Single Rear Drive Axles, Rear-Rear Tandem Drive …

1 maintenance manual 5 ASingle-Reduction Differential CarriersSingle rear Drive Axles, Rear-Rear Tandem Drive Axles and front Drive Steer 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 5A (Revised 02-18)About This ManualThis manual provides instructions for the Meritor MX, RS, RT and RF Series axles and 59000 Series angle Drive You and understand all instructions and procedures before you begin to service and observe all Warning and Caution hazard alert messages in this publication.

2 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.@ 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).

3 Or email Tools and Supplies are Specified in This ManualContact Meritor s Commercial Vehicle Aftermarket at 1: Exploded ViewsExploded ViewsSingle-Reduction Differential Carrier5 Section 2: IntroductionDescriptionStandard Single -Reduction Carriers Without Differential LockSingle-Reduction Carriers with Driver-Controlled Main Differential Lock (DCDL)6 axle Models Covered in This ManualStall-Testing Can Damage a Drive AxleUse of Traction Chains7 Section 3: Removal and DisassemblyRemovalAxle ShaftsAxle Shaft Removal Methods8 axle Shafts from the axle Housing9 Differential Carrier from the axle Housing10 Measure Ring Gear BacklashDifferential and Ring Gear from the Carrier12 DisassemblyDifferential and Ring Gear Assembly13 RemovalDrive Pinion and Bearing Cage from the Carrier14 DisassemblyDrive Pinion and Bearing Cage17 Section 4.

4 Prepare Parts for AssemblyClean, Dry and Inspect PartsClean and Inspect Yokes18 Clean Ground and Polished PartsClean Rough PartsClean axle AssembliesDrying Parts After CleaningPrevent Corrosion on Cleaned PartsInspect Parts21 Repair or Replace PartsWelding on axle Housings22Do Not Bend or Straighten a Damaged Drive axle HousingRemoving Fasteners Secured with Adhesive23 New Fasteners with Pre-Applied AdhesiveOriginal or Used FastenersMeritor Specification 2297-T-4180 Adhesive in the Differential Bearing BoresCarrier-to-Housing Joint Sealing Procedure25 General Yoke and U-Joint

5 ReassemblyIdentificationGear Sets26 Section 5: Assembly and InstallationAssemblyDrive Pinion, Bearings and Bearing Cage27 InstallationOne-Piece Spigot Bearing on the Drive Pinion with a Snap RingOne-Piece Spigot Bearing on the Drive Pinion Without a Snap Ring28 Two-Piece Spigot Bearing on the Drive Pinion30 Drive PinionAdjustmentPinion Bearing Preload32 Shim Pack Thickness for a New Drive Pinion34 InstallationDrive Pinion, Bearing Cage and Shim Pack into the CarrierTight Fit Yokes and POSE Seal36 Any Type Yoke with a Unitized Pinion Seal (UPS)38 Clean, Inspect and Install the Yoke After Installing a Unitized Pinion Seal39 Any Type Yoke with a Multiple Lip Seal (MLS)41 AssemblyMain Differential and Ring Gear Assembly43 InspectionDifferential Gears Rotating Resistance44 InstallationDifferential and Ring Gear Assembly45 AdjustmentDifferential Bearing Preload47 Ring Gear Runout48 Ring Gear Backlash49 Gear Set Tooth Contact Patterns (Backlash)52 InstallationThrust Screw (If Equipped)53 Differential Carrier into the axle Housing56 Section 6.

6 Driver-Controlled Main Differential LockDescription58 Vehicle TowingRemovalDifferential Carrier from the axle HousingAxle Setup for DCDL DisassemblyDCDL Assembly manual Engaging Methods59 Differential and Gear Assembly60 InstallationDCDL Assembly into the Carrier64 Differential Lock Assembly Cover Plates65 Carrier into the axle Housing66 Check the Differential Driver Caution Alert LabelDriver Instruction Information Available68 Section 7: LubricationSpecifications70 Section 8: SpecificationsFastenersAmerican Standard FastenersMetric Fasteners71 Torque Specifications76 Section 9: Adjustment78 Section 10: Special ToolsSpecificationsCarrier Repair Stand79 How to Make a Yoke BarUnitized Pinion Seals and Seal Drivers81 Multiple Lip Seals (MLS) and Seal Drivers82 Section 11.

7 Vehicle Towing InstructionsType of AxleSingle axle with DCDL Screw-In (Threaded) Shift Assembly, or Tandem axle with DCDL Screw-In (Threaded) Shift Assembly and with Inter- axle Differential (IAD)86 Single axle with DCDL Bolt-On Shift Assembly, or Tandem axle with DCDL Bolt-On Shift Assembly and with Inter- axle Differential (IAD)90 Single axle Without DCDL or Tandem axle Without DCDL and with Inter- axle Differential (IAD)92 Section 12: DiagnosticsTroubleshootingVehicle Will Not Move93 Differential Making Noise94 Oil Leak95 Contaminated Lubricant Found During Preventive Maintenance1 Exploded Views1 Meritor maintenance manual 5A (Revised 02-18)

8 1 Exploded ViewsExploded ViewsSingle-Reduction Differential CarrierFigure Pinion Nut*2 Drive Pinion Washer*3 Input Yoke or Flange*3 ADeflector4 POSE Seal5 Triple-Lip or Main Seal6 Outer Bearing Cone7 Inner Bearing Cup8 Sensor Switch9 Sensor Switch Locknut29 Lock Plate Capscrews*30 Lock Plate Washers*31 Adjusting Ring Lock Plate32 Differential Bearing Cap Capscrews33 Washers34 Differential Bearing Caps56 Differential Bearing Cap Capscrews57 Washers58 Differential Bearing Cap59 Carrier60 Adjusting Ring61 Adjusting Ring Cotter Pin, Spring Pin (Spirol ) or Capscrews62 Thrust Screw Jam Nut*63 Thrust Screw*64 Snap RingItemDescription1 Exploded Views 2 Meritor maintenance manual 5A (Revised 02-18) * Some Meritor carriers do not have these Bearing66 Drive Pinion67 Pinion Inner Bearing Cone68 Pinion Inner Bearing Cup69 Pinion Bearing Spacer70 Shims71 Drive Pinion Bearing Cage72 Bearing Cage Capscrew73 Washer74 Clip and Cable HolderItemDescription1 Exploded Views3 Meritor maintenance manual 5A (Revised 02-18)

9 Figure DCDL1002980eItemDescription10 Plug*11 Right-Hand Adjusting Ring12 Shift Fork13 Shift Shaft Spring14 Shift Shaft15 Spring Retaining Pin16 Air Cylinder Washer or Silastic*17 Air Cylinder Tube18 AScrew-In Differential Lock Cylinder18 BCylinder CoverItemDescription1 Exploded Views 4 Meritor maintenance manual 5A (Revised 02-18) * Some Meritor carriers do not have these Actuation Capscrew20 Cylinder Cover Plug20 ACover Plug Gasket21 Cylinder Cover Capscrews22 Cylinder Cover Washers23 Cylinder Cover Plug23 ACover Plug Gasket24 Cylinder Cover Copper Gasket25 Piston O-Ring26 Piston27 Shift Collar28 Shift Fork Pins35 Differential Side Gears36 Differential Pinion Thrust Washers37 Differential Pinions38 Differential Side Gears39 Differential Side Gear Thrust Washers40 Differential Bearing Cone41 Differential Bearing Cup42 Thru Bolt43 Differential Case Bolts*44 Differential Case Washers45

10 Main Differential Case Assembly46 Differential Spider47 Ring Gear and Case Half Bolts or Rivets*48 Ring Gear49 Flange Case Half50 Case Half Washers51 Case Half Nuts*52 Left-Hand Differential Bearing Cone53 Left-Hand Differential Bearing Cup54 Thru Bolt Washer55 Thru Bolt Nut64 Snap Ring75 Bolt-On CoverItemDescription76 Washer77 Bolt78 Screw-In CoverItemDescription2 Introduction5 Meritor maintenance manual 5A (Revised 02-18)2 IntroductionDescription Standard Single -Reduction Carriers Without Differential LockMeritor Single -reduction standard carriers are used in most Meritor Single axles, rear of Tandem axles and front Drive steer axles.