Meritor Axle MS-113

8/9/2019 Meritor Axle MS-113

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Rear AxleSingle-Reduction Carrier

Model MS-113

Maintenance Manual MM-0230

Revised 08-10


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Service Notes

Service NotesService NotesAbout This Manual

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

Before You Begin1. Read and understand all instructions and

procedures before you begin to servicecomponents.

2. Read and observe all Warning and Cautionhazard alert messages in this publication. Theyprovide information that can help preventserious personal injury, damage tocomponents, or both.

3. Follow your company’s maintenance andservice, installation, and diagnosticsguidelines.

4. Use special tools when required to help avoidserious personal injury and damage tocomponents.

Hazard Alert Messages and TorqueSymbols

WARNING

A Warning alerts you to an instruction orprocedure that you must follow exactly to avoidserious personal injury and damage tocomponents.

CAUTION

A Caution alerts you to an instruction orprocedure that you must follow exactly to avoiddamage to components.

This symbol alerts you to tighten fasteners to aspecified torque value.

How to Obtain AdditionalMaintenance and ServiceInformation

On the Web

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

Literature on Demand DVD (LODonDVD)

The LODonDVD contains product, service andwarranty information for ArvinMeritorcomponents. To order the DVD, visit Literature on

Demand at arvinmeritor.com and specify TP-0742.

How to Obtain Supplies Specified in ThisManual

Call ArvinMeritor’s Commercial VehicleAftermarket at 888-725-9355 to obtain Meritorsupplies.

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

T


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Table of Contents

Table of Contents

Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Section 2: Removal and Disassembly

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Axle Shafts from the Axle Assembly

Differential Carrier from the Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Differential Case and Ring Gear from the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Drive Pinion from the Carrier

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Differential Case and Ring Gear

Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Section 3: Prepare Parts for AssemblyClean Ground and Polished Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Clean Rough Parts

Clean Axle Assemblies

Dry Parts After Cleaning

Prevent Corrosion on Cleaned PartsInspect Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Repair or Replace Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Repair Welding on Axle Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

For Complete Welding Instructions on Meritor Drive Axle Housings

Prepare the Axle

Do Not Bend or Straighten a Damaged Drive Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Removing Fasteners Secured with Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Install Fasteners

New Fasteners with Pre-Applied Adhesive

Original or Used Fasteners Using Meritor Liquid Adhesive 2297-C-7049 or

Loctite® 680 Adhesive, or Equivalent

Applying Meritor Specification 2297-T-3994, Loctite® 680 Adhesive, or Equivalent

in the Bearing Bores Differential

Applying Loctite® 5699 Silicone Gasket Material, or Equivalent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Gear Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Examples

Section 4: Assembly and InstallationAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Drive Pinion


Differential Gears Rotating Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Installation

Drive Pinion into the Carrier

Differential Case and Ring Gear into the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Adjust Differential Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Check Ring Gear Runout (Radial Movement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Ring Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Check the Tooth Contact Patterns (Backlash) of the Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Differential Carrier into the Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Axle Shafts in the Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fill the Axle with Lubricant


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Table of Contents

Section 5: DiagnosticsVehicle Will Not Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Differential Making Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Oil Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Contaminated Lubricant Found During Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Section 6: Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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

Section 8: Towing InstructionsBefore Towing or Drive-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

After Towing or Drive-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Section 9: Special ToolsCarrier Repair Stand Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

How to Make a Yoke Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Seal Driver Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40


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Exploded View

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

Exploded View

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

2 Yoke 14 Carrier 26 Differential Pinion Shaft

3 Seal 15 Differential Cap Capscrew, M14 x 2.0 27 Differential Case

4 Screws, M6 x 1.0 16 Cotter Pins 28 Differential Case Capscrew, M12 x 1.75

5 Lock Plate 17 Thrust Washer 29 Carrier-to-Housing Capscrew, M12 x 1.75 x 60

6 Pinion Cage 18 Differential Pinion 30 Carrier-to-Housing Capscrew, M12 x 1.75 x 30

7 O-Ring 19 Adjusting Ring 31 Breather

8 Outer Bearing Cup 20 Bearing Cup 32 Axle Housing

9 Outer Bearing Cone 21 Bearing Cone 33 Fill Plug

10 Drive Pinion 22 Ring Gear 34 Drain Plug11 Shim 23 Differential Case — Ring Gear Side 35 Axle Shaft

12 Inner Bearing Cone 24 Thrust Washer

12

3

4

11

1312

14

10

5

9

76

8

272821

1920

24

16

25

15

17

18

26

17

18

25

23

24

2221

1920

3334

32

31

29

30

35

35


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Section 1Introduction


Section 1IntroductionMeritor’s model MS-113 single-reduction rearaxle has a single-reduction carrier, which isfront-mounted into the axle housing. Figure 1.1.The carrier has a hypoid drive pinion and ring gearset. Bevel gears are used in the differential

assembly. All bearings in the carrier are taperedroller bearings.

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

Figure 1.1

1 ADJUSTING RING

2 CARRIER

3 RING GEAR AND DRIVE PINION

4 TAPERED ROLLER BEARING

5 TAPERED ROLLER BEARING

6 HOUSING

7 DIFFERENTIAL PINION

8 COTTER PIN

1

2

4

3

58

7

6


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Section 2Removal and Disassembly

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


WARNING

To prevent serious eye injury, always wear safeeye protection when you perform vehicle

maintenance or service.

Park the vehicle on a level surface. Block thewheels to prevent the vehicle from moving.Support the vehicle with safety stands. Do notwork under a vehicle supported only by jacks.Jacks can slip and fall over. Serious personalinjury and damage to components can result.

Use a brass or leather mallet for assembly anddisassembly procedures. Do not hit steel partswith a steel hammer. Pieces of a part can break offand cause serious personal injury.

Removal

Axle Shafts from the Axle Assembly

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

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

3. Place a drain pan under the rear axle.

4. Remove the drain plug from the bottom of theaxle housing. Drain the lubricant from the

assembly. Install the drain plug and tighten itto 35-50 lb-ft (48-67 N•m).

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

Figure 2.1

T

SAFETYSTANDS

1002983a

Figure 2.2

1 FULL ROUND BEARING CUPS

2 END YOKE

3 YOKE SADDLE

4 WELD YOKE

5 BEARING STRAP

6 CAPSCREWS7 EASY-SERVICE BEARING CUPS

8 U-JOINT CROSS

9 SLIP YOKE

10 CAPSCREWS

11 END YOKE

12 WELD YOKE

13 SLIP YOKE

14 U-JOINT CROSS

15 CAPSCREWS

16 END YOKE

17 WELD YOKE

18 SLIP YOKE19 U-JOINT CROSS

20 CAPSCREWS

21 END YOKE

22 SLIP YOKE

23 TUBING

24 U-JOINT CROSS

25 WELD YOKE

12

13

11

14

10

7

8

6

4

5

1

2

3

9

16

15

17

18

19

1002984b

EASY SERVICETM

WING SERIESPERMALUBETM

FULL-ROUND

“RPL” SERIES,PERMALUBETM

23

24 22

20

2125


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Differential Case and Ring Gear from theCarrier

NOTE: Before working on the differential carrier,inspect the gear set for damage. If the gear set isnot damaged, it can be reused. Measure thebacklash of the gear set and record the dimension.Figure 2.6. Refer to Section 4.

1. Remove the cotter pins from the side gearadjusting rings. Figure 2.7.

2. Remove the differential bearing cap capscrewsand the cap. Figure 2.8.

3. Remove the differential adjusting ring and

bearing cup from bolted-on bearing cap side.Figure 2.9.

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

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

Drive Pinion from the Carrier

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

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

Figure 2.6

Figure 2.7

1 COTTER PIN

11

Figure 2.8

1 CAPSCREWS

2 DIFFERENTIAL CAP

Figure 2.9

1 BEARING CUP

2 ADJUSTING RING

1

2

1

2


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3. Remove the yoke from the drive pinion.

If the yoke is tight on the drive pinion: Use apuller to remove the yoke.

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

5. Use a spanner wrench to unscrew the pinioncage from the carrier.

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

7. Remove the drive pinion inner bearing cupfrom the carrier.

Disassembly

WARNING

Observe all warnings and cautions provided bythe press manufacturer to avoid damage tocomponents and serious personal injury.


1. Remove the capscrews from the differentialcase. Figure 2.13.

Figure 2.10

1 YOKE BAR

Figure 2.11

1 LOCK PLATE

2 CAPSCREW

3 PINION CAGE

4 YOKE LOCKNUT

1

3

4

1

2

Figure 2.12

1 CAPSCREW

2 LOCK PLATE

Figure 2.13

1 CAPSCREWS

2

1

1


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

3. Remove the differential pinion shaft,

differential pinions and thrust washers.Figure 2.16.

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

Figure 2.14

Figure 2.15

1 THRUST WASHER

2 SIDE GEAR

1

2

Figure 2.16


2 THRUST WASHER

3 DIFFERENTIAL PINION SHAFT

Figure 2.17

1 SIDE GEAR

2 THRUST WASHER

Figure 2.18

1 RING GEAR

2 DIFFERENTIAL CASE

1 2

3

1

2

1 2


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

Drive Pinion

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

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

3. Use a bearing puller or a press to remove theinner and outer bearing cones from the drivepinion.

4. Remove the shim from the drive pinion.

Figure 2.19

1 DIFFERENTIAL CASE

Figure 2.20

1 PINION CAGE

2 O-RING

3 OUTER BEARING CUP

4 OUTER BEARING CONE

5 DRIVE PINION

6 SHIM

7 INNER BEARING CONE

1

1

7

23 4 5

6


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Section 3Prepare Parts for Assembly



WARNING



Solvent cleaners can be flammable, poisonousand cause burns. Examples of solvent cleaners arecarbon tetrachloride, emulsion-type cleaners andpetroleum-based cleaners. To avoid seriouspersonal injury when you use solvent cleaners,you must carefully follow the manufacturer’sproduct instructions and these procedures:

Wear safe eye protection.

Wear clothing that protects your skin.

Work in a well-ventilated area.

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

You must use hot solution tanks or alkalinesolutions correctly. Follow the manufacturer’sinstructions carefully.

Clean Ground and Polished Parts

1. Use a cleaning solvent to clean ground orpolished parts or surfaces. Kerosene or dieselfuel oil can be used for this purpose. DO NOTUSE GASOLINE.

2. Use a tool with a flat blade if required,

to remove sealant material from parts.Be careful not to damage the polished orsmooth surfaces.

CAUTION

Do not use hot solution tanks or water andalkaline solutions to clean ground or polishedparts. Damage to parts will result.

3. Do not clean ground or polished parts withwater or steam. Do not immerse ground orpolished parts in a hot solution tank or usestrong alkaline solutions for cleaning, or the

smooth sealing surface may be damaged.

Clean Rough Parts

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

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

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

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

Clean Axle Assemblies

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

2. Before the axle is steam cleaned, close orplace a cover over all openings in the axle

assembly. Examples of openings are breathersor vents in air chambers.

Dry Parts After Cleaning

1. Parts must be dried immediately aftercleaning and washing.

2. Dry the parts using soft, clean paper or clothrags.

CAUTION

Damage to bearings can result when they arerotated and dried with compressed air.

3. Except for bearings, parts can be dried withcompressed air.

Prevent Corrosion on Cleaned Parts

1. Apply axle lubricant to cleaned and driedparts that are not damaged and are tobe assembled.

2. To store parts, apply a special material thatprevents corrosion to all surfaces. Wrapcleaned parts in a special paper that willprotect the parts from moisture and

prevent corrosion.


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Inspect Parts

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

1. Inspect the cup, cone, rollers and cage of alltapered roller bearings in the assembly. If anyof the following conditions exist, replace thebearing.

The center of the large-diameter end of therollers is worn level with or below the outersurface. Figure 3.1.

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

There is a visible roller groove in the cup orcone inner race surfaces. The groove can beseen at the small- or large-diameter end of

both parts. Figure 3.2. There are deep cracks or breaks in the cup,

cone inner race or roller surfaces.Figure 3.2.

There are bright wear marks on the outersurface of the roller cage. Figure 3.3.

There is damage on the rollers and on thesurfaces of the cup and cone inner race thattouch the rollers. Figure 3.4.

There is damage on the cup and cone innerrace surfaces that touch the rollers.Figure 3.5.

Figure 3.1

1003017b

WORN RADIUS

WORN SURFACE

Figure 3.2

Figure 3.3

Figure 3.4

1003018b

WEARGROOVES

CRACK

1003019a

WEAR MARKS

1003020a

ETCHING AND PITTING


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CAUTION

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

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

CAUTION

A thrust washer, differential side gear and pinion

gear are machined as a matched set. When youreplace any of these parts, you must install a newmatched set. Do not mix old and new parts.Damaged to components can result.

3. Inspect the following main differentialassembly parts for wear or stress. Replaceparts that are damaged. Figure 3.6.

Inside surfaces of both case halves

Both surfaces of all thrust washers

The differential pinion shaft

Teeth and splines of both differentialside gears

Teeth and bore of all differential pinions

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

Repair or Replace Parts

NOTE: Threads must be without damage andclean so that accurate adjustments and correcttorque values can be applied to fasteners andparts.

1. Replace any fastener if corners of the headare worn.

2. Replace washers if damaged.

3. Replace gaskets, oil seals or grease seals at

the time of axle or carrier repair.4. Clean parts and apply new silicone gasket

material where required when the axle orcarrier is assembled. Figure 3.7.

5. Remove nicks, marks and burrs from partswith machined or ground surfaces. Use a finefile, india stone, emery cloth or crocus cloth.

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

Figure 3.5

1003021b

SPALLING AND FLAKING

Figure 3.6

1 CASE HALVES

2 PINION AND THRUST WASHER

3 SIDE GEAR AND THRUST WASHER


1

2

2

3

4

3 1


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

Repair Welding on Axle Housings

For Complete Welding Instructions on

Meritor Drive Axle Housings

Refer to Maintenance Manual 8, Drive AxleHousings. To obtain this publication, refer to theService Notes page on the front inside cover ofthis manual.

WARNING

Wear safe clothing and eye protection when youuse welding equipment. Welding equipment canburn you and cause serious personal injury. Followthe operating instructions and safety procedures

recommended by the welding equipmentmanufacturers.

Axle weld locations and welding procedures mustadhere to Meritor‘s standards. Welding atlocations other than those authorized by Meritorwill void the warranty and can reduce axle beamfatigue life. Serious personal injury and damage tocomponents can result.

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

Housing-to-cover weld joints

Snorkel welds

Housing seam welds between the suspensionattaching brackets

Bracket welding to the drive axle housing

Prepare the Axle

WARNING

The high temperature caused by the open flame

from the cutting torch can ignite the oil in the axlehousing and can cause serious personal injury.

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

CAUTION

Remove the differential carrier from the axlehousing before you weld onto an axle. Do notweld onto an axle with the differential carrierinstalled. Electrical arching and damage tocomponents can result.

2. Remove the differential carrier from the axlehousing. Refer to the correct Meritor carriermaintenance manual or the vehiclemanufacturer’s instructions.

CAUTION

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

3. Remove the wheel-end components and brake

air chambers from the axle. Refer to thecorrect Meritor brake maintenance manual orthe vehicle manufacturer’s instructions.

4. For housing-to-cover welds, clean the outsidehousing-to-cover weld area 2.00-3.00-inches(50.8-76.2 mm) past each end or side of thecrack. Clean the inside area where the covermates with the housing. Clean the areacompletely around the cover. Use a wire brushand a cleaning solvent that will remove dirtand grease from these areas. Figure 3.8.

Figure 3.7

1 REMOVE SILICONE GASKET FROM PARTS.

1003028b

1


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5. For suspension bracket welds, clean bothlower and upper suspension brackets and theareas of the axle housing around each bracket.

Use a wire brush and a cleaning solvent thatwill remove dirt and grease from these areas.Figures 3.9 and 3.10.

WARNING

The axle housing must be 70°F (21°C) or warmerbefore you weld onto the axle. Do not weld onto a

cold axle or weld cold parts onto an axle. Cracksin the weld area, damage to components andserious personal injury can result.

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

If the axle housing temperature measuresless than 70°F (21°C): Store the axle in aheated room until the housing reaches thecorrect temperature.

7. Heat the damaged area to approximately300°F (149°C) before you begin welding.

8. Use suitable weld wire electrodes when you

weld. Suitable weld wire electrodes includeeither BS EN 499 – E 42 2 B 32 H5 orBS EN 440 – G 42 2 M GSi (American WeldingSociety equivalents E7018 and ER70S3,respectively).

9. For complete welding instruction, refer toMaintenance Manual 8. To obtain thispublication, refer to the Service Notes pageon the front inside cover of this manual.

Do Not Bend or Straighten a DamagedDrive Axle Housing

WARNING

Replace damaged or out-of-specification axlecomponents. Do not bend, repair or reconditionaxle components by welding or heat-treating. Abent axle beam reduces axle strength, affectsvehicle operation and voids Meritor’s warranty.Serious personal injury and damage tocomponents can result.

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

Figure 3.8

Figure 3.9

Figure 3.10

Clean this area.4000309a

Clean these areas.

4000310a

LOWERBRACKET

Clean this area.

4000310a

Clean these areas.

UPPERBRACKET


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Removing Fasteners Secured withAdhesiveIf it’s difficult to remove fasteners secured withDri-Loc®, Meritor specification 2297-P-3994,

Loctite® 680 adhesive, or equivalent, use thefollowing procedure.

CAUTION

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

1. Heat a fastener for three to five seconds only.Try to loosen the fastener with a wrench. Donot use an impact wrench or hit the fastener

with a hammer.

2. Repeat Step 1 until you can remove thefastener.

Install Fasteners

New Fasteners with Pre-Applied Adhesive

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

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

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

3. Tighten fasteners to the required torque valuefor that size fastener.

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

WARNING

Take care when you use Loctite® to avoid seriouspersonal injury. Follow the manufacturer’sinstructions to prevent irritation to the eyesand skin.

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

2. Apply four or five drops of Meritor liquidadhesive, Loctite® 680 adhesive, or equivalent,inside each threaded hole or bore. Do notapply adhesive directly to fastener threads.Figure 3.11.

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

3. Tighten the fasteners to the required torquevalue for that size fastener.

Applying Meritor Specification2297-P-3994, Loctite® 680 Adhesive,or Equivalent in the Bearing BoresDifferential

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

1. Clean the oil and dirt from the outer diametersof the bearing cups and bearing bores in thecarrier and bearing caps. There is no specialcleaning required.

2. Apply axle lubricant to the bearing cones andthe inner diameters of the bearing cups of themain differential. Do not get oil onto the outer

diameter of the bearing cup and do not permitoil to drip onto the bearing bores.

Figure 3.11

1003025a

FOUR TOFIVE DROPS

ON BORETHREADS


19/46



3. Apply a single continuous bead of adhesive tothe bearing bores in the carrier and bearingcap. Apply the adhesive around thecircumference of the smooth, ground surfacesonly. On the integral cap side, apply the

adhesive near the thread end. Do not applyadhesive onto the threaded areas. Figure 3.12.

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

apply new adhesive.

4. Install the main differential assembly, bearingcups and bearing cap into the carrier. Thebearing cup of the integral bearing cap sidemust be assembled from the thread side. Referto Section 4. Remove excess adhesive afterassembly.

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

Applying Loctite® 5699 SiliconeGasket Material, or Equivalent

WARNING

When you apply some silicone gasket materials,small amounts of acid vapor are present. Toprevent serious personal injury, ensure that thework area is well ventilated. If the silicone gasketmaterial gets into your eyes, flush them withwater for 15 minutes. Have your eyes checked by aphysician as soon as possible.

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

Loctite® 5699 silicone gasket material

Loctite® 18581 Ultra Grey adhesive/sealant

Meritor gasket material/part number2297-F-7052. To obtain this gasket material, referto the Service Notes page on the front insidecover of this manual.

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

2. Use a cleaning solvent to clean the surfaceswhere you will apply silicone gasket material.Remove all oil, grease, dirt and moisturewithout damaging the mating surfaces.Figure 3.13.

3. Dry surfaces.

Figure 3.12

ADHESIVE BEARINGCAP

CARRIERLEG

1003026a

Figure 3.13

1003027c

sealant material.

HOUSING AND CARRIERSHOWN


20/46



CAUTION

Apply silicone gasket material in a continuous 1/8-inch (3 mm) bead. If you use more than this

amount, the gasket material can break off andplug lubrication passages. Damage tocomponents can result.

4. Apply a 1/8-inch (3 mm) diameter continuousbead of the silicone gasket material aroundone surface. Also apply the gasket materialaround the edge of all fastener holes on thatsurface. Figure 3.14.

5. Assemble the components immediately topermit the silicone gasket material tocompress evenly between the parts. Tightenfasteners to the required torque value for thatsize fastener. Refer to Section 6.

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

Gear Sets

Refer to the following examples for information onidentifying gear sets with matched parts. Alwayscheck match numbers to verify that the gear setyou will install has matched parts. Figure 3.15.

Examples

Gear Set

Gear Set Tooth Combination Number

Gear Set Match Number

NOTE: Meritor’s drive pinions and ring gears areonly available as matched sets. Each gear in a set

has an alpha-numeric match number.

Figure 3.14

1 0.125” (3 MM) DIAMETER SILICONE GASKET BEAD

1003028b

1

Figure 3.15

ALTERNATE LOCATIONS:1 PART NUMBER, TOOTH COMBINATION NUMBER,

GEAR SET MATCH NUMBER, PINION CONEVARIATION NUMBER

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

VARIATION NUMBER

4 PART NUMBER, TOOTH COMBINATION NUMBER,GEAR SET MATCH NUMBER

5 PART NUMBER, TOOTH COMBINATION NUMBERGEAR SET MATCH NUMBER

Part Number Location

Conventional ring

gear

36786 On the front face

or outer diameter

Conventional drivepinion

36787 At the end atthreads

Gear Set TeethDrive PinionLocation

Ring GearLocation

5-37 = gear set

has a five-toothdrive pinion and a37-tooth ring gear

At the end at

threads

On the front face

or outer diameter

Match NumberDrive PinionLocation

Ring GearLocation

M29 At the end of thegear head

On the front faceor outer diameter

4

5

1

2 3

1003031a


21/46



Pinion Cone Variation Number

NOTE: Don’t use the pinion cone variationnumber when you check for a matched gear set.Use this number when you adjust the pinion depth

in the carrier. Refer to Section 4.

Pinion Cone(PC) VariationNumber

Drive PinionLocation

Ring GearLocation

PC+3+2+0.01 mmPC-5

–1–0.02 mm

At the end of thepinon gear head

On the outerdiameter


22/46

Section 4Assembly and Installation



WARNING



Observe all warnings and cautions provided bythe press manufacturer to avoid damage tocomponents and serious personal injury.

Assembly

Drive Pinion

1. Apply Meritor specification 2297-W-4287,2297-U-4519 or 076328-4 lubricant to the newO-ring, carrier threads, O-ring bore, pinioncage threads and the inner and outer bearings.

Figure 4.1. To obtain this lubricant, refer to theService Notes page on the front inside cover ofthis manual.

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

3. Install the shim onto the drive pinion.

4. Use a press to install the inner and outer

bearing cones onto the drive pinion.


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

CAUTIONHeat the ring gear before seating it onto thedifferential case. Do not press a cold ring gearonto the differential case. A cold ring gear willdamage the differential case because of thetight fit.

2. Heat the ring gear. A maximum temperature of340°F (170°C) can be applied at the gear web.The temperature at the gear teeth must notexceed 250°F (120°C). Wear safe clothing andgloves while working with the hot ring gear.

3. Position the differential case on a workbenchwith the bearing cone on top.

4. Place the ring gear over the differential caseimmediately after the gear is heated.

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

5. Align the ring gear and differential casecapscrew holes. Rotate the ring gear asnecessary.

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

If the gap exceeds 0.001-inch (0.025 mm)at more than three places with an arclength greater than 1.0-inch (25.4 mm): Inspect the differential case and ring gearfor wear or damage. Repair or replace partsas necessary.

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

8. Apply Meritor specification 2297-W-4287,2297-U-4519 or 076328-4 lubricant to thedifferential pinion shaft, thrust washers,differential pinions and side gears. To obtain

this lubricant, refer to the Service Notes pageon the front inside cover of this manual.

Figure 4.1

1 PINION CAGE

2 O-RING

3 OUTER BEARING CUP

4 OUTER BEARING CONE

5 DRIVE PINION

6 SHIM

7 INNER BEARING CONE

1

7

23 4 5

6


23/46


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

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

10. Slide the differential pinions and thrustwashers onto the differential pinion shaft.

Figure 4.3.11. Position the differential pinion shaft in the

differential case on top of the side gear. Theholes in the differential pinion shaft must alignwith the capscrew holes in the differentialcase. Figure 4.4.

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

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

Figure 4.2

1 SIDE GEAR

2 THRUST WASHER

Figure 4.3


2 THRUST WASHER


1

2

1 2

3

Figure 4.4

1 Align holes.

Figure 4.5

1 THRUST WASHER

2 SIDE GEAR

Figure 4.6

1

1

2


24/46



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

15. Inspect the differential gears rotatingresistance. Use the following procedure.

Differential Gears Rotating Resistance

1. Make an inspection tool using an axle shaftthat matches the spline size of the differentialside gear. Cut the shaft to approximately12-inches (304.8 mm). Weld a nut onto the endof the shaft. Figure 4.8.

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

3. Install the tool into the differential until the

spines on the tool are engaged with oneside gear.

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

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

Installation

Drive Pinion into the Carrier

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

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

3. Apply axle lubricant onto the pinion inner andouter cone.

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

5. Coat the pinion cage seal bore with GL-5 gearoil prior to installing the new seal. To obtainthis lubricant, refer to the Service Notes pageon the front inside cover of this manual.

6. Use a seal driver to install a new seal into thepinion cage. Refer to the tool drawing inSection 9 to fabricate the seal driver.

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

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

9. Place the pinion cage onto the carrier. Useyour hands to screw the pinion cage into thecarrier to verify that the cage is correctlyinstalled.

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

Figure 4.7

1 CAPSCREWS

Figure 4.8

T

1

1003071a

APPROXIMATELY304.8 MM (12-INCHES)

SIDE VIEWWeld nut toend of shaft.

ENDVIEW


25/46


26/46



Adjust Differential Bearing Preload

Use Method 1 or Method 2 below to adjustdifferential bearing preload.

Specifications

Method 1

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

2. Use a T-bar wrench to loosen the bearing

adjusting ring that is opposite the ring gear.Figure 4.13. The dial indicator will show asmall amount of end play.

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

A. Insert two pry bars between the bearingadjusting rings and the ends of thedifferential case. Figure 4.14. The pry barsmust not touch the differential bearings.

B. Insert two pry bars between the differentialcase, or the ring gear and the carrier atlocations other than specified in Step A.Figure 4.15. The pry bars must not touchthe differential bearings.

4. Tighten the bearing adjusting ring until thedial indicator reads ZERO end play. Move thedifferential ring to the LEFT and RIGHT asneeded. If necessary, repeat Step A or B.

5. Tighten each bearing adjusting ring one notchfrom ZERO. Proceed to Check Ring GearRunout (Radial Movement) in this section.

Differential bearingpreload

15-35 lb-in

(1.7-3.5 N•m)

Expansion betweenbearing caps

0.006-0.013-inch

(0.15-0.33 mm)

Figure 4.12

Figure 4.13

1 T-BAR WRENCH

2 ADJUSTING RING OPPOSITE RING GEAR

1

2

Figure 4.14

1 Pry bars must not touch bearings.

Figure 4.15

1 Pry bars must not touch bearings.

1

1


27/46



Method 2

1. Hand-tighten both adjusting rings against thedifferential bearings.

2. Use a micrometer to measure the opposite

surfaces of the bearing caps at X or Y.Figures 4.16 and 4.17. Record themeasurement.

3. Tighten each bearing adjusting ring one notch.

4. Measure the opposite surfaces of the bearingcaps at X or Y again. Compare themeasurement with the one you obtained inStep 2.

5. Subtract the measurement you obtained inStep 2 from the measurement in Step 4. Thedifference is the amount the bearing caps haveexpanded. Refer to the following example.

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

If the measurement is not within thespecification above: Repeat Steps 3 and 4 asnecessary.

Sample Differential Bearing Preload Calculation

Check Ring Gear Runout (RadialMovement)

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

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

Figure 4.16

Figure 4.17

1 MICROMETER

1

X or YMeasurementBefore TighteningAdjusting Rings

X or YMeasurementAfter TighteningAdjusting Rings

AmountBearingCaps HaveExpanded

13.927-inch

(353.74 mm)

13.936-inch

(353.97 mm)

0.009-inch

(0.23 mm)

Figure 4.18


28/46



3. Rotate the differential and ring gear. Readthe dial indicator. Runout must not exceed0.008-inch (0.200 mm).

If runout exceeds the specification above:

Remove the differential and ring gearassembly from the carrier. Refer toSection 2 and Steps 4-5 below.

If runout is within specification: Proceed toRing Gear Backlash in this section.

4. Check the differential parts including thecarrier for wear and damage. Repair or replaceparts as necessary.

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

Ring Gear Backlash

Specifications

After checking the tooth contact patterns, thebacklash can be adjusted within specificationlimits, if needed. To change the location of thepattern, use the following procedures.

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

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

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

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

If the backlash reading is withinspecification: Check the tooth contactpatterns.

If the backlash reading is not withinspecification: Adjust backlash as necessary.

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

To increase backlash: Move the ring gearaway from the drive pinion.

To decrease backlash: Move the ring gear

toward the drive pinion.

Backlash setting range forold gear sets

0.008-0.018-inch(0.20-0.46 mm)

Backlash setting for newgear sets

0.005-0.015-inch(0.13-0.38 mm)

Figure 4.19

Figure 4.20

1 Tighten adjusting ring this side.

2 Increase backlash.

3 Loosen adjusting ring this side.

Figure 4.21

1 Loosen adjusting ring this side.

2 Decrease backlash.

3 Tighten adjusting ring this side.

1

2

3

1

2

3


29/46



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

6. Repeat Steps 2-5 until the backlash is withinspecifications.

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

In the following procedures, movement of thecontact pattern in the length of the tooth isindicated as toward the heel or toe of the ringgear. Figure 4.22.

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

1. Adjust the backlash of a new gear set to0.005-0.015-inch (0.13-0.38 mm). Adjust thebacklash of an old gear set to the setting thatyou measured before the carrier wasdisassembled. Refer to Ring Gear Backlash in

this section.

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

3. Rotate the ring gear forward and backward sothat the 12 gear teeth go past the drive pinionsix times to get the contact patterns. Repeat ifneeded to get a clearer pattern.

4. Look at the contact patterns on the ring gearteeth. Compare the patterns to Figures 4.25,

4.26 and 4.27.

The location of good hand-rolled contactpatterns for new gear sets is toward the toeof the gear tooth and in the center betweenthe top and bottom of the tooth. Figure 4.25.

When the carrier is operated, a good patternwill extend approximately the full length ofthe gear tooth. The top of the pattern will benear the top of the gear tooth. Figure 4.28.

The location of a good hand-rolled contactpattern for an old gear set must match thewear pattern in the ring gear. The new

contact pattern will be smaller in area thanthe old wear pattern.

Figure 4.22

1 HEEL

2 TOE

Figure 4.23

1

1003090e

2

DRIVESIDE

(CONCAVE)

Figure 4.24


30/46



A high contact pattern indicates that the drivepinion was not installed deep enough into thecarrier. A low contact pattern indicates that thedrive pinion was installed too deep in the

carrier.

If the contact patterns require adjustment: Continue by following Step 5 to move thecontact patterns between the top andbottom of the gear teeth.

If the contact patterns are in the centerof the gear teeth: Continue by followingStep 6.

5. Adjust the position of the drive pinion in thecarrier to move the contact patterns betweenthe top and bottom of the gear teeth. Use thefollowing procedure.

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

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

C. Change the bearing shim.

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

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

D. Install the inner bearing cone onto the

drive pinion. Install the drive pinion intothe carrier. Refer to the appropriateprocedures in this section.

E. Repeat Steps 2-5 until the contact patternsare in the center between the top andbottom of the gear teeth.

Figure 4.25

Figure 4.26

Figure 4.27

GOOD HAND-ROLLED PATTERN,HYPOID GENEROID GEARS

1001092c

HIGH PATTERN1001093c

1001094a

LOW PATTERN, HYPOID GENEROID GEARS

Figure 4.28

GOOD PATTERN IN OPERATION, GENEROID GEARS


31/46



6. Adjust the backlash of the ring gear within thespecification range to move the contactpatterns to the correct location in the length ofthe gear teeth. Refer to Ring Gear Backlash inthis section.

A. Decrease backlash to move the contactpatterns toward the toe of the ring gearteeth. Figure 4.29.

B. Increase backlash to move the contactpatterns toward the heel of the ring gearteeth. Figure 4.30.

C. Repeat Steps 2-4 and 6 until the contactpatterns are at the correct location in thelength of the gear teeth.

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

Figure 4.29

Figure 4.30

Move pattern toward toe,loosen adjusting ringthis side

Decrease backlash.

Tighten adjusting ring.

1003103b

Move pattern toward toe,loosen adjusting ringthis side

Decrease backlash.Loosen adjusting ring.

1003104b

Figure 4.31

1 COTTER PINS

11


32/46



Differential Carrier into the Axle Housing

WARNING

Solvent cleaners can be flammable, poisonous

and cause burns. Examples of solvent cleaners arecarbon tetrachloride, emulsion-type cleaners andpetroleum-based cleaners. To avoid seriouspersonal injury when you use solvent cleaners,you must carefully follow the manufacturer’sproduct instructions and these procedures:

Wear safe eye protection.

Wear clothing that protects your skin.

Work in a well-ventilated area.

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

You must use hot solution tanks or alkalinesolutions correctly. Follow the manufacturer’sinstructions carefully.

When you apply some silicone gasket materials,small amounts of acid vapor are present. Toprevent serious personal injury, ensure that thework area is well ventilated. If the silicone gasketmaterial gets into your eyes, flush them withwater for 15 minutes. Have your eyes checked by aphysician as soon as possible.

1. Clean the inside of the axle housing and thecarrier mounting surfaces. Use a cleaningsolvent and rags to remove dirt. Blow dry thecleaned areas with air. Refer to Section 3.

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

3. Apply Loctite® 242 threadlocker, or equivalent,into the threaded holes in the axle housing. Toobtain this threadlocker, refer to the ServiceNotes page on the front inside cover of thismanual. Refer to Section 3.

4. Apply silicone gasket material onto the carriermounting surface of the housing. Refer toSection 3.

WARNING

To avoid serious personal injury and damage tocomponents, take care when using lifting devices

during service and maintenance procedures.Inspect a lifting strap to ensure that it is notdamaged. Do not subject lifting straps to shocksor drop-loading.

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

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

7. Carefully push the carrier into position.

Tighten the four capscrews two or three turnseach in a CRISSCROSS pattern.

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

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

Figure 4.32

1001105b

T

T


33/46



Axle Shafts in the Axle Assembly

1. Clean the mating surfaces of the axle shaftflange and the wheel hub.

2. Apply a 1/8-inch (3 mm) diameter bead of RTV

sealant around the mating surface of the huband around the edge of each fastener hole.

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

4. Install the capscrews and tighten them to105-115 lb-ft (140-155 N•m).

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

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

Fill the Axle with Lubricant

1. Park the vehicle on a level surface.

2. Remove the fill plug from the axle housing.

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

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

5. Road test the vehicle in an unloaded conditionfor one to two miles (1.6-3.2 km). Do notexceed 25 mph (40 km/h).

6. Recheck the lubricant level. Adjust the

lubricant level as necessary.

Figure 4.33

1 CAPSCREW

2 AXLE SHAFT FLANGE

3 AXLE SHAFT HUB

321

T

T


34/46

Section 5Diagnostics


Section 5DiagnosticsVehicle Will Not Move

Damaged?Yes

No

Damaged?

Yes

Damaged?Yes

No

Contaminated?

Determine

the source of

contamination.

Yes

No

Damaged?

No

Yes

Backlash

within spec?

When the carrier is

reassembled later, set

the backlash to spec.Refer to Section 4.

When the carrier is

reassembled later,

set the backlash tothe recorded reading.

Yes No

Damaged?

Yes

No

Disassemble the main differentialand ring gear. Refer to Section 2.

Damaged?Yes

No

Reset the backlash.

Refer to Section 4.

Install a new

unitized seal.

Reassemble and installthe main differential.

Refer to Section 4.

Inspect the differential

case bearings for damage.

Refer to TP-0445, Parts

Failure Analysis.

Inspect the main differential bearings

for damage. Refer to TP-0445,

Parts Failure Analysis.

Install the carrier.Refer to Section 4.

Test drive the vehicle.Return the vehicle to service.

Visually inspectthe carrier in

the axle housing.

Remove thecarrier from theaxle housing.

Repair the carrieror install a

remanufacturedcarrier. Referto Section 2.

Drain and inspectthe lubricant.

Refer to MM 1.

Remove the carrierfrom the axle housing.

Refer to Section 2.

Visually inspect the ringgear and pinion fordamage. Refer to

TP-0445, Parts FailureAnalysis.

Repair the carrier

or install a




Check the ring gearbacklash and record the

reading. Refer to Section 4.

Use the backlash reading when

you reassemble the carrier.

Remove the main

differential andring gear from

the carrier. Referto Section 2.



Inspect the main differential case and sidegears for damage. Refer to TP-0445,




Inspect the drive pinion and innerdrive pinion bearing for

damage. Refer to TP-0445,Parts Failure Analysis.



Check the drive pinion end play.

Refer to Section 4. Any end playlooseness indicates possible

bearing damage.


35/46



Differential Making Noise

Damaged?Yes

No

Damaged?Yes

Inspect the differential

bearings for damage. Refer to

TP-0445, Parts Failure Analysis.

Damaged?Yes

No

Contaminated?

Determine

the source of

contamination.

Yes

No

Damaged?

No

Yes

Backlash

within spec?

When the carrier is

reassembled later, setthe backlash to spec.Refer to Section 4.

When the carrier is

reassembled later,

set the backlash to

the recorded reading.

Yes No

Disassemble the

main differential

and ring gear.

Refer to Section 2.

Damaged?Yes

No

Damaged?

Reassemble and install the main

differential. Refer to Section 4.

Yes

No

Reset the backlash.

Refer to Section 4.

Install a new

unitized seal.

Inspect the main differential bearings

for damage. Refer to TP-0445,


Install the carrier. Refer toSection 4. Test drive the vehicle.

Return the vehicle to service.

Visually inspect

the carrier in

the axle housing.



remanufactured

carrier.Refer to Section 2.

Drain and inspect

the lubricant.

Refer to MM 1.

Check the drive pinion

end play. Refer to Section 4.Any end play looseness

indicates possible

bearing damage.

Remove the carrier from the

axle housing. Refer to Section 2.

Visually inspect the ring gear

and pinion for damage. Refer to

TP-0445, Parts Failure Analysis.

Repair the carrier

or install aremanufactured

carrier. Refer

to Section 4.


remanufactured

carrier. Referto Section 4.

Check the ring gear

backlash and record the

reading. Refer to Section 4.

Use the backlash reading whenyou reassemble the carrier.

Remove the maindifferential and

ring gear from

the carrier. Referto Section 2.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.

Inspect the main differential case and side

gears for damage. Refer to TP-0445, Parts

Failure Analysis.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 4.

Inspect the drive pinion and inner drive pinion

bearing for damage. Refer to TP-0445, Parts

Failure Analysis.


remanufactured

carrier. Referto Section 4.


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Oil Leak

Damaged?

Inspect the

breather.

Yes

No

Breather

clogged?

Clean or replace the

breather. A clogged

breather can causea seal leak.

Yes

No

Inspect the

pinion seals

for leaks.

Seal

leaking?

Replace the pinion

seal with a

unitized seal.

Replace the pinion

cage O-ring with

a new O-ring.

Yes

No

Jointleaking?

No

Yes

Inspect thecarrier-to-housing

joint for leaks.

Test drive the vehicle to

confirm that the leak is

repaired. Return the

vehicle to service.

Visually inspect

the carrier in

the axle housing.

Remove the carrier

from the axle housing.

Repair the carrier

or install a

remanufactured

carrier. Refer

to Section 2.

Inspect the axle housing

welds for cracks or leaks.

If you find weld cracks,

contact Meritor for repair

welding procedures.

Fill the carrier with the

correct amount of the

specified lubricant.

Refer to Section 6.

Clean the seal area.

Test drive the vehicle

to confirm that the

leak is repaired.

Return the vehicle to

service.

Drain and inspect

the lubricant.

Refer to MM 1.


Refer to Section 2.

Clean and prepare the

housing and carrier

flanges. Apply the correct

gasket or silicone.

Refer to Section 3.

Install the carrier.

Refer to Section 4.

Fill the carrier with

the correct amount

of the specified lubricant.

Refer to Section 6.


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Section 6Torque Specifications


Section 6Torque Specifications

Description Specification

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

Differential Bearing Preload 15-35 lb-in

(1.7-3.5 N•m)Expansion Between Bearing Caps 0.0 06-0.013-inch

(0.15-0.33 mm)

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

Ring Gear Runout 0.008-inch(0.200 mm) maximum

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

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

Fastener Size Torque Valuelb-ft (N•m)

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

Adjusting Ring Lock PlateCapscrews

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

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

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

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

83-110(110-150)

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

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

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


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Section 7Lubrication


Section 7LubricationFor complete information on lubricating driveaxles and carriers, refer to Maintenance Manual 1,Preventive Maintenance and Lubrication. To obtainthis publication, refer to the Service Notes page onthe front inside cover of this manual.

Lubricant Capacity

Oil Change Intervals and Specifications for All Rear Drive Axles

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

This interval applies to approved semi-synthetic and full synthetic oils only. For list of approved extended-drain axle oils, referto TP-9539, Approved Rear Drive Axle Lubricants. To obtain this publication, refer to the Service Notes page on the front insidecover of this manual.

MS Series

U.S. Pints Liters

14 6.8

Vocation orVehicle Operation

MotorhomeRecreational Vehicle

Commercial VanBeverage TruckStake TruckWreckerCity DeliverySchool BusFire TruckMunicipal TruckUtility Truck

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

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

Every 10,000 miles (16 000 km),once a month, or the fleetmaintenance interval (whichevercomes first)

Petroleum Based Oil Change on Axle withor without Pump and Filter System

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


Synthetic Oil Change on Axle without Pumpand Filter System


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

Synthetic Oil Change on Axle with Pump andFilter System

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

Filter Change on Axle with Pump and FilterSystem

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


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Section 8Towing Instructions



WARNING



When transporting a vehicle with the wheels of oneor both drive axles on the road, it is possible todamage the axles if the wrong procedure is usedbefore transporting begins. Meritor recommendsthat you use the following procedure.

Before Towing or Drive-Away

WARNING

Engage the parking brake to prevent the vehiclefrom moving before you begin maintenance orservice procedures that require you to be underthe vehicle. Serious personal injury can result.

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

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

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

3. Identify each axle shaft that is removed fromthe axle assembly so they can be installed inthe same location after transporting or repairis completed. Example: Match mark a matingaxle shaft and hub.

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

5. Install a cover over the open end of each hubwhere an axle shaft was removed. This willprevent dirt from entering the bearing cavityand loss of lubricant.

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

6. Connect an auxiliary air supply to the brakesystem of the vehicle that is being transported.Before moving the vehicle, charge the brakesystem with the correct amount of air pressureto operate the brakes. Refer to the instructionssupplied by the vehicle manufacturer forprocedures and specifications. If an auxiliary airsupply is not used, continue with Step 8.

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

WARNING

When you work on a spring chamber, carefullyfollow the service instructions of the chambermanufacturer. Sudden release of a compressedspring can cause serious personal injury.

8. If there are spring parking brakes on the axle(s)that will remain on the road when the vehicle istransported, and they cannot be released by airpressure, manually compress and lock eachspring so that the brakes are released. Refer tothe manufacturer’s instructions.

Figure 8.1

1 CAPSCREW

2 AXLE SHAFT FLANGE

3 AXLE SHAFT HUB

321


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After Towing or Drive-Away

WARNING

Engage the parking brake to prevent the vehiclefrom moving before you begin maintenance orservice procedures that require you to be underthe vehicle. Serious personal injury can result.

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

WARNING

When you work on a spring chamber, carefullyfollow the service instructions of the chamber

manufacturer. Sudden release of a compressedspring can cause serious personal injury.

2. Apply the vehicle spring parking brakes bymanually releasing each spring that wascompressed before transporting started. Referto the manufacturer’s instructions.

3. Disconnect the auxiliary air supply, if used,from the brake system of the vehicle that wastransported. Connect the vehicle’s air supply tothe brake system.

4. Remove the covers from the hubs.

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

5. Install the axle shaft into the axle housing andcarrier in the same location it was removedfrom. The flange of the axle shaft must be flatagainst the hub. Rotate the axle shaft or thedriveline as necessary to align the splines andthe holes in the flange with the studs in thehub. Figure 8.1.

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

7. Check the lubricant level in the axles and hubswhere the axle shafts were removed. Refer toSection 7 for specifications and intervals. Foradditional information, refer to MaintenanceManual 1, Preventive Maintenance and

Lubrication. To obtain this publication, refer tothe Service Notes page on the front insidecover of this manual.

T


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Section 9Special Tools


Section 9Special ToolsCarrier Repair Stand Specifications

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

1 Plates 8’ (2.44 mm) long x 3/4” (19.05 mm) thick x 1-1/4” (31.75 mm) wide with a tongue to fit slot in bar weld plates to bar2 Handle 7” (177.8 mm) long with slot in one end to fit clamp screw3 Bar 2” (50.8 mm) diameter x 9” (228.6 mm) long with one end slotted to fit plate4 Weld all around after pressing plug into pipe.5 Weld6 Shape and size of holes to fit carrier7 23-1/2” (596.9 mm) center to center of pipe8 Chamfer end of pipe for welding.9 4” (101.6 mm) diameter pipe10 Plug 4” (101.6 mm) diameter x 7” (177.8 mm) long with one end turned 3” (76.2 mm) long to fit pipe. Drill 2” (50.8 mm) hole

and mill 3/16” (4.76 mm) wide slot 2” (50.8 mm) from top.

11 Screw 3-1/2” (88.9 mm) long x 5/8” (15.86 mm) diameter with flats onto end to fit handle and 2-1/2” (63.5 mm) length ofthread on other end

12 Drill 3/8” (9.5 mm) hole through handle and screw.

2

1

4

3

6

5

8

7

10

9

12

11

SPX Kent-Moore

part number J-3409-D

1002990e


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How to Make a Yoke Bar

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

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

WARNING

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

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

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

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

Figure 9.1

1 YOKE

A

B

YOKE

1003459a

Figure 9.2

C

D

YOKE

BAR

1003460a


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Seal Driver Tool

Figure 9.3

1

2

3

8

6

910

1112

13 14

4 5

7

4006989a

SEAL PILOTED,READY FOR

INSTALLATION

SEALDRIVER

SEALINSTALLED,SEATED

SEAL DRIVER MATERIALRECOMMENDATIONS

ALLOY STEEL 8620RC 45-50 HARDNESS VALUEBLACK OXIDE FINISH

25

24

15

17

18

1619

20

21

22

23

26

1 2.25" (57.15 MM) DIAMETER

2 2" (50.8 MM) DIAMETER

3 0.06" (1.524 MM) RADIUS

4 0.03" (0.762 MM) X 45 DEGREE CHAMFER


6 STAMP TOOL AND DETAIL NUMBER

7 0.25" (6.35 MM) RADIUS8 0.38" (9.652 MM) RADIUS



11 0.06" (1.524 MM) RADIUS

12 0.03" (0.762 MM) X 45 DEGREE CHAMFER (2)


14 1.5" (38.1 MM) DIAMETER

15 1.75" (44.45 MM) DIAMETER

16 2.25" (57.15 MM) DIAMETER

17 4.3" (109.22 MM) DIAMETER

18 4.5" (114.3 MM) DIAMETER

19 0.875" (22.225 MM)

20 0.955" (24.257 MM)

21 1.5" (38.1 MM)22 1.63" (41.402 MM)

23 2.75" (69.85 MM)

24 1.375" (34.925 MM)

25 3.875" (98.425 MM)

26 6" (152.4 MM)

27 8" (203.2 MM) RADIUS

27


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Meritor Axle MS-113

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Transcript of Meritor Axle MS-113