Maintenance Manual MM-15103

13X Series Rear Differential Carrier

MS1713X, MS1913X and MS2113X Models
Issued 07-17

Y – 7
R 0 -1
TA -2
I E 0 4
P R D
O AS E
R
– P ELE
T R
NO
Service Notes

About This Manual If Tools and Supplies are Specified in

This manual provides service and repair procedures for Meritor 13X This Manual
series rear differential carriers. Contact Meritor’s Commercial Vehicle Aftermarket at
888-725-9355.
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 [email protected].

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 MM-15103 (Issued 07-17)

 Contents

pg. 1 Section 1: Exploded View pg. 24 Drive Pinion Shim Pack Thickness
13X Series Carrier and Axle Housing Assembly 25 Assembly
“Dry Fit”Assembly of the Drive Pinion to Verify Shim Pack
3 Section 2: Introduction
27 Installation
Description
Drive Pinion
13X Series Rear Differential Carrier
28 Assembly
Stall-Testing Can Damage a Drive Axle
Main Differential and Ring Gear
Use of Traction Chains
31 Check the Rotating Resistance of the Differential Assembly
Identification
32 Installation
Model Number
“Dry Fit” Installation of the Main Differential Case and Ring
6 Section 3: Removal and Disassembly Gear Assembly Into the Carrier
Removal 33 Adjustment of Pinion Shim Pack and Backlash for Contact
Fasteners Secured with Adhesive Pattern
Axle Shafts Ring Gear Backlash
8 Differential Carrier from the Axle Housing 34 Gear Set Tooth Contact Patterns
9 Differential and Ring Gear from the Carrier 38 Installation
13 Drive Pinion from the Carrier “Final” Installation of the Drive Pinion and Bearing Preload
16 Section 4: Prepare Parts for Assembly Adjustment
Clean, Dry and Inspect Parts 40 “Final” Installation of the Main Differential Case and Ring
Gear Assembly Into the Carrier
Clean Ground and Polished Parts
41 Adjustment
Clean Rough Parts
Clean Axle Assemblies Differential Bearings Preload
43 Ring Gear Runout
Dry Parts Immediately After Cleaning
44 Installation
17 Corrosion Protection
Prevent Corrosion on Cleaned Parts Unitized Pinion Seal and Yoke
46 Install the Differential Carrier into the Axle Housing
Inspection
47 Install the Axle Shafts
Inspect Parts
18 Repair 49 Section 6: Lubrication
Repair or Replace the Parts Lubrication
19 Repair Welding on Axle Housings
50 Section 7: Specifications
Removal
Fasteners
Fasteners Secured with Adhesive
Installation 54 Section 8: Vehicle Towing Instructions
Fasteners Before Towing or Drive-Away
20 Prepare the Differential for Reassembly 55 After Towing or Drive-Away
Prepare the Carrier and Axle Housing for Installation 56 Section 9: Special Tools
Applying Adhesive and Silicone Gasket Material Special Tools
21 Identification How to Make a Yoke Bar
Gear Sets 57 Carrier Repair Stand Specifications
22 Checking the Ratio in the Event of a Damaged Axle Tag 58 Multiple Lip Seals (MLS) and Seal Drivers
Verify the Actual Gear Set Ratios
23 Inspection
Yoke
24 Section 5: Assembly and Installation
Installation
“Dry Fit” and “Final” Assembly and Installation Procedures
Installing the Drive Pinion, Adjusting Pinion Depth and
Contact Pattern
 1 Exploded View

13X Series Carrier and Axle Housing Assembly

1 Exploded View

Figure 1.1

50

47 49 51
48
52
53

27 28
29 46 54
43
37 38 45
39
44
37

36 31
42 30
41
40 36
17 16
13
14 25
15 35
34
24 33
26 32
23
19
22 20
10 21
11
9
8

7
18 14 15
6
5
12
4
3

2
1

4011902a

Item Description Item Description

1 Yoke Locknut 7 Bearing Cup
2 Flat Washer 8 Capscrew
3 Yoke 9 Hardened Washer
4 Deflector 10 Tapered Dowel
5 Oil Seal Assembly 11 Name Plate
6 Bearing Cone 12 Carrier Housing

Meritor Maintenance Manual MM-15103 (Issued 07-17) 1

1 Exploded View

Item Description Item Description

13 Bearing Cap, Plain Half 48 Breather
14 Washer 49 Breather Hose
15 Capscrew 50 Magnetic Plug
16 Bearing Cap Capscrew, Plain Half 51 Heat Indicator Plug
17 Washer, Plain Half 52 Fill Plug
18 Bearing Cap, Flange Half 53 Axle Housing
19 Bearing Cap Capscrew, Flange Half 54 Long Axle Shaft
20 Washer, Flange Half
21 Spacer
22 Large Spacer
23 Drive Pinion Shims
24 Bearing Cup
25 Bearing Cone
26 Drive Pinion
27 Adjusting Ring, Plain Half
28 Bearing Cup, Plain Half
29 Bearing Cone, Plain Half
30 Adjusting Ring, Flange Half
31 Bearing Cup, Flange Half
32 Bearing Cone, Flange Half
33 Flange-to-Ring Gear-to-Plain Case Capscrew
34 Flange Case Half
35 Ring Gear
36 Thrust Washer, Flat
37 Side Gear
38 Short Spider Pin
39 Roll Pin
40 Thrust Washer, Spherical
41 Pinion Gear
42 Long Spider Pin
43 Plain Case Half
44 Magnetic Plug
45 Magnets
46 Name Plate
47 Short Axle Shaft

2 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 2 Introduction

Description Stall-Testing Can Damage a Drive Axle

2 Introduction

Stall-testing is a procedure used to troubleshoot transmissions,

13X Series Rear Differential Carrier evaluate vehicle performance, and test the service and park brakes.
The Meritor 13X series single rear differential carrier is a
During stall-testing, or any similar procedure, the drive axle input
single-reduction, front-mounted carrier designed for medium duty receives multiplied torque, which can exceed the specified torque
applications. It utilizes the latest axle technology to offer optimized
rating. Excessive torque can damage a drive axle, which will affect
power density, light weight and high efficiency. The MS-13X is a
axle performance and component life. A drive axle damaged by
replacement option for applicable MS-14X and RS-145 models. stall-testing will void Meritor’s warranty.
Figure 2.1.
Call the Meritor OnTrac™ Customer Call Center at 866-OnTrac1
The 13X offers the following features:
(668-7221) if you have questions regarding stall-testing.
앫 Up to 59 pounds lighter than the MS-14X carrier
앫 Uses same axle housing as currently used in MX-14X/RS-145
Use of Traction Chains
designs Meritor recommends that if you are using traction chains, you
should install chains on both tires on each side of all drive axles on
앫 GAWR: 17,000-21,000 pounds
the vehicle.
앫 GCW: 40,000 pounds
앫 L and R spindle options Identification
앫 Ratio range of 3.90-6.50 Model Number
앫 Driveline parking brake-compatible An identification tag is attached to the axle housing or the
앫 All bearings in the carrier are tapered roller bearings differential carrier. Figure 2.2 and Figure 2.3. Use the model
number and the ratio number marked on the identification tag and
Figure 2.1 the number on the carrier to obtain replacement parts.

Figure 2.2

AXLE IDENTIFICATION TAG INFORMATION

Model No. . . . . . . . . . . . . . . . . . . .
Customer No. . . . . . . . . . . . . . . . .
TAPERED
DRIVE PINION
ROLLER Serial No. . . . . . . . . Plant . . . . . . . .
AND RING
BEARINGS Ratio . . . . . . . . . . . .
GEAR

IDENTIFICATION TAG

LOCATION OF THE IDENTIFICATION TAG, OR STAMP

TAPERED TAPERED NUMBER, FOR THE AXLES. LOCATION IS
ROLLER ROLLER DETERMINED FROM THE LEFT DRIVER SIDE
BEARING BEARING LOOKING TOWARD THE FRONT OF THE VEHICLE.
FRONT ENGINE DRIVE — RIGHT REAR,
NEXT TO COVER

DIFFERENTIAL
GEARS
4011903a
4008141a
Figure 2.1 Figure 2.2

Meritor Maintenance Manual MM-15103 (Issued 07-17) 3

2 Introduction

Figure 2.3

CARRIER PART NO.

CUSTOMER NO.
SERIAL NO.
RATIO

CARRIER
IDENTIFICATION TAG 4008212b

Figure 2.3

Refer to Figure 2.4 for an explanation of the model number.

4 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 2 Introduction

Figure 2.4

Meritor MS-13X Drive Axle Model Nomenclature

Housing Wall
0 = Cast
1 = TBD
2 = 0.31 in. (8 mm)
3 = 0.37/0.39 in. (9.5/10.0 mm)
GAWR 4 = 0.43 in. (11 mm)
xx = GAWR (000) Pounds or Tons 5 = 0.50/0.51 in. (12.7/13.0 mm)
(dependent on mfg. location) 6 = 0.56 in. (14.3 mm)
7 = TBD
8 = 0.63 in. (16 mm)
9 = TBD
Relative Gearing
Axle Model Type Size or Series
Carrier Variation
S= Single Rear (Solo) 0 = No Gearing A = Aluminum
D= Fwd Rear w/IAD 1 = 292/347 B = Aluminum/Ductile Amboid (Tandem Split)
N= Fwd Rear less IAD 2 = 337/387 C = Ductile/Ductile Amboid (Tandem Split)
P= Fwd Rear w/Pump 3 = 341/355 D = Ductile Rear, Hyboid
R= Rear Rear 4 = 381/432 E = Aluminum/Ductile (Tandem Split)
T= Tandem Drive 5 = 415/432 F = Ductile Amboid/Ductile Hypoid (Tandem Split)
Z= Tridem Drive 6 = 432/457 M= Ductile Rear, Amboid
C= Coach 7 = 457 N= No Carrier
H= High Entry 8 = 460/498 R = Ductile Front Drive Axle Carrier, Right Hand

M x - xx - x x x x x x x x x - x x x - x x x x
M S - 21 - 1 3 X 5 D B B N Q - 1 2 3 - 3 5 5

Axle Type Ratio 1

0 = No Carrier
MFG Location
M = Meritor 1 = Single Speed
A = Australia/Asia/Africa
2 = Two Speed
E = Europe
3 = Helical Double Reduction
N = North America
4 = Salisbury
S = South America Specification Number
5 = Planetary Double Reduction
T = Telma Retarder
6 = Planetary Hub Reduction Includes: TRACK, PARKING
(U.S.A.)
7 = Portal BRAKE, OTHER.
8 = Bevel Hub Reduction
9 = Single Speed with Torque
Output Limited Engine Brake Type
B = “B” Frame Brake
Main Differential Nest Type C = Air Disc Brake
A = DCDL/Standard (Tandem Wheel End/Brake Attachment D = Wedge Brake, Dual Air Chambers
Split) A = Conventional Spindle/Conventional E = Wedge Brake, Dual Hydraulic
B = Special Differential Brake Cylinders
C = Driver Controlled Differential E = Unitized Spindle/Conventional Brake F = Wedge Brake, Single Hydraulic
Lock — DCDL J = Conventional Spindle/Integral Brake Cylinder
D = DCDL/NoSPIN® (Tandem L = Conventional L Spindle/Conventional G = DuraPark® Hydraulic Drum
Split) Brake H = Quadraulic™ Disc
E = Standard/DCDL (Tandem N = Unitized Spindle/Integral Brake K = EX+™ Air Disc
Split) R = Conventional R Spindle/Conventional L = Q+™ Cam Brake
F = Standard Differential Brake N = None
G = Standard/NoSPIN® S = Bolt on Conventional Spindle/ P = “P” Series Cam Brake
(Tandem Split) Conventional Brake Q = “Q” Series Cam Brake
H = High Traction Differential R = Cast+™ Brake
J = NoSPIN®/DCDL (Tandem NOTE: The term “Tandem Split” refers to S = Wedge Brake, Single Air Chamber
Split) when there is a difference between the T = “T” Series Cam Brake
Forward axle and Rear axle of the Tandem V = Simplex Air Cam Brake
K = NoSPIN®/Standard (Tandem
or Tridem axle set when the Tandem or W = “W” Series Cam Brake
Split)
Tridem axle set part number is used. The Z = Non-Meritor Brake
L = No Differential value to the left of the “/” references the
N = NoSPIN® Forward axle, and the number to the right
of the “/” references the Rear axle. For
information related to the Middle axle of a
Tridem axle set part number, refer to the
Bills of Material. 4012320a

Figure 2.4

Meritor Maintenance Manual MM-15103 (Issued 07-17) 5

3 Removal and Disassembly

Hazard Alert Messages 4. Place jackstands under each spring seat of the axle to hold the
3 Removal and Disassembly

vehicle in the raised position. Figure 3.1.

Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent Figure 3.1

serious personal injury, damage to components, or both.

WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.

Park the vehicle on a level surface. Block the wheels to

prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.

Use a brass or synthetic mallet for assembly and disassembly SAFETY

procedures. Do not hit steel parts with a steel hammer. Pieces STANDS
1002983a
of a part can break off. Serious personal injury and damage to
components can result. Figure 3.1

Removal 5. Remove the plug from the bottom of the axle housing and drain
the lubricant from the assembly.
Fasteners Secured with Adhesive 6. Disconnect the driveline universal joint from the pinion input
 yoke or flange on the carrier. Figure 3.2.
If it’s difficult to remove fasteners secured with Dri-Loc , Meritor
specification 2297-T-4180 or Loctite 277 adhesive, use the
following procedure.

CAUTION
When you remove fasteners secured with adhesive, slowly
heat the fastener to 350°F (177°C). Do not exceed this
temperature, or heat fasteners quickly. Damage to
components can result.

1. Heat a fastener for three to five seconds only. Try to loosen the
fastener with a wrench. Do not use an impact wrench or hit the
fastener with a hammer.
2. Repeat Step 1 until you can remove the fastener.

Axle Shafts
1. Wear safe eye protection.
2. Park the vehicle on a level surface and block the wheels to
prevent the vehicle from moving.
3. Raise the end of the vehicle where the axle is mounted. Use a
jack or other lifting tool, and place safety stands under each
side of the axle.

6 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 3 Removal and Disassembly

Figure 3.2 7. Remove the stud nuts and washers from the flanges of both
axle shafts.
1
EASY SERVICETM
8. Loosen the tapered dowels, if equipped, in the axle flanges of
2 both axle shafts using one of the following methods.
9

3
Brass Drift Method
4
8
5
WARNING
Do not strike the round driving lugs on the flange of an axle
6
shaft. Pieces can break off and cause serious personal injury.
7

NOTE: You can use a 1-1/2-inch (38 mm) diameter brass hammer
10 as a drift.
WING SERIES
11
PERMALUBETM
1. Hold a 1-1/2-inch (38 mm) diameter brass drift against the
12 center of the axle shaft, inside the round driving lugs.
14
13 Figure 3.3.

Figure 3.3

FULL-ROUND
BRASS
15 HAMMER

16

19 17
18
DRIVING
“RPL” SERIES, LUGS 1003117b
PERMALUBETM
Figure 3.3
25 20
21
2. Use a 5-6 lb (2-3 kg) hammer to strike the end of the drift to
loosen the axle shaft and tapered dowels.
22
24
23 3. Mark each axle shaft to identify it before you remove it from the
1002984b
axle assembly.
1 FULL-ROUND BEARING CUPS 14 U-JOINT CROSS
2 END YOKE 15 CAPSCREWS 4. Remove the tapered dowels. Separate the axle shafts from the
3 YOKE SADDLE 16 END YOKE main axle hub assembly. Figure 3.4.
4 WELD YOKE 17 WELD YOKE
5 BEARING STRAP 18 SLIP YOKE
6 CAPSCREWS 19 U-JOINT CROSS
7 EASY-SERVICE™ BEARING CUPS 20 CAPSCREWS
8 U-JOINT CROSS 21 END YOKE
9 SLIP YOKE 22 SLIP YOKE
10 CAPSCREWS 23 TUBING
11 END YOKE 24 U-JOINT CROSS
12 WELD YOKE 25 WELD YOKE
13 SLIP YOKE
Figure 3.2

Meritor Maintenance Manual MM-15103 (Issued 07-17) 7

3 Removal and Disassembly

Figure 3.4 3. Mark each axle shaft to identify it before you remove it from the
STUD WASHER STUD axle assembly.
NUT GASKET
4. Remove the tapered dowels. Separate the axle shaft from the
main axle hub assembly. Figure 3.4.
5. Install a cover over the open end of each axle assembly hub
TAPERED where an axle shaft was removed.
DOWEL,
IF EQUIPPED
Differential Carrier from the Axle Housing
AXLE HUB 1. Place a hydraulic roller jack under the differential carrier to
SHAFT OR
FLANGE 1002581d support the assembly. Figure 3.6.

Figure 3.4 Figure 3.6

5. Install a cover over the open end of each axle assembly hub
where an axle shaft was removed.

Air Hammer Vibration Method

CAUTION WOOD
Do not use a chisel or wedge to loosen the axle shaft and BLOCK
tapered dowels, which can damage the axle shaft, gasket and
seal, and axle hub.
ROLLER
JACK
4011956a
1. Use a round hammer bit and an air hammer to loosen the
tapered dowels and axle shaft. Figure 3.6

2. Place the round hammer bit against the axle shaft between the
hub studs. Operate the air hammer at alternate locations 2. Remove all but the top two carrier-to-housing capscrews or
between the studs to loosen the tapered dowels and axle shaft stud nuts and washers.
from the hub. Figure 3.5. 3. Loosen the top two carrier-to-housing fasteners, but leave
them attached to the assembly. The fasteners will hold the
Figure 3.5

carrier in the housing.

ROUND HAMMER BIT
BETWEEN HUB STUDS
WARNING
Use a brass or synthetic mallet for assembly and disassembly
procedures. Do not hit steel parts with a steel hammer. Pieces
of a part can break off. Serious personal injury and damage to
components can result.

4. Loosen the differential carrier in the axle housing. Use a leather

mallet to hit the mounting flange of the carrier at several
points.
5. After the carrier is loosened, remove the top two fasteners.
1002987a

Figure 3.5

8 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 3 Removal and Disassembly

CAUTION Figure 3.8

When you use a pry bar, be careful not to damage the carrier
or housing flange. Damage to these surfaces will cause oil
leaks.

6. Carefully remove the carrier from the axle housing using the
hydraulic roller jack. Use a pry bar that has a round end to help
remove the carrier from the housing. Take care that you don’t
damage the carrier or housing flange with the pry bar.

NOTE: A carrier stand is available from SPX Kent-Moore. To obtain

this tool, refer to the Service Notes page on the front inside cover of
this manual.

7. Use a lifting tool to lift the differential carrier by the input yoke
4009986b
or flange. Do not lift the carrier by hand. Place the assembly in
a carrier stand. Figure 3.7. Refer to Section 9 to build a stand.

Figure 3.7

Figure 3.8

DIFFERENTIAL 3. Rotate the differential carrier in the repair stand until the ring
CARRIER
gear is at the TOP of the assembly.
4. Use a center punch and hammer to mark one carrier leg and
bearing cap to correctly match the parts during carrier
assembly. Figure 3.9.

REPAIR Figure 3.9

STAND

4011957a
CARRIER
Figure 3.7 MATCH CAP
MARKS CARRIER
LEG
Differential and Ring Gear from the Carrier
1. Before you begin service procedures on the differential carrier,
inspect the gear set for damage.
4011960a
앫 If the gear set isn’t damaged: You can reuse the gear set.
Figure 3.9
앫 If the gear set is damaged: Replace it with a new gear
set.
5. Remove the capscrews and washers that secure the bearing
2. Measure and record gear set backlash. Figure 3.8. Refer to adjusting rings in position. Figure 3.10.
Step 1 through Step 4 under Ring Gear Tooth Contact Pattern,
Backlash in Section 5 for instructions. Adjust backlash to the
original dimension when you install the gear set into the carrier
during assembly procedures.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 9

3 Removal and Disassembly

Figure 3.10 8. Use a lifting strap to lift the main differential and ring gear
assembly from the carrier. Place the assembly onto a work
bench. Figure 3.13.

Figure 3.13

CAPSCREW
AND
WASHER

4011961a

Figure 3.10

6. Remove the two capscrews and washers that secure the two
bearing caps onto the carrier. Figure 3.11.
4011964a
Figure 3.11

CAPSCREWS Figure 3.13

AND WASHERS
9. Remove the bearing cups from the bearings. Figure 3.14.

Figure 3.14

BEARING BEARING
CUP CUP

4011962a

Figure 3.11
4011965a
7. Remove the bearing caps and bearing adjusting rings from the
carrier. Figure 3.12. Figure 3.14

Figure 3.12

BEARING Disassemble the Differential and Ring Gear

CAP Assembly
NOTE: The marks on the plain half and flange half of the differential
ADJUSTING assembly case will help you to match them correctly when you
RING
assemble the carrier.

1. If the match marks on the plain half and flange half of the
differential assembly case are not visible, mark each case half
with a center punch and hammer. Figure 3.15.

4011963a

Figure 3.12

10 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 3 Removal and Disassembly

Figure 3.15 Figure 3.17

FLANGE
HALF

MATCH
MARKS

4011966a

Figure 3.15 PLAIN CASE

HALF
2. Remove the capscrews that secure the ring gear to the case
4011992a
halves. Figure 3.16.
Figure 3.17
Figure 3.16

CAPSCREW
4. Remove the thrust washer and side gear from the plain half
case. Figure 3.18.

Figure 3.18

THRUST
WASHER

SIDE GEAR

4011959a

Figure 3.16

WARNING
Use a brass or synthetic mallet for assembly and disassembly
procedures. Do not hit steel parts with a steel hammer. Pieces
4011987a
of a part can break off. Serious personal injury and damage to
components can result. Figure 3.18

3. Remove the flange half from the ring gear and plain case half. 5. Use a press to separate the ring gear from the plain case half.
Figure 3.17. Figure 3.19.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 11

3 Removal and Disassembly

Figure 3.19 Figure 3.21

RING
GEAR

GUIDE GUIDE ROLL ROLL

PIN PIN PIN PIN

PLAIN
CASE
HALF 4012098b

Figure 3.21
4011988a

Figure 3.19 7. Drive out the two short spider pins from the plain half case.
Remove the thrust washers and pinions from the top of the
6. From the top, drive out the two roll pins from the plain half plain half case. Figure 3.22.
case. Figure 3.20 and Figure 3.21.
Figure 3.22

Figure 3.20
PINION

ROLL PINS
THRUST
WASHER

SHORT
SPIDER PIN
4012099a
PLAIN HALF-
TOP DOWN Figure 3.22
4012098a
8. Drive out the long spider pin from the plain half case. Remove
Figure 3.20
the thrust washers and pinions from the top of the case.
Figure 3.23.

12 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 3 Removal and Disassembly

Figure 3.23 Figure 3.25

PINION PRESS

THRUST
WASHER

LONG
SPIDER PIN

4011968b

Figure 3.25

4012300a Figure 3.26

Figure 3.23

9. Remove the thrust washer and side gear from the plain half PULLER
case. Figure 3.24.

Figure 3.24

SIDE
GEAR
4011968a

THRUST Figure 3.26

WASHER

Drive Pinion from the Carrier

1. Fasten a yoke or flange bar to the input yoke. This will be used
to hold the drive pinion stationary when the nut is removed.
Refer to Section 5 for instructions to make a yoke bar.
Figure 3.27.

Figure 3.27

4012301a

Figure 3.24

FLANGE/
10. If you need to replace the differential bearings, use a bearing YOKE BAR
puller or press to remove the bearing cones from the case
halves. Figure 3.25 and Figure 3.26.
4011969a

Figure 3.27

Meritor Maintenance Manual MM-15103 (Issued 07-17) 13

3 Removal and Disassembly

2. Remove the nut and washer, if equipped, from the drive pinion. Figure 3.29

Figure 3.27.
3. Remove the yoke or flange bar.

CAUTION
If the yoke and flange are difficult to remove from the drive
pinion during disassembly, use a puller. Do not use a hammer
or mallet, which can damage components and affect driveline
alignment and end play.

4. Remove the yoke from the drive pinion. If the yoke is tight on
the pinion, use a puller. Figure 3.28.

Figure 3.28

4011971a
YOKE
PULLER Figure 3.29

WARNING
Observe all warnings and cautions provided by the press
manufacturer to avoid damage to components and serious
personal injury.

6. Place the carrier assembly in a press with the threaded end of

the pinion shaft pointing UP. Figure 3.30.

Figure 3.30

4011970a

Figure 3.28

NOTE: Always use a new oil seal during reassembly. Don’t reuse a
seal that’s been removed.

5. Use appropriate prying tools to remove the unitized oil seal

from the carrier. Place the blades of the prying tools under the
flange to remove the oil seal. Figure 3.29.
4011972a

Figure 3.30

7. Press the pinion shaft out of the outer bearing cone. Do not let
the pinion shaft drop to the ground after being pressed out.
Figure 3.30.
8. Remove the outer bearing cone from the carrier.

14 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 3 Removal and Disassembly

앫 If you need to replace the pinion bearings: Use a

suitable puller to remove the inner and outer bearing cups
from the carrier.
9. Remove the shims from the carrier.
앫 If the shims are in good condition: Keep the shims
together for use when the carrier is assembled.
앫 If the shims are to be discarded because of damage:
First measure the total thickness of the pack. Make a note
of the dimension. You will need the dimension to calculate
the depth of the drive pinion in the carrier when the gear set
is installed.
10. Remove the bearing spacer and variable spacer from the pinion
shaft. Figure 3.31.
앫 If you need to replace the pinion bearings: Use a press
or bearing puller to remove the inner bearing cone from the
drive pinion. The puller must fit under the inner race of the
cone to remove the cone correctly without damage.
Figure 3.32.

Figure 3.31

SPACERS

4000170a

Figure 3.31

Figure 3.32

PRESS
DRIVE
PINION
INNER
BEARING
CONE BEARING
PULLER

SUPPORTS
1003012d

Figure 3.32

Meritor Maintenance Manual MM-15103 (Issued 07-17) 15

4 Prepare Parts for Assembly

Hazard Alert Messages Clean, Dry and Inspect Parts

4 Prepare Parts for Assembly

Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent Clean Ground and Polished Parts
serious personal injury, damage to components, or both. 1. Use a cleaning solvent to clean ground or polished parts or
surfaces. Kerosene or diesel fuel oil can be used for this
WARNING purpose. DO NOT USE GASOLINE.
To prevent serious eye injury, always wear safe eye protection
2. Use a tool with a flat blade, if required, to remove sealant
when you perform vehicle maintenance or service.
material from parts. Be careful not to damage the polished or
smooth surfaces.
Solvent cleaners can be flammable, poisonous and cause
burns. Examples of solvent cleaners are carbon tetrachloride,
and emulsion-type and petroleum-base cleaners. Read the
CAUTION
Do not use hot solution tanks or water and alkaline solutions to
manufacturer’s instructions before using a solvent cleaner,
clean ground or polished parts. Damage to parts can result.
then carefully follow the instructions. Also follow the
procedures below.
3. Do not clean ground or polished parts with water or steam. Do
앫 Wear safe eye protection. not immerse ground or polished parts in a hot solution tank or
use strong alkaline solutions for cleaning, or the smooth
앫 Wear clothing that protects your skin.
sealing surface may be damaged.
앫 Work in a well-ventilated area.
앫 Do not use gasoline or solvents that contain gasoline. Clean Rough Parts
Gasoline can explode. 1. Clean rough parts with the same method as cleaning ground
앫 You must use hot solution tanks or alkaline solutions and polished parts.
correctly. Read the manufacturer’s instructions before 2. Rough parts can be cleaned in hot solution tanks with a weak
using hot solution tanks and alkaline solutions. Then or diluted alkaline solution.
carefully follow the instructions.
3. Parts must remain in hot solution tanks until heated and
Take care when you use Loctite adhesive to avoid serious completely cleaned.
personal injury. Read the manufacturer’s instructions before 4. Parts must be washed with water until all traces of the alkaline
using this product. Follow the instructions carefully to prevent solution are removed.
irritation to the eyes and skin. If Loctite adhesive material
gets into your eyes, follow the manufacturer’s emergency Clean Axle Assemblies
procedures. Have your eyes checked by a physician as soon as
1. A complete axle assembly can be steam cleaned on the
possible.
outside to remove dirt.
When you apply some silicone gasket materials, a small 2. Before the axle is steam cleaned, close or place a cover over all
amount of acid vapor may be present. To prevent serious openings in the axle assembly. Examples of openings are
personal injury, ensure that the work area is well-ventilated. breathers or vents in air chambers.
Read the manufacturer’s instructions before using a silicone
gasket material, then carefully follow the instructions and use Dry Parts Immediately After Cleaning
appropriate safety equipment. If a silicone gasket material
gets into your eyes, follow the manufacturer’s emergency All Parts Except Bearings
procedures. Have your eyes checked by a physician as soon as Use soft, clean paper, cloth rags or compressed air to dry parts
possible. immediately after cleaning.

16 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 4 Prepare Parts for Assembly

Bearings 앫 There is damage on the cup and cone inner race surfaces
that touch the rollers. Figure 4.5.
CAUTION
Use soft, clean paper or cloth rags to dry bearings immediately Figure 4.1

after cleaning. Do not use compressed air, which can damage 1

the bearings when they are rotated and dried.

Use soft, clean paper or cloth rags to dry bearings immediately after
cleaning. Do not use compressed air.

Corrosion Protection
Prevent Corrosion on Cleaned Parts 2
1003017c
1. Apply axle lubricant to cleaned and dried parts that are not
Figure 4.1
damaged and are to be assembled.
2. To store parts, apply a special material that prevents corrosion Figure 4.2

to all surfaces. Wrap cleaned parts in a special paper that will

protect the parts from moisture and prevent corrosion.

Inspection
WEAR
CRACK
Inspect Parts GROOVES

It is very important to inspect all parts carefully and completely

before the axle or carrier is assembled. Check all parts for wear and
replace damaged parts.
1. Inspect the cup, cone, rollers and cage of all tapered roller
bearings in the assembly. If any of the following conditions
exist, replace the bearing.
1003018b
앫 The outer ring of the large-diameter end of the rollers is
worn level with or below the center surface. Figure 4.1. Figure 4.2

앫 The radius at the large-diameter end of the rollers is worn

to a sharp edge. Figure 4.1. Figure 4.3

앫 There is a visible roller groove in the cup or cone inner race

surfaces. The groove can be seen at the small- or
large-diameter end of both parts. Figure 4.2.
앫 There are deep cracks or breaks in the cup, cone inner race
or roller surfaces. Figure 4.2.
앫 There are bright wear marks on the outer surface of the
roller cage. Figure 4.3.
WEAR MARKS
앫 There is damage on the rollers and on the surfaces of the 1003019a
cup and cone inner race that touch the rollers. Figure 4.4.
Figure 4.3

Meritor Maintenance Manual MM-15103 (Issued 07-17) 17

4 Prepare Parts for Assembly

Figure 4.4 앫 The four trunnion legs of the spider pins

ETCHING AND PITTING 앫 Teeth, flat backface and splines of both differential side
gears
앫 Teeth, bore and spherical backface of all differential pinions

Figure 4.6

PINION AND LONG

1003020a THRUST SPIDER
WASHER PIN
Figure 4.4

Figure 4.5
SIDE GEAR
FLAT AND THRUST
BACKFACE WASHER

SHORT
SPIDER
SPALLING AND FLAKING PIN
4011973a

Figure 4.6

4. Inspect the axle shafts for wear and cracks at the flange, shaft
and splines. Replace the axle shafts, if required.
1003021b
Repair
Figure 4.5

Repair or Replace the Parts

CAUTION
A drive pinion and ring gear is machined as a matched set. NOTE: Threads must be without damage and clean so that
When you replace either a drive pinion or a ring gear, you must accurate adjustments and correct torque values can be applied to
replace both parts as a matched set. Do not mix old and new fasteners and parts.
parts. Damage to components can result.
1. Replace any fastener if corners of the head are worn.
2. Inspect pinions and gears for wear or damage. Replace pinions 2. Replace the washers if damaged.
and gears that are worn or damaged.
3. Replace the gaskets, oil seals or grease seals at the time of
axle or carrier repair.
CAUTION
When you need to replace either a thrust washer, differential 4. Clean the parts and apply new silicone gasket material where
side gear or pinion gear, you must replace all of these parts required when the axle or carrier is assembled. Figure 4.7.
with a new set. Do not mix old and new parts. Damage to
components can result.

3. Inspect the following main differential assembly parts for wear

or stress. Replace parts that are damaged. Figure 4.6.
앫 Inside surfaces of both case halves
앫 Both surfaces of all thrust washers

18 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 4 Prepare Parts for Assembly

Figure 4.7
Installation
Remove silicone
gasket from parts. Fasteners
New Fasteners with Pre-Applied Adhesive
NOTE: No drying time is required for fasteners with pre-applied
adhesive.

1. Use a wire brush to clean oil and dirt from threaded holes.
1003023a 2. Install new fasteners with pre-applied adhesive to assemble
Figure 4.7 parts. Do not apply adhesives or sealants to fasteners with
pre-applied adhesive, or to fastener holes.
5. Remove nicks, marks and burrs from parts with machined or 3. Tighten fasteners to the required torque value for that size
ground surfaces. Use a fine file, india stone, emery cloth or fastener.
crocus cloth.
Original or Used Fasteners Using Meritor Liquid
6. Clean and repair threads of fasteners and holes. Use a die, a Adhesive 2297-M-5213, Loctite 277 or 270
tap of the correct size, or a fine file. Adhesive, or Equivalent

Repair Welding on Axle Housings WARNING

Take care when you use Loctite adhesive to avoid serious
For Complete Welding Instructions on Meritor Drive personal injury. Read the manufacturer’s instructions before
Axle Housings using this product. Follow the instructions carefully to prevent
Refer to Maintenance Manual 8, Drive Axle Housings. To obtain this irritation to the eyes and skin.
publication, refer to the Service Notes page on the front inside cover
1. Use a wire brush to clean the oil, dirt and old adhesive from all
of this manual.
threads and threaded holes.

Removal 2. Apply four or five drops of Meritor liquid adhesive, Loctite 277
or 270 adhesive, or equivalent, inside each threaded hole or
bore. Do not apply adhesive directly to fastener threads.
Fasteners Secured with Adhesive
Figure 4.8.
If it’s difficult to remove fasteners secured with Dri-Loc, Meritor
specification 2297-T-4180 or Loctite 277 adhesive, use the NOTE: There is no drying time required for Meritor specification
following procedure. 2297-K-5523 liquid adhesive, Loctite 680 adhesive, or equivalent.

3. Tighten the fasteners to the required torque value for that size
CAUTION
fastener.
When you remove fasteners secured with adhesive, slowly
heat the fastener to 350°F (177°C). Do not exceed this Figure 4.8

temperature, or heat fasteners quickly. Damage to

components can result.

1. Heat a fastener for three to five seconds only. Try to loosen the
fastener with a wrench. Do not use an impact wrench or hit the
fastener with a hammer. FOUR TO
FIVE DROPS
2. Repeat Step 1 until you can remove the fastener. ON BORE
THREADS
1003025a

Figure 4.8

Meritor Maintenance Manual MM-15103 (Issued 07-17) 19

4 Prepare Parts for Assembly

Prepare the Differential for Figure 4.10

Reassembly Remove old

sealant material.
1. Use a wire brush to remove any hardened adhesive material
from the fasteners.
2. Clean the oil and dirt from the outer diameters of the bearing
cups and bearing bores in the carrier and bearing caps. There
is no special cleaning required.
HOUSING AND
3. Apply axle lubricant to the bearing cones and the inner CARRIER SHOWN
diameters of the bearing cups of the main differential. Do not
1003027a
get oil on the outer diameter of the bearing cup and do not
permit oil to drip on the bearing bores of the carrier. Figure 4.10

Prepare the Carrier and Axle Housing 3. Remove metal filings from the magnets inside the housing.
for Installation 4. Use solvent to clean the inside of the housing.
1. Remove all debris from inside the housing. 5. Use Loctite ODC Free cleaner or brake cleaner to clean the
housing and carrier faces.
CAUTION
When you clean the silicone from the mounting surfaces, use a 6. Dry the housing and carrier faces.
rotary tool with a mild, non-abrasive pad and keep it
perpendicular to the housing and carrier face. Take care to CAUTION
ensure you do not remove the base housing flange material. New capscrew kits have blue Dri-Loc STS threadlocker, an
Use care especially at the 6 o’clock position where most leaks equivalent to Loctite 242 threadlocker, applied to the
occur and where there is the least amount of housing and capscrews. Do not remove the blue Dri-Loc STS threadlocker
carrier surface area. A leak can result in damage to from the capscrews. Damage to components can result.
components.
7. If you reuse the carrier-to-housing capscrews, use a rotary
2. Use a rotary tool with a mild, non-abrasive pad to clean all wire brush to remove any threadlocker material and clean the
silicone residue from the housing and carrier faces. Figure 4.9. capscrew threads. Use a clean cloth to wipe the threads.
Surfaces must be clean, dry and free of contaminants. The
surfaces must not be oily to the touch. Figure 4.10. 8. Use a tap to clean the internal threads in the housing.

Figure 4.9

Clean the housing face with a rotary tool and a mild, Applying Adhesive and Silicone Gasket
non-abrasive pad. Keep the tool perpendicular to the surface.
Material
NOTE: The following silicone gasket products or equivalent can be
used for Meritor components.

앫 Loctite Ultra Grey Adhesive/Sealant number 18581

CORRECT INCORRECT 앫 Meritor part number 2297-H-7054 gasket material. To obtain

this gasket material, refer to the Service Notes page on the front
HOUSING HOUSING
FACE FACE inside cover of this manual.
1. Use a tool with a flat blade, if required, to remove all old gasket
ROTARY
material from surfaces. Figure 4.11.
ROTARY TOOL TOOL
4007816a
Figure 4.9

20 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 4 Prepare Parts for Assembly

Figure 4.11 5. Assemble the components immediately to permit the silicone

HOUSING AND CARRIER SHOWN gasket material to compress evenly between the parts. Tighten
Remove old fasteners to the required torque value for that size fastener.
sealant Refer to Table H in Section 7.
material.
6. Wait 20 minutes before filling the assembly with the correct
lubricant. Refer to Section 4.

Identification
Gear Sets
Refer to the following examples for information on identifying gear
4012514a
sets with matched parts. Always check the match numbers to verify
Figure 4.11 that the gear set you will install has matched parts. Figure 4.13.

2. Use a cleaning solvent to clean the surfaces where you will

Figure 4.13

apply silicone gasket material. Remove all oil, grease, dirt and ALTERNATE LOCATIONS
moisture without damaging the mating surfaces. Figure 4.11. 1

3. Dry all surfaces. 2

3

CAUTION
Apply silicone gasket material in a continuous 0.25-inch
(6 mm) bead. If you use more than this amount, the gasket 4

material can break off and plug lubrication passages. Damage 1003031d
to components can result.
1 PART NUMBER, TOOTH COMBINATION NUMBER, GEAR SET MATCH
NUMBER, PINION CONE VARIATION NUMBER
4. Apply a 0.25-inch (6 mm) diameter continuous bead of the 2 PART NUMBER, TOOTH COMBINATION NUMBER
silicone gasket material around one surface. Also apply the 3 GEAR SET MATCH NUMBER, PINION CONE VARIATION NUMBER
gasket material around the edge of all fastener holes on that 4 PART NUMBER, TOOTH COMBINATION NUMBER, GEAR SET MATCH
NUMBER
surface. Figure 4.12.
Figure 4.13
Figure 4.12

Examples
Gear Set

Part Number Location

Conventional XXXXX, XXXXXK2, On the outer
ring gear XXXXXK3, diameter
XXXXXK4,
XXXXXK5
0.25" (6 MM) Conventional XXXXX, XXXXXK2, At the end at
DIAMETER SILICONE
GASKET BEAD 1003028f drive pinion XXXXXK3, threads
XXXXXK4,
Figure 4.12 XXXXXK5

Meritor Maintenance Manual MM-15103 (Issued 07-17) 21

4 Prepare Parts for Assembly

Gear Set Tooth Combination Number Checking the Ratio in the Event of a
Damaged Axle Tag
Drive Pinion Ring Gear
Gear Set Teeth Location Location To Identify the Gear Teeth Number on the Rear Axle
5-37 = gear set has At the end at On the outer Drive Pinion
a five-tooth drive threads diameter
pinion and a WARNING
37-tooth ring gear Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
Gear Set Match Number safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
NOTE: Meritor drive pinions and ring gears are only available as damage to components can result.
matched sets. Each gear in a set has an alphanumeric match
number. 1. Park the vehicle on a level surface.
2. Block the wheels to prevent the vehicle from moving.
Drive Pinion Ring Gear 3. Remove the drive shaft. Refer to the vehicle manufacturer’s
Match Number Location Location procedures.
M29 At the end of the On the outer 4. Identify and record the gear set teeth numbers stamped on the
gear head diameter end of the rear axle drive pinion. Figure 4.14.

Pinion Cone Variation Number Figure 4.14

NOTE: Don’t use the pinion cone variation number when you check
for a matched gear set. Use this number when you adjust the pinion
depth in the carrier. Refer to Section 5.

4
10 - 7

Pinion Cone (PC) Drive Pinion Ring Gear

Variation Number Location Location
PC+3 At the end of the On the outer
LARGER NUMBER
pinion gear head diameter = GEAR SET RATIO 4012513a
+2 SMALLER NUMBER

+0.01 mm Figure 4.14

PC–5
–1 5. Calculate the gear set ratio by dividing the larger number by
the smaller number. Figure 4.14.
–0.02 mm
Verify the Actual Gear Set Ratios
You can check the actual gear set ratios when you remove the
differential carriers from the axle housings for service or repair.
Refer to the following procedure to calculate the actual gear set
ratios.
1. Count the number of ring gear teeth. Figure 4.15.

22 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 4 Prepare Parts for Assembly

Figure 4.15 3. Remove the driveline.

4. Remove the pinion shaft nut.
5. Attempt to remove the yoke by hand.
앫 If you can remove the yoke by hand: The yoke is worn.
Replace the yoke.
RING 6. Use a correct yoke puller tool to remove the yoke.
GEAR PINION
TEETH GEAR TEETH
Check for a Tight-Fit Condition
RING GEAR TEETH = ACTUAL
PINION GEAR TEETH GEAR SET RATIO 4012516a
NOTE: You can check for a tight-fit condition when you install any
Figure 4.15 serviceable yoke.

2. Count the number of pinion gear teeth. Figure 4.15. 1. Attempt to install the yoke by hand.

3. Divide the number of ring gear teeth by the number of pinion 앫 If the yoke bottoms out against the adjacent bearing:
gear teeth to determine the actual gear set ratio for each axle. Replace the yoke.
Figure 4.15. 2. Use a correct yoke installation tool to install the yoke.
4. Calculate the percentage difference between the gear set 3. As you install the yoke, you should detect resistance between
ratios. All ratios must match within one percent. the yoke and shaft.
앫 If the actual gear set ratios are not within one percent 앫 If you do not detect resistance between the yoke and
of each other: Refer to the vehicle manufacturer for further shaft: Replace the yoke.
information.
4. Install and tighten the pinion shaft nut to the correct torque.
Refer to Section 7.
Inspection
5. Install the driveline.
Yoke 6. Remove the safety stands.
All current Meritor axles feature helical splines at the yoke interface.
7. Lower the vehicle.
This feature provides a tight fit between the yoke and input shaft,
output shaft and pinion shaft. For the axle to operate correctly, the
input shaft, output shaft and pinion shaft must fit tightly to the
corresponding yoke.

Check for Yoke Wear

WARNING
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.

1. Park the vehicle on a level surface. Block the wheels to prevent

the vehicle from moving.
2. Use a jack to raise the vehicle so that the wheels to be serviced
are off the ground. Support the vehicle with safety stands.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 23

5 Assembly and Installation

Hazard Alert Messages Installing the Drive Pinion, Adjusting Pinion

5 Assembly and Installation

Read and observe all Caution and Warning safety alerts below and Depth and Contact Pattern
those that precede instructions or procedures you will perform. The procedure in this manual is to perform a “dry fit” installation of
the pinion, bearings and calculated shim pack into the case
WARNING WITHOUT the two spacers. You must also install the ring gear and
To prevent serious eye injury, always wear safe eye protection set the backlash to 0.012-inch (0.3 mm). After you check and
when you perform vehicle maintenance or service. adjust the tooth contact patterns to determine the correct pinion
position, remove the ring gear and drive pinion. You must then install
Take care when you use Loctite adhesive to avoid serious the drive pinion with the two spacers as well as the correct shims.
personal injury. Read the manufacturer’s instructions before Once you’ve obtained the correct adjustments, continue a “final”
using this product. Follow the instructions carefully to prevent installation of the ring gear and adjust as necessary.
irritation to the eyes and skin. If Loctite adhesive material
gets into your eyes, follow the manufacturer’s emergency Drive Pinion Shim Pack Thickness
procedures. Have your eyes checked by a physician as soon as
possible. NOTE: If the original gear set and shim pack are being installed, go
to the “dry fit” drive pinion assembly procedure in this section. If the
Observe all warnings and cautions provided by the press pinion depth shims are misplaced during carrier repair, use
manufacturer to avoid damage to components and serious 0.030-inch (0.76 mm) for the initial pinion position and continue to
personal injury. the “dry fit” drive pinion assembly procedure in this section. In all
other cases, continue with the following procedure. Figure 5.1.
To avoid serious personal injury and damage to components,
take care when using lifting devices during service and
maintenance procedures. Inspect a lifting strap to ensure that Figure 5.1

it is not damaged. Do not subject the lifting straps to shocks or

drop-loading. SHIMS

Installation
“Dry Fit” and “Final” Assembly and
Installation Procedures
Correct assembly of the carrier requires a “dry fit” installation of the
drive pinion and ring gear to determine the correct drive pinion shim
pack thickness. The carrier is then disassembled and reassembled
using the spacers and adjusted shim pack. If the drive pinion is
correctly adjusted, perform the “final” installation steps to complete
4011974a
the installation.
Figure 5.1

1. Use a micrometer to measure the thickness of the shim pack

that was removed from the differential carrier. Record the
measurement. Figure 5.2.

24 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

Figure 5.2 7. If the new pinion cone number is a plus (+), SUBTRACT the
number from the standard shim pack thickness that was
calculated in Step 4 or Step 5. Use new shims to make a shim
pack to the determined thickness. Refer to Table A.
8. If the new pinion cone number is a minus (–), ADD the number
to the standard shim pack thickness that was calculated in
Step 4 or Step 5. Use new shims to make a shim pack to the
determined thickness. Refer to Table A.

Table A:
1002764a Examples Inches mm
Figure 5.2 1. Old Shim Pack Thickness 0.030 0.760
Old PC Number, PC +2 + 0.002 + 0.050
2. Find the pinion cone (PC) variation number on the drive pinion
Standard Shim Pack Thickness = 0.032 = 0.810
you’ll replace. Record the number. Figure 5.3. The pinion cone
number can be one of the following formats. New PC Number, PC +5 – 0.005 – 0.120
New Shim Pack Thickness = 0.027 = 0.690
앫 PC +6, PC –6, +6 or –6 = 0.006-inch
2. Old Shim Pack Thickness 0.030 0.760
앫 PC +.15, PC 0.15 mm, +0.15 mm or –0.15 = 0.15 mm
Old PC Number, PC –2 – 0.002 – 0.050
Figure 5.3
Standard Shim Pack Thickness = 0.028 = 0.710
New PC Number, PC +5 – 0.005 – 0.120
New Shim Pack Thickness = 0.023 = 0.590
3. Old Shim Pack Thickness 0.030 0.760
Old PC Number, PC +2 + 0.002 + 0.050
Standard Shim Pack Thickness = 0.032 = 0.810
PINION CONE New PC Number, PC –5 + 0.005 + 0.120
VARIATION
NUMBER New Shim Pack Thickness = 0.037 = 0.930
1003032d 4. Old Shim Pack Thickness 0.030 0.760

Figure 5.3 Old PC Number, PC –2 – 0.002 – 0.050

Standard Shim Pack Thickness = 0.028 = 0.710
3. If you can’t find the PC number or it’s unreadable, install a new New PC Number, PC –5 + 0.005 + 0.120
shim pack of the same thickness that you measured in Step 1.
New Shim Pack Thickness = 0.033 = 0.830
4. If the old pinion cone number is a plus (+), ADD the cone
number to the old shim pack thickness that was measured in
Step 1.
Assembly
5. If the old pinion cone number is a minus (–), SUBTRACT the “Dry Fit”Assembly of the Drive Pinion to
cone number from the old shim pack thickness that was Verify Shim Pack
measured in Step 1.
6. Find the pinion cone variation number on the new drive pinion NOTE: For initial assembly to verify the shim pack, the spacers are
that will be installed. Record the number. not installed. For final assembly, the spacers are installed and
preload must be established.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 25

5 Assembly and Installation

1. If you are installing a new ring gear and drive pinion, the E. Place a sleeve or a bearing driver tool onto the cup and
correct thickness of the shim pack between the pinion inner press the cup into the bore until the bottom of the cup
bearing cup and the carrier must be determined. Refer to the touches the shims. If a press is not available, use a
procedure in this section before temporarily assembling and sleeve, a brass drift or a bearing driver tool and a hammer
installing the drive pinion assembly according to this to install the cup. Figure 5.6.
procedure.
Figure 5.5

If you are installing the original ring gear and drive pinion,
temporarily install the drive pinion assembly. SHIMS
2. If removed, use a press and a sleeve to install the inner bearing
cone onto the drive pinion. Place the sleeve onto the inner race
of the bearing. Apply pressure until the bottom of the cone
touches the shoulder on the pinion. Figure 5.4.

Figure 5.4

PRESS
AND SLEEVE

4011974a

Figure 5.5

Figure 5.6

1002766a
PRESS
Figure 5.4

3. Apply axle lubricant to the bearing cups and cones.

4. If removed, install the shim pack and the inner bearing cup of
the drive pinion.
A. Place the carrier into a press so that the legs of the carrier
are toward the TOP of the press.
B. Install the correct amount of shims into the bore for the BEARING
inner bearing cup of the drive pinion. Figure 5.5. CUP 4011976a

C. Place the cup into the bore. Figure 5.5. Figure 5.6

D. Place supports under the differential carrier so that the

carrier is level. 5. If removed, install the outer bearing cup for the drive pinion.
A. Place the carrier into a press so that the legs of the carrier
CAUTION are toward the BOTTOM of the press. Place supports
Do not allow the bearing cup installation tool to contact the under the carrier so that the carrier is level.
active raceway surface during installation. Damage to the
B. Place the outer bearing cup for the drive pinion into the
bearing cup can result.
bore of the carrier.

26 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

C. Use a sleeve or a bearing driver tool and a press to install 3. Place the outer bearing cone onto the pinion shaft. Figure 5.9.
the cup. Press the cup into the carrier until the bottom of
the cup touches the bottom of the bore. If a press is not Figure 5.9

available, use a sleeve, a brass drift or a bearing driver

tool and a hammer to install the cup. Figure 5.7.

Figure 5.7

PRESS

4011979a
4011977a
Figure 5.9
Figure 5.7

Installation CAUTION
Do not use excessive press load when you install the outer
Drive Pinion pinion cone during the “dry fit” assembly procedure. Damage
to the bearings can result.
1. Place the drive pinion into the carrier so that the pinion is
through the inner and the outer bearing cups.
4. Use a press and a sleeve to install the outer bearing cone onto
2. Place the carrier into a press so that the legs of the carrier are the pinion. Apply no more than two tons (1814 kg) of force to
toward the BOTTOM of the press. Place a support such as a verify that the bearing cone is correctly installed. Figure 5.10.
block of wood under the head of the drive pinion so that the
inner bearing cone on the pinion shaft touches the inner Figure 5.10

bearing cup in the carrier. Do not allow the carrier to contact

the surface of the press. Figure 5.8.

Figure 5.8

SLEEVE

Carrier should
not touch 4011980a
the surface
of the press. Figure 5.10

CAUTION
Do not use excessive pinion nut torque during the “dry fit”
PRESS assembly procedure. Damage to the bearings can result.
SURFACE

5. Install the drive pinion nut to contact the bearings while

BLOCK OF WOOD
SUPPORTING PINION 4011978c allowing free movement of the pinion.
Figure 5.8

Meritor Maintenance Manual MM-15103 (Issued 07-17) 27

5 Assembly and Installation

Assembly Figure 5.13

Main Differential and Ring Gear SIDE

GEAR
1. If removed, use a press and appropriate size sleeve to install
the bearing cones on the case halves. Figure 5.11 and
Figure 5.12. THRUST
WASHER

Figure 5.11

PRESS

BEARING
ROLLER SLEEVE
CAGE
BEARING
CASE CONE
HALF

SUPPORT SUPPORT
4012301a

Figure 5.13

4011984a
4. Locate the flat sides on the plain half case. Notice these sides
Figure 5.11 do not have holes for roll pins above them. This is the correct
position for installing the long spider pin. Figure 5.14.
Figure 5.12

Figure 5.14

PRESS

BEARING SLEEVE SHORT

ROLLER SPIDER
CAGE PINS
BEARING
CONE No hole LONG
indicates SPIDER
FLANGE position of PIN
HALF long spider
pin. Roll pin hole
4012332a indicates
position of
Figure 5.12 short spider
pins.

2. Apply axle lubricant on the inside surfaces of both case halves,

spider pins, thrust washers, side gears and differential pinions. PLAIN HALF CASE
TOP DOWN VIEW 4012541a
3. Install the thrust washer and side gear in the plain half case.
Figure 5.14
Figure 5.13.

5. Install the pinion and thrust washer into the plain half case
where the long spider pin will pass through. Figure 5.15.

28 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

Figure 5.15 10. From the top, drive the two roll pins through the holes in the
PINION plain half case and short spider pins to secure the short spider
pins in place. Make sure to drive the roll pins in until they are
THRUST
WASHER
flush with the case and do not stick out beyond. Figure 5.17.

Figure 5.17

ROLL
PINS
LONG
SPIDER PIN

4012300a

Figure 5.15

6. Insert the long spider pin through the plain case half and the
pinion and thrust washer. 4012512a

7. Install another pinion and thrust washer in the plain case half. Figure 5.17
Insert the long spider pin through the pinion and thrust washer
and into the other side of the plain case half. CAUTION
8. Locate the holes for installing the short spider pins in the plain Heat the ring gear before seating it onto the plain case half. Do
half case. The areas have holes for installing the roll pins above not press a cold ring gear on the plain case half. A cold ring
them. Figure 5.14. gear will damage the case half because of the tight fit.

9. Install a thrust washer and pinion in the plain case half. Insert a 11. Expand the ring gear by heating the gear in a tank of water to
short spider pin through the plain case half, thrust washer and 160-180°F (71-82°C) for 10 to 15 minutes. The temperature
pinion, and into the notch on the long spider pin. Repeat this of the ring gear should not exceed 340°F (170°C) at the web
process to install the other pinion, thrust washer and short pin. and 250°F (120°C) at the gear teeth.
Figure 5.16.

Figure 5.16
WARNING
Wear safe clothing and gloves for protection from injury when
PINION
working with the hot ring gear.

THRUST 12. Install guide pins to align the ring gear and flange half on the
WASHER plain half case.
13. Use a lifting tool to safely lift the ring gear from the tank of
water.
14. Install the ring gear onto the plain case half immediately after
the gear is heated.
SHORT 앫 If the ring gear does not fit easily on the case half: Heat
SPIDER PIN the gear again.
4012099a

Figure 5.16

Meritor Maintenance Manual MM-15103 (Issued 07-17) 29

5 Assembly and Installation

15. Align the ring gear and plain case half match marks and Figure 5.20

fastener holes. Rotate the ring gear as necessary. Allow the FLANGE
HALF
assembly to cool. Figure 5.18.

Figure 5.18

RING
GEAR

GUIDE GUIDE PLAIN CASE

PIN PIN HALF

4011992a

PLAIN Figure 5.20

CASE
HALF
Figure 5.21

4011988a

Figure 5.18

16. Install the side gear and thrust washer in the plain half case.
Figure 5.19.
MATCH
MARKS
Figure 5.19

THRUST
WASHER
4011966b

SIDE GEAR Figure 5.21

18. Install the fasteners through the flange half, ring gear and plain
case half. Figure 5.22.

Figure 5.22

CAPSCREW

4011987a

Figure 5.19

17. Install the flange half on top of the ring gear and plain half
case. Align the match marks and fastener holes. Figure 5.20
and Figure 5.21.
4011959a

Figure 5.22

30 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

19. Tighten the bolts using the torque plus angle method: 150 lb-ft Check the Rotating Resistance of the
(203 N폷m) plus 30 degrees ± 1 degree angle. The resultant
peak torque must be a minimum of 260 lb-ft (352 N폷m) or
Differential Assembly
higher. Follow the tightening pattern shown in Figure 5.23. @ 1. Make an inspection tool using an axle shaft that matches the
spline size of the differential side gear. Cut the shaft to
Figure 5.23
approximately 12-inches (304.8 mm). Weld a nut onto the end
CRISSCROSS TIGHTENING PATTERN of the shaft. Figure 5.25.
14 10
6
4 Figure 5.25

2
APPROXIMATELY
8 12" (304.8 MM)
16
SIDE
12 VIEW
11
15
END WELD NUT
7 VIEW TO END
1 OF SHAFT 1003071c
3
5
9 13 4011982a Figure 5.25

Figure 5.23
2. Place the differential and ring gear assembly flat on a work
bench. Figure 5.26.
20. Inspect for gaps between the back surface of the ring gear and
the case flange. Use a feeler gauge to inspect at four points Figure 5.26

around the assembly. No gap is allowed. Figure 5.24.

앫 If a gap is found: Inspect the case halves and ring gear for
the problem that causes the gap. Repair or replace parts as
TOOL FOR
necessary. Reassemble the ring gear on the plain case half. CHECKING
Reinspect for gaps. RESISTANCE

Figure 5.24

4012321a

Figure 5.26

3. Install the tool into the differential until the splines of the tool
are engaged with one side gear. Figure 5.26.
4. Place a torque wrench onto the nut of the tool and, while
Check for gaps
at four locations. retaining the ring gear, rotate the differential gears. As the
differential gears rotate, read the value indicated on the torque
4011983a
wrench. Figure 5.27.
Figure 5.24

21. Check the rotating resistance of the differential gears. The

differential assembly must rotate freely.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 31

5 Assembly and Installation

앫 If the torque value exceeds 10 lb-ft (13.6 N폷m): Figure 5.28

Disassemble the differential gears from the case halves. PRESS

Inspect the case halves, spider, gears and thrust washers.
Repair or replace parts. Assemble the parts and repeat Step
2 through Step 4. BEARING
CONE SLEEVE

Figure 5.27

Read torque
value.

4012323a

Figure 5.28

2. Install the bearing cups over the bearing cones on the case
halves. Figure 5.29.

Figure 5.29

4012322a

Figure 5.27

Installation
“Dry Fit” Installation of the Main Differential
Case and Ring Gear Assembly Into the
Carrier
To carry out preliminary checks for drive pinion adjustments, 4011964a
perform a “dry fit” installation of the differential and ring gear
Figure 5.29
assembly. Do not lubricate, apply sealant or tighten the fasteners
completely. Once adjustments are made, perform the “final”
installation steps to complete the procedure. 3. Use a lifting device to safely lift the differential and ring gear
assembly and install it into the carrier. The bearing cups must
1. If the bearing cones on the main differential case were be flat against the bores between the carrier legs. Figure 5.29.
removed, install a new cone and cup in a fully-matched set
from the same manufacturer. Bearing cups and cones from 4. Install the bearing adjusting rings between the carrier legs.
different manufacturers are not interchangeable. Use a press Figure 5.30.
and sleeve to install the cones onto the case. Press only on the
inner race of the bearing. Figure 5.28.

32 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

Figure 5.30

CAUTION
Correctly install the bearing caps into their original locations
ADJUSTING on the carrier. Do not force the bearing caps into position,
RING which can damage the carrier. If the bearing caps are not
installed correctly, the bores and threads in the cap will not
match the carrier. Damage to the adjusting rings by
cross-threading can result.

6. Use a light leather plastic or rubber mallet to seat each bearing

cap. The caps must fit easily against the bearings, adjusting
rings and carrier. Do not force the bearing caps into position.
4012324a
앫 If the bearing caps do not correctly fit into position:
Figure 5.30 Check the alignment of the match marks between the caps
and carrier. Remove the caps and repeat Step 4 through
Step 6.
CAUTION
Correctly install the bearing caps into their original locations 7. Hand-tighten the adjusting rings against the bearing cups to
on the carrier. Do not force the bearing caps into position, position the ring gear to the pinion with 0.012-inch (0.3 mm)
which can damage the carrier. If the bearing caps are not backlash.
installed correctly, the bores and threads in the cap will not 8. Install the capscrews and washers that secure the bearing
match the carrier. Damage to the adjusting rings by caps to the carrier. Tighten the capscrews to 25 lb-ft (34 N폷m).
cross-threading can result. @

5. Install the bearing caps over the bearings and adjusting rings in Do not install the capscrews and washers that secure the
the correct location as marked before removal. Figure 5.31. bearing adjusting rings in position. After the ring gear is
installed, you must adjust the backlash of the ring gear, inspect
Figure 5.31
the tooth contact patterns, then adjust the preload of the
differential bearings before the capscrews and washers are
installed.

CARRIER Adjustment of Pinion Shim Pack and

MATCH CAP
Backlash for Contact Pattern
MARKS CARRIER
LEG
Ring Gear Backlash
Table B: Specifications
4011960a Backlash Setting for New Backlash Setting Range for
Gear Sets Used Gear Sets
Figure 5.31
0.012-inch (0.30 mm) 0.008-0.018-inch
(0.20-0.46 mm)
WARNING
Use a brass or synthetic mallet for assembly and disassembly
After checking the tooth contact patterns for top to root position, the
procedures. Do not hit steel parts with a steel hammer. Pieces
backlash can be readjusted within the specification limits for toe to
of a part can break off. Serious personal injury and damage to
heel position, if needed. To change the location of the pattern, use
components can result.
the following procedures.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 33

5 Assembly and Installation

1. Attach a dial indicator onto the carrier mounting flange. Figure 5.34

Figure 5.32. Loosen adjusting

ring this side.
Figure 5.32

DIAL Decrease backlash.

INDICATOR

Tighten adjusting
ring this side.
1002796b

Figure 5.34

NOTE: When you adjust the backlash, only move the ring gear. Do
4011958a not move the drive pinion.
Figure 5.32
6. Repeat Step 2 through Step 5 until the backlash is within
2. Adjust the dial indicator so that the plunger is against the tooth specification. Record the setting for use when you adjust the
surface. pinion bearing preload.

3. Adjust the dial indicator to ZERO. Hold the drive pinion in Gear Set Tooth Contact Patterns
position.
4. After reading the dial indicator, rotate the differential and ring Old Gear Set and Old Shim Pack
gear a small amount in both directions against the drive pinion Adjust ring gear tooth contact patterns and backlash to the setting
teeth. Refer to Table B. that was measured before the carrier was disassembled. Refer to
Table B for the correct specification.
앫 If the backlash reading is within the specification:
Check the tooth contact patterns. New Gear Set and/or New Shim Pack
앫 If the backlash reading is not within the specification: Adjust ring gear tooth contact patterns and backlash to the correct
Adjust the backlash as needed. specification from Table B.
5. Loosen one bearing adjusting ring one notch. Tighten the In the following procedures, movement of the contact pattern in the
opposite ring by the same amount. length of the tooth is indicated as TOWARD the “heel” or “toe” of the
앫 To increase the backlash: Move the ring gear away from ring gear. Figure 5.35.
the drive pinion. Figure 5.33.
Figure 5.35

앫 To decrease the backlash: Move the ring gear toward the

HEEL
drive pinion. Figure 5.34.

Figure 5.33

Tighten adjusting
ring this side. TOE

Loosen adjusting 1003090h

Increase backlash. ring this side.
Figure 5.35
1002795b

Figure 5.33

34 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

The drive side of a hypoid is the convex side of the ring gear teeth. 앫 If the contact patterns require adjustment: Continue by
The drive side always takes precedence over the coast side; but the following Step 4 to move the contact patterns between the
coast side should be evaluated as well. Figure 5.37. top and root of the gear teeth.

Check Gear Set Tooth Contact Patterns 앫 If the contact patterns are centered top to root of the
gear teeth: Proceed to Step 5.
1. Apply a marking compound, Multan Gear Mark™ 39SY201
or equivalent, onto approximately 12 gear teeth of the ring Figure 5.37

gear. Rotate the ring gear so that the 12 gear teeth are next to
GOOD HAND-ROLLED
the drive pinion. Figure 5.36. PATTERN

Figure 5.36
TOP

ROOT
CONCAVE
4012515a

Figure 5.37

1003092d
Figure 5.38

Figure 5.36 GOOD HAND-ROLLED

PATTERN
2. Rotate the ring gear FORWARD and BACKWARD so that the 12
gear teeth go past the drive pinion six times to get the contact
patterns. Repeat if needed to get a more clear pattern.
3. Look at the contact patterns on the ring gear teeth. Compare
the patterns to Figure 5.37, Figure 5.38, Figure 5.39,
Figure 5.40, Figure 5.41, Figure 5.42, Figure 5.43 and
Figure 5.44. CONVEX 4008132a

The toe-to-heel position of the contact pattern on a good Figure 5.38

hand-rolled gear set is toe to toe-center on both sides.
Figure 5.37 and Figure 5.38. Figure 5.39

NOTE: When the carrier is in operation under load, a good HIGH PATTERN (BAD)
contact pattern will extend approximately the full length of the
gear tooth. The top of the pattern will be near the top of the
gear tooth. Figure 5.45 and Figure 5.46.
The location of a good hand-rolled contact pattern for a used
gear set will generally follow the new criteria, although the
pattern may be narrower or the center may not be filled in.
A high-contact pattern indicates that the drive pinion was not CONCAVE
installed deep enough into the carrier. A low-contact pattern 4008133a
indicates that the drive pinion was installed too deep in the Figure 5.39
carrier.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 35

5 Assembly and Installation

Figure 5.40 Figure 5.43

HIGH PATTERN (BAD) SHORT AND EXTREME

TOE PATTERN (BAD)

CONCAVE
CONVEX 4008134a 4008137a

Figure 5.40 Figure 5.43

Figure 5.41 Figure 5.44

LOW PATTERN (BAD) SHORT AND EXTREME

HEEL PATTERN (BAD)

CONCAVE CONCAVE
4008135a 4008138a

Figure 5.41 Figure 5.44

Figure 5.42 Figure 5.45

LOW PATTERN (BAD)

CONVEX SATISFACTORY PATTERN IN OPERATION

4008136a
1001095d
Figure 5.42
Figure 5.45

36 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

Figure 5.46 Figure 5.47

SATISFACTORY PATTERN IN OPERATION

Increase shim pack.

1003102f

Figure 5.47

CONVEX 4008139a
Figure 5.48

Figure 5.46

4. Change the thickness of the shim pack under the inner pinion
bearing cup to move the contact patterns between the top and
root of the gear teeth. Use the following procedure.
Decrease shim pack.
NOTE: If the shim pack is changed, the bearing preload must
1003101f
be rechecked.
Figure 5.48
A. Remove the drive pinion, inner bearing cup and shims
from the carrier. Refer to Section 3.
5. Adjust ring gear backlash within the correct specification to
앫 To correct a high-contact pattern: Increase the move the contact patterns to the correct location in the length
thickness of the shim pack under the inner bearing of the gear teeth. Refer to Ring Gear Tooth Contact Pattern,
cup, which moves the drive pinion TOWARD the ring Backlash in this section.
gear. This also moves the convex contact pattern
A. Decrease the backlash to move the convex pattern toward
towards the heel and concave pattern towards the toe.
the toe and concave pattern toward the heel. Figure 5.49.
Figure 5.38 and Figure 5.47.
B. Increase the backlash to move the convex pattern toward
앫 To correct a low-contact pattern: Decrease the
the heel and the concave pattern toward the toe.
thickness of shim pack under the inner bearing cup,
Figure 5.50.
which moves the drive pinion AWAY from the ring gear.
This also moves the convex contact pattern towards C. Repeat Step 1 through Step 3 and Step 5 until the contact
the toe and concave pattern towards the heel. patterns are at the correct location in the length of the
Figure 5.48. gear teeth.
B. Install the drive pinion, inner bearing cup and shims into
Figure 5.49

the carrier. The pinion cone number can be either 100ths

Move pattern toward
of a millimeter or 1,000ths of an inch. toe, loosen adjusting
C. Repeat Step 1 through Step 4 until the contact patterns ring this side.
Decrease
are in the center between the top and bottom of the gear backlash.
teeth.

Tighten adjusting
ring this side. 1002804b

Figure 5.49

Meritor Maintenance Manual MM-15103 (Issued 07-17) 37

5 Assembly and Installation

Figure 5.50
Install the Drive Pinion
Move pattern toward 1. Apply axle lubricant to the pinion bearing cups and cones.
toe, tighten adjusting
ring this side. 2. Place the carrier into a press. Figure 5.51.

Figure 5.51

Increase. Loosen adjusting

backlash. ring this side.
1002805b

Figure 5.50 Carrier should

not touch
6. If the backlash and contact patterns are correct, remove the the surface
of the press.
leg cap capscrews. Use an appropriate lifting device to remove
the ring gear.

Installation
PRESS
“Final” Installation of the Drive Pinion and SURFACE

Bearing Preload Adjustment

BLOCK OF WOOD
Use the shim pack and backlash established by the “dry fit” SUPPORTING PINION 4011978c
procedure for final assembly.
Figure 5.51
The preload of the bearings on the drive pinion is controlled by a
variable spacer behind the outer bearing cone. 3. Install the pinion shaft assembly into the carrier. Seat the inner
bearing cone fully against the inner bearing cup. Figure 5.51.
Adjust the preload by changing the size of the spacer.
4. Support the pinion shaft with blocks of wood so that the inner
앫 To decrease the preload: Use a thicker spacer.
bearing cone remains in contact with the inner bearing cup.
앫 To increase the preload: Use a thinner spacer. Figure 5.51.
If the depth of the drive pinion is changed, the thickness of the 5. Install the fixed spacer onto the pinion stem.
spacer must also be changed the same amount. Refer to the
6. Install the variable spacer onto the pinion stem. If the depth of
following examples.
the drive pinion has increased or decreased, select a variable
앫 If a 0.003-inch (0.076 mm) shim is ADDED to the shim pack spacer with the same change in thickness. Figure 5.52.
to INCREASE the depth of the drive pinion: A 0.003-inch
(0.076 mm) larger spacer must be installed to keep the preload
on the bearings.
앫 If a 0.003-inch (0.076-mm) shim is REMOVED from the shim
pack to DECREASE the depth of the drive pinion: A
0.003-inch (0.076 mm) smaller spacer must be installed to keep
the preload on the bearings.

38 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

Figure 5.52 Figure 5.54

SLEEVE

SPACERS Carrier should

SHIMS not touch
the surface
of the press.

4011980a

Figure 5.54

PRESS
SURFACE Check Pinion Bearing Preload
Table C: Specifications
BLOCK OF WOOD
SUPPORTING PINION 4011978b
New pinion bearings 30-60 lb-in (3-6 N폷m)
Figure 5.52
Used pinion bearings in good 20-50 lb-in (2.25-5.65 N폷m)
condition
7. Install the outer bearing cone onto the pinion stem.
Figure 5.53.
CAUTION
Figure 5.53
Do not install tight-fitting yokes or flanges on the shafts using
a hammer or mallet. A hammer or mallet will damage the yoke
or flange.

1. For the purpose of gauging preload, install a used yoke or

flange that fits loosely on the shaft. Do not install the intended
service yoke or flange for this procedure. Align the splines of
the test yoke or flange with the shaft splines. Slide the yoke or
flange over the shaft splines until seated.
2. Install the nut onto the drive pinion.
3. Fasten a yoke or flange bar to the input yoke or flange. The bar
4011979a will hold the drive pinion in position when the nut is tightened.

Figure 5.53 4. Tighten the nut onto the drive pinion to the correct torque
value. Refer to Table H in Section 7.
8. Using a sleeve that is the same size as the bearing cone, press 5. Remove the yoke bar.
the bearing onto the pinion shaft until it is fully seated in the
carrier. Figure 5.54. 6. Attach a torque wrench onto the drive pinion nut. Rotate the
drive pinion and read the value indicated on the torque wrench.
7. If the preload or torque of the pinion bearings is not within
specification, remove the drive pinion assembly from the
carrier. Replace the variable spacer to increase or decrease
preload. Refer to the procedure in this section. Repeat Steps 1
through Step 6 to recheck preload.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 39

5 Assembly and Installation

앫 To increase preload: Install a thinner bearing variable 4. Apply Meritor specification 2297-P-3994, Loctite 680
spacer. adhesive or equivalent 360 degrees around the outside
diameter of the bearing cups. The adhesive must not contact
앫 To decrease preload: Install a thicker bearing variable
the adjusting ring threads. Refer to Section 4.
spacer.
5. Install the bearing cups over the bearing cones in the case
8. Once the desired preload is obtained, remove the used yoke.
halves. Figure 5.55.
Install the seal and the service yoke. Refer to the procedures in
this section. Figure 5.55

Replace the Variable Spacer to Adjust Pinion

Bearing Preload
NOTE: Do not grind spacers by hand. The surfaces must be parallel
within 0.0001-inch (0.0020 mm). You must use the correct
spacers.

If you must adjust preload, use the following procedure to replace

the variable spacer with one of a different thickness.
1. Install a yoke or flange bar to prevent the drive pinion assembly
4011964a
from rotating. Remove the nut and the washer from the shaft of
the drive pinion. Figure 5.55

2. Press the drive pinion out of the bearing cone. Remove the
outer bearing cone from the differential carrier. 6. Safely lift the differential and ring gear assembly and install it
into the carrier. The bearing cups must be flat against the
3. Reinstall the drive pinion assembly using the correct size bores between the carrier legs. Figure 5.55.
variable spacer.
7. Install the bearing adjusting rings between the carrier legs.
4. Recheck the drive pinion bearing preload using the procedure Figure 5.56.
in this section.
Figure 5.56

“Final” Installation of the Main Differential

Case and Ring Gear Assembly Into the ADJUSTING
Carrier RING

1. Rotate the carrier in the repair stand until the back surface of
the ring gear is toward the TOP.
2. Clean and dry the bearing cups and bores of the carrier legs
and bearing caps.
3. Apply axle lubricant to the bearing cones and inside surface of
the bearing cups.
4012324a
NOTE: Meritor specification 2297-P-3994 adhesive will dry in
Figure 5.56
approximately two hours. You must complete the procedure within
two hours from the time you apply the adhesive. If two hours have
passed since application, clean the adhesive from the parts and
apply new adhesive.

40 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

10. Hand-tighten the adjusting rings against the bearing cups to

CAUTION
position the ring gear to the pinion with 0.012-inch (0.3 mm)
Correctly install the bearing caps into their original locations
backlash.
on the carrier. Do not force the bearing caps into position,
which can damage the carrier. If the bearing caps are not 11. Install the capscrews and washers that secure the bearing
installed correctly, the bores and threads in the cap will not caps to the carrier. Tighten the capscrews to 25 lb-ft (34 N폷m).
match the carrier. Damage to the adjusting rings by This is an initial tightening torque and will be increased later in
cross-threading can result. the procedure. @
Do not install the capscrews and washers that secure the
8. Install the bearing caps over the bearings and adjusting rings in
bearing adjusting rings in position. After the ring gear is
the correct location. Check the shape of the mounting face on
installed, you must adjust the backlash of the ring gear, inspect
the carrier legs to ensure the bearing caps are installed in the
the tooth contact patterns, then adjust the preload of the
correct position. Figure 5.57.
differential bearings before the capscrews and washers are
Figure 5.57
installed.
BEARING
CAP Adjustment
Differential Bearings Preload
Use either the dial indicator or the large micrometer method to
inspect and adjust the main differential side bearings preload.

NOTE: The capscrews and washers for the adjusting rings are
installed after the tooth contact pattern is rechecked.
4011991a

Figure 5.57 Dial Indicator Method

1. Attach a dial indicator onto the carrier mounting flange so that
WARNING the plunger or the pointer is against the back surface of the
Use a brass or synthetic mallet for assembly and disassembly ring gear. Figure 5.58.
procedures. Do not hit steel parts with a steel hammer. Pieces
Figure 5.58

of a part can break off. Serious personal injury and damage to

components can result. DIAL
INDICATOR

CAUTION
Correctly install the bearing caps into their original locations
on the carrier. Do not force the bearing caps into position,
which can damage the carrier. If the bearing caps are not
installed correctly, the bores and threads in the cap will not
match the carrier. Damage to the adjusting rings by
cross-threading can result. 4011994a

Figure 5.58
9. Use a light leather, plastic or rubber mallet to seat each bearing
cap. The caps must fit easily against the bearings, adjusting
rings and carrier. Do not force the bearing caps into position.
앫 If the bearing caps do not correctly fit into position:
Check that the bearing caps are installed in the correct
position. Remove the caps and reinstall them.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 41

5 Assembly and Installation

CAUTION Figure 5.61

When you turn the adjusting rings, always use a tool that
engages two or more opposite notches in the ring. An
adjusting ring tool can be used for this purpose. If the tool does
not correctly fit into the notches, damage to the lugs will occur.
Pry bars must
2. Use an adjusting ring tool to loosen the adjusting ring that is not touch
bearings.
opposite the ring gear. A small amount of end play will show on
the dial indicator. Figure 5.59.

Figure 5.59

ADJUSTING
RING TOOL 4012312a

Figure 5.61

4. Tighten the bearing adjusting ring until the dial indicator reads
ZERO end play. Move the differential and ring gear to the left
ADJUSTING and right as needed. If necessary, repeat Step A or Step B.
RING
5. Tighten each bearing adjusting ring one notch from ZERO. The
side bearings of the differential should have a preload of
4011993a 15-35 lb-in (1.7-3.5 N폷m). Figure 5.62. @
Figure 5.59
This procedure should expand the caps 0.002-0.009-inch
(0.05-0.23 mm), and place the correct preload on the bearings
3. Use one of the following methods to move the differential and
when they are installed into the banjo housing.
the ring gear carefully to the left and right while you read the
dial indicator. Figure 5.62

A. Insert two pry bars between the bearing adjusting rings

ADJUSTING
and the ends of the differential case. The pry bars must RING TOOL
not touch the differential bearings. Figure 5.60.
B. Insert two pry bars between the differential case or the
ring gear and the carrier at locations other than described
in Step A. The pry bars must not touch the differential
bearings. Figure 5.61.
Tighten each
Figure 5.60
ring one notch.

4012327a

Figure 5.62

6. Proceed to check ring gear runout.

Bars must not
touch bearings.

4012325a

Figure 5.60

42 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

Large Micrometer Method 4. Measure distance X and Y again. Compare the measurements
with the distances X and Y measured in Step 2. The difference
1. Hand-tighten the adjusting rings against the differential
between the two distances is the amount the bearing caps
bearings.
have expanded. Refer to Table D.
2. Use a large 13-14-inch micrometer to measure distance X and
Y between the opposite surfaces of the bearing caps. Record Table D: Example
the measurement. Figure 5.63 and Figure 5.64. Distances X and Y BEFORE = 13.927-inches (353.75 mm)
tightening the adjusting rings
Figure 5.63

Distances X and Y AFTER = 13.932-inches (353.87 mm)

tightening the adjusting rings
13.932-inches – = 0.005-inch difference
13.927-inches
353.87 mm – 353.75 mm = 0.12 mm difference

5. If the difference is at or between 0.002-0.009-inch

(0.05-0.23 mm): Continue by checking the runout.

1003082d If the difference is not within 0.002-0.009-inch

(0.05-0.23 mm): Repeat as needed.
Figure 5.63
Ring Gear Runout
Figure 5.64

1. Attach a dial indicator onto the carrier mounting flange.

LARGE
MICROMETER
Figure 5.65.

Figure 5.65

Rotate ring
gear.

DIAL
INDICATOR

4012313a

Figure 5.64
4012314a

Figure 5.65
CAUTION
When turning the adjusting rings, always use a tool that
2. Adjust the dial indicator so that the plunger or pointer is against
engages two or more opposite notches in the ring. An
the back surface of the ring gear. Figure 5.65. Set the dial
adjusting ring tool can be used for this purpose. If the tool does
indicator to ZERO.
not correctly fit into the notches, damage to the lugs will occur.
3. Rotate the differential and ring gear. Read the dial indicator.
3. Use an adjusting ring tool to tighten each bearing adjusting ring The ring gear runout must not exceed 0.008-inch (0.200 mm).
one notch. Figure 5.59.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 43

5 Assembly and Installation

앫 If the ring gear runout is within the specification: Set B. Tighten the adjusting ring capscrews to 22-30 lb-ft
the backlash and contact patterns to the settings (30-40 N폷m). @
determined in the “Check Gear Set Tooth Contact Patterns”
procedure in this section. Installation
앫 If the ring gear runout exceeds the specification:
Remove the differential and ring gear assembly from the Unitized Pinion Seal and Yoke
carrier. 1. Remove the old seal. Do not damage the seal area of the
A. Inspect the differential parts, including the carrier, for carrier. Do not touch or allow dirt or grease to contaminate the
wear and damage. Repair or replace parts as necessary. sealing surface areas or the adjacent bearings.

B. Install the main differential case and ring gear assembly 2. Inspect the seal area of the carrier for damage that could
into the carrier. Refer to the procedure in this section. cause lubricant leaks after you install the seal. Use emery
paper or an equivalent product to remove scratches, nicks or
C. Repeat the procedure for preload adjustment of the burrs only.
differential side bearings.
4. Once the adjustments are complete, tighten the bearing cap CAUTION
capscrews as follows. Inspect the axle breather for contaminants, such as dirt,
lubrication or debris, which can cause pressure to build inside
앫 Flange side bearing cap capscrews: Tighten to
the axle. Damage to the seal and premature seal lip wear can
320-400 lb-ft (430-540 N폷m). @
result. Remove the axle breather. Use a safe cleaning solvent
앫 Plain half side bearing cap capscrews: Tighten to to clean the inside and outside of the breather.
200-258 lb-ft (270-350 N폷m). @
3. Inspect the axle breather for contaminants, such as dirt,
5. Once all adjustments are complete, install the capscrews and
lubrication or debris.
washers that hold the two bearing adjusting rings in position.
Use the following procedure. 앫 If you find contaminants in the axle breather: Remove
the axle breather. Use a safe cleaning solvent to clean the
A. On each bearing cap, install two capscrews and washers
inside and outside of the breather.
in the holes on the bearing cap so that the capscrews are
between the lugs of the adjusting ring. New capscrews 4. Remove the replacement unitized seal from the package.
include a locking patch, which can only be used once. If Figure 5.67.
you are installing used capscrews, apply Loctite 242
threadlocker to the capscrew threads before installing the Figure 5.67

capscrews. Figure 5.66.

Figure 5.66

CAPSCREW
AND
WASHER 4005523a

Figure 5.67

4011961a

Figure 5.66

44 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

7. Visually inspect the seal to verify that it is seated correctly.

CAUTION
If a yoke is removed after it has been partially or fully installed, 8. Use a feeler gauge to check the seal gap. The seal is correctly
the unitized pinion seal will be damaged. Remove and discard installed if the gap is less than 0.010-inch (0.25 mm) around
the original unitized pinion seal and replace it with a new one. the circumference of the seal flange. If necessary, continue to
drive the seal in until the correct gap is obtained.
If a yoke has been installed into the unitized pinion seal and
9. Apply clean axle lubricant around the end of the yoke or flange.
then removed, the inner sleeve of the seal will be damaged.
Install a new seal. 10. Align the yoke or flange splines with the shaft splines. Slide the
yoke or flange over the shaft splines.
5. Place the seal, part number A1-1205Z2730, and seal driver,
tool number 2730T1, in position on the carrier. Figure 5.68. CAUTION
Use a press and a sleeve or yoke installation tool to install the
Figure 5.68

yoke or flange. Do not use a hammer or mallet. Using a

hammer or mallet can damage the bearings, yoke or flange.

11. Use a press and a sleeve or special yoke/flange driver tool,

Meritor part number MST-YT114, SPX Kent-Moore part
number J 48718, to install the yoke or flange. Do not use the
nut to draw on the yoke or flange. The yoke or flange must be
SEAL seated against the outer bearing. If a press and sleeve are
DRIVER used, verify that the drive pinion is well supported. Figure 5.70.
4012315a

Figure 5.68 Figure 5.70

CAUTION
Use a rubber mallet to install the seal. Do not use a steel, brass
or plastic hammer. Using a steel, brass or plastic hammer can
damage the seal and driver tool.

6. Use a rubber mallet to drive the seal into or against the carrier.
The seal must fully seat into or against the carrier. Figure 5.69.

Figure 5.69
4012317a

Figure 5.70
RUBBER SEAL
MALLET DRIVER
12. Install the washer and nut onto the drive pinion.
13. Fasten a yoke or flange bar to the input yoke or flange. The bar
will hold the drive pinion in position when the nut is tightened.
Figure 5.71.

The seal must be fully

seated in or against
the carrier.
4012316a

Figure 5.69

Meritor Maintenance Manual MM-15103 (Issued 07-17) 45

5 Assembly and Installation

Figure 5.71 1. Clean the axle housing and the carrier mounting surfaces
according to the detailed instructions in Section 4.
2. Inspect the axle housing for damage. Repair or replace the axle
housing. Refer to Section 4.

CAUTION
FLANGE/ Apply silicone gasket material in a continuous 0.25-inch
YOKE BAR (6 mm) bead. If you use more than this amount, gasket
material can break off and plug lubrication passages. Damage
to components can result.
4011969a

Figure 5.71
3. Apply a continuous 0.25-inch (6 mm) bead of Loctite Ultra
Grey sealant, Meritor specification 2297-H-7054, to the
14. Tighten the nut onto the drive pinion to the correct torque mounting surface of the housing where the carrier fastens.
value. Refer to Table H in Section 7. Refer to Section 4. Figure 5.72.

Install the Differential Carrier into the Axle

Figure 5.72

Housing
WARNING
Solvent cleaners can be flammable, poisonous and cause
burns. Examples of solvent cleaners are carbon tetrachloride,
and emulsion-type and petroleum-base cleaners. Read the
manufacturer’s instructions before using a solvent cleaner,
then carefully follow the instructions. Also follow the 0.25" (6 MM)
procedures below. DIAMETER SILICONE
GASKET BEAD 4004435a
앫 Wear safe eye protection.
Figure 5.72
앫 Wear clothing that protects your skin.
앫 Work in a well-ventilated area. 4. Install the carrier into the axle housing. Use a hydraulic roller
앫 Do not use gasoline or solvents that contain gasoline. jack or a lifting tool.
Gasoline can explode.
CAUTION
앫 You must use hot solution tanks or alkaline solutions
Do not install the carriers using a hammer or mallet. A hammer
correctly. Read the manufacturer’s instructions before
or mallet will damage the mounting flange of the carrier and
using hot solution tanks and alkaline solutions. Then
cause oil leaks.
carefully follow the instructions.
5. Install tapered dowels, if equipped, at the locations shown in
When you apply some silicone gasket materials, a small
Figure 5.73.
amount of acid vapor may be present. To prevent serious
personal injury, ensure that the work area is well-ventilated.
Read the manufacturer’s instructions before using a silicone
gasket material, then carefully follow the instructions and use
appropriate safety equipment. If a silicone gasket material
gets into your eyes, follow the manufacturer’s emergency
procedures. Have your eyes checked by a physician as soon as
possible.

46 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 5 Assembly and Installation

Figure 5.73
Install the Axle Shafts
TAPERED DOWELS
Straight Holes with Nuts and Hardened Washers
1. Clean the mating surfaces of the axle shaft and the wheel hub.
2. Install the gasket and axle shaft into the axle housing and
carrier. The gasket and flange of the axle shafts must fit flat
against the wheel hub. Figure 5.75.
앫 If a gasket is not available: Apply a 0.125-inch (3 mm)
diameter bead of grey sealant, Meritor specification
TAPERED 2297-H-7054, around the mating surface of the hub and
DOWEL around the edge of each fastener hole. Install the axle shaft
4012318b
into the axle housing and carrier.
Figure 5.73
Figure 5.75

6. Apply Loctite 242 threadlocker to the threads of two STUD WASHER STUD
NUT GASKET
1.75-inch and two 2.25-inch capscrews.
7. Install the washers and correct-size capscrews at the dowel
locations shown in Figure 5.73. Tighten the capscrews in a
crisscross pattern to 80-100 lb-ft (109-136 N폷m). @ TAPERED
DOWEL,
8. Apply Loctite 242 threadlocker to the threads of the IF EQUIPPED
remaining capscrews.
AXLE SHAFT
9. Install the remaining washers and correct-size capscrews at SHAFT OR HUB
FLANGE AXLE 1002581c
the locations shown in Figure 5.74. Tighten the capscrews in a
crisscross pattern to 80-100 lb-ft (109-136 N폷m). @ Figure 5.75

Figure 5.74

NOTE: You can also install lock washers as an alternative.

CAPSCREWS CAPSCREWS

3. Install the Grade 8 nuts and hardened washers on the stud.

Tighten the stud nuts to the torque specified in Table E.

Table E: Shaft-to-Hub Torque Fastener Chart

Torque Value — Grade 8 Nuts lb-ft
Thread (N폷m)
Fastener Size Plain Nut Locknut
Stud Nut 0.62-18 180-230 (244-312) 150-190 (203-258)
CAPSCREWS CAPSCREWS or Axle 0.75-16 310-400 (420-542) 270-350 (366-475)
4012319b Shaft
Figure 5.74 Studs All Install the coarse thread end of the stud
into the hub and tighten to the last thread.
10. Tighten all the capscrews in a crisscross pattern to 225 lb-ft
(305 N폷m). @
11. Connect the driveline universal joint to the pinion input yoke or
flange on the carrier.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 47

5 Assembly and Installation

Tapered Dowel with Hardened Washer and 3. Fill the axle with lubricant until the lubricant level is to the
Hardened Nut bottom of the fill plug hole. Refer to Section 6.
1. Clean the mating surfaces of the axle shaft and the wheel hub. 4. Install the fill plug. Tighten the fill plug to 35 lb-ft (47 N폷m).
When correctly installed, one complete thread of the fill plug is
2. Install the gasket and axle shaft into the axle housing and
visible between the housing and plug head. @
carrier. The gasket and flange of the axle shafts must fit flat
against the wheel hub. Figure 5.75. 5. Road test the vehicle in an unloaded condition for one to two
miles (1.6-3.2 km) at speeds not more than 25 mph (40 kmh).
앫 If a gasket is not available: Apply a 0.125-inch (3 mm)
Recheck the lubricant levels and all the fasteners.
diameter bead of grey sealant, Meritor specification
2297-H-7054, around the mating surface of the hub and
around the edge of each fastener hole. Install the axle shaft
into the axle housing and carrier.
3. Install solid tapered dowels over each stud and into the flange
of the axle shaft. Use a punch or a drift and hammer, if
necessary.

NOTE: You can also install lock washers as an alternative.

4. Install the Grade 8 nuts and hardened washers on the stud.

Tighten the stud nuts to the torque specified in Table E.

Fill the Axle with Lubricant

NOTE: For additional lubrication information, refer to Maintenance
Manual 1, Preventive Maintenance and Lubrication. To obtain this
publication, refer to the Service Notes page on the front inside cover
of this manual.

1. Park the vehicle on a level surface. When the angle of the drive
pinion changes, the lubricant capacity of the axle will change.
2. Remove the fill plug from the side of the bowl cover of the axle
housing. Figure 5.76.

Figure 5.76

FILL PLUG LOCATION IN BACK

OF AXLE HOUSING BOWL

FILL
PLUG
TEMPERATURE
INDICATOR
PLUG — DO
NOT REMOVE

1002591e

Figure 5.76

48 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 6 Lubrication

Lubrication
6 Lubrication

NOTE: For complete information on lubricating drive axles and

carriers as well as lubricant capacities, refer to Maintenance Manual
1, Preventive Maintenance and Lubrication. To obtain this
publication, refer to the Service Notes page on the front inside cover
of this manual.

Refer to Table F and Table G for information on lubricants and

schedules. To obtain lubricants, refer to the Service Notes page on
the front inside cover of this manual.

Table F: Lubricant Cross Reference, Viscosity and Temperature Chart

Meritor Lubricant Minimum Outside Maximum Outside

Specification Description Cross Reference Temperature Temperature
O-76-A Hypoid Gear Oil GL-5, S.A.E. 85W/140 10°F (–12.2°C) - - -**
O-76-B Hypoid Gear Oil GL-5, S.A.E. 80W/140 –15°F (–26.1°C) - - -**
O-76-D Hypoid Gear Oil GL-5, S.A.E. 80W/90 –15°F (–26.1°C) - - -**
O-76-E Hypoid Gear Oil GL-5, S.A.E. 75W/90 –40°F (–40°C) - - -**
O-76-J Hypoid Gear Oil GL-5, S.A.E. 75W –40°F (–40°C) 35°F (1.6°C)
O-76-L Hypoid Gear Oil GL-5, S.A.E. 75W/140 –40°F (–40°C) - - -**
**There is no upper limit on these outside temperatures, but the axle sump temperature must never exceed 250°F (121°C).

Table G: Oil Change Intervals and Specifications for 13X Series Rear Drive Axles

Interval
Check Oil Level Every 10,000 miles (16 000 km), once a month or the fleet maintenance interval (whichever
comes first)
Petroleum based oil change Every 50,000 miles (80 000 km) or annually, whichever comes first
Synthetic oil change* Every 100,000 miles (160 000 km) or annually, whichever comes first
*This interval applies to approved semi-synthetic and full-synthetic oils only. For a list of approved extended-drain axle oils, refer to TP-9539, Approved Rear
Drive Axle Lubricants. To obtain this publication, refer to the Service Notes page on the front inside cover of this manual.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 49

7 Specifications

Fasteners
7 Specifications

Examples
The torque values in Table H are for fasteners that have a light Fastener Type How to Measure
application of oil on the threads.
M8 x 1.25 M8 = the diameter in
앫 If the fasteners are dry: Increase the torque values by 10%. Metric (Figure 7.2) millimeters, dimension X
앫 If the fasteners have a heavy application of oil on the 1.25 = the distance between
threads: Decrease the torque values by 10%. two threads, pitch

If you do not know the size of the fastener that is being installed,
measure the fastener. Use the following procedure. Figure 7.1

AMOUNT
American Standard Fasteners OF THREADS
IN 1"
1. Measure the diameter of the threads in inches, dimension X. 1"
Figure 7.1.
2. Count the amount of threads there are in one-inch. Figure 7.1.
X
3. Compare the size of the fastener measured to the list of
fasteners in Table H to find the correct torque value.
X DIMENSION = EXAMPLE 1/2" 1003113a
Example
American Standard size fastener is 0.50-13. Figure 7.1

앫 0.50 is the diameter of the fastener in inches or dimension Figure 7.2

X.
PITCH
앫 13 is the amount of threads in one-inch.

Metric Fasteners
1. Measure the diameter of the threads in millimeters (mm),
dimension X. Figure 7.2.
X
2. Measure the distance of 10 threads, point to point in
millimeters (mm), dimension Y. Make a note of dimension Y. Y
Figure 7.2. X DIMENSION = EXAMPLE M8 OR 8 MM
Y DIMENSION = DISTANCE OF 10 THREADS
3. Divide the dimension Y by 10. The result will be the distance 1003114b
between two threads or pitch.
Figure 7.2
4. Compare the size of the fastener measured to the list of
fasteners in Table H to find the correct torque value.

Examples
Fastener Type How to Measure
0.50-13 0.50 = the diameter of the
Standard American size fastener in inches, dimension
(Figure 7.1) X
13 = the number of threads in
one-inch

50 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 7 Specifications

Figure 7.3

4011902b
Figure 7.3

Table H: Torque Chart

Torque Value
Fastener Thread Size lb-ft N폷m
1 Yoke Nut M39 x 1.5 920-1130 (1250-1535)
2 Carrier-to-Axle Housing 0.625″-11 225 (305)
Capscrew
3 Adjusting Ring Capscrew M8 x 1-5g Class 10.9 22-30 (30-40)

Meritor Maintenance Manual MM-15103 (Issued 07-17) 51

7 Specifications

Torque Value
Fastener Thread Size lb-ft N폷m
4 Flange Side Bearing Cap M20 x 2.5-6g Class 10.9 Initial torque: 20 ± 8 (25 ± 10)
Capscrew Final torque: 320-400 (430-540)
5 Plain Side Bearing Cap M16 x 2.0-6g Class 10.9 Initial torque: 20 ± 8 (25 ± 10)
Capscrew Final torque: 200–258 (270-350)
6 Flange-to-Ring M16 x 2.0-6g Class 12.9 Preferred Method
Gear-to-Plain Case 150 lb-ft (203 N폷m) plus angle tighten to 30 degrees ± 1
Capscrew degrees
Resultant peak torque must be a minimum of 260 lb-ft
(352 N폷m).
Optional Method (393 ± 20)
290 ± 15
7 Drain and Fill Plugs 0.75″-14 35 Minimum (47.5 Minimum)
8 Breather 0.38″-18 25 ± 5 (30 ± 7)

Table I: Drive Pinion Bearings — Preload

Specification New bearings 30-60 lb-ft (3-6 N폷m)

Used bearings 20-50 lb-in (2.25-5.65 N폷m)
Adjustment Preload is controlled by the To increase preload, install a thinner spacer.
thickness of the spacer between
To decrease preload, install a thicker spacer.
bearings.

Table J: Drive Pinion — Depth in Carrier

Specification Install the correct amount of shims between the bearing cage and carrier. To calculate, use old shim
pack thickness and new and old pinion cone numbers.
Adjustment Change the thickness of the shim pack to get a good gear tooth contact pattern.

Table K: Main Differential Bearings — Preload

Specification 15-35 lb-in (1.7-3.5 N폷m)

Expansion between bearing caps — 0.002-0.009-inch (0.050-0.23 mm)
Adjustment Preload is controlled by tightening both adjusting rings after ZERO end play is reached.

Table L: Main Differential Gears — Rotating Resistance

Specification 10 lb-ft (13.6 N폷m) applied to one side gear

52 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 7 Specifications

Table M: Ring Gear — Backlash

Specification 0.008-0.018-inch (0.20-0.46 mm) for a used gear set

0.012-inch (0.30 mm) for a new gear set
Adjustment Backlash is controlled by the To increase backlash, move the ring gear away from the drive
position of the ring gear. Change pinion.
backlash within specifications to To decrease backlash, move the ring gear toward the drive
get a good tooth contact pattern.
pinion.

Table N: Ring Gear — Runout

Specification 0.008-inch (0.20 mm) maximum

Meritor Maintenance Manual MM-15103 (Issued 07-17) 53

8 Vehicle Towing Instructions

Hazard Alert Messages

8 Vehicle Towing Instructions

Figure 8.1

STUD WASHER STUD

Read and observe all Warning and Caution hazard alert messages in NUT GASKET
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.

WARNING
TAPERED
To prevent serious eye injury, always wear safe eye protection DOWEL,
when you perform vehicle maintenance or service. IF EQUIPPED

AXLE SHAFT
When transporting a vehicle with the wheels of one or both drive SHAFT OR HUB
axles on the road, it is possible to damage the axles if the wrong FLANGE AXLE 1002581c
procedure is used before transporting begins. Meritor recommends
Figure 8.1
that you use the following procedure.
4. Identify each axle shaft that is removed from the axle assembly
Before Towing or Drive-Away so they can be installed in the same location after transporting
or repair is completed. Example: Match mark a mating axle
WARNING shaft and hub.
Engage the parking brake to prevent the vehicle from moving
before you begin maintenance or service procedures that 5. Remove the tapered dowels, gasket, if used, and the axle shaft
require you to be under the vehicle. Serious personal injury from the axle assembly. Figure 8.1.
can result. 6. Install a cover over the open end of each hub where an axle
shaft was removed. This will prevent dirt from entering the
1. Apply the vehicle parking brakes using the switch inside the bearing cavity and loss of lubricant.
cab of the vehicle.
NOTE: If an air supply will be used for the brake system of the
NOTE: Remove both axle shafts from the axle(s) that will remain on transported vehicle, continue with Step 7 and Step 8, otherwise
the road when the vehicle is transported. continue with Step 9.

2. Remove the stud nuts and washers from the flange of the axle 7. Connect an auxiliary air supply to the brake system of the
shafts. Figure 8.1. vehicle that is being transported. Before moving the vehicle,
charge the brake system with the correct amount of air
CAUTION pressure to operate the brakes. Refer to the instructions
Do not use a chisel or wedge to loosen the axle shaft and supplied by the vehicle manufacturer for procedures and
tapered dowels. Using a chisel or wedge can result in damage specifications. If an auxiliary air supply is not used, continue
to the axle shaft, the gasket and seal, and the axle hub. with Step 9.

3. Loosen the tapered dowels, if used, in the flange of the axle 8. When the correct amount of air pressure is in the brake
shaft. Refer to Section 3 and Figure 8.1. system, release the parking brakes of the vehicle that is being
transported. Step 9 is not required.

54 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 8 Vehicle Towing Instructions

5. Install the gasket, if used, and axle shaft into the axle housing
WARNING
and carrier in the same location it was removed from. The
Before you service a spring chamber, carefully follow the
gasket and flange of the axle shaft must be flat against the
manufacturer’s instructions to compress and lock the spring to
hub. Rotate the axle shaft or the driveline as necessary to align
completely release the brake. Verify that no air pressure
the splines and the holes in the flange with the studs in the
remains in the service chamber before you proceed. Sudden
hub. Figure 8.1.
release of compressed air can cause serious personal injury
and damage to components. 앫 If a gasket is not available: Apply a 0.125-inch (3 mm)
diameter bead of grey sealant, Meritor specification
9. If there are spring or parking brakes on the axle(s) that will 2297-H-7054, around the mating surface of the hub and
remain on the road when the vehicle is transported, and they around the edge of each fastener hole. Install the axle shaft
cannot be released by air pressure, manually compress and into the axle housing and carrier.
lock each spring so that the brakes are released. Refer to the
6. Install the dowels, if used, over each stud and into the tapered
manufacturer’s instructions.
holes of the flange.
After Towing or Drive-Away 7. Install the washers and stud nuts. Determine the size of the
fasteners and tighten the nuts to the corresponding torque
WARNING value shown Table O.
Engage the parking brake to prevent the vehicle from moving
before you begin maintenance or service procedures that Table O: Shaft-to-Hub Torque Fastener Chart
require you to be under the vehicle. Serious personal injury Torque Value — Grade 8 Nuts lb-ft
can result. (N폷m)
Thread
Fastener Size Plain Nut Locknut
1. If an auxiliary air supply was used, apply the vehicle parking
brakes using the switch inside the cab of the vehicle. If an Stud Nut 0.62-18 180-230 (244-312) 150-190 (203-258)
auxiliary air supply was not used, begin with Step 2. or Axle 0.75-16 310-400 (420-542) 270-350 (366-475)
Shaft
WARNING Studs All Install the coarse thread end of the stud
Before you service a spring chamber, carefully follow the into the hub and tighten to the last thread.
manufacturer’s instructions to compress and lock the spring to
completely release the brake. Verify that no air pressure 8. Check the lubricant level in the axles and hubs where the axle
remains in the service chamber before you proceed. Sudden shafts were removed. Add the correct type and amount of
release of compressed air can cause serious personal injury lubricant if necessary. For information about lubrication, refer
and damage to components. to Maintenance Manual 1, Preventive Maintenance and
Lubrication, or refer to the Lubrication Section of the
2. Apply the vehicle spring or parking brakes by manually Maintenance Manual for the axle model you are working with.
releasing each spring that was compressed before transporting To obtain this publication, refer to the Service Notes page on
started. Refer to the manufacturer’s instructions. the front inside cover of this manual.
3. Disconnect the auxiliary air supply, if used, from the brake
system of the vehicle that was transported. Connect the
vehicle’s air supply to the brake system.
4. Remove the covers from the hubs.

NOTE: Continue with Step 5 through Step 7 to install all axle shafts.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 55

9 Special Tools

Hazard Alert Messages

9 Special Tools

WARNING
Read and observe all Warning and Caution hazard alert messages in Wear safe clothing and eye protection when you use welding
this publication. They provide information that can help prevent equipment. Welding equipment can burn you and cause
serious personal injury, damage to components, or both. serious personal injury. Follow the operating instructions and
safety procedures recommended by the welding equipment
WARNING manufacturer.
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. 3. To make the box section, cut and weld 1-inch x 2-inch
(25.4 mm x 50.8 mm) of mild steel square stock according to
dimensions C and D. Figure 9.2.
Special Tools
4. Cut a 4-foot x 1.25-inch (1.21 m x 31.75 mm) piece of mild
How to Make a Yoke Bar steel round stock to make the yoke bar handle. Center weld
this piece to the box section. Figure 9.2.
1. Measure dimensions A and B of the yoke you are servicing.
Figure 9.1. 앫 To increase yoke bar rigidity: Weld two angle pieces onto
the handle. Figure 9.2.
Figure 9.1

YOKE
1003459a

Figure 9.1

2. Calculate dimensions C and D of the yoke bar by adding

0.125-0.250-inch (3.175-6.35 mm) to dimensions A and B of
the yoke. Figure 9.2.

Figure 9.2

YOKE
BAR

C
1003460a

Figure 9.2

56 Meritor Maintenance Manual MM-15103 (Issued 07-17)

 9 Special Tools

Carrier Repair Stand Specifications

Figure 9.3

HANDLE 7" LONG

DRILL 3/8" HOLE PLATES 8" LONG x 3/4" WITH SLOT IN
THROUGH HANDLE THICK x 1-1/4" WIDE WITH ONE END TO FIT
AND SCREW A TONGUE TO FIT SLOT IN CLAMP SCREW
BAR WELD PLATES TO BAR

SCREW 3-1/2" LONG

x 5/8" DIAMETER WITH
FLATS ON END TO FIT BAR 2" DIAMETER x 9"
HANDLE AND 2-1/2" LENGTH LONG WITH ONE END
OF THREAD ON OTHER END SLOTTED TO FIT PLATE

PLUG 4" DIAMETER x 7" LONG

WITH ONE END TURNED 3" LONG SHAPE AND SIZE
TO FIT PIPE. DRILL 2" HOLE AND OF HOLES TO FIT
MILL 3/16" WIDE SLOT 2" FROM TOP CARRIER
WELD ALL AROUND
AFTER PRESSING
PLUG IN PIPE

23-1/2" CENTER
TO CENTER OF PIPE

4" DIAMETER
PIPE WELD

CHAMFER END
OF PIPE FOR
WELDING 1002990a

Figure 9.3

Refer to the Service Notes page on the front inside cover of this
manual to obtain this repair stand.

Meritor Maintenance Manual MM-15103 (Issued 07-17) 57

9 Special Tools

Multiple Lip Seals (MLS) and Seal Drivers

Refer to Table P for information on the multiple lip seal and seal
driver. To obtain Meritor seal driver KIT 4454, refer to the Service
Notes page on the front inside cover of this manual.

Table P: Multiple Lip Seal and Seal Driver

Model Axle Model and Position Seal Service Part Number Seal Driver
MS-13X Rear-Rear Unit Input (RUI) A1-1205Z2730 2730T1

58 Meritor Maintenance Manual MM-15103 (Issued 07-17)

Meritor Heavy Vehicle Systems, LLC
2135 West Maple Road Printed in USA
Troy, MI 48084 USA
866-OnTrac1 (668-7221) Copyright 2017 Issued 07-17
meritor.com Meritor, Inc. Maintenance Manual MM-15103 (16579)