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.

2 -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.

3 @ 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.

4 , 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.

5 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.

6 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

7 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 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.

8 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.

9 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.

10 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: 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)