Meritor forward tandem drive axles maintenance service manual

Maintenance Manual 5L Single-Reduction Forward Differential Carriers on Tandem and Tridem Axles Revised 08-15

Service Notes Information 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 time. Meritor Maintenance Manual 5L (Revised 08-15) About This Manual This 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 models. Before You Begin 1. Read and understand all instructions and procedures before you begin to service components. 2. Read 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 both. 3. Follow your company’s maintenance and service, installation, and diagnostics guidelines. 4. Use special tools when required to help avoid serious personal injury and damage to components. Hazard Alert Messages and Torque Symbols WARNING A Warning alerts you to an instruction or procedure that you must follow exactly to avoid serious personal injury and damage to components. CAUTION A 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 value. How to Obtain Additional Maintenance, Service and Product Information Visit Literature on Demand at meritor.com to access and order additional information. Contact the Meritor OnTrac™ Customer Call Center at 866-668-7221 (United States and Canada); 001-800-889-1834 (Mexico); or email OnTrac@meritor.com. If Tools and Supplies are Specified in This Manual Contact Meritor’s Commercial Vehicle Aftermarket at 888-725-9355 to obtain Meritor tools and supplies. SPX Kent-Moore, 28635 Mound Road, Warren, Michigan, 48092. Call the company’s customer service center at 800-345-2233, or visit their website at spxkentmoore.com. Kiene 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 kienediesel.com. SPX/OTC Service Solutions, 655 Eisenhower Drive, Owatonna, MN 55060. Call the company’s customer service center at 800-533-6128, or visit their website at otctools.com.

pg. pg. Contents 1 Section 1: Exploded Views Single-Reduction Forward Differential Carrier 4 Section 2: Introduction Description Forward Tandem Axle Axle Models Covered in This Manual Optional Pressurized Lubrication System Optional Driver-Controlled Main Differential Lock (DCDL) 5 Inter-Axle Main Differential (IAD) Stall-Testing Can Damage a Drive Axle Use of Traction Chains Identification Model Number 7 Section 3: Removal and Disassembly Removal Axle Shafts Axle Shaft Removal Methods 9 Axle Shafts from the Axle Housing 10 Thru-Shaft 11 Differential Carrier from the Axle Housing 12 Disassembly Thru-Shaft and Output Bearing Cage Assembly 13 Removal Bearing Cone from the Thru-Shaft Measure Ring Gear Backlash 14 Input Shaft and Inter-Axle Differential Assembly 16 Disassembly Input Shaft, Bearing Cage, Oil Pump and Inter-Axle Differential 19 Removal Inter-Axle Differential Lock IAD Shift Unit 20 Driver-Controlled Main Differential Lock (DCDL) Main Differential Case and Ring Gear Assembly 21 Disassembly Main Differential Case and Ring Gear 22 Removal Ring Gear from the Differential Case 23 Drive Pinion Assembly Before You Work on a Differential Carrier Assembly Procedures 25 Section 4: Prepare Parts for Assembly Clean, Dry and Inspect Parts Clean and Inspect Yokes 26 Clean Ground and Polished Parts Clean Rough Parts Clean Axle Assemblies 26 Drying Parts After Cleaning Prevent Corrosion on Cleaned Parts Inspect Parts 28 Repair or Replace Parts Welding on Axle Housings 29 Do Not Bend or Straighten a Damaged Drive Axle Housing Removing Fasteners Secured with Adhesive 30 New Fasteners with Pre-Applied Adhesive Original or Used Fasteners Meritor Specification 2297-T-4180 Adhesive in the Differential Bearing Bores Carrier-to-Housing Joint Sealing Procedure 32 General Yoke and U-Joint Reassembly Identification Gear Sets 33 Check for Mismatched Ratios on Tandem Axles Hypoid Gear Set Ratios Listed on the Identification Tags Rotate the Forward Drive Shaft to Check the Hypoid Gear Set Ratio 34 Hypoid Gear Set Teeth Numbers Stamped on the Forward and Rear Axle Drive Pinions 35 Verify the Actual Hypoid Gear Set Ratios Inspection Yoke 36 Tire Matching for Tandem and Tridem Axles 37 Section 5: Assembly and Installation Installation Installing the Drive Pinion and Adjusting Pinion Depth and Preload Adjustment Shim Pack Thickness for a New Drive Pinion 38 Assembly Drive Pinion Assembly 40 Installation Drive Pinion Assembly 41 Adjustment Drive Pinion Bearing Preload 45 Assembly Main Differential and Ring Gear 47 Check the Rotating Resistance of the Differential Assembly 48 Installation Main Differential Case and Ring Gear Assembly Into the Carrier 50 Adjustment Differential Bearings Preload 52 Ring Gear Runout Ring Gear Backlash

Contents pg. pg. 53 Gear Set Tooth Contact Patterns, Backlash 57 Installation Thrust Screw (If Equipped) Air Shift Unit for the Inter-Axle Differential Lock 59 Assembly Input Shaft, Bearing Cage, Oil Pump and Inter-Axle Differential 63 Installation Input Shaft Assembly 64 Inspection Adjust the Input Bearing End Play 67 Installation Driver-Controlled Main Differential Lock Output Bearings and Thru-Shaft 68 Inspection Adjust the Output Bearing End Play Installation Unitized Pinion Seal 71 Installing a Multiple-Lip Seal (MLS) 75 Clean and Inspect the Yoke After Installing a Unitized Pinion Seal 76 Tight Fit Yokes and POSE™ Seal 77 Output Yoke or Flange and Oil Seal for the Output Bearing Cage 78 Differential Carrier into the Axle Housing 81 Axle Shaft 83 Fill the Axle with Lubricant 84 Section 6: Driver-Controlled Main Differential Lock Description Removal Differential Carrier from the Axle Housing 85 Engagement or Lockout of the DCDL 86 Differential and Gear Assembly and Main Differential Lock 89 Installation Differential Shift Assembly 94 Differential Lock Assembly Cover Plates Differential Carrier Into the Forward Axle Housing 96 Check the Differential Lock DCDL Driver Caution Alert Label 97 Driver Instruction Information Available 98 Section 7: Lubrication Specifications 100 Section 8: Specifications 105 Section 9: Adjustment 107 Section 10: Special Tools Specifications Carrier Repair Stand 108 How to Make a Yoke Bar 109 How to Make a Drive Flange Retainer Tool 110 Unitized Pinion Seals and Seal Drivers 112 Section 11: Vehicle Towing Instructions Type of Axle Forward 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) 119 Forward Tandem Axle, without Driver-Controlled Main Differential Lock (DCDL), with Inter-Axle Differential (IAD) 121 Section 12: Diagnostics Troubleshooting Vehicle Will Not Move 123 Differential Making Noise 125 Oil Leak 126 Contaminated Lubricant Found During Preventive Maintenance

1 Exploded Views 1 Meritor Maintenance Manual 5L (Revised 08-15) 1 Exploded Views Single-Reduction Forward Differential Carrier Item Description 1 Nut — Input Yoke 1A Washer — Input Yoke 2 Input Yoke 3 Deflector 4 Capscrew — Cage-to-Carrier 5 Washer — Cage-to-Carrier 6 Oil Seal — Triple-Lip (Main) Seal 6A POSE™ Seal 7 Input Bearing Cage 8 Shims 9 O-Ring — Input Bearing Cage 10 Bearing Cup — Input Shaft 11 Bearing Cone — Input Shaft 12 Oil Baffle (Units Without Oil Pump) 13 Washer — Oil Baffle 14 Capscrew — Oil Baffle 15 Input Shaft 16 Thrust Washer — Helical Drive Gear 17 Helical Drive Gear 18 Inter-Axle Differential Case Assembly 19 Snap Ring — Inter-Axle Differential Case 20 Clutch Collar — Inter-Axle Differential Case 21 Rear Side Gear 22 Shift Fork 23 Bearing Cone — Rear Side Gear 24 Bearing Cup — Rear Side Gear 25 Adjusting Screw — Shift Shaft 26 Jam Nut — Adjusting Screw 27 Spring — Shift Shaft 28 Shift Shaft and Piston 28A “E” Clip (Reverse Shift IAD Only) 29 Air Shift Chamber Assembly — Bolt-On IAD 29A Air Shift Chamber Assembly — Screw-In IAD 30 Capscrew — Air Shift Chamber Assembly 31 Differential Carrier and Caps 32 Washer — Differential Carrier-to-Axle Housing 33 Nut — Differential Carrier-to-Axle Housing 34 Capscrew — Differential Carrier-to-Axle Housing 35 Ring Gear and Drive Pinion 36 Inner Bearing Cone — Drive Pinion 37 Inner Bearing Cup — Drive Pinion 38 Shims 39 Inner Spacer 40 Helical Driven Gear 41 Outer Spacer 42 Outer Bearing Cup — Drive Pinion 43 Outer Bearing Cone — Drive Pinion 44 Washer — Drive Pinion 45 Nut — Drive Pinion 46 Cover — Drive Pinion 47 Washer — Drive Pinion Cover 48 Capscrew — Drive Pinion Cover 49 Bearing Adjusting Ring 50 Cup — Main Differential Bearing 51 Cone — Main Differential Bearing 52 Capscrew — Main Differential Case Halves 53 Washer — Main Differential Case Halves 54 Main Differential Case Assembly 55 Bolt — Ring Gear (145 and 160 Series) 56 Washer — Differential Bearing Cap 57 Capscrew — Differential Bearing Cap 58 Roll Pin, Cotter Pin or Capscrew — Differential Bearing Cap 59 Thrust Washer — Main Differential Side Gear 60 Side Gear — Main Differential 61 Spider — Main Differential 62 Pinion Gear — Main Differential 63 Thrust Washer — Main Differential 63A NoSPIN  Main Differential 1 64 Washer — Ring Gear (145 and 160 Series) 65 Nut — Ring Gear (145 and 160 Series) 66 Sensor Switch — Main Differential Lock 67 Locknut — Main Differential Lock Sensor Switch (Early Design) 68 Spring — Main Differential Lock 68A Spring — Main Differential Lock — Current Design 69 Lock Pin — Spring Retaining (Early Design) 70 Shift Shaft — Main Differential Lock Item Description 70A Shift Shaft — Main Differential Lock — Current Design 71 Piston — Main Differential Lock 71A Piston — Main Differential Lock — Current Design 72 O-Ring — Piston 72A O-Ring — Piston — Current Design 73 DCDL Cylinder — Shift Shaft 73A DCDL Cylinder — Shift Shaft — Current Screw-In DCDL Design 74 Copper Gasket — Cover (160 Series) 75 Capscrew — Manual Engaging 75A Capscrew — Manual Engaging — Current Design 76 Cover — Main Differential Lock (Early Design) 77 Plug — Manual Engaging (Early Design) 78 Washer — Manual Engaging Capscrew 79 Capscrew — Cover (Early Design) 80 Washer — Cover (Early Design) 81 Shift Collar — Main Differential Lock 82 Shift Fork — Main Differential Lock 82A Shift Fork — Main Differential Lock — Current Design 83 Roll Pin — Shift Fork (Early Design) 84 Oil Filter Shield 85 Plug — Oil Pressure Relief Valve 86 Washer — Oil Pressure Relief Valve 87 Spring — Oil Pressure Relief Valve 88 Oil Pressure Relief Valve 89 Dowel — Input Cage to Oil Pump (Early Design) 90 O-Ring — Oil Pump 91 Oil Pump 92 Washer — Oil Pump 93 Capscrew — Oil Pump 94 Oil Filter 95 Adapter — Oil Filter 96 Oil Screen and Plug Assembly 1 NoSPIN  is a registered trademark of Tractech, a division of Dyneer Corp. Item Description

1 Exploded Views 2 Meritor Maintenance Manual 5L (Revised 08-15) Figure 1.1 L.H. SIDE INPUT WITH OIL PUMP PARTS STANDARD DIFFERENTIAL CARRIER WITHOUT DIFFERENTIAL LOCK AND WITHOUT OIL PUMP OIL PUMP PARTS DIFFERENTIAL LOCK PARTS 93 92 15 91 90 15 14 12 13 11 10 9 8 7 6 6A 5 4 3 2 1A 1 84 85 86 87 88 7 89 30 29 28 27 31 26 25 24 23 22 21 20 19 18 17 16 48 47 46 45 44 43 42 41 40 39 38 37 36 35 94 95 96 66 67 68 31 33 32 34 32 82 83 81 69 70 71 72 73 74 75 76 78 77 79 80 75 A 73 A 71 A 72 A 70 A 68 A 28 A 29 A 82 A 71 A 72 A 1003392a

1 Exploded Views 3 Meritor Maintenance Manual 5L (Revised 08-15) Figure 1.2 R.H. SIDE PLAIN CASE HALF GEAR CASE HALF 49 54 MAIN DIFFERENTIAL CASE ASSEMBLY 49 50 51 65 64 54 59 60 63 62 61 60 59 31 58 58 57 56 55 53 52 49 50 51 54 35 EARLY DESIGN DCDL 68 71 74 80 79 77 78 76 75 73 72 70 69 67 OIL PUMP 90 91 92 93 15 CURRENT DCDL 68 A 70 A 72 A 71 A 73 A 75 A NoSPIN ® ASSEMBLY 63 A 63 A 1002701c

2 Introduction 4 Meritor Maintenance Manual 5L (Revised 08-15) 2 Introduction Description Forward Tandem Axle The 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 2.1. Figure 2.1 The 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 2.1 and Figure 2.2. Figure 2.2 Axle Models Covered in This Manual NOTE: 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. To obtain these publications, refer to the Service Notes page on the front inside cover of this manual. Optional Pressurized Lubrication System The 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 differential. Optional 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.  When the carrier operates with the DCDL in the locked position, there is no differential action between the wheels.  When the carrier is operated in the unlocked position, there is normal differential action between the wheels at all times. Figure 2.1 Figure 2.2 OIL PUMP HELICAL GEAR INTER-AXLE DIFFERENTIAL OUTPUT SHAFT RING GEAR DRIVE PINION INPUT SHAFT 1002702c Notch on inter-axle differential case. Notches are provided for clearance in assembly and disassembly. HELICAL DRIVEN GEAR 1002703c RT-160 SERIES SHOWN Tandem Models RT-34-140 RT-40-145P RT-46-160 RT-34-144 RT-40-149 RT-46-160EH RT-34-145 RT-40-160 RT-46-160P RT-34-145P RT-40-169 RT-46-169 RT-40-140 RT-44-145 RT-50-160 MT-40-143 RT-44-145P RT-50-160P RT-40-145 RT-46-16H EH RT-52-160P RT-40-145A Tridem Models RZ-166 RZ-186 RZ-188

2 Introduction 5 Meritor Maintenance Manual 5L (Revised 08-15) Inter-Axle Main Differential (IAD) The Meritor inter-axle differential (IAD) is a driver-controlled, air-actuated traction device. The IAD allows for speed differences between the forward and rear axles in a tandem while also providing equal pulling power from each axle of the tandem. By activating the IAD switch located in the vehicle dash, improved traction is provided for each axle. The inter-axle differential is also known as a power divider or third differential. Stall-Testing Can Damage a Drive Axle Stall-testing is a procedure used to troubleshoot transmissions, evaluate vehicle performance, and test the service and park brakes. During stall-testing, or any similar procedure, the drive axle input receives multiplied torque, which can exceed the specified torque rating. Excessive torque can damage a drive axle, which will affect axle performance and component life. A drive axle damaged by stall-testing will void Meritor’s warranty. Call the Meritor OnTrac™ Customer Call Center at 866-668-7221 if you have questions regarding stall-testing. Use of Traction Chains Meritor recommends that if you are using traction chains, you should install chains on both tires on each side of all drive axles on the vehicle. Identification Model Number An identification tag is riveted on the axle housing or on the differential carrier. Figure 2.3 and Figure 2.4. Use the model number and the ratio number marked on the identification tag and the number on the carrier to order replacement parts. Figure 2.3 Figure 2.4 Refer to Figure 2.5 for an explanation of the model number. Figure 2.3 Figure 2.4 Model No. . . . . . . . . . . . . . . . . . . . Customer No. . . . . . . . . . . . . . . . . Serial No. . . . . . . . . Plant . . . . . . . . Ratio . . . . . . . . . . . . IDENTIFICATION TAG LOCATION OF THE IDENTIFICATION TAG, OR STAMP NUMBER, FOR THE AXLES. LOCATION IS DETERMINED FROM THE LEFT DRIVER SIDE LOOKING TOWARD THE FRONT OF THE VEHICLE. A — FRONT ENGINE DRIVE — RIGHT REAR, NEXT TO COVER B — REAR ENGINE DRIVE — LEFT OR RIGHT REAR, NEXT TO DRIVE UNIT A B 1002704c AXLE IDENTIFICATION TAG INFORMATION CARRIER PART NO. CUSTOMER NO. SERIAL NO. RATIO Model No. Customer No. Serial No. Plant Ratio Date CARRIER PART NO. CUSTOMER NO. SERIAL NO. RATIO Model No. Customer No. Serial No. Plant Ratio Date AXLE IDENTIFICATION TAG CARRIER IDENTIFICATION TAG AXLE HOUSING IDENTIFICATION TAG 4000625a

2 Introduction 6 Meritor Maintenance Manual 5L (Revised 08-15) Figure 2.5 Figure 2.5 Axle Design V ariation: Indicates axle design level or variation, (e.g., RS-23-161 has a thicker wall housing than RS-23-160). For information, refer to the Bill of Materials for that specific axle model. Carrier Type: Carrier size. Larger numbers indicate a higher GCW rated Carrier; i.e., larger ring gear, etc. Gearing Type: 1 = Single Speed 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. Meritor M T - - 1 4 X Axle Type D = Forward-Rear Axle of a Drive T andem with Inter-Axle Differential N = Forward-Rear Axle of a Drive T andem without Inter-Axle Differential P = Forward-Rear Axle of a Drive T andem with Inter-Axle Differential and Pump T = T andem Drive Axle Set 40 CARRIER MODEL TAG NUMBER INFORMATION 1002705e

Meritor forward tandem drive axles maintenance service manual

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