Maintenance Manual 1 Preventive Maintenance and …

1 Maintenance Manual 1 Preventive Maintenance and LubricationRevised 08-21 2 Meritor Maintenance Manual MM-1 (Revised 08-21) About This ManualThis Manual provides Maintenance intervals and procedures, lubricant specifications, and product capacities for Meritor You and understand all instructions and procedures before you begin to service and observe all hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or your company s Maintenance and service, installation, and diagnostics special tools when required to help avoid serious personal injury and damage to Alert MessagesDANGERI ndicates imminent danger. Failure to follow this instruction will result in death or serious injury. WARNINGI ndicates a possibly impending danger.

2 Failure to follow this instruction can result in death or serious a hazardous situation or unsafe practice which, if not avoided, could result in injury or damage to to Obtain Additional Maintenance , Service and Product InformationVisit Literature on Demand at to access and order additional you have questions about the procedures in this bulletin, contact the Meritor OnTrac Customer Call Center at 866-668-7221 (US and Canada) between 7:30 AM and 10:00 PM ET Monday through Friday, and between 9:00 AM and 6:00 PM ET on Saturday; 001-800-889-1834 (Mexico); or visit our website: # Tools and Supplies are Specified in This ManualContact Meritor s Commercial Vehicle Aftermarket at 1: IntroductionOverviewRegularly-Scheduled MaintenanceOil LubricantsViscosityOil Change SchedulesOil Drain Conditions2 National Lubricating Grease Institute (NLGI) StandardsExtreme Pressure (EP) Lubricants4 Section 2.

3 Bus and CoachTechnical PublicationsHow to Obtain Additional Maintenance and Service InformationDescriptionFront Axles5 Rear Axles6 Center Axles7 Important InformationCam Brakes8 Important InformationStopmaster Wedge BrakesEX+ Brakes9T Series Parking BrakeIdentificationModel Nomenclature12 InspectionFront Axles13 LubricationKing Pin Bushings14 Tie RodGrease-Lubricated Wheel BearingsOil-Lubricated Wheel BearingsRear Drive Axles16 Inverted Portal Drive Axle17 Planetary Drive Axles18 Cam Brakes20T Series Parking BrakeStopmaster Brakes21 Lubrication Intervals and Specifications25 Stopmaster Wedge Brakes26 Section 3: ClutchesTechnical PublicationsHow to Obtain Additional Maintenance and Service InformationDescriptionIdentification27 Model Nomenclature28 InspectionWhen to Inspect the ClutchClutch Linkage29 Internal Parts of the Clutch31 LubricationRelease BearingClutch HousingLinkage32 Lubrication Intervals and SpecificationsTroubleshooting36 Special Tools37 Section 4.

4 DrivelinesTechnical PublicationsHow to Obtain Additional Maintenance and Service InformationDescriptionRPL Series Permalube (Non-Greaseable)Wing-Style Permalube Full-Round, Easy Service , Wing-Style and 155R Series (Greaseable)38 IdentificationInspectionDriveline39 End Yokes40 Universal JointsCenter Bearings41 Slip Yoke42 Universal Joint Capscrews43 LubricationXtended Lube MXL 17N, 176N and 18N Series Drivelines (Full Round)Universal Joint44 Slip Yoke SplinesRPL Series Permalube Driveline Universal Joint, Slip Yoke and SplinesStandard/Conventional Driveline Universal Joint45 Standard/Conventional Driveline Slip Yoke and SplinesWing-Style Permalube Driveline Universal JointWing-Style Greaseable Driveline Universal JointWing-Style Permalube and Greaseable Driveline Slip Yoke and Splines46 IntervalsInspection and Maintenance48 Lubrication Intervals and Specifications49 Lubrication Intervals for Xtended Lube MXL Series 5.

5 Front Drive Steer AxlesTechnical PublicationsHow to Obtain Additional Maintenance and Service InformationDescriptionFront Drive Steer Axles55 IdentificationModel NomenclatureFront Drive Steer Axles57 Front Drive Steer Axles, Prior Models59 InspectionSteering-Related ComponentsSteering Knuckle Vertical End PlayUpper and Lower Knuckle Bushings60 Tie Rod Ends61 Servicing the Tie Rod EndsWhy It s Important to Inspect the Tie Rod Ends for Wear and Allowable Movement at the Regularly-Scheduled Intervals62 Tie Rod Assembly Movement64 Steering Arm BoltsSealed Hub Units65 CarrierCheck and Adjust the Oil LevelDrain and Replace the Oil66 LubricationKing Pin Bushings67 Camshaft Retainer Bushing and Cam BushingCross Tube End AssemblyDrive Axle Shaft Universal JointsAxle Shaft Spline and Thrust Washer68 Knuckle BushingWheel BearingsTie Rod End69 Steering Knuckle SocketsLubrication Intervals and Specifications72 Troubleshooting74 Section 6.

6 Front Non-Drive Steer AxlesHow to Obtain Additional Maintenance and Service InformationDescriptionIdentification75 Model Nomenclature77 InspectionParts78 Steering Knuckle Vertical End Play80 Upper and Lower King Pin Bushings81 Unitized Wheel End83 Tie Rod and Cross Tube Assembly85 Department of Transportation Roadside Tie Rod Assembly Replacement CriteriaLubricationTie Rod End87 King Pin Bushings88 Ball Studs on the Steering Arm and the Tie Rod Arm Ends89 Grease-Lubricated Wheel BearingsOil-Lubricated Wheel Bearings90 Check and AdjustSteering Arm BoltsTighten Draw Key NutsLubrication Intervals and Specifications92 LubricantTroubleshooting94 Section 7: BrakesCam BrakesTechnical PublicationsDescription95 Identification96 Model Nomenclature97 Important InformationCam brake Inspection Intervals and ProceduresOn-Highway Linehaul ApplicationsOff-Highway Linehaul ApplicationsQ+ LX500 and MX500 Cam Brakes with Automatic Slack AdjustersDo Not Lubricate the LX500 and MX500 Brakes and Automatic Slack Adjuster Before the Specified Time or Mileage IntervalsInspection Procedure98 Cam Brakes, All Models99 Important InformationCommercial Vehicle Safety Alliance (CVSA)

7 Guidelines100 Cam brake Lubrication Intervals and Procedures102Q+ LX500 and MX500 Cam Brakes and Automatic Slack Adjusters After the Specified Time or Mileage Intervals103 Cam brake Tips104 Approved Lubricants106 Important InformationCam brake TroubleshootingDiagnostic Charts107 Air disc BrakesTechnical disc brake Inspection Intervals and ProceduresInspection Schedules110 Important InformationCommercial Vehicle Safety Alliance (CVSA) Guidelines112 Important InformationChecking the Adjusted Chamber Stroke Length on EX+ DX195 and DX225 Air disc BrakesEX+ DX195 and DX225 Air disc brake Components114 Air disc brake Model ADB 1560 Lubrication Intervals and ProceduresLubrication Procedures115 Approved Lubricants116 Important InformationAir disc brake TroubleshootingBrake Diagnostic Charts119 Important InformationEX+ DX195 and DX225 Air disc Brakes121 Automatic Slack AdjustersImportant InformationTechnical PublicationsIntervalsIdentification122 ProceduresAt brake Reline123 Approved LubricantsAnti-Seize CompoundImportant Information124 Automatic Slack Adjuster TroubleshootingDiagnostic Charts125 Wedge BrakesTechnical PublicationsDescriptionIdentification126 Important InformationBrake Adjustment Procedure127

8 Inspection Procedure128 LubricationApproved LubricantsImportant Information129 Wedge brake TroubleshootingDiagnostic Charts132 Four-Piston Quadraulic disc BrakesTechnical PublicationsDescriptionIdentification133 Four-Piston Quadraulic disc brake Inspection134 Bleeding the brake System134 Four-Piston Quadraulic disc brake TroubleshootingDiagnostic Charts136 DuraPark Hydraulic Drum BrakesTechnical PublicationsDescriptionDuraPark Hydraulic brake Product Update138 Adjustment Procedures139 brake Drums and RotorsTechnical PublicationsBrake Drum Inspection and Failure Analysis140 brake Drum Wear InspectionClean the Mounting Surfaces141 brake Drum Procedures142 brake Drum Wear Conditions147 Conditions That Can Affect brake Drum Wear148 brake Drum Diagnostics149 Rotors150 Rotor Wear InspectionMeasuring the Thickness of the Rotor or Disc151 Section 8: Rear Drive AxlesTechnical PublicationsHow to Obtain Additional Maintenance and Service InformationDescriptionIdentification152 Model NomenclatureAxle Model Numbers and Designations155 InspectionCarrier156 Oil Seals157 Seal Test ProcedureCleaningAxles Equipped with Meritor Lubrication Management System (MLMS)LubricationFill Plug Location158 Check and Adjust the Oil LevelDrain and Replace the OilLegacy Model AxlesFill Plug Locations159 Inter-Axle Assemblies with Separate HousingsLimited Slip Friction Modifiers160 Lubrication Intervals and SpecificationsLubrication Analysis Recommendations166 TroubleshootingAll Rear 9.

9 SuspensionsTechnical PublicationsHow to Obtain Additional Maintenance and Service InformationRideStar RHP Series Trailer Air Suspension SystemsSingle-Axle System168 Sliding Tandem System169 InspectionSingle-Axle and Sliding Tandem SuspensionsMaintenanceSingle-Axle and Sliding Tandem Suspensions170 Upper Control Arm Bushing Periodic Inspection Guidelines: All RideStar RHP Series Trailer Air Suspension Systems171 Slider on Sliding Tandem Suspension System172 RideStar RFS Series Trailer Air Suspension SystemRide Height174 Tire Clearance175 Maintenance176 Inspect the Shock Absorbers179 Section 10: Trailer AxlesImportant InformationTechnical PublicationsHow to Obtain Additional Maintenance and Service InformationDescriptionAxle ModelsAxle Designs180TB Series Trailer Axles with Unitized Wheel-End Assemblies181 How to Identify Trailer Axles with Unitized Wheel EndsHow to Find the Model Number, Serial Number and Date of ManufactureWhat the Numbers MeanModel NumberSerial NumberDate of Manufacture182 Model NomenclatureCurrent Production Model Numbers184 Section 11.

10 Transfer CasesTechnical PublicationsHow to Obtain Additional Maintenance and Service InformationDescriptionIdentification185 Model Nomenclature186 Lubricant TemperaturesMeritor MTC-4208, MTC-4209 and MTC-4210 Series Transfer CasesOther Meritor Transfer CasesDo Not Install API GL-5 OilsInspectionMagnets and Magnetic Drain Plugs187 Operating InformationBreatherSealsCheck and Adjust the Oil Level188 Drain and Replace the OilTransfer Case OilIntervalsTowing Procedures189 Specifications190 Capacities191 Troubleshooting197 Section 12: TransmissionsTechnical PublicationsHow to Obtain Additional Maintenance and Service InformationDescriptionManual Transmissions198 Engine Synchro Shift (ESS ) Transmission Shift SystemSureShift TransmissionZF-FreedomLine TransmissionIdentificationModel Nomenclature200 IntervalsEvery 10,000 Miles (16 000 km) of Vehicle OperationEvery 50,000 Miles (80 000 km) of Vehicle Operation (Approved Petroleum Base and Heavy-Duty Engine Oils)Every 500,000 Miles (400 000 km) of Vehicle Operation (Approved Full-Synthetic Oils)