Maintenance Manual MM-0208 Single Reduction Differential...

Maintenance Manual MM-0208

Single Reduction DifferentialRear or Solo Carrier MS - MR15Issue September 2017

2 Meritor Rear or Solo Carrier MS - MR15

Service Notes

Before You BeginThis publication provides installation and maintenance proceduresfor the MERITOR Single Reduction Differential Rear or Solo CarrierMS - MR15.

The information contained in this publication was current at thetime of printing and is subject to revision without notice or liability.

You must understand all procedures and instructions before youbegin maintenance and service procedures.

You must follow your company's maintenance and service guidelines.

You must use special tools, when required, to avoid seriouspersonal injury and damage to components.

MERITOR uses the following notations to alert the user of possiblesafety issues and to provide information that will help to preventdamage to equipment and components.

WARNINGA WARNING indicates a procedure that you must followexactly to avoid serious personal injury.

CAUTIONA CAUTION indicates a procedure that you must followexactly to avoid damaging equipment or components.Serious personal injury can also occur.

NOTE: A note indicates an operational, procedure or instructionthat is important for proper service. A NOTE can also supplyinformation that will help to make service quicker and easier.

This symbol indicates that you must tighten fasteners to a specific torque.

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

Access Information on Meritor's Web SiteAdditional maintenance and service information for Meritor'scommercial vehicle systems component lineup is also available atwww.meritor.com

To access information, click on Products, Publications. The screenwill display an index of publications by type.

All rights reserved.

No part of this publication may be reproduced in any form or byany means or granted to any third parties without the writtenpermission of MERITOR.

MERITOR reserves the right to publish revisions at any time fortechnical or commercial purposes. Therefore all materialcontained in this manual is based on the latest informationavailable at time of publication approval.

Copyright 2017 by MERITOR

3Meritor Rear or Solo Carrier MS - MR15

Terms used in this manual

Manufacturer:MERITOR

Manual: Maintenance manual no. MM-0208

Device: Single Reduction Differential Rear or Solo Carrier MS - MR15

Technician:Qualified personnel working on the carrier maintenance andservicing.

Maintenance and servicing: Maintenance and servicing refer to periodical checks and/orreplacement of the leading axle carrier parts or components. It also refers to the determining of the cause of a malfunction inorder to restore the initial operating conditions.

Operator: Any person who will use the single reduction rear or solo carrieras part of a more complex device.

WarrantyWarranty applies to the leading axle carrier installed on vehiclesfor which it was designed. Warranty is void in the following cases:

• Improper use of the vehicle on which the single reductioncarrier is installed (usage conditions, overloading etc.)

• Tampering with vehicle components that may affect thecarrier performance.

• Use of non-original spare parts.

• Improper installation, adjustment, repair or modification.

• Poor or improper maintenance (including consumables other than those specified).

Further information on warranty conditions may be obtaineddirectly from the manufacturer or by referring to the Meritor website www.meritor.com


Contents

05 Section 1: Introduction 06 Single Reduction Differential Rear or Solo Carrier

MS - MR15 - Exploded view07 Single Reduction Differential Rear or Solo Carrier

MS - MR15 - Parts list08 Single Reduction Differential Rear or Solo Carrier

MS - MR15 - Exploded view09 Single Reduction Differential Rear or Solo Carrier

MS - MR15 - Parts list10 Curvic Design Differential Lock Feature

13 Section 2: Disassembly 14 Removing the Diff. Carrier from the Axle Housing 14 Raising the Vehicle 14 Carrier Removal 15 Differential Ring Gear and Pinion 17 Differential Bearings 18 Drive Pinion from the Bearing Cage

19 Section 3: Preparing the Parts for Assembly20 Cleaning Ground and Polished Parts 20 Cleaning Rough Parts 20 Cleaning Axle Assemblies 20 Drying Parts After Cleaning20 Preventing Corrosion on Cleaned Parts 21 Inspecting Parts 23 Repairing or Replacing Parts

25 Section 4: General Information26 Application of Three Bond 1216 or Equivalent Silicone Gasket Material 27 Clean, Inspect and Install the Yoke after Installing a Unitized Pinion Seal27 Checking for Mismatched Ratios on Tandem Axles 28 Check the Hypoid Gear Set Ratios listed on the Identification Tags 28 Rotate the Forward Driveshaft to Check the Hypoid Gear Set Ratio 29 Verify the Actual Hypoid Gear Set Ratios 30 Torque Plus Angle Recommendations 30 Tire Matching for Tandem and Tridem Axles

31 Section 5: Assembly 32 Assembly 32 Main Differential Case and Ring Gear34 Checking the Rotating Resistance of the Differential Assembly35 DrivePinion 35 Installing the Spigot Bearing on the Drive Pinion 36 Pinion and Drive Gear Assembly 37 Adjusting the Pinion Cage Shim Pack Thickness 38 Differential Carrier Installation 41 Adjust Differential Bearing Preload 41 Adjust Hypoid Ring Gear Backlash 42 Tooth Contact Pattern 45 Install and Adjust the Differential Lock Sensor Switch46 Replace the Pinion-Pac Seal 47 Installing the Differential Carrier 48 Filling the Axle With Lubricant

49 Section 6: Torque Specifications 51 Torque Plus Angle Recommendations 41 Torque Plus Angle Method

53 Section 7: Special Tools 54 Carrier Repair Stand Specifications 55 How to Make a Yoke Bar56 MST440157 MST480758 MST4808

59 Section 8: Vehicle Towing Instructions60 General Information60 Before Towing or Drive-Away 61 After Towing or Drive-Away

63 Section 9: Diagnostic Flowcharts64 Rear Tandem Carrier - Vehicle Will Not Move65 Rear Tandem Carrier - Differential Making Noise66 Rear Tandem Carrier - Oil Leak 67 All Rear Axles - Contaminated Lubricant found during Preventive Maintenance

pg. pg.


pg.

1

Introduction

06 Single Reduction Differential Rear or Solo Carrier MS - MR15 - Exploded view

07 Single Reduction Differential Rear or Solo Carrier MS - MR15 - Parts list

08 Single Reduction Differential Rear or Solo Carrier MS - MR15 - Exploded view

09 Single Reduction Differential Rear or Solo Carrier MS - MR15 - Parts list

10 Curvic Design Differential Lock Feature


Exploded viewSingle Reduction Differential Rear or Solo Carrier MS - MR15

Fig. 1.1


Parts listSingle Reduction Differential Rear or Solo Carrier MS - MR15

Ref. Description 1 Carrier 2 Bearing Cap L.H. 3 Pin 4 Bearing Cap R.H. 5 Bearing Cap Washer 6 Bearing Cap Capscrew 7 Identification Plate 8 Pinion Bearing Cage (Pinion-Pac) 9 0-Ring (Pinion Cage) 10 Pinion Cage Shim 11 Pinion Cage Shim 12 Pinion Cage Shim 13 Pinion Cage Capscrew 14 Plane Half Differential Case 15 Differential Bearing Cup L.H. 16 Differential Bearing Cone L.H. 17 Differential Bearing Cup R.H. 18 Differential Bearing Cone R.H. 19 Adjusting Ring

Ref. Description

20 Differential Case Screw 21 Cotter Pin 22 Spiral Pin 23 Plug 24 Thrust Screw 25 Wear Pad 26 Thrust Screw Nut 27 Differential Spider 28 Differential Pinion 29 Differential Pinion Thrust Washer 30 Differential Side Gear 31 Side Gear Thrust Washer 32 Drive Pinion 33 Drive Gear 34 Flange Half Differential Case 35 Pinion Spigot Bearing 36 Drive Pinion Nut 37 Drive Gear Screw 38 Shift Fork 39 Shift Fork Pin


Exploded viewSingle Reduction Differential Rear or Solo Carrier MS - MR15

Fig. 1.2


Parts listSingle Reduction Differential Rear or Solo Carrier MS - MR15

Ref. Description 40 Shift Shaft41 Shift Shaft Spring42 Piston43 Piston O-Ring44 Cylinder End Cover45 Cylinder Cover Gasket46 Cover Capscrew47 Cover Capscrew Washer48 Plug49 Sensor Switch50 Lock Nut-Sensor Switch51 Clutch Collar52 Fixed Collar53 Spacer54 Retaining Ring55 Companion Flange56 Deflector57 Pinion Pac-Seal

Model Without Differential Lock

Ref. Description

58 End Cover

59 Sensor Switch Hole Blanking Plug

60 Washer Plug

61 End Cover Capsrew

62 End Cover Capsrew Washer

63 End Cover Gasket

64 Snap Ring


Curvic Design Differential Lock Feature

Description The differential unit is a single-reduction design featuring ahypoid gear set. The pinion gear is mounted on two taper rollerbearings (pinion unit) and a third straight roller bearing.The piniongear setting relative to the drive gear can be adjusted by varyingthe thickness of the shim pack located between the differentialcarrier and the pinion bearing cage.

The differential gear case is supported on two taper rollerbearings and is adjusted for end play through two threadedadjusting rings. The MR-150-E rear differential carrier unit isavailable with a differential lock.

Fig. 1.3


1 Introduction

Carrier Model Tag Location

Fig. 1.4

Carrier Model Tag Number Information

Fig. 1.5

Manufacturing Location:N = N.A.S = S.A.E = EuropeA = Australia/Asia

Gearing Type1 = Single Speed

Axle Design Variation:Indicates axle design level or variation(Housing Wall e.g.: 0 = Cast5 = 12.7 - 13mm)

Carrier TypeCarrier size. Large numbers indicate a higher GCW rated Carrier;i.e., larger ring gear, etc.

Nominal Axle Load Rating (GAWR): in thousands of pounds.Individual forward and rear axles of a tandem set (D, N, P) are rated as single axles.A tandem set (T) is rated as the combination of the two axles.

Axle TypeS = Single Rear (Solo)R = Rear-Rear Axle of a Drive TandemT = Tandem Drive Axle Set

Meritor (Rockwell)


pg.

2

Disassembly

14 Removing the Diff. Carrier from the Axle Housing 14 Raising the Vehicle 14 Carrier Removal 15 Differential Ring Gear and Pinion 17 Differential Bearings 18 Drive Pinion from the Bearing Cage


WARNINGTo prevent serious eye injury, always wear safe eyeprotection when you perform vehicle maintenance orservice.

Removing the Differential Carrier From theAxle HousingRaising the Vehicle1. Make sure the vehicle is on a level surface.

WARNING Park the vehicle on a level surface. Block the wheels toprevent the vehicle from moving. Support the vehicle withsafety stands. Do not work under a vehicle supported onlyby jacks. Jacks can slip and fall over. Serious personalinjury and damage to components can result.

2. Raise the vehicle so that the wheels are off the ground.Support the vehicle with safety stands.

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

4. Disconnect the driveline from the input yoke.

5. Disconnect the vehicle air line from the inter-axle differentialand main differential lock actuator assemblies.

6. Disconnect the driveline universal joint from the pinion inputyoke or flange on the carrier. For driveline and U-jointdisassembly and service, refer to the manufacturer’sinstructions.

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

8. Loosen the tapered dowels* in the axle flanges of both axleshafts using one of the following methods. *Some Meritorcarriers do not have these described parts.

9. Remove the axle shafts per the vehicle manufacturerrecommended procedures.

Carrier Removal 1. Place a hydraulic roller jack under the differential carrier to

support the assembly.

2. Remove all but the top two carrier-to-housing capscrews orstud nuts and washers.

3. Loosen, but do not remove, the top two carrier-to-housingfasteners. The fasteners will hold the carrier in the housing.

4. Loosen the differential carrier in the axle housing. Use aplastic mallet to hit the mounting flange of carrier at severalpoints.

5. After the carrier is loosened, remove the top two stud nutsand washers that hold the assembly in the axle housing.

CAUTION When using a pry bar, be careful not to damage the carrieror housing flange. Damage to these surfaces will cause oilleaks.

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

7. On axles with a driver controlled main differential lock, if airpressure is used to shift the differential to the locked(engaged) position, release the air pressure. Disconnect theair hose from the shift unit.

8. Lift the differential carrier by the input yoke or flange andplace the assembly in a repair stand. Use a lifting tool for thisprocedure. Do not lift by hand. For carrier repair standspecifications, refer to Section 8.

2 Disassembly


Differential Ring Gear and Pinion 1. Mount the carrier unit in a suitable stand or secure it to a

work bench. If available, mount the unit securely in a carrierstand. Fig. 2.1

2. Loosen the sensor switch. Fig. 2.2

3. Loosen the four screws and remove the cylinder end coverand gasket. Fig. 2.2

4. Remove the piston, shaft and spring. Fig. 2.2

5. Loosen the thrust screw nut and thrust screw (if present) Fig. 2.3

6. Remove the shift fork together with the clutch collar. Fig. 2.4

7. Remove the spiral pin and cotter pin. Fig. 2.4

2 Disassembly

Fig. 2.1

Fig. 2.2

Fig. 2.3

Fig. 2.4


2 Disassembly

8. Remove the bearing adjusting rings. Fig. 2.5

9. Use a suitable wrench to loosen and remove the bearing capcapscrews and washers. Repeat on the opposite side. Fig. 2.5

10. Remove the bearing caps. Fig. 2.5

11. Use a lifting device to remove the differential gear case withthe drive gear and bearing cups. Fig. 2.6

WARNINGTo avoid serious personal injury and damage to components,take care when using lifting devices during service andmaintenance procedures. Inspect a lifting strap to ensurethat it is not damaged. Do not subject lifting straps toshocks or drop-loading.

12. Use a companion flange socket, retainer or other suitabledevice to hold the flange stationary. Fig. 2.7

13. Use a wrench and torque multiplier to loosen the drive pinionnut. Do not remove the nut. Fig. 2.7

14. Remove the capscrews, fastening drive pinion bearing cage tothe carrier. Fig. 2.8

Fig. 2.6

Fig. 2.7

Fig. 2.8

Fig. 2.5


2 Disassembly

NOTE: Use two bolts or screws to ensure differential unitalignment before you remove the bearing cage from the carrier.

15. Remove the bearing cage from the carrier. Loosen the drivepinion nut. Remove the companion flange. Use a puller, ifnecessary. Fig. 2.8

16. Remove the pinion-to-drive gear backlash adjustment shims.Measure the overall shim thickness with a micrometer gauge.Fig. 2.8

Differential Bearings

WARNING Observe all warnings and cautions provided by the pressmanufacturer to avoid damage to components and seriouspersonal injury.

1. Use a puller to remove the bearing on the plain half case.Fig. 2.9

2. Use a puller to turn over the differential case assembly. Pull the bearing off the flange half. Fig. 2.10

3. Secure the ring gear assembly to a suitable fixture. If none isavailable, place the ring gear assembly on a work bench andsupport the underside with wood blocks.

4. Remove the capscrews that fasten the ring gear to the flangehalf differential case. Fig. 2.11


5. To remove the ring gear from the differential case, use eithera brass drift or a press. Fig. 2.11

Fig. 2.9

Fig. 2.10

Fig. 2.11


2 Disassembly

6. Mark the two case halves and the spider for correct mating atreassembly. Figure 2.12.

7.Remove the capscrews and remove the flange half differentialcase. Figure 2.12.

Drive Pinion from the Bearing Cage1. Inspect the drive pinion bearing for wear or damage.

If the pinion spigot bearing is worn or damaged: Replace the bearing. Use a puller to remove it from the

pinion gear. Fig. 2.13

Use snap ring pliers to remove the snap ring from the end ofthe drive pinion. Use a bearing puller to remove the spigotbearing from the drive pinion.

WARNINGObserve all warnings and cautions provided by the pressmanufacturer to avoid damage to components and seriouspersonal injury.

2. Use a press to push the pinion gear off the bearing cage. Fig. 2.14

3. Use a bearing puller or other suitable tool to remove thebearing. Fig. 2.15

Fig. 2.13

Fig. 2.14

Fig. 2.15

Fig. 2.12


pg.

3

Preparing the Parts forAssembly

20 Cleaning Ground and Polished Parts 20 Cleaning Rough Parts 20 Cleaning Axle Assemblies 20 Drying Parts After Cleaning20 Preventing Corrosion on Cleaned Parts 21 Inspecting Parts 23 Repairing or Replacing Parts


Cleaning Ground and Polished Parts


Solvent cleaners can be flammable, poisonous and causeburns. Examples of solvent cleaners are carbontetrachloride, emulsion-type cleaners and petroleum-basedcleaners. To avoid serious personal injury when you usesolvent cleaners, you must carefully follow themanufacturer’s product instructions and these procedures: - Wear safe eye protection.- Wear clothing that protects your skin. - Work in a well-ventilated area. - Do not use gasoline, or solvents that contain gasoline.Gasoline can explode.

- You must use hot solution tanks or alkaline solutionscorrectly. Follow the manufacturer’s instructions carefully.

1. Use a cleaning solvent to clean ground or polished parts orsurfaces. Kerosene or diesel fuel oil can be used for thispurpose. DO NOT USE GASOLINE.

2. Use a tool with a flat blade if required, to remove sealantmaterial from parts. Be careful not to damage the polished orsmooth surfaces.

CAUTIONUse only solvent cleaners to clean ground or polished metalparts. Hot solution tanks or water and alkaline solutions willdamage these parts. Isopropyl alcohol, kerosene or dieselfuel can be used for this purpose. If required, use a sharpknife to remove gasket material from parts. Be careful not todamage the ground or polished surfaces.

3. DO NOT clean ground or polished parts with water or steam.Do not immerse ground or polished parts in a hot solutiontank or use strong alkaline solutions for cleaning, or thesmooth sealing surface may be damaged.

Cleaning Rough Parts

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

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

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

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

Cleaning Axle Assemblies1. 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 overall openings in the axle assembly. Examples of openings arebreathers or vents in air chambers.

Drying Parts After Cleaning

CAUTIONDamage to bearings can result when they are rotated anddried 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.

Preventing Corrosion on Cleaned Parts 1. Apply axle lubricant to cleaned and dried parts that are not

damaged and are to be assembled.

2. To store parts, apply a special material that prevents corrosionto all surfaces. Wrap cleaned parts in a special paper that willprotect the parts from moisture and prevent corrosion.

3 Preparing the Parts for Assembly


Inspecting PartsIt is very important to inspect all parts carefully and completelybefore the axle or carrier is assembled. Inspect all parts for wearand replace damaged parts. Replacement of damaged or wornparts now, will prevent failure of the assembly later.

1. Inspecting Tapered Roller Bearings: Inspect the cup, cone,rollers and cage of all tapered roller bearings in the assembly.If any of the following conditions exist, the bearing MUST bereplaced.

- The center of large-diameter end of rollers worn level withor below the outer surface. Fig. 3.1

- The radius at large-diameter end of rollers worn to a sharpedge. Fig. 3.1

- A visible roller groove in the cup or cone inner racesurfaces. The groove can be seen at the small- or large-diameter end of both parts. Fig. 3.2

- Deep cracks or breaks in the cup, cone inner race or rollersurfaces. Fig. 3.2

- Bright wear marks on the outer surface of the roller cage.Fig. 3.3


Fig. 3.2

Fig. 3.3Fig. 3.1



- Damage on rollers and on surfaces of the cup and coneinner race that touch the rollers. Fig. 3.4

- Damage on the cup and cone inner race surfaces that touchthe rollers. Fig. 3.5

CAUTIONHypoid drive pinions and ring gears are machined inmatched sets. When a drive pinion or ring gear of a hypoidset needs to be replaced, both drive gear and pinion must bereplaced at the same time.

2. Inspect hypoid pinions and gears for wear or damage. Gearsthat are worn or damaged MUST be replaced.

CAUTIONAlways replace thrust washers, differential side gears andpinion gears in full matched sets. A higher stress on originalparts and early failure of the entire assembly will result if anew part is used in combination with parts that are older orworn.

3. Inspect the Main Differential Assembly:Inspect the followingparts for wear or stress. Parts that are damaged MUST bereplaced. Fig. 3.6

- Inside surfaces of both case halves. - Both surfaces of all thrust washers. - The four trunnion ends of the spider (cross). - Teeth and splines of both differential side gears. - Teeth and bore of all differential pinions.

Fig. 3.4

Fig. 3.5



4. Inspect Axle Shafts:

- Inspect axle shafts for wear and cracksat the flange, shaftand splines.

- Replace axle shafts, if required.

5. Inspect the breather.

A. - Remove the breather from the axle housing. B. - Clean the breather. If the breather remains dirty after cleaning, replace the breather. C. - Apply compressed air to breather. If compressed air does not pass through the breather, replace the breather. D. - Install the breather in the axle housing.

Repairing or Replacing Parts

WARNINGWhen you apply some silicone gasket materials, smallamounts of acid vapor are present. To prevent seriouspersonal injury, ensure that the work area is well ventilated.If the silicone gasket material gets into your eyes, flushthem with water for 15 minutes. Have your eyes checked bya physician as soon as possible.

CAUTIONThreads must be clean and undamaged so that accurateadjustments and correct torque values can be applied tofasteners and parts.

Replace worn or damaged parts of the axle assembly.

1. Replace any fastener if the corners of the head are worn.

2. Replace any damaged washers.

3. Replace the gaskets, oil seals or grease seals at the time ofaxle or carrier reassembly.

Fig. 3.6


4. Clean the parts and apply new silicone gasket material whererequired when the axle or carrier is assembled. Fig. 3.7.

5. Remove nicks, marks and burrs from parts having machinedor ground surfaces. Use a fine file, india stone, emery cloth orcrocus cloth for this purpose.

6. Clean and repair the threads of fasteners and holes. Use a dieor tap of the correct size or a fine file for this purpose.

7. Tighten all fasteners to the correct torque values. Refer toSection 6 for torque values of fasteners.

8. DO NOT repair axle housings by bending or straightening.

CAUTIONRepair of axle housings by bending or straightening willcause poor performance, early failure and possible unsafeoperation of the axle. Do not attempt this type of repair.

NOTE: For cast-iron axle housings, refer to Maintenance Manual8, Drive Axle Housings, for approved axle welding procedures.

9. Welding cannot be used to repair ductile housings. If damageis found on a ductile housing, replace the housing.


Fig. 3.7


pg.

4

General Information

26 Application of Three Bond 1216 or Equivalent Silicone Gasket Material

27 Clean, Inspect and Install the Yoke after Installing a Unitized Pinion Seal27 Checking for Mismatched Ratios on Tandem Axles 28 Check the Hypoid Gear Set Ratios listed on the Identification Tags 28 Rotate the Forward Driveshaft to Check the Hypoid Gear Set Ratio 29 Verify the Actual Hypoid Gear Set Ratios 30 Torque Plus Angle Recommendations 30 Tire Matching for Tandem and Tridem Axles


4 General Information

Fig. 4.1

Application of Three Bond 1216 orEquivalent Silicone Gasket Material


NOTE: The following silicone gasket products or equivalent areavailable in 3 oz (85 gram) tubes and can be used for Meritorcomponents:

- Three Bond Liquid Gasket No. TB 1216-AF — (Grey) Meritor Part Number 2297-Z-7098

- Loctite® Ultra Grey Adhesive/Sealant #18581 Meritor Part Number 2297-A-7021

Also available in 120 oz (3.4 kg) cartridges:

- Three Bond RTV1216-AG (Grey) Meritor Part Number 2297-E-7051

1. Remove all old gasket material from both surfaces. Fig.4.1.

2. Clean the surfaces where silicone gasket material will beapplied. Remove all oil, grease, dirt and moisture withoutdamaging the mating surfaces. Fig. 4.1

3. Dry both surfaces.

CAUTIONThe amount of silicone gasket material applied must notexceed 3 mm (0.125-inch) diameter bead. Too much gasketmaterial can block lubrication passages and result indamage tothe components.

4. Apply 3 mm (0.125-inch) diameter continuous bead of thesilicone gasket material around one surface. Also apply thegasket material around the edge of all fastener holes on thatsurface. Fig. 4.1

5. Assemble the components immediately to permit the siliconegasket material to compress evenly between the parts.Tighten fasteners to the required torque value for that sizefastener. There is no special procedure or additional torquevalue required. Refer to Section 6.

6. Wait 20 minutes before filling the assembly with lubricant.

NOTE: Meritor adhesive products are available from MeritorHeavy Vehicle Systems, LLC.



Fig. 4.2

Clean, Inspect and Install the Yoke AfterInstalling a Unitized Pinion Seal

WARNINGSolvent cleaners can be flammable, poisonous and causeburns. Examples of solvent cleaners are carbontetrachloride, emulsion-type cleaners and petroleum-basedcleaners. To avoid serious personal injury when you usesolvent cleaners, you must carefully follow themanufacturer’s product instructions and these procedures:- Wear safe eye protection.- Wear clothing that protects your skin.- Work in a well-ventilated area.- Do not use gasoline, or solvents that contain gasoline. Gasoline can explode.

- You must use hot solution tanks or alkaline solutionscorrectly. Follow the manufacturer’s instructions carefully.

1. Clean the ground and polished surface of the yoke journalusing a clean shop towel and a safe cleaning solvent. Do notuse gasoline, abrasive cleaners, towels, or scrubbers to cleanthe yoke. Do not attempt to polish the yoke.

NOTE: The unitized seal features a rubber inner sleeve that isdesigned to seal and rotate with the yoke. This feature allows youto reuse a yoke with minor grooves.

2. Inspect the yoke seal surface for grooves. - If you find grooves on the yoke: Use calipers to measure

the groove diameters. If any groove diameter measures lessthan the dimensions shown in Fig. 4.2, replace the yoke.

CAUTIONDo not use thin metal wear sleeves to refresh the yokesurface. Wear sleeves pressed onto the yoke can preventcorrect seating of the pinion seal, damage the pinion sealassembly and can cause the seal to leak.

3. Before you install the yoke, lightly lubricate or coat the yokeseal journal with axle oil.

4. Align the yoke splines with the shaft splines. Slide the yokeover the shaft spline.

Checking for Mismatched Ratios onTandem AxlesFor a tandem axle pair to function correctly, the forward and rearaxles must operate with axle ratios within one percent. A mismatched tandem axle pair can cause carrier overheating,hypoid gear set wear, metal debris to collect on the magneticdrain plug, carrier lubricant additive depletion, excessive interaxlewear and noise.

To determine if the tandem axle ratios operate within allowablelimits, refer to one of the following procedures. Perform theprocedure that will work best for the vehicle you are servicing.



Check the Hypoid Gear Set Ratios Listed onthe Identification Tags 1. Locate the identification tags riveted to the forward and rear

axle differential carriers. Figure 4.3

2. Compare the axle ratios shown on both tags. To operatecorrectly, the axle ratios for both axles must be within onepercent of each other. To calculate the percentage differencebetween the axle ratios, refer to the equation below.

Percentage DifferenceLarger Ratio - Smaller Ratio x 100 =

Between Axle RatiosSmaller Ratio

- If the axle ratios shown on the identification tags arenot within one percent of each other: Refer to the vehiclemanufacturer for further information.


Fig. 4.3

Fig. 4.4

Rotate the Forward Driveshaft to Check theHypoid Gear Set Ratio

WARNINGPark the vehicle on a level surface. Block the wheels toprevent the vehicle from moving. Support the vehicle withsafety stands. Do not work under a vehicle supported onlyby jacks. Jacks can slip and fall over. Serious personal injuryand damage to components can result.

1. Park the vehicle on a level surface.

2. Engage the power divider and shift the transmission intoNEUTRAL.

3. Place blocks under the wheels to prevent the vehicle frommoving.

4. Use a jack to raise the vehicle until all tandem drive axlewheels clear the ground. Support the vehicle with safetystands.

5. Mark the forward and rear tires at identical relative positions.Fig. 4.4


6. Turn the forward driveshaft in one direction by hand until theforward tire completes two rotations. Fig. 4.5 Ensure that theforward tire rotates two times only. If the forward tire rotatesmore than or less than two rotations, the anglemeasurements you make in Step 7 will be inaccurate.

7. Note the positions of the tire marks you previously made. Ona correctly matched tandem axle gear set, both tire marks willbe within ± 3.6 degrees of each other. Figure 4.6.

- If the positions of the tire marks are more than 3.6degrees from each other: Refer to the vehiclemanufacturer for further information.

8. Remove the safety stands and lower the vehicle.

Verify the Actual Hypoid Gear Set Ratios You can check the actual hypoid gear set ratios when you removethe differential carriers from the axle housings for service orrepair. Refer to the following procedure to calculate the actualgear set ratios.

1. Count the number of ring gear teeth. Figure 4.7

2. Count the number of pinion gear teeth. Figure 4.7

3. Divide the number of ring gear teeth by the number of piniongear teeth to determine the actual hypoid gear set ratio foreach axle. Fig. 4.7

4. Calculate the percentage difference between the hypoid gearset ratios using the equation below. All ratios must matchwithin one percent.

Percentage DifferenceLarger Ratio - Smaller Ratio x 100 =

Between Axle RatiosSmaller Ratio

- If the actual hypoid gear set ratios are not within onepercent of each other: Refer to the vehicle manufacturerfor further information.


Fig. 4.5

Fig. 4.6

Fig. 4.7



Torque Plus Angle RecommendationsWhen tightening ring gear capscrews, housing nuts andcapscrews, torque to correct specifications using the standardtorque method or the torque plus angle method.

Torque Plus Angle Method- To tighten the ring gear capscrews: Torque the capscrews in a criss-cross sequence. - Use a torque wrench to tighten the capscrews to

100 N•m (73.75 lb-ft). - Then, tighten the capscrews an additional 80-90 degrees

- To tighten the plain half differential case capscrews: Torque the capscrews in a criss-cross sequence. - Use a torque wrench to tighten the capscrews

to 100 N•m (73.75 lb-ft). - Then, tighten the capscrews an additional 110-120

degrees.

- To tighten the pinion cage capscrews: - Use a torque wrench to tighten the capscrews

to 100 N•m (73.75 lb-ft). - Then, tighten the capscrews an additional 60-70 degrees.

- To tighten nuts for studs and capscrews on the housing: - Use a torque wrench to tighten the capscrews

to 100 N•m (73.75 lb-ft). - Then, tighten the nuts and capscrews an additional 80-90

degrees.

Tire Matching for Tandem and Tridem Axles

CAUTIONUnmatched tires on both tandem drive units and tridemdrive units will cause tire wear and scuffing and possibledamage to the drive units. Meritor recommends that thetires be matched to within 3.18 mm (1/8-inch) of the samerolling radius, 19.05 mm (3/4-inch) of the same rollingcircumference.

Tandem AxlesThe four largest tires should never be installed on one driving axleor the four smallest tires on the other driving axle. Such tiremounting will cause an interaxle “fight,” unusually high axlelubricant temperatures that result in premature lubricantbreakdown and possible costly axle service.In addition tomatching individual tire rolling radii or rolling circumference,Meritor recommends matching, as nearly as possible, the total tirecircumference of one driving axle to the total tire circumference ofthe other driving axle. This will usually result in satisfactorytandem axle lubricant temperatures that lengthen drive unitservice with higher tire mileage.Park the vehicle on a levelsurface. The vehicle must carry a correctly distributed ratedcapacity load. All the tires must be the same size. Measure newtires to verify that they will be correctly matched.

1. Inflate all tires to the same pressure.

2. Carefully measure the rolling circumference of each tire witha steel tape.

3. Mark the size on each tire with chalk and arrange the tires inorder of size, largest to smallest.

4. Mount the two largest tires on one side of one axle andmount the two smallest on the opposite side of the same axle.

5. Mount the four other tires on the other axle in the samemanner.

6. Test run the vehicle to gather accurate rear axle lubricanttemperature readings on the two axle lubricant temperaturegauges.

7. Vary tire air pressure within the tire manufacturer’srecommended range so the lubricant temperature of bothaxles is within–1°C (30°F) of each other and not in excess of93°C (200°F). This will usually result in uniform tire loadingand good tire life.


pg.

5

Assembly

32 Assembly 32 Main Differential Case and Ring Gear34 Checking the Rotating Resistance of the Differential Assembly35 DrivePinion 35 Installing the Spigot Bearing on the Drive Pinion 36 Pinion and Drive Gear Assembly 37 Adjusting the Pinion Cage Shim Pack Thickness 38 Differential Carrier Installation 41 Adjust Differential Bearing Preload 41 Adjust Hypoid Ring Gear Backlash 42 Tooth Contact Pattern 45 Install and Adjust the Differential Lock Sensor Switch46 Replace the Pinion-Pac Seal 47 Installing the Differential Carrier 48 Filling the Axle With Lubricant


5 Assembly

WARNINGTo prevent serious eye injury, always wear safe eyeprotection when you perform vehicle maintenance orservice. Wear gloves and protective clothing when youhandle a hot bearing to prevent serious personal injury.Observe all warnings and cautions provided by the pressmanufacturer to avoid damage to components and seriouspersonal injury.

Assembly

Main Differential Case and Ring Gear

CAUTIONDo not press a cold ring gear on the flange case half. A coldring gear will damage the case half because of the tight fit.Metal particles between the parts will cause gear runoutthat exceeds the Meritor specification of 0.008-inch (0.200mm).

1. Expand the ring gear by heating the gear in a tank of water toa temperature of 71°C-82°C (160°F to 180°F) for 10 to 15minutes.

WARNING Wear safe clothing and gloves for protection from injurywhen working with the hot ring gear.

2. Use a lifting tool to safely lift the ring gear from the tank ofwater.

3. Install the ring gear on the flange case half immediately afterthe gear is heated. If the ring gear does not fit easily on thecase half, heat the gear again. Repeat Step 1.

4. Align fastener holes of the ring gear and flange case half.Rotate the ring gear as needed.

5. Install new capscrews that hold the ring gear to the flangecase half. Figure 5.1.

Fig. 5.1

6. Tighten the capscrews in a criss-cross sequence. Tighten tothe correct value. Refer to the following table or Section 6.

Torque Torque Plus Angle520-540 N•m 100 N•m (73.75 lb-ft)(383-398 lb-ft) 80-90 degree angle

A. After the bolts are installed, inspect for gaps between theback surface of the ring gear and the case flange. Use an0.080 mm (0.003-inch) feeler gauge and inspect at fourpoints around the assembly.

B. Inspect the flange case half and ring gear for the problemthat causes the gap. Repair or replace parts.

C. After the parts are repaired or replaced, assemble the ringgear on the flange case half. Repeat the previousprocedure, and these Steps A-C.

7. Install the bearing cones on both of the case halves. Use apress and sleeve of the correct size.

8. Apply axle lubricant on the inside surfaces of both casehalves, spider (cross), thrust washers, side gears anddifferential pinions.


5 Assembly

9. Place the plain case half on a bench.

10. Install one thrust washer and side gear into the plain casehalf. Figure 5.2.

11. Align spider match marks and install the spider (cross),differential pinions and thrust washers into the case half.Figure 5.3.

12. Install the second side gear and thrust washer over spiderand differential pinions. Figure 5.3.

13. Place the flange half case with the ring gear over the plainhalf and gears. Rotate the flange half as needed to align thematch marks. Figure 5.4.

14. Install the other fasteners into the case halves. Tighten thefasteners to the correct torque value. Refer to the followingtable or Section 6.


15. Inspect the rotating resistance of the differential gears. Be certain the differential assembly freely rotates.

Fig. 5.2

Fig. 5.4

Fig. 5.3


5 Assembly

Checking the Rotating Resistance of theDifferential AssemblyNOTE: Make a tool to check the rotating resistance of thedifferential gears. The tool can be made from an axle shaft thatmatches the spline size of the differential side gear. Figure 5.5.

1. Install soft metal covers over vise jaws to protect the ringgear. Figure 5.6.

2. Place the differential and ring gear assembly in the vise.Secure the ring gear in vise.

3. Install the tool into the differential until the splines of the tooland one side gear are engaged. Figure 5.6.

4. Attach a wrench to the nut of the tool and rotate thedifferential gears. The differential assembly must freely rotate.Figure 5.7.

5. If the differential assembly does not rotate freely, disassemblethe differential gears from the case halves.

6. Check the case halves, spider, gears and thrust washers forthe problem that causes the rotation resistance. Repair orreplace parts.

7. After the parts are repaired or replaced, reassemble thedifferential cage assembly parts and repeat Steps 1-6.

Fig. 5.5

Fig. 5.7

Fig. 5.6


5 Assembly

Drive Pinion


1. Use a sleeve and heavy press to press the bearing cage ontothe pinion gear. Fig. 5.8.

Installing the Spigot Bearing on the DrivePinion 1. Place the drive pinion in a press with the gear head (teeth) on

the TOP. Fig. 5.9.

2. Press the spigot bearing onto the end of the drive pinion withthe larger radius TOWARD the pinion head, until the bearing isflat against the gear head. Use the correct sleeve against thebearing in race. Fig. 5.10.

NOTE: Some Meritor carriers do not use snap rings.

Fig. 5.8

Fig. 5.10

Fig. 5.9


5 Assembly

3. If necessary, use snap ring pliers to install the snap ring intothe groove into the end of the drive pinion. Figures 5.11 and5.12.

Pinion and Drive Gear Assembly

CAUTION When you install a pinion and drive gear set, verify that bothparts have the same match number to avoid damage tocomponents.

1. Use a press and suitable drift to install the drive input flangeand deflector. Temporarily tighten the retaining nut. Figure5.13.

2. Follow the procedure below if you use the same pinion drivegear during reassembly.

A. Position the previously measured shim pack and pinionbearing cage with the carrier’s bearing cage O-ring. Fig. 5.14.

B. Verify that the oil passage groove is aligned correctly.

Fig. 5.11

Fig. 5.12

Fig. 5.14

Fig. 5.13


5 Assembly

Adjusting the Pinion Cage Shim PackThickness Each drive gear is marked with a variation number (H number)that indicates the nominal assembly distance. Use this number tocalculate the thickness of the shim pack between the pinionbearing cage and differential carrier. This variation number isstamped on outer face of the drive gear; for example, H + 0.1mm or H – 0.1 mm.

Use the value obtained in Example 2 to calculate the thickness ofthe shim pack that you’ll install between the pinion bearing cageand the differential carrier.

Shims between the differential carrier and bevel pinion bearingcage are available in thicknesses of 0.125/0.200/0.500 mm.

1. Use a micrometer or a gauge to measure the thickness of theshim pack that you removed with the old pinion-drive gearassembly. Record the measurement. Fig. 5.15.In case the shim pack used is not available it is possible touse the average of Manufacturer’s Adjusted Shim Pack valuewhich is 1 mm for the MS/MR15 carrier.

2. Read the H marked on the drive gear you’ll replace.

- If the number is positive (+): Subtract the number from the value you obtained in Step 1.

- If the number is negative (–): Add the number to the value you obtained in Step 1.

3. Read the H marked on the new drive gear. Add (+) or subtract(–) the value from the measurement you obtained in Step 1,depending on the variation sign. The sum or remainder youobtain indicates the thickness of the new shim pack you’llinstall.

Fig. 5.15

Fig. 5.15a Fig. 5.15b

NOTE: The following examples provide all possible calculationcombinations.

All final drive sets are stamped with a number that indicates thenominal backlash between the pinion and drive gear wasmachining was completed. This backlash value is shown on thedrive gear outer diameter.

Examples mm Inches

1. Original shim pack thickness 0.75

H marked on old drive gear +0.05 -0.05

Resulting Value 0.70

H marked on new drive gear +0.10 +0.10

Thickness for new shim pack 0.80


H marked on old drive gear -0.05 +0.05


H marked on new drive gear +0.15 +0.15



H marked on old drive gear +0.05 -0.05


H marked on new drive gear -0.05 -0.05



H marked on old drive gear -0.10 +0.10


H marked on new drive gear -0.15 -0.15



5 Assembly

Calculating the Pinion Shim Pack Value. Original Ring Gear & Pinion with REFERENCE NUMBER NOT AVAILABLE and Shim Pack with REFERENCE NUMBER AVAILABLE OR NOT AVAILABLE

If you can’t find the H number or it is unreadable, re-install thesame shim that you measured in Step 1. In case the shim packused is not available it is possible to use the average ofManufacturer’s Adjusted Shim Pack value which is 1,0 mm forthe MS15 carrier. Check tooth contact pattern and adjust theshim pack thickness as necessary to achieve the correct contactpattern.

Differential Carrier Installation1. Install the capscrews. Follow the sequence below to tightenthem.- Use a torque wrench to tighten the capscrews to 100 N•m(73.75 lb-ft). Fig. 5.16.

2. Use a box wrench to tighten the capscrews to the correctspecification.


3. Turn the unit around 90 degrees. Use a retainer to hold thecompanion flange stationary. Fig. 5.17.

4. Use a socket, torque multiplier and torque wrench to tightenthe drive pinion nut to 1350-1670 N•m (995-1231 lb-ft).

5. Align the bearing caps with the locating dowels. Insert thecapscrews and washers. Use a torque wrench to tighten thecapscrews and washers to 650-810 N•m (479-597 lb-ft).Fig. 5.18.

Fig. 5.16

Fig. 5.18

Fig. 5.17


5 Assembly

Fig. 5.19

Fig. 5.20

Fig. 5.21

6. Verify that the bearing cups easily slide into their housingswithout sticking.

7. Unscrew the bearing capscrews and washers. Remove thebearing caps. Install the bearing cups onto the case ends.

WARNINGTo avoid serious personal injury and damage to components,take care when using lifting devices during service andmaintenance procedures. Inspect a lifting strap to ensurethat it is not damaged. Do not subject lifting straps toshocks or drop-loading.

8. Use a suitable lifting device or lifting strap to lift the ring gearassembly onto the carrier. Install the bearing caps. Fig. 5.19.

9. Install the bearing caps. Install the bearing capscrews andwashers. Use a torque wrench to tighten the capscrews, butdo not tighten them completely. Fig. 5.20.

10. Lubricate the roller bearings with axle oil. Manually install theadjusting rings until they touch the bearing caps. Fig. 5.21.Tighten the capscrews to 650-810 N•m (479-597 lb-ft).


5 Assembly

11. Once preload and backlash is set, install the pins. Follow theprocedures below. Fig. 5.22. - Install the cotter pin through the bearing cap and into theadjusting collar. Bend the cotter pin ends. Install the spiralpin into the cap on the collar’s opposite side.

12. Install adapter on differential case and secure with spacerand snap ring.

13. Install the shift fork and clutch collar. Coat the slanted face ofthe shift fork with Molikote Gn Plus grease. Figure 5.23.

14. Position the shift fork and collar together with the spring andshift shaft. Install the piston. - If the O-ring seal was removed: Coat it with Molikote 44Medium grease. Install the O-ring onto the piston.

15. Install the cylinder end cover and gasket. Install thecapscrews and washers. Use a torque wrench to tighten themto 12-16 N•m (8.85-11.8 lb-ft).

16. Install the thrust screw and nut and tighten until the nut stopsagainst the drive gear face.

17. Loosen the thrust screw approximately 180 degrees.Clearance should be between 0.65-1.14 mm (0.025-0.044-inch). Figure 5.24.

18. Tighten the nut to 270-335 N•m (200-248 lb-ft)

Fig. 5.22

Fig. 5.24

Fig. 5.23


5 Assembly

Adjust Differential Bearing Preload Use one of the following methods to adjust preload.

Large Micrometer Method 1. Use a wrench or other suitable tool to tighten the bearing

adjusting rings until the pinion-to-drive gear end play andbacklash readings are zero. Verify that the drive gear is notjammed against the pinion. Figure 5.25.

2. Position an appropriate micrometer at points X and Y.Measure the distance between the caps.

3. Tighten the adjusting rings until the difference in themeasurement at X and Y reads 0.15-0.33 mm (0.0056-0.012-inch) and corresponds to a bearing preload of 1.7-3.9N•m (1.25-2.87 lb-ft).

Dial Indicator Method 1. Place two dial indicator gauges with magnetic bases in center

and crosswise positions on the outer machined faces of thebearing cap. Figure 5.26.

2. Perform Step 2 under Large Micrometer Method.

3. When backlash and end play are ZERO, continue to tightenboth adjusting rings until the difference in the measurementat X and Y reads 0.15-0.33 mm (0.0056-0.12-inch), whichcorresponds to the sum of the dial indicator gauge readings.

Adjust Hypoid Ring Gear BacklashBacklash: 0.20-0.45 mm

1. Use a suitable tool to hold the pinion stationary. Fig. 5.27.

2. Position a magnetic-base dial indicator gauge.

3. Use a wrench to loosen the adjusting ring on the drive gearside. Tighten the adjusting ring on the opposite side by thesame amount.

4. Continue until you obtain 0.20-0.45 backlash

Fig. 5.25

Fig. 5.27

Fig. 5.26


5 Assembly

5. Check backlash at four evenly spaced points.

6. Use a magnetic-base dial indicator gauge to measure ringgear runout. This measurement should not exceed 0.20 mm(0.0078-inch). - If backlash is not within specification: Disassemble andinspect the differential assembly. Fig. 5.28.

7. Reassemble the unit. Repeat the above adjusting procedures.With a brush, apply a thin coat of Prussian blue to the drivegear teeth. Rotate the pinion and examine the contact marksleft by the pinion teeth on the ring gear teeth. Figure 5.29.

Fig. 5.28

Fig. 5.30

Fig. 5.29

The following figures illustrate the possible types of contact andthe methods for correcting these conditions.

Tooth Contact Pattern 1. Adjust the backlash of a new gear set to either 0.305 mm

(0.012-inch) or 0.380 mm (0.015-inch) depending on thesize of the ring gear. Adjust the backlash of an old gear set tothe setting that was measured before the carrier wasdisassembled. Refer to Adjust Hypoid Ring Gear Backlash inthis section.

2. Apply a marking compound to approximately 12 gear teeth ofthe ring gear. Rotate the ring gear so that the 12 gear teethare next to the drive pinion.

3. Rotate the ring gear forward and backward so that the 12gear teeth go past the drive pinion six times to get the contactpattern. Repeat, if needed, to get a more clear pattern.

4. Look at the contact patterns on the ring gear teeth. Comparethe patterns to Figures 5.30, 5.31 and 5.32.


5 Assembly

Fig. 5.31

Fig. 5.32

Fig. 5.33

The location of a good hand-rolled contact pattern for a new gearset is toward the toe of the gear tooth and in the center, betweenthe top and the bottom of the tooth.

When the carrier is being operated under load, the pattern willextend approximately the full length of the tooth. The top of thepattern will be near the top of the gear tooth. Fig. 5.33.

The location of a good hand-rolled pattern for a used gear setmust match the wear pattern in the ring gear. The contact patternwill be smaller in area than the wear pattern.

If the contact pattern requires adjustment, continue by followingStep 5 to move the contact patterns to a deeper or shallowerposition on the gear teeth. If the contact patterns are in the centerof the gear teeth, continue by following Step 6.

NOTE: A high-contact pattern indicates that the drive pinion wasnot installed deep enough into the carrier. A deep-contact patternindicates that the drive pinion was installed too far in the carrier.


5 Assembly

5. Change the thickness of the shim pack between the pinioninner bearing cup and the differential carrier to move thecontact patterns between the top and the bottom of the gearteeth. Use the following procedure:

A. Remove the drive pinion, the inner bearing cup and theshims from the carrier. Refer to Section 2.

B. To correct a high-contact pattern, increase the thickness ofthe shim pack. When you increase the thickness of theshim pack, the drive pinion will move toward the ring gear.Fig. 5.34. To correct a deep pattern, decrease the thicknessof the shim pack. When you decrease the thickness of theshim, the drive pinion will move away from the ring gear.Fig. 5.35.

C. Install the inner bearing cup, the shims and the drive pinioninto the carrier. Refer to Pinion and Drive Gear Assembly inthis section.

Fig. 5.34

Fig. 5.35 Fig. 5.37

Fig. 5.36

D. Repeat Steps 2-6 until the contact patterns are in thecenter between the top and bottom of the gear teeth.

6. Adjust the backlash of the ring gear within the specificationrange to move the contact patterns to the correct locationalong the length of the gear teeth. Refer to the procedure inTooth Contact Pattern in this section.

A. Decrease backlash to move the contact patterns towardthe toe of the ring gear teeth. Figure 5.36.

B. Increase backlash to move the contact patterns toward theheel of the ring gear teeth. Figure 5.37.

C. Repeat Steps 2-4 and 6 until the contact patterns are atthe correct location along the length of the gear teeth.

7. After all the adjustments are finally completed, install the rollpin on the bearing cap so that the pin is between the lugs ofthe adjusting ring.


5 Assembly

Fig. 5.38

Install and Adjust the Differential Lock Sensor Switch

WARNINGTake care when you use Loctite® to avoid serious personalinjury. Follow the manufacturer’s instructions to preventirritation to the eyes and skin.

NOTE: You can test and adjust the differential switch with therear axle installed on the vehicle.

1. Coat the differential lock sensor switch with Molikote Gn Plusgrease. Install the switch to three threads. Apply Loctite 573sealant on the threads.

2. Engage the differential lock. Tighten the sensor switch untilthe switch point slightly touches the shift fork. Verify that thewarning lamp illuminates on the instrument panel. Figure 5.38

3. When the warning lamp comes ON in the cab, turn the switchone additional rotation. Tighten the lock nut 35-45 N•m(25.81-33.20 lb-ft)

4. Use approximately 6 kg/cm2/6 bar (90 psi) air to check thedifferential lock engagement. Release the lock. Verify that thewarning lamp in the cab is OFF.

5. Repeat this procedure several times before you return thevehicle to service.


5 Assembly

Replace the Pinion-Pac SealNOTE: You can perform the following procedure with thedifferential carrier installed on the vehicle.

Pinion Seal Removal (Carrier Installed)1. Remove the nuts that secure the driveshaft to the differential

companion flange. Fig. 5.39. Disconnect the driveshaft andsecure it tothe chassis.

2. Use suitable tool to hold the companion flange stationary. Fig. 5.40. Use a wrench with a torque multiplier to loosen thepinion nut and remove the flange.

3. Use a suitable tool to pry the outer edge of the metal innerring at two opposite points. Fig. 5.41. Use a pry bar to removethe inner ring. Fig. 5.42 and 5.43.

Fig. 5.39

Fig. 5.40

Fig. 5.42

Fig. 5.43

Fig. 5.41


5 Assembly

Pinion Seal Installation1. Carefully clean dirt and contaminants from the seal ring seat.

Install a new seal ring. Figure 5.44.

2. Machine a guide nut from the old drive pinion nut. Fit theguide nut on a seal installer tool. Install the seal ring until itstops.

3. Loosen the guide nut, remove the installer tool andreassemble the flange. Install a new drive pinion nut.

4. Use a wrench with a torque multiplier to lock the nut to thespecified torque. Reassemble the axle and tighten thefastening nuts to the specified torque.

Installing the Differential Carrier


To avoid serious personal injury and damage to components,take care when using lifting devices during service andmaintenance procedures. Inspect a lifting strap to ensurethat it is not damaged. Do not subject lifting straps to shocks or drop-loading.

CAUTIONOnly use lubricants specified by Meritor and genuine Meritorparts during differential carrier maintenance and service toprevent damage to components.

1. Thoroughly clean all mounting surfaces and threads. Coat therear axle mounting surface with Dow Corning 9071 siliconesealant. Fig. 5.45.

2. Use a lifting device to set the axle on heavy jack stands. Alignthe differential unit with the carrier housing.

3. Install the differential into the carrier housing. Guide theassembly carefully to ensure correct alignment.

Fig. 5.44

Fig. 5.45


5 Assembly

4. Install the rear axle housing screws and tighten them tospecification. Install the differential lock sensor switchcoupling.

5. Install the air line to the shift sensor. Install the driveshaft tothe carrier. Install the axle shafts. Engage the differential lock.

6. Install the axle shaft mounting screws and washers. Install theoil plug into the bottom of the axle.

Filling the Axle With Lubricant1. Fill the axle with the specified lubricant according to the

following procedure:

NOTE: For additional lubrication information, refer toMaintenance Manual 1, Lubrication.

2. Make sure the vehicle is parked on a level surface. When theangle of the drive pinion changes, the lubricant capacity ofthe axle will change.

3. Remove the fill plug from the side of the bowl cover of theaxle housing.

4. Place the specified axle lubricant in through the fill plug hole.Fill the axle with lubricant until the lubricant level is to thebottom of the fill plug hole. Refer to the oil change intervalsand specifications table in Section 6.

5. Install the fill plug and tighten to a minimum torque of 60-100N•m (44-74 lb-ft). When correctly installed, one completethread of the fill plug is visible between housing and plug head.

6. Road test the vehicle in an unloaded condition for 1.6-3.2 km(1 to 2 miles) at speeds not more than 40 kmh (25 mph).Recheck the lubricant levels and all the fasteners.

Model Description Liter

MR11-155 Fabricate housing 18.5

MR11-150 Casting housing 14 ÷ 14.5*

NOTE: The variance of the shape is defined in base of specificCustomer requirements. This variants generate a little differencein oil quantity in the same spec.


pg.

6

Torque Specifications

51 Torque Plus Angle Recommendations 41 Torque Plus Angle Method


6 Torque Specifications

Torque Table TorqueDescription N•m (lb-ft) Kgm1. Stud nuts and/or capscrews carrier stage 1 torque 100 (73.75) 10 to housing stage 2 angle 80° to 90°

2. Differential case capscrews stage 1 torque 100 (73.75) 10 stage 2 angle 110° to 120°

3. Drive gear capscrews stage 1 torque 100 (73.75) 10 stage 2 angle 80° to 89°

4. Drive pinion nut 1350 to 1670 (995-1157) 135 to 167

5. Pinion cage capscrews stage 1 torque 100 (73.75) 10 stage 2 angle 60° to 70°

6. Lock nut sensor switch 35 to 45 (25.81-33.2) 3.5 to 4.5

7. Cover capscrews 10 to 12 (7.37-8.85) 1.0 to 1.2

8. Thrust screw nut 270 to 335 (199-247) 27.0 to 33.5

Bearing cap capscrews (not shown) 650 to 810 (479-597) 65 to 81


6 Torque Specifications

Torque Plus Angle RecommendationsWhen tightening ring gear capscrews, housing nuts andcapscrews, torque to correct specifications using the standardtorque method or the torque plus angle method.

Torque Plus Angle Method- To tighten the ring gear capscrews: Torque the capscrews

in a criss-cross sequence.- Use a torque wrench to tighten the capscrews to 100 N•m(73.75 lb-ft).

- Then, tighten the capscrews an additional 80-90 degrees.

- To tighten the plain half differential case capscrews: Torque the capscrews in a criss-cross sequence.

- Use a torque wrench to tighten the capscrews to 100 N•m(73.75 lb-ft).

- Then tighten the capscrews an additional 110-120 degrees.

- To tighten pinion cage capscrews:

- Use a torque wrench to tighten the capscrews to 100 N•m(73.75 lb-ft).

- Then, tighten the capscrews an additional 60-70 degrees.

- To tighten nuts for studs and capscrews on the housing:

- Use a torque wrench to tighten the nuts and capscrews to100 N•m (73.75 lb-ft).

- Then, tighten the nuts and capscrews an additional 80-90degrees.


pg.

7

Special Tools

54 Carrier Repair Stand Specifications 55 How to Make a Yoke Bar56 MST440157 MST480758 MST4808


7 Special Tools

Carrier Repair Stand Specifications

Fig. 7.1


7 Special Tools

How to Make a Yoke Bar1. Measure dimensions “A” and “B” of the yoke you are

servicing. Fig. 7.2.

2. Calculate dimensions “C” and “D” of the yoke bar by adding3.175 to 6.35 mm (0.125-0.250-inch) to dimensions “A” and“B” of the yoke. Fig. 7.3.

WARNINGWear safe clothing and eye protection when you use weldingequipment. Welding equipmentcan burn you and causeserious personal injury. Follow the operating instructions andsafety procedures recommended by the welding equipmentmanufacturer.

3. To make the “box” section, cut and weld25.4 mm x 50.8 mm(1.0-inch x 2.0-inch) mild steel square stock according todimensions “C” and “D.” Fig. 7.3.

4. Cut a 1.21 m x 31.75 mm (4.0-foot x 1.25-inch) piece ofmild steel round stock to make the yoke bar handle. Centerweld this piece to the “box” section. Fig. 7.3.

- To increase yoke bar rigidity: Weld two angle pieces onto thehandle. Fig. 7.3.

Fig. 7.2

Fig. 7.3


7 Special ToolsMST4401 - Seal removal tool

Fig. 7.4


7 Special ToolsMST4807 - Inner Deflector

Fig. 7.5


7 Special ToolsMST4808 - Inner Ring

Fig. 7.6


pg.

8

Vehicle Towing Instructions

60 General Information60 Before Towing or Drive-Away 61 After Towing or Drive-Away


8 Vehicle Towing Instructions

General InformationThese instructions are for vehicles equipped with Meritor MR-150-E drive axles. When transporting a vehicle with thewheels of one or both drive axles on the road, it is possible todamage the axles if the wrong procedure is used beforetransporting begins. Meritor recommends that you use thefollowing procedure.

Before Towing or Drive-Away


Engage the parking brake to prevent the vehicle frommoving before you begin maintenance or service proceduresthat require you to be under the vehicle. Serious personalinjury can result.

1. Apply the vehicle parking brakes using the switch inside thecab of the vehicle.

2. Shift the transmission into neutral and start the vehicle’sengine.

3. Shift the IAD to the unlocked (disengaged) position using theswitch inside the cab of the vehicle. The indicator light in thecab will go off.

4. Stop the engine.

NOTE: Remove both axle shafts from the axle(s) that will remainon the road when the vehicle is transported. Refer to vehiclemanufacturer instructions for removing axle shafts.

5. Identify each axle shaft that is removed from the axleassembly so they can be installed in the same location aftertransporting or repair is completed. (Example: Match mark amating axle shaft and hub.)

6. Remove the tapered dowels, gasket (if used) and the axleshaft from the axle assembly. Fig. 8.1.

7. Install a cover over the open end of each hub where an axleshaft was removed. This will prevent dirt from entering thebearing cavity and loss of lubricant.

NOTE: If an air supply will be used for the brake system of thetransported vehicle, continue with Steps 8 and 9, otherwisecontinue with Step 10.

8. Connect an auxiliary air supply to the brake system of thevehicle that is being transported. Before moving the vehicle,charge the brake system with the correct amount of airpressure to operate the brakes. Refer to the instructionssupplied by the manufacturer of the vehicle for proceduresand specifications. If an auxiliary air supply is not used,continue with Step 10.

9. When the correct amount of air pressure is in the brakesystem, release the parking brakes of the vehicle that is beingtransported. Step 10 is not required.

Fig. 8.1


8 Vehicle Towing Instructions

WARNING Before you service a spring chamber, carefully follow themanufacturer’s instructions to compress and lock the springto completely release the brake. Verify that no air pressureremains in the service chamber before you proceed. Suddenrelease of compressed air can cause serious personal injuryand damage to components.

10. If there are spring (parking) brakes on the axle(s) that willremain on the road when the vehicle is transported, and theycannot be released by air pressure, manually compress andlock each spring so that the brakes are released. Refer to themanufacturer’s instructions.

After Towing or Drive-Away

WARNING To prevent serious eye injury, always wear safe eyeprotection when you perform vehicle maintenance orservice.Engage the parking brake to prevent the vehiclefrom moving before you begin maintenance or serviceprocedures that require you to be under the vehicle. Seriouspersonal injury can result.

1. If an auxiliary air supply was used, apply the vehicle parkingbrakes using the switch inside the cab of the vehicle. If anauxiliary air supply was not used, begin with Step 2.

WARNING Before you service a spring chamber, carefully follow themanufacturer’s instructions to compress and lock the springto completely release the brake. Verify that no air pressureremains in the service chamber before you proceed. Suddenrelease of compressed air can cause serious personal injuryand damage to components.

2. Apply the vehicle spring (parking) brakes by manuallyreleasing each spring that was compressed beforetransporting started. Refer to manufacturer’s instructions.

3. Disconnect the auxiliary air supply, if used, from the brakesystem of the vehicle that was transported. Connect thevehicle’s air supply to the brake system.

4. Remove the covers from the hubs.

5. Install the axle shafts. Refer to the axle shaft manufacturerinstructions.

6. Inspect the lubricant level in the axles and hubs where theaxle shafts were removed. Add the correct type and amountof lubricant if necessary. For information about lubrication,refer to the Maintenance Manual 1, Lubrication, or refer to theLubrication Section of the Meritor Maintenance Manual for theaxle model you are working with.


pg.

9

Diagnostic Flowcharts

64 Rear Tandem Carrier - Vehicle Will Not Move65 Rear Tandem Carrier - Differential Making Noise66 Rear Tandem Carrier - Oil Leak 67 All Rear Axles - Contaminated Lubricant found during Preventive Maintenance


9 Diagnostic FlowchartsRear Tandem Carrier — Vehicle Will Not Move

Fig. 9.1


9 Diagnostic FlowchartsRear Tandem Carrier — Differential Making Noise

Fig. 9.2


9 Diagnostic FlowchartsRear Tandem Carrier — Oil Leak

Fig. 9.3


9 Diagnostic FlowchartsAll Rear Axles — Contaminated Lubricant Found During Preventive Maintenance

Fig. 9.4

Meritor HVS Cameri S.p.A.Strada Prov. Cameri-Bellinzago km. 5 Printed in Italy28062 Cameri (NO), Italy Tel.: +39 0321 4231 Issue September 2017Fax: +39 0321 423424www.meritor.com © Meritor 2017 M-graph - MM0208

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