Maintenance Manual 5L Single-Reduction Forward ...

1 Maintenance Manual 5 LSingle-Reduction Forward differential Carriers on Tandem and Tridem AxlesRevised 02-18 Service NotesInformation contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the information presented or to discontinue the production of parts described at any Maintenance Manual 5L (Revised 02-18)About This ManualThis Manual provides Maintenance and service information for the Meritor Forward tandem drive axles, including the RT-140; -144; -145; -149; -160; -169; RZ-166; -186 and -188 Series You and understand all instructions and procedures before you begin to service and observe all Warning and Caution 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 Messages and Torque SymbolsWARNINGA Warning alerts you to an instruction or procedure that you must follow exactly to avoid serious personal injury and damage to Caution alerts you to an instruction or procedure that you must follow exactly to avoid damage to components.

2 @ This symbol alerts you to tighten fasteners to a specified torque to Obtain Additional Maintenance , Service and Product InformationVisit Literature on Demand at to access and order additional the Meritor OnTrac Customer Call Center at 866-668-7221 (United States and Canada); 001-800-889-1834 (Mexico); or email Tools and Supplies are Specified in This ManualContact Meritor s Commercial Vehicle Aftermarket at 888-725-9355 to obtain Meritor tools and Kent-Moore, 28635 Mound Road, Warren, Michigan, 48092. Call the company s customer service center at 800-345-2233, or visit their website at 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 Service Solutions, 655 Eisenhower Drive, Owatonna, MN 55060. Call the company s customer service center at 800-533-6128, or visit their website at 1: Exploded ViewsSingle-Reduction Forward differential Carrier4 Section 2: IntroductionDescriptionForward Tandem AxleAxle Models Covered in This ManualOptional Pressurized Lubrication SystemOptional Driver- controlled Main differential Lock (DCDL)5 Inter-Axle Main differential (IAD)Stall-Testing Can Damage a Drive AxleUse of Traction ChainsIdentificationModel Number7 Section 3.

3 Removal and DisassemblyRemovalAxle ShaftsAxle Shaft Removal Methods9 Axle Shafts from the Axle Housing10 Thru-Shaft11 differential Carrier from the Axle Housing12 DisassemblyThru-Shaft and Output Bearing Cage Assembly13 RemovalBearing Cone from the Thru-ShaftMeasure Ring Gear Backlash14 Input Shaft and Inter-Axle differential Assembly16 DisassemblyInput Shaft, Bearing Cage, Oil Pump and Inter-Axle Differential19 RemovalInter-Axle differential Lock IAD Shift Unit20 Driver- controlled Main differential Lock (DCDL)Main differential Case and Ring Gear Assembly21 DisassemblyMain differential Case and Ring Gear22 RemovalRing Gear from the differential Case23 Drive Pinion AssemblyBefore You Work on a differential CarrierAssembly Procedures25 Section 4: Prepare Parts for AssemblyClean, Dry and Inspect PartsClean and Inspect Yokes26 Clean Ground and Polished PartsClean Rough PartsClean Axle Assemblies26 Drying Parts After CleaningPrevent Corrosion on Cleaned PartsInspect Parts29 Repair or Replace PartsWelding on Axle Housings30Do Not Bend or Straighten a Damaged Drive Axle HousingRemoving Fasteners Secured with AdhesiveNew Fasteners with Pre-Applied AdhesiveOriginal or Used FastenersMeritor Specification 2297-T-4180 Adhesive in the differential Bearing Bores31 Carrier-to-Housing Joint Sealing Procedure32 General Yoke and U-Joint ReassemblyIdentificationGear Sets33 Check for Mismatched Ratios on Tandem AxlesHypoid Gear Set Ratios Listed on the Identification Tags34 Rotate the Forward Drive Shaft to Check the Hypoid Gear Set Ratio35 Hypoid Gear Set Teeth Numbers Stamped on the Forward and Rear Axle Drive PinionsVerify the Actual Hypoid Gear Set Ratios36 InspectionYoke37 Tire Matching for

4 Tandem and Tridem Axles38 Section 5: Assembly and InstallationInstallationInstalling the Drive Pinion and Adjusting Pinion Depth and PreloadAdjustmentShim Pack Thickness for a New Drive Pinion39 AssemblyDrive Pinion Assembly41 InstallationDrive Pinion Assembly42 AdjustmentDrive Pinion Bearing Preload46 AssemblyMain differential and Ring Gear48 Check the Rotating Resistance of the differential Assembly49 InstallationMain differential Case and Ring Gear Assembly Into the Carrier51 AdjustmentDifferential Bearings Preload53 Ring Gear RunoutRing Gear Set Tooth Contact Patterns, Backlash58 InstallationThrust Screw (If Equipped)Air Shift Unit for the Inter-Axle differential Lock60 AssemblyInput Shaft, Bearing Cage, Oil Pump and Inter-Axle Differential64 InstallationInput Shaft Assembly65 InspectionAdjust the Input Bearing End Play68 InstallationDriver- controlled Main differential LockOutput Bearings and Thru-Shaft69 InspectionAdjust the Output Bearing End PlayInstallationUnitized Pinion Seal72 Installing a Multiple-Lip Seal (MLS)76 Clean and Inspect the Yoke After Installing a Unitized Pinion Seal77 Tight Fit Yokes and POSE SealOutput Yoke or Flange and Oil Seal for the Output Bearing Cage79 differential Carrier into the Axle Housing82 Axle Shaft83 Fill the Axle with Lubricant85 Section 6.

5 Driver- controlled Main differential LockDescriptionRemovalDifferential Carrier from the Axle HousingEngagement or Lockout of the DCDL87 differential and Gear Assembly and Main differential Lock90 InstallationDifferential Shift Assembly95 differential Lock Assembly Cover PlatesDifferential Carrier Into the Forward Axle Housing97 Check the differential LockDCDL Driver Caution Alert Label98 Driver Instruction Information Available99 Section 7: LubricationSpecifications101 Section 8: Specifications106 Section 9: Adjustment108 Section 10: Special ToolsSpecificationsCarrier Repair Stand109 How to Make a Yoke BarHow to Make a Drive Flange Retainer Tool110 Unitized Pinion Seals and Seal Drivers112 Section 11: Vehicle Towing InstructionsType of AxleForward Tandem Axle, with Driver- controlled Main differential Lock (DCDL Screw-In DCDL Shift Assembly) and with Inter-Axle differential (IAD)116 Forward Tandem Axle, with Driver- controlled Main differential Lock (DCDL Bolt-On DCDL Shift Assembly) and with Inter-Axle differential (IAD)120 Forward Tandem Axle, without Driver- controlled Main differential Lock (DCDL), with Inter-Axle differential (IAD)122 Section 12.

6 DiagnosticsTroubleshootingVehicle Will Not Move124 differential Making Noise126 Oil Leak127 Contaminated Lubricant Found During Preventive Maintenance1 Exploded Views1 Meritor Maintenance Manual 5L (Revised 02-18)1 Exploded ViewsSingle-Reduction Forward differential CarrierItemDescription1 Nut Input Yoke1 AWasher Input Yoke2 Input Yoke3 Deflector4 Capscrew Cage-to-Carrier5 Washer Cage-to-Carrier6 Oil Seal Triple-Lip (Main) Seal6 APOSE Seal7 Input Bearing Cage8 Shims9O-Ring Input Bearing Cage10 Bearing Cup Input Shaft11 Bearing Cone Input Shaft12 Oil Baffle (Units Without Oil Pump)13 Washer Oil Baffle14 Capscrew Oil Baffle15 Input Shaft16 Thrust Washer Helical Drive Gear17 Helical Drive Gear18 Inter-Axle differential Case Assembly19 Snap Ring Inter-Axle differential Case20 Clutch Collar Inter-Axle differential Case21 Rear Side Gear22 Shift Fork23 Bearing Cone Rear Side Gear24 Bearing Cup Rear Side Gear25 Adjusting Screw Shift Shaft26 Jam Nut Adjusting Screw27 Spring Shift Shaft28 Shift Shaft and Piston28A E Clip (Reverse Shift IAD Only)

7 29 Air Shift Chamber Assembly Bolt-On IAD29 AAir Shift Chamber Assembly Screw-In IAD30 Capscrew Air Shift Chamber Assembly31 differential Carrier and Caps32 Washer differential Carrier-to-Axle Housing33 Nut differential Carrier-to-Axle Housing34 Capscrew differential Carrier-to-Axle Housing35 Ring Gear and Drive Pinion36 Inner Bearing Cone Drive Pinion37 Inner Bearing Cup Drive Pinion38 Shims39 Inner Spacer40 Helical Driven Gear41 Outer Spacer42 Outer Bearing Cup Drive Pinion43 Outer Bearing Cone Drive Pinion44 Washer Drive Pinion45 Nut Drive Pinion46 Cover Drive Pinion47 Washer Drive Pinion Cover48 Capscrew Drive Pinion Cover49 Bearing Adjusting Ring50 Cup Main differential Bearing51 Cone Main differential Bearing52 Capscrew Main differential Case Halves53 Washer Main differential Case Halves54 Main differential Case Assembly55 Bolt Ring Gear (145 and 160 Series)56 Washer differential Bearing Cap57 Capscrew differential Bearing Cap58 Roll Pin, Cotter Pin or Capscrew differential Bearing Cap59 Thrust Washer Main differential Side Gear60 Side Gear Main Differential61 Spider Main Differential62 Pinion Gear Main Differential63 Thrust Washer Main Differential63 ANoSPIN Main Differential164 Washer Ring Gear (145 and 160 Series)65 Nut Ring Gear (145 and 160 Series)66 Sensor Switch Main differential Lock67 Locknut Main differential Lock Sensor Switch (Early Design)68 Spring Main differential Lock68 ASpring Main differential Lock Current Design69 Lock Pin Spring Retaining (Early Design)

8 70 Shift Shaft Main differential Lock70 AShift Shaft Main differential Lock Current Design71 Piston Main differential LockItemDescription71 APiston Main differential Lock Current Design72O-Ring Piston72AO-Ring Piston Current Design73 DCDL Cylinder Shift Shaft73 ADCDL Cylinder Shift Shaft Current Screw-In DCDL Design74 Copper Gasket Cover (160 Series)75 Capscrew Manual Engaging75 ACapscrew Manual Engaging Current Design76 Cover Main differential Lock (Early Design)77 Plug Manual Engaging (Early Design)78 Washer Manual Engaging Capscrew79 Capscrew Cover (Early Design)80 Washer Cover (Early Design)81 Shift Collar Main differential Lock82 Shift Fork Main differential Lock82 AShift Fork Main differential Lock Current Design83 Roll Pin Shift Fork (Early Design)84 Oil Filter Shield85 Plug Oil Pressure Relief Valve86 Washer Oil Pressure Relief Valve87 Spring Oil Pressure Relief Valve88 Oil Pressure Relief Valve89 Dowel Input Cage to Oil Pump (Early Design)90O-Ring Oil Pump91 Oil Pump92 Washer Oil Pump93 Capscrew Oil Pump94 Oil Filter95 Adapter Oil Filter96 Oil Screen and Plug Assembly1 NoSPIN is a registered trademark of Tractech, a division of Dyneer Exploded Views 2 Meritor Maintenance Manual 5L (Revised 02-18) Figure SIDEINPUT WITHOIL PUMP PARTSSTANDARD DIFFERENTIALCARRIER WITHOUT DIFFERENTIALLOCK AND WITHOUT OIL PUMPOIL PUMPPARTSDIFFERENTIALLOCK PARTS939215919015141213111098766A54321A1 8485868788789302928273126252423222120191 8171648474645444342414039383736359495966 6676831333234328283816970717273747576787 7798075A73A71A72A70A68A28A29A82A71A72A10 03392a1 Exploded Views3 Meritor Maintenance Manual 5L (Revised 02-18)

9 Figure SIDEPLAINCASE HALFGEARCASE HALF4954 MAIN DIFFERENTIALCASE ASSEMBLY49505165645459606362616059315858 57565553524950515435 EARLY DESIGN DCDL6871748079777876757372706967 OIL PUMP9091929315 CURRENT DCDL 68A70A72A71A73A75 ANoSPIN ASSEMBLY63A63A1002701c2 Introduction 4 Meritor Maintenance Manual 5L (Revised 02-18) 2 IntroductionDescription Forward Tandem AxleThe inter-axle differential is located behind the helical gear on the input shaft. The Forward side gear of the inter-axle differential is part of the upper helical gear hub. The thru-shaft is splined to the rear side gear of the inter-axle differential . Figure Meritor 140, 145 and 160 Forward tandem axles use a Single-Reduction , thru-drive carrier. The drive gearing is a two-helical gear train and a hypoid ring gear and pinion. Bevel gears are used in the main differential and the inter-axle differential . Figure and Figure Models Covered in This ManualNOTE: For service procedures on rear carriers, refer to Maintenance Manual 5, Single-Reduction differential Carriers, for models preceding RS-, RT- and RF-Series, and Maintenance Manual 5A, Single-Reduction differential Carriers, for MX-, RS-, RT- and RF-Series.

10 To obtain these publications, refer to the Service Notes page on the front inside cover of this Pressurized Lubrication SystemThe Forward axles can be equipped with an optional pressurized lubrication system. This filtered system has an oil pump driven by the input shaft. The pump circulates lubricant to the journals in the Forward and rear input shaft bearings and directly to the inter-axle Driver- controlled Main differential Lock (DCDL)Both the Forward and rear axles can be equipped with an optional driver- controlled main differential lock (DCDL). The differential lock is operated by an air-actuated shift unit located on the Forward axle carrier. When the differential lock is activated, the shift collar moves along the splines of the axle shaft toward the differential case. When the collar splines engage with the splines on the differential case, the axle shaft and the differential assembly lock together.