Meritor Differential Carriers Maintenance Manual

Single-Reduction

Differential Carriers

Maintenance Manual 5

Revised 10-06

Standard Carriers Including: Single Axles, Rear of Tandem Axles, Front Drive Steering Axles

Excluding RS and RT Series (Rear Only), Single-Reduction Axles and RF Series Front Drive Axles

Service Notes

Before You Begin

This manual provides instructions for Meritor’s early production non-RF, -RS or -RT Series axles. Before you begin procedures:

1. Read and understand all instructions an procedures before you begin to service components.

2. Read and observe all Caution and Warning safety alerts that precede instructions or procedures you will perform. These alerts help to avoid damage to components, serious personal injury, or both.

3. Follow your company’s maintenance and service, installation, and diagnostics guidelines.

4. Use special tools when required to help avoid serious personal injury and damage to components.

Safety Alerts, Torque Symbol and Notes

A Warning alerts you to an

WARNING

CAUTION

NOTE

instruction or procedure that you must follow exactly to avoid serious personal injury and damage to components.

A Caution alerts you to an instruction or procedure that you must follow exactly to avoid damage to components and possible serious injury.

A torque symbol alerts you to tighten fasteners to a specified torque value.

A Note provides information or suggestions that help you correctly service a component.

Access Information on ArvinMeritor’s Website

Additional maintenance and service information for ArvinMeritor’s commercial vehicle systems component lineup is also available at www.arvinmeritor.com.

To access information, click on Products & Services/Tech Library Icon/HVS Publications. The screen will display an index of publications by type.

Additional Information

For complete maintenance and service procedures for all single-reduction differential carriers, call ArvinMeritor’s Customer Service Center at 800-535-5560 to order the following publications.

앫 Traction Controls package contains two videos —

Splitting the Difference T-87127V and Driver-Controlled Full Locking Main Differential

T-9007V. $50. Order T-95125V for this package or each video is available individually as well.

앫 Technical Electronic Library on CD. Features

product and service information on most ArvinMeritor, ZF Meritor and Meritor WABCO components. $20. Order TP-9853.

How to Obtain Tools and Supplies Specified in This Manual

Kiene Diesel Accessories, Inc., 325 S. Fairbanks Street, Addison, IL 60101. Call the company’s customer service center at 800-264-5950, or visit their website at kienediesel.com.

SPX/OTC Service Solutions, 655 Eisenhower Drive, Owatonna, MN 55060. Call the company’s service center at 800-533-6128, or visit their website at otctools.com.

Table of Contents

Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Section 1: Introduction

Standard Single-Reduction Carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Axle Models Covered in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Section 2: Disassembly

Axle Shaft Removal Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Brass Drift Method Air Hammer Vibration Method

Remove Differential Carrier from Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Carrier Removal from Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Remove the Differential and Ring Gear from the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Disassemble the Differential and Ring Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Remove the Drive Pinion and Bearing Cage from Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Disassemble the Drive Pinion and Bearing Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Section 3: Preparing the Parts for Assembly

Cleaning Ground and Polished Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Cleaning Rough Parts Cleaning Axle Assemblies Drying Parts After Cleaning

Preventing Corrosion on Cleaned Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Inspecting Parts

Repair or Replacement of Parts, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Repair Axle by Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Bending or Straightening Drive Axle Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Removing Dri-Loc

Section 4: General Information

Installing Fasteners with Pre-Applied Adhesive, Meritor Liquid Adhesive 2297-C-7049,

Loctite Installing New Fasteners with Pre-applied Adhesive Patches Installing Original or Used Fasteners Using Meritor Liquid Adhesive 2297-C-7049 or

Loctite Application of Meritor Adhesive 2297-T-4180 in Bearing Bores for the Differential

Application of Three Bond 1216 or Equivalent Silicone Gasket Material . . . . . . . . . . . . . . . . . . . . . . . .27

Installing Tight Fit Yokes and POSE™ Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

General Yoke and U-Joint Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Gear Set Information (Drive Pinion and Ring Gear Marks)

Section 5: Assembly

Assemble the Drive Pinion, Bearings and Bearing Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Adjusting Preload of Pinion Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Adjusting Shim Pack Thickness for the Pinion Cage (Depth of Pinion) . . . . . . . . . . . . . . . . . . . . . . . . . .41

Installing the Drive Pinion, Bearing Cage and Shim Pack into the Carrier . . . . . . . . . . . . . . . . . . . . . . . 43

Installing Tight Fit Yokes and POSE™ Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Assemble the Main Differential and Ring Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Inspecting the Rotating Resistance of the Differential Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Install the Differential and Ring Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Adjust Preload of Differential Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Method 1

Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Inspect Runout of Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Ring Gear Backlash Adjustment

Inspect Tooth Contact Patterns of the Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Install and Adjust the Thrust Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Install Differential Carrier into Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Straight Holes, Nuts and Hardened Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Tapered Dowel, Hardened Washer and Hardened Nut

Fasteners

680 Liquid Adhesive or Equivalent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

680 or Equivalent

Table of Contents

Section 6: Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Axle Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Section 7: Fastener Torque Information

Torque Values for Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

General Information American Standard Fasteners Metric Fasteners

Section 8: Adjustments and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Section 9: Vehicle Towing Instructions (Non-DCDL)

Before Towing or Drive-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

After Towing or Drive-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Exploded View — Legend

Exploded View

1 Nut — Drive Pinion

2 Washer — Drive Pinion*

3 Input Yoke* or Flange*

4 Deflector

5 Oil Seal

6 Capscrew — Bearing Cage

7 Washer

8 Bearing Cone — Pinion Outer

9 Bearing Cup — Pinion Outer

10 Bearing Cage — Drive Pinion

11 Shims

12 Spacer— Pinion Bearing

13 Bearing Cup — Pinion Inner

14 Bearing Cone — Pinion Inner

15 Drive Pinion

16 Spigot Bearing

16A Snap Ring

17 Carrier

18 Thrust Screw*

19 Jam Nut* — Thrust Screw*

20 Adjusting Ring — L.H.

26 Washers* — Lock Plate

27 Capscrews* — Lock Plate*

28 Adjusting Ring — R.H.

29 Plug* — Oil Fill Hole (carrier)

30 Washer* — Capscrew/Plug*

31 Capscrew/Plug — Sensor Hole

32 Thrust Block*

33 Washers* — Differential Case

34 Nuts* — Differential Case

35 Bearing Cup — Differential L.H.

36 Bearing Cone — Differential L.H.

37 Nuts* — Ring Gear and Case Half

38 Case Half — Flange

39 Ring Gear

40 Bolts* or Rivets* — Ring Gear and

Case Half

41 Side Gears —Differential

42 Thrust Washers — Differential Pinion

43 Pinions — Differential

44 Spider — Differential

45 Thrust Washers — Differential Side

Gear

21 Cotter* or Pin*

22 Caps — Differential Bearing

23 Washers

24 Capscrews — Differential Bearing Cap

25 Lock Plate* — Adjusting Ring

* Some Meritor carriers do not have these described parts.

NoSPIN® is a registered trademark of Tractech, a division of Dyneer Corp.

46 Capscrews — Differential Case

47 Bolts* — Differential Case

48 Bearing Cup — Differential R.H.

49 Bearing Cone — Differential R.H.

50 Case Half — Plain

Exploded View

Single-Reduction Differential Carrier

Exploded View

Section 1 Introduction

Section 1Introduction

Standard Single-Reduction Carriers

NOTE: For carriers with a differential lock, refer

to Maintenance Manual 5A.

Meritor single-reduction standard carriers, Figure 1.1, are used in most Meritor single axles, rear of tandem axles and front drive steering axles.

Figure 1.1

The single-reduction carrier models are front mounted into the axle housing. These carriers have a hypoid drive pinion and ring gear set and bevel gears in the differential assembly.

A straight roller bearing (spigot) is mounted on the head of the drive pinion. All other bearings in the carrier are tapered roller bearings.

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

1 TAPERED ROLLER BEARINGS 2 CARRIER 3 STRAIGHT ROLLER BEARING 4 TAPERED ROLLER BEARING

5 BEVEL DIFFERENTIAL GEARS 6 HOUSING 7 TAPERED ROLLER BEARING 8 HYPOID DRIVE PINION AND RING GEAR

Axle Models Covered in This Manual

The following table lists all axle models covered in this manual.

Single Drive Axles:

A-150 E-100 F-140 H-172 Q-100 R-163

B-100 E-105 G-161 L-100 Q-145 R-170

B-140 E-150 H-100 L-140 RL-170 S-170

B-150 F-100 H-140 L-155 R-100 U-140

C-100 F-106 H-150 L-172 R-140 W-170

D-100 F-120 H-162 M-172 R-155

D-140 F-121 H-170 QT-140 R-160

Rear Axle of Tandem Axles:

SDHD SL-100 SQHD SSHD SU-170

Section 1

Introduction

For All RS & RT Single-Reduction Axle Model Series, Refer to Maintenance Manual 5A.

SFHD SLHD SR-170 ST-170 SUHD

SHHD SQ-100 SRHD STHD SW-170

Front Drive Steering Axles:

FDS-75 FDS-85 FDS-93 FDS-1807 FDS-2100 FDS-2107 FDS-2111

FDS-78 FDS-90 FDS-1600 FDS-1808 FDS-2101 FDS-2110 FDS-2117

Section 2 Disassembly

Section 2 Disa ssemb ly

Axle Shaft Removal Methods

Meritor Recommends Using Special Tools

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 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 obtain the tools.

앫 If the tools are not available when you remove

the axle shaft: Follow procedures for using the

Brass Drift Method or the Air Vibration Method.

Tool Part Number Manufacturer

Axle Shaft Remover

Axle Stud Cone Plier

K-1280 Kiene Diesel

Accessories, Inc.

7077 SPX OTC

Brass Drift Method

2. Strike the end of the drift with a large hammer, five to six pounds, and the axle shaft and tapered dowels will loosen.

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 2.2.

Figure 2.2

WARNING

Do not strike the round driving lugs on the flange of an axle shaft. Pieces can break off and cause serious personal injury.

1. Hold a 1-1/2 -inch diameter brass drift or brass hammer against the center of the axle shaft, inside the round driving lugs. Figure 2.1.

Figure 2.1

5. Install a cover over the open end of each axle assembly hub where an axle shaft was removed.

Air Hammer Vibration Method

WARNING

Wear safe eye protection when using an air hammer. When using power tools, axle components can loosen and break off causing serious personal injury.

CAUTION

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

1. Use a round hammer bit and an air hammer to loosen the 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 axle shaft from the hub. Figure 2.3.

Section 2

Disassembly

Figure 2.3

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

4. Remove the tapered dowels and separate the axle shaft from the main axle hub assembly.

Figure 2.2.

Remove Differential Carrier from Axle Housing

WARNING

To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.

1. Raise the end of vehicle where the axle is mounted. Use a jack or other lifting tool, and place safety stands under each side of the axle.

Figure 2.4.

Figure 2.4

1 SAFETY STANDS

3. Remove the plug from bottom of axle housing and drain lubricant from the assembly.

4. Disconnect the driveline universal joint from the pinion input yoke or flange on the carrier. Figure 2.5.

5. Remove the capscrews* and washers or stud nuts* and washers from the flanges of both axle shafts.*

6. Loosen the tapered dowels* if applicable, in the axle flanges of both axle shafts using either the Brass Drift or the Air Hammer Vibration method. Refer to Axle Shaft Removal Methods in this section.

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 or fall over. Serious personal injury can result.

2. Place jack stands under each spring seat of the axle to hold vehicle in the raised position. Figure 2.4.

*Some Meritor carriers do not have these

described parts.

Section 2 Disassembly

Figure 2.5

1 FULL ROUND BEARING CUPS 2 END YOKE 3 YOKE SADDLE 4 WELD YOKE 5 BEARING STRAP 6 CAPSCREWS 7 EASY-SERVICE BEARING CUPS 8 U-JOINT CROSS 9 SLIP YOKE

10 CAPSCREWS 11 END YO K E 12 WELD YOKE 13 SLIP YOKE 14 U-JOINT CROSS 15 CAPSCREWS 16 END YOKE 17 WELD YOKE

18 SLIP YOKE 19 U-JOINT CROSS 20 CAPSCREWS 21 END YOKE 22 SLIP YOKE 23 TUBING 24 U-JOINT CROSS 25 WELD YOKE

Carrier Removal from Axle

1. Place a hydraulic roller jack under the differential carrier to support the assembly. Figure 2.6.

2. Remove all but the top two carrier to housing capscrews or stud nuts and washers.

3. Loosen the top two carrier-to-housing fasteners and leave attached to the assembly. The fasteners will hold the carrier in the housing.

4. Loosen the differential carrier in the axle housing. Use a leather mallet to hit the mounting flange of carrier at several points.

5. After the carrier is loosened, remove the top two fasteners.

Figure 2.6

Section 2

Disassembly

CAUTION

When using a pry bar be careful not to damage the carrier or housing flange. Damage to these surfaces will cause oil leaks.

6. Carefully remove the carrier from the axle housing using the hydraulic roller jack. Use a pry bar that has a round end to help remove the carrier from the housing.

7. Lift the differential carrier by the input yoke or flange and place the assembly in a repair stand. Figure 2.7. Use a lifting tool for this procedure. Do not lift by hand. A carrier stand can be built by referring to Figure 2.8.

Figure 2.7

1 WOOD BLOCK 2 ROLLER JACK

1 DIFFERENTIAL CARRIER 2 REPAIR STAND

Section 2 Disassembly

A carrier stand, part number J 3409-D is available from Kent-Moore, Heavy-Duty Division, 28635 Mound Road, Warren, MI 48092.

Figure 2.8

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

CARRIER STAND

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

Section 2

Disassembly

Remove the Differential and Ring Gear from the Carrier

NOTE: Before working on the differential carrier,

inspect the hypoid gear set for damage. If inspection shows no damage, the same gear set can be used again. Measure the backlash of the gear set and make a record of the dimension. Figure 2.9. (Refer to “Ring Gear Backlash Adjustment” in Section 5, Steps 1-5.) During differential reassembly, adjust the backlash to the original recorded dimension when the gear set is installed into the carrier.

1. Loosen the jam nut* on the thrust screw*.

Figure 2.10.

Figure 2.9

2. Remove the thrust screw* and jam nut* from the differential carrier. Figure 2.11.

3. Rotate the differential carrier in the repair stand until the ring gear is at the top of the assembly.

4. Mark one carrier leg and bearing cap to correctly match the parts during carrier assembly. Mark the parts using a center punch and hammer. Figure 2.12.

Figure 2.11

1 DIAL INDICATOR

Figure 2.10

1 THRUST SCREW AND JAM NUT

Figure 2.12

1 BEARING CAP 2 CARRIER LEG 3 MATCH MARKS

*Some Meritor carriers do not have these

described parts.

Section 2 Disassembly

5. Remove the cotter keys*, pins* or lock plates* that hold the two bearing adjusting rings in position. Use a small drift and hammer to remove pins. Each lock plate is held in position by two capscrews. Figure 2.13.

6. Remove the capscrews and washers that hold the two bearing caps on the carrier. Each cap is held in position by two capscrews and washers. Figure 2.14.

7. Remove the bearing caps and bearing adjusting rings from the carrier. Figure 2.15.

8. Safely lift the main differential and ring gear assembly from the carrier. Place the assembly on a work bench. Figure 2.16.

Figure 2.13

Figure 2.14

1 BEARING CAP

Figure 2.15

1 REMOVING COTTER KEY 2 REMOVING LOCK PLATE

*Some Meritor carriers do not have these

described parts.

1 BEARING CAP 2 BEARING ADJUSTING RING

Figure 2.16

Section 2

Disassembly

Disassemble the Differential and Ring Gear Assembly

1. If the matching marks on the case halves of the differential assembly are not visible, mark each case half with a center punch and hammer. The purpose of the marks is to match the plain half and flange half correctly when you assemble the carrier. Figure 2.17.

Figure 2.17

5. If the ring gear needs to be replaced, remove the bolts*, nuts*, and washers* that hold the gear to the flange case half.

Figure 2.18

1 MATCH MARKS 2 MATCH MARKS

2. Remove the capscrews* and washers* or bolts*, nuts* and washers that hold the case halves together.

WARNING

Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury.

3. Separate the case halves. If necessary, use a brass, plastic or leather mallet to loosen the parts.

4. Remove the differential spider (cross), four pinion gears, two side gears and six thrust washers from inside the case halves.

Figure 2.18.

1 THRUST WASHER 2 SIDE GEAR 3 SPIDER, PINIONS AND THRUST WASHERS

WARNING

Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury.

CAUTION

Do not remove the rivets or rivet heads with a chisel and hammer. Using a flat edge tool can cause damage to the flange case.

6. If rivets* hold the ring gear to the flange case half, remove the rivets as follows:

7. Carefully center punch each rivet head in the center, on the ring gear side of the assembly.

*Some Meritor carriers do not have these

described parts.

Section 2 Disassembly

8. Drill each rivet head on the ring gear side of the assembly to a depth equal to the thickness of one rivet head. Use a drill bit that is 1/32 of an inch smaller than the body diameter of the rivets. Figure 2.19.

Figure 2.19

DRILLING RIVET FROM HEAD

9. Press the rivets through holes in the ring gear and flange case half. Press from the drilled rivet head.

Figure 2.20

1 CASE HALF 2 PRESS 3 PLATE 4 SUPPORTS

11. If the differential bearings need to be replaced, remove the bearing cones from the case halves. Use a bearing puller or press. Figure 2.21.

WARNING

Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury.

10. Separate the case half and ring gear using a press. Support the assembly under the ring gear with metal or wood blocks and press the case half through the gear. Figure 2.20.

Figure 2.21

Section 2

Disassembly

Remove the Drive Pinion and Bearing Cage from Carrier

1. Fasten a flange bar to the input yoke or flange. When the nut is removed, the bar will hold the drive pinion in position. Figure 2.22.

Figure 2.22

Figure 2.23

1 FLANGE BAR 2 YOKE BAR

2. Remove the nut and washer* from the drive pinion. Figure 2.22.

3. Remove the yoke or flange bar.

CAUTION

Do not use a hammer or mallet to loosen and remove the yoke or flange. A hammer or mallet can damage the parts and cause driveline runout, or driveline imbalance problems after carrier to driveline assembly.

4. Remove the yoke or flange from the drive pinion. If the yoke or flange is tight on the pinion, use a puller for removal. Figure 2.23.

5. Remove the capscrews and washers that hold the bearing cage in the carrier. Figure 2.24.

*Some Meritor carriers do not have these

described parts.

Figure 2.24

1 BEARING CAGE 2 CARRIER

Section 2 Disassembly

WARNING

Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury.

CAUTION

Do not use a pry bar to remove the bearing cage from the carrier. A pry bar can damage the bearing cage, shims and carrier.

6. Remove the drive pinion, bearing cage and shims from the carrier. If the bearing cage is tight in the carrier, hit the bearing cage at several points around the flange area with a leather, plastic or rubber mallet. Figure 2.25.

Figure 2.25

Disassemble the Drive Pinion and Bearing Cage

Figure 2.26

1 DRIVE PINION 2 OIL SEAL 3 OUTER BEARING (CUP AND CONE) 4 INNER BEARING (CUP AND CONE) 5 SPIGOT BEARING 6 SNAP RING 7 BEARING SPACER

1 DRIVE PINION AND BEARING CAGE 2 SHIMS

7. If the shims are in good condition, keep the shims together for use later when the carrier is assembled.

8. If shims are to be discarded because of damage, first measure the total thickness of the pack. Make a note of the dimension. The dimension will be needed to calculate the depth of the drive pinion in the carrier when the gear set is installed.

WARNING

Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury.

1. Place the drive pinion and bearing cage in a press. The pinion shaft must be toward the top of the assembly. Figure 2.27.

Section 2

Disassembly

Figure 2.27

1 PRESS 2 DRIVE PINION 3 OIL SEAL 4 BEARING CAGE 5 SUPPORT 6 SPIGOT BEARING 7 SUPPORT

2. Support the bearing cage under the flange area with metal or wood blocks. Figure 2.27.

3. Press the drive pinion through the bearing cage. Figure 2.27.

Figure 2.28

1 OIL SEAL

WARNING

Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury.

6. If the pinion bearings need to be replaced, remove the inner and outer bearing cups from the inside of cage. Use a press and sleeve, bearing puller, bearing driver or a small drift hammer. The type of tool used depends on the design of the bearing cage. Figure 2.29.

When a press is used, support the bearing cage under the flange area with metal or wood blocks.

WARNING

Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury.

NOTE: The inner bearing cone and bearing spacer will remain on the pinion shaft.

4. If a press is not available, use a leather, plastic or rubber mallet to drive the pinion through the bearing cage.

CAUTION

Be careful when removing the seal. Do not damage the wall of bore. Damage to the bore wall can result in oil leaks.

NOTE: When the oil seal has been removed, always replace it with a new triple-lip (main) seal during component reassembly.

5. If the pinion oil seal is mounted directly in the outer bore of the bearing cage, remove the seal at this time.

Be careful that you do not damage the mounting surfaces of the bearing cage.

Figure 2.28.

Figure 2.29

Section 2 Disassembly

7. If the pinion bearings need to be replaced, remove the inner bearing cone from the drive pinion with a press or bearing puller. The puller MUST fit under the inner race of the cone to remove the cone correctly without damage. Figure 2.30.

Figure 2.30

Figure 2.31

1 SPIGOT BEARING 2 SNAP RING

Figure 2.32

1 PRESS 2 DRIVE PINION 3 BEARING PULLER 4 SUPPORTS 5 INNER BEARING CONE

8. If the spigot bearing needs to be replaced, place the drive pinion in a vise. Install a soft metal cover over each vise jaw to protect the drive pinion.

9. Remove the snap ring* from the end of drive pinion with snap ring pliers that expand.

Figure 2.31.

NOTE: Some spigot bearings are fastened to

the drive pinion with a special peening tool.

Figure 2.32.

1 PEENING POINTS

*Some Meritor carriers do not have these

described parts.

10. Remove the spigot bearing from the drive pinion with a bearing puller. Figure 2.33.

NOTE: Some spigot bearings are a two-piece assembly. Remove the inner race from the pinion with a bearing puller. Remove the outer race/roller assembly from carrier with a drift or a press.

Figure 2.34.

Figure 2.33

Section 2

Disassembly

1 BEARING PULLER 2 SPIGOT BEARING

Figure 2.34

1 REMOVE OUTER RACE AND ROLLER ASSEMBLY FROM

CARRIER

2 REMOVE INNER RACE FROM PINION

Section 3 Preparing the Parts for Assembly

Section 3Preparing the Parts for Assembly

Cleaning Ground and Polished Parts

WARNING

To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.

Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion-type cleaners and petroleum-based cleaners. To avoid serious personal injury when you use solvent cleaners, you must carefully follow the manufacturer's product instructions and these procedures:

앫 Wear safe eye protection.

앫 Wear clothing that protects you 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. Follow the manufacturer's instructions carefully.

CAUTION

Use only solvent cleaners to clean ground or polished metal parts. Hot solution tanks or water and alkaline solutions will damage parts. Isopropyl alcohol, kerosene or diesel fuel can be used for this purpose. If required, use a sharp knife to remove gasket material from parts. Be careful not to damage the ground or polished surfaces.

1. Use a cleaning solvent to clean ground or polished parts or surfaces. Kerosene or diesel fuel oil can be used for this purpose. Do not

use gasoline.

2. Use a tool with a flat blade, if required, to remove sealant material from parts. Be careful not to damage the polished or smooth surfaces.

3. Do not clean ground or polished parts with water or steam. Do not immerse ground or polished parts in a hot solution tank or use strong alkaline solutions for cleaning, or the smooth sealing surface may be damaged.

Cleaning Rough Parts

WARNING

앫 Wear safe eye protection.

앫 Wear clothing that protects you 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. Follow the manufacturer's instructions carefully.

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

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

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

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

Cleaning Axle Assemblies

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

2. Before the axle is steam cleaned, close or place a cover over all openings in the axle assembly. Examples of openings are breathers or vents in air chambers.

Drying Parts After Cleaning

CAUTION

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

1. Parts must be dried immediately after cleaning and washing.

2. Dry the parts using soft, clean paper or cloth rags.

3. Except for bearings, parts can be dried with compressed air.

+ 55 hidden pages

Meritor Differential Carriers Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual