Carrier-to-Axle 68A Spring — Main Differential Lock —
Housing Current Design
33 Nut — Differential Carrier-to-Axle 69 Lock Pin — Spring Retaining (Early
Housing Design)
34 Capscrew — Differential 70 Shift Shaft — Main Differential Lock
Carrier-to-Axle Housing
70A Shift Shaft — Main Differential Lock
35 Ring Gear and Drive Pinion — Current Design
36 Inner Bearing Cone — Drive Pinion 71 Piston — Main Differential Lock
37 Inner Bearing Cup — Drive Pinion

Meritor Maintenance Manual 5L (Revised 02-18) 1

1 Exploded Views

Figure 1.1

93
92
88 91
INPUT WITH 89 90
OIL PUMP PARTS 86 87 7
85 15

84
15
14
11 12
10
9
8
7
6
6A
13
5
4
3
2
1A
1
STANDARD DIFFERENTIAL
CARRIER WITHOUT DIFFERENTIAL
LOCK AND WITHOUT OIL PUMP

29

26 30
31
25 27 28

24 72 A
23 71 A

19
18
17 28 A
16 29 A

21 32
20 34
22
33 32

35
36 82 A
37
38 L.H. SIDE
48 39
40
41
42
43
44 31
47 46 45 71
83
82 74
81 80

94 69 70
95
72
73 79
OIL PUMP
PARTS 68 75
75 A 76 78
77
96 66
67 70 A
DIFFERENTIAL
68 A 72 A 71 A 73 A LOCK PARTS 1003392a

2 Meritor Maintenance Manual 5L (Revised 02-18)

 1 Exploded Views

Figure 1.2

58 58 57
49 63
65
50
51 64
54 62
59 56
60 31
61 55 53 52
59
51 50 49
R.H. SIDE

60

54
63 A 35

CURRENT DCDL EARLY DESIGN DCDL

68
71
68 A 75 A 74
70 A 80

72 A 70
67 69
71 A 72
73 79
73 A 75
76
78 77

NoSPIN® ASSEMBLY OIL PUMP

92 93
91
90

15
63 A

54 MAIN DIFFERENTIAL
CASE ASSEMBLY
PLAIN
CASE HALF

GEAR
CASE HALF

1002701c

Meritor Maintenance Manual 5L (Revised 02-18) 3

2 Introduction

Description Axle Models Covered in This Manual

2 Introduction

Forward Tandem Axle Tandem Models

The inter-axle differential is located behind the helical gear on the RT-34-140 RT-40-145P RT-46-160
input shaft. The forward side gear of the inter-axle differential is part RT-34-144 RT-40-149 RT-46-160EH
of the upper helical gear hub. The thru-shaft is splined to the rear RT-34-145 RT-40-160 RT-46-160P
side gear of the inter-axle differential. Figure 2.1.
RT-34-145P RT-40-169 RT-46-169
Figure 2.1 RT-40-140 RT-44-145 RT-50-160
HELICAL MT-40-143 RT-44-145P RT-50-160P
OIL GEAR
PUMP INTER-AXLE
INPUT DIFFERENTIAL RT-40-145 RT-46-16H EH RT-52-160P
SHAFT OUTPUT
SHAFT RT-40-145A
Tridem Models
RZ-166 RZ-186 RZ-188

NOTE: For service procedures on rear carriers, refer to

Maintenance Manual 5, Single-Reduction Differential Carriers, for
RING models preceding RS-, RT- and RF-Series, and Maintenance Manual
DRIVE GEAR 5A, Single-Reduction Differential Carriers, for MX-, RS-, RT- and
PINION 1002702c
RF-Series. To obtain these publications, refer to the Service Notes
Figure 2.1 page on the front inside cover of this manual.

The Meritor 140, 145 and 160 forward tandem axles use a Optional Pressurized Lubrication System
single-reduction, thru-drive carrier. The drive gearing is a The forward axles can be equipped with an optional pressurized
two-helical gear train and a hypoid ring gear and pinion. Bevel gears lubrication system. This filtered system has an oil pump driven by
are used in the main differential and the inter-axle differential. the input shaft. The pump circulates lubricant to the journals in the
Figure 2.1 and Figure 2.2. forward and rear input shaft bearings and directly to the inter-axle
differential.
Figure 2.2

RT-160 SERIES SHOWN Optional Driver-Controlled Main Differential

Notch on inter-axle Lock (DCDL)
differential case.
Notches are provided Both the forward and rear axles can be equipped with an optional
for clearance in driver-controlled main differential lock (DCDL). The differential lock
assembly and
disassembly.
is operated by an air-actuated shift unit located on the forward axle
carrier.
앫 When the differential lock is activated, the shift collar moves
HELICAL along the splines of the axle shaft toward the differential case.
DRIVEN
GEAR 1002703c 앫 When the collar splines engage with the splines on the
differential case, the axle shaft and the differential assembly lock
Figure 2.2
together.
앫 When the carrier operates with the DCDL in the locked position,
there is no differential action between the wheels.
앫 When the carrier is operated in the unlocked position, there is
normal differential action between the wheels at all times.

4 Meritor Maintenance Manual 5L (Revised 02-18)

 2 Introduction

Inter-Axle Main Differential (IAD) Figure 2.3

AXLE IDENTIFICATION TAG INFORMATION

The Meritor inter-axle differential (IAD) is a driver-controlled,
air-actuated traction device. The IAD allows for speed differences
Model No. . . . . . . . . . . . . . . . . . . .
between the forward and rear axles in a tandem while also providing Customer No. . . . . . . . . . . . . . . . .
equal pulling power from each axle of the tandem. By activating the
IAD switch located in the vehicle dash, improved traction is provided Serial No. . . . . . . . . Plant . . . . . . . .
Ratio . . . . . . . . . . . .
for each axle.
The inter-axle differential is also known as a power divider or third
differential. IDENTIFICATION TAG

LOCATION OF THE IDENTIFICATION TAG, OR STAMP

NUMBER, FOR THE AXLES. LOCATION IS
Stall-Testing Can Damage a Drive Axle DETERMINED FROM THE LEFT DRIVER SIDE
LOOKING TOWARD THE FRONT OF THE VEHICLE.
Stall-testing is a procedure used to troubleshoot transmissions,
A
evaluate vehicle performance, and test the service and park brakes.
During stall-testing, or any similar procedure, the drive axle input
receives multiplied torque, which can exceed the specified torque B
rating. Excessive torque can damage a drive axle, which will affect
A — FRONT ENGINE DRIVE — RIGHT REAR, NEXT
axle performance and component life. A drive axle damaged by TO COVER
stall-testing will void Meritor’s warranty. B — REAR ENGINE DRIVE — LEFT OR RIGHT REAR,
NEXT TO DRIVE UNIT
1002704c
Call the Meritor OnTrac™ Customer Call Center at 866-668-7221 if
you have questions regarding stall-testing. Figure 2.3

Use of Traction Chains Figure 2.4

Meritor recommends that if you are using traction chains, you

should install chains on both tires on each side of all drive axles on
the vehicle.

Identification AXLE HOUSING

IDENTIFICATION TAG
Model Number
CARRIER PART NO.
CUSTOMER NO.
SERIAL NO.
RATIO

. nt
l No . Pla

An identification tag is riveted on the axle housing or on the

de r No te
Mo me Da
sto .
Cu
l No
ria
Se
tio
Ra

differential carrier. Figure 2.3 and Figure 2.4. Use the model
number and the ratio number marked on the identification tag and
the number on the carrier to order replacement parts.
Model No. CARRIER PART NO.
Customer No. CUSTOMER NO.
Serial No. Plant SERIAL NO.

AXLE Ratio Date RATIO

CARRIER
IDENTIFICATION TAG IDENTIFICATION TAG
4000625a

Figure 2.4

Refer to Figure 2.5 for an explanation of the model number.

Meritor Maintenance Manual 5L (Revised 02-18) 5

2 Introduction

Figure 2.5

CARRIER MODEL TAG NUMBER INFORMATION

M T - 40 - 1 4 X
Axle Design Variation: Indicates
axle design level or variation,
(e.g., RS-23-161 has a thicker
Meritor wall housing than RS-23-160).
For information, refer to the Bill
of Materials for that specific
axle model.
Carrier Type: Carrier size. Larger numbers
indicate a higher GCW rated Carrier; i.e.,
larger ring gear, etc.
Gearing Type:
1 = Single Speed
Nominal Axle Load Rating (GAWR): In thousands of pounds.
Individual forward and rear axles of a tandem set (D, N, P) are rated
as single axles. A tandem set (T) is rated as the combination of the
two axles.
Axle Type
D = Forward-Rear Axle of a Drive Tandem with Inter-Axle Differential
N = Forward-Rear Axle of a Drive Tandem without Inter-Axle Differential
P = Forward-Rear Axle of a Drive Tandem with Inter-Axle Differential and Pump
T = Tandem Drive Axle Set 1002705e

Figure 2.5

6 Meritor Maintenance Manual 5L (Revised 02-18)

 3 Removal and Disassembly

Hazard Alert Messages

3 Removal and Disassembly

Tool Part Number Manufacturer

Read and observe all Warning and Caution hazard alert messages in Axle Shaft K-1280 Kiene Diesel
this publication. They provide information that can help prevent Remover Accessories, Inc.
serious personal injury, damage to components, or both. Axle Stud Cone 7077 SPX OTC
Plier
WARNING
To prevent serious eye injury, always wear safe eye protection Air Hammer Vibration Method
when you perform vehicle maintenance or service.
WARNING
Use a brass or synthetic mallet for assembly and disassembly Wear safe eye protection when using an air hammer. When
procedures. Do not hit steel parts with a steel hammer. Pieces using power tools, axle components can loosen and break off
of a part can break off. Serious personal injury and damage to causing serious personal injury.
components can result.
CAUTION
Observe all warnings and cautions provided by the press
Do not use a chisel or wedge to loosen the axle shaft and
manufacturer to avoid damage to components and serious
tapered dowels. Using a chisel or wedge can result in damage
personal injury.
to the axle shaft, the gasket and seal, and the axle hub.

Removal 1. Use a round hammer bit and an air hammer to loosen the
tapered dowels and axle shaft.
Axle Shafts
2. Place the round hammer bit against the axle shaft or flange
Before the axle shafts and differential carrier can be removed or between the hub studs. Operate the air hammer at alternate
installed, the driver-controlled differential lock (DCDL), if equipped, locations between the studs to loosen the tapered dowels and
must be shifted into and held in the locked or engaged position. The axle shaft from the hub. Figure 3.1.
locked position gives enough clearance between the shift collar and
the axle housing to permit the removal or installation of the axle Figure 3.1

shafts and carrier. Refer to Section 6 for service information on the ROUND HAMMER
DCDL. If the drive axle is not equipped with DCDL, continue on with BIT BETWEEN HUB
STUDS
axle shaft removal in this section.

Axle Shaft Removal Methods

Use Special Tools Recommended by Meritor
To help prevent serious personal injury and damage to components
when you remove the axle shaft from the housing, Meritor
recommends that you use the following tools in the table below.
Refer to the Service Notes page at the front inside cover of this
manual for information on how to contact the manufacturers to 1002987c
obtain the tools.
Figure 3.1
앫 If the tools are not available when you remove the axle
shaft:Follow procedures for using the Brass Drift Method or the
3. Mark each axle shaft before it is removed from the axle
Air Vibration Method.
assembly.
4. Remove the tapered dowels and separate the axle shaft from
the main axle hub assembly. Figure 3.1.

Meritor Maintenance Manual 5L (Revised 02-18) 7

3 Removal and Disassembly

Brass Drift Method 5. Install a cover over the open end of each axle assembly hub
where an axle shaft was removed.
WARNING
Do not strike the round driving lugs on the flange of an axle Air Hammer Vibration Method
shaft. Pieces can break off and cause serious personal injury.
WARNING
1. Hold a 1-1/2-inch diameter brass drift or brass hammer Wear safe eye protection when using an air hammer. When
against the center of the axle shaft, inside the round driving using power tools, axle components can loosen and break off
lugs. Figure 3.2. causing serious personal injury.

Figure 3.2

CAUTION
Do not use a chisel or wedge to loosen the axle shaft and
BRASS
HAMMER tapered dowels. Using a chisel or wedge can result in damage
to the axle shaft, the gasket and seal, and the axle hub.

DRIVING 1. Use a round hammer bit and an air hammer to loosen the
LUGS tapered dowels and axle shaft.
2. Place the round hammer bit against the axle shaft or flange
between the hub studs. Operate the air hammer at alternate
locations between the studs to loosen the tapered dowels and
1002707b axle shaft from the hub. Figure 3.4.
Figure 3.2
Figure 3.4

ROUND HAMMER
2. Strike the end of the drift with a large hammer, five to six BIT BETWEEN HUB
pounds, and the axle shaft and tapered dowels will loosen. STUDS

3. Mark each axle shaft before it is removed from the axle

assembly.
4. Remove the tapered dowels and separate the axle shafts from
the main axle hub assembly. Figure 3.3.

Figure 3.3

STUD TAPERED
NUT DOWEL
GASKET STUD
WASHER 1002987c

Figure 3.4

3. Mark each axle shaft before it is removed from the axle

assembly.

CAPSCREW 4. Remove the tapered dowels and separate the axle shaft from
AXLE
WASHER SHAFT the main axle hub assembly. Figure 3.4.
SHAFT OR
FLANGE HUB
AXLE 1002708b

Figure 3.3

8 Meritor Maintenance Manual 5L (Revised 02-18)

 3 Removal and Disassembly

Axle Shafts from the Axle Housing An alternate method to obtain clearance is to remove the cover
of the air shift unit from the differential carrier. Remove the
WARNING piston. Remove the shift shaft and spring from the fork. The
Park the vehicle on a level surface. Block the wheels to fork and the clutch collar will fall into the carrier and the carrier
prevent the vehicle from moving. Support the vehicle with can be removed. Remove the fork and the clutch collar after
safety stands. Do not work under a vehicle supported only by the carrier is removed.
jacks. Jacks can slip or fall over. Serious personal injury and 8. Disconnect the driveline universal joint from the pinion input
damage to components can result. yoke or flange on the carrier. Figure 3.6.

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

the vehicle from moving. Set the parking brake.
2. Use a jack to raise the vehicle so that the wheels to be serviced
are off the ground. Support the vehicle with safety stands.
3. Remove the oil drain plug from the bottom of the axle housing.
Drain the axle lubricant from the housing assembly.
4. For axles with an oil pump, remove the oil filter shield from the
input bearing cage.
5. Use a filter strap wrench to remove the oil filter. Be careful that
the oil inside does not spill when removing the filter. Discard
the filter. Figure 3.5.

Figure 3.5

OIL
FILTER

OIL FILTER
ADAPTER

1002706b

Figure 3.5

6. Inspect the oil filter adapter threads.

앫 If the adapter threads are damaged: Remove and
replace the oil filter adapter.
7. On an axle with a driver-controlled main differential lock, shift
the lock into and hold the lock in the locked or engaged
position. The locked position provides enough clearance
between the shift collar and the axle housing for carrier
removal. Refer to Section 6.

Meritor Maintenance Manual 5L (Revised 02-18) 9

3 Removal and Disassembly

Figure 3.6 9. Remove the capscrews and washers or stud nuts and washers,
if equipped, from the flanges of both axle shafts.
1
EASY SERVICETM
10. Loosen the tapered dowels, if equipped, in the axle flanges of
2 both axle shafts. Refer to the removal methods in this section.
9

3 Thru-Shaft
8 4 1. Disconnect the forward and rear drive shafts.
5
6 CAUTION
7 Always use a flange or yoke bar during removal and
installation of the flange yoke nut to prevent damage to the
10 gearing.
WING SERIES
11
PERMALUBETM
2. Attach a flange bar to the flange or place a yoke bar over the
12 input or output yoke to hold the yoke or flange while you
14
13 remove the pinion nut. Figure 3.7. Refer to Section 10 to make
a yoke bar.

FULL-ROUND Figure 3.7

15

16

19 17
18

RPL SERIES,
PERMALUBETM YOKE BAR 1003451b

20 Figure 3.7
25
21

3. Disconnect the air lines at the inter-axle differential shift unit.

22
24
23 4. Remove the thru-shaft nut, washer and yoke or flange. Use a
1002984c
puller tool to remove the yoke or flange from the shaft.
1 FULL-ROUND BEARING CUPS 14 U-JOINT CROSS Figure 3.8.
2 END YOKE 15 CAPSCREWS
3 YOKE SADDLE 16 END YOKE
4 WELD YOKE 17 WELD YOKE
5 BEARING STRAP 18 SLIP YOKE
6 CAPSCREWS 19 U-JOINT CROSS
7 EASY SERVICE™ BEARING CUPS 20 CAPSCREWS
8 U-JOINT CROSS 21 END YOKE
9 SLIP YOKE 22 SLIP YOKE
10 CAPSCREWS 23 TUBING
11 END YOKE 24 U-JOINT CROSS
12 WELD YOKE 25 WELD YOKE
13 SLIP YOKE
Figure 3.6

10 Meritor Maintenance Manual 5L (Revised 02-18)

 3 Removal and Disassembly

Figure 3.8 Figure 3.10

REMOVING
THE FLANGE TOP TWO
FASTENERS

REMOVING
THE YOKE

1002712d

Figure 3.8
ROLLER
JACK 1002714c
5. Remove the thru-shaft bearing cage capscrews and washers.
Figure 3.10
6. Pull the bearing cage, bearings and shaft assembly from the
axle housing. If necessary, loosen the cage from the housing
2. Remove all but the top two carrier-to-housing capscrews or
with a soft mallet. Figure 3.9.
stud nuts and washers. Figure 3.10.
Figure 3.9
3. Loosen, but do not remove, the top two carrier-to-housing
THRU-SHAFT AND fasteners. The fasteners will hold the carrier in the housing.
BEARING CAGE ASSEMBLY
4. Loosen the differential carrier in the axle housing. Use a plastic
mallet to hit the carrier mounting flange at several points.
5. After the carrier is loosened, remove the top two stud nuts and
washers that hold the assembly in the axle housing.

CAUTION
When using a pry bar, be careful not to damage the carrier or
housing flange. Damage to these surfaces will cause oil leaks.
1002713a
6. Use the hydraulic roller jack to remove the carrier from the axle
Figure 3.9 housing. Use a pry bar that has a round end to help remove the
carrier from the housing.
Differential Carrier from the Axle Housing 7. On axles with a driver-controlled main differential lock, if air
1. Place a hydraulic roller jack under the differential carrier to pressure is used to shift the differential to the locked or
support the assembly. Figure 3.10. engaged position, release the air pressure. Disconnect the air
hose from the shift unit.

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.

Meritor Maintenance Manual 5L (Revised 02-18) 11

3 Removal and Disassembly

8. Use a lifting tool to lift the differential carrier by the input yoke Figure 3.13

or flange and place the assembly in a repair stand. Do not lift BEARING
by hand. Refer to Section 10 to make a carrier repair stand. CAGE
Figure 3.11. SNAP
RING
Figure 3.11

THRU-SHAFT
END VIEW

1002717b

Figure 3.13

NOTE: When you press the thru-shaft from the cage, the inner cup
1002715c remains in the cage. The outer cup is removed with the thru-shaft
and the cones.
Figure 3.11

4. If necessary, remove the thru-shaft and the bearing cones as

Disassembly an assembly from the output bearing cage.
A. Place the thru-shaft and the output bearing cage in a
Thru-Shaft and Output Bearing Cage
press. Figure 3.14.
Assembly
B. Press the thru-shaft and cones from the bearing cage.
1. Remove and discard the original oil seal. Use a new triple-lip or
main oil seal when the carrier is assembled. Figure 3.12. C. Remove the outer cup from the thru-shaft.

Figure 3.12 Figure 3.14

BEARING SNAP PRESS

ASSEMBLIES RING
THRU-SHAFT

OUTPUT
YOKE

OIL
SPACER SEAL 1002716b 1002718b

Figure 3.12 Figure 3.14

NOTE: If you replace either the bearing cup or the cone, replace 5. Use a press or a bearing puller to remove the bearing cones
both parts in a fully-matched set from the same manufacturer. from the thru-shaft. Refer to the procedure in this section.

2. Remove the external snap ring or yoke-to-cone spacer from

the thru-shaft.
3. Remove the internal snap ring that holds the bearing cup in the
output cage. Figure 3.13.

12 Meritor Maintenance Manual 5L (Revised 02-18)

 3 Removal and Disassembly

Removal 3. Remove the bearing cones from the thru-shaft. Discard the
bearing cones.
Bearing Cone from the Thru-Shaft 4. If necessary, use a brass drift and hammer to carefully tap the
inner cup from the cage. Discard the cup. Figure 3.17.
Press Method
1. Place a used bearing cup on the inner bearing cone. Figure 3.17

2. Place the thru-shaft into a press. Figure 3.15. The used

bearing cup supports the thru-shaft.

Figure 3.15

PRESS

USED BEARING
CUP

1002721b

Figure 3.17

1002719c
Measure Ring Gear Backlash
Before the carrier is disassembled, use a dial indicator to measure
Figure 3.15
and record ring gear backlash at three locations on the ring gear.
This will help you to correctly reassemble the ring gear and drive
3. Press the thru-shaft through the bearing cones. Discard the
pinion.
bearing cones.
1. Rotate the carrier in the stand to access the ring gear teeth.
Bearing Puller Method
2. Install a dial indicator onto the flange of the carrier. Place the
1. Place a used bearing cup on the inner bearing cone. tip of the indicator against the drive side of a ring gear tooth.
2. Install a bearing puller tool onto the thru-shaft. Figure 3.16. Adjust the dial indicator to ZERO. Figure 3.18.
The bearing cup supports the thru-shaft.
Figure 3.18

Figure 3.16
DIAL
INDICATOR

USED BEARING
CUP

1002722c

1002720b Figure 3.18

Figure 3.16

Meritor Maintenance Manual 5L (Revised 02-18) 13

3 Removal and Disassembly

3. Read the dial indicator while you slightly rotate the ring gear in 4. Use the correct tool to hold the input yoke or flange. Loosen,
both directions. When you rotate the ring gear to measure the but do not remove, the nut that fastens the yoke or flange to
backlash, the drive pinion must not move. Record the reading the input shaft. Figure 3.21.
on the dial indicator.
Figure 3.21

4. Repeat the procedure at two more locations on the ring gear.

앫 If the smallest of the three measurements is not
0.008-0.018-inch (0.20-0.46 mm) for 145 Series or
0.010-0.020-inch (0.25-0.51 mm) for 160 Series:
Replace the ring gear and drive pinion as a set.

Input Shaft and Inter-Axle Differential

Assembly
1. Rotate the carrier in the stand to access the input shaft.
1002725b
2. Remove the capscrews and the washers that fasten the drive
Figure 3.21
pinion cover to the differential carrier. Remove the cover.
Remove all gasket material from the cover and the differential
5. Remove the capscrews and washers that fasten the input
carrier. Figure 3.19.
bearing cage to the differential carrier. Figure 3.22.
Figure 3.19

Figure 3.22

PINION
COVER

1002723b 1002726b
Figure 3.19 Figure 3.22

3. Use the correct tool to hold the input yoke or flange. Loosen, 6. Rotate the carrier in the stand until the yoke or flange is on top.
but do not remove, the drive pinion nut. Figure 3.20. Connect a lifting device to the input yoke.

Figure 3.20
NOTE: Paint alignment marks on the helical drive gear and the
helical driven gear before you remove the input shaft assembly from
the carrier. This will ensure exact reassembly for the original mesh
of the mated gears.

7. Paint alignment marks on the helical drive gear and the helical
driven gear.
앫 For a driven gear: Paint the ends of two adjacent teeth.
앫 For a drive gear: Paint the top land of the matching tooth
1002724b and guide it into the two painted teeth of the driven gear.
Figure 3.20

14 Meritor Maintenance Manual 5L (Revised 02-18)

 3 Removal and Disassembly

CAUTION Figure 3.24

Rotate the shaft so the notch

On all 160 Series carriers and 145 Series carriers on the case is aligned
manufactured before September 1998, there are two notches over the teeth of the gear.
HELICAL
on the side of the inter-axle differential case. One of the DRIVEN INPUT
notches on the case must be aligned with the helical driven GEAR SHAFT
gear. If the notch is not aligned over the gear, the gear will
prevent the removal of the input shaft assembly and cause NOTCH
damage to the assembly.

8. Remove the input shaft, oil pump, if used, and inter-axle

differential from the carrier.
1002728b
A. Lift the input shaft assembly until the bearing cage is
Figure 3.24
separated from the carrier. If necessary, tap on the
bearing cage with a brass or plastic mallet to separate the
cage from the carrier. Figure 3.23.
Figure 3.25

Notches on the case

B. For 160 Series carriers and 145 Series carriers must be aligned over the
INTER-AXLE
DIFFERENTIAL helical driven gear.
manufactured after September 1998, slowly lift the input
CASE
shaft assembly.
앫 If the input shaft assembly comes out of the HELICAL
carrier easily: Remove the assembly. DRIVEN
GEAR
앫 If the input shaft assembly cannot be removed
easily: The inter-axle differential case must be
rotated. Rotate the input shaft until one of the notches
on the case is aligned over the helical driven gear.
Remove the input shaft assembly from the carrier. 1002729b

Figure 3.24 and Figure 3.25. Figure 3.25

C. Place the input shaft assembly on a bench.

9. Remove the shims from between the bearing cage and the
Figure 3.23
differential carrier.
10. Remove the rear side gear and the bearing cone from the
carrier. Remove the collar. Figure 3.26.

Figure 3.26

REAR SIDE
GEAR

1002727b 1002730b

Figure 3.23 Figure 3.26

Meritor Maintenance Manual 5L (Revised 02-18) 15

3 Removal and Disassembly

NOTE: If you replace either the bearing cup or the cone, replace Figure 3.29

both parts in a fully-matched set from the same manufacturer. 10

1 11 15
12 13
11. Use a press, sleeve and bearing puller to remove the cone from
the rear side gear. Figure 3.27. 5

Figure 3.27

PRESS
2 16
9
4 6 8 14
3 7
1002732b
1 PRESSURE RELIEF VALVE 9 INPUT SHAFT
ASSEMBLY 10 OIL BAFFLE — UNITS WITHOUT
2 OIL SEAL OIL PUMP
3 BEARING CAGE 11 WASHER
4 O-RING 12 CAPSCREWS
5 BEARING CUP 13 THRUST WASHER
1002731c 6 BEARING CONE 14 HELICAL DRIVE GEAR
7 O-RING 15 INTER-AXLE DIFFERENTIAL
Figure 3.27 8 OIL PUMP — UNITS WITH OIL 16 SNAP RING
PUMP

12. Use a brass drift and hammer to remove the cup of the rear Figure 3.29
side gear cone from the differential side of the carrier.
CAUTION
Disassembly Carefully remove the pinion seal from the yoke or carrier. Do
not damage the seal bore when you remove the seal. Damage
Input Shaft, Bearing Cage, Oil Pump and to components can result.
Inter-Axle Differential
NOTE: Meritor recommends replacing all seals with the triple-lip or
1. Use the correct tool to remove the yoke or flange from the input
main oil seal. The addition or replacement of a POSE™ seal is also
shaft. Figure 3.28. If the carrier is not equipped with an oil
highly recommended.
pump, remove the bearing cage from the input shaft.
Figure 3.29.
2. Pry under the oil seal flange to remove the oil seal from the
input bearing cage. Discard the oil seal. Figure 3.30.
Figure 3.28

Figure 3.30

YOKE
PULLER 1002734a

1002733a Figure 3.30

Figure 3.28
3. Remove the snap ring that fastens the inter-axle differential
assembly to the input shaft. Remove the inter-axle differential
assembly from the input shaft. Figure 3.31.

16 Meritor Maintenance Manual 5L (Revised 02-18)

 3 Removal and Disassembly

Figure 3.31 Figure 3.33

RT-160 SHOWN
SNAP RING

NEST AND CASE THRUST

ASSEMBLY 1002735b WASHER 1002737b

Figure 3.31 Figure 3.33

NOTE: Disassemble the bolted inter-axle differential and inspect the

CAUTION
components. The welded inter-axle differential is serviced as an
If the following procedure is not followed, the oil pump or the
assembly and cannot be disassembled.
bearing cage will be damaged during removal. Never apply
4. Disassemble the bolted inter-axle differential case. Inspect the direct pressure to the surface of the pump or the bearing cage.
components. Replace any damaged components.
6. If an oil pump is used, remove the input bearing cage and the
A. Use a punch and hammer to place an alignment mark on oil pump from the input shaft.
each half of the inter-axle differential case. The alignment
A. Place a bearing puller under the oil pump. The rivets on
marks will help you mate the case halves correctly during
the back of the pump must not touch the bearing puller.
assembly. Figure 3.32.
The bearing puller provides a level surface so that the
B. Remove the capscrews that fasten the case halves of the shaft can be pressed straight out of the assembly.
inter-axle differential. Separate the case halves. Figure 3.34.
C. Remove the spider assembly from the case halves. B. Place the assembly on a press so that it rests on the
Remove the four pinion gears and the four thrust washers puller. Figure 3.35.
from the spider.
C. Place a protector on top of the threaded part of the shaft.
Figure 3.32
Press the input shaft from the assembly. Remove the
bearing puller. Figure 3.35.
BOLTED D. Remove the capscrews that fasten the oil pump to the
IAD input bearing cage. Separate the oil pump from the cage.
CASE
SHOWN
Figure 3.36.
MATCH E. If the pump is worn or damaged, replace the pump. If the
MARKS
drive flats or the splines in the pump do not move, replace
the pump.

1002736b

Figure 3.32

5. Remove the helical drive gear from the input shaft. Remove the
thrust washer from the gear. Figure 3.33.

Meritor Maintenance Manual 5L (Revised 02-18) 17

3 Removal and Disassembly

Figure 3.34 Figure 3.36

OIL
BEARING PUMP
PULLER
BEARING
CONE

RELIEF
VALVE

BEARING
OIL CAGE
PUMP
1002740b

Figure 3.36

7. Remove the O-rings from the bearing cage and, if used, the oil
Rivets must pump assembly.
not touch
bearing puller. 8. Remove the cone from the input bearing cage.
1002738b
NOTE: If you replace either the bearing cup or the cone, replace
Figure 3.34 both parts in a fully-matched set from the same manufacturer.

Figure 3.35
9. If necessary, use a press and sleeve to remove the cup from
the input bearing cage.
PRESS
10. If necessary, remove the pressure relief valve assembly from
PROTECTOR the front of the bearing cage. Remove the plug, spring and
relief valve from the bore. Figure 3.37.
BEARING
CAGE
Figure 3.37

OIL
PUMP PLUG, EARLY
BEARING MODELS ONLY
PULLER
SPRING

INPUT
SHAFT

1002739b

Figure 3.35
RELIEF
VALVE 1002741a

Figure 3.37

11. Remove the oil screen and plug assembly from the suction line
at the front of the carrier. Figure 3.38.

18 Meritor Maintenance Manual 5L (Revised 02-18)

 3 Removal and Disassembly

Figure 3.38 앫 If the shift shaft cannot be removed by hand: Remove

the adjusting bolt and jam nut. Place a brass drift through
the adjusting bolt hole against the rear of the shift shaft.
Use a hammer on the brass drift to remove the shift shaft.
Inspect the shift shaft for damage.
4. From the input shaft bore, remove the collar and fork.
5. If necessary, remove the jam nut and the adjusting bolt.

Spring Applied and Air Release Models, Reverse

Shifter
1002742b
1. Remove the four capscrews that fasten the shift cylinder cover
Figure 3.38 to the differential carrier.
2. Remove the two capscrews and washers that fasten the cover
12. Clean the oil screen. Refer to Section 4.
to the shift cylinder. Remove the cover and spring. Figure 3.40.

Removal Figure 3.40

BOLT-ON DCDL REVERSE SHIFTER

Inter-Axle Differential Lock IAD Shift Unit “E” CLIP SLOT O-RING SHIFT
CYLINDER
Air Applied and Spring Release Models, Standard
SPRING
1. Remove the cylinder.
A. For flange-type cylinders, remove the capscrews that
fasten the cylinder to the carrier. Remove the cylinder. COVER

B. For threaded cylinders, remove the cylinder. SMALL

SHIFT O-RING PISTON SNAP
SHAFT O-RING
2. Remove the piston from the shift shaft. Figure 3.39. “E” CLIP RING
REMOVED
1002744b
Figure 3.39

JAM BOLT-ON CAPSCREW Figure 3.40

ADJUSTING
NUT SHIFT DCDL
BOLT
SHAFT COVER 3. Remove the small snap ring from the cover end of the shift
SPRING
shaft.
COLLAR
4. Remove the cylinder assembly from the shaft.

O-RING 5. Rotate the shift shaft until the “E” clip ahead of the shift fork is
at approximately the five o’clock position. Figure 3.41.
PISTON

SCREW-IN
DCDL COVER
FORK 1002743b

Figure 3.39

3. Remove the shift shaft from the differential carrier. When you
remove the shift shaft, the fork and the spring may fall.

Meritor Maintenance Manual 5L (Revised 02-18) 19

3 Removal and Disassembly

Figure 3.41 Figure 3.42

“E” CLIP BASE BEARING

ROTATED TO THE CAP
FIVE O’CLOCK POSITION
CARRIER
LEG

Remove “E”
clip from shaft
before reverse MATCH
MARKS
shifter removal.
1002994a
1002745b
Figure 3.42
Figure 3.41

3. Remove the capscrews, cotter pins, roll pins or lock plates, if

6. With the “E” clip base in the five o’clock position, use
equipped, that hold the bearing adjusting rings in position. Use
needlenose vise grips or equivalent to remove the “E” clip.
a small drift and hammer to remove the pins. Each lock plate is
7. Remove the shift shaft from the carrier. When you remove the held in position by two capscrews. Figure 3.43.
shaft, the fork may fall.
Figure 3.43

8. Remove the piston from the shift cylinder. Inspect the O-rings
for wear and damage. Replace the O-rings, if necessary.
REMOVING REMOVING
LOCK
Driver-Controlled Main Differential Lock COTTER PIN
PLATE
(DCDL)
If the axle is equipped with a driver-controlled main differential lock,
refer to Section 6 for removal procedures.

Main Differential Case and Ring Gear

Assembly 1002995c

1. Rotate the carrier in the stand until the ring gear is toward you. Figure 3.43

2. Use a punch and hammer to mark the position of each bearing

cap on the differential carrier legs. The marks help you CAUTION
correctly match the caps to the carrier legs during assembly. Do not hit the adjusting ring with a hammer. Do not use a
Figure 3.42. hammer and a drift to loosen the adjusting rings. Using these
methods will damage the adjusting rings.

4. Use a T-bar wrench or equivalent tool to loosen the adjusting

rings. Do not remove the adjusting rings. If necessary, loosen,
but do not remove, the capscrews on the bearing caps to move
the adjusting rings. Figure 3.44.

20 Meritor Maintenance Manual 5L (Revised 02-18)

 3 Removal and Disassembly

Figure 3.44 Figure 3.46

T-BAR
WRENCH

ADJUSTING
RING OPPOSITE
RING GEAR 1002747c 1002749g

Figure 3.44 Figure 3.46

5. Remove the capscrews and washers that fasten the bearing NOTE: If you replace either the bearing cup or the cone, replace
caps to the differential carrier. Mark the bearing caps and the both parts in a fully-matched set from the same manufacturer. The
carrier to help you correctly assemble the caps into the carrier. bearing cones are not interchangeable.

NOTE: Each bearing cap must be installed on the carrier leg from 8. If the bearing cones on the main differential case need to be
which it was removed. The caps are matched to the carrier legs. Do replaced, use a bearing puller to remove the cones.
not mix bearing caps on carrier legs. Figure 3.47.

6. Remove the bearing caps, adjusting rings and bearing cups Figure 3.47

from the differential carrier. Figure 3.45.

PULLER

Figure 3.45

PRESS
BEARING
ADJUSTING
BEARING RING
CAP

1002750b

Figure 3.47

1002748d
Disassembly
Figure 3.45 Main Differential Case and Ring Gear
1. Use a punch and hammer to mark the case halves. The marks
7. Use an appropriate lifting device to remove the main differential
will help you correctly align the case halves during assembly.
case and ring gear assembly from the carrier. Figure 3.46.
Figure 3.48.

Meritor Maintenance Manual 5L (Revised 02-18) 21

3 Removal and Disassembly

Figure 3.48
Removal
Ring Gear from the Differential Case
1. For 145 and 160 Series axles, remove the bolts, washers and
nuts that fasten the ring gear to the differential case.

CAUTION
Do not remove the rivets or the rivet heads with a chisel and
hammer. A chisel and hammer can damage the differential
case.
MARKS 1002751b
2. For 140 Series axles, remove the rivets that fasten the ring
Figure 3.48
gear to the differential case.

2. Remove the capscrews and washers that fasten the halves of A. Carefully center-punch each rivet head in the center on
the main differential together. the ring gear side of the assembly.

3. Remove the spider, pinions, thrust washers and side gears B. Drill each rivet head on the ring gear side of the assembly
from the separated case assembly. Figure 3.49. to a depth equal to the thickness of one rivet head. Use a
drill bit that is 0.0312-inch (0.8000 mm) smaller than the
NOTE: There are two different design versions of the pinions
body diameter of the rivets. Figure 3.50.
and side gears: the original design and a new version with
tooth profile enhancements. If the pinions or side gears must C. Press the rivets through the holes in the ring gear and the
be replaced, the replacement part must be of the same design differential case. Press on the drilled rivet head.
version as the mating part. Do not mix original design pinions
with new design side gears and vice versa. Refer to Section 4 Figure 3.50

for further information about replacing these parts.

DRILLING RIVET FROM HEAD
Figure 3.49

THRUST
WASHER

SIDE
SPIDER, PINIONS
GEAR
AND THRUST
WASHER

1003001e

Figure 3.50

3. Place the ring gear and case assembly on a press so that the
teeth of the gear are toward you. Place supports under the
gear.
1002752b 4. Place a sleeve or a flat metal plate on top of the case. Press
the main differential case from the ring gear. Figure 3.51.
Figure 3.49

22 Meritor Maintenance Manual 5L (Revised 02-18)

 3 Removal and Disassembly

Figure 3.51 2. Remove the drive pinion from the carrier.

PRESS A. Place the differential carrier into a press so that the
PLATE threaded end of the drive pinion is facing UP. Place
supports under the carrier mounting flange.
B. Place a protector onto the top of the drive pinion shaft.
Figure 3.53.

CAUTION
The drive pinion must not fall on the floor when the drive
1002754b pinion is pressed from the carrier. If the drive pinion falls to the
Figure 3.51
floor, the gear teeth may be damaged.

C. Press the pinion through the outer bearing cone and the
Drive Pinion Assembly helical driven gear. Remove the drive pinion from the
bottom of the carrier.
Before You Work on a Differential Carrier
D. Remove the outer spacer, outer bearing cone and helical
Inspect the hypoid ring gear set for damage. If it is not damaged, driven gear from the carrier. Remove the inner spacer
you can reuse the ring gear set at assembly. Measure and record from the drive pinion.
the gear set backlash. Figure 3.8. Refer to Measure Ring Gear
Backlash in this section. Figure 3.53

PRESS
Assembly Procedures
1. Remove the nut and washer from the drive pinion. You PROTECTOR

loosened the drive pinion nut when you removed the input shaft DRIVE
PINION
assembly. Figure 3.52.

Figure 3.52

1002756c

Figure 3.53

NOTE: If you replace either the bearing cup or the cone, replace
both parts in a fully-matched set from the same manufacturer.

NOTE: If a new ring gear and drive pinion are being installed, the
inner bearing cup must be removed to change the shim pack
between the cup and the carrier.

1002755b 3. If necessary, remove the inner and the outer bearing cups from
1 NUT 7 INNER SPACER
the carrier. Use a hammer and drift to remove the cups from
2 WASHER 8 SHIMS the carrier. Replace any shims that are damaged. Measure and
3 OUTER BEARING CONE 9 INNER BEARING CUP record the thickness of the shim pack for assembly.
4 OUTER BEARING CUP 10 INNER BEARING CONE
Figure 3.54.
5 OUTER SPACER 11 DRIVE PINION
6 HELICAL DRIVEN GEAR
Figure 3.52

Meritor Maintenance Manual 5L (Revised 02-18) 23

3 Removal and Disassembly

Figure 3.54

INNER
BEARING
CUP

OUTER
BEARING CUP 1002757c

Figure 3.54

4. If necessary, remove the inner bearing cone from the drive

pinion. Place a bearing puller under the inner race to support
the bearing. Place a protector on top of the pinion shaft and
press the drive pinion out of the bearing cone. Figure 3.55.

Figure 3.55

PRESS

BEARING
PULLER

1002758b

Figure 3.55

24 Meritor Maintenance Manual 5L (Revised 02-18)

 4 Prepare Parts for Assembly

Hazard Alert Messages Clean, Dry and Inspect Parts

4 Prepare Parts for Assembly

Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent Clean and Inspect Yokes
serious personal injury, damage to components, or both.
CAUTION
WARNING Do not install a press-on shaft excluder or POSE™ seal after
you install a unitized pinion seal. The use of a POSE™ seal will
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. prevent correct seating of the unitized pinion seal on the yoke
and will result in lubricant leakage at the seal. POSE™ seal
Solvent cleaners can be flammable, poisonous and cause installation is recommended only for triple-lip and other
burns. Examples of solvent cleaners are carbon tetrachloride, previous design seals.
and emulsion-type and petroleum-base cleaners. Read the
Do not use thin metal wear sleeves to refresh the yoke surface.
manufacturer’s instructions before using a solvent cleaner,
Wear sleeves pressed onto the yoke will prevent correct
then carefully follow the instructions. Also follow the
procedures below. seating of the pinion seal and damage the pinion seal
assembly. Wear sleeve usage will cause the seal to leak.
앫 Wear safe eye protection.
1. Clean the ground and polished surface of the yoke journal
앫 Wear clothing that protects your skin.
using a clean shop towel and a safe cleaning solvent. Do not
앫 Work in a well-ventilated area. use abrasive cleaners, towels or scrubbers to clean the yoke or
flange surface. Do not use gasoline.
앫 Do not use gasoline, or solvents that contain gasoline.
Gasoline can explode. NOTE: The unitized seal features a rubber inner sleeve that is
앫 You must use hot solution tanks or alkaline solutions designed to seal and rotate with the yoke. This feature allows you to
correctly. Read the manufacturer’s instructions before reuse a yoke with minor grooves.
using hot solution tanks and alkaline solutions. Then
2. Inspect the yoke seal surface for grooves.
carefully follow the instructions.
앫 If you find grooves on yoke hubs used with single or

Take care when you use Loctite adhesive to avoid serious triple-lip seals: Replace the yokes.
personal injury. Read the manufacturer’s instructions before 앫 If you find grooves on the yoke: Use calipers to measure
using this product. Follow the instructions carefully to prevent the groove diameters. If any groove diameter measures less
irritation to the eyes and skin. If Loctite adhesive material than the dimensions shown in Figure 4.1, replace the yoke.
gets into your eyes, follow the manufacturer’s emergency
procedures. Have your eyes checked by a physician as soon as Figure 4.1

possible. UNITIZED PINION SEAL (UPS)

When you apply some silicone gasket materials, a small

amount of acid vapor is present. To prevent serious personal
A B
injury, ensure that the work area is well-ventilated. Read the
manufacturer’s instructions before using a silicone gasket
material, then carefully follow the instructions. If a silicone
gasket material gets into your eyes, follow the manufacturer’s
Yoke Seal Minimum Yoke Diameter
emergency procedures. Have your eyes checked by a Diameter at Groove (Inches)
physician as soon as possible. 3.000/3.005" 2.990"
3.250/3.255" 3.240" 1003390e

A MINIMUM GROOVE DEPTH — DIAMETER

B YOKE SEAL DIAMETER
Figure 4.1

Meritor Maintenance Manual 5L (Revised 02-18) 25

4 Prepare Parts for Assembly

Clean Ground and Polished Parts Prevent Corrosion on Cleaned Parts

1. Use a cleaning solvent, kerosene or diesel fuel to clean ground 1. Apply axle lubricant to cleaned and dried parts that are not
or polished parts or surfaces. Do not use gasoline. damaged and are to be assembled.
2. Use a tool with a flat blade if required, to remove sealant 2. To store parts, apply a special material that prevents corrosion
material from parts. Be careful not to damage the polished or to all surfaces. Wrap cleaned parts in a special paper that will
smooth surfaces. protect the parts from moisture and prevent corrosion.

CAUTION Inspect Parts

Do not use hot solution tanks or water and alkaline solutions to It is very important to inspect all parts carefully and completely
clean ground or polished parts. Damage to parts can result. before the axle or carrier is assembled. Check all parts for wear and
replace damaged 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 1. Inspect the cup, cone, rollers and cage of all tapered roller
use strong alkaline solutions for cleaning, or the smooth bearings in the assembly. If any of the following conditions
sealing surface may be damaged. exist, replace the bearing.
앫 The center of the large-diameter end of the rollers is worn
Clean Rough Parts level with or below the outer surface. Figure 4.2.
1. Clean rough parts with the same method as cleaning ground 앫 The radius at the large-diameter end of the rollers is worn
and polished parts. to a sharp edge. Figure 4.2.
2. Rough parts can be cleaned in hot solution tanks with a weak 앫 There is a visible roller groove in the cup or cone inner race
or diluted alkaline solution. surfaces. The groove can be seen at the small- or
3. Parts must remain in hot solution tanks until heated and large-diameter end of both parts. Figure 4.3.
completely cleaned. 앫 There are deep cracks or breaks in the cup, cone inner race
4. Parts must be washed with water until all traces of the alkaline or roller surfaces. Figure 4.3.
solution are removed. 앫 There are bright wear marks on the outer surface of the
roller cage. Figure 4.4.
Clean Axle Assemblies
앫 There is damage on the rollers and on the surfaces of the
1. A complete axle assembly can be steam cleaned on the cup and cone inner race that touch the rollers. Figure 4.5.
outside to remove dirt.
앫 There is damage on the cup and cone inner race surfaces
2. Before the axle is steam cleaned, close or place a cover over all that touch the rollers. Figure 4.6.
openings in the axle assembly. Examples of openings are
breathers or vents in air chambers. Figure 4.2

WORN RADIUS
Drying Parts After Cleaning
1. Parts must be dried immediately after cleaning and washing.
2. Dry the parts using soft, clean paper or cloth rags.

CAUTION
Damage to bearings can result when they are rotated and
dried with compressed air.
WORN SURFACE 1003017b
3. Except for bearings, parts can be dried with compressed air. Figure 4.2

26 Meritor Maintenance Manual 5L (Revised 02-18)

 4 Prepare Parts for Assembly

Figure 4.3 Figure 4.6

WEAR
CRACK
GROOVES SPALLING AND FLAKING

1003021b

1003018b Figure 4.6

Figure 4.3
CAUTION
A drive pinion and ring gear are machined as a matched set.
Figure 4.4

When you replace either a drive pinion or a ring gear, you must
replace both parts as a matched set. Do not mix old and new
parts. Damage to components can result.

2. Inspect hypoid pinions and gears for wear and damage.

Replace gears that are worn or damaged.

CAUTION
A thrust washer, differential side gear and pinion gear are
WEAR MARKS machined as a matched set. When you replace any of these
1003019a
parts, you must install a new matched set. Do not mix old and
Figure 4.4 new parts. Damage to components can result.

Figure 4.5 3. Inspect the following main differential assembly parts for wear
ETCHING AND PITTING or stress. Replace parts that are damaged. Figure 4.7.
앫 Inside surfaces of both case halves
앫 Both surfaces of all thrust washers
앫 The four trunnion ends of the spider or cross
앫 Teeth and splines of both differential side gears
1003020a
앫 Teeth and bore of all differential pinions
Figure 4.5

Meritor Maintenance Manual 5L (Revised 02-18) 27

4 Prepare Parts for Assembly

Figure 4.7 Figure 4.8

NEW 14X/145 DESIGN

Inspect
DIFFERENTIAL PINION SIDE GEAR
inside
surfaces.
DIFFERENTIAL
CASE HALVES

SIDE GEAR
PINION AND AND THRUST
THRUST WASHER 4013353a
Inspect.
WASHER
Figure 4.8

Figure 4.9

ORIGINAL 14X/145 DESIGN

Inspect.
DIFFERENTIAL PINION SIDE GEAR

DIFFERENTIAL
GEAR NEST
ASSEMBLY
SPIDER OR
Inspect. CROSS
1003022f

Figure 4.7

Important Note about Replacing Differential Pinions and 4013352a

Side Gears Figure 4.9

The main differential pinions and side gears on 14X/145 series

differential carriers have been redesigned as of May 1, 2017. CAUTION
The new design, shown in Figure 4.8, features tooth profile Original and new design parts must NOT be mixed together
enhancements from the original version, shown in Figure 4.9. during service. The differential pinion version must match the
If the pinions or side gears must be replaced, the replacement side gear version used. Mixing original design parts with new
part must be of the same design version as the mating part, design parts will result in a locked up differential and possible
i.e., original design pinions used only with original design side damage to components.
gears. Original design pinions must NOT be used with new
design side gears and vice versa. 4. Inspect the axle shafts for wear and cracks at the flange, shaft
NOTE: If original design version parts are not available to and splines. Replace the axle shafts, if required.
match the original design version mating part, you must 5. Inspect the breather.
replace BOTH the pinions and side gears using new design
A. Remove the breather from the axle housing.
version parts.
B. Clean the breather.
앫 If the breather remains dirty after cleaning:
Replace the breather.
C. Apply compressed air to the breather.
앫 If compressed air does not pass through the
breather: Replace the breather.
D. Install the breather into the axle housing.

28 Meritor Maintenance Manual 5L (Revised 02-18)

 4 Prepare Parts for Assembly

Repair or Replace Parts Refer to Maintenance Manual 8, Drive Axle Housings. To obtain this
publication, refer to the Service Notes page on the front inside cover
Threads must be without damage and clean so that accurate of this manual.
adjustments and correct torque values can be applied to fasteners
and parts. Meritor permits drive axle housing assembly repair welding in the
following locations only.
1. Replace any fastener if the corners of the head are worn.
앫 Housing-to-cover weld joints
2. Replace the washers if damaged.
앫 Snorkel welds
3. Replace the gaskets, oil seals or grease seals at the time of
axle or carrier repair. 앫 Housing seam welds between the suspension attaching brackets

4. Clean the parts and apply new silicone gasket material where 앫 Bracket welding to the drive axle housing
required when the axle or carrier is assembled. Figure 4.10.
Prepare the Axle
Figure 4.10

WARNING
Remove silicone
gasket from parts. 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.

1003023a CAUTION
Remove the differential carrier from the axle housing before
Figure 4.10 you weld onto an axle. Do not weld onto an axle with the
differential carrier installed. Electrical arcing and damage to
5. Remove nicks, mars and burrs from parts with machined or components can result.
ground surfaces. Use a fine file, india stone, emery cloth or
crocus cloth. 2. Remove the differential carrier from the axle housing. Refer to
6. Clean and repair the threads of fasteners and holes. Use a die the correct Meritor carrier maintenance manual or the vehicle
or tap of the correct size or a fine file. manufacturer’s instructions.

Welding on Axle Housings CAUTION

Remove the brake air chambers before you weld onto an axle.
WARNING Do not expose a brake air chamber to more than 250°F
Wear safe clothing and eye protection when you use welding (121°C). Damage to the air chamber can result.
equipment. Welding equipment can burn you and cause
3. Remove the wheel-end components and brake air chambers
serious personal injury. Follow the operating instructions and
from the axle. Refer to the correct Meritor brake maintenance
safety procedures recommended by the welding equipment
manual or the vehicle manufacturer’s instructions.
manufacturer.
4. For housing-to-cover welds, clean the outside
Axle weld locations and welding procedures must adhere to housing-to-cover weld area two to three-inches
Meritor standards. Welding at locations other than those (50.8-76.2 mm) past each end or side of the crack. Clean the
authorized by Meritor will void the warranty and can reduce inside area where the cover mates with the housing. Clean the
axle beam fatigue life. Serious personal injury and damage to area completely around the cover. Use a wire brush and a
components can result. cleaning solvent that will remove dirt and grease from these
areas.

Meritor Maintenance Manual 5L (Revised 02-18) 29

4 Prepare Parts for Assembly

5. For suspension bracket welds, clean both lower and upper When you remove fasteners secured with adhesive, slowly heat the
suspension brackets and the areas of the axle housing around fastener to 350°F (177°C). Do not exceed this temperature, or heat
each bracket. Use a wire brush and a cleaning solvent that will fasteners quickly. Damage to components can result.
remove dirt and grease from these areas.
1. Heat the fastener for three to five seconds. Try to loosen the
fastener with a wrench. Do not use an impact wrench or hit the
WARNING fastener with a hammer.
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 2. Repeat Step 1 until you can remove the fastener.
parts onto an axle. Cracks in the weld area, damage to
components, and serious personal injury can result. New Fasteners with Pre-Applied Adhesive
1. Use a wire brush to clean the oil and dirt from threaded holes.
6. Ensure that the axle housing temperature measures 70°F
(21°C) or warmer. 2. Install new fasteners with pre-applied adhesive to assemble
parts. Do not apply adhesives or sealants to fasteners with
앫 If the axle housing temperature measures less than pre-applied adhesive, or to fastener holes.
70°F (21°C): Store the axle in a heated room until the
housing reaches the correct temperature. 3. Tighten the fasteners to the required torque value for that size
fastener. No drying time is required for fasteners with
7. Heat the damaged area to approximately 300°F (149°C) before pre-applied adhesive.
you begin welding.
8. Use suitable weld wire electrodes when you weld. Suitable Original or Used Fasteners
weld wire electrodes include either BS EN 499 – E 42 2 B 32 1. Use a wire brush to clean the oil, dirt and old adhesive from all
H5 or BS EN 440 – G 42 2 M GSi (American Welding Society threads and threaded holes.
equivalents E7018 and ER70S3, respectively).
2. Apply liquid adhesive to the bolt threads or bore threads as
9. For complete welding instructions, refer to Maintenance required for the specific component.
Manual 8, Drive Axle Housings. To obtain this publication, refer
to the Service Notes page on the front inside cover of this 3. Tighten the fasteners to torque specified in Section 8.
manual.
Meritor Specification 2297-T-4180 Adhesive
Do Not Bend or Straighten a Damaged Drive in the Differential Bearing Bores
Axle Housing
NOTE: Use Meritor specification 2297-T-4180 adhesive for all
WARNING axles.
Replace damaged or out-of-specification axle components. Do
1. Clean the oil and dirt from the outer diameters of the bearing
not bend, repair or recondition axle components by welding or
cups and bearing bores in the carrier and bearing caps. There
heat-treating. A bent axle beam reduces axle strength, affects
is no special cleaning required.
vehicle operation and voids Meritor’s warranty. Serious
personal injury and damage to components can result. 2. Apply axle lubricant to the bearing cones and the inner
diameters of the bearing cups of the main differential. Do not
Always replace a damaged drive axle housing. Do not bend or get oil on the outer diameter of the bearing cup and do not
straighten a damaged housing, which can misalign or weaken it, permit oil to drip onto the bearing bores.
and void Meritor’s warranty.
NOTE: Meritor specification 2297-T-4180 adhesive will dry in
Removing Fasteners Secured with Adhesive approximately two hours. You must complete the procedure within
two hours from the time you apply the adhesive. If two hours have
If it is difficult to remove fasteners secured with Dri-Loc, Meritor
passed since application, clean the adhesive from the parts and
adhesive or Loctite 277 adhesive, use the following procedure.
apply new adhesive.

30 Meritor Maintenance Manual 5L (Revised 02-18)

 4 Prepare Parts for Assembly

3. Apply a single continuous bead of the adhesive to the bearing Figure 4.12

bores in the carrier and bearing caps. Apply the adhesive Cleaning the housing face with a rotary
around the circumference of the smooth, ground surfaces only. tool and a mild, non-abrasive pad.
Do not place the adhesive on the threaded areas. Figure 4.11.

Figure 4.11

ADHESIVE BEARING
CAP

CARRIER
LEG

4000621a

Figure 4.12

1003026a 4. Remove metal filings from the magnets inside the housing.

Figure 4.11
5. Use solvent to clean the inside of the housing.
6. Use Loctite ODC Free cleaner or brake cleaner to clean the
4. Install the main differential assembly, bearing cups and bearing housing and carrier faces.
caps into the carrier. Refer to Section 5.
7. Dry the housing and carrier faces.
5. Adjust the preload of the differential bearings, backlash and
tooth contact patterns of the gear set as required. Refer to CAUTION
Section 5. New capscrew kits have blue Dri-Loc STS threadlocker, an
equivalent to Loctite 242 threadlocker, applied to the
Carrier-to-Housing Joint Sealing Procedure capscrews. Do not remove the blue Dri-Loc STS threadlocker
1. Remove the carrier from the housing. Refer to Section 3. from the capscrews. Damage to components can result.

2. Remove all debris from inside the housing. 8. If you reuse the carrier-to-housing capscrews, use a rotary
wire brush to remove any threadlocker material and clean the
CAUTION capscrew threads. Use a clean cloth to wipe the threads.
Use a mild, non-abrasive pad for cleaning the housing and
9. Use a tap to clean the internal threads in the housing.
carrier faces. Do not use an abrasive scour pad or other similar
material, which can result in the removal of metal and damage
the mounting face.
CAUTION
Apply silicone gasket material in a continuous 0.125-inch
3. Use a rotary tool with a mild, non-abrasive pad to clean all (3 mm) bead. If you use more than this amount, gasket
silicone residue from the housing and carrier faces. material can break off and plug lubrication passages. Damage
Figure 4.12. Surfaces must be clean, dry and free of foreign to components can result.
matter. The surfaces must not be oily to the touch.
10. Apply a 0.25-inch (6 mm) bead of Loctite 5699 silicone
gasket material to the housing face. Do not use ThreeBond
1216E silicone products. Figure 4.13.

Meritor Maintenance Manual 5L (Revised 02-18) 31

4 Prepare Parts for Assembly

Figure 4.13 14. Install the capscrews. Use a crossing pattern to tighten the
capscrews evenly. The capscrews must be tightened within 10
minutes of initial application of Loctite 242 threadlocker.
앫 Tighten the 1/2-inch capscrews to 140 lb-ft (190 N폷m). @
앫 Tighten the 5/8-inch capscrews to 225 lb-ft (306 N폷m). @
15. Wait a minimum of 60 minutes before filling the assembly with
lubricant. Refer to Section 7.
0.25" (6 MM)
DIAMETER SILICONE General Yoke and U-Joint Reassembly
GASKET BEAD 4004435a
Install the end yoke hub capscrews by hand after seating the U-joint.
Figure 4.13 Tighten the capscrews according to the manufacturer’s torque
specifications.
11. Install two long studs in the carrier to guide the carrier into the
housing. Identification
12. Immediately install the carrier into the housing to enable the
silicone gasket material to compress evenly between the faces. Gear Sets
If using a new capscrew kit with blue Dri-Loc STS pre-applied Refer to Table A, Table B, Table C and Table D for information on
threadlocker, skip the next step. identifying gear sets with matched parts. Always check match
numbers to verify that the gear set you will install has matched
CAUTION parts. Figure 4.15.
Apply silicone gasket material in a continuous 0.25-inch
(6 mm) bead. If you use more than this amount, gasket Figure 4.15

material can break off and plug lubrication passages. Damage ALTERNATE LOCATIONS
to components can result.

13. Apply a 0.125-inch (3 mm) bead of Loctite 242 threadlocker

around the capscrew threads approximately 0.25-inch (6 mm)
from the end. Apply a 0.125-inch (3 mm) bead of Loctite 242
threadlocker across the length of the threads. Figure 4.14.

Figure 4.14

1003031b
LOCTITE® 242 THREADLOCKER APPLICATION
1 PART NUMBER, TOOTH COMBINATION NUMBER, GEAR SET MATCH
360˚ LOCTITE® BEAD NUMBER, PINION CONE VARIATION NUMBER
2 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
0.25" (6 MM) Figure 4.15
4000623b

Figure 4.14

32 Meritor Maintenance Manual 5L (Revised 02-18)

 4 Prepare Parts for Assembly

Examples Table D: Pinion Cone Variation Number

Table A: Gear Set Part Numbers Pinion Cone (PC) Drive Pinion Ring Gear
Variation Number Location Location
Part Number Location
PC+3 At the end of the On the outer
Conventional ring 36786 On the front face pinion gear head diameter
+2
gear or outer diameter
+0.01 mm
Conventional drive 36787 At the end at
pinion threads PC–5
Generoid ring gear 36786 K or 36786 On the front face –1
K2 or outer diameter –0.02 mm
Generoid drive 36787 K or 36787 At the end at
pinion K2 threads Check for Mismatched Ratios on
Table B: Gear Set Tooth Combination Number
Tandem Axles
For a tandem axle pair to function correctly, the forward and rear
Drive Pinion Ring Gear
axles must operate with axle ratios within one percent. A
Gear Set Teeth Location Location
mismatched tandem axle pair can cause carrier overheating, hypoid
5-37 = gear set At the end at On the front face gear set wear, metal debris to collect on the magnetic drain plug,
has a five-tooth threads or outer diameter carrier lubricant additive depletion, excessive inter-axle wear and
drive pinion and a noise.
37-tooth ring gear
To determine if the tandem axle ratios operate within allowable
limits, refer to one of the following procedures. Perform the
NOTE: Meritor drive pinions and ring gears are only available as
procedure that will work best for the vehicle you are servicing.
matched sets. Each gear in a set has an alphanumeric match
number.
Hypoid Gear Set Ratios Listed on the
Table C: Gear Set Match Number Identification Tags
Drive Pinion Ring Gear 1. Locate the identification tags riveted to the forward and rear
Match Number Location Location axle differential carriers. Figure 4.16.
M29 At the end of the On the front face Figure 4.16

gear head or outer diameter

NOTE: Don’t use the pinion cone variation number when you check
for a matched gear set. Use this number when you adjust the pinion
depth of the carrier. Refer to Section 5.
10 -41

MODEL
1 CUSTOMER NO. 2
SERIAL NO.
RATIO

1 FORWARD
2 REAR
Figure 4.16

Meritor Maintenance Manual 5L (Revised 02-18) 33

4 Prepare Parts for Assembly

2. Compare the axle ratios shown on both tags. To operate 6. Turn the forward drive shaft in one direction by hand until the
correctly, the axle ratios for both axles must be within one forward tire completes two rotations. Figure 4.18. The forward
percent of each other. To calculate the percentage difference tire must rotate two times only. If the forward tire rotates more
between the axle ratios, refer to the equation in Table E. than or less than two rotations, the angle measurements you
make in Step 7 will be inaccurate.
Table E:
Figure 4.18

Larger Ratio – Smaller

Ratio Percentage Difference
X 100 =
Between Axle Ratios
Smaller Ratio

앫 If the axle ratios shown on the identification tags are

not within one percent of each other: Refer to the vehicle
manufacturer for further information.
Rotate two full turns
Rotate the Forward Drive Shaft to Check the of forward tire.
Hypoid Gear Set Ratio 1003454b

WARNING Figure 4.18

Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with 7. Note the positions of the tire marks you previously made. On a
safety stands. Do not work under a vehicle supported only by correctly matched tandem axle gear set, both tire marks will be
jacks. Jacks can slip and fall over. Serious personal injury and within ± 3.6 degrees of each other. Figure 4.19.
damage to components can result. 앫 If the positions of the tire marks are more than 3.6
degrees from each other: Refer to the vehicle
1. Park the vehicle on a level surface. manufacturer for further information.
2. Engage the power divider and shift the transmission into
NEUTRAL. Figure 4.19

If the mark appears in

3. Block the wheels to prevent the vehicle from moving. the shaded area, the tandem
gear set is incorrectly matched.
4. Use a jack to raise the vehicle until all the tandem drive axle
wheels clear the ground. Support the vehicle with safety
stands.
5. Mark the forward and rear tires at identical relative positions.
Figure 4.17.

Figure 4.17

3.6 3.6

If the mark appears in

this area, the tandem axle
gear set is correctly matched.
1003455a

Figure 4.19

MARKS MARKS 1003453a

8. Remove the safety stands and lower the vehicle.
Figure 4.17

34 Meritor Maintenance Manual 5L (Revised 02-18)

 4 Prepare Parts for Assembly

Hypoid Gear Set Teeth Numbers Stamped on 2. Identify and record the gear set teeth numbers stamped on the
the Forward and Rear Axle Drive Pinions end of the rear axle drive pinion. Figure 4.21.

When the inter-axle driveline or differential carrier is removed for Figure 4.21

service, you can check the hypoid gear set teeth numbers stamped
on the forward and rear axle drive pinions.

WARNING
Park the vehicle on a level surface. Block the wheels to
-4
prevent the vehicle from moving. Support the vehicle with 10 1

10-41
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. LARGER NUMBER
= GEAR SET RATIO
SMALLER NUMBER
1. Park the vehicle on a level surface. 1003457b

2. Block the wheels to prevent the vehicle from moving. Figure 4.21

To Identify the Gear Teeth Number on the Forward 3. Calculate the hypoid gear set ratio by dividing the larger
Axle Drive Pinion number by the smaller number. Figure 4.21.
1. Remove the forward carrier pinion cover. Refer to the vehicle
manufacturer’s procedures. Compare Both Hypoid Gear Set Ratios
2. Look into the carrier housing. Identify and record the gear set 1. Both ratios must be within one percent of each other. To
teeth numbers stamped on the drive pinion end. Figure 4.20. calculate the percentage difference between the axle ratios,
refer to the equation in Table E.
Figure 4.20

앫 If the axle ratios shown on the identification tags are

not within one percent of each other: Refer to the vehicle
manufacturer for further information.
LARGER NUMBER = HYPOID GEAR
SMALLER NUMBER SET RATIO 2. Install the inter-axle drive shaft. Refer to the vehicle
manufacturer’s procedures.
3. Install the pinion cover. Refer to the vehicle manufacturer’s
4
10- 1
procedures.
4. Remove the safety stands and lower the vehicle.

1003456c Verify the Actual Hypoid Gear Set Ratios

Figure 4.20 You can check the actual hypoid gear set ratios when you remove
the differential carriers from the axle housings for service or repair.
3. Calculate the hypoid gear set ratio by dividing the larger Refer to the following procedure to calculate the actual gear set
number by the smaller number. Figure 4.20. ratios.
1. Count the number of ring gear teeth. Figure 4.22.
To Identify the Gear Teeth Number on the Rear Axle
Drive Pinion
1. Remove the inter-axle drive shaft. Refer to the vehicle
manufacturer’s procedures.

Meritor Maintenance Manual 5L (Revised 02-18) 35

4 Prepare Parts for Assembly

Figure 4.22 2. Use a jack to raise the vehicle so that the wheels to be serviced
RING are off the ground. Support the vehicle with safety stands.
PINION
GEAR TEETH GEAR
TEETH 3. Remove the driveline.
4. Remove the input, output or pinion shaft nut.
5. Attempt to remove the yoke by hand.
앫 If you can remove the yoke by hand: The yoke is worn.
Replace the yoke.
RING GEAR TEETH = ACTUAL HYPOID 6. Use a correct yoke puller tool to remove the yoke.
PINION GEAR TEETH GEAR SET RATIO
1003458d Check for a Tight-Fit Condition
Figure 4.22
NOTE: You can check for a tight-fit condition when you install any
serviceable yoke.
2. Count the number of pinion gear teeth. Figure 4.22.
3. Divide the number of ring gear teeth by the number of pinion 1. Attempt to install the yoke by hand.
gear teeth to determine the actual hypoid gear set ratio for 앫 If the yoke bottoms out against the adjacent bearing:
each axle. Figure 4.22. Replace the yoke.
4. Calculate the percentage difference between the hypoid gear 2. Use a correct yoke installation tool to install the yoke.
set ratios using the equation in Table E. All ratios must match
within one percent. 3. As you install the yoke, you should detect resistance between
the yoke and shaft.
앫 If the actual hypoid gear set ratios are not within one
percent of each other: Refer to the vehicle manufacturer 앫 If you do not detect resistance between the yoke and
for further information. shaft: Replace the yoke.
4. Install and tighten the input, output or pinion shaft nut to the
Inspection correct torque. Refer to Section 8.
5. Install the driveline.
Yoke
6. Remove the safety stands.
All current Meritor axles feature helical splines at the yoke interface.
This feature provides a tight fit between the yoke and input shaft, 7. Lower the vehicle.
output shaft and pinion shaft. For the axle to operate correctly, the
input shaft, output shaft and pinion shaft must fit tightly to the
corresponding yoke.

Check for Yoke Wear

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

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

the vehicle from moving.

36 Meritor Maintenance Manual 5L (Revised 02-18)

 4 Prepare Parts for Assembly

Tire Matching for Tandem and Tridem Axles Tridem Axles

When three driving axles are used together in a tridem series,
CAUTION unmatched tires will compound the problems described in the
Unmatched tires on both tandem drive units and tridem drive preceding paragraphs. Meritor recommends matching, as nearly as
units will cause tire wear and scuffing and possible damage to possible, the total tire circumference of each of the three driving
the drive units. Meritor recommends that the tires be matched axles.
to within 0.125-inch (3.18 mm) of the same rolling radius,
0.75-inch (19.05 mm) of the same rolling circumference. To match tires on tridem units, follow the same procedure used for
tandem units.
Tandem Axles Arrange the tires in order of size.
The four largest tires should never be installed onto one driving axle 앫 The two largest and two smallest go on one axle.
or the four smallest tires onto the other driving axle. Such tire
mounting will cause an inter-axle fight, unusually high axle lubricant 앫 The next two largest and smallest go on the second axle.
temperatures that result in premature lubricant breakdown and 앫 The remaining four tires go on the third axle.
possible costly axle service.
In addition to matching individual tire rolling radii or rolling
circumference, Meritor recommends matching, as nearly as
possible, the total tire circumference of one driving axle to the total
tire circumference of the other driving axle. This will usually result in
satisfactory tandem axle lubricant temperatures that lengthen drive
unit service with higher tire mileage.
Park the vehicle on a level surface. The vehicle must carry a
correctly distributed rated capacity load. All the tires must be the
same size. Measure new tires to verify that they will be correctly
matched.
1. Inflate all tires to the same pressure.
2. Carefully measure the rolling circumference of each tire with a
steel tape.
3. Mark the size on each tire with chalk and arrange the tires in
order of size, largest to smallest.
4. Mount the two largest tires onto one side of one axle and
mount the two smallest onto the opposite side of the same
axle.
5. Mount the four other tires onto the other axle in the same
manner.
6. Test run the vehicle to gather accurate rear axle lubricant
temperature readings on the two axle lubricant temperature
gauges.
7. Vary tire air pressure within the tire manufacturer’s
recommended range so the lubricant temperature of both axles
is within 30°F (–1°C) of each other and not in excess of 250°F
(121°C). This will usually result in uniform tire loading and
good tire life.

Meritor Maintenance Manual 5L (Revised 02-18) 37

5 Assembly and Installation

Hazard Alert Messages

5 Assembly and Installation

Figure 5.1

OUTER OUTER
Read and observe all Warning and Caution hazard alert messages in BEARING BEARING
this publication. They provide information that can help prevent CONE CUP
serious personal injury, damage to components, or both. SPACER
HELICAL
DRIVEN
WARNING GEAR
To prevent serious eye injury, always wear safe eye protection
SHIMS
when you perform vehicle maintenance or service. SPACER

Observe all warnings and cautions provided by the press

manufacturer to avoid damage to components and serious INNER
personal injury. DRIVE BEARING
INNER CONE
BEARING PINION
CUP 1002763a
Installation
Figure 5.1
Installing the Drive Pinion and Adjusting
Pinion Depth and Preload 1. Use a micrometer to measure the thickness of the shim pack
that was removed from the differential carrier. Record the
There are two procedures for adjusting pinion depth. The procedure measurement. Figure 5.2.
in this manual is to install the pinion, bearings and calculated shim
pack into the case WITHOUT the helical gear and two spacers. After Figure 5.2

you check the tooth contact patterns to determine the correct pinion
position, you must disassemble the carrier to install the helical gear
and two spacers.
An optional procedure is to install the pinion, bearings and
calculated shim pack into the case WITH the helical gear and two
spacers. After you check the tooth contact patterns to determine the
correct pinion position, you only need to disassemble the carrier if
an adjustment is necessary. Both procedures are acceptable.

Adjustment 1002764a

Figure 5.2
Shim Pack Thickness for a New Drive Pinion
NOTE: Use this procedure if you’ll install a new drive pinion and ring 2. Find the pinion cone (PC) variation number on the drive pinion
gear set or if you have to adjust the depth of the drive pinion. If the you’ll replace. Record the number. Figure 5.3. The pinion cone
pinion depth shims are misplaced during carrier repair, use number can be one of the following values.
0.030-inch (0.76 mm) for 145 Series axles and 0.050-inch 앫 PC +3, PC –3, +3 or –3 = 0.003-inch
(1.27 mm) for 160 Series axles for the initial pinion position.
Figure 5.1. 앫 PC +.03, PC 0.03 mm, +0.03 mm or –0.03 = 0.03 mm

38 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Figure 5.3 Table F:

Examples Inches mm
1. Old Shim Pack Thickness 0.030 0.760
Old PC Number, PC +2 + 0.002 + 0.050
Standard Shim Pack Thickness = 0.032 = 0.810
New PC Number, PC +5 – 0.005 – 0.120
PINION CONE New Shim Pack Thickness = 0.027 = 0.690
VARIATION
NUMBER 2. Old Shim Pack Thickness 0.030 0.760
1003032d Old PC Number, PC –2 – 0.002 – 0.050

Figure 5.3
Standard Shim Pack Thickness = 0.028 = 0.710
New PC Number, PC +5 – 0.005 – 0.120
3. If you can’t find the PC number or it’s unreadable, install a new New Shim Pack Thickness = 0.023 = 0.590
shim pack of the same thickness that you measured in Step 1.
3. Old Shim Pack Thickness 0.030 0.760
NOTE: The following calculation is the opposite for a rear carrier, Old PC Number, PC +2 + 0.002 + 0.050
tandem or single. Standard Shim Pack Thickness = 0.032 = 0.810

4. If the old pinion cone number of a forward tandem carrier is a New PC Number, PC –5 + 0.005 + 0.120
plus (+), ADD the cone number to the old shim pack thickness New Shim Pack Thickness = 0.037 = 0.930
that was measured in Step 1. 4. Old Shim Pack Thickness 0.030 0.760
5. If the old pinion cone number of a forward tandem carrier is a Old PC Number, PC –2 – 0.002 – 0.050
minus (–), SUBTRACT the cone number from the old shim pack
Standard Shim Pack Thickness = 0.028 = 0.710
thickness that was measured in Step 1.
New PC Number, PC –5 + 0.005 + 0.120
6. Find the pinion cone variation number on the new drive pinion
New Shim Pack Thickness = 0.033 = 0.830
that will be installed. Record the number.
7. If the new pinion cone number of a forward tandem carrier is a
plus (+), SUBTRACT the number from the standard shim pack
Assembly
thickness that was calculated in Step 4 or Step 5. Use new
shims to make a shim pack to the determined thickness. Refer
Drive Pinion Assembly
to Table F. The depth of the drive pinion and ring gear contact is controlled by
the thickness of the shim pack. Figure 5.4.
8. If the new pinion cone number of a forward tandem carrier is a
minus (–), ADD the number to the standard shim pack 앫 To increase the thickness of the drive pinion contact:
thickness that was calculated in Step 4 or Step 5. Use new Increase the thickness of the shim pack.
shims to make a shim pack to the determined thickness. Refer
앫 To decrease the depth of the drive pinion pattern: Decrease
to Table F.
the thickness of the shim pack.

Meritor Maintenance Manual 5L (Revised 02-18) 39

5 Assembly and Installation

Figure 5.4 2. If removed, use a press and a sleeve to install the inner bearing
OUTER OUTER cone onto the drive pinion. Place the sleeve onto the inner race
BEARING BEARING of the bearing. Apply pressure until the bottom of the cone
CONE CUP
touches the shoulder on the pinion. Figure 5.5.

Figure 5.5

PRESS
AND SLEEVE
SHIMS

INNER
BEARING
INNER DRIVE CONE
BEARING PINION
CUP 1002765c

Figure 5.4
1002766a

The preload of the bearings on the drive pinion is controlled by a Figure 5.5
spacer between the outer bearing cone and the helical driven gear.
3. Apply axle lubricant to the bearing cups and cones.
Adjust the preload by changing the size of the spacer.
앫 To decrease the preload: Use a thicker spacer. 4. If removed, install the shim pack and the inner bearing cup of
the drive pinion.
앫 To increase the preload: Use a thinner spacer.
A. Place the carrier into a press so that the legs of the carrier
If the depth of the drive pinion is changed, the thickness of the are toward the TOP of the press.
spacer must also be changed the same amount. Refer to the
B. Install the correct amount of shims into the bore for the
following examples.
inner bearing cup of the drive pinion. Figure 5.6.
앫 If a 0.003-inch (0.076 mm) shim is ADDED to the shim pack
to INCREASE the depth of the drive pinion: A 0.003-inch C. Place the cup into the bore. Figure 5.6.
(0.076 mm) larger spacer must be installed to keep the preload D. Place supports under the differential carrier so that the
on the bearings. carrier is level.
앫 If a 0.003-inch (0.076-mm) shim is REMOVED from the shim E. Place a sleeve or a bearing driver tool onto the cup and
pack to DECREASE the depth of the drive pinion: A press the cup into the bore until the bottom of the cup
0.003-inch (0.076 mm) smaller spacer must be installed to keep touches the shims. If a press is not available, use a
the preload on the bearings. sleeve, a brass drift or a bearing driver tool and a hammer
to install the cup. Figure 5.7.
NOTE: The helical driven gear and the spacers are installed when
the bearing preload on the drive pinion is inspected and adjusted.

1. If you are installing a new ring gear and drive pinion, the
correct thickness of the shim pack between the pinion inner
bearing cup and the carrier must be determined. Refer to the
procedure in this section before temporarily assembling and
installing the drive pinion assembly according to this
procedure.
If you are installing the original ring gear and drive pinion,
temporarily install the drive pinion assembly.

40 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Figure 5.6 Figure 5.8

BEARING
CUP PRESS

SHIMS

1002769c
1002767b
Figure 5.8
Figure 5.6

Figure 5.7
Installation
PRESS
Drive Pinion Assembly
1. Place the drive pinion into the carrier so that the pinion is
through the inner and the outer bearing cups.
2. Place the carrier into a press so that the legs of the carrier are
toward the BOTTOM of the press. Place supports under the
carrier so that the carrier is level. Place a support under the
head of the drive pinion so that the inner bearing cone on the
BEARING
CUP
pinion shaft touches the inner bearing cup in the carrier.
1002768b
3. Place the outer bearing cone onto the pinion shaft.
Figure 5.7
4. Use a press and a sleeve to install the bearing cone onto the
5. If removed, install the outer bearing cup for the drive pinion. pinion. Apply no more than two tons (1814 kg) of force to verify
that the bearing cone is correctly installed. Figure 5.9.
A. Place the carrier into a press so that the legs of the carrier
are toward the BOTTOM of the press. Place supports Figure 5.9

under the carrier so that the carrier is level.

B. Place the outer bearing cup for the drive pinion into the SLEEVE
bore of the carrier.
C. Use a sleeve or a bearing driver tool and a press to install
the cup. Press the cup into the carrier until the bottom of
the cup touches the bottom of the bore. If a press is not
available, use a sleeve, a brass drift or a bearing driver
tool and a hammer to install the cup. Figure 5.8.

1002770a

Figure 5.9

Meritor Maintenance Manual 5L (Revised 02-18) 41

5 Assembly and Installation

Adjustment Figure 5.11

PRESS OUTER
Drive Pinion Bearing Preload BEARING
CONE
NOTE: If the depth of the drive pinion was changed, then the
DRIVE
amount of the change must be added or subtracted to the thickness PINION
of the spacer between the outer bearing cup and the helical driven
gear. SUPPORT WOOD
BLOCK
After you obtain the correct gear tooth contact pattern and the
correct shim pack thickness, you must adjust the bearing preload on SUPPORT
the drive pinion. The preload is controlled by the thickness of the 1002772b
spacer between the helical driven gear and the outer bearing cone.
Figure 5.11
Figure 5.10.

Figure 5.10
3. Turn the carrier over so that the legs of the carrier are UP. Place
supports under the carrier so that the carrier is level.
SPACER — AVAILABLE OUTER
IN DIFFERENT SIZES
TO ADJUST PRELOAD
BEARING 4. Place the helical driven gear over the pinion bore in the carrier
ASSEMBLY
so that the splines inside the gear are toward the FRONT of the
SPACER — ONLY carrier. Place the large spacer on top of the helical driven gear
AVAILABLE IN so that the spacer is toward the inner bearing cup.
ONE SIZE
Figure 5.12.

Figure 5.12

PRESS
PROTECTOR
INNER
BEARING
ASSEMBLY 1002771c
DRIVE
Figure 5.10 PINION

SPACER
1. Place the carrier into a press so that the threaded end of the
pinion is UP. Place supports under the flange of the carrier so HELICAL
DRIVEN
that the carrier is level. Place a wood block under the head of GEAR
the pinion. Figure 5.11.
2. Press the drive pinion out of the outer bearing cone. Remove SUPPORT SUPPORT
the cone. Figure 5.11. 1002773b

Figure 5.12

5. Install the drive pinion into the helical driven gear. Verify that
the splines on the pinion engage the splines inside the gear.
Figure 5.12.

42 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

10. Place the two pieces of lead or solder so that the pieces are
CAUTION
opposite each other on top of the helical driven gear.
Do not apply pressure after the inner bearing cone touches the
inner bearing cup. If more pressure is applied, the cup, cone 11. Place the outer bearing cone into the cup over the two pieces
and drive pinion will be damaged. of lead or solder on top of the helical driven gear.
12. Remove the support from the flange of the carrier. Place a
6. Place a protector onto the head of the drive pinion. Use a press
sleeve on top of the outer bearing cone. Use a press to apply
to install the pinion into the carrier so that the inner bearing
two tons (1814 kg) of force to the outer bearing cone. The
cone touches the bearing cup. At this time, the helical driven
force of the press compresses the lead or solder pieces to the
gear will not be completely installed on the drive pinion.
correct size. Do not apply more than two tons (1814 kg) of
Figure 5.12.
force. Figure 5.14.
7. Place the carrier into a press so that the threaded end of the
pinion is toward the TOP of the press. Place supports under the Figure 5.14

flange of the carrier so that the carrier is level. Place a wood PRESS — DO NOT
block under the head of the drive pinion so the inner pinion APPLY MORE THAN
TWO TONS (1814 KG)
bearing cone touches the inner bearing cup. Figure 5.13. OF PRESSURE
SLEEVE
OUTER BEARING
CAUTION CONE
Do not apply pressure after the helical driven gear touches the PIECES OF HELICAL DRIVEN
LEAD OR GEAR
spacer in front of the inner bearing on the drive pinion. If SOLDER
pressure is applied after the parts touch each other, the gear
will damage the spacer.
WOOD BLOCK —
8. Use a press and a sleeve to completely install the helical driven MUST SUPPORT
HEAD OF PINION
gear onto the drive pinion. Use a sleeve on the hub of the gear
1002775b
that fits inside the pinion bore in the carrier. Press the gear
onto the drive pinion until the gear touches the spacer. Figure 5.14
Figure 5.13.
13. Release the pressure and remove the wood block from under
Figure 5.13
the head of the drive pinion.
PRESS 14. Use a press and a sleeve to press the shaft of the drive pinion
HELICAL SLEEVE out of the outer bearing cone. Do not press the shaft of the
DRIVEN
GEAR
drive pinion out of the helical driven gear.
WOOD BLOCK 15. Remove the outer bearing cone and the two pieces of lead or
AND END OF
DRIVE PINION solder from the outer bearing cone.
WOOD
MUST TOUCH
BLOCK 16. Use a micrometer to measure the thicknesses of the
compressed pieces of lead or solder. Add the measurements of
SUPPORT SUPPORT
the two pieces and divide by two (2) to determine the average
1002774b
size of the pieces. Add 0.004-inch (0.100 mm) to the average
Figure 5.13 size. Use this dimension to determine the size of the spacer to
install between the helical driven gear and the outer bearing.
9. Cut two pieces of lead or solder approximately 0.5625-inch Refer to Table G.
(14 mm) long and 0.625-inch (16 mm) wide. Use the two
pieces of solder or lead as gauge blocks to determine the
correct thickness of the spacer between the helical driven gear
and the outer bearing.

Meritor Maintenance Manual 5L (Revised 02-18) 43

5 Assembly and Installation

Table G 18. Use a press and a sleeve to completely install the helical driven
gear onto the drive pinion. Use a sleeve on the hub of the gear
Example Inch (mm)
that fits inside the pinion bore in the carrier. Press the gear
Thickness of piece number 1 0.504 (12.800) onto the drive pinion until the gear touches the spacer. Do not
Thickness of piece number 2 +0.506 (12.852) remove the wood block at this time. Figure 5.14.
Total thickness 1.010 (25.652) 19. Install the correct size spacer onto the shaft of the pinion in
Divide by two (2) to determine 0.505 (12.826) front of the helical driven gear.
the average thickness
NOTE: Verify that the wood block is still under the head of the drive
Add 0.004-inch (0.100 mm) to 0.509 (12.926)
pinion. The inner bearing cone on the pinion must touch the cup in
determine the thickness of the the carrier.
spacer
20. Install the outer bearing cone onto the shaft of the drive pinion.
17. Place a wood block under the head of the drive pinion so that Figure 5.15.
the inner bearing cone on the pinion touches the inner bearing
cup in the carrier. Remove the supports from the carrier. A. Place the outer bearing cone onto the shaft of the drive
Figure 5.15. pinion.
B. Place a sleeve onto the top, inner race, of the outer
Figure 5.15

bearing cone.
OUTER PRESS — DO NOT
BEARING APPLY MORE THAN C. Use a press to apply two tons (1814 kg) of force on the
CONE TWO TONS (1814 KG) bearing cone to install the cone onto the shaft of the drive
SPACER
OF PRESSURE
pinion. Rotate the carrier in both directions, so that the
HELICAL SLEEVE
DRIVEN carrier pivots on the drive pinion, while the cone is being
GEAR installed to verify that the bearing cone is correctly
SPACER installed.
ROTATE CARRIER
IN THESE 21. Release the pressure and remove the carrier from the press.
DIRECTIONS AS Place the carrier in a repair stand.
CONE IS PRESSED
ON PINION 22. Install the washer and the nut onto the drive pinion. Prevent the
drive pinion assembly from rotating by using a fixture to hold
the teeth of the helical driven gear or place wood blocks
WOOD BLOCK — MUST between the head of the pinion and the carrier wall. Tighten the
TOUCH HEAD OF
DRIVE PINION
nut to the specified torque. Refer to Section 8. Remove the
1002776b
holding fixture or the wood blocks.
Figure 5.15
23. Use an inch-pound torque wrench or a spring scale to inspect
the preload of the bearings on the drive pinion.
CAUTION
Do not apply pressure after the helical driven gear touches the
spacer in front of the inner bearing on the drive pinion. If
pressure is applied after the parts touch each other, the gear
will damage the spacer.

NOTE: The inner bearing cone on the drive pinion must touch the
inner bearing cup in the carrier when the helical driven gear is being
installed.

44 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Torque Wrench Method Figure 5.17

1. Place an inch-pound (N폷m) torque wrench and the correct

socket onto the drive pinion nut. Figure 5.16.

Figure 5.16

Read
rotating
torque.
1002778c
Read
Figure 5.17
rotating
torque.
4. Measure the outer diameter of the washer under the drive
pinion. Divide the outer diameter of the washer by two (2) to
1002777c get the radius of the washer. Multiply the radius of the washer
by the reading on the spring scale to get the preload on the
Figure 5.16
pinion bearings.

2. Use the torque wrench to rotate the drive pinion assembly. Table H: Example
Inspect and record the torque level. Read while rotating the
Outer diameter of the washer = 3.00-inches (76.20 mm)
assembly. Record the dynamic or rotating torque not the
breakaway torque. Spring scale reading = 9 lbs (4 kg)

3. The preload of the drive pinion bearings must be within the

following limits. Inch (mm)
앫 For new pinion bearings: 5-45 lb-in (0.56-5.08 N폷m) Outer diameter of the 3.00 (76.20)
rotational torque washer

앫 For used pinion bearings: 10-30 lb-in (1.13-3.39 N폷m) Divide the outer diameter by 1.50 (38.10)
rotational torque two (2) to get the radius of
the washer
앫 If the preload is not within the specified limits: Remove
Multiply the radius of the 13.50 lb-in (1.49 N폷m)
and replace the spacer between the outer bearing cone and
washer by the spring scale
the helical driven gear. Refer to the procedure below.
reading
— To decrease the preload: Install a thicker spacer.
— To increase the preload: Install a thinner spacer. 5. The preload of the drive pinion bearings must be within the
following limits.
Spring Scale Method 앫 For new pinion bearings: 5-45 lb-in (0.56-5.08 N폷m)
1. Wind a cord around the washer under the nut of the drive rotational torque
pinion. 앫 For used pinion bearings: 10-30 lb-in (1.13-3.39 N폷m)
2. Attach a spring scale to the end of the cord. rotational torque
앫 If the preload is not within the specified limits: Remove
3. Pull the spring scale and cord in a horizontal direction while
and replace the spacer between the outer bearing cone and
looking at the reading on the spring scale. Figure 5.17.
the helical driven gear. Refer to the procedure below.
— To decrease the preload: Install a thicker spacer.
— To increase the preload: Install a thinner spacer.

Meritor Maintenance Manual 5L (Revised 02-18) 45

5 Assembly and Installation

Spacer Replacement Assembly

NOTE: Do not grind spacers by hand. The surfaces must be parallel Main Differential and Ring Gear
within 0.0001-inch (0.0020 mm). You must use the correct
spacers. CAUTION
Heat the ring gear before seating it onto the differential case.
1. Prevent the drive pinion assembly from rotating by using a Do not press a cold ring gear on the flange case half. A cold
fixture to hold the teeth of the helical driven gear or place wood ring gear will damage the case half because of the tight fit.
blocks between the head of the pinion and the carrier wall.
Remove the nut and the washer from the shaft of the drive 1. Expand the ring gear by heating the gear in a tank of water to
pinion. Figure 5.18. 160-180°F (71-82°C) for 10 to 15 minutes.

Figure 5.18
WARNING
Wear safe clothing and gloves for protection from injury when
working with the hot ring gear.
OUTER
BEARING
SPACER CONE 2. Use a lifting tool to safely lift the ring gear from the tank of
water.
WOOD BLOCK 3. Install the ring gear onto the flange case half immediately after
DOES NOT the gear is heated.
TOUCH DRIVE
DRIVE PINION PINION 앫 If the ring gear does not fit easily on the case half: Heat
the gear again.
SUPPORT SUPPORT 4. Align the ring gear and flange case half fastener holes. Rotate
1002779c
the ring gear as necessary.
Figure 5.18
NOTE: If rivets were used to hold the ring gear to the flange case
half, replace them with bolts, nuts and washers. 140 Series carriers
2. Place the carrier into a press so that the threaded end of the
with rivets are serviced with bolt kits for reassembly.
pinion is toward the TOP of the press. Place supports under the
flange of the carrier so that the carrier is level. Place a wood 5. Install the bolts, nuts and washers, if equipped, that hold the
block under the head of the pinion. Verify that the wood block ring gear to the flange case half. Install the bolts from the front
does not touch the head of the drive pinion. side of the gear. The bolt threads must be installed from the
3. Press the drive pinion out of the bearing cone. Remove the inside face of the ring gear and the nuts tightened from the
outer bearing cone from the differential carrier. back of the ring gear. Figure 5.19.

4. Install the correct size spacer onto the shaft of the pinion over Figure 5.19

the helical driven gear. FLANGE RING

CASE GEAR
5. Repeat Step 20 through Step 23 under Section 5 in this HALF
section.
BOLT HEAD
INSTALLED
6. When the preload is within the specified range, install the main FROM FRONT
differential case and ring gear assembly into the carrier. Refer OF GEAR
to procedure in this section.

1002780d

Figure 5.19

46 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

6. Tighten the bolts and nuts, if equipped, to the correct torque 9. Apply axle lubricant on the inside surfaces of both case halves,
value. Refer to Section 8. spider or cross, thrust washers, side gears and differential
pinions.
7. Inspect for gaps between the back surface of the ring gear and
the case flange. Use a 0.003-inch (0.080 mm) feeler gauge to 10. Place the flange case half onto a bench with the ring gear teeth
inspect at four points around the assembly. Figure 5.20. toward the TOP.
앫 If the gaps exceed specification: Inspect the flange case
half and ring gear for the problem that causes the gap.
CAUTION
Repair or replace parts as necessary. Reassemble the ring The side gears in some carrier models have hubs of different
gear on the flange case half. Reinspect for gaps. lengths. Install the correct length side gear into the flange
case half. Damage to components can result.
Figure 5.20

11. Install one thrust washer and side gear into the flange case
half. Figure 5.22.
NOTE: There are two different design versions of the pinions
and side gears: the original design and a new version with
tooth profile enhancements. If the pinions or side gears must
be replaced, the replacement part must be of the same design
version as the mating part. Do not mix original design pinions
with new design side gears and vice versa. Refer to Section 4
Check for
for further information about replacing these parts.
0.003" (0.080 mm)
gap at four Figure 5.22

locations. 1002781d
SIDE
Figure 5.20 GEAR
THRUST
WASHER
8. Use a press and the correct size sleeve to install the bearing
FLANGE
cones onto both of the case halves. Figure 5.21. CASE HALF

Figure 5.21

PRESS

SLEEVE 1003066b

BEARING Figure 5.22

CONE
CASE
HALF
12. Install the spider or cross, differential pinions and thrust
washers into the flange case half. Figure 5.23.
SUPPORT SUPPORT

1002782d

Figure 5.21

Meritor Maintenance Manual 5L (Revised 02-18) 47

5 Assembly and Installation

Figure 5.23 15. Install Dri-Loc or equivalent fasteners into the case halves.
SPIDER, PINION Refer to Section 4.
AND THRUST
WASHERS A. Install four capscrews and washers or bolts, nuts and
washers into the case halves. The distance between the
fasteners must be equal. Tighten the fasteners to the
correct torque value in a crisscross pattern opposite each
other. Refer to Section 8. Figure 5.26.
B. Install the other fasteners into the case halves. Tighten
the fasteners to the correct torque value. Refer to Section
1003067d
8.
Figure 5.23
Figure 5.26

13. Install the second side gear and thrust washer over the spider CRISSCROSS TIGHTENING PATTERN
and differential pinions. Figure 5.24.
10 6
4 2
Figure 5.24

13 15
8 12
THRUST
WASHER

11 7
SIDE 1 14
PLAIN GEAR
CASE 16 3
HALF 5 9
1003070g

Figure 5.26

1003068b
16. Check the rotating resistance of the differential gears. The
Figure 5.24 differential assembly must rotate freely.

14. Place the plain half of the differential case over the flange half Check the Rotating Resistance of the
and gears. Rotate the plain half as needed to align the match
marks. Figure 5.24 and Figure 5.25. Differential Assembly
1. Make an inspection tool using an axle shaft that matches the
Figure 5.25

spline size of the differential side gear. Cut the shaft to

PLAIN approximately 12-inches (304.8 mm). Weld a nut onto the end
CASE
HALF of the shaft. Figure 5.27.

Figure 5.27

MATCH
MARKS APPROXIMATELY
12" (304.8 MM)

SIDE
VIEW

1003069e
END WELD NUT
Figure 5.25 VIEW TO END
OF SHAFT 1003071c

Figure 5.27

48 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

2. Place the differential and ring gear assembly into a vise. Install Installation
soft metal covers over the vise jaws to protect the ring gear.
Figure 5.28. Main Differential Case and Ring Gear
Figure 5.28
Assembly Into the Carrier
1. If the bearing cones on the main differential case were
TOOL FOR removed, install a new cone and cup in a fully-matched set
CHECKING
RESISTANCE from the same manufacturer. The bearing cones are not
interchangeable. Use a press and sleeve to install the cones
onto the case. Press only on the inner race of the bearing.
Figure 5.30.

Figure 5.30

SOFT PRESS
METAL
COVER
1003072f
BEARING
Figure 5.28 CONE SLEEVE

3. Install the tool into the differential until the splines of the tool
are engaged with one side gear. Figure 5.28.
4. Place a torque wrench onto the nut of the tool and rotate the
differential gears. As the differential gears rotate, read the
value indicated on the torque wrench. Figure 5.29.
1002786f
앫 If the torque value exceeds 50 lb-ft (67.8 N폷m):
Disassemble the differential gears from the case halves. Figure 5.30
Inspect the case halves, spider, gears and thrust washers.
Repair or replace parts. Assemble the parts and repeat Step 2. Clean and dry the bearing cups and bores of the carrier legs
2 through Step 4. and bearing caps.
3. Apply axle lubricant to the bearing cups and cones.
Figure 5.29

4. Apply Meritor specification 2297-T-4180 adhesive evenly in

the bearing bores of the carrier legs and bearing caps. Cover
the surfaces completely. The adhesive must not contact the
adjusting ring threads. Figure 5.31. Refer to Section 4.

Figure 5.31

ADHESIVE BEARING CAP

Read torque value. CARRIER LEG

1003073d

Figure 5.29

1003026d
Figure 5.31

Meritor Maintenance Manual 5L (Revised 02-18) 49

5 Assembly and Installation

5. Install the bearing cups over the bearing cones in the case Figure 5.34

halves. Figure 5.32.

Figure 5.32

BEARING
CAP
MATCH
BEARING MARKS
CUP
BEARING
CUP
LEG 1002790c
BORE
Figure 5.34

1002788d WARNING
Figure 5.32 Use a brass or synthetic mallet for assembly and disassembly
procedures. Do not hit steel parts with a steel hammer. Pieces
6. Safely lift the differential and ring gear assembly and install it of a part can break off. Serious personal injury and damage to
into the carrier. The bearing cups must be flat against the components can result.
bores between the carrier legs. Figure 5.32.
7. Install the bearing adjusting rings between the carrier legs. CAUTION
Hand-tighten the adjusting rings against the bearing cups. If bearing caps are not installed correctly in the original carrier
Figure 5.33. locations, the bores and threads in the caps will not match the
carrier. Forcing the bearing caps into the incorrect position will
Figure 5.33
result in damage to the carrier.
ADJUSTING
RING 9. Use a light leather plastic or rubber mallet to seat each bearing
cap. The caps must fit easily against the bearings, adjusting
rings and carrier. Do not force the bearing caps into position.
앫 If the bearing caps do not correctly fit into position:
Check the alignment of the match marks between the caps
and carrier. Remove the caps and repeat Step 7 through
Step 9.
LEG 10. Install the capscrews and washers that secure the bearing
1002789d caps to the carrier. Hand-tighten the capscrews four to six
Figure 5.33 turns, then tighten the capscrews to the correct torque value.
Refer to Section 8.

CAUTION Do not install the capscrews, cotter pins or roll pins, if

The bearing caps must be correctly installed or the adjusting equipped, that secure the bearing adjusting rings in position.
rings will be damaged by cross-threading. Forcing the caps Continue by adjusting the preload of the differential bearings,
into position can damage the caps and the carrier housing. adjust the backlash of the hypoid gear and inspect the tooth
contact patterns.
8. Install the bearing caps over the bearings and adjusting rings in
the correct location as marked before removal. Figure 5.34.

50 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Adjustment Figure 5.36

T-BAR
Differential Bearings Preload WRENCH

Use either the dial indicator or the large micrometer method to

inspect and adjust the main differential side bearings preload.

NOTE: The roll pins for the adjusting rings are installed after the
tooth contact pattern is checked.

Dial Indicator Method ADJUSTING

RING OPPOSITE
1. Attach a dial indicator onto the carrier mounting flange so that RING GEAR 1002791d

the plunger or the pointer is against the back surface of the Figure 5.36
ring gear. Figure 5.35.
3. Use one of the following methods to move the differential and
Figure 5.35

the ring gear carefully to the left and right while you read the
DIAL
INDICATOR dial indicator.
A. Insert two pry bars between the bearing adjusting rings
and the ends of the differential case. The pry bars must
not touch the differential bearings. Figure 5.37.
B. Insert two pry bars between the differential case or the
ring gear and the carrier at locations other than described
in Step A. The pry bars must not touch the differential
bearings. Figure 5.38.
1003078d

Figure 5.37

Figure 5.35

CAUTION
When you turn the adjusting rings, always use a tool that
engages two or more opposite notches in the ring. A T-bar
wrench can be used for this purpose. If the tool does not
correctly fit into the notches, damage to the lugs will occur.
Bars must not
touch bearings.
NOTE: On 160 Series axles, half of the bearing assembly extends
out of the bearing cap and carrier.
1003080f
2. Use a T-bar wrench to loosen the adjusting ring that is opposite
the ring gear. A small amount of end play will show on the dial Figure 5.37
indicator. Figure 5.36.

Meritor Maintenance Manual 5L (Revised 02-18) 51

5 Assembly and Installation

Figure 5.38 Figure 5.40

Bars must not

touch bearings.

1003082d
1003081g
Figure 5.40
Figure 5.38

Figure 5.41

4. Tighten the bearing adjusting ring until the dial indicator reads
ZERO end play. Move the differential and ring gear to the left MICROMETER
and right as needed. If necessary, repeat Step A or Step B.
5. Tighten each bearing adjusting ring one notch from ZERO. The
side bearings of the differential should have a preload of
15-35 lb-in (1.7-3.9 N폷m). Figure 5.39. @
This procedure should expand the caps 0.008-0.010-inch
(0.203-0.254 mm), and place the correct preload on the
bearings when they are installed into the banjo housing.
1003083d

Figure 5.39
Figure 5.41
T-BAR
WRENCH
CAUTION
When turning the adjusting rings, always use a tool that
engages two or more opposite notches in the ring. A T-bar
wrench can be used for this purpose. If the tool does not
correctly fit into the notches, damage to the lugs will occur.

3. Use a T-bar wrench to tighten each bearing adjusting ring one

Tighten each notch. Figure 5.36.
ring one notch.
1002794c
4. Measure distance X and Y again. Compare the measurements
Figure 5.39 with the distances X and Y measured in Step 2. The difference
between the two distances is the amount the bearing caps
6. Proceed to check ring gear runout. have expanded. Refer to Table I.

Large Micrometer Method

1. Hand-tighten the adjusting rings against the differential
bearings.
2. Use a large micrometer to measure distance X and Y between
the opposite surfaces of the bearing caps. Record the
measurement. Figure 5.40 and Figure 5.41.

52 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Table I: Example 앫 If the ring gear runout is within the specification:

Proceed to Ring Gear Backlash.
Distances X and Y BEFORE = 15.315-inches (389 mm)
tightening the adjusting rings 앫 If the ring gear runout exceeds the specification:
Distances X and Y AFTER = 15.324-inches (389.230 mm) Remove the differential and ring gear assembly from the
tightening the adjusting rings carrier. Refer to Section 3.

15.324-inches – = 0.009-inch difference A. Inspect the differential parts, including the carrier, for
15.315-inches wear and damage. Repair or replace parts as necessary.
389.230 mm – 389.000 mm = 0.230 mm difference B. Install the main differential case and ring gear assembly
into the carrier. Refer to the procedure in this section.
5. If the difference is at or within the specification in Table J:
C. Repeat the procedure for preload adjustment of the
Continue by checking the runout.
differential side bearings.
If the difference is less than the specification: Repeat as
needed. Ring Gear Backlash
Table J: Expansion Between Bearing Caps Table K: Specifications

RS-140, RS-145 and 0.002-0.009-inch Ring Gear Pitch Range of Backlash Setting
RS-160 carrier models (0.050-0.229 mm) Diameter Backlash Setting for New Gear Sets
RS 120 and all other carrier 0.006-0.013-inch Less than 17-inches 0.008-0.018-inch 0.012-inch
models (0.15-0.33 mm) (431.8 mm) (0.20-0.46 mm) (0.30 mm)
Greater than 0.010-0.020-inch 0.015-inch
Ring Gear Runout 17-inches (0.25-0.51 mm) (0.38 mm)
(431.8 mm)
1. Attach a dial indicator onto the carrier mounting flange.
Figure 5.42.
Measure the outer diameter of the ring gear for the approximate
Figure 5.42
pitch diameter. Figure 5.43.
Rotate ring gear. 앫 If the old gear set is installed: Adjust the backlash to the
setting that was measured before the carrier was disassembled.
앫 If a new gear set is installed: Adjust the backlash to the
DIAL
INDICATOR correct specification for new gear sets.

Figure 5.43

1003084c

Figure 5.42
Measure outer
diameter for
2. Adjust the dial indicator so that the plunger or pointer is against approximate
pitch diameter.
the back surface of the ring gear. Figure 5.42. Set the dial
indicator to ZERO. 1003090k

3. Rotate the differential and ring gear. Read the dial indicator. Figure 5.43
The ring gear runout must not exceed 0.008-inch (0.200 mm).

Meritor Maintenance Manual 5L (Revised 02-18) 53

5 Assembly and Installation

After checking the tooth contact patterns, the backlash can be Figure 5.45

adjusted within the specification limits, if needed. To change the Tighten adjusting
location of the pattern, use the following procedures. ring this side.

1. Attach a dial indicator onto the carrier mounting flange.

Figure 5.44.

Figure 5.44 Loosen adjusting

Increase backlash. ring this side.
1002795b

Figure 5.45

Figure 5.46

Loosen adjusting
ring this side.

Decrease backlash.
1003086d

Figure 5.44
Tighten adjusting
ring this side.
2. Adjust the dial indicator so that the plunger is against the tooth 1002796b
surface.
Figure 5.46
3. Adjust the dial indicator to ZERO. Hold the drive pinion in
position.
NOTE: When you adjust the backlash, only move the ring gear. Do
4. After reading the dial indicator, rotate the differential and ring not move the drive pinion.
gear a small amount in both directions against the drive pinion
teeth. 6. Repeat Step 2 through Step 5 until the backlash is within
specification. Record the setting for use when you adjust the
앫 If the backlash reading is within the specification:
pinion bearing preload.
Check the tooth contact patterns.
앫 If the backlash reading is not within the specification: Gear Set Tooth Contact Patterns, Backlash
Adjust the backlash as needed.
Meritor carriers can have a conventional or a generoid hypoid gear
5. Loosen one bearing adjusting ring one notch. Tighten the set. The tooth contact patterns for each type of gear set are
opposite ring by the same amount. different. Check the part numbers to determine what type of gear
set is in the carrier. Refer to Figure 5.47 for the location of part
앫 To increase the backlash: Move the ring gear away from
numbers. Refer to Section 4.
the drive pinion. Figure 5.45.
앫 To decrease the backlash: Move the ring gear toward the Figure 5.47

drive pinion. Figure 5.46.

PART
NUMBER
PART
NUMBER
PART NUMBER
OPTION

1003089c

Figure 5.47

54 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Examples Figure 5.50

The following are part numbers for generoid gear sets.

앫 36786-K or 36786-K2 for the ring gear
앫 36787-K or 36787-K2 for the drive pinion
In the following procedures, movement of the contact pattern along
the length of the tooth is indicated as toward the heel or toe of the
ring gear. Figure 5.48.

1003092c
Figure 5.48

HEEL Figure 5.50

3. Rotate the ring gear forward and backward so that the 12 gear
TOE
teeth go past the drive pinion six times to get the contact
pattern. Repeat, if needed, to get a more clear pattern.
4. Look at the contact patterns on the ring gear teeth. Compare
the patterns to Figure 5.51, Figure 5.52 and Figure 5.53.
1003090h
The location of a good hand-rolled contact pattern for a new
Figure 5.48 gear set is toward the toe of the gear tooth and in the center
between the top and bottom of the tooth.
Always check the tooth contact patterns on the drive side of the gear When the carrier is operated, a good pattern will extend
teeth. Figure 5.49.
approximately the full length of the gear tooth. The top of the
pattern will be near the top of the gear tooth. Figure 5.54.
Figure 5.49

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.
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.
DRIVE
SIDE 앫 If the contact pattern requires adjustment: Continue by
(CONVEX) 1002797c
following Step 5 to move the contact patterns between the
Figure 5.49 top and bottom of the gear teeth.
앫 If the contact patterns are in the center of the gear
1. Adjust the backlash of a new gear set to either 0.012-inch
teeth: Continue by following Step 6.
(0.305 mm) or 0.015-inch (0.380 mm) depending on the size
of the ring gear. Adjust the backlash of an old gear set to the
setting that was measured before the carrier was
disassembled. Refer to procedure 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 5.50.

Meritor Maintenance Manual 5L (Revised 02-18) 55

5 Assembly and Installation

Figure 5.51 Figure 5.54

GOOD HAND-ROLLED POSITION 1002798c

GOOD PATTERN IN OPERATION
Figure 5.51
1002801c

Figure 5.52
Figure 5.54

5. Change the thickness of the shim pack between the pinion

inner bearing cup and the differential carrier to move the
contact patterns between the top and the bottom of the gear
teeth.
A. Remove the drive pinion, inner bearing cup and shims
from the carrier. Refer to Section 3.
앫 To correct a high-contact pattern: Increase the
thickness of the shim pack. When you increase the
HIGH PATTERN 1002799b
thickness of the shim pack, the drive pinion will move
Figure 5.52 toward the ring gear. Figure 5.55.
앫 To correct a low contact pattern: Decrease the
Figure 5.53

thickness of the shim pack. When you decrease the

thickness of the shim, the drive pinion will move away
from the ring gear. Figure 5.56.
B. Install the inner bearing cup, the shims and the drive
pinion into the carrier. Refer to the procedure in this
section.
C. Repeat Step 2 through Step 5 until the contact patterns
are in the center between the top and bottom of the gear
teeth.
LOW PATTERN 1002800c

Figure 5.53

56 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Figure 5.55 Figure 5.57

Move pattern toward

toe, loosen adjusting
ring this side.
Decrease
backlash.

Tighten adjusting
ring this side. 1002804b

Increase shim pack. Figure 5.57

1002802b
Figure 5.58

Figure 5.55
Move pattern toward
toe, tighten adjusting
ring this side.
Figure 5.56

Increase. Loosen adjusting

backlash. ring this side.
1002805b

Figure 5.58
Decrease shim pack.
1002803b
CAUTION
Figure 5.56 If the carrier has cotter pins or capscrews, lock the adjusting
rings only with cotter pins or capscrews. If the carrier has roll
6. Adjust the ring gear backlash within the specification range to pins, reuse the roll pins. Do not force a roll pin into a cotter pin
move the contact patterns to the correct location along the hole. Damage to components can result.
length of the gear teeth. Refer to procedure in this section.
7. Install the capscrews, cotter pins, roll pins or lock plates, if
A. Decrease the backlash to move the contact patterns equipped, that hold the two bearing adjusting rings in position.
toward the toe of the ring gear teeth. Figure 5.57. Use the following procedures.
B. Increase the backlash to move the contact patterns A. Install capscrews between the lugs of the adjusting ring
toward the heel of the ring gear teeth. Figure 5.58. and through the boss of the bearing cap. New capscrews
C. Repeat Step 2 through Step 4 and Step 6 until the contact include a locking patch, which can only be used once. If
patterns are at the correct location along the length of the you are installing used capscrews, apply Loctite
gear teeth. threadlocker to the capscrew threads before you install
the capscrews. Figure 5.59.
B. Install cotter pins between the lugs of the adjusting ring
and through the boss of the bearing cap. Bend the two
ends of the cotter pin around the boss. Figure 5.59.
C. Use a drift and hammer to install the roll pin through the
boss of the bearing cap until the roll pin is between the
lugs of the adjusting ring. Figure 5.59.

Meritor Maintenance Manual 5L (Revised 02-18) 57

5 Assembly and Installation

D. Install the lock plate onto the bearing cap so that the tab 3. Install the thrust screw into the carrier. Use a feeler gauge to
is between the lugs of the adjusting ring. Install the two verify that the clearance between the thrust screw and the ring
capscrews and washers that hold the lock plate to the gear is 0.025-0.045-inch (0.65-1.14 mm).
bearing cap. Tighten the capscrews to the correct torque
4. Loosen the thrust screw one-half turn or 180 degrees.
value. Refer to Section 8. Figure 5.59.
Figure 5.61.
Figure 5.59

Figure 5.61

CAPSCREW COTTER PIN ROLL PIN

REAR CARRIER EXAMPLE

Loosen thrust screw

1/2 turn.
LOCK
PLATE

THREADED HOLES IN
CAP WHEN LOCK
PLATE IS USED

1002807c

Figure 5.61
1003105e

Figure 5.59 5. Tighten the jam nut, if equipped, to the correct torque value
against the carrier. Refer to Section 8. Figure 5.62.
Installation To complete the assembly of axles equipped with
driver-controlled main differential locks, refer to Section 6.
Thrust Screw (If Equipped)
Figure 5.62

1. Rotate the carrier in the repair stand until the back surface of
the ring gear is toward the TOP. REAR CARRIER EXAMPLE

2. Install the jam nut onto the thrust screw. Thread the jam nut to Hold thrust screw Tighten jam nut to
the middle of the thrust screw. Figure 5.60. in position. correct torque value.

Figure 5.60

REAR CARRIER EXAMPLE

THRUST SCREW
AND JAM NUT

1002808c

Figure 5.62

Air Shift Unit for the Inter-Axle Differential

Lock
1002806c
Air Applied and Spring Release Models, Standard
Figure 5.60
1. Inspect the shift shaft for damage. Use an emery cloth to
remove any small damage. If necessary, replace the shift shaft.
Figure 5.63.

58 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Figure 5.63 NOTE: The adjusting screw is set to the specified distance after the
BOLT-ON input shaft assembly is installed.
IAD
COVER CAPSCREW
ADJUSTING 8. Install the adjusting bolt and the jam nut.
BOLT JAM
NUT SHIFT
SHAFT Spring Applied and Air Release Models (Reverse
SPRING Shift Systems)
COLLAR
1. Lubricate all the parts with axle lubricant. Figure 5.64.

O-RING Figure 5.64

PISTON BOLT-ON IAD REVERSE SHIFTER

O-RING SHIFT
SCREW-IN “E” CLIP CYLINDER
FORK IAD COVER SLOT
SPRING
1002809b

Figure 5.63
COVER
2. Place the spring and the shift fork into position in the carrier.
SMALL
The spring must touch the screw side of the carrier. The boss SHIFT PISTON
SNAP RING
SHAFT O-RING
on the fork must be toward the adjusting bolt. “E” CLIP
O-RING
REMOVED 1002810b
3. Install the shift shaft so the smaller part of the shaft goes
through the fork and the spring. Figure 5.64

4. If removed, install the O-ring onto the piston. Apply axle

2. Inspect the shift shaft for damage. If necessary, replace the
lubricant to the O-ring.
shift shaft.
5. Install the piston onto the shift shaft.
3. If removed, install new O-rings into the groove in the shift
shaft, into the groove in the shift cylinder and onto the piston.
WARNING
When you apply some silicone gasket materials, a small 4. Lubricate the bore of the shift cylinder with axle lubricant.
amount of acid vapor is present. To prevent serious personal 5. Install the piston into the shift cylinder.
injury, ensure that the work area is well-ventilated. Read the
manufacturer’s instructions before using a silicone gasket 6. Insert the shift shaft into the piston and shift cylinder assembly.
material, then carefully follow the instructions. If a silicone 7. Install the small snap ring that fastens the piston onto the shift
gasket material gets into your eyes, follow the manufacturer’s shaft.
emergency procedures. Have your eyes checked by a
physician as soon as possible. 8. Install the spring into the piston bore.
9. Install the gasket so that the tab on the gasket is under the
6. On flange-type cylinders, apply silicone gasket material onto right capscrew bore.
the mounting surface of the cylinder.
10. Place the shift cover onto the shift cylinder housing. Install two
On threaded cylinders, apply a continuous 0.06-inch (1.5 mm) capscrews and washers to fasten the shift cover to the cylinder.
diameter bead of Loctite flange sealant, Meritor part number
2297-D-7076, around the cylinder thread circumference. 11. Install the assembly into the carrier so that the shift shaft is in
the bore of the shift fork.
7. Install the cylinder. On flange-type cylinders, install and tighten
the capscrews 7-12 lb-ft (10-16 N폷m). @ 12. Install the “E” clip onto the shift shaft slot in front of the shift
fork.

Meritor Maintenance Manual 5L (Revised 02-18) 59

5 Assembly and Installation

13. Install the capscrews and washers that fasten the assembly to Figure 5.66

the carrier. Tighten the capscrews to 7-12 lb-ft (10-16 N폷m).

@

NOTE: The adjusting screw is set to the specified distance after the
input shaft assembly is installed. TRIPLE-LIP SEAL
WITHOUT POSETM
14. Install the adjusting bolt and jam nut. FEATURE

Assembly TRIPLE-LIP SEAL

WITH POSETM
FEATURE
1003396b
Input Shaft, Bearing Cage, Oil Pump and
Inter-Axle Differential Figure 5.66

1. Apply axle lubricant to the parts as they are being assembled.

A. Apply axle lubricant to the inner bore of the bearing cage
Figure 5.65.
or the outer diameter of the new oil seal.
Figure 5.65

CAUTION
1 8 Hold the seal only on the outer diameter. Do not touch the lips
9
10 13 15
in the inner diameter of the seal. If you touch the lips on the
5 inner diameter of the seal, you will contaminate the lips and
could cause a leak between the shaft and the seal.

B. Place the oil seal into the bearing cage so that the flange
2 is parallel to the top of the cage.
12 16
3 4 6 7 11 14 C. Use a press and driver or flat metal plate to install the oil
1002811d seal into the bearing cage. Figure 5.67.
1 PRESSURE RELIEF VALVE 9 WASHER
ASSEMBLY 10 CAPSCREWS CAUTION
2 OIL SEAL 11 OIL PUMP — UNITS WITH OIL Do not apply pressure after the seal flange touches the top of
3 BEARING CAGE PUMP
the cage or you will damage the cage.
4 O-RING 12 INPUT SHAFT
5 BEARING CUP 13 THRUST WASHER
6 BEARING CONE 14 HELICAL DRIVE GEAR D. Apply pressure until the metal flange of the seal is seated
7 O-RING 15 INTER-AXLE DIFFERENTIAL to the top of the cage.
8 OIL BAFFLE — UNITS WITHOUT 16 SNAP RING
OIL PUMP E. After the seal is installed, a gap of 0.015-0.030-inch
Figure 5.65 (0.381-0.762 mm) can exist between the flange and the
cage. The gap is a normal condition because of the
2. If removed, install the bearing cup into the input bearing cage. flexible coating on the flange of the seal. Use a feeler
Use a press and a sleeve to install the cup into the cage. The gauge to measure the gap between the complete
cup is correctly installed when the bottom of the cup is fully flange-to-cage area.
seated in the cage bore.
앫 If the gap varies more than 0.010-inch (0.254 mm)
3. If removed, install a new oil seal into the input bearing cage. between the highest and lowest measurement:
Remove and reseat the seal. Figure 5.68.
앫 For unitized pinion seals: Refer to the unitized pinion seal
installation procedure in this section and then proceed to
Step 4. Figure 5.66.
앫 For all other seals: Refer to the following instructions.

60 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Figure 5.67 Figure 5.69

PRESS

SLEEVE

1002540c

Figure 5.67 BEARING

CONE
1002812b
Figure 5.68

Figure 5.69
MEASURING SEAL GAP 0.015-0.03"
(0.381-0.762 MM)

CAUTION
On early design forward carriers, verify that the drive flats in
the bore of the pump are aligned with the flats on the input
shaft. If the flats are not aligned, the pump will be damaged.

1002541c NOTE: If you replace either the bearing cup or cone, replace both
parts in a fully-matched set from the same manufacturer.
Figure 5.68

5. On carriers that use an oil pump, install the input bearing cage
NOTE: If you replace either the bearing cup or cone, replace both and oil pump.
parts in a fully-matched set from the same manufacturer.
A. Position the input shaft so that the threads are toward
4. On carriers that do not use an oil pump, install the input you.
bearing cage. 앫 If dowel pins are used: Install the oil pump onto the
A. If removed, install the bearing cone onto the input shaft. input shaft so that the dowel pin hole in the pump is
Use a press and sleeve to install the cone onto the input toward the threads on the shaft.
shaft until it bottoms on the shoulder of the shaft. 앫 If a drive flat design pump is used: Verify that the
Figure 5.69. drive flats in the bore of the pump are aligned with the
B. Install the O-ring onto the input bearing cage. flats on the input shaft.

C. Place the cage over the input shaft so that the cup in the 앫 If a spline design pump is used: Verify that the
cage is against the bearing cone. splines in the pump are aligned with the splines on the
shaft. Figure 5.70.

CAUTION
When the bearing cone and the oil pumps are installed on the
input shaft, place supports under the input shaft. Do not place
supports under the oil pump. The oil pump will be damaged if
pressure is applied to the body of the pump.

B. Place supports under the input shaft.

Meritor Maintenance Manual 5L (Revised 02-18) 61

5 Assembly and Installation

C. Use a press and a sleeve to install the bearing cone onto Figure 5.71

the input shaft. The cone is correctly installed when the

bottom of the cone touches the shoulder on the shaft.
PRESS
Figure 5.71.
D. If removed, install the pressure relief valve assembly into SLEEVE
the input bearing cage. Install the relief valve, spring and
plug into the bore. Tighten the plug to 20-40 lb-ft BEARING
(27-54 N폷m). Figure 5.72. @ CONE

E. Install the input bearing cage over the input shaft on the OIL
PUMP
oil pump.
앫 If dowel pins are used: Verify that the dowel pins in
the cage are aligned with the holes in the oil pump. 1002543b

F. Install the capscrews that fasten the oil pump to the input
Figure 5.71
bearing cage. Tighten the capscrews to 22-23 lb-ft
(30-31 N폷m). @
Figure 5.72

G. Install the O-rings onto the oil pump and input bearing PLUG
SPRING
cage.

Figure 5.70

OIL RELIEF
PUMP VALVE 1002544b

Figure 5.72
SPLINES

CAUTION
Do not use a Speedi-Sleeve with Meritor triple-lip oil seals.
INPUT The edge of the sleeve will catch and roll the center dust lip
SHAFT
and result in early seal leakage. Damage to components can
1002542b
result.
Figure 5.70
6. Inspect the yoke surface.
앫 If you installed a unitized pinion seal on the output
bearing cage: Refer to the clean and inspect the yoke after
installing a unitized pinion seal procedure in this section
and then proceed to Step 7. Figure 5.66.
앫 For all other seals: Refer to the following instructions.
A. Inspect the yoke for scratches, corrosion or a wear track
from the previous oil seal. Replace the yoke if any of these
conditions exist.

62 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

B. Inspect the lead chamfer of the yoke for nicks and burrs 9. Place the thrust washer into the pilot bore on the end of the
which may damage the sealing tip during installation. helical drive gear. The oil groove in the thrust washer must face
the input shaft flange. Install the helical drive gear and the
C. Wipe clean the yoke sealing surface and face.
thrust washer onto the input shaft so that the thrust washer is
앫 If a yoke POSE™ seal is used: Install the seal toward the input bearing cage. Figure 5.74.
1/2-inch (13 mm) onto the yoke hub. Refer to
procedure in this section. Figure 5.74

CAUTION
Use a press and a sleeve or yoke installation tool to install the
yoke. Do not use a hammer or mallet. Using a hammer or
mallet can damage the bearings, yoke or flange.

7. Use a press and sleeve or an installation tool to install the yoke

or the flange onto the input shaft. If a press and sleeve are
used, verify that the input shaft is well supported. Figure 5.73.
THRUST
If a yoke is removed after it has been partially or fully installed, WASHER 1002814b
the unitized pinion seal will be damaged. Remove and discard
the original unitized pinion seal and replace it with a new one. Figure 5.74

If a yoke has been installed into the unitized pinion seal and 10. If disassembled, assemble the inter-axle differential.
then removed, the inner sleeve of the seal will be damaged.
Install a new seal. A. Apply axle lubricant to all of the inter-axle differential
parts.
B. Install the pinion gears and the thrust washers onto the
Figure 5.73

PRESS
spider.
SLEEVE
C. Place the spider and pinion assembly into one of the case
YOKE, halves of the inter-axle differential.
SHOWN
INPUT
INPUT
D. Install the remaining case half over the case half with the
SHAFT
BEARING spider assembly. Verify that the marks on each case half
CAGE are aligned.
E. Install four of the capscrews that fasten the case halves
together. Install the capscrews so that the capscrews are
the same distance away from each other. Equally tighten
the capscrews to bring the case halves together.
1002813b F. Install the rest of the capscrews. Tighten the capscrews to
45-55 lb-ft (60-75 N폷m). @
Figure 5.73
11. Install the inter-axle differential to the input shaft so that the
8. Install the nut that fastens the yoke or the flange to the input teeth in the differential case are away from the helical drive
shaft. Hand-tighten the nut. Do not tighten the nut to the gear. Install the snap ring that fastens the case to the shaft.
specified torque until the bearing cage and pump assembly is Figure 5.75.
installed into the housing.

Meritor Maintenance Manual 5L (Revised 02-18) 63

5 Assembly and Installation

Figure 5.75 13. If removed, install the bearing cone onto the rear side gear. Use
INPUT a press and sleeve to install the cone onto the gear. The cone is
SNAP SHAFT correctly installed when the bottom of the cone touches the
INTER-AXLE
RING
DIFFERENTIAL shoulder on the side gear.
14. Install the oil screen and plug assembly into the suction line in
front of the carrier. Tighten the screen and plug assembly to
48 lb-ft (65 N폷m). Figure 5.77. @

Figure 5.77

HELICAL
HEADS OF BOLTS FACING
DRIVE
HELICAL DRIVE GEAR,
GEAR
EXCLUDES WELDED CASES 1002815b

Figure 5.75

NOTE: If you replace either the bearing cup or the cone, replace
1002817b
both parts in a fully-matched set from the same manufacturer.
Figure 5.77
12. If removed, install the bearing cup for the rear side gear into
the differential carrier. Use a press and a sleeve to install the
cup into the carrier. If a press is not available, use a sleeve or a
Installation
long, brass drift and a hammer to install the cup. The cup is
correctly installed when the bottom of the cup is seated against
Input Shaft Assembly
the bottom of the bore. Figure 5.76. NOTE: The shim pack under the input bearing cage is installed after
the end play of the input bearing is inspected and adjusted.
Figure 5.76

REAR SIDE GEAR

BEARING CUP 1. Place the differential carrier into a repair stand so that the ring
CARRIER gear is facing DOWN.
INPUT BORE
2. If necessary, place the clutch collar into the differential carrier
so that the teeth on the outside of the collar are toward the
input yoke. Install the clutch collar onto the shift fork so the
tabs of the fork fit into the slot of the clutch collar.
3. Install the rear side gear and bearing assembly through the
clutch collar and into the differential carrier. Figure 5.78.
1002816b

Figure 5.76

NOTE: If you replace either the bearing cup or the cone, replace
both parts in a fully-matched set from the same manufacturer.

64 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Figure 5.78 Figure 5.80

Notches on case must

REAR SIDE be aligned over helical
GEAR
INTER-AXLE driven gear.
DIFFERENTIAL
CASE HELICAL
DRIVEN
GEAR

1002818b

Figure 5.78

4. Verify that the painted alignment marks on the teeth of the

helical gears are visible during the installation of the input shaft
assembly. Figure 5.79.
1002820b
Figure 5.79

Figure 5.80

Figure 5.81

MATCH
MARKS

1002819e

Figure 5.79

5. Install the input shaft assembly into the differential carrier. 1002821b

A. Connect a lifting device to the input yoke. Lift the input Figure 5.81
shaft assembly over the bore in the differential carrier.
B. Lubricate the O-rings with axle oil. Inspection
C. On 160 Series carriers, rotate the inter-axle differential Adjust the Input Bearing End Play
case so that one of the notches on the case is aligned
with the helical driven gear in the carrier. Figure 5.80. 1. Install the capscrews, but not the washers, that fasten the
input bearing cage to the carrier. Rotate the input shaft in each
D. Lower the input shaft assembly into the differential carrier. direction to verify that the bearings are correctly installed while
Figure 5.81. you hand-tighten the capscrews. Do not tighten the capscrews.

Meritor Maintenance Manual 5L (Revised 02-18) 65

5 Assembly and Installation

2. Use a feeler gauge to measure the gap between the input 5. Remove the capscrews that fasten the input bearing cage to
bearing cage and the differential carrier. Inspect the gap at four the carrier.
equally-spaced places on the cage. Figure 5.82.
6. Install the shim pack.
Figure 5.82
A. Connect a lifting device to the input yoke. Lift the input
shaft assembly until there is 0.25-0.50-inch (6-12 mm)
between the cage and carrier mounting surface.
B. Install the shim pack under the bearing cage. Verify that
the hole pattern of the shim pack matches the hole
pattern of the cage. Figure 5.84.
C. Install the capscrews and washers that fasten the cage to
the carrier. Verify that the capscrews are aligned with the
holes in the shim pack. Tighten the capscrews so that the
threads engage in the holes of the carrier.
D. Lower the input shaft assembly so that the cage and the
shim pack are installed against the carrier. Remove the
lifting device from the yoke or flange.
E. Tighten the capscrews to 75-95 lb-ft (100-127 N폷m)
1002574c while rotating the input shaft in each direction to verify
that the bearings are correctly installed. @
Figure 5.82
Figure 5.84

3. Add up the four measurements and determine the average gap

between the cage and the carrier. Add 0.005-inch (0.130 mm)
to the average gap measurement to determine the size of the
shim pack between the cage and the carrier. Figure 5.83.

Figure 5.83

INPUT
BEARING
CAGE

SHIMS
SHIM PACK 1002575c
CONTROLS END
PLAY OF Figure 5.84
INPUT BEARING

7. Apply Loctite 277 threadlocker to the input shaft threads of all

forward carriers prior to installation of the nut. Begin at the top
of the threaded area and allow the Loctite threadlocker to run
1002822b down the length of the threaded area.
8. Place a holding tool onto the input yoke or flange and tighten
Figure 5.83
the nut to the specified torque. Refer to Section 8.
4. Build a shim pack. Use at least three shims when you build a 9. Rotate the yoke at least one full turn after you tighten the yoke
shim pack. Always place the thickest shims in the middle of the nut to the correct torque specification to ensure that the seal
shim pack. seats correctly.

66 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

10. Inspect the end play of the input shaft. 12. On RT-145 carriers that do not use an oil pump, use the
following procedure.
A. Rotate the input shaft in each direction and push the yoke
or flange toward the bearing cage. This ensures that the A. Remove the input shaft assembly from the carrier.
input shaft assembly is at the bottom of its travel.
B. Use a dial indicator with a magnetic base or a C-clamp
WARNING
base to inspect the end play of the input bearing. Verify Take care when you use Loctite adhesive to avoid serious
that the pointer of the dial indicator is against the top of personal injury. Read the manufacturer’s instructions before
the input shaft. Set the dial indicator to ZERO. using this product. Follow the instructions carefully to prevent
Figure 5.85. irritation to the eyes and skin. If Loctite adhesive material
gets into your eyes, follow the manufacturer’s emergency
C. Use a pry bar and a support to push the yoke or the flange procedures. Have your eyes checked by a physician as soon as
away from the carrier. Read the dial indicator. The reading possible.
must be 0.002-0.008-inch (0.050-0.200 mm).
Figure 5.86. B. Spray Loctite Primer N sealant on the cage and carrier
앫 If the end play of the input bearing is not faces around the perimeter of the lube trough hole at the
0.002-0.008-inch (0.050-0.200 mm): Add or two o’clock position. Figure 5.87. Allow the primer to dry
remove shims from the shim pack. Repeat Step 5 three to five minutes.
through Step 9. C. Carefully apply Loctite 518 sealant to the cage and
11. Place the shield for the oil filter onto the bearing cage. carrier faces around the lube trough hole. Avoid allowing
any excess Loctite sealant accumulation in the bearing
Figure 5.85
cage bore. Figure 5.87.
DIAL
INDICATOR D. Use guide studs to install the input shaft and cage
assembly with the appropriate shim pack. Tighten the
capscrews to 95 lb-ft (128 N폷m). @
E. Allow four hours for the Loctite 518 sealant to cure
before returning the vehicle to service.

Figure 5.87

PLATE GUIDE LUBE

STUD TROUGH
LOCATIONS
1002576b

Figure 5.85

Figure 5.86

Apply Loctite®
sealant here.

1002823b

Figure 5.87

1002577b

Figure 5.86

Meritor Maintenance Manual 5L (Revised 02-18) 67

5 Assembly and Installation

Installation 4. Use a press and sleeve to install the outer bearing cup into the
cage over the thru-shaft. Figure 5.90.
Driver-Controlled Main Differential Lock Figure 5.90

Refer to Section 6 for installation procedures. PRESS

SLEEVE
Output Bearings and Thru-Shaft OUTER
1. Apply axle lubricant to bearing cups and cones. Figure 5.88. BEARING
CUP

Figure 5.88 OUTER

BEARING
BEARING CONE
THRU-SHAFT ASSEMBLIES SNAP
RING

OUTPUT CAGE INNER

YOKE BEARING
CUP 1002826d

Figure 5.90
OIL
SPACER SEAL 1002824b 5. Install the snap ring that fastens the outer cup in the cage. The
Figure 5.88 snap ring controls the end play of the output bearing.
Figure 5.91.
NOTE: If you replace either the bearing cup or the cone, replace
Figure 5.91

both parts in a fully-matched set from the same manufacturer.

BEARING
CAGE
2. If the bearing cones were removed from the thru-shaft, install
SNAP
new bearing cones. Place both cones back-to-back onto the RING
thru-shaft. Use a press and sleeve to install both cones. Apply
pressure until the inner cone seats onto the shoulder of the
thru-shaft. Figure 5.89.

Figure 5.89 THRU-SHAFT

END VIEW
PRESS
SLEEVE 1002717b

Figure 5.91

6. Install the snap ring or the yoke-to-cone spacer onto the

THRU-SHAFT thru-shaft until the snap ring touches the outer cone.
7. Inspect and adjust the end play of the thru-shaft bearing.
1002825b

Figure 5.89

3. Use a press and sleeve to install the inner bearing cup into the
cage. Place the thru-shaft and bearing assembly into the cage.

68 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Inspection 앫 If the end play reading is not 0.001-0.004-inch

(0.025-0.102 mm): Remove and replace the snap ring that
Adjust the Output Bearing End Play fastens the bearings in the cage. Install a thinner snap ring
to increase the end play. Install a thicker snap ring to
The output bearing end play is controlled by the size of the snap ring decrease the end play. Figure 5.93.
that holds the bearings in the output cage. The snap rings are
available in increments of 0.003-inch (0.076 mm). Install the snap 7. Remove the nut that fastens the yoke or flange to the
ring which results in an end play of 0.001-0.004-inch thru-shaft. Use the correct puller tool to remove the yoke.
(0.025-0.102 mm).
Figure 5.93

1. Place the thru-shaft and the bearing cage assembly into a vise OUTPUT BEARING END PLAY
with soft metal covers on the jaws of the vise.
SNAP
2. Use an installation tool to install the yoke or flange onto the RING
thru-shaft. Do not use the nut to draw the yoke onto the shaft.
Do not install the oil seal at this time.
3. Install the nut that fastens the yoke or flange to the thru-shaft.
Place a holding tool on the yoke or flange and tighten the nut to
the specified torque. Refer to Section 8.
4. Push the yoke or flange toward the cage and rotate the shaft in
each direction to verify that the bearings are correctly installed.
5. Install a dial indicator so that the base of the indicator is on the To increase end play, install a thinner snap ring.
To decrease end play, install a thicker snap ring.
mounting flange of the cage. The pointer of the indicator must
1002585c
touch the yoke or flange end of the thru-shaft. Set the dial
indicator to ZERO. Figure 5.92. Figure 5.93

Figure 5.92

Installation
Unitized Pinion Seal
1. Remove the old seal. Do not damage the bearing cage seal
surface area. Do not touch or allow dirt or grease to
contaminate the sealing surface areas or the adjacent
bearings.
2. Inspect the bearing cage seal area for damage that could
cause lubricant leaks after you install the seal. Use emery
1002828b paper or an equivalent product to remove scratches, nicks or
burrs only.
Figure 5.92

6. Place pry bars under the yoke or flange and push the yoke or
flange away from the cage. Record the reading on the dial
indicator. The reading must be 0.001-0.004-inch
(0.025-0.102 mm). The reading is the measurement of the
end play on the output bearing.

Meritor Maintenance Manual 5L (Revised 02-18) 69

5 Assembly and Installation

CAUTION
Inspect the axle breather for contaminants, such as dirt,
lubrication or debris, which can cause pressure to build inside
the axle. Damage to the seal and premature seal lip wear can
result. Remove the axle breather. Use a safe cleaning solvent
to clean the inside and outside of the breather.

3. Inspect the axle breather for contaminants, such as dirt,

lubrication or debris.
앫 If you find contaminants in the axle breather: Remove
the axle breather. Use a safe cleaning solvent to clean the
inside and outside of the breather.
4. Remove the replacement unitized seal from the package.
Figure 5.94.

Figure 5.94

4005523a

Figure 5.94

CAUTION
If a yoke is removed after it has been partially or fully installed,
the unitized pinion seal will be damaged. Remove and discard
the original unitized pinion seal and replace it with a new one.

If a yoke has been installed into the unitized pinion seal and
then removed, the inner sleeve of the seal will be damaged.
Install a new seal.

5. Select the correct seal driver from Table L. Each seal driver is
designed to correctly install a specific diameter seal. To
determine the yoke seal diameter, measure the yoke journal. To
obtain the Meritor seal driver KIT 4454, refer to the Service
Notes page on the front inside cover of this manual.

70 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Table L: Unitized Pinion Seals and Seal Drivers*

Seal Service Previous Seal Seal
Single Models Tandem Models Axle Model and Position Part Number Part Number Drivers Sleeve Drivers
MX-21-160 RT-34-144 /P 14X/16X/18X/38X A1-1205X2728 A-1205R2592 2728T1 2728T2
MX-23-160R RT-34-145 /P Forward-Rear Unit Input
(FUI)
RF-16-145 MT-40-143
14X/16X Forward-Rear Unit A1-1205Y2729 A-1205P2590 2729T1 2729T2
RF-21-160 RT-40-145 /A /P Output (FUO)
RF-22-166 RT-40-149 /A /P
14X Rear-Rear Unit Input A1-1205Z2730 A-1205N2588 2730T1 Not Required —
RF-23-185 RT-44-145 /P (RUI) Sleeve is unitized
RS-17-145 RT-40-160 /A /P 16X/18X Rear-Rear Unit A1-1205A2731 A-1205Q2591 2731T1 Not Required —
RS-19-145 RT-40-169 /A /P Input (RUI) Sleeve is unitized

RS-21-145 RT-46-160 /A /P
RS-21-160 RT-46-169 /A /P
RS-23-160 /A RT-46-164EH /P
RS-23-161 /A RT-46-16HEH /P
RS-25-160 /A RT-50-160 /P
RS-23-186 RT-52-185*
RS-26-185 RT-58-185*
RS-30-185
* Forward and rear input only.
Forward input and output seals must be serviced with the seal and sleeve. The service part number provides both when required.

6. Position the driver and seal. Figure 5.95. Figure 5.95

앫 If you use the R4422401 driver tool to install a forward

tandem axle seal: The driver tool outer spokes or fins Position the seal
must fit between the bearing cage bolts. Ensure that the driver to prevent the
driver spokes from
bolts on the bottom of the bearing cage are not in the path hitting the fastener
of the driver spokes. SEAL heads on the
DRIVER forward tandem
앫 If the driver spokes contact the bearing cage bolts: The output seals.
driver will incorrectly install the seal into the bearing cage
SEAL DRIVER
seat and can also result in damage to the driver. The R4422401
reference mark on the driver tool must be in the 12 o’clock FASTENER
HEADS 1003388c
or the 6 o’clock positions when you install the new seal.
Figure 5.95

Meritor Maintenance Manual 5L (Revised 02-18) 71

5 Assembly and Installation

CAUTION
Use a rubber mallet to install the seal. Do not use a steel, brass
or plastic hammer. Using a steel, brass or plastic hammer can
damage the seal and driver tool.

7. Use a rubber mallet to drive the seal into or against the bearing
cage. The seal must fully seat into or against the bearing cage.
Figure 5.96.

Figure 5.96

RUBBER REFERENCE
MALLET MARK

The seal must

be fully seated
in or against
SEAL the bearing cage.
DRIVER
R4422401 1003389d

Figure 5.96

8. Visually inspect the seal to verify that it is seated correctly.

Installing a Multiple-Lip Seal (MLS)

140, 160 and 180 Series Single Drive Axles
140, 160, 180 and 380 Series Tandem Drive Axles
Meritor multiple-lip seals feature a separable sleeve installed onto
the yokes at the tandem forward-rear input and forward-rear output
positions. No sleeve is used on the rear-rear input.
Installation of the new seals requires a set of four seal drivers and
two sleeve drivers. Refer to Table M for part numbers.
Forward input and output seals must be serviced with the seal and
sleeve. The service part number provides both when required.
Check your application carefully before installing the multiple-lip
seal.

72 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Table M: Multiple-Lip Seal (MLS) Seal Drivers and Sleeves Part Numbers
Seal Service Part Previous Seal Part
Axle Model and Position Number Number Seal Drivers Sleeve Drivers
140, 160, 180 and 380 A1-1205X2728 A-1205R2592 2728T1 2728T2
Forward-Rear Unit Input (FUI)
140 and 160 Forward-Rear A1-1205Y2729 A-1205P2590 2729T1 2729T2
Unit Output (FUO)
140 Rear-Rear Unit Input (RUI) A1-1205Z2730 A-1205N2588 2730T1 Not Required —
Sleeve is unitized
160 and 180 Rear-Rear Unit A1-1205A2731 A-1205Q2591 2731T1 Not Required —
Input (RUI) Sleeve is unitized

Special Tools for Installing Multiple-Lip Seals (MLS) 앫 Do not use gasoline, or solvents that contain gasoline.
Gasoline can explode.
There are six new installation drivers required for replacement of the
multiple-lip axle yoke seals. Figure 5.97. To obtain these sleeves, 앫 You must use hot solution tanks or alkaline solutions
seals and drivers, call Meritor’s Commercial Vehicle Aftermarket at correctly. Read the manufacturer’s instructions before
888-725-9355. using hot solution tanks and alkaline solutions. Then
carefully follow the instructions.
앫 A sleeve driver and seal driver for the forward-rear input
앫 A sleeve driver and seal driver for the forward-rear output 1. Clean the ground and polished surface of the yoke journal
using a clean shop towel and a safe cleaning solvent. Do not
앫 Two model specific seal drivers for the rear-rear input
use abrasive cleaners, towels or scrubbers to clean the yoke or
Figure 5.97
flange surface. Do not use gasoline.

2729T1 2730T1
2730T1A 2728T1 2. Inspect the yoke seal area for damage that could cause
lubricant leaks after you install the seal. Use emery paper or an
equivalent product to remove scratches, nicks or burrs only.
2728T2
3. Install the deflector, if equipped, onto the yoke. You must install
the deflector before you install the sleeve into the yoke.
2731T1 Figure 5.98.
2729T2 4005371a

Figure 5.97
Figure 5.98

WARNING
Solvent cleaners can be flammable, poisonous and cause
burns. Examples of solvent cleaners are carbon tetrachloride,
YOKE
and emulsion-type and petroleum-base cleaners. Read the
manufacturer’s instructions before using a solvent cleaner, DEFLECTOR,
then carefully follow the instructions. Also follow the IF EQUIPPED
procedures below. SLEEVE

앫 Wear safe eye protection.

DRIVER 4004889a
앫 Wear clothing that protects your skin.
Figure 5.98
앫 Work in a well-ventilated area.

Meritor Maintenance Manual 5L (Revised 02-18) 73

5 Assembly and Installation

WARNING Figure 5.100

Observe all warnings and cautions provided by the press

manufacturer to avoid damage to components and serious
personal injury.

Do not hit steel parts with a steel hammer. Pieces of a part can YOKE
break off. Serious personal injury and damage to components
can result.

SLEEVE
4. Apply a light coat of axle oil to the yoke seal journal. Position
the sleeve into the forward-rear axle output yoke sleeve driver.
DRIVER
Do not touch the greased areas of the sleeve. The sleeve must End of the yoke
be kept clean prior to assembly into the seal. Use an arbor must bottom out
press and the appropriate driver to install the sleeve into the in the sleeve driver.
yoke. Verify that the sleeve is fully-seated in the yoke to
prevent damage to components. Figure 5.99.
INPUT POSITION:
The yoke must be fully pressed into the sleeve driver until the
0.087" ± 0.030"
end of the yoke bottoms out in the sleeve driver. This will (2.21 MM ± 0.76 MM)
correctly position the sleeve on the yoke. When correctly
seated, the forward-rear output sleeve is positioned 4004990a
0.200-inch ± 0.030-inch (5 mm ± 0.75 mm) from the end of
Figure 5.100
the yoke. Figure 5.100.
앫 If you do not have a press: Position the yoke on a Figure 5.101

five-inch (127 mm) spacer on a workbench. Use a

dead-blow hammer and the appropriate driver to install the
sleeve into the yoke. Figure 5.101.

Figure 5.99

FORWARD REAR OUTPUT

WITHOUT DEFLECTOR
5" (127 MM)
SPACER

4004991a

Figure 5.101

SLEEVE 5. Apply a light coat of axle oil to the yoke seal journal. Position
the sleeve into the forward-rear axle input yoke sleeve driver.
4004874a Do not touch the greased areas of the sleeve. The sleeve must
be kept clean prior to assembly into the seal. Use an arbor
Figure 5.99 press and the appropriate driver to install the sleeve into the
yoke. Verify that the sleeve is fully-seated in the yoke.
Figure 5.102.

74 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

The yoke must be fully pressed into the sleeve driver until the
CAUTION
end of the yoke bottoms out in the sleeve driver. This will
On axles that have the bolt-on deflector on the forward-rear
correctly position the sleeve on the yoke. When correctly
output shaft bearing cage, the deflector must be removed and
seated, the forward-rear input sleeve is positioned 0.030-inch
discarded. The new forward output sleeve will not assemble
± 0.030-inch (0.75 mm ± 0.75 mm) from the end of the yoke.
correctly to the new output seal with the bolt-on deflector in
Figure 5.100.
place. Remove the deflector from the output shaft bearing
앫 If you do not have a press: Position the yoke on a cage and reassemble the output cage hex-head capscrews
five-inch (127 mm) spacer on a workbench. Use a and washers according to the appropriate maintenance
dead-blow hammer and the appropriate driver to install the manual instructions. Damage to components can result.
sleeve into the yoke. Figure 5.101.
7. Install the forward-rear axle output seal. Hold the sleeve and
Figure 5.102

seal only on the outer diameter. Position the seal onto the seal
FORWARD-REAR INPUT
WITH DEFLECTOR driver and align it with the forward-rear axle output shaft. Do
not touch the lips in the inner diameter of the seal. Use a
dead-blow hammer and the appropriate driver to install the
seal onto the output shaft. Figure 5.104.

Figure 5.104

FORWARD-REAR OUTPUT
SLEEVE

4004875a

Figure 5.102

CAUTION
Hold the sleeve and seal only on the outer diameter. Do not
touch the greased inner diameter of the seal and the greased
area of the sleeve. This can contaminate the seal and cause a
leak between the shaft and the seal. Damage to components 4004878a
can result.
Figure 5.104

6. Install the forward-rear axle input seal. Hold the sleeve and
seal only on the outer diameter. Position the seal into the seal 8. Install the rear-rear axle input seal. Hold the seal only on the
driver and align it with the forward-rear axle input bearing outer diameter. Position the seal into the seal driver and align it
cage. Do not touch the lips in the inner diameter of the seal. with the rear-rear axle input bearing cage. Use a dead-blow
Use a dead-blow hammer and the appropriate driver to install hammer and the appropriate driver to install the seal into the
the seal into the bearing cage. Figure 5.103. bearing cage. Figure 5.105.

Figure 5.105
Figure 5.103

FORWARD-REAR INPUT REAR-REAR INPUT

4004879a
4004876a
Figure 5.105
Figure 5.103

Meritor Maintenance Manual 5L (Revised 02-18) 75

5 Assembly and Installation

9. Use a feeler gauge to check the seal gap at all three axle 1. Use a clean shop towel and a safe cleaning solvent to clean the
positions. The seal is correctly installed if the gap is less than ground and polished surface of the yoke journal. Do not use
0.005-inch (0.127 mm) around the circumference of the seal gasoline, abrasive cleaners, towels or scrubbers to clean the
flange. Figure 5.106. yoke. Do not attempt to polish the yoke.
앫 If the gap is more than 0.005-inch (0.127 mm): Use a
NOTE: The unitized seal features a rubber inner sleeve that is
dead-blow hammer and the appropriate driver to
designed to seal and rotate with the yoke. This feature allows you to
completely install the seal.
reuse a yoke with minor grooves.
Figure 5.106

2. Inspect the yoke seal surface for grooves.

앫 If you find grooves on the yoke: Use calipers to measure
the groove diameters. If any groove diameter measures less
than the dimensions shown in Figure 5.107, replace the
yoke.

Figure 5.107

UNITIZED PINION SEAL (UPS)

4004877a

Figure 5.106 A B

Clean and Inspect the Yoke After Installing a

Unitized Pinion Seal Yoke Seal Minimum Yoke Diameter
Diameter at Groove (Inches)
3.000/3.005" 2.990"
WARNING 3.250/3.255" 3.240" 1003390e
Solvent cleaners can be flammable, poisonous and cause
burns. Examples of solvent cleaners are carbon tetrachloride, A MINIMUM GROOVE DEPTH — DIAMETER
and emulsion-type and petroleum-base cleaners. Read the B YOKE SEAL DIAMETER

manufacturer’s instructions before using a solvent cleaner, Figure 5.107

then carefully follow the instructions. Also follow the
procedures below. CAUTION
앫 Wear safe eye protection. Do not install a POSE™ seal after you install a unitized pinion
seal. The use of a POSE™ seal will prevent correct seating of
앫 Wear clothing that protects your skin.
the unitized pinion seal on the yoke and can result in lubricant
앫 Work in a well-ventilated area. leakage at the seal. POSE™ seal installation is recommended
only for triple-lip and other previous design seals.
앫 Do not use gasoline, or solvents that contain gasoline.
Gasoline can explode.
Do not use thin metal wear sleeves to refresh the yoke surface.
앫 You must use hot solution tanks or alkaline solutions Wear sleeves pressed onto the yoke can prevent correct
correctly. Read the manufacturer’s instructions before seating of the pinion seal, damage the pinion seal assembly
using hot solution tanks and alkaline solutions. Then and can cause the seal to leak.
carefully follow the instructions.
3. Before you install the yoke, lightly lubricate or coat the yoke
seal journal with axle oil.

76 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

4. Align the yoke splines with the shaft splines. Slide the yoke NOTE: The POSE™ seal will position itself correctly as the yoke or
over the shaft spline. flange is pressed on the shaft.

Tight Fit Yokes and POSE™ Seal 5. Install the yoke or flange using the correct procedure. The yoke
must be completely seated before you tighten the pinion nut to
1. Apply axle lubricant to the hub of the yoke or flange.
the input shaft.
Figure 5.108.

Figure 5.108
Output Yoke or Flange and Oil Seal for the
Lubricate triple-lip Output Bearing Cage
or main seal.
CAUTION
Hold the seal only on the outer diameter. Do not touch the lips
in the inner diameter of the seal. If you touch the lips on the
INPUT SHAFT inner diameter of the seal, you will contaminate the lips and
OR PINION cause a leak between the shaft and the seal.

Inspect POSETM SEAL,

0.25-0.50" Do not apply pressure after the flange of the seal touches the
yoke (6.4-12.7 MM)
hub. top of the cage or you will damage the seal.
ONTO HUB 1002761b

Figure 5.108 1. Prepare the seal for installation.

A. Apply axle lubricant to the inner bore of the output bearing
2. Verify that the lips of the POSE™ seal and the outer retainer of cage or the outer diameter of the new oil seal.
the triple-lip seal or main seal are clean and free from dirt and
particles that may cause lubricant leakage between the seals. B. Place the oil seal into the cage so that the flange is
parallel to the top of the cage.
3. Install the POSE™ seal onto the hub of the yoke or flange by
hand. The lips of the seal must face toward the end of the hub, C. Use a press and sleeve, or a mallet and sleeve, to install
opposite shoulder. Slide the POSE™ seal onto the hub until the the seal into the cage. The seal is correctly installed when
lips are 0.25-0.50-inch (6.4-12.7 mm) from the end of the the metal flange of the seal seats on the top of the cage.
hub. Do not install the POSE™ seal against the shoulder. Figure 5.110.
Figure 5.109.
NOTE: The gap cannot be measured in the RT-40-145. The seal
Figure 5.109
seats below the lip.
0.25-0.50"
(6.4-12.7 MM) D. After the seal is installed, a gap of 0.015-0.030-inch
(0.381-0.762 mm) can exist between the flange and the
cage. The gap is a normal condition because of the
flexible coating on the flange of the seal. Use a feeler
gauge to measure the gap around the complete
YOKE HUB
flange-to-cage area.
FACE SEAL ASSEMBLY, 앫 If the gap varies more than 0.010-inch (0.254 mm)
POSETM SEAL ELEMENT between the highest and lowest measurement:
1002762a Remove and reseat the seal. Figure 5.111.
Figure 5.109

4. Before you install the yoke or flange onto the shaft, apply axle
lubricant to the hub.

Meritor Maintenance Manual 5L (Revised 02-18) 77

5 Assembly and Installation

Figure 5.110 D. Clean the splines in the yoke or flange and on the
PRESS FLAT METAL thru-shaft.
PLATE
E. Apply axle lubricant to the splines in the yoke or flange
and the thru-shaft.
SLEEVE
OIL 앫 If a POSE™ seal is used: Refer to the tight fit yokes
SEAL and POSE™ seal installation procedure in this section.

CAUTION
Use a press and a sleeve or yoke installation tool to install the
BEARING CAGE
1002829b yoke. Do not use a hammer or mallet. Using a hammer or
mallet can damage the bearings, yoke or flange.
Figure 5.110

If a yoke is removed after it has been partially or fully installed,

Figure 5.111
the unitized pinion seal will be damaged. Remove and discard
MEASURING SEAL GAP 0.015-0.03" the original unitized pinion seal and replace it with a new one.
(0.381-0.762 MM)
If a yoke has been installed into the unitized pinion seal and
then removed, the inner sleeve of the seal will be damaged.
Install a new seal.

3. Use a press and sleeve or an installation tool to install the yoke

1002541c
or flange onto the thru-shaft. Verify that the splines inside the
yoke or flange are aligned with the splines on the thru-shaft. If
Figure 5.111 a press and sleeve are used, verify that the thru-shaft is
supported.
CAUTION 4. Apply a single bead of Loctite 277 adhesive (part number
Do not use a Speedi-Sleeve with Meritor triple-lip oil seals. 1199Y3795) or Loctite 270 adhesive (part number
The edge of the sleeve will catch and roll the center dust lip 2297M5213) at the top of the thru-shaft threads from inboard
and result in early seal leakage. to outboard. The bead should be 0.120-inch wide.
5. Install the nut that fastens the output yoke or flange to the
2. Inspect the yoke surface.
thru-shaft. Place a holding tool on the yoke or flange and
앫 If you installed a unitized pinion seal on the output tighten the nut to the specified torque. Refer to Section 8.
bearing cage: Refer to the clean and inspect the yoke after
6. Rotate the yoke at least one full turn after the yoke nut is
installing a unitized pinion seal procedure in this section
tightened to the correct torque specification. This ensures
and then proceed to Step 3.
correct seating of the seal.
앫 For all other seals: Refer to the instructions below.
A. Inspect the yoke surface for scratches, corrosion or a
wear track from the previous oil seal. Replace the yoke if
any of these conditions exist.
B. Inspect the lead chamfer of the yoke for nicks and burrs
which may damage the sealing lip during installation. Use
an emery cloth to repair nicks and burrs.
C. Wipe clean the yoke sealing surface and face.

78 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Differential Carrier into the Axle Housing CAUTION

Apply silicone gasket material in a continuous 0.25-inch
WARNING (6 mm) bead. If you use more than this amount, gasket
Solvent cleaners can be flammable, poisonous and cause material can break off and plug lubrication passages. Damage
burns. Examples of solvent cleaners are carbon tetrachloride, to components can result.
and emulsion-type and petroleum-base cleaners. Read the
manufacturer’s instructions before using a solvent cleaner, 5. Apply a 0.25-inch (6 mm) continuous bead of silicone gasket
then carefully follow the instructions. Also follow the material to the mounting surface of the housing where the
procedures below. carrier fastens. Figure 5.112.
앫 Wear safe eye protection.
Figure 5.112

앫 Wear clothing that protects your skin.

앫 Work in a well-ventilated area.
앫 Do not use gasoline, or solvents that contain gasoline.
Gasoline can explode.
앫 You must use hot solution tanks or alkaline solutions
correctly. Read the manufacturer’s instructions before
using hot solution tanks and alkaline solutions. Then
0.25" (6 MM)
carefully follow the instructions. DIAMETER SILICONE
GASKET BEAD 4004435a
1. Use a cleaning solvent and rags to clean the inside of the axle
Figure 5.112
housing and the carrier mounting surface. Refer to Section 4.
2. Inspect the axle housing for damage. Repair or replace the axle 6. On an axle with a driver-controlled main differential lock, shift
housing. Refer to Section 4. the lock into and hold the lock in the locked or engaged
3. Check for loose studs, if equipped, in the mounting surface of position. The locked position provides enough clearance
the housing where the carrier fastens. Remove and clean the between the shift collar and the axle housing for carrier
studs that are loose. installation. Refer to Section 6.

4. Install the studs into the axle housing. Refer to procedure in 7. Use a hydraulic roller jack or a lifting tool to install the carrier
this section. Tighten the studs to 150-230 lb-ft into the axle housing. Figure 5.113.
(203-312 N폷m). @
Figure 5.113

WARNING
When you apply some silicone gasket materials, a small
amount of acid vapor is present. To prevent serious personal
injury, ensure that the work area is well-ventilated. Read the
manufacturer’s instructions before using a silicone gasket
material, then carefully follow the instructions. If a silicone
gasket material gets into your eyes, follow the manufacturer’s
emergency procedures. Have your eyes checked by a ROLLER
physician as soon as possible. JACK
1002831d

Figure 5.113

Meritor Maintenance Manual 5L (Revised 02-18) 79

5 Assembly and Installation

WARNING Figure 5.115

Take care when you use Loctite adhesive to avoid serious

personal injury. Read the manufacturer’s instructions before FASTENER

using this product. Follow the instructions carefully to prevent

irritation to the eyes and skin. If Loctiteadhesive material FASTENER,
gets into your eyes, follow the manufacturer’s emergency HIDDEN

procedures. Have your eyes checked by a physician as soon as

possible.

8. Spray the capscrew threads with Loctite sealant. Allow the

primer to dry for three to five minutes.

CAUTION
FASTENERS 1002832b
Do not use a hammer or mallet to install the carrier. A hammer
or mallet will damage the mounting flange of the carrier and Figure 5.115
cause oil leaks.
11. Repeat Step 10 until the four fasteners are tightened to the
NOTE: Nord-Lock washers are reusable, but replace them if they correct torque value.
are leaking.
앫 For fasteners with standard flat washers: Tighten the
9. Install the nuts and washers or the capscrews and washers fasteners to 150-230 lb-ft (204-312 N폷m). @
into the four corner locations around the carrier and the axle 앫 For fasteners with Nord-Lock washers: Tighten the
housing. Hand-tighten the fasteners. Do not tighten to the fasteners to 210 lb-ft (287 N폷m). @
specified torque.
12. Install the remaining fasteners and the washers that hold the
앫 For fasteners with Nord-Lock washers: Install the carrier in the axle housing. Tighten the fasteners to the correct
washers with the radial teeth side facing the carrier. torque value. Refer to Section 8.
Figure 5.114.
13. Install the washers and tighten the capscrews that fasten the
10. Carefully push the carrier into position. Alternately tighten the output bearing cage to the axle housing. Tighten the
four fasteners two or three turns. Figure 5.115. capscrews to 35-50 lb-ft (48-67 N폷m). @
Figure 5.114 14. Adjust the shift fork for the inter-axle differential lock. The
RADIAL movement of the shift fork is controlled by the adjusting screw
TEETH for the air-shift cylinder.
SIDE
A. Loosen the jam nut on the adjusting screw. Loosen the
adjusting screw so that the screw does not touch the shift
shaft. Figure 5.116.
B. Apply and hold 60 psi (413 kPa) of air pressure to the
shift cylinder so that the shift collar engages the splines in
the inter-axle differential case.
CAM C. Verify that the adjusting screw does not touch the shift
SIDE
1003391b shaft when the shift collar engages the inter-axle
differential case.
Figure 5.114
D. Tighten the adjusting screw until the tip of the screw
touches the end of the shift shaft. Release the air
pressure.

80 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

E. When the screw touches the shaft, tighten the adjusting 16. Connect the air lines to the inter-axle differential air cylinder
screw an additional one turn. Apply air pressure, then and, if used, the main differential lock cylinder.
tighten the jam nut. Figure 5.117.
17. On axles with a main differential lock, connect the electrical
F. Disengage the inter-axle differential lock by holding the connector of the sensor unit. Verify that the main differential
input yoke or flange and rotating the output yoke or lock is disengaged.
flange. The output yoke or flange should rotate with less
18. If removed, install the oil filter adapter onto the differential
than 50 lb-ft (67 N폷m) of torque applied. @
carrier. Use Meritor specification 2297-T-4180 adhesive or
G. Apply and hold 60 psi (413 kPa) of air pressure to the equivalent. Refer to Section 4. Tighten the adapter to 40-60
shift cylinder to verify that the shift collar engages the lb-ft (55-80 N폷m). Figure 5.118. @
splines in the inter-axle differential case. When the input
yoke or flange is rotated, the output yoke or flange must CAUTION
rotate. Release the air pressure. If the oil filter is tightened more than 3/4 of a turn after it
H. Apply a rust prevention oil such as Meritor part number contacts the carrier, the oil filter will be damaged and leak
1199-U-1113 or equivalent to the inlet of the air cylinder. fluid. Damage to components can result.

Figure 5.116
19. Apply axle lubricant to the gasket of the new oil filter. Install the
SHIFT
oil filter onto the adapter. When the gasket on the filter
Loosen the jam nut SHAFT contacts the carrier, tighten the oil filter an additional 3/4 of a
and adjusting screw.
turn. If necessary, use an oil filter wrench to tighten the filter.
Figure 5.118.

Figure 5.118

OIL
1002833c FILTER

Figure 5.116 OIL FILTER

ADAPTER

Figure 5.117

Tighten the adjusting

screw one turn after
the screw touches Apply 60 psi (413 kPa)
the end of the shaft. of air pressure here. 1002706b

Figure 5.118

SHIFT
SHAFT 1002834b

Figure 5.117

15. Connect the vehicle driveshafts to the input and the thru yokes
or flanges.

Meritor Maintenance Manual 5L (Revised 02-18) 81

5 Assembly and Installation

Axle Shaft 5. If the wheel hubs have straight hole studs, install the nuts and
washers onto the studs. Figure 5.119. Tighten the nuts to the
WARNING correct torque value. Refer to Section 8.
When you apply some silicone gasket materials, a small 6. Position the gasket between the thru-shaft bearing cage and
amount of acid vapor is present. To prevent serious personal the axle housing.
injury, ensure that the work area is well-ventilated. Read the
manufacturer’s instructions before using a silicone gasket 7. Install the thru-shaft and bearing cage assembly into the axle
material, then carefully follow the instructions. If a silicone housing. Rotate the thru-shaft to align the splines of the
gasket material gets into your eyes, follow the manufacturer’s thru-shaft with the splines of the rear side gear.
emergency procedures. Have your eyes checked by a 8. Clean the cage-to-housing capscrews. Remove RTV residue
physician as soon as possible. from the thru-drilled tapped holes.

Take care when you use Loctite adhesive to avoid serious 9. Apply a 0.25-inch (6 mm) length bead of Loctite 518 sealant
personal injury. Read the manufacturer’s instructions before in the thru-drilled tapped holes located at the two, five and
using this product. Follow the instructions carefully to prevent eight o’clock positions. Figure 5.120.
irritation to the eyes and skin. If Loctiteadhesive material 10. Install the gasket and axle shaft into the housing. The gasket
gets into your eyes, follow the manufacturer’s emergency and flange of the axle shaft must fit flat against the wheel hub.
procedures. Have your eyes checked by a physician as soon as Figure 5.119.
possible.
Figure 5.120

Tapered Dowel, Hardened Washer and Hardened Nut AXLE

HOUSING TAPPED BLIND
1. Clean the mating surfaces of the axle shaft and wheel hub. HOLE THRU-SHAFT
TAPPED
HOLE
CAGE
2. If silicone gasket material is used, apply a 0.125-inch (3 mm)
diameter bead of the gasket material around the mating
surface of the hub and around the edge of each fastener hole.
3. Install the gaskets and axle shafts into the axle housing and
carrier. The gasket and flange of the axle shafts must fit flat
against the wheel hub. Figure 5.119.
4. If the wheel hubs have tapered hole studs, install solid tapered YOKE
dowels onto each stud and onto the flange of the axle shaft. CAPSCREW THRU-DRILLED
THRU-DRILLED TAPPED HOLE
Figure 5.119. TAPPED HOLE 1002836b

Figure 5.119 Figure 5.120

TAPERED DOWEL RETENTION
STUD
STUD WASHER 11. Install solid tapered dowels over each stud and into the flange
NUT GASKET
TAPERED of the axle shaft. Use a punch or a drift and hammer, if
DOWEL
necessary.
12. Install the Grade 8 nuts and hardened washers onto the stud.
Lock washers are an acceptable alternative. Tighten the stud
nuts to the torque specified in Table N.
WASHER
CAPSCREW AXLE SHAFT
SHAFT OR HUB
NON-TAPERED FLANGE AXLE
DOWEL RETENTION 1002581b

Figure 5.119

82 Meritor Maintenance Manual 5L (Revised 02-18)

 5 Assembly and Installation

Table N: Shaft-to-Hub Torque Fastener Chart — Tapered Dowel Figure 5.121

Applications AXLE
HOUSING TAPPED BLIND
Torque Value — Grade 8 Nuts lb-ft HOLE THRU-SHAFT
TAPPED
HOLE
Thread (N폷m) CAGE

Fastener Size Plain Nut Locknut

Stud Nut 0.44-20 50-75 (68-102) 40-65 (54-88)
or Axle 0.50-20 75-115 (102-156) 65-100 (88-136)
Shaft
0.56-18 110-165 (150-224) 100-145 (136-197)
0.62-18 150-230 (204-312) 130-190 (176-258)
Studs All Install the coarse thread end of the stud CAPSCREW
YOKE
THRU-DRILLED
into the hub and tighten to the last thread. THRU-DRILLED TAPPED HOLE
TAPPED HOLE 1002836b

13. Fill the axle with the specified lubricant. Refer to procedure in Figure 5.121
this section.
10. Install the gasket and axle shaft into the housing. The gasket
Straight Holes, Nuts and Hardened Washers
and flange of the axle shaft must fit flat against the wheel hub.
1. Clean the mating surfaces of the axle shaft and wheel hub. Figure 5.119.
2. If silicone gasket material is used, apply a 0.125-inch (3 mm) 11. Install the Grade 8 nuts and hardened washers on the stud.
diameter bead of the gasket material around the mating Lock washers are an acceptable alternative. Tighten the stud
surface of the hub and around the edge of each fastener hole. nuts to the torque specified in Table O.
3. Install the gaskets and axle shafts into the axle housing and 12. Fill the axle with the specified lubricant. Refer to procedure in
carrier. The gasket and flange of the axle shafts must fit flat this section.
against the wheel hub. Figure 5.119.
Table O: Shaft-to-Hub Torque Fastener Chart — Non-Tapered
4. If the wheel hubs have tapered hole studs, install solid tapered
Dowel Applications
dowels onto each stud and onto the flange of the axle shaft.
Figure 5.119. Torque Value — Grade 8 Nuts lb-ft
Thread (N폷m)
5. If the wheel hubs have straight hole studs, install the nuts and
washers on the studs. Tighten the nuts to the correct torque Fastener Size Plain Nut Locknut
value. Refer to Section 8. Stud Nut 0.62-18 150-230 (203-312) 130-190 (176-258)
6. Position the gasket between the thru-shaft bearing cage and or Axle 0.75-16 310-400 (420-542) 270-350 (366-475)
the axle housing. Shaft
Studs All Install the coarse thread end of the stud
7. Install the thru-shaft and bearing cage assembly into the axle
into the hub and tighten to the last thread.
housing. Rotate the thru-shaft to align the splines of the
thru-shaft with the splines of the rear side gear.
Fill the Axle with Lubricant
8. Clean the cage-to-housing capscrews. Remove RTV residue
from the thru-drilled tapped holes. NOTE: For additional lubrication information, refer to Maintenance
 Manual 1, Preventive Maintenance and Lubrication. To obtain this
9. Apply a 0.25-inch (6 mm) length bead of Loctite 518 sealant
in the thru-drilled tapped holes located at the two, five and publication, refer to the Service Notes page on the front inside cover
eight o’clock positions. Figure 5.121. of this manual.

1. Park the vehicle on a level surface. When the angle of the drive
pinion changes, the lubricant capacity of the axle will change.

Meritor Maintenance Manual 5L (Revised 02-18) 83

5 Assembly and Installation

2. Remove the fill plug from the side of the bowl cover of the axle
housing. Figure 5.122.

Figure 5.122

FILL PLUG LOCATION IN BACK

OF AXLE HOUSING BOWL

FILL
PLUG
TEMPERATURE
INDICATOR
PLUG — DO
NOT REMOVE

1002591c

Figure 5.122

3. Fill the axle with lubricant until the lubricant level is to the
bottom of the fill plug hole. Refer to Section 7.
4. Install the fill plug. Tighten the fill plug to 35 lb-ft (47 N폷m).
When correctly installed, one complete thread of the fill plug is
visible between the housing and plug head. @
5. Road test the vehicle in an unloaded condition for one to two
miles (1.6-3.2 km) at speeds not more than 25 mph (40 kmh).
Recheck the lubricant levels and all the fasteners.
6. If used, inspect the operation of the driver-controlled main
differential lock. Refer to Section 6.

84 Meritor Maintenance Manual 5L (Revised 02-18)

 6 Driver-Controlled Main Differential Lock

Hazard Alert Messages The Axle Shafts Were Removed for Towing with the
6 Driver-Controlled Main Differential Lock

Differential in the Unlocked or Disengaged Position

Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent Install the left-hand axle shaft into the housing before continuing.
serious personal injury, damage to components, or both. Perform the following steps for reinstalling the axle shafts into the
axle housing.
WARNING 1. Remove the protective covers, if used, from the wheel-end
To prevent serious eye injury, always wear safe eye protection hubs.
when you perform vehicle maintenance or service.
2. If the drive axles are equipped with a main differential lock,
Description shift the differential to the unlocked or disengaged position.
Install the axle shafts with two sets of splines and new gaskets
Some Meritor drive axle models have a driver-controlled main in the correct location as follows. Figure 5.119.
differential lock (DCDL). This differential lock is operated by a
carrier-mounted, air-actuated shift unit. When activated, the shift A. Push the axle shaft and gasket into the hub and housing
unit moves a sliding collar which is installed on the splines of the until the shaft stops against the differential lock collar.
axle shaft. When engaged, the collar locks the axle shaft to a B. Push down and in on the axle shaft flange and rotate the
second set of splines on the differential case. Both driven wheels shaft until the splines of the shaft and the shift collar are
are then simultaneously engaged. Figure 6.1. engaged.
Figure 6.1 C. Push the axle shaft further into the housing until the shaft
SHIFT stops against the differential side gear.
COLLAR
D. Push down on the axle shaft flange and rotate the shaft
until the splines of the shaft and the side gear are
engaged.
E. Push the axle shaft completely into the housing until the
SHIFT
FORK axle shaft flange and gasket are flush against the wheel
SENSOR
hub.
O-RING
PISTON
CYLINDER Engagement or Lockout of the DCDL
SPRING
CAPSCREW
SHIFT SHAFT MANUAL WARNING
ENGAGING
During DCDL disassembly or carrier removal, when the DCDL is
1002837c
in the locked or engaged position and one of the vehicle’s
Figure 6.1
wheels is raised from the floor, do not start the engine and
engage the transmission. The vehicle can move and cause
Meritor carrier models with driver-controlled differential lock
serious personal injury. Damage to components can result.
equipment are manufactured in metric dimensions and sizes. When
these carriers are serviced, it is important to use the correct metric Park the vehicle on a level surface. Block the wheels to
size tools on the fasteners. Refer to Section 8. prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
Removal jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
Differential Carrier from the Axle Housing
Before the differential carrier can be removed or installed, the Manual Method
differential lock must be shifted into and held in the locked or
engaged position. The locked position gives enough clearance Use the following manual engaging method to shift the DCDL into
between the shift collar and the axle housing to permit the removal the locked position.
or installation of the carrier.

Meritor Maintenance Manual 5L (Revised 02-18) 85

6 Driver-Controlled Main Differential Lock

If an auxiliary air supply is not available or if the differential carrier is 4. Place a jackstand under the left-hand spring seat to hold the
to be stored for later use, use this manual engaging method for the vehicle in the raised position.
DCDL. Figure 6.2 and Figure 6.3.
5. Disconnect the driveline from the input yoke.
Figure 6.2
6. Disconnect the vehicle air line from the inter-axle differential
SCREW-IN DCDL
and main differential lock actuator assemblies.
7. For a bolt-on style differential lock cylinder, remove the plug
and gasket from the hole in the center of the screw-in DCDL
STORAGE cylinder or bolt-on DCDL cover.
HOLE
AIR 8. Remove the manual engaging capscrew from the top storage
HOSE CYLINDER hole in the cylinder cover or the shift tower of the carriers with
the threaded type shift assembly. Figure 6.2 and Figure 6.3.

NOTE: For a bolt-on DCDL shift assembly, the storage hole for the
plug and gasket is the opposite end of the storage hole for the
manual engaging capscrew. Figure 6.3.
MANUAL ENGAGING
CAPSCREW 1002838c
9. Install the plug and gasket into the bottom storage hole in the
Figure 6.2 cylinder cover or in the shift tower.
10. Install the manual engaging capscrew into the threaded hole in
Figure 6.3
the center of the cylinder cover or cylinder.
BOLT-ON DCDL
TOP STORAGE HOLE, CAUTION
FOR MANUAL There will be a small amount of spring resistance felt when
ENGAGING CAPSCREW
AIR LINE you turn in the manual engaging capscrew. If a high resistance
is felt before reaching the locked or engaged position, stop
turning the capscrew, or the cover, fork and capscrew threads
CYLINDER
MANUAL COVER will be damaged.
ENGAGING
CAPSCREW
11. Turn the manual adjusting capscrew to the right until the head
WIRE
is approximately 0.25-inch (6 mm) from the cylinder cover. Do
not turn the capscrew beyond its normal stop.
PLUG AND OPERATING A high resistance on the capscrew indicates that the splines of
GASKET POSITION
BOTTOM HOLE the shift collar and the differential case half are not aligned or
STORAGE
HOLE FOR engaged. To align the splines, use the following procedure.
PLUG AND
GASKET 1002839b A. Rotate the left-hand wheel to align the splines of the shift
collar and case half while you turn in the manual
Figure 6.3 engaging capscrews.

1. Park the vehicle on a level surface. Block the wheels to prevent B. When the normal amount of spring resistance is again felt
the vehicle from moving. on the capscrew, the splines are engaged. Continue to
turn in the manual engaging capscrew until the head is
2. Remove the drain plug from the bottom of the housing and approximately 0.25-inch (6 mm) from the cylinder cover.
drain the lubricant. The capscrew is now in the service position and the main
3. Use a jack to raise the left-hand wheel of the drive axle. differential lock is completely engaged.
12. Remove the carrier from the axle housing. Refer to Section 3.

86 Meritor Maintenance Manual 5L (Revised 02-18)

 6 Driver-Controlled Main Differential Lock

13. Release the differential lock by removing the manual engaging Differential and Gear Assembly and Main
capscrew and seal from the cylinder cover or cylinder. Differential Lock
Auxiliary Air Supply Method Screw-In DCDL Shift Assembly
1. Park the vehicle on a level surface. Block the wheels to prevent The current design shift fork does not employ roll pins. Nubs on the
the vehicle from moving. inner face of the fork hold the shift collar in place. Figure 6.4.
2. Use a jack to raise the left-hand wheel of the drive axle. Place a
safety stand under the left-hand axle housing leg to support the Figure 6.4

vehicle in the raised position.

3. Remove the drain plug from the bottom of the housing and
NUBS
drain the lubricant.
4. Disconnect the driveline from the input yoke.
5. Disconnect the vehicle air line from the inter-axle differential
and main differential lock actuator assemblies.
6. Install a suitable air line coupling into the main differential
actuator assembly. 1002840b

7. Install the air line into the coupling. Figure 6.4

CAUTION 1. Verify that the differential lock is released and the engaging
When you use an auxiliary air supply to engage the DCDL, you capscrew and seal are removed from the shift cylinder.
must supply air to the DCDL until you remove the carrier. Do
2. Tap the shift collar with a rubber mallet to loosen and remove
not disconnect the air line or reduce air pressure to the DCDL
the collar from the shift fork. Figure 6.5.
before you remove the carrier from the housing. Damage to
components can result. Figure 6.5

8. Supply 120 psi (827 kPa) regulated air pressure through the air
line.
9. Verify that the DCDL is engaged.
10. Remove the carrier from the axle housing. Refer to Section 3.
11. Shut-off the air supply to the DCDL.
12. Disconnect the air line from the main differential actuator
assembly coupling. SHIFT
SHIFT
COLLAR
FORK 1002841b

Figure 6.5

3. Remove the differential lock sensor switch, if used, and jam nut
from the carrier. Figure 6.6.

Meritor Maintenance Manual 5L (Revised 02-18) 87

6 Driver-Controlled Main Differential Lock

Figure 6.6 6. Carefully remove the O-ring from the piston. Use a thin pointed
tool to remove the O-ring. Do not damage the piston.
Figure 6.9.

Figure 6.9

1002842b

Figure 6.6

1002845b
4. Remove the shift cylinder and piston assembly from the carrier
by turning it to the left. Figure 6.7. Figure 6.9

Figure 6.7

7. Inspect the O-ring for any damage such as cracks, cuts or

breaks.
앫 If the O-ring is damaged: Replace it with a new O-ring
when you assemble the components.
8. Clean and inspect all shift assembly parts. Refer to Section 4.
9. Pull the shift shaft from the fork and out of the carrier.
Figure 6.10.

Figure 6.10

1002843b
SHIFT
Figure 6.7 FORK

5. Place the shift cylinder and piston assembly in a vise that has
brass covers over the jaws. Remove the piston and O-ring from
inside the cylinder. Use a narrow drift through the hole in the
top of the cylinder to push out the piston. It may be necessary
to use a mallet to tap out the piston. Figure 6.8. DCDL
CASTING
Figure 6.8

SHIFT
SHAFT 1002846b

Figure 6.10
DRIFT

10. Remove the shift shaft spring and fork from the carrier.
Figure 6.11.

1002844b

Figure 6.8

88 Meritor Maintenance Manual 5L (Revised 02-18)

 6 Driver-Controlled Main Differential Lock

Figure 6.11
Bolt-On DCDL Shift Assembly
SHIFT 1. To remove the differential lock sliding shift collar, tap out the
SHAFT
SPRING two retainer roll pins until they are level with the inner face of
the shift fork. Figure 6.13.

Figure 6.13

FORK

1002847b
ROLL PINS — TAP
Figure 6.11 UNTIL EVEN WITH
INNER FACE OF
SHIFT FORK
11. If roll pins are used, use a hammer and brass drift to remove
the roll pins for the adjusting rings on the bearing caps. If
1002849d
capscrews or cotter pins are used, remove the capscrews or
cotter pins. Figure 6.13

12. Remove the bearing cap capscrews and washers, the bearing
2. If required, remove the differential lock shift unit.
caps and adjusting rings. Match mark one bearing cap and one
carrier leg so that these parts will be assembled in the correct A. Remove the sensor switch and jam nut.
positions.
B. Remove the four capscrews and washers that hold the
13. Lift the differential and gear assembly from the carrier. cylinder cover. Remove the cover. On the 160 Series,
Figure 6.12. remove the copper gasket. Figure 6.14.
Further disassembly of these carriers is the same as axles C. Remove the shift cylinder and piston.
without the driver-controlled main differential lock. To continue
D. Remove the shift shaft from the shift fork. It may be
disassembly, follow the procedures in Section 3.
necessary to use heat to separate the shaft from the fork
Figure 6.12
to loosen it.

NOTE: Some models use silastic seal instead of the flat washer in
Step E. Also, a roll pin is installed in the shift shaft and is used as a
stop for the shift shaft spring. It is not necessary to remove this roll
pin during a normal disassembly.

E. Remove the shift shaft spring and flat washer.

F. Remove the shift fork and continue with Step 11 in the
1002848a previous procedure.
Figure 6.12

Meritor Maintenance Manual 5L (Revised 02-18) 89

6 Driver-Controlled Main Differential Lock

Figure 6.14 Figure 6.15

SHIFT SHAFT
AND SPRING ELECTRIC
CONNECTION
FOR SENSOR

CAPSCREW AND
WASHER, FOUR
CORNERS COVER, COPPER CYLINDER
GASKET UNDER
COVER — 160
SERIES ONLY 1002850b
SHIFT
Figure 6.14 FORK

Installation
4005499b

Differential Shift Assembly

SCREW-IN STYLE WITH O-RING

WARNING Figure 6.15

When you apply some silicone gasket materials, a small

amount of acid vapor is present. To prevent serious personal Figure 6.16

injury, ensure that the work area is well-ventilated. Read the

manufacturer’s instructions before using a silicone gasket
material, then carefully follow the instructions. If a silicone
gasket material gets into your eyes, follow the manufacturer’s SHIFT SHAFT
AND SPRING
emergency procedures. Have your eyes checked by a
physician as soon as possible. ELECTRIC
CONNECTION
FOR SENSOR
Take care when you use Loctite adhesive to avoid serious
personal injury. Read the manufacturer’s instructions before
using this product. Follow the instructions carefully to prevent
CYLINDER
irritation to the eyes and skin. If Loctite adhesive material
gets into your eyes, follow the manufacturer’s emergency
procedures. Have your eyes checked by a physician as soon as
possible. SHIFT
FORK

Screw-In DCDL Shift Assembly

Install the differential shift assembly after the differential carrier is
assembled and the gear and bearing adjustments are made. The
4005500b
screw-in DCDL shift assembly is shown in Figure 6.15 and
Figure 6.16. SCREW-IN STYLE WITH BONDED LIP SEAL PISTON
Figure 6.16

90 Meritor Maintenance Manual 5L (Revised 02-18)

 6 Driver-Controlled Main Differential Lock

1. Install the shift fork into the shift of the carrier. The “L” shape of Figure 6.19

the fork and the bore for the shift shaft must face out toward
SHIFT
the cylinder bore in the side of the carrier. Figure 6.17. FORK

Figure 6.17

SHIFT
SHAFT 1002854b

Figure 6.19

“L” SHAPE
OF FORK FACE 5. If required, lubricate a new O-ring with axle lubricant. Install
OUT 1002852b
the O-ring into the piston groove.
Figure 6.17 6. Install the piston and O-ring assembly into the shift cylinder,
bevel end first. Push on the piston until it is against the bottom
2. Compress the shift shaft spring as required and install it of the cylinder. Figure 6.20.
between the back of the fork and carrier wall inside the carrier.
Figure 6.18. Figure 6.20

Figure 6.18 BEVEL

END
SHIFT SHAFT
SPRING

SHIFT
CYLINDER

1002855b

Figure 6.20

7. Apply a continuous 0.06-inch (1.5 mm) diameter bead of

INSTALL SPRING
BEHIND FORK 1002853b
Loctite flange sealant, Meritor part number 2297-D-7076,
around the DCDL cylinder threads.
Figure 6.18
8. Turn the shift cylinder and piston assembly to the right until it
bottoms in the carrier casting bore. Figure 6.21.
3. Align the spring and bore in the shift fork with the shift shaft
bore in the carrier.
4. Install the shift shaft through the bore in the carrier, fork and
spring until it is against the shift fork. Figure 6.19.

Meritor Maintenance Manual 5L (Revised 02-18) 91

6 Driver-Controlled Main Differential Lock

Figure 6.21 Figure 6.23

SCREW-IN
DCDL SHIFT
CYLINDER

1002856b

Figure 6.21
MANUAL
ENGAGING CAPSCREW 1002858b
9. Position the shift collar over the fork. The large splines of the
collar must face toward the main differential. Use a rubber Figure 6.23
mallet to tap the shift collar through the nubs of the shift fork.
Figure 6.22. 11. Turn the manual adjusting capscrew to the right until the head
is approximately 0.25-inch (6 mm) from the cylinder cover. Do
Figure 6.22
not turn the capscrew beyond its normal stop. The capscrew is
now in the service position and the main differential lock is
LARGE SPLINES completely engaged.
OF MAIN
DIFFERENTIAL NOTE: The differential must be in the locked position to install the
CASE
axle shaft into the axle housing.

12. With the shift collar in the locked position, install the sensor
switch into the threaded hole in the front of the carrier.
Figure 6.24.

Figure 6.24

NUBS OF
SHIFT FORK 1002857b

Figure 6.22

10. Engage the splines of the collar with the splines of the
differential case. Insert the manual engaging capscrew through
the top of the shift cylinder to move the shift collar toward the
differential case. Rotate the collar as necessary to align the
splines. Figure 6.23.
1002842b

Figure 6.24

13. Connect a volt-ohm meter to the sensor switch. Select ohms

on the meter. With the DCDL engaged, the circuit should be
closed, showing less than one ohm resistance. If the resistance
is over one ohm, check the sensor.

92 Meritor Maintenance Manual 5L (Revised 02-18)

 6 Driver-Controlled Main Differential Lock

A. Verify that the fork is aligned with the sensor switch when Figure 6.26

it is in the engaged position. SHIFT

FORK
B. Check for a loose wiring connection. The connector must ROLL PIN
be tightly seated.
C. Verify that the sensor switch is fully seated against the
carrier.
앫 If the resistance is greater than one ohm after INNER
these checks: Replace the sensor switch. YOKE FACES

Bolt-On DCDL Shift Assembly

1002861b
Install the differential shift assembly after the differential carrier is
assembled and the gear and bearing adjustments are made. The Figure 6.26
bolt-on type shift assembly is shown in Figure 6.25.
2. If the spring stop roll pin was removed from the head of the
Figure 6.25

shift shaft, reinstall the pin at this time.

BOLT-ON DCDL
3. On models without roll pins, snap the fork into position.
2
1
3 4. Apply Loctite 222 threadlocker, Meritor part number
2297-B-6112, to the threads of the shift shaft.
5 4
5. Install the shift fork into its correct position in the carrier case.
6
13 Figure 6.27.
7
Figure 6.27

9
10

11
12
1002860b

1 FLAT WASHER OR SILASTIC AS 7 DISENGAGED

REQUIRED 8 ENGAGED
2 CYLINDER 9 COPPER GASKET
3 ELECTRIC CONNECTION FOR 10 PIN
SENSOR 11 SHIFT FORK 1002862b
4 AIR LINE 12 COLLAR
5 O-RING 13 SHIFT SHAFT AND SPRING Figure 6.27
6 PISTON
Figure 6.25 6. Hold the shift fork in position. Install the shift shaft spring into
the shift shaft opening in the carrier, through the shift fork bore
1. On carrier models with shift fork roll pins, install the two roll and into the bore for the shift shaft spring. Figure 6.28.
pins into the ends of the shift fork. Tap the pins into position
until they are level with the inner yoke face. Figure 6.26. Do
not install completely at this time.

Meritor Maintenance Manual 5L (Revised 02-18) 93

6 Driver-Controlled Main Differential Lock

Figure 6.28 Figure 6.30

Apply Loctite® 222 CYLINDER

AND
threadlocker. BOLT-ON STYLE
PISTON
PILOT
SPRING
JOURNAL

SHIFT SHAFT SHIFT

SHAFT

1002863b 1002865b

Figure 6.28 Figure 6.30

7. Slide the shift shaft over the spring. Install the shaft into the 11. Install the copper gasket, if used, into its bore on the inside of
shift fork. Tighten it to 20-25 lb-ft (27-34 N폷m). @ the cylinder cover. Place the cover into position over the
cylinder so that the air intake port will point up when the carrier
8. Install the copper gasket or apply silastic sealant, Meritor part
is installed into the housing. Install the cover with the four
number 1199-Q-2981, to the bottom of the cylinder bore.
attaching capscrews and washers. Tighten the capscrews to
Figure 6.29.
4-6 lb-ft (5.5-8.5 N폷m). Figure 6.31. @
Figure 6.29

Figure 6.31

AIR
CYLINDER CYLINDER
BOLT-ON STYLE COVER

PISTON AND
O-RING CAPSCREW
4-6 LB-FT
(5.5-8.5 N•m)

SHIFT
SHAFT

APPLY SILASTIC
Install flat washer
SEALANT
or apply silastic sealant. 1002864b
1002866b
Figure 6.29
Figure 6.31

9. Lubricate the O-ring with axle lubricant. Install the O-ring into
12. Apply a bead of silastic sealant, Meritor part number
its groove on the piston. Carefully install the piston into the air
cylinder. Figure 6.29. Do not damage the O-ring. 1199-Q-2981, to the cylinder housing joint.
13. Slide the shift collar into the fork and engage the shift collar
10. Install the cylinder into the housing bore. Verify that the pilot
splines with the splines of the differential case. Use the manual
journal on the piston is against its bore on the shift shaft.
Figure 6.30. actuation capscrew to move the shift collar splines onto the
differential case splines. Refer to Section 6 in this section.
14. Hold the shift collar in the locked or engaged position and tap
in the two roll pins in the shift fork ends until they are even with
the outer yoke faces. Figure 6.32.

94 Meritor Maintenance Manual 5L (Revised 02-18)

 6 Driver-Controlled Main Differential Lock

Figure 6.32 2. Apply silicone gasket material to the cover plate mounting
BOLT-ON STYLE surface on the carrier. Refer to Section 4.
MANUAL
SHIFT ACTUATION 3. Install the four washers and capscrews. Tighten the capscrews
COLLAR CAPSCREW
to 7.4-8.9 lb-ft (10-12 N폷m). Figure 6.33. @
SHIFT
FORK
Screw-In DCDL Cover Plate Assemblies
1. Apply Loctite 518 liquid adhesive to the plate threads.
2. Install the bolts and washers and tighten the plate into the
carrier opening to 7.5-9.0 lb-ft (10-12 N폷m). @

1002867b Differential Carrier Into the Forward Axle

Figure 6.32
Housing
WARNING
15. While the shift collar is still in the locked position, place the
Solvent cleaners can be flammable, poisonous and cause
sensor switch, with the locknut loosely attached, into its hole.
burns. Examples of solvent cleaners are carbon tetrachloride,
16. Connect a volt-ohm meter to the sensor switch. Select ohms and emulsion-type and petroleum-base cleaners. Read the
on the meter. Rotate the switch CLOCKWISE until the meter manufacturer’s instructions before using a solvent cleaner,
reading changes from infinity to less than one ohm. Turn the then carefully follow the instructions. Also follow the
switch one additional turn and tighten the locknut to procedures below.
25-35 lb-ft (35-45 N폷m). @
앫 Wear safe eye protection.
Differential Lock Assembly Cover Plates 앫 Wear clothing that protects your skin.
For carriers without the differential lock or air shift, assemble the 앫 Work in a well-ventilated area.
sensor switch plug and cover plate as follows.
앫 Do not use gasoline, or solvents that contain gasoline.
Bolt-On DCDL Cover Plate Assemblies Gasoline can explode.

1. Install the washer and plug into the hole for the sensor switch. 앫 You must use hot solution tanks or alkaline solutions
Tighten the plug from 45-55 lb-ft (60-74 N폷m). Figure 6.33. correctly. Read the manufacturer’s instructions before
@ using hot solution tanks and alkaline solutions. Then
carefully follow the instructions.
Figure 6.33

SCREW-IN COVER PLATE NOTE: When you install the carrier into the axle housing, the shift
(APPLY LOCTITE® 518
LIQUID ADHESIVE TO collar must be held in the engaged position. This can be done by
COVER PLATE THREADS) keeping the air pressure applied to the shift cylinder by using the
manual engaging capscrew. Refer to the procedure in this section.
WASHER WASHER The differential must be in the locked or engaged position to install
the carrier assembly into the axle housing. After you install the
carrier into the axle housing, shift the differential into the unlocked
SENSOR CAPSCREW or disengaged position to permit the installation of the left-hand axle
SWITCH shaft.
PLUG BOLT-ON COVER
PLATE (APPLY
SILICONE GASKET Manual Method
MATERIAL)
1. Use a cleaning solvent and rags to clean the inside of the axle
1002868b
housing and the carrier mounting surface. Refer to Section 4.
Figure 6.33

Meritor Maintenance Manual 5L (Revised 02-18) 95

6 Driver-Controlled Main Differential Lock

2. Check the axle housing for damage. If necessary, repair or Figure 6.34

replace the housing. Refer to Section 4. TOP STORAGE HOLE FOR

MANUAL ENGAGING
3. Check for loose studs in the carrier mounting surface. Remove CAPSCREW BOLT-ON DCDL
SHIFT ASSEMBLY
and replace the studs where required. Apply liquid adhesive to
MANUAL
the holes. Install and tighten the stud to 150-230 lb-ft ENGAGING AIR
(204-312 N폷m). @ CAPSCREW LINE

4. The differential lock must be manually engaged before PLUG

CYLINDER
AND
installing the differential carrier into the housing. Refer to the GASKET COVER
procedure in this section.
5. Install the differential carrier into the housing. Refer to Section WIRE
5.
6. Install and tighten the carrier-to-housing capscrews to the BOTTOM STORAGE SERVICE
HOLE FOR PLUG POSITION
specified torque. AND GASKET CAPSCREW
HOLE 1002869b
7. Install the right- and left-hand axle shafts. Refer to Section 5.
Figure 6.34
NOTE: When the manual engaging capscrew is removed from the
service position in the center of the DCDL actuator, the main Figure 6.35

differential lock is disengaged. SCREW-IN DCDL SHIFT ASSEMBLY

8. Remove the long manual engaging capscrew from the center

STORAGE
of either the bolt-on or screw-in DCDL. HOLE
9. Clean the plug, gasket, cylinder cover and threaded service CYLINDER
position hole in the center of the bolt-on DCDL cylinder cover,
or in the center of the screw-in DCDL.
10. Verify that the sealing gasket is under the head of the
capscrew. MANUAL
ENGAGING
11. Install the manual engaging capscrew into the DCDL storage AIR CAPSCREW
HOSE 1002870b
hole in the bolt-on or the screw-in DCDL assembly. Figure 6.34
and Figure 6.35. Figure 6.35

A. On a bolt-on DCDL shift assembly, remove the short plug

and gasket from the storage hole of the DCDL. 12. Tighten the plug to 44-55 lb-ft (60-75 N폷m). Tighten the
manual engaging capscrew to 22-28 lb-ft (30-38 N폷m) for
Install the short plug and gasket into the service position bolt-on DCDL style cylinders and to 7-11 lb-ft (10-15 N폷m) for
hole in the center of the DCDL. Figure 6.34. screw-in DCDL type reverse shifters. @
B. On a screw-in DCDL shift assembly, install the short 13. Connect the vehicle air line to the differential lock actuator
screw or plug into the storage hole located in the top of assembly.
the screw-in DCDL shift assembly. Figure 6.35.
14. Install the electrical connection on the sensor switch located in
the carrier, below the actuator assembly.
15. Remove the jackstand from under the drive axle. Lower the
vehicle to the floor.
16. Fill the axle with lubricant. Refer to Section 7.

96 Meritor Maintenance Manual 5L (Revised 02-18)

 6 Driver-Controlled Main Differential Lock

17. Proceed to procedure in this section to check the differential Check the Differential Lock
lock.
1. Shift the vehicle transmission into neutral. Start the engine to
Auxiliary Air Supply Method get the system air pressure to the normal level.
1. Use a cleaning solvent and rags to clean the inside of the axle
housing and the carrier mounting surface. Refer to Section 4. WARNING
During DCDL disassembly, when the DCDL is in the locked or
2. Check the axle housing for damage. If necessary, repair or engaged position and one of the vehicle’s wheels is raised
replace the housing. Refer to Section 4. from the floor, do not start the engine and engage the
3. Check for loose studs in the carrier mounting surface. Remove transmission. The vehicle can move and cause serious
and replace the studs where required. Apply liquid adhesive to personal injury and damage to components.
the holes. Install and tighten the stud to 150-230 lb-ft
(204-312 N폷m). @ 2. Place the differential lock switch in the cab of the vehicle in the
unlocked or disengaged position.
4. Connect an air line to the main differential lock actuator
assembly coupling. 3. Drive the vehicle at 5-10 mph (8-16 km/h) and check the
differential lock indicator light. The light must be off when the
5. Supply 120 psi (827 kPa) regulated air pressure through the air switch is in the unlocked or disengaged position.
line.
4. Continue to drive the vehicle and place the differential lock
6. Verify that the DCDL engaged. switch in the locked or engaged position. Let up on the
7. Install the differential carrier into the housing. Refer to Section accelerator to remove the driveline torque and permit the shift.
5. The light must be on when the switch is in the locked position.

8. Install and tighten the carrier-to-housing capscrews to the 앫 If the indicator light remains ON with the switch in the
specified torque. unlocked position: The differential is still in the locked
position. Verify that the manual engaging capscrew was
9. Install the right- and left-hand axle shafts. Refer to Section 5. removed from the cylinder cover of the DCDL shift
10. Remove the air line coupling from the main differential actuator assembly. Refer to the procedure in this section.
assembly.
11. Clean the plug, gasket, cylinder cover and threaded service DCDL Driver Caution Alert Label
position hole in the center of the bolt-on DCDL cylinder cover, Verify that the driver caution label is installed in the vehicle cab.
or in the center of the screw-in DCDL. Figure 6.36. The caution label must be placed in a location that is
12. Tighten the plug to 44-55 lb-ft (60-75 N폷m). Tighten the easily visible to the driver. The recommended location is on the
manual engaging capscrew to 22-28 lb-ft (30-38 N폷m) for instrument panel, next to the differential lock switch and lock
bolt-on DCDL style cylinders and to 7-11 lb-ft (10-15 N폷m) for indicator light.
screw-in DCDL type reverse shifters. @
Figure 6.36

13. Connect the vehicle air line to the differential lock actuator
assembly. This vehicle is equipped with Meritor’s driver-controlled, full-locking
differential (DCDL).
• Engage DCDL only under poor road conditions.
14. Install the electrical connection onto the sensor switch located • Do not engage DCDL during downhill operation.
in the carrier, below the actuator assembly. • Do not engage DCDL or operate the vehicle at speeds above 25 mph.
When DCDL is engaged, an “understeer” condition can occur when
making turns, so operate the vehicle carefully. When you disengage
15. Remove the jackstand from under the drive axle. Lower the DCDL, normal steering resumes.
Refer to the vehicle manufacturer’s manual or Meritor technical
vehicle to the floor. bulletin TP-9579. To obtain this bulletin, visit Literature on Demand at
meritor.com or call 866-OnTrac1 (668-7221).
16. Fill the axle with lubricant. Refer to Section 7. TP-9579ALBL (04-06)

4008262a
17. Proceed to the procedure in this section to check the
differential lock. Figure 6.36

Meritor Maintenance Manual 5L (Revised 02-18) 97

6 Driver-Controlled Main Differential Lock

Driver Instruction Information Available

Refer to the Service Notes page on the front inside cover of this
manual to obtain the following publications
앫 DCDL Caution Alert Label/Order part number TP9579ALBL.
앫 DCDL Driver Instruction Kit/Contains a compilation of technical
bulletins covering DCDL and inter-axle differential (IAD)
operation; the DCDL Caution alert label; and instructions to
prepare an axle for towing or new vehicle drive-away
(piggybacking). Order part number TP9579.
앫 Traction Controls for Drive Axles DVD/Order part number
SP03105.

98 Meritor Maintenance Manual 5L (Revised 02-18)

 7 Lubrication

Specifications
7 Lubrication

Meritor recommends using a lubricant analysis program. Perform

lubricant analysis at regularly-scheduled preventive maintenance
intervals.
For complete information on lubricating drive axles and carriers as
well as lubricant capacities, refer to Maintenance Manual 1,
Preventive Maintenance and Lubrication. To obtain this publication,
refer to the Service Notes page on the front inside cover of this
manual.
Refer to Table P and Table Q for standard information on lubricants
and schedules.

Table P: Lubricant Cross Reference (Viscosity) and Temperature Chart

Meritor
Lubricant Minimum Outside Maximum Outside
Specification Description Cross Reference Temperature Temperature
O-76-A Hypoid Gear Oil GL-5, S.A.E. 85W/140 +10°F (–12.2°C) *
O-76-B Hypoid Gear Oil GL-5, S.A.E. 80W/140 –15°F (–26.1°C) *
O-76-D Hypoid Gear Oil GL-5, S.A.E. 80W/90 –15°F (–26.1°C) *
O-76-E Hypoid Gear Oil GL-5, S.A.E. 75W/90 –40°F (–40°C) *
O-76-J Hypoid Gear Oil GL-5, S.A.E. 75W –40°F (–40°C) +35°F (+1.6°C)
O-76-L Hypoid Gear Oil GL-5, S.A.E. 75W/140 –40°F (–40°C) *
*There is no upper limit on these outside temperatures, but the axle sump temperature must never exceed 250°F (+121°C).

Meritor Maintenance Manual 5L (Revised 02-18) 99

7 Lubrication

Table Q: Oil Change Intervals and Specifications for All Rear Drive Axles
Construction, Transit Bus,
City Delivery, School Refuse, Yard Tractor, Logging,
Vocation or Bus, Fire Truck, Heavy Haul, Mining, Oil Field,
Vehicle Operation Linehaul Intercity Coach Motorhome Rescue
Initial Oil Change Not required Not required Not required Not required
Check Oil Level Every 25,000 miles Every 25,000 miles Every 10,000 miles Every 5,000 miles (8000 km),
Add the correct type (40 000 km), or the (40 000 km), or the (16 000 km), once a once a month, or the fleet
and amount of oil as fleet maintenance fleet maintenance month, or the fleet maintenance interval, whichever
required. interval, whichever interval, whichever maintenance interval, comes first1
comes first comes first whichever comes first
Petroleum-Based Every 100,000 Every 100,000 miles Every 50,000 miles Every 25,000 miles (40 000 km)
Oil miles (160 000 km) (160 000 km) or (80 000 km) or annually, or annually, whichever comes
Change on axles or annually, annually, whichever whichever comes first first
with or without a whichever comes comes first
pump and filter first
system.
Synthetic Oil Every 500,000 Every 250,000 miles Every 250,000 miles Every 100,000 miles
Change on axles miles (800 000 km), (400 000 km), or every (400 000 km), or every 3 (160 000 km), or every 2 years,
with or without a or every 4 years, 4 years, whichever years, whichever comes whichever comes first3
pump and filter whichever comes comes first first
system.2 first

Filter Change Every 100,000 Every 100,000 miles Every 100,000 miles Every 100,000 miles
Change on axles miles (160 000 km) (160 000 km) (160 000 km) (160 000 km)
with a pump and
filter system.
1
For continuous heavy-duty operation, check the oil level every 1,000 miles (1600 km).
2
This interval applies to approved semi-synthetic and full-synthetic oils only. For a list of approved extended-drain axle oils, refer to TP-9539, Approved Rear
Drive Axle Lubricants. To obtain this publication, refer to the Service Notes page on the front inside cover of this manual.
3
The change interval for transit bus can be increased to 150,000 miles (241 401 km) or three years, whichever comes first, contingent upon the following
three conditions. 폷 Documentation verifies a 10% fleet oil sampling with results that are below the guidelines specified in Maintenance Manual 1, Preventive
Maintenance and Lubrication. To obtain this publication, refer to the Service Notes page on the front inside cover of this manual. 폷 There is a minimum of six
magnets in the housing. Meritor 61163/71163 drive axles come standard with six magnets in the housing. 폷 Approved extended-drain interval lubricants are
used according to TP-9539, Approved Rear Drive Axle Lubricants. (Drive axles excluded are RC-26-633/634 and RC-26/27-720.)

100 Meritor Maintenance Manual 5L (Revised 02-18)

 8 Specifications

8 Specifications

Figure 8.1

1
2

23

6 26

3 4

11C
11A
13
12
10 11B
14
11C
9
24
25

15

19
18 16
20
17

RADIAL
11C TEETH SIDE
(OUTSIDE)
22

Only Models:
21 RT-40-160 RT-46-164EH
RT-40-169 RT-46-169 CAM SIDE
RT-46-160 RT-46-16HEH (INSIDE)

1002872c

Figure 8.1

Meritor Maintenance Manual 5L (Revised 02-18) 101

8 Specifications

Table R: Torque Specifications

Axle Torque
Item Description Application Size Lb-Ft N폷m
1 Output Yoke-to-Thru-Shaft Nut Refer to Table S, Table T or Table U
2 Output Bearing Cage-to-Carrier Capscrew All 0.38"-16 35-50 47-68
3 Drain and Fill Plugs* All 0.75"-14 35 Min. 47.5 Min.
4 Bearing Cap-to-Carrier Capscrew 140 and 145 M20 x 2.5 320-400 430-540
160 M22 x 2.5 480-600 650-810
5 Main Differential Case Halves Capscrew 140 and 145 M12 x 1.75 105-125 143-168
Class 12.9
Std. Hex Head
140 and 145 M12 x 1.75 75-95 100-127
Class 10.9
160 M16 x 2.0 220-310 300-420
Class 12.9
Std. Hex Head
6 Ring Gear-to-Case Nut and Bolt 180 and 380 0.87-14 600-700 816-952
145 M16 x 1.5 160-210 220-290
Class 10
Std. Hex Head
160 M16 x 1.5 196-262 265-355
Class 12
Std. Hex Head
7 Oil Pump-to-Input Bearing Cage Capscrew 145 and 160 M8 x 1.25 22-33 30-45
8 Pressure Relief Valve Plug 145 and 160 M16 x 1.5 20-40 27-54
9 Input Bearing Cage-to-Carrier Capscrew All M12 x 1.75 75-105 100-145
(Hex Capscrew
with Washer)
M12 x 1.75 100-120 135-163
(Flanged
Capscrew)
10 Input Yoke-to-Input Shaft Nut Refer to Table S, Table T or Table U
11A Differential Carrier-to-Axle Housing Nut All 5/8"-18 150-230 203-312
11B Differential Carrier-to-Axle Housing Capscrew All — Standard 5/8"-11 150-230 203-312
or Nylon
Fasteners

102 Meritor Maintenance Manual 5L (Revised 02-18)

 8 Specifications

Axle Torque
Item Description Application Size Lb-Ft N폷m
11C Nord-Lock Washer RT-40-160 — 210 285
RT-40-169
RT-46-160
RT-46-164EH
RT-46-169
RT-46-16HEH
12 Air Shift Cylinder-to-Carrier Capscrew — All M6 x 1.0 7-12 10-16
Inter-Axle Differential
13 Air Shift Adjusting Screw Jam Nut — All M12 x 1.5 40-55 55-75
Inter-Axle Differential
14 Oil Filter Adapter-to-Carrier 145 and 160 M22 x 2.5 40-60 55-80
15 Main Differential Lock Cover-to-Carrier All M6 x 1.0 7-12 10-16
Capscrew
16 Manual Actuation Plug — Main Differential All M10 x 1.5 15-25 20-35
Lock
17 Cover Capscrew — Axles without Main All M6 x 1.0 7-12 10-16
Differential Lock
— Air Line-to-Main Differential Lock Cover All M12 x 1.5 22-30 30-40
Adapter
18 Main Differential Lock Sensor Jam Nut All M16 x 1.0 25-35 35-45
19 Plug — Axles without Main Differential Lock All M16 x 1.0 45-55 60-75
Sensor
20 Carrier Oil Screen and Plug Assembly All M26 x 1.5 48 Min. 65 Min.
21 Drive Pinion Nut All M50 x 2.0 1200-1500 1625-2035
22 Drive Pinion Cover-to-Carrier Capscrew All M10 x 1.5 35-50 48-68
23 Breather Vent All 3/8"-18 20 Min. 27 Min.
— Heat Indicator Plug All 1/2"-14 25 Min. 34 Min.
— Axle Shaft-to-Wheel Hub Capscrew All 1/2"-13 85-115 115-156
— Axle Shaft-to-Wheel Hub Nut All Plain Nut 75-115 102-156
1/2"-20 150-230 203-312
5/8"-18
Locknut 65-100 88-136
1/2"-20 130-190 176-258
5/8"-18
— Inter-Axle Differential Case Half All M10 x 1.5 45-55 60-75
— Stud-to-Carrier All 5/8" x 11 150-230 203-312

Meritor Maintenance Manual 5L (Revised 02-18) 103

8 Specifications

Axle Torque
Item Description Application Size Lb-Ft N폷m
— Axle Shaft Stud Nut All Plain Nut 310-400 420-542
3/4"-16
Locknut 270-350 366-475
3/4"-16
24 Screw-In DCDL Assembly Housing Current DCDL M60 x 2.0 80-100 109-136
Option
25 Screw-In DCDL Plug or Cap Non-DCDL M60 x 2.0 80-100 109-136
Options
26 Adjusting Rings Capscrews 145 and 160 — 21-28 28-38
*Minimum torque. Tighten until one thread is visible.

Input and Output Yoke Pinion Nut Fastener Torque Specifications

Table S: Single Axles
Axle Model
Pinion Nut RS-120, RS-125, RS-160, RS-161, RS-210, RS-220,
Location RS-140 RS-145 RS-185, RS-186 RS-230 RS-240 RS-380
Carrier 740-920 lb-ft 920-1130 lb-ft 1000-1230 lb-ft 740-920 lb-ft 740-920 lb-ft 800-1100 lb-ft
Input Yoke (1000-1245 N폷m) (1250-1535 N폷m) (1350-1670 N폷m) (1000-1245 N폷m) (1000-1245 N폷m) (1085-1496 N폷m)
Fastener M32 X 1.5 M39 X 1.5 M45 X 1.5 M32 X 1.5 M39 X 1.5 1-1/2 - 12 UNF
Size

Table T: Tandem Axles

Axle Model
Pinion Nut RT-160, RT-164, RT-380 Without
Location RT-140 RT-145, RT-149 RT-169 RT-185 RT-380 With IAD IAD
First Carrier 750-850 lb-ft 750-850 lb-ft 750-850 lb-ft 750-850 lb-ft 750-850 lb-ft 900-1200 lb-ft
Input Yoke* (1020-1150 N폷m) (1020-1150 N폷m) (1020-1150 N폷m) (1020-1150 N폷m) (1020-1150 N폷m) (1224-1632 N폷m)
Fastener M45 X 1.5 M45 X 1.5 M45 X 1.5 1-3/4 - 12 UN 1-3/4 - 12 UN 1-3/4 - 12 UN
Size
First Carrier 600-700 lb-ft 600-700 lb-ft 600-700 lb-ft 600-700 lb-ft 600-700 lb-ft 600-700 lb-ft
Output Yoke* (815-950 N폷m) (815-950 N폷m) (815-950 N폷m) (815-950 N폷m) (815-950 N폷m) (815-950 N폷m)
Fastener M32 X 1.5 M39 X 1.5 M39 X 1.5 1-1/2 - 12 UNF 1-1/2 - 12 UNF 1-1/2 - 12 UNF
Size
Second 740-920 lb-ft 920-1130 lb-ft 1000-1230 lb-ft 1000-1230 lb-ft 800-1100 lb-ft 800-1100 lb-ft
Carrier Input (1000-1245 N폷m) (1250-1535 N폷m) (1350-1670 N폷m) (1350-1670 N폷m) (1085-1496 N폷m) (1085-1496 N폷m)
Yoke*
Fastener M32 X 1.5 M39 X 1.5 M45 X 1.5 M45 X 1.5 1-1/2 - 12 UNF 1-1/2 - 12 UNF
Size
*Apply Loctite 277 threadlocker to the input shaft threads before installing the nut.

104 Meritor Maintenance Manual 5L (Revised 02-18)

 8 Specifications

Table U: Tridem Axles

Axle Model
Pinion Nut
Location RZ-164 RZ-166 RZ-186 RZ-188
First Carrier Input 600-800 lb-ft 750-850 lb-ft 750-850 lb-ft 750-850 lb-ft
Yoke (815-1085 N폷m) (1020-1150 N폷m) (1020-1150 N폷m) (1020-1150 N폷m)
Fastener Size M45 X 1.5 M45 X 1.5 1-3/4 - 12 UN 1-3/4 - 12 UN
First Carrier 450-650 lb-ft 600-700 lb-ft 600-700 lb-ft 600-700 lb-ft
Output Yoke (610-880 N폷m) (815-950 N폷m) (815-950 N폷m) (815-950 N폷m)
Fastener Size M39 X 1.5 M39 X 1.5 1-1/2 - 12 UNF 1-1/2 - 12 UNF
Second Carrier 600-800 lb-ft 750-850 lb-ft 750-850 lb-ft 750-850 lb-ft
Input Yoke (815-1085 N폷m) (1020-1150 N폷m) (1020-1150 N폷m) (1020-1150 N폷m)
Fastener Size M45 X 1.5 M45 X 1.5 M45 X 1.5 1-3/4 - 12 UN
Second Carrier 450-650 lb-ft 600-700 lb-ft 600-700 lb-ft 600-700 lb-ft
Output Yoke (610-880 N폷m) (815-950 N폷m) (815-950 N폷m) (815-950 N폷m)
Fastener Size M39 X 1.5 M39 X 1.5 M39 X 1.5 1-1/2 - 12 UNF
Third Carrier 920-1130 lb-ft 1000-1230 lb-ft 1000-1230 lb-ft 1000-1230 lb-ft
Input Yoke (1250-1535 N폷m) (1350-1670 N폷m) (1350-1670 N폷m) (1350-1670 N폷m)
Fastener Size M39 X 1.5 M45 X 1.5 M45 X 1.5 M45 X 1.5

Meritor Maintenance Manual 5L (Revised 02-18) 105

9 Adjustment

Hazard Alert Messages

9 Adjustment

Table V: Drive Pinion Bearings — Preload

Specification New bearings
5-45 lb-in (0.56-5.08 N폷m)
Used bearings in good condition
10-30 lb-in (1.13-3.39 N폷m)
Adjustment Preload is controlled by the thickness of the spacer between bearing cones.
To increase preload, install a thinner spacer.
To decrease preload, install a thicker spacer.

Table W: Drive Pinion — Depth in Carrier

Specification Install the correct amount of shims between the inner bearing cup of the drive pinion and the
carrier. To calculate, use the old shim pack thickness and the new and old pinion cone numbers.
Adjustment Change the thickness of the shim pack to get a good gear tooth contact pattern.

Table X: Hypoid Gear Set — Tooth Contact Patterns (Hand Rolled)

Specification Toward the toe of the gear tooth and in the center between the top and bottom of the tooth.
Adjustment Tooth contact patterns are controlled by the thickness of the shim pack between the inner bearing
cone of the drive pinion and the carrier and by ring gear backlash.
To move the contact pattern lower, increase the thickness of the shim pack between the inner
bearing cup of the drive pinion and the carrier.
To move the contact pattern higher, decrease the thickness of the shim pack between the inner
bearing cup of the drive pinion and the carrier.
To move the contact pattern toward the toe of the tooth, decrease backlash of the ring gear.
To move the contact pattern toward the heel of the tooth, increase backlash of the ring gear.

Table Y: Main Differential Bearings — Preload

Specification 15-35 lb-in (1.7-3.9 N폷m)
or
Expansion between bearing caps
140 and 145 Series — 0.003-0.009-inch (0.08-0.22 mm)
160 Series — 0.006-0.013-inch (0.15-0.33 mm)
Adjustment Preload is controlled by tightening both adjusting rings after zero end play is reached.

Table Z: Main Differential Gears — Rotating Resistance

Specification 50 lb-ft (68 N폷m) maximum torque applied to one side gear

106 Meritor Maintenance Manual 5L (Revised 02-18)

 9 Adjustment

Table AA: Input Shaft End Play Adjustment

End Play of the Input Shaft 0.002-0.008-inch (0.050-0.200 mm)

Table AB: Output Bearing — End Play and Preload

Specification 0.001-0.004-inch (0.025-0.102 mm) bearing end play
Adjustment End play is controlled by the size of the snap ring in the output bearing cage.
Increase end play by installing a thinner snap ring.
Decrease end play by installing a thicker snap ring.

NOTE: If the end play on the output bearing measures ZERO, a thinner snap ring is required.

Table AC: Ring Gear — Backlash

Specification 145 Series:
Range: 0.008-0.018-inch (0.20-0.460 mm)
Backlash setting for new gear sets: 0.012-inch (0.300 mm)
160 Series:
Range: 0.010-0.020-inch (0.25-0.510 mm)
Backlash setting for new gear sets: 0.012-inch (0.300 mm)
Adjustment Backlash is controlled by the position of the ring gear. Change backlash within specifications to
get a good tooth contact pattern.
To increase backlash, move the ring gear away from the drive pinion.
To decrease backlash, move the ring gear toward the drive pinion.

Table AD: Ring Gear — Runout

Specification 0.008-inch (0.200 mm) maximum

Table AE: Sensor Switch — Installation (Carriers with Differential Lock Only)
Adjustment Shift the differential to the locked position.
Tighten the sensor switch into the carrier until the test light illuminates.
Tighten the sensor switch one additional turn.
Tighten the jam nut to the specified torque.

Meritor Maintenance Manual 5L (Revised 02-18) 107

10 Special Tools

Specifications
10 Special Tools

Carrier Repair Stand

Figure 10.1

1 2
12

11
3

10
4

9 5

SPX Kent-Moore
8
part number J-3409-D
1002990f

1 PLATES 8′ LONG x 3/4″ THICK x 1-1/4″ WIDE WITH A TONGUE TO FIT SLOT IN BAR WELD PLATES TO BAR
2 HANDLE 7″ LONG WITH SLOT IN ONE END TO FIT CLAMP SCREW
3 BAR 2″ DIAMETER x 9″ LONG WITH ONE END SLOTTED TO FIT PLATE
4 WELD ALL AROUND AFTER PRESSING PLUG IN PIPE
5 WELD
6 SHAPE AND SIZE OF HOLES TO FIT CARRIER
7 23-1/2″ CENTER TO CENTER OF PIPE
8 CHAMFER END OF PIPE FOR WELDING
9 4″ DIAMETER PIPE
10 PLUG 4″ DIAMETER x 7″ LONG WITH ONE END TURNED 3″ LONG TO FIT PIPE. DRILL 2″ HOLE AND MILL 3/16″ WIDE SLOT 2″ FROM TOP
11 SCREW 3-1/2″ LONG x 5/8″ DIAMETER WITH FLATS ON END TO FIT HANDLE AND 2-1/2″ LENGTH OF THREAD ON OTHER END
12 DRILL 3/8″ HOLE THROUGH HANDLE AND SCREW
Figure 10.1

To obtain a repair stand, refer to the Service Notes page on the front
inside cover of this manual.

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 10 Special Tools

How to Make a Yoke Bar 앫 To increase yoke bar rigidity: Weld two angle pieces onto
the handle. Figure 10.3.
1. Measure dimensions A and B of the yoke you are servicing.
Figure 10.2.
How to Make a Drive Flange Retainer Tool
Figure 10.2 1. Obtain a 1/4-inch thick piece of flat steel.
A 2. Cut and drill the plate using the dimensions in Figure 10.4.

YOKE 1003459b

Figure 10.2

2. Calculate dimensions C and D of the yoke bar by adding

0.125-0.250-inch to dimensions A and B of the yoke.
Figure 10.3.

Figure 10.3

YOKE BAR

C
1003460b

Figure 10.3

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

3. To make the box section, cut and weld one-inch x two-inch

mild steel square stock according to dimensions C and D.
Figure 10.3.
4. Cut a four-foot x 1.25-inch piece of mild steel round stock to
make the yoke bar handle. Center weld this piece to the box
section. Figure 10.3.

Meritor Maintenance Manual 5L (Revised 02-18) 109

10 Special Tools

Figure 10.4

180 MM

61.43 MM 61.43 MM
26.99 MM

28.57 MM 28.57 MM
43.01 MM

110 MM
140 MM

43.01 MM
15 MM

26.99 MM

4011995a

Figure 10.4

WARNING Figure 10.5

Wear safe clothing and eye protection when you use welding
equipment. Welding equipment can burn you and cause Position the seal
serious personal injury. Follow the operating instructions and driver to prevent the
driver spokes from
safety procedures recommended by the welding equipment hitting the fastener
manufacturer. SEAL heads on the
DRIVER forward tandem
output seals.
3. Cut a 4-foot x 1.25-inch piece of mild steel round stock to
make the handle. Center weld the handle to the flat plate SEAL DRIVER
section. Weld two angle pieces to the plate to increase the R4422401
FASTENER
rigidity as shown in Figure 10.3. HEADS 1003388c

Figure 10.5
Unitized Pinion Seals and Seal Drivers
Refer to Table AF and Figure 10.5 for information on unitized pinion
seals and seal drivers. To obtain Meritor seal driver KIT 4454, refer
to the Service Notes page on the front inside cover of this manual.

110 Meritor Maintenance Manual 5L (Revised 02-18)

 10 Special Tools

Table AF: Unitized Pinion Seals and Seal Drivers*

Tandem Axle Model and Seal Service Previous Seal Sleeve
Single Models Models Position Part Number Part Number Seal Drivers Drivers
MX-21-160 RT-34-144 /P 14X/16X/18X/38X A1-1205X2728 A-1205R2592 2728T1 2728T2
MX-23-160R RT-34-145 /P Forward-Rear Unit
Input (FUI)
RF-16-145 MT-40-143
14X/16X A1-1205Y2729 A-1205P2590 2729T1 2729T2
RF-21-160 RT-40-145 /A /P Forward-Rear Unit
RF-22-166 RT-40-149 /A /P Output (FUO)
RF-23-185 RT-44-145 /P 14X Rear-Rear Unit A1-1205Z2730 A-1205N2588 2730T1 Not Required
RS-17-145 RT-40-160 /A /P Input (RUI) — Sleeve is
unitized
RS-19-145 RT-40-169 /A /P
16X/18X Rear-Rear A1-1205A2731 A-1205Q2591 2731T1 Not Required
RS-21-145 RT-46-160 /A /P
Unit Input (RUI) — Sleeve is
RS-21-160 RT-46-169 /A /P unitized
RS-23-160 /A RT-46-164EH /P
RS-23-161 /A RT-46-16HEH /P
RS-25-160 /A RT-50-160 /P
RS-23-186 RT-52-185*
RS-26-185 RT-58-185*
RS-30-185
*Forward and rear input only.

Forward input and output seals must be serviced with the seal and
sleeve. The service part number provides both when required.

Meritor Maintenance Manual 5L (Revised 02-18) 111

11 Vehicle Towing Instructions

Hazard Alert Messages When transporting a vehicle with the wheels of one or both drive
11 Vehicle Towing Instructions

axles on the road, it is possible to damage the axles if the wrong

Read and observe all Warning and Caution hazard alert messages in procedure is used before transporting begins. Meritor recommends
this publication. They provide information that can help prevent that you use the following procedure.
serious personal injury, damage to components, or both.

WARNING
Type of Axle
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Forward Tandem Axle, with Driver-Controlled
Main Differential Lock (DCDL — Screw-In
Park the vehicle on a level surface. Block the wheels to DCDL Shift Assembly) and with Inter-Axle
prevent the vehicle from moving. Support the vehicle with Differential (IAD)
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and Before Towing or Drive-Away
damage to components can result. 1. Apply the vehicle parking brakes using the switch inside the
cab of the vehicle.
Before you service a spring chamber, carefully follow the
manufacturer’s instructions to compress and lock the spring to 2. Shift the transmission into neutral and start the vehicle’s
completely release the brake. Verify that no air pressure engine.
remains in the service chamber before you proceed. Sudden 3. Shift the DCDL to the unlocked or disengaged position using
release of compressed air can cause serious personal injury the switch inside the cab of the vehicle. The DCDL indicator
and damage to components. light in the cab will go off. Shift the IAD to the unlocked or
disengaged position using the switch inside the cab of the
Engage the parking brake to prevent the vehicle from moving vehicle. The IAD indicator light in the cab will go off, if
before you begin maintenance or service procedures that equipped.
require you to be under the vehicle. Serious personal injury
can result. 4. Stop the engine.
5. Refer to and identify which axle shafts must be removed based
CAUTION on how the vehicle will be towed.
If the vehicle is equipped with a front drive axle, tow the
Table AG
vehicle from the front, with the front wheels off the ground. If
this is not possible, you must remove the front drive shaft Single Axles
before towing. Damage to components can result. Remove both axle shafts.

Do not use a chisel or wedge to loosen the axle shaft and Tandem Axles
tapered dowels. A chisel or wedge can result in damage to the Forward Axle (Towing from Front):
axle shaft, the gasket and seal, and the axle hub. No need to remove axle shafts.

NOTE: For complete towing information, refer to Technical Bulletin Forward Axle (Towing from Rear):
TP-9579, Driver Instruction Kit. To obtain this publication, refer to Remove both axle shafts.
the Service Notes page on the front inside cover of this manual. Rear Axle (Towing from Front):

These instructions supersede all other instructions for the purpose Remove both axle shafts.
of transporting vehicles for service or new vehicle drive-away dated Rear Axle (Towing from Rear):
before April 1995, including those contained in Meritor maintenance No need to remove axle shafts.
manuals.

112 Meritor Maintenance Manual 5L (Revised 02-18)

 11 Vehicle Towing Instructions

6. On axles equipped with a DCDL, the shift collar splines must be Figure 11.2

engaged with the differential case splines before removing the MANUAL THREADED
axle shaft. Engage the DCDL shift collar using the Manual ENGAGING SHIFT ASSEMBLY
Engaging Method as follows. CAPSCREW

CAUTION
On single and tandem rear axles equipped with a DCDL, when
removing the curb-side (right) axle shaft, the DCDL shift collar
splines must be engaged with the differential case splines.
The collar splines must be completely engaged with the
differential case splines. This must be done to prevent the shift 4007977a
collar from dropping out of position when removing the axle
Figure 11.2
shaft. Cage (engage) the shift collar with the differential case
before removing the axle shaft or damage to components can
result. CAUTION
When you turn the capscrew in Step D and you feel a high
A. Disconnect the air hose from the shift cylinder. resistance, STOP TURNING THE CAPSCREW. A high resistance
Figure 11.1. against the capscrew indicates that the splines of the shift
collar and differential case are not aligned. Damage to the
Figure 11.1
threads of the cylinder and capscrew will result. To align the
THREADED splines, continue with Steps D and F.
STORAGE SHIFT ASSEMBLY
HOLE D. Turn the capscrew to the right until the head is
approximately 0.25- to 0.50-inch (6.4 to 12.7 mm) from
SHIFT the cylinder. The capscrew is now in the service position
CYLINDER TOWER
and the DCDL shift collar is locked (engaged).
Figure 11.3. When turning the capscrew you will feel a
small amount of resistance. This is normal. If you feel a
MANUAL ENGAGING high resistance before achieving the 0.25- to 0.50-inch
AIR HOSE CAPSCREW 4007979a distance between the capscrew head and cylinder, STOP
Figure 11.1
TURNING THE CAPSCREW and continue with Steps E and
F.
B. Remove the manual engaging capscrew from the storage
Figure 11.3

hole. The storage hole of threaded shift assemblies is

located in the shift tower of the carrier, next to the
cylinder. Figure 11.1.
0.25-0.50"
C. Install the manual engaging capscrew into the threaded (6.4-12.7 mm)
hole in the center of the cylinder. Figure 11.2.

CYLINDER
4007978a

Figure 11.3

Meritor Maintenance Manual 5L (Revised 02-18) 113

11 Vehicle Towing Instructions

E. Raise the tire and wheel (DCDL axle side) off of the floor NOTE: If an air supply will be used for the brake system of the
(leave the opposite tire and wheel on the floor) and transported vehicle, continue with Steps 13 and 14, otherwise
support the axle with jack stands. Slowly rotate the wheel continue with Step 15.
of the DCDL axle shaft that is to be removed by hand.
13. Connect an auxiliary air supply to the brake system of the
F. Verify that the clutch collar is engaged by attempting to
vehicle that is being transported. Before moving the vehicle,
rotate the elevated wheel. If it does not rotate, the collar is
charge the brake system with the correct amount of air
successfully caged. The axle shaft can now be removed.
pressure to operate the brakes. Refer to the instructions
앫 If you still feel a high resistance: Stop turning the supplied by the manufacturer of the vehicle for procedures and
capscrew, disassemble and inspect components for specifications. If an auxiliary air supply is not used, continue
damage and wear. Replace as necessary. with Step 15.
7. Identify each axle shaft to be removed from the axle assembly 14. When the correct amount of air pressure is in the brake
so they can be installed in the same location after transporting system, release the parking brakes of the vehicle that is being
or repair is completed. (Example: Match mark a mating axle transported. Step 15 is not required.
shaft and hub.)
8. Remove the stud nuts or capscrews and the washers from the
WARNING
flange of the axle shaft. Figure 11.4. When you work on a spring chamber, carefully follow the
service instructions of the chamber manufacturer. Sudden
Figure 11.4
release of a compressed spring can cause serious personal
TAPERED DOWEL RETENTION
injury.
STUD
STUD WASHER 15. If there are spring or parking brakes on the axle(s) that will
NUT GASKET
TAPERED
DOWEL
remain on the road when the vehicle is transported, and they
cannot be released by air pressure, manually compress and
lock each spring so that the brakes are released. Refer to the
manufacturer’s instructions.

After Towing or Drive-Away

WASHER
CAPSCREW 1. If an auxiliary air supply was used, apply the vehicle parking
AXLE SHAFT
SHAFT OR HUB brakes using the switch inside the cab of the vehicle. If an
NON-TAPERED FLANGE AXLE auxiliary air supply was not used, begin with Step 2.
DOWEL RETENTION 1002581b

Figure 11.4 WARNING

When you work on a spring chamber, carefully follow the
9. Loosen the tapered dowels, if used, in the flange of the axle service instructions of the chamber manufacturer. Sudden
shaft. Refer to Section 3 for the recommended tools and release of a compressed spring can cause serious personal
removal procedures. Figure 11.4. injury.

10. Remove the tapered dowels, the axle shafts and gaskets, if 2. Apply the vehicle spring or parking brakes by manually
used. Figure 11.4. releasing each spring that was compressed before transporting
11. Remove the remaining axle shaft(s) as necessary from the started. Refer to the manufacturer’s instructions.
axle(s) that will remain on the road when the vehicle is 3. Disconnect the auxiliary air supply, if used, from the brake
transported according to Table AG. system of the vehicle that was transported. Connect the
12. Install a cover over the open end of each hub where an axle vehicle’s air supply to the brake system.
shaft was removed. This will prevent dirt from entering the 4. Remove the covers from the hubs.
bearing cavity and minimize loss of lubricant.

114 Meritor Maintenance Manual 5L (Revised 02-18)

 11 Vehicle Towing Instructions

5. Install the axle shaft(s) indicated in Table AH. Axle shafts with a Figure 11.5

DCDL have a double row of splines that engage with the SINGLE AXLE OR REAR AXLE OF TANDEM SHOWN
splines of the side gear and shift collar in the differential case. WITH SCREW-IN DCDL SHIFT ASSEMBLY AND
SHOWN IN THE LOCKED OR ENGAGED POSITION
Figure 11.5. Continue with Step 6.

Table AH
Single Axles
Remove both axle shafts.
Tandem Axles 2
Forward Axle (Towing from Front):
No need to remove axle shafts. 1

Forward Axle (Towing from Rear): 3

Remove both axle shafts. 4

Rear Axle (Towing from Front):
Remove both axle shafts.
Rear Axle (Towing from Rear): 5

No need to remove axle shafts.

6

8
1002609b

1 LEFT-HAND, ROADSIDE, AXLE SHAFT

2 SHIFT ASSEMBLY
3 SHIFT COLLAR
4 RIGHT-HAND, CURBSIDE, AXLE SHAFT
5 DOUBLE ROW OF SPLINES
6 SHIFT COLLAR AND DIFFERENTIAL CASE SPLINES ENGAGED OR LOCKED
7 SIDE GEAR
8 DIFFERENTIAL CASE
Figure 11.5

NOTE: Make sure to engage the axle shaft splines for the
differential side gear and the shift collar. They must be fully
engaged.

6. Install the gasket, if used, and axle shaft into the axle housing
and carrier in the same location. The gasket and 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 11.4.
7. Install the dowels, if used, over each stud and into the tapered
holes of the flange.

Meritor Maintenance Manual 5L (Revised 02-18) 115

11 Vehicle Towing Instructions

8. Install the washers and capscrews or stud nuts. Determine the 2. Shift the transmission into neutral and start the vehicle’s
size of the fasteners and tighten the capscrews or nuts to the engine.
corresponding torque value shown in Table AI.
3. Shift the DCDL to the unlocked or disengaged position using
Table AI the switch inside the cab of the vehicle. The DCDL indicator
light in the cab will go off. Shift the IAD to the unlocked or
Fastener Thread Size Torque Value lb-ft (N폷m) disengaged position using the switch inside the cab of the
Capscrews 0.31"-24 18-24 (24-33) vehicle. The IAD indicator light in the cab will go off, if
0.50"-13 85-115 (115-156) equipped.

Stud Nuts 0.44"-20 50-75 (68-102) 4. Stop the engine.

Plain Nut 0.50"-20 75-115 (102-156) 5. Refer to and identify which axle shafts must be removed based
on how the vehicle will be towed.
0.56"-18 110-165 (149-224)
0.62"-18 150-230 (203-312) Table AJ
0.75"-16 310-400 (420-542) Single Axles
Locknut 0.44"-20 40-65 (54-88) Remove both axle shafts.
0.50"-20 65-100 (88-136) Tandem Axles
0.56"-18 100-145 (136-197) Forward Axle (Towing from Front):
0.62"-18 130-190 (176-258) No need to remove axle shafts.
0.75"-16 270-350 (366-475) Forward Axle (Towing from Rear):
Remove both axle shafts.
9. Unlock or disengage the DCDL by removing the manual
engaging capscrew from the shift assembly. Rear Axle (Towing from Front):
Remove both axle shafts.
10. Install the manual engaging capscrew into the storage hole.
The storage hole of threaded shift assemblies is located in the Rear Axle (Towing from Rear):
shift tower of the carrier next to the cylinder. Tighten the No need to remove axle shafts.
capscrew to 15-25 lb-ft (20-35 N폷m). Figure 11.1. @
11. Connect the air hose to the shift cylinder. Tighten the air hose 6. On axles equipped with a DCDL, the shift collar splines must be
to 22-30 lb-ft (30-40 N폷m). @ engaged with the differential case splines before removing the
axle shaft. Engage the DCDL shift collar using the Manual
12. Install the remaining axle shaft into the axle housing and
Engaging Method as follows.
carrier.
13. Check the lubricant level in the axles and hubs where the axle CAUTION
shafts were removed. Add the correct type and amount of On single and tandem rear axles equipped with a DCDL, when
lubricant if necessary. Refer to Section 7. removing the curb-side (right) axle shaft, the DCDL shift collar
splines must be engaged with the differential case splines.
Forward Tandem Axle, with Driver-Controlled The collar splines must be completely engaged with the
Main Differential Lock (DCDL — Bolt-On differential case splines. This must be done to prevent the shift
DCDL Shift Assembly) and with Inter-Axle collar from dropping out of position when removing the axle
shaft. Cage (engage) the shift collar with the differential case
Differential (IAD) before removing the axle shaft or damage to components can
Before Towing or Drive-Away result.

1. Apply the vehicle parking brakes using the switch inside the A. Disconnect the air hose from the shift cylinder.
cab of the vehicle. Figure 11.6.

116 Meritor Maintenance Manual 5L (Revised 02-18)

 11 Vehicle Towing Instructions

Figure 11.6 D. Turn the capscrew to the right until the head is
BOLT-ON SHIFT ASSEMBLY approximately 0.25- to 0.50-inch (6.4 to 12.7 mm) from
TOP STORAGE HOLE
the cylinder. The capscrew is now in the service position
FOR MANUAL and the DCDL shift collar is locked (engaged).
ENGAGING AIR LINE Figure 11.8. When turning the capscrew you will feel a
CAPSCREW
small amount of resistance. This is normal. If you feel a
MANUAL
ENGAGING
high resistance before achieving the 0.25- to 0.50-inch
CAPSCREW distance between the capscrew head and cylinder, STOP
PLUG AND CYLINDER
TURNING THE CAPSCREW and continue with Steps E and
GASKET COVER F.

WIRE Figure 11.8

BOTTOM STORAGE SERVICE POSITION

HOLE FOR PLUG CAPSCREW HOLE
AND GASKET 1002613b

Figure 11.6

B. Remove the manual engaging capscrew from the storage

hole. The storage hole of threaded shift assemblies is
located in the shift tower of the carrier, next to the 0.25-0.50"
cylinder. Figure 11.6. (6.4-12.7 MM) 1002615b

C. Install the manual engaging capscrew into the threaded Figure 11.8
hole in the center of the cylinder. Figure 11.7.
E. Raise the tire and wheel (DCDL axle side) off of the floor
Figure 11.7

(leave the opposite tire and wheel on the floor) and

BOLT-ON SHIFT ASSEMBLY support the axle with jack stands. Slowly rotate the wheel
MANUAL of the DCDL axle shaft that is to be removed by hand.
ENGAGING
CAPSCREW F. Verify that the clutch collar is engaged by attempting to
rotate the elevated wheel. If it does not rotate, the collar is
successfully caged. The axle shaft can now be removed.
앫 If you still feel a high resistance: Stop turning the
capscrew, disassemble and inspect components for
1002614b
damage and wear. Replace as necessary.
7. Identify each axle shaft to be removed from the axle assembly
Figure 11.7
so they can be installed in the same location after transporting
or repair is completed. (Example: Match mark a mating axle
CAUTION shaft and hub.)
When you turn the capscrew in Step D and you feel a high
8. Remove the stud nuts or capscrews and the washers from the
resistance, STOP TURNING THE CAPSCREW. A high resistance
flange of the axle shaft. Figure 11.9.
against the capscrew indicates that the splines of the shift
collar and differential case are not aligned. Damage to the
threads of the cylinder and capscrew will result. To align the
splines, continue with Steps E and F.

Meritor Maintenance Manual 5L (Revised 02-18) 117

11 Vehicle Towing Instructions

Figure 11.9

WARNING
TAPERED DOWEL RETENTION When you work on a spring chamber, carefully follow the
STUD
STUD WASHER service instructions of the chamber manufacturer. Sudden
NUT GASKET
TAPERED release of a compressed spring can cause serious personal
DOWEL
injury.

15. If there are spring or parking brakes on the axle(s) that will
remain on the road when the vehicle is transported, and they
cannot be released by air pressure, manually compress and
WASHER lock each spring so that the brakes are released. Refer to the
CAPSCREW AXLE SHAFT manufacturer’s instructions.
SHAFT OR HUB
NON-TAPERED FLANGE AXLE
DOWEL RETENTION 1002581b
After Towing or Drive-Away
1. If an auxiliary air supply was used, apply the vehicle parking
Figure 11.9
brakes using the switch inside the cab of the vehicle. If an
auxiliary air supply was not used, begin with Step 2.
9. Loosen the tapered dowels, if used, in the flange of the axle
shaft. Refer to Section 3 for the recommended tools and
WARNING
removal procedures. Figure 11.9.
When you work on a spring chamber, carefully follow the
10. Remove the tapered dowels, the axle shafts and gaskets, if service instructions of the chamber manufacturer. Sudden
used. Figure 11.9. release of a compressed spring can cause serious personal
injury.
11. Remove the remaining axle shaft(s) as necessary from the
axle(s) that will remain on the road when the vehicle is
2. Apply the vehicle spring or parking brakes by manually
transported according to .
releasing each spring that was compressed before transporting
12. Install a cover over the open end of each hub where an axle started. Refer to the manufacturer’s instructions.
shaft was removed. This will prevent dirt from entering the
3. Disconnect the auxiliary air supply, if used, from the brake
bearing cavity and minimize loss of lubricant.
system of the vehicle that was transported. Connect the
vehicle’s air supply to the brake system.
NOTE: If an air supply will be used for the brake system of the
transported vehicle, continue with Steps 13 and 14, otherwise 4. Remove the covers from the hubs.
continue with Step 15.
5. Install the axle shaft(s) indicated in Table AK. Axle shafts with a
DCDL have a double row of splines that engage with the
13. Connect an auxiliary air supply to the brake system of the
splines of the side gear and shift collar in the differential case.
vehicle that is being transported. Before moving the vehicle,
Figure 11.10. Continue with Step 6.
charge the brake system with the correct amount of air
pressure to operate the brakes. Refer to the instructions Table AK
supplied by the manufacturer of the vehicle for procedures and
specifications. If an auxiliary air supply is not used, continue Single Axles
with Step 15. Remove both axle shafts.
14. When the correct amount of air pressure is in the brake Tandem Axles
system, release the parking brakes of the vehicle that is being Forward Axle (Towing from Front):
transported. Step 15 is not required.
No need to remove axle shafts.
Forward Axle (Towing from Rear):
Remove both axle shafts.

118 Meritor Maintenance Manual 5L (Revised 02-18)

 11 Vehicle Towing Instructions

7. Install the dowels, if used, over each stud and into the tapered
Rear Axle (Towing from Front):
holes of the flange.
Remove both axle shafts.
8. Install the washers and capscrews or stud nuts. Determine the
Rear Axle (Towing from Rear):
size of the fasteners and tighten the capscrews or nuts to the
No need to remove axle shafts. corresponding torque value shown in Table AL.

Table AL
Figure 11.10

Fastener Thread Size Torque Value lb-ft (N폷m)

SINGLE AXLE OR REAR AXLE OF TANDEM SHOWN
WITH BOLT-ON DCDL SHIFT ASSEMBLY AND Capscrews 0.31"-24 18-24 (24-33)
SHOWN IN THE LOCKED, ENGAGED POSITION
0.50"-13 85-115 (115-156)
Stud Nuts 0.44"-20 50-75 (68-102)
Plain Nut 0.50"-20 75-115 (102-156)
0.56"-18 110-165 (149-224)
2 0.62"-18 150-230 (203-312)
1 0.75"-16 310-400 (420-542)
3
Locknut 0.44"-20 40-65 (54-88)
4
0.50"-20 65-100 (88-136)
0.56"-18 100-145 (136-197)
0.62"-18 130-190 (176-258)
5 0.75"-16 270-350 (366-475)
6

9. Unlock or disengage the DCDL by removing the manual

7 engaging capscrew from the shift assembly.
8
1002616b 10. Install the manual engaging capscrew into the storage hole.
1 LEFT-HAND, ROADSIDE, AXLE SHAFT
The storage hole of bolted on shift assemblies is located in the
2 SHIFT ASSEMBLY top side of the shift cylinder cover. Tighten the capscrew to
3 SHIFT COLLAR 15-25 lb-ft (20-35 N폷m). Figure 11.6. @
4 RIGHT-HAND, CURBSIDE, AXLE SHAFT
5 DOUBLE ROW OF SPLINES 11. Remove the plug and gasket from the storage hole. Install the
6 SHIFT COLLAR AND DIFFERENTIAL CASE SPLINES ENGAGED OR LOCKED plug and gasket into the threaded hole in the center of the shift
7 SIDE GEAR
8 DIFFERENTIAL CASE cylinder cover. Tighten to 15-25 lb-ft (20-35 N폷m). @
Figure 11.10 12. Install the remaining axle shaft(s) into the axle housing and
carrier. Follow Steps 6-8.
NOTE: Make sure to engage the axle shaft splines for the
13. Check the lubricant level in the axles and hubs where the axle
differential side gear and the shift collar. They must be fully
shafts were removed. Add the correct type and amount of
engaged.
lubricant if necessary. Refer to Section 7.
6. Install the gasket, if used, and axle shaft into the axle housing
and carrier in the same location. The gasket and 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 11.9.

Meritor Maintenance Manual 5L (Revised 02-18) 119

11 Vehicle Towing Instructions

Forward Tandem Axle, without 10. Install a cover over the open end of each hub where an axle
Driver-Controlled Main Differential Lock shaft was removed. This will prevent dirt from entering the
bearing cavity and loss of lubricant.
(DCDL), with Inter-Axle Differential (IAD)
Before Towing or Drive-Away NOTE: If an air supply will be used for the brake system of the
transported vehicle, continue with Step 11 and Step 12, otherwise
1. Park the vehicle on a level surface. Block the wheels to prevent continue with Step 13.
the vehicle from moving.
2. Apply the vehicle parking brakes using the switch inside the 11. Connect an auxiliary air supply to the brake system of the
cab of the vehicle. vehicle that is being transported. Before moving the vehicle,
charge the brake system with the correct amount of air
3. Shift the transmission into neutral and start the vehicle’s pressure to operate the brakes. Refer to the instructions
engine. supplied by the manufacturer of the vehicle for procedures and
4. Shift the IAD to the unlocked or disengaged position using the specifications. If an auxiliary air supply is not used, continue
switch inside the cab of the vehicle. The indicator light in the with Step 13.
cab will go off. 12. When the correct amount of air pressure is in the brake
5. Stop the engine. system, release the parking brakes of the vehicle that is being
transported. Step 13 is not required.
NOTE: Remove both axle shafts from the axle(s) that will remain on
13. If there are spring or parking brakes on the axle(s) that will
the road when the vehicle is transported. remain on the road when the vehicle is transported, and they
cannot be released by air pressure, manually compress and
6. Remove the stud nuts or capscrews and washers from the
lock each spring so that the brakes are released. Refer to the
flange of the axle shaft. Figure 11.11.
manufacturer’s instructions.
7. Loosen the tapered dowels, if used, in the flange of the axle
shaft. Figure 11.11. Refer to Section 3. After Towing or Drive-Away
1. If an auxiliary air supply was used, apply the vehicle parking
Figure 11.11

brakes using the switch inside the cab of the vehicle. If an

TAPERED DOWEL RETENTION auxiliary air supply was not used, begin with Step 2.
STUD
STUD WASHER
NUT GASKET 2. Apply the vehicle spring or parking brakes by manually
TAPERED
DOWEL releasing each spring that was compressed before transporting
started. Refer to the manufacturer’s instructions.
3. Disconnect the auxiliary air supply, if used, from the brake
system of the vehicle that was transported. Connect the
vehicle’s air supply to the brake system.
WASHER
4. Remove the covers from the hubs.
CAPSCREW AXLE SHAFT
SHAFT OR HUB 5. Install the gasket, if used, and axle shaft into the axle housing
NON-TAPERED FLANGE AXLE
DOWEL RETENTION 1002581b and carrier in the same location. The gasket and flange of the
axle shaft must be flat against the hub. Rotate the axle shaft or
Figure 11.11 the driveline as necessary to align the splines and the holes in
the flange with the studs in the hub. Figure 11.11.
8. Identify each axle shaft that is removed from the axle assembly
6. Install the dowels, if used, over each stud and into the tapered
so they can be installed in the same location after transporting
holes of the flange.
or repair is completed.
9. Remove the tapered dowels, gasket, if used, and the axle shaft
from the axle assembly. Figure 11.11.

120 Meritor Maintenance Manual 5L (Revised 02-18)

 11 Vehicle Towing Instructions

7. Install the washers and capscrews or stud nuts. Determine the

size of the fasteners and tighten the capscrews or nuts to the
torque value shown in Table AM.

Table AM
Fastener Thread Size Torque Value lb-ft (N폷m)
Capscrews 0.31"-24 18-24 (24-33)
0.50"-13 85-115 (115-156)
Stud Nuts 0.44"-20 50-75 (68-102)
Plain Nuts 0.50"-20 75-115 (102-156)
0.56"-18 110-165 (149-224)
0.62"-18 150-230 (203-312)
0.75"-16 310-400 (420-542)
Locknut 0.44"-20 40-65 (54-88)
0.50"-20 65-100 (88-136)
0.56"-18 100-145 (136-197)
0.62"-18 130-190 (176-258)
0.75"-16 270-350 (366-475)

8. Check the lubricant level in the axles and hubs where the axle
shafts were removed. Add the correct type and amount of
lubricant if necessary. Refer to Section 7.

Meritor Maintenance Manual 5L (Revised 02-18) 121

12 Diagnostics

Troubleshooting
12 Diagnostics

Vehicle Will Not Move

Figure 12.1

Visually inspect
the carrier
in the axle Check for further carrier
housing. damage. If none is found,
Damaged or Yes repair or replace the oil
contaminated? pump, clean or replace
Remove the the oil screen and install
carrier from the the carrier. Refer to
Yes axle housing. Sections 3 and 5.
Damaged? Repair the carrier No
or install a
remanufactured
Inspect the inter-axle differential
No carrier.
assembly for damage. Refer to
TP-9955, Failure Analysis for
Drive Axle Components.
Drain and inspect
the lubricant. Check for further carrier
Refer to MM 1. damage. If none is found,
replace the damaged
Yes inter-axle differential
Damaged?
components and install the
carrier. Refer to Sections
No 3 and 5.
Yes Determine the
Contaminated? source of
contamination.
Inter-axle
Welded differential case
No bolted or
welded?

Remove the Bolted

carrier from the
Inspect the pinion
housing. Refer to
gears and spider. Disassemble the
Section 3.
Refer to TP-9955, inter-axle
Failure Analysis differential case.
for Drive Axle
Components.

Visually inspect the ring

pinion gear set for Inspect the inter-axle differential
damage. Refer to TP-9955, spider, side gears, thrust washers
Failure Analysis for and bearings. Refer to TP-9955,
Drive Axle Components. Failure Analysis for Drive
Axle Components.

Check for further carrier

Repair the carrier damage. If none is found,
or install a replace the inter-axle
Yes remanufactured
Damaged? differential components
carrier. Yes and install the carrier. If
Refer to Sections Damaged? the inter-axle differential
3 and 5. case is welded, replace
No the entire inter-axle
differential case. Refer
No to Sections 3 and 5.
Remove and
disassemble the input
shaft and inter-axle differential Inspect the main differential
bearings for damage.
assembly. Refer to Section 3.
Refer to TP-9955,
Failure Analysis for
Drive Axle Components.

If the carrier is a pump model, Repair the carrier

inspect the input shaft oil or install a
pump for damage and the oil Yes
Damaged? remanufactured
screen for contamination. Refer carrier. Refer to
to TP-9955, Failure Analysis for Sections 3 and 5.
Drive Axle Components. No

Check the ring gear backlash

and record the reading.
Refer to Section 4. Use the
backlash reading when
you reassemble the carrier.

This flowchart continues

on the next page.

Figure 12.1

122 Meritor Maintenance Manual 5L (Revised 02-18)

 12 Diagnostics

Figure 12.2

This flowchart continues

from the previous page.

When the carrier is When the carrier is

reassembled later, reassembled later, If damaged, repair the
Yes Backlash No input shaft, inter-axle
set the backlash set the backlash
to the recorded within spec? to spec. Refer to differential, side gears or
reading. Section 5. bearings. Install the input
shaft. Refer to Sections 3 and 5.

Remove the main

differential and
ring gear from
the carrier. Install a new
Refer to Section 3. unitized seal.

Inspect the main differential

bearings for damage. Refer Set the input
to TP-9955, Failure Analysis shaft end play to
for Drive Axle Components. the correct
specification.
Refer to Section 5.
Repair the carrier
or install a
Yes
Damaged? remanufactured
carrier.
Refer to Sections
No 3 and 5. Install the carrier.
Refer to Section 5.
Test drive the vehicle.
Disassemble the Return the vehicle to service.
main differential.
Refer to Section 3.

Inspect the main

differential case, side gears
and spider for damage.
Refer to TP-9955,
Failure Analysis for Drive
Axle Components.

Repair the carrier

or install a
Yes
Damaged? remanufactured
carrier.
Refer to Sections
No 3 and 5.

Inspect the drive pinion,

inner drive pinion bearing
and spigot bearing for damage.
Refer to TP-9955, Failure
Analysis for Drive
Axle Components.

Repair the carrier

Yes or install a
Damaged? remanufactured
carrier.
Refer to Sections
No 3 and 5.

Reassemble and
install the main
differential.
Refer to Section 5.

Reset the backlash.

Refer to Section 5.

Figure 12.2

Meritor Maintenance Manual 5L (Revised 02-18) 123

12 Diagnostics

Differential Making Noise

Figure 12.3

Visually inspect
the carrier in
the axle housing.
Check for further carrier
damage. If none is found,
Remove the Damaged or Yes repair or replace the
carrier from the contaminated? oil pump, clean or replace
Yes axle housing. the oil screen and install
Damaged? Repair the carrier the carrier. Refer to
or install a Sections 3 and 5.
remanufactured No
No carrier.

Inspect the inter-axle

Check the input differential assembly for
shaft end play. damage. Refer to TP-9955,
Refer to Section 5. Failure Analysis for Drive
Axle Components.

Check for further carrier

Set the input
Inspect the damage. If none is found,
End play No shaft end
lubricant. Yes replace the damaged
within spec? play to spec.
Refer to MM 1. Damaged? inter-axle differential
Refer to Section 5.
components and install
the carrier. Refer to
Yes
Sections 3 and 5.
No
Drain and inspect Yes
the lubricant. Contaminated?
Refer to MM 1.
Inter-axle
Welded differential case
No
bolted or
welded?
Yes Fill the carrier with
Determine the correct amount
Contaminated? the source of of the specified Inspect the Bolted
contamination. lubricant. Refer to pinion gears
Section 7. Test drive and spider.
No the vehicle. Refer to Disassemble
Remove the carrier TP-9955, the inter-axle
from the housing. Failure differential case.
Refer to Section 3. Yes Analysis for
Noisy? Drive Axle
Components.

No
Inspect the inter-axle
Visually inspect the ring
differential spider, side gears,
gear and pinion for Return the
thrust washers and bearings.
damage. Refer to TP-9955, vehicle to
Refer to TP-9955,
Failure Analysis for service.
Failure Analysis for
Drive Axle Components.
Drive Axle Components.

Check for further carrier

Repair the carrier or damage. If none is found, replace
Yes Yes the damaged inter-axle
Damaged? install a remanufactured
Damaged? differential components and
carrier. Refer to
Sections 3 and 5. install the carrier. Refer to
Sections 3 and 5.
No No

Remove and Inspect the main

disassemble the input differential bearings for damage.
shaft and inter-axle Refer to TP-9955, Failure Analysis
differential assembly. for Drive Axle Components.
Refer to Section 3.

Repair the carrier or

Yes install a remanufactured
Inspect the input shaft Damaged?
oil pump for damage carriet. Refer to
and the oil screen for Sections 3 and 5.
contamination. Refer to No
TP-9955, Failure
Analysis for Drive Axle Check the ring gear
Components. backlash and
record the reading.
Refer to Section 5.

This flowchart continues

on the next page.

Figure 12.3

124 Meritor Maintenance Manual 5L (Revised 02-18)

 12 Diagnostics

Figure 12.4

This flowchart continues

from the previous page.

When the main When the main

differential is differential is Reassemble and install
reassembled later, Yes Backlash No reassembled later, set the main differential.
set the backlash to within spec? the backlash to spec. Refer to Section 5.
the recorded reading. Refer to Section 5.

Remove the main

differential and Reset the backlash.
ring gear from Refer to Section 5.
the carrier.
Refer to Section 3.

If damaged, repair the

input shaft, inter-axle
differential, side gears
Inspect the main differential or bearings. Install the input
bearings for damage. shaft. Refer to Sections 3 and 5.
Refer to TP-9955, Failure
Analysis for Drive Axle
Components.

Install a new
unitized seal.
Repair the carrier
Yes or install a
Damaged? remanufactured
carrier. Refer to
Sections 3 and 5. Set the input shaft
No end play to the
correct specification.
Refer to Section 5.
Disassemble the
main differential.
Refer to Section 3.
Install the carrier.
Refer to Section 5.
Test drive the vehicle.
Return the vehicle to service.
Inspect the main
differential case, side
gears and spider for
damage. Refer to TP-9955,
Failure Analysis for Drive
Axle Components.

Repair the carrier

Yes or install a
Damaged? remanufactured
carrier. Refer to
Sections 3 and 5.
No

Inspect the drive pinion,

inner drive pinion
bearing and spigot bearing
for damage. Refer to
TP-9955, Failure Analysis
for Drive Axle Components.

Repair the carrier

Yes or install a
Damaged? remanufactured
carrier. Refer to
Sections 3 and 5.
No

Figure 12.4

Meritor Maintenance Manual 5L (Revised 02-18) 125

12 Diagnostics

Oil Leak
Figure 12.5

Visually inspect
the carrier in the
axle housing.
Drain and inspect
Remove the carrier the lubricant.
from the axle housing. Refer to MM 1.
Yes Repair the carrier or
Damaged? install a
remanufactured
carrier. Refer to
No Sections 3 and 5. Remove the carrier
from the axle housing.
Refer to Section 3.
Inspect the
breather.

Clean and prepare

the housing and
carrier flanges.
Clean or replace the Apply the correct
Yes breather. A clogged gasket or silicone.
Breather
Refer to Section 4.
clogged? breather can cause
a seal leak.

No
Install the carrier.
Refer to Section 5.
Inspect the
input shaft seal
for leaks.

Fill the carrier with

the correct amount
of the specified lubricant.
Seal Yes Replace the input Refer to Section 7.
leaking? shaft seal with
a unitized seal.

No
Test drive the vehicle
Fill the carrier with to confirm that the
Inspect the ouput the correct amount leak is repaired. Return
of the specified the vehicle to service.
shaft seal for
lubricant.
leakage.
Refer to Section 7.
Clean the seal area.

Replace the output

shaft seal with Yes Seal
a unitized seal. leaking? Test drive the vehicle
to confirm that
No the leak is repaired.
Return the vehicle
Fill the carrier with the to service.
correct amount of the Inspect the
specified lubricant. carrier-to-housing
Refer to Section 7. joint for leaks.
Clean the seal area.

Inspect the axle

housing welds for
Test drive the vehicle Joint No cracks or leaks. If you
to confirm that the leaking? find weld cracks, contact
leak is repaired. Return Meritor for repair
the vehicle to service. welding procedures.
Yes

Figure 12.5

126 Meritor Maintenance Manual 5L (Revised 02-18)

 12 Diagnostics

Contaminated Lubricant Found During Preventive Maintenance

Figure 12.6

Visually
inspect the
lubricant.

Clean and prepare the

Indicates Milky, Indicates housing and carrier
that water Brownish Silvery
Lubricant metallic flanges. Apply the correct
is entering gasket or silicone.
color? contamination.
the axle. Refer to Section 4.

Send out a lubrication

sample for analysis. Install the carrier.
Inspect the Advise the owner to Refer to Section 5.
breather. return for the results.

If analysis results Fill the carrier with

Clean or replace the
Breather Yes indicate wear or the correct amount
breather. A clogged
clogged? breakdown in the carrier, of the specified lubricant.
breather can cause
refer to the Differential Refer to Section 7.
a seal leak.
Making Noise diagnostic
flowchart in this publication.
No

Test drive the vehicle

Inspect the
to confirm that the
carrier seals
leak is repaired. Return
for leaks.
the vehicle to service.

Seal No Inspect the

leaking? carrier-to-housing
joint for leaks.

Yes

Inspect the axle housing

Replace the leaking Joint No welds for cracks or leaks.
seal with a leaking? If you find weld cracks,
unitized seal. contact Meritor for
repair welding procedures.
Yes

Fill the carrier Drain and

with the correct inspect the
amount of the lubricant.
specified lubricant. Refer to MM 1.
Refer to Section 7.
Clean the seal area.

Remove the
carrier from
Test drive the the axle. Refer to
vehicle to confirm Section 3.
that the leak is
repaired. Return the
vehicle to service.

Figure 12.6

Meritor Maintenance Manual 5L (Revised 02-18) 127

Meritor Heavy Vehicle Systems, LLC
2135 West Maple Road Printed in USA
Troy, MI 48084 USA
866-OnTrac1 (668-7221) Copyright 2018 Revised 02-18
meritor.com Meritor, Inc. Maintenance Manual 5L (16579)