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MAINTENANCE MANUAL Edition october/11Differential axles TandemMT 46-145MT 50-168

9IntroductionMAINTENANCE MANUALInter Axle Differential (IAD)The Meritor inter-axle differential (IAD) is a driv-er controlled,Air actuated traction de

99LubricationMAINTENANCE MANUALSpecicationsFor complete information on lubricating drive axles and differentials, refer to Maintenance Manual 1, Lub

Lubrication100 MAINTENANCE MANUALOil Capacity Axle Model Axle ModelDifferentialPints LitersRT-34-140Forward 26,0 12,3Rear 35,0 16,6RT-34-145Forward 2

101Information on Fasteners and its TorquesMAINTENANCE MANUALOnly Models:RT- 40- 160RT- 40- 169RT- 46- 160RT- 46- 164EHRT- 46- 169RT- 46- 16HEHRADIAL

Information on Fasteners and its Torques102 MAINTENANCE MANUALÍtem Description Axle Application SizeTorque ValueLb-Ft N.m1 Output Fork Nut See the Ta

103Information on Fasteners and its TorquesMAINTENANCE MANUALTabelaQ:GeneralTorquesSpecications(Continuation)Ítem Description Axle Application

Information on Fasteners and its Torques104 MAINTENANCE MANUALTabela S: Mounted on Tandem Axles (Track)Axle ModelsRT - 140RT - 145RT - 149RT - 160RT

105SpecicationsAdjustmentsMAINTENANCE MANUALTable U: Drive Pinion Bearings — Preload (See to Section 5)Specication New bearings5-45 lb-in (0.56-5

SpecicationsAdjustments106 MAINTENANCE MANUALTable Z: utput Bearing — Clearance and Preload (See to Section 5)Clearance input axle 0.050-0.200 mm (

107Special ToolsMAINTENANCE MANUALSpecifcationsMounting Bracket to Differential Repairs1 - PLATES 8” (203,2 mm) Long X 3/4”(19,05 mm) THICK X 1-1/4”

Special Tools108 MAINTENANCE MANUALHow to Make a Fork Tool to Detencion1. Measure dimensions A and B of the fork you are servicing. Figure 10.1.2. Cal

Introduction10 MAINTENANCE MANUALAxle Design Variation: Indicates axle design level or variation, (e.g., RS-23-161 has a thicker wall housing than

109Special ToolsMAINTENANCE MANUALSingle Models Tandem ModelsUnitilized Pinion SealSeal poSition Seal toolSDiameter Seat Sealer in the ForkMX-21-160 R

Vehicle Towing Instructions110 MAINTENANCE MANUALHazard Alert MessagesRead and observe all Warning and Caution hazard alert messages in this publicati

111Vehicle Towing InstructionsMAINTENANCE MANUAL7. Release conical washers, if used, of the angeoftheaxleshaf.Figure.FIGURE11.1.8. Identify e

Vehicle Towing Instructions112 MAINTENANCE MANUAL2. Apply the vehicle spring or parking brakes by manually releasing each spring that was compressed b

113Vehicle Towing InstructionsMAINTENANCE MANUALPrevious Tandem Axle, with Driver-Con-trolled Main Differential Lock (DCDL — Bolt-On DCDL Shift Assem

Vehicle Towing Instructions114 MAINTENANCE MANUALBOLT ON SHIFT ASSEMBLYTOP STORAGE HOLE FOR MANUAL ENGAGING CAPSCREWWIREAIR LINEMANUAL ENGAGING CAPSCR

115Vehicle Towing InstructionsMAINTENANCE MANUAL14. Lock or engaged the main differential Cage using the manual engaging methoid.A. Install the manua

Vehicle Towing Instructions116 MAINTENANCE MANUALNote:Install the axle shaft(s) indicated in Table AJ. Axle shafts with a DCDL have a double row of sp

117Vehicle Towing InstructionsMAINTENANCE MANUAL8. Identify each axle shaft that is removed from the axle assembly so they can be installed in the sa

MAINTENANCE MANUALAlways use the Technical Manuals from...

11Removal and DisassemblyMAINTENANCE MANUALHazard Alert MessagesRead and observe all Warning and Caution hazard alert messages in this publication. Th

Always use original parts For more details, see the Spare Parts Catalog Customer service 55 11 3684.674155 11 3684.6867Purchase the CD-ROM failure ana

Removal and Disassembly12 MAINTENANCE MANUAL8.Disconnectthedrivelineuniversaljointfromthepinioninputyokeorangeonthediffer-ential. Figu

13Removal and DisassemblyMAINTENANCE MANUALAir Hammer Vibration Method WARNINGWear safe eye protection when using an air ham-mer. When using power too

Removal and Disassembly14 MAINTENANCE MANUAL5. Remove the output shaft bearing cage cap-screws and washers.6. Pull the bearing cage, bearings and shaf

15Removal and DisassemblyMAINTENANCE MANUALDisasssembly Output Shaft and Bea-ring Cage Assembly1. Remove and discard the original oil seal. Use a new

Removal and Disassembly16 MAINTENANCE MANUAL4. If necessary, remove the output shaft and the bearing cones as an assembly from the output bearing cag

17Removal and DisassemblyMAINTENANCE MANUAL3. Press the output shaft through the bearing cones. Discard the used bearing cones.Bearing Puller Method1.

Removal and Disassembly18 MAINTENANCE MANUAL3.Usethecorrecttooltoholdtheforkorangeof the input shaft. Loosen, but do not remove, the drive

MAINTENANCE MANUALIndex1 - Exploded Views ...042 - I

19Removal and DisassemblyMAINTENANCE MANUALB. For 160 Series differential and 145 Series differential manufactured after September 1998, slowly lift

Removal and Disassembly20 MAINTENANCE MANUAL12. Use a brass drift and hammer to remove the cup of the rear side gear cone from the cage of differentia

21Removal and DisassemblyMAINTENANCE MANUALNOTE:Disassemble the bolted inter-axle differen-tial and inspect the components. The weld-ed inter-axle dif

Removal and Disassembly22 MAINTENANCE MANUALB. Place the assembly on a press so that ex-traction tool it rests on the differential. Figure 3.34.C. Pla

23Removal and DisassemblyMAINTENANCE MANUALRemoval Inter-Axle Differential Lock IAD Shift UnitAir Applied and Spring Release Models, Standard.1. Remov

Removal and Disassembly24 MAINTENANCE MANUALRemoval Driver-Controlled Main Diffe-rential Lock system (DCDL)If the axle is equipped with a driver-contr

25Removal and DisassemblyMAINTENANCE MANUAL7. Use an appropriate lifting device to remove the main differential case and ring gear assembly from the c

Removal and Disassembly26 MAINTENANCE MANUALRemoval Ring Gear from the Differen-tial CaseNOTE:If ring gear needs replaced use the follow-ing procedure

27Removal and DisassemblyMAINTENANCE MANUAL2. Remove the drive pinion from the Cage of differential.A. Place the differential carrier into a press s

Prepare Parts for Reassembly28 MAINTENANCE MANUALHazard Alert MessagesRead and observe all Warning and Caution hazard alert messages in this publicati

29Prepare Parts for ReassemblyMAINTENANCE MANUALClean Ground and Polished Parts1. Use a cleaning solvent, kerosene or diesel fuel to clean ground or p

Prepare Parts for Reassembly30 MAINTENANCE MANUAL CAUTIONA DRIVE PINION AND RING GEAR ARE MA-CHINED AS A MATCHED SET. WHEN YOU REPLACE EITHER A DRIVE

31Prepare Parts for ReassemblyMAINTENANCE MANUAL CAUTIONA THRUST WASHER, DIFFERENTIAL SIDE GEAR AND PINION GEAR ARE MACHINED AS A MATCHED SET. WHEN YO

Prepare Parts for Reassembly32 MAINTENANCE MANUALWelding on Axle Housings WARNINGWear safe clothing and eye protection when you use welding equipment.

33Prepare Parts for ReassemblyMAINTENANCE MANUALDo Not Bend or Straighten a Damaged Drive Axle Housing WARNINGReplace damaged or out-of specicati

Prepare Parts for Reassembly34 MAINTENANCE MANUAL1. Clean the oil and dirt from the outer diameters of the bearing cups and bearing bores in the diffe

35Prepare Parts for ReassemblyMAINTENANCE MANUAL11. Install two long studs in the differential to guide the differential into the housing.12. Immediat

Prepare Parts for Reassembly36 MAINTENANCE MANUALNOTE: Meritor drive pinions and ring gears are only available as matched sets. Each gear in a set has

37Prepare Parts for ReassemblyMAINTENANCE MANUALHypoid Gear Set Ratios Listed on theIdenticationTags1.Locatethe identicationtags rivetedtoth

Prepare Parts for Reassembly38 MAINTENANCE MANUAL• If the positions of the tire marks are morethan3.6 degrees from each other: Check to the

3 MAINTENANCE MANUALNotesAbout This ManualThis manual provides maintenance and service information for theMeritor forward tandem drive axles, includin

39Prepare Parts for ReassemblyMAINTENANCE MANUAL• Iftheaxleratiosshownontheidenticationtags are not within one percent of each oth-er: See t

Prepare Parts for Reassembly40 MAINTENANCE MANUAL2. Use a correct yoke installation tool to install the yoke.3. As you install the fork, you should de

41Assembly and InstallationMAINTENANCE MANUALHazard Alert Messages Read and observe all Warning and Caution hazard alert messages in this publication.

Assembly and Installation42 MAINTENANCE MANUAL3.Ifyoucan’tndthePCnumberorit’sunread-able, install a new shim pack of the same thickness tha

43Assembly and InstallationMAINTENANCE MANUALThe preload of the bearings on the drive pin-ion is controlled by a spacer between the outer bearing cone

Assembly and Installation44 MAINTENANCE MANUAL5. If removed, install the outer bearing cap for the drive pinion.A. Place the differential caser in the

45Assembly and InstallationMAINTENANCE MANUAL1. Place the differential case in the press so that the threaded end of the pinion is UP. Place supports

Assembly and Installation46 MAINTENANCE MANUAL6. Place a protector in the head of the drive pinion. Use a press to install the pinion into the differe

47Assembly and InstallationMAINTENANCE MANUAL14. Use a press and a sleeve to press the shaft of the drive pinion out of the outer bearing cone. Do not

Assembly and Installation48 MAINTENANCE MANUAL22. Install the washer and the nut the drive pin-ion. Prevent the drive pinion assembly from rotating by

Exploded Views4 MAINTENANCE MANUALINPUT WITHOIL PUMP PARTSOIL PUMP PARTSSTANDARD DIFFERENTIAL WITHOUT DIFFERENTIAL LOCK AND WITHOUT OIL PUMPLEFT. SID

49Assembly and InstallationMAINTENANCE MANUAL4. Measure the outer diameter of the washer under the drive pinion. Divide the outer diam-eter of the was

Assembly and Installation50 MAINTENANCE MANUAL1. Expand the ring gear by heating the gear in a tank of water to 160-180°F (71-82°C) for 10 to 15 minut

51Assembly and InstallationMAINTENANCE MANUAL9. Apply axle oil lubricant on the inside surfaces of both case halves, spider or cross, thrust washers,

Assembly and Installation52 MAINTENANCE MANUALA. Install four capscrews and washers or bolts, nuts and washers into the case halves. The distance bet

53Assembly and InstallationMAINTENANCE MANUALInstallation Case Halves and Ring Gear In the Differential 1. If the bearing cones on the main differenti

Assembly and Installation54 MAINTENANCE MANUALFigure 5.34 CAUTIONTHE BEARING CAPS MUST BE CORRECT-LY INSTALLED OR THE ADJUSTING RINGS WILL BE DAMAGED

55Assembly and InstallationMAINTENANCE MANUALNOTE: The roll pins for the adjusting rings are in-stalled after the tooth contact pattern is checked.Dia

Assembly and Installation56 MAINTENANCE MANUALLarge Micrometer Method 1.Hand-tighten the adjusting rings against themain differential bearings.

57Assembly and InstallationMAINTENANCE MANUALRing Gear Runout 1. Attach a dial indicator in the differential case mountingange.Figure5.42.2.Adjus

Assembly and Installation58 MAINTENANCE MANUALAfter checking the tooth contact patterns, the backlashcanbeadjustedwithinthespecica-tion limits,

5Exploded ViewsMAINTENANCE MANUAL01 Nut - Input Fork01A Washer - Input Fork02 Input Fork03 Deector04 Capscrew - Cage-to-Differential Input Sh

59Assembly and InstallationMAINTENANCE MANUALAlways check the tooth contact patterns on the drive side of the gear teeth. Figure 5.49.ExamplesThe foll

Assembly and Installation60 MAINTENANCE MANUAL4. Look at the contact patterns on the ring gear teeth. Compare the patterns to Figure 5.51, Figure 5.52

61Assembly and InstallationMAINTENANCE MANUAL5. Change the thickness of the shim pack be-tween the pinion inner bearing cap and the differential case

Assembly and Installation62 MAINTENANCE MANUALIf the differential has cotter pins or cap-screws, lock the adjusting rings only with cotter pins or cap

63Assembly and InstallationMAINTENANCE MANUAL5.Tightenthejamnut,ifequipped,tothecor-rect torque value against the differential case. See the

Assembly and Installation64 MAINTENANCE MANUAL2. Inspect the shift shaft for damage. If neces-sary, replace the shift shaft.3. If removed, install ne

65Assembly and InstallationMAINTENANCE MANUALA. Apply axle lubricant to the inner bore of the bearing cage or the outer diameter of the new oil seal.

Assembly and Installation66 MAINTENANCE MANUAL CAUTIONON EARLY DESIGN FORWARD DIFFEREN-TIAL , VERIFY THAT THE DRIVE FLATS IN THE BORE OF THE PUMP ARE

67Assembly and InstallationMAINTENANCE MANUALE. Install the input bearing cage over the input shaft on the oil pump.• Ifdowelpinsareused,verify

Assembly and Installation68 MAINTENANCE MANUAL10. If disassembled, assemble the inter-axle differential.A. Apply axle lubricant to all of the inter-a

Exploded Views6 MAINTENANCE MANUALITEM Description ITEM Description65 Nut — Ring Gear (145 and 160 Series)66 Sensor Switch — Main Differential L

69Assembly and InstallationMAINTENANCE MANUALNOTE: The shim pack under the input bear-ing cage is installed after the clearanceof the input bearing is

Assembly and Installation70 MAINTENANCE MANUAL1.Install the capscrews, but not the washers, that fasten the input shaft bearing cage to the differenti

71Assembly and InstallationMAINTENANCE MANUALFigure 5.86Figure 5.879. Inspect the clearance operation of the input shaft assembly.A. Rotate the input

Assembly and Installation72 MAINTENANCE MANUALFigure 5.88Figure 5.89Figure 5.90Figure 5.91Installation Driver-Controlled Main Diffe-rential Lock See t

73Assembly and InstallationMAINTENANCE MANUALInspection Adjust of the clearance of the Output shaft BearingsThe clearance the output shaft bearing is

Assembly and Installation74 MAINTENANCE MANUAL CAUTIONINSPECT THE AXLE BREATHER FOR CON-TAMINANTS, SUCH AS DIRT, LUBRICATION OR DEBRIS, WHICH CAN CAUS

75Assembly and InstallationMAINTENANCE MANUAL6. Position the installation tool and seal. Figure 5.95.• IfyouusetheR4422401tooltoinstallafor-

Assembly and Installation76 MAINTENANCE MANUALNOTE: The unitized seal features a rubber inner sleeve that is designed to seal and ro-tate with the for

77Assembly and InstallationMAINTENANCE MANUALTight Fit Forks and POSE™ Seal .1. Apply axle lubricant to the hub of the fork or ange.Figure5.98.2. V

Assembly and Installation78 MAINTENANCE MANUALOutput Flange fork or Oil Sealer Box Output Shaft Bearings. CAUTIONHOLD THE SEAL ONLY ON THE OUTER DIAME

7Exploded ViewsMAINTENANCE MANUALCURRENT DCDLNO SPIN® ASSEMBLYANTERIOR DESIGN DCDLOIL PUMPRIGHT. SIDEMAIN DIFFERENTIAL CASEMLAIN DIFFFERENTIALWITHOUT

79Assembly and InstallationMAINTENANCE MANUAL CAUTIONUSE A PRESS AND A SLEEVE OR FORK IN-STALLATION TOOL TO INSTALL THE FORK. DO NOT USE A HAMMER OR M

Assembly and Installation80 MAINTENANCE MANUAL6. On an axle with a driver-controlled main dif-ferential lock, shift the lock into and hold the lock in

81Assembly and InstallationMAINTENANCE MANUAL14.Adjusttheshiftforkfortheinter-axlediffer-ential lock. The movement of the shift fork is contr

Assembly and Installation82 MAINTENANCE MANUAL18.If removed, install the oil lter adapter ofthe differential housing. Use Meritor adhe-sive

83Assembly and InstallationMAINTENANCE MANUAL5. Iftheaxleshaftangehavecylindricalholeforscrew mounting, install the screws and wash-ers in

Assembly and Installation84 MAINTENANCE MANUALCylindrical Holes, Nuts and Washers 1. Clean the mounting surfaces of the axle shaft and wheel hub.2. If

85Assembly and InstallationMAINTENANCE MANUALFill the Axle with Lubricant NOTE: For additional lubrication information, See the Maintenance Manual 1,

Driver-Controlled Main Differential Lock86 MAINTENANCE MANUALHazard Alert MessagesRead and observe all Warning and Caution hazard alert messages in th

87Driver-Controlled Main Differential LockMAINTENANCE MANUALEngagement or Lockout of the DCDL WARNINGDuring DCDL disassembly or differential re-mov

Driver-Controlled Main Differential Lock88 MAINTENANCE MANUAL10.Install the manual engaging capscrew into the threaded hole in the center of the cylin

Introduction8 MAINTENANCE MANUALRT-160 SERIES SHOWNIntroductionDescriptionForward Tandem AxleThe inter axle differential (IAD) is located be-hind the

89Driver-Controlled Main Differential LockMAINTENANCE MANUALDifferential and Gear Assembly and Main Differential LockThreaded DCDL Shift AssemblyThe c

Driver-Controlled Main Differential Lock90 MAINTENANCE MANUAL9. Pull the shift shaft from the fork and out of the differential. Figure 6.10.10. Remove

91Driver-Controlled Main Differential LockMAINTENANCE MANUALNOTE:Some models use silastic seal instead of theatwasherinStepE.Also,arollpini

Driver-Controlled Main Differential Lock92 MAINTENANCE MANUAL2. Compress the shift shaft spring as required and install it between the back of the for

93Driver-Controlled Main Differential LockMAINTENANCE MANUAL10. Engage the splines of the collar with the splines of the main differential case. Inser

Driver-Controlled Main Differential Lock94 MAINTENANCE MANUAL1. On differential models with shift fork roll pins, install the two roll pins into the

95Driver-Controlled Main Differential LockMAINTENANCE MANUAL9. Lubricate the O-ring with axle lubricant. Install the O-ring into its groove on the pi

Driver-Controlled Main Differential Lock96 MAINTENANCE MANUAL16. Connect a volt-ohm meter to the sensor switch. Select ohms on the meter. Rotate the s

97Driver-Controlled Main Differential LockMAINTENANCE MANUAL5. Install the differential into the housing. See the Section 5.6. Install and tighten t

Driver-Controlled Main Differential Lock98 MAINTENANCE MANUAL7. Install the differential as s embl y into the housing. See the Section 5.8. Install