MT-14X Series Single-Reduction Forward Differential Carriers On Tandem Axles

Maintenance Manual MM-0970
MT-14X Series Single-Reduction Forward

Differential Carriers on Tandem Axles
Revised 11-17
Service Notes
About This Manual How to Obtain Additional Maintenance,

This manual provides service and repair procedures for Meritor Service and Product Information
MT-14X Series single-reduction forward differential carriers on Visit Literature on Demand at meritor.com to access and order
tandem axles. additional information.
Contact the Meritor OnTrac™ Customer Call Center at
Before You Begin 866-668-7221 (United States and Canada); 001-800-889-1834
1. Read and understand all instructions and procedures before (Mexico); or email OnTrac@meritor.com.
you begin to service components.
2. Read and observe all Warning and Caution hazard alert If Tools and Supplies are Specified in
messages in this publication. They provide information that can This Manual
help prevent serious personal injury, damage to components,
Contact Meritor’s Commercial Vehicle Aftermarket at
or both.
888-725-9355.
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.
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-0970 (Revised 11-17)

Contents
pg. 1 Section 1: Exploded Views pg. 29 Removing Fasteners Secured with Adhesive
New Fasteners with Pre-Applied Adhesive
5 Section 2: Introduction
Original or Used Fasteners
Description
Preparing the Differential for Reassembly
Forward Tandem Axle
30 Carrier-to-Housing Joint Cleaning Procedure
Optional Pressurized Lubrication System
31 General Yoke and U-Joint Reassembly
Optional Driver-Controlled Main Differential Lock (DCDL)
Identification
Inter-Axle Differential (IAD) Lock
Gear Sets
Stall-Testing Can Damage a Drive Axle
32 Check for Mismatched Ratios on Tandem Axles
6 Use of Traction Chains
Gear Set Ratios Listed on the Identification Tags
New and Old Design Carriers
33 Rotate the Forward Drive Shaft to Check the Gear Set Ratio
7 Identification
Gear Set Teeth Numbers Stamped on the Forward and
Model Number
Rear Axle Drive Pinions
9 Section 3: Removal and Disassembly 34 Verify the Actual Gear Set Ratios
Removal 35 Inspection
Axle Shafts Yoke
Axle Shaft Removal Methods Tire Matching for Tandem Axles
10 Axle Shafts from the Axle Housing
11 Thru-Shaft
37 Section 5: Assembly and Installation
Installation
12 Differential Carrier from the Axle Housing
“Dry Fit” and “Final” Assembly and Installation Procedures
13 Disassembly
Installing the Drive Pinion, Adjusting Pinion Depth and
Thru-Shaft and Output Bearing Cage
Contact Pattern
14 Removal
Drive Pinion Shim Pack Thickness
Input Shaft and Inter-Axle Differential (IAD)
38 Assembly
18 Disassembly
“Dry Fit”Assembly of the Drive Pinion to Verify Shim Pack
Input Shaft and Inter-Axle Differential
40 Installation
20 Removal
Drive Pinion
Driver-Controlled Main Differential Lock (DCDL)
Assembly
Measure Ring Gear Backlash
Main Differential and Ring Gear
Main Differential Case and Ring Gear
43 Check the Rotating Resistance of the Differential Assembly
22 Disassembly
44 Installation
“Dry Fit” Installation of the Main Differential Case and Ring
23 Removal
Gear Assembly Into the Carrier
Ring Gear from the Differential Case
45 Adjustment of Pinion Shim Pack and Backlash for Contact
Drive Pinion
Pattern
25 Section 4: Prepare Parts for Assembly Ring Gear Backlash
Clean, Dry and Inspect Parts 46 Gear Set Tooth Contact Patterns
Clean and Inspect Yokes 50 Installation
26 Clean Ground and Polished Parts “Final” Installation of the Drive Pinion and Bearing Preload
Clean Rough Parts Adjustment
Clean Axle Assemblies 53 “Final” Installation of the Main Differential Case and Ring
Dry Parts Immediately After Cleaning Gear Assembly Into the Carrier
Prevent Corrosion on Cleaned Parts 55 Adjustment
Inspect Parts Differential Bearings Preload
29 Repair or Replace Parts 57 Ring Gear Runout
Welding on Axle Housings 58 Installation
Do Not Bend or Straighten a Damaged Drive Axle Housing Thrust Screw (44,000-Lb Model Only)
Contents
pg. 58 Assembly pg. 107 Centering Tool

Input Shaft and Inter-Axle Differential (Oil Pump Model) Service Tools
59 Input Shaft and Inter-Axle Differential (Non-Pump Model) 109 Multiple-Lip Seals, Seal Drivers and Yoke Sleeve Drivers
60 Installation
110 Section 11: Vehicle Towing Instructions
Input Shaft Assembly and Cover (Oil Pump Models)
After Towing or Drive-Away
65 Input Shaft Assembly and Cover (Non-Pump Models)
69 Inspection 112 Section 12: Diagnostics
Adjust the Input Bearing End Play Troubleshooting
71 Installation Vehicle Will Not Move
Multiple-Lip Seal (MLS) and Yoke Sleeve 114 Differential Making Noise
74 Input Yoke 116 Oil Leak
75 Output Bearing Cage and Thru-Shaft 117 Contaminated Lubricant Found During Preventive
76 Adjustment Maintenance
Adjust the Output Bearing End Play
77 Installation
Output Yoke and Seal for the Output Bearing Cage
78 Driver-Controlled Main Differential Lock
Differential Carrier into the Axle Housing
80 Axle Shaft
81 Fill the Axle with Lubricant
82 Section 6: Driver-Controlled Main
Differential Lock (DCDL)
Description
Removal
Differential Carrier from the Axle Housing
83 Engagement or Lockout of the DCDL
84 DCDL Shift Unit with Bolt-On Cover
86 DCDL Shift Unit with Screw-In Cover
88 Installation
DCDL Shift Unit with Bolt-On Cover
91 DCDL Shift Unit with Screw-In Cover
93 Check the Differential Lock
DCDL Driver Caution Alert Label
94 Driver Instruction Information Available
95 Section 7: Lubrication
Specifications
97 Section 8: Specifications
Specifications
102 Section 9: Adjustment
Adjustment
104 Section 10: Special Tools
Specifications
Carrier Repair Stand
105 How to Make a Yoke Bar
How to Make a Drive Flange Retainer Tool
1 Exploded Views
1 Exploded Views
Figure 1.1
MT-14X SERIES DIFFERENTIAL CARRIER

18
17
16
15
14
13
12
11
9 10 16
18
8
8 11
7
6A 10
9 28 17
6
5 27
7
4 19
20 26
3 21
25 22
2 6A
23 29
24 6
1 30
23 31
OIL PUMP 5 24
MODEL
4
NON-PUMP 3 32
MODEL 1 2
34
33
39
40
35 41
36
37
42
38 51 50
43
60
52 44
61 45
46
47
48
49
62
63
54 52
64 65
55 53
56
57
58
59 4007390b
Meritor Maintenance Manual MM-0970 (Revised 11-17) 1

1 Exploded Views
Item Description Item Description

1 Input Shaft Locknut 34 Differential Spider
2 Flat Washer 35 Differential Pinion Gear
3 Input Yoke 36 Helical Drive Gear
4 Deflector 37 Thrust Bearing
5 Oil Seal 38 Needle Bearing Assembly
6 Bearing Adjusting Ring 39 Pinion Gear
6A Adjusting Ring O-Ring (New Design Carriers 40 Bearing Cone
Only) 41 Bearing Cup
7 Bearing Cup 42 Drive Pinion Shims
8 Bearing Cone 43 Drive Pinion Spacer
9 Capscrew 44 Helical Driven Gear
10 Adjusting Ring Lock Plate 45 Pinion Bearing Shim Spacer
11 Front Cover 46 Bearing Cup
12 Oil Pump Gear Assembly 47 Bearing Cone
13 Oil Pump Plate 48 Pinion Nut Washer
14 Flat Washer 49 Pinion Locknut
15 Capscrew 50 Differential Lock Switch
16 Clutch Collar 51 Carrier Housing
17 Shift Fork 52 Hardened Washer
18 Input Shaft 53 1.75-inch Capscrew
19 Pressure Relief Valve 54 Shift Spring
20 Spring 55 Shims
21 Sealing Ring Washer 56 Shift Pushrod
22 Pressure Relief Plug 57 Piston O-Ring
23 Hardened Washer 58 Piston
24 Capscrew 59 Housing O-Ring
25 Oil Screen and Plug Assembly 60 Tapered Dowel
26 Oil Dam Baffle 61 2.25-inch Capscrew
27 Hardened Washer 62 Washer
28 Capscrew 63 Nut
29 Bearing Cup 64 Stud
30 Bearing Cone 65 DCDL Assembly
31 Differential Side Gear
32 Snap Ring
33 Inter-Axle Differential Case
2 Meritor Maintenance Manual MM-0970 (Revised 11-17)

1 Exploded Views
Figure 1.2
1
MAIN DIFFERENTIAL CASE AND
2
RING GEAR ASSEMBLY
4 10 11
5
12
13
6 13 18
7 12
8
9 14 21 8
7
6 3
15
16 4
17 19
DCDL WITH BOLT-ON COVER
20 1
2
6 10 11 5
DCDL WITH SCREW-IN COVER

1
2
3
3
6
4 7
5 12
7
8 9
9
2
4
5
4007390d

1 Capscrew 15 Pinion Gear
2 Lock Plate 16 Thrust Washer
3 Bearing Cap Capscrew 17 Ring Gear
4 Hardened Washer 18 Ring Gear-to-Flange Half Capscrew
5 Bearing Cap 19 Differential Case Plain Half
6 Bearing Adjusting Ring 20 Plain Half-to-Flange Half Capscrew
7 Bearing Cup 21 DCDL Shift Collar, If Equipped
8 Bearing Cone DCDL (If Equipped)
9 Differential Case Flange Half 1 Shims
10 Locknut 2 Shift Spring
11 Washer 3 Shift Fork
12 Differential Washer 4 Shift Pushrod
13 Differential Side Gear 5 O-Ring
14 Differential Spider 6 Piston

1 Exploded Views
Item Description
7 Gasket
8 DCDL Cover (Bolt-On Style)
9 Plug Cup
10 Washer
11 Capscrew
12 DCDL Cover (Screw-In Style)
Figure 1.3
AXLE HOUSING WITH THRU-SHAFT
7 8
6 9
10
11
5
12
1
13
4
3
14
2
7
15
16
17
18 19
20
21
4007391b
1 Short Axle Shaft 13 Cup Spacer
2 Thru-Shaft Cage Assembly 14 Oil Seal Assembly
3 Hardened Washer 15 Breather Hose
4 Capscrew 16 Breather
5 Thru-Shaft 17 Oil Fill Plug
6 Bearing Cone 18 Magnetic Fill Plug (Optional)
7 Bearing Cup 19 Long Axle Shaft
8 Output Yoke 20 Magnetic Plug
9 Locknut 21 Housing
10 Flat Washer
11 Thru-Shaft Snap Ring Spacer
12 Tapered Snap Ring

2 Introduction
Description Optional Pressurized Lubrication System

2 Introduction
The forward axles can be equipped with an optional pressurized

Forward Tandem Axle lubrication system. This system has an oil pump driven by the input
The Meritor MT-14X Series forward tandem axles use a shaft. The pump circulates lubricant to the journals in the forward
single-reduction, thru-drive carrier. The drive gearing is a input shaft bearings and directly to the inter-axle differential.
two-helical gear train and an amboid ring gear and pinion. Bevel
gears are used in the main differential and the inter-axle differential. Optional Driver-Controlled Main Differential
Figure 2.1 and Figure 2.2. Lock (DCDL)
The inter-axle differential is located behind the helical gear on the The forward axle can be equipped with an optional driver-controlled
input shaft. The forward side gear of the inter-axle differential is part main differential lock (DCDL). The differential lock is operated by an
of the upper helical gear hub. The thru-shaft is splined to the rear air-actuated shift unit located on the forward axle carrier.
side gear of the inter-axle differential. Figure 2.1 and Figure 2.2.
앫 When the differential lock is activated, the shift collar moves
Figure 2.1
along the splines of the axle shaft toward the differential case.
DRIVE
HELICAL INTER-AXLE 앫 When the collar engages with the clutch teeth on the differential
GEAR DIFFERENTIAL case, the axle shaft and the differential assembly lock together.
INPUT
SHAFT THRU-SHAFT 앫 When the carrier operates with the DCDL in the locked position,
there is no differential action between the wheels.
앫 When the carrier is operated in the unlocked position, there is
normal differential action between the wheels at all times.
OIL
PUMP
Inter-Axle Differential (IAD) Lock
RING
GEAR The Meritor inter-axle differential (IAD) lock is a driver-controlled,
DRIVEN DRIVE air-actuated traction device. The IAD allows for speed differences
HELICAL PINION
GEAR 1002702d between the forward and rear axles in a tandem while also providing
OIL PUMP MODEL equal pulling power from each axle of the tandem. By activating the
IAD switch located in the vehicle dash, improved traction is provided
Figure 2.1
for each axle.
Figure 2.2 The inter-axle differential is also known as a power divider or third
DRIVE differential.
HELICAL INTER-AXLE
GEAR DIFFERENTIAL
INPUT
SHAFT THRU-SHAFT
Stall-Testing Can Damage a Drive Axle
Stall-testing is a procedure used to troubleshoot transmissions,
evaluate vehicle performance, and test the service and park brakes.
During stall-testing, or any similar procedure, the drive axle input
receives multiplied torque, which can exceed the specified torque
rating. Excessive torque can damage a drive axle, which will affect
RING axle performance and component life. A drive axle damaged by
GEAR
stall-testing will void Meritor’s warranty.
DRIVEN DRIVE
HELICAL PINION Call the Meritor OnTrac™ Customer Call Center at 866-OnTrac1
GEAR 1002702e
(668-7221) if you have questions regarding stall-testing.
NON-PUMP MODEL
Figure 2.2

2 Introduction
Use of Traction Chains Identifying New Design Carriers

Meritor recommends that if you are using traction chains, you The newly designed covers have rough part numbers located
should install chains on both tires on each side of all drive axles on adjacent to the internal pinion stem. Figure 2.5 and Figure 2.6. Both
the vehicle. covers shown are the new O-ring design. Covers that do not have
one of these two rough part numbers are the old “non-O-ring”
design.
New and Old Design Carriers
Meritor 14X series forward differential carriers, manufactured after Figure 2.5
February 28, 2015, have been redesigned at the input adjusting NEW DESIGN COVER, PUMP VERSION,
ring-to-front cover interface. The new interface now incorporates an PART NUMBER 3226T1710
O-ring at the inboard end of the adjusting ring. Figure 2.3 and
Figure 2.4.
Figure 2.3
NEW DESIGN
ROUGH PART
O-RING NUMBER
J1
70
0
ADJUSTING
RING
4011802a
Figure 2.5
Figure 2.6
4011800a NEW DESIGN COVER, NON-PUMP VERSION,

PART NUMBER 3226S1709
Figure 2.3
Figure 2.4
OLD DESIGN
ADJUSTING
RING
ROUGH PART
NUMBER
E1
695
4011803a
Figure 2.6
4011801a
Figure 2.4

2 Introduction
Service Recommendations Figure 2.8
Any 14X forward carrier is compatible with both the new or old
design cover. If you are replacing the cover of an old design carrier,
Meritor recommends using a new design cover as a replacement,
although the old design cover can be used if preferred. Note that the
adjusting rings in the new and old design covers are NOT
INTERCHANGEABLE. Always replace an adjusting ring with the CARRIER PART NO.
CUSTOMER NO.
correct type designed for the cover. SERIAL NO.
RATIO
CARRIER
Identification IDENTIFICATION TAG 4008142a
Model Number Figure 2.8
An identification tag is attached to the axle housing or the Refer to Figure 2.9 for an explanation of the model number.
differential carrier. Figure 2.7 and Figure 2.8. Use the model
number and the ratio number marked on the identification tag and
the number on the carrier to obtain replacement parts.
Figure 2.7
AXLE IDENTIFICATION TAG INFORMATION
Model No. . . . . . . . . . . . . . . . . . . .
Customer No. . . . . . . . . . . . . . . . .
Serial No. . . . . . . . . Plant . . . . . . . .

Ratio . . . . . . . . . . . .
IDENTIFICATION TAG
LOCATION OF THE IDENTIFICATION TAG, OR STAMP

NUMBER, FOR THE AXLES. LOCATION IS
DETERMINED FROM THE LEFT DRIVER SIDE
LOOKING TOWARD THE FRONT OF THE VEHICLE.
FRONT ENGINE DRIVE — RIGHT REAR,
NEXT TO COVER
4008141a
Figure 2.7

2 Introduction
Figure 2.9
Housing Wall
0 = Cast
1 = TBD
GAWR 2 = 0.31 in. (8 mm)
3 = 0.37/0.39 in. (9.5/10.0 mm)
xx = GAWR (000) Pounds or Tons 4 = 0.43 in. (11 mm)
(dependent on mfg. location) 5 = 0.50/0.51 in. (12.7/13.0 mm)
6 = 0.56 in. (14.3 mm)
7 = TBD
Axle Model Type* 8 = 0.63 in. (16 mm)
S= Single Rear (Solo) 9 = TBD
D= Fwd Rear w/IAD
N= Fwd Rear less IAD Carrier Variation
P= Fwd Rear w/Pump A = Aluminum
R= Rear Rear
Carrier Type B = Aluminum/Ductile Amboid (Tandem Split)
T= Tandem Drive Carrier size. C = Ductile/Ductile Amboid (Tandem Split)
Z= Tridem Drive Larger numbers D = Ductile Rear, Hyboid
C= Coach indicate a higher E = Aluminum/Ductile (Tandem Split)
H= High Entry GCW rated F = Ductile Amboid/Ductile Hypoid (Tandem Split)
V= Fwd Rear w/no carrier; i.e., larger M= Ductile Rear, Amboid
thru shaft ring gear etc. N= No Carrier
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 4 X 5 D B R 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
* For Front Drive Steer Axles, of the “/” references the Rear axle. For
refer to page 6. information related to the Middle axle of a
Tridem axle set part number, refer to the
Bills of Material.
4007403b
Figure 2.9

3 Removal and Disassembly
Hazard Alert Messages

Tool Part Number Manufacturer

Read and observe all Warning and Caution hazard alert messages in Axle Shaft K-1280 Kiene Diesel
this publication. They provide information that can help prevent Remover Accessories, Inc.
serious personal injury, damage to components, or both. Axle Stud Cone 7077 SPX OTC
Plier
WARNING
To prevent serious eye injury, always wear safe eye protection Brass Drift Method
when you perform vehicle maintenance or service.
WARNING
Use a brass or synthetic mallet for assembly and disassembly Do not strike the round driving lugs on the flange of an axle
procedures. Do not hit steel parts with a steel hammer. Pieces shaft. Pieces can break off and cause serious personal injury.
of a part can break off. Serious personal injury and damage to
components can result. 1. Hold a 1-1/2-inch diameter brass drift or brass hammer
against the center of the axle shaft, inside the round driving
Observe all warnings and cautions provided by the press lugs. Figure 3.1.
manufacturer to avoid damage to components and serious
personal injury. Figure 3.1
BRASS
Removal HAMMER
Axle Shafts
DRIVING
Before the axle shafts and differential carrier can be removed or LUGS
installed, the driver-controlled differential lock (DCDL), if equipped,
must be shifted into and held in the locked or engaged position. The
locked position gives enough clearance between the shift collar and
the axle housing to permit the removal or installation of the carrier.
Refer to Section 6 for service information on the DCDL. If the drive 1002707b
axle is not equipped with DCDL, continue on with axle shaft removal
Figure 3.1
in this section.
2. Strike the end of the drift with a large hammer, five to six
Axle Shaft Removal Methods pounds, and the axle shaft and tapered dowels, if equipped,
Use Special Tools Recommended by Meritor will loosen.
To help prevent serious personal injury and damage to components 3. Mark each axle shaft before it is removed from the axle
when you remove the axle shaft from the housing, Meritor assembly.
recommends that you use the following tools in the table below. 4. Remove the tapered dowels, if equipped, and separate the axle
Refer to the Service Notes page at the front inside cover of this shafts from the axle hub assembly. Figure 3.2.
manual for information on how to contact the manufacturers to
obtain the tools.
앫 If the tools are not available when you remove the axle
shaft: Follow procedures for using the Brass Drift Method or the
Air Vibration Method.

Figure 3.2 Figure 3.3
STUD TAPERED DOWEL, ROUND HAMMER

NUT IF EQUIPPED BIT BETWEEN HUB
GASKET STUD STUDS
WASHER
CAPSCREW AXLE
WASHER SHAFT
SHAFT OR
FLANGE HUB
AXLE 1002708e
1002987c
Figure 3.2
Figure 3.3
5. Install a cover over the open end of each axle assembly hub
where an axle shaft was removed. 3. Mark each axle shaft before it is removed from the axle
assembly.
Air Hammer Vibration Method
4. Remove the tapered dowels, if equipped, and separate the axle
WARNING shaft from the main axle hub assembly. Figure 3.3.
Wear safe eye protection when using an air hammer. When
using power tools, axle components can loosen and break off Axle Shafts from the Axle Housing
causing serious personal injury.
WARNING
CAUTION Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
Do not use a chisel or wedge to loosen the axle shaft and
safety stands. Do not work under a vehicle supported only by
tapered dowels. Using a chisel or wedge can result in damage
jacks. Jacks can slip or fall over. Serious personal injury and
to the axle shaft, the gasket and seal, and the axle hub.
damage to components can result.
1. Use a round hammer bit and an air hammer to loosen the
1. Park the vehicle on a level surface. Block the wheels to prevent
tapered dowels, if equipped, and axle shaft.
the vehicle from moving. Set the parking brake.
2. Place the round hammer bit against the axle shaft or flange
2. Use a jack to raise the vehicle so that the wheels to be serviced
between the hub studs. Operate the air hammer at alternate
are off the ground. Support the vehicle with safety stands.
locations between the studs to loosen the tapered dowels, if
equipped, and axle shaft from the hub. Figure 3.3. 3. Remove the oil drain plug from the bottom of the axle housing.
Drain the axle lubricant from the housing assembly.
4. On an axle with a driver-controlled main differential lock, shift
the lock into and hold the lock in the locked or engaged
position. The locked position provides enough clearance
between the shift collar and the axle housing for carrier
removal. Refer to Section 6.
5. Disconnect the driveline universal joint from the input yoke or
flange on the carrier. Figure 3.4.

Figure 3.4 6. Remove the stud nuts and washers from the flanges of both
1 axle shafts.
EASY SERVICETM,
MXL 7. Loosen the tapered dowels, if equipped, in the axle flanges of
9
2 both axle shafts. Refer to the procedures in this section for the
removal methods.
3
8 4 Thru-Shaft
5
1. Disconnect the inter-axle drive shaft.
6
7
CAUTION
Always use a flange or yoke bar during removal and
10 installation of the flange yoke nut to prevent damage to the
WING SERIES
PERMALUBETM
11 gearing.
12
14 2. Attach a flange bar to the flange or place a yoke bar over the
13 input or output yoke to hold the yoke or flange while you
remove the pinion nut. Figure 3.5. Refer to Section 10 to make
a yoke bar.
FULL-ROUND
15 Figure 3.5
16
19 17
18
RPL SERIES,
PERMALUBETM
YOKE BAR 1003451c
25 20
21
Figure 3.5
22
24 3. Remove the thru-shaft nut, washer and yoke or flange. Use a
23
1002984e puller tool to remove the yoke or flange from the shaft.
1 FULL-ROUND BEARING CUPS 14 U-JOINT CROSS Figure 3.6.
2 END YOKE 15 CAPSCREWS
3 YOKE SADDLE 16 END YOKE
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 3.4

REMOVING
THE FLANGE
TOP TWO
FASTENERS
REMOVING
THE YOKE
1002712d
Figure 3.6 ROLLER

JACK 1002714d
4. Remove the thru-shaft bearing cage capscrews and washers. Figure 3.8
5. Pull the bearing cage, bearings and thru-shaft assembly from

the axle housing. If necessary, loosen the cage from the 4. Remove all but the top two carrier-to-housing capscrews or
housing with a soft mallet. Figure 3.7. stud nuts and washers. Figure 3.8.
5. Loosen, but do not remove, the top two carrier-to-housing
Figure 3.7
fasteners. The fasteners will hold the carrier in the housing.

THRU-SHAFT AND
BEARING CAGE ASSEMBLY
6. Loosen the differential carrier in the axle housing. Use a plastic
mallet to hit the carrier mounting flange at several points.
7. After the carrier is loosened, remove the top two stud nuts and
washers that hold the assembly in the axle housing.
CAUTION
When using a pry bar, be careful not to damage the carrier or
housing flange. Damage to these surfaces will cause oil leaks.
1002713c
Figure 3.7 8. Use the hydraulic roller jack to remove the carrier from the axle
housing. Use a pry bar that has a round end to help remove the
carrier from the housing.
Differential Carrier from the Axle Housing
1. Disconnect the forward drive shaft from the input yoke. 9. On axles with a driver-controlled main differential lock, if air
pressure is used to shift the differential to the locked or
2. Disconnect the air line from the inter-axle shift unit. engaged position, release the air pressure after the carrier is
3. Place a hydraulic roller jack under the differential carrier to removed from the axle housing while the carrier is still on the
support the assembly. Figure 3.8. roller jack. Disconnect the air hose from the shift unit.
NOTE: A carrier stand is available from SPX Kent-Moore. Refer to

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

10. Use a lifting tool to lift the differential carrier by the input yoke Figure 3.11
or flange and place the assembly in a repair stand. Do not lift

SNAP
by hand. Refer to Section 10 to make a carrier repair stand. RING
Figure 3.9.
Figure 3.9
THRU-SHAFT
SNAP RING SPACER 4008194b
Figure 3.11
3. Remove the snap ring from the bearing cage assembly.
1002715d
4. Install the thru-shaft assembly into a press with the threaded
end DOWN and the bearing cage resting on the press. Press
Figure 3.9 down on the shaft end until the bearing cones, cup spacer and
outer bearing cup are free from the bearing cage.
Disassembly 5. Use a bearing cup remover or other suitable tool to remove the
inner bearing cup from the bearing cage.
Thru-Shaft and Output Bearing Cage
6. Install the thru-shaft in a press with the threads facing UP. Use
1. Remove and discard the oil seal. a suitable tool or fixture to support the bearing cones. Press
2. Remove the thru-shaft snap ring spacer from the thru-shaft. down on the shaft until the bearing cones are free from the
Figure 3.10 and Figure 3.11. shaft.
Figure 3.10
3 4
2
7
1 6
5
4008193a
1 THRU-SHAFT
2 BEARING CAGE
3 INNER BEARING CUP AND CONE
4 CUP SPACER
5 OUTER BEARING CUP AND CONE
6 SNAP RING
7 THRU-SHAFT SNAP RING SPACER
Figure 3.10

Removal Figure 3.13
8 9
7
Input Shaft and Inter-Axle Differential (IAD) 10
5
Refer to Figure 3.12 and Figure 3.13 for the correct carrier version. 4 14
Figure 3.12
13 15
6 12
10 11
8 9
7
3
5
4 2A
16 16
2 17
17
15 1 18
14 19
11 20
1002732d
6 1 OIL SEAL 10 BEARING CONE

3 2 BEARING ADJUSTING RING 11 INPUT SHAFT
2A 2A ADJUSTING RING O-RING (NEW 12 NEEDLE BEARING ASSEMBLIES
18 DESIGN CARRIERS ONLY) 13 THRUST BEARING
2 19
3 BEARING CUP 14 HELICAL GEAR
1 20 4 CAPSCREW 15 BEARING CONE
21
12 13 5 LOCK PLATE 16 REAR SIDE GEAR
22
1002732c 6 COVER 17 SNAP RING
7 OIL BAFFLE FLANGE 18 IAD CASE
1 OIL SEAL 12 OIL SCREEN AND PLUG 8 WASHER 19 PINION GEAR
2 BEARING ADJUSTING RING ASSEMBLY 9 CAPSCREW 20 SPIDER
2A ADJUSTING RING O-RING (NEW 13 INPUT SHAFT NON-PUMP MODEL
DESIGN CARRIERS ONLY) 14 NEEDLE BEARING ASSEMBLIES
3 BEARING CUP 15 THRUST BEARING Figure 3.13
4 CAPSCREW 16 HELICAL GEAR
5 LOCK PLATE 17 BEARING CONE
6 BEARING CONE 18 REAR SIDE GEAR
1. Rotate the carrier in the stand to access the input yoke.
7 COVER 19 SNAP RING Figure 3.14.
8 OIL PUMP GEARS 20 IAD CASE
9 OIL PUMP PLATE 21 PINION GEAR Figure 3.14
10 WASHER 22 SPIDER
11 CAPSCREW
OIL PUMP MODEL
Figure 3.12
1002715d
Figure 3.14
2. Use the correct tool to hold the input yoke in place. Remove the
input yoke nut and washer. Figure 3.15.

Figure 3.15 5. Remove the lock plate and capscrew from the adjusting ring.
Remove the adjusting ring.
6. For new design carriers, remove the O-ring from the adjusting
ring. Inspect the O-ring for damage and replace it if necessary.
7. For oil pump models, use the following procedure to remove
the cover.
A. If equipped with an oil pump, remove the oil screen and
plug assembly from the cover. Clean the oil screen. Refer
1002725c
to Section 4. Figure 3.18.
Figure 3.15
Figure 3.18
3. Use a yoke puller or other suitable tool to remove the yoke from
the input shaft. Figure 3.16.
Figure 3.16
YOKE
PULLER
1002817c
Figure 3.18
B. Remove the capscrews and washers that fasten the cover

1002733c
to the carrier housing. Figure 3.19.
Figure 3.16
Figure 3.19
CAUTION
Carefully remove the oil seal from the adjusting ring. Do not
damage the seal bore when you remove the seal. Damage to
components can result.
4. Pry under the oil seal flange to remove the oil seal from the
adjusting ring. Discard the oil seal. Figure 3.17.
Figure 3.17
ADJUSTING SEAL PRY

RING TOOL 1002723d
Figure 3.19
C. Install the front cover puller over the input shaft and
thread it into the adjusting ring threads in the cover.
Figure 3.20.
4008186a
Figure 3.17

Figure 3.20 9. Remove the IAD housing O-ring from the face of the housing.
Inspect the O-ring for damage such as cracks, cuts or breaks
and replace if necessary. If the O-ring needs to be replaced,
TOOL PART
NUMBER make sure to replace it with one of the same thickness.
COVER 3256N1236
(OIL PUMP 10. Use a high-powered magnet or the magnetic base of a dial
MODELS)
PRY indicator to remove the IAD piston from the carrier housing. If
BAR
necessary, tap on the piston to loosen it for removal.
Figure 3.22 and Figure 3.23.
Figure 3.22
4008153a
Figure 3.20
6
8
D. Use a wrench to tighten the screw on the tool using light
5
pressure. Use pry bars to loosen the cover from the 3 4
carrier housing. Continue tightening the screw until the 2
1
cover is free from the input shaft. Figure 3.20. Remove
the cover. Remove all gasket material from the cover.
7
E. If necessary, remove the bearing cup and cone from the 1002743c
cover. Figure 3.12.
1 HOUSING O-RING
8. For non-pump models, use the following procedure to remove 2 PISTON
3 PISTON O-RING
the cover.
4 SHIFT SHAFT
A. Remove the capscrews and washers that fasten the cover 5 SHIMS
6 CLUTCH COLLAR
to the carrier housing. Remove the cover. Remove all 7 SHIFT FORK
gasket material from the cover. Figure 3.21. 8 SPRING
IAD SHIFT ASSEMBLY
Figure 3.21
Figure 3.22
Figure 3.23
MAGNET
PISTON
1002723c
Figure 3.21 4008158a
Figure 3.23
B. Remove the input bearing cup. Figure 3.13.
C. If necessary, remove the capscrews and washers from the 11. Remove the shift shaft and shims from the bore.
cover and remove the oil baffle.

12. NOTE: There are two versions of spring compression tools that Figure 3.26
can be used to service the carrier: The new style tool, part M12 CAPSCREW IAD SERVICE
AND WASHER
number A-3256V1348, which uses an IAD adapter plate, and
RETAINING
the old style tool, part number A-3256L1234. Figure 3.24 and SCREW
NEW STYLE TOOL,
Figure 3.25. PART NUMBER
A-3256V1348
Figure 3.24
NEW STYLE TOOL, PART NUMBER A-3256V1348

RETAINING
SCREW
IAD
IAD ADAPTER PLATE ADAPTER
A E D PLATE
M12 CAPSCREW
B AND WASHER 4013848a
C
Figure 3.26
Figure 3.27
IAD ADAPTER PLATE

4013812b
A E D
Figure 3.24
Figure 3.25
B
C
OLD STYLE TOOL,

PART NUMBER
4013749a
A-3256L1234
Figure 3.27
13. Install the spring compression tool over the IAD adapter plate
and into the housing (new tool, part number A-3256V1348),
Figure 3.26, or the IAD bore (old tool, part number
4008683b A-3256L1234), Figure 3.28. Position the spring pins through
the recesses in the housing bore and around the fork.
Figure 3.25
Figure 3.28
If you are using a new style spring compression tool, part OLD STYLE TOOL,
number A-3256V1348, place the IAD adapter plate over the PART NUMBER
A-3256L1234
IAD bore. Figure 3.26. Secure the IAD adapter plate to the
COLLAR
carrier using two M10 capscrews and washers in holes A and
SPRING
C. Figure 3.27. COMPRESSION
TOOL
SHIFT FORK 4008154c
Figure 3.28

14. Tighten the retaining screws down into the holes on the IAD
CAUTION
adapter plate or the housing.
If you replace either the bearing cup or the cone, replace both
15. Tighten the tool handle down until the spring is compressed parts in a fully-matched set from the same manufacturer. Do
solid. not mix old and new parts. Damage to components can result.
16. Withdraw and remove the fork from the carrier.
21. Use a press, sleeve and bearing puller to remove the bearing
17. Remove the spring from the bore. cone from the rear side gear. Figure 3.31.
18. Install a nut modified with a lifting loop. Connect a lifting device Figure 3.31
to the nut loop and lift out the input shaft and inter-axle
differential from the carrier. Figure 3.29. PRESS
Figure 3.29
1002731c
Figure 3.31
Disassembly
Input Shaft and Inter-Axle Differential
1002727c 1. Remove the snap ring that fastens the inter-axle differential
Figure 3.29 assembly to the input shaft. Remove the inter-axle differential
assembly from the input shaft. Figure 3.32, Figure 3.33 and
19. Place the assembly on a bench. Remove the lifting nut from the Figure 3.34.
input shaft.
20. Remove the rear side gear and the bearing cone from the
carrier. Figure 3.30.
Figure 3.30
REAR SIDE
GEAR
1002818c
Figure 3.30

10 11 8 9
7
8 9 10
7 5
4 14
5
4 13 15
16
17 6 12
15
14
3
6
2A
3 16
2 17
2A
18 1 18
2 19
19
1 20 11 20
21 1002732d
12 13 22
1002732c 1 OIL SEAL 11 INPUT SHAFT
2 BEARING ADJUSTING RING 12 NEEDLE BEARING ASSEMBLIES
1 OIL SEAL 12 OIL SCREEN AND PLUG 2A ADJUSTING RING O-RING (NEW 13 THRUST BEARING
2 BEARING ADJUSTING RING ASSEMBLY DESIGN CARRIERS ONLY) 14 HELICAL GEAR
2A ADJUSTING RING O-RING (NEW 13 INPUT SHAFT 3 BEARING CUP 15 BEARING CONE
DESIGN CARRIERS ONLY) 14 NEEDLE BEARING ASSEMBLIES 4 CAPSCREW 16 REAR SIDE GEAR
3 BEARING CUP 15 THRUST BEARING 5 LOCK PLATE 17 SNAP RING
4 CAPSCREW 16 HELICAL GEAR 6 COVER 18 IAD CASE
5 LOCK PLATE 17 BEARING CONE 7 OIL BAFFLE FLANGE 19 PINION GEAR
6 BEARING CONE 18 REAR SIDE GEAR 8 WASHER 20 SPIDER
7 COVER 19 SNAP RING 9 CAPSCREW
8 OIL PUMP GEARS 20 IAD CASE 10 BEARING CONE
9 OIL PUMP PLATE 21 PINION GEAR
10 WASHER 22 SPIDER
NON-PUMP MODEL
11 CAPSCREW Figure 3.33
OIL PUMP MODEL
SNAP RING INPUT SHAFT
INTER-AXLE
DIFFERENTIAL
HELICAL
GEAR
1002815c
Figure 3.34
2. Remove the spider assembly from the inter-axle differential

case. Remove the four pinion gears from the spider. Inspect the
components. Replace any damaged components.
3. Remove the helical drive gear and thrust bearing from the input
shaft. Figure 3.35.

Figure 3.35 2. Install a dial indicator onto the flange of the carrier. Place the
tip of the indicator against the convex side of a ring gear tooth.
HELICAL Adjust the dial indicator to ZERO. Figure 3.37.
GEAR
Figure 3.37
DIAL
INDICATOR
THRUST
BEARING
1002814c
Figure 3.35
4. Remove the needle bearing assemblies.

1002722d
5. On non-pump models, use a bearing separator, sleeve and
press to remove the bearing cone from the input shaft. Figure 3.37
Figure 3.36.
3. Read the dial indicator while you slightly rotate the ring gear in
Figure 3.36 both directions. When you rotate the ring gear to measure the
backlash, the drive pinion must not move. Record the reading
PRESS
on the dial indicator.
4. Repeat the procedure at two more locations on the ring gear.
앫 If the smallest of the three measurements is not
0.008-0.018-inch (0.20-0.46 mm): Replace the ring gear
and drive pinion as a set.

4008144a 1. Rotate the carrier in the stand until the ring gear is toward you.
Figure 3.36
NOTE: Each bearing cap must be installed on the carrier leg from
which it was removed. The caps are matched to the carrier legs. Do
Removal not mix bearing caps on carrier legs.
Driver-Controlled Main Differential Lock 2. Use a punch and hammer to mark the position of each bearing
(DCDL) cap on the differential carrier legs. The marks are required to
help you correctly match the caps to the carrier legs during
If the axle is equipped with a driver-controlled main differential lock,
reassembly. Figure 3.38.
refer to Section 6 for removal procedures.
Measure Ring Gear Backlash

Before the carrier is disassembled, use a dial indicator to measure
and record ring gear backlash at three equally spaced teeth on the
ring gear. This will help you to correctly reassemble the ring gear
and drive pinion.
1. Rotate the carrier in the stand to access the ring gear teeth.

BEARING ADJUSTING
CAP RING TOOL
CARRIER
LEG
ADJUSTING
RING OPPOSITE
RING GEAR 1002747d
MATCH
MARKS
Figure 3.40
1002994b
Figure 3.38 6. Remove the capscrews and washers that fasten the bearing
caps to the differential carrier. Check to ensure the bearing
3. Remove the capscrews and lock plates that hold the bearing caps and the carrier have been marked to help you correctly
adjusting rings in position. Figure 3.39. install the caps during reassembly.
7. Remove the bearing caps, adjusting rings and bearing cups
Figure 3.39
from the differential carrier. Figure 3.41.
LOCK Figure 3.41
PLATE BEARING
ADJUSTING
BEARING RING
CAP
THREADED HOLES
IN CAP
1003105f
1002748e
Figure 3.39
Figure 3.41
4. Loosen the bearing cap capscrews, but do not remove them

8. Use an appropriate lifting device to remove the main differential
completely. Loosening the capscrews is required to allow the
case and ring gear assembly from the carrier. Figure 3.42.
adjusting rings to be loosened.
CAUTION
Do not hit the adjusting ring with a hammer. Do not use a
hammer and a drift to loosen the adjusting rings. Damage to
the adjusting rings will result.
5. Use an adjusting ring tool or equivalent tool to loosen the

adjusting rings. Figure 3.40.

PULLER
PRESS
1002750c
1002749h Figure 3.44
Figure 3.42
Disassembly
9. Use a brass drift and hammer to remove the rear side gear
bearing cup from the carrier. Figure 3.43. Main Differential Case and Ring Gear
Figure 3.43
1. Measure and record the gear set backlash. Refer to Measure
Ring Gear Backlash in this section.
REAR SIDE GEAR
BEARING CUP 2. Use a punch and hammer to mark the case halves. The marks
will help you correctly align the case halves during assembly.
Figure 3.45.
Figure 3.45
MARKS ON
BOTH HALVES
OF THE
DIFFERENTIAL
ASSEMBLY
1002816c CASE
Figure 3.43
NOTE: If you replace either the bearing cup or the cone, replace
both parts in a fully-matched set from the same manufacturer. The
bearing cones are not interchangeable.
1002751c
10. If the bearing cones on the main differential case need to be
Figure 3.45
replaced, use a bearing puller to remove the cones.
Figure 3.44.
3. Remove the capscrews that fasten the halves of the main
differential together.
4. Remove the spider, pinions, thrust washers and side gears
from the separated case assembly. Figure 3.46.

THRUST
WASHER
SIDE
SPIDER, PINIONS
GEAR
AND THRUST
WASHERS
1002724c
Figure 3.47
1002752c 2. Remove the drive pinion from the carrier.

Figure 3.46 A. Place the differential carrier into a press so that the
threaded end of the drive pinion is facing UP. Place
NOTE: There are two different design versions of the pinions supports under the carrier mounting flange.
and side gears: the original design and a new version with
B. Place a protector onto the top of the drive pinion shaft.
tooth profile enhancements. If the pinions or side gears must Figure 3.48.
be replaced, the replacement part must be of the same design
version as the mating part. Do not mix original design pinions Figure 3.48
with new design side gears and vice versa. Refer to Section 4
for further information about replacing these parts. PRESS
PROTECTOR
Removal DRIVE
PINION
Ring Gear from the Differential Case
1. For SFR gear set ratios 2.47 and 2.64, remove the bolts from
the flange side of the differential case. For all other gear set
ratios, remove the bolts, washers and nuts that fasten the ring
1002756d
gear to the differential case.
Figure 3.48
2. Use a brass hammer, dead blow hammer or press to remove
the ring gear from the differential case. Take care not to
damage the ring gear teeth. CAUTION
The drive pinion must not fall on the floor when the drive
3. Inspect the hypoid ring gear set for damage. If it is not
pinion is pressed from the carrier. If the drive pinion falls to the
damaged, you can reuse the ring gear set at assembly.
floor, the gear teeth may be damaged.
Drive Pinion C. Press the pinion through the outer bearing cone and the
1. Install a block of wood between the pinion gear teeth and the helical driven gear. Remove the drive pinion from the
carrier to keep the pinion from rotating. Remove the nut and bottom of the carrier.
washer from the drive pinion. Figure 3.47.
D. Remove the outer bearing cone, outer spacer, helical
driven gear, inner spacer and shims from the differential
carrier. Figure 3.49.

Figure 3.49 4. When you remove the inner pinion bearing cup, also remove
the shims from the carrier. Measure and record the thickness
4 5 6
of the shim pack for assembly. Replace any shims that are
2 3 damaged. Figure 3.51.
1
Figure 3.51
11 BEARING
CUP
10
9 SHIMS
8
7
1002755c
1 NUT 7 INNER SPACER

2 WASHER 8 SHIMS
3 OUTER BEARING CONE 9 INNER BEARING CUP
4 OUTER BEARING CUP 10 INNER BEARING CONE
5 OUTER SPACER 11 DRIVE PINION
6 HELICAL DRIVEN GEAR 1002767b
Figure 3.49
Figure 3.51
CAUTION 5. If necessary, remove the inner bearing cone from the drive
If you replace either the bearing cup or the cone, replace both pinion. Place a bearing puller under the inner race to support
parts in a fully-matched set from the same manufacturer. Do the bearing. Place a protector on top of the pinion shaft and
not mix old and new parts. Damage to components can result. press the drive pinion out of the bearing cone. Figure 3.52.
NOTE: If a new ring gear and drive pinion are being installed, the Figure 3.52
inner bearing cup must be removed to change the shim pack

PRESS
between the cup and the carrier.
3. If necessary, remove the inner and the outer bearing cups from
the carrier. Use a hammer and drift to remove the cups from
the carrier. Figure 3.50.
BEARING
PULLER
Figure 3.50
INNER
BEARING
CUP 1002758b
Figure 3.52
OUTER
BEARING CUP 1002757d
Figure 3.50

4 Prepare Parts for Assembly
Hazard Alert Messages Clean, Dry and Inspect Parts

Read and observe all Warning and Caution hazard alert messages in
Clean and Inspect Yokes
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both. CAUTION
Do not install a press-on shaft excluder or POSE™ seal after
WARNING you install a unitized pinion seal. The use of a POSE™ seal will
To prevent serious eye injury, always wear safe eye protection prevent correct seating of the unitized pinion seal on the yoke
when you perform vehicle maintenance or service. and will result in lubricant leakage at the seal. POSE™ seal
installation is recommended only for triple-lip and other
Solvent cleaners can be flammable, poisonous and cause previous design seals.
burns. Examples of solvent cleaners are carbon tetrachloride,
and emulsion-type and petroleum-base cleaners. Read the Do not use thin metal wear sleeves to refresh the yoke surface.
manufacturer’s instructions before using a solvent cleaner, Wear sleeves pressed onto the yoke will prevent correct
then carefully follow the instructions. Also follow the seating of the pinion seal and damage the pinion seal
procedures below. assembly. Wear sleeve usage will cause the seal to leak.
앫 Wear safe eye protection. 1. Clean the ground and polished surface of the yoke journal
앫 Wear clothing that protects your skin. using a clean shop towel and a safe cleaning solvent. Do not
use abrasive cleaners, towels or scrubbers to clean the yoke or
앫 Work in a well-ventilated area.
flange surface. Do not use gasoline.
앫 Do not use gasoline or solvents that contain gasoline.
Gasoline can explode. NOTE: The unitized seal features a rubber inner sleeve that is
designed to seal and rotate with the yoke. This feature allows you to
앫 You must use hot solution tanks or alkaline solutions
reuse a yoke with minor grooves.
correctly. Read the manufacturer’s instructions before
using hot solution tanks and alkaline solutions. Then
2. Inspect the yoke seal surface for grooves.
carefully follow the instructions.
앫 If you find grooves on yoke hubs used with single or
 triple-lip seals: Replace the yokes.
Take care when you use Loctite adhesive to avoid serious
personal injury. Read the manufacturer’s instructions before
앫 If you find grooves on the yoke: Use calipers to measure
using this product. Follow the instructions carefully to prevent the groove diameters. If any groove diameter measures less
irritation to the eyes and skin. If Loctite adhesive material
than the dimensions shown in Figure 4.1, replace the yoke.
gets into your eyes, follow the manufacturer’s emergency
procedures. Have your eyes checked by a physician as soon as Figure 4.1
possible. UNITIZED PINION SEAL (UPS)
When you apply some silicone gasket materials, a small

amount of acid vapor is present. To prevent serious personal
A B
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. If a silicone
gasket material gets into your eyes, follow the manufacturer’s
Yoke Seal Minimum Yoke Diameter
emergency procedures. Have your eyes checked by a Diameter at Groove (Inches)
physician as soon as possible. 3.000/3.005" 2.990"
3.250/3.255" 3.240" 1003390e
A MINIMUM GROOVE DEPTH — DIAMETER

B YOKE SEAL DIAMETER
Figure 4.1

Clean Ground and Polished Parts Bearings

1. Use a cleaning solvent to clean ground or polished parts or
CAUTION
surfaces. Do not use gasoline.
Use soft, clean paper or cloth rags to dry bearings immediately
2. Use a tool with a flat blade if required, to remove sealant after cleaning. Do not use compressed air, which can damage
material from parts. Be careful not to damage the polished or the bearings when they are rotated and dried.
smooth surfaces.
Use soft, clean paper or cloth rags to dry bearings immediately after
CAUTION cleaning. Do not use compressed air.
Do not use hot solution tanks or water and alkaline solutions to
clean ground or polished parts. Damage to parts can result. Prevent Corrosion on Cleaned Parts
1. Apply axle lubricant to cleaned and dried parts that are not
3. Do not clean ground or polished parts with water or steam. Do
damaged and are to be assembled.
not immerse ground or polished parts in a hot solution tank or
use strong alkaline solutions for cleaning, or the smooth 2. To store parts, apply a special material that prevents corrosion
sealing surface may be damaged. to all surfaces. Wrap cleaned parts in a special paper that will
protect the parts from moisture and prevent corrosion.
Clean Rough Parts
Inspect Parts
1. Clean rough parts with the same method as cleaning ground
and polished parts. It is very important to inspect all parts carefully and completely
before the axle or carrier is assembled. Check all parts for wear and
2. Rough parts can be cleaned in hot solution tanks with a weak
replace damaged parts.
or diluted alkaline solution.
1. Inspect the cup, cone, rollers and cage of all tapered roller
3. Parts must remain in hot solution tanks until heated and bearings in the assembly. If any of the following conditions
completely cleaned.
exist, replace the bearing.
4. Parts must be washed with water until all traces of the alkaline
앫 The center of the large-diameter end of the rollers is worn
solution are removed. level with or below the outer surface. Figure 4.2.
Clean Axle Assemblies 앫 The radius at the large-diameter end of the rollers is worn
to a sharp edge. Figure 4.2.
1. A complete axle assembly can be steam cleaned on the
outside to remove dirt. 앫 There is a visible roller groove in the cup or cone inner race
surfaces. The groove can be seen at the small- or
2. Before the axle is steam cleaned, close or place a cover over all
large-diameter end of both parts. Figure 4.3.
openings in the axle assembly. Examples of openings are
breathers or vents in air chambers. 앫 There are deep cracks or breaks in the cup, cone inner race
or roller surfaces. Figure 4.3.
Dry Parts Immediately After Cleaning 앫 There are bright wear marks on the outer surface of the
roller cage. Figure 4.4.
All Parts Except Bearings
Use soft, clean paper, cloth rags or compressed air to dry parts 앫 There is damage on the rollers and on the surfaces of the
cup and cone inner race that touch the rollers. Figure 4.5.
immediately after cleaning.
앫 There is damage on the cup and cone inner race surfaces
that touch the rollers. Figure 4.6.

WORN RADIUS ETCHING AND PITTING
1003020a
WORN SURFACE Figure 4.5

1003017b
Figure 4.3
SPALLING AND FLAKING

WEAR
CRACK
GROOVES
1003021b
Figure 4.6
1003018b 2. Inspect the needle bearing assemblies for damage and replace
if necessary.
Figure 4.3
CAUTION
Figure 4.4
A drive pinion and ring gear are machined as a matched set.

When you replace either a drive pinion or a ring gear, you must
replace both parts as a matched set. Do not mix old and new
parts. Damage to components can result.
3. Inspect hypoid pinions and gears for wear and damage.

Replace pinions and gears that are worn or damaged.
CAUTION
WEAR MARKS When you need to replace a thrust washer, differential side
1003019a
gear or pinion gear, you must replace all of these parts with a
Figure 4.4 new set. Do not mix old and new parts. Damage to
4. Inspect the following main differential assembly parts for wear

or stress. Replace parts that are damaged. Figure 4.7.

앫 Inside surfaces of both case halves Figure 4.8
NEW 14X/145 DESIGN

앫 Both surfaces of all thrust washers DIFFERENTIAL PINION SIDE GEAR
앫 The four trunnion legs of the spider
앫 Teeth and splines of both differential side gears
앫 Teeth, bore and spherical back face of all differential
pinions
Figure 4.7
Inspect 4013353a
inside
surfaces. Figure 4.8
DIFFERENTIAL
CASE HALVES Figure 4.9
ORIGINAL 14X/145 DESIGN

DIFFERENTIAL PINION SIDE GEAR
SIDE GEAR
AND THRUST
WASHER
PINION AND
THRUST Inspect.
WASHER
Inspect. 4013352a
Figure 4.9
DIFFERENTIAL
GEAR NEST
ASSEMBLY
SPIDER CAUTION
Inspect. OR CROSS 1003022i Original and new design parts must NOT be mixed together
during service. The differential pinion version must match the
Figure 4.7
side gear version used. Mixing original design parts with new
design parts will result in a locked up differential and possible
Important Note about Replacing Differential Pinions and
damage to components.
Side Gears
The main differential pinions and side gears on 14X/145 series 5. Inspect the axle shafts for wear and cracks at the flange, shaft
differential carriers have been redesigned as of May 1, 2017. and splines. Replace the axle shafts, if required.
The new design, shown in Figure 4.8, features tooth profile
6. Inspect the breather.
enhancements from the original version, shown in Figure 4.9.
If the pinions or side gears must be replaced, the replacement A. Remove the breather from the axle housing.
part must be of the same design version as the mating part,
B. Clean the breather.
i.e., original design pinions used only with original design side
gears. Original design pinions must NOT be used with new 앫 If the breather remains dirty after cleaning:
design side gears and vice versa. Replace the breather.
NOTE: If original design version parts are not available to C. Apply compressed air to the breather.
match the original design version mating part, you must 앫 If compressed air does not pass through the
replace BOTH the pinions and side gears using new design breather: Replace the breather.
version parts.
D. Install the breather into the axle housing.

Repair or Replace Parts Always replace a damaged drive axle housing. Do not bend or
straighten a damaged housing, which can misalign or weaken it,
Threads must be without damage and clean so that accurate and void Meritor’s warranty.
adjustments and correct torque values can be applied to fasteners
and parts. Removing Fasteners Secured with Adhesive
1. Replace any fastener if the corners of the head are worn. If it is difficult to remove fasteners secured with Dri-Loc, Meritor
2. Replace the washers if damaged. adhesive or Loctite 277 adhesive, use the following procedure.
3. Replace the gaskets, oil seals or grease seals at the time of When you remove fasteners secured with adhesive, slowly heat the
axle or carrier repair. fastener to 350°F (177°C). Do not exceed this temperature, or heat
fasteners quickly. Damage to components can result.
4. Clean the parts and apply new silicone gasket material where
required when the axle or carrier is assembled. Figure 4.10. 1. Heat the fastener for three to five seconds. Try to loosen the
fastener with a wrench. Do not use an impact wrench or hit the
Figure 4.10 fastener with a hammer.
Remove silicone 2. Repeat Step 1 until you can remove the fastener.
gasket from parts.
New Fasteners with Pre-Applied Adhesive

1. Use a wire brush to clean the oil and dirt from threaded holes.
2. Install new fasteners with pre-applied adhesive to assemble
parts. Do not apply adhesives or sealants to fasteners with
pre-applied adhesive, or to fastener holes.
1003023a
3. Tighten the fasteners to the required torque value for that size
Figure 4.10
fastener. No drying time is required for fasteners with
pre-applied adhesive.
5. Remove nicks, mars and burrs from parts with machined or
ground surfaces. Use a fine file, india stone, emery cloth or Original or Used Fasteners
crocus cloth.
1. Use a wire brush to clean the oil, dirt and old adhesive from all
6. Clean and repair the threads of fasteners and holes. Use a die threads and threaded holes.
or tap of the correct size or a fine file.
2. Apply liquid adhesive to the bolt threads or bore threads as
Welding on Axle Housings required for the specific component.
For complete welding instructions, refer to Maintenance Manual 8, 3. Tighten the fasteners to the torque specified in Section 8.
Drive Axle Housings. To obtain this publication, refer to the Service
Notes page on the front inside cover of this manual. Preparing the Differential for Reassembly
1. Use a wire brush to remove hardened adhesive material.
Do Not Bend or Straighten a Damaged Drive
2. Clean the oil and dirt from the outer diameters of the bearing
Axle Housing cups and bearing bores in the carrier and bearing caps. There
is no special cleaning required.
WARNING
Replace damaged or out-of-specification axle components. Do 3. Apply axle lubricant to the bearing cones and the inner
not bend, repair or recondition axle components by welding or diameters of the bearing cups of the main differential. Do not
heat-treating. A bent axle beam reduces axle strength, affects get oil on the outer diameter of the bearing cup and do not
vehicle operation and voids Meritor’s warranty. Serious permit oil to drip onto the bearing bores.
personal injury and damage to components can result.

Carrier-to-Housing Joint Cleaning Procedure Figure 4.11
1. Remove the carrier from the housing. Refer to Section 3. 3M™ BRAND
ROLOC™ GREEN
2. Remove all debris from inside the housing. BRISTLE DISC
CAUTION
Use a rotary tool with a 3M™ brand Roloc™ green bristle disc
to clean the sealant from the housing and carrier face. Use of AXLE HOUSING
MOUNTING
other types of discs may damage the mating surfaces. FACE
CAUTION 4013559a
When cleaning, take care not to remove the base housing Figure 4.11
flange material. Removal of flange material, especially near
the 6 o’clock position, may make the axle more susceptible to
Figure 4.12
leaks. Without sufficient lubricant, damge to components can

occur.
CAUTION
When cleaning, take care not to remove milling marks on the
carrier and housing mating surfaces. Removal of these milling
marks may affect the adhesion of the sealant to the mating
surface and the bond strength of the adhesive, making the
axle more susceptible to leaks. Removal of these milling
marks may also affect flatness of the interface surfaces which 4013543a
can affect the seal between the housing and carrier, making
Figure 4.12
the axle more susceptible to leaks. Without sufficient
lubricant, damage to components can occur.
Figure 4.13
3. Use a rotary tool with a 3M™ brand Roloc™ green bristle Remove old
sealant material.
disc to clean all sealant residue from the housing and carrier
faces. Figure 4.11 and Figure 4.12. Use of other types of discs
may damage the mating surfaces. After cleaning, surfaces
must be clean, dry and free of foreign matter. The
surfaces must not be oily to the touch. Figure 4.13.
IMPORTANT! Do not remove the milling marks on the carrier HOUSING AND
CARRIER SHOWN
and housing mating surfaces. The milling marks provide a
textured surface necessary for the sealant to adhere to the 1003027a
parts. Removal of the milling marks may also affect the
flatness of the mating surfaces. Figure 4.14. Figure 4.13
NOTE: The use of other types of discs with a rotary tool is not
recommended for cleaning. Other types of discs may remove
component material and may reduce flatness on the mating
surfaces which can make the axle more susceptible to leaks.

Figure 4.14 8. Dry the housing and carrier faces.

MILLING MARKS
9. Use a 5/8″ x 11 bottoming tap to clean all old Dri-Loc from
the threaded holes in the axle housing.
General Yoke and U-Joint Reassembly

Install the end yoke hub capscrews by hand after seating the U-joint.
Tighten the capscrews according to the manufacturer’s torque
specifications.
Identification
MILLING MARKS 4013558a
Gear Sets
Figure 4.14
Refer to Table A, Table B, Table C and Table D for information on
identifying gear sets with matched parts. Always check match
4. Check the flatness of the carrier and axle housing mating
numbers to verify that the gear set you will install has matched
surfaces as follows. Place a good machined straight edge
parts. Figure 4.16.
against the carrier or housing mating surface and try to insert a
feeler gauge to check for a gap of 0.003″ (0.076 mm) or Figure 4.16
greater. Figure 4.15. ALTERNATE LOCATIONS
Figure 4.15
MACHINED
STRAIGHT
EDGE
1003031c
1 PART NUMBER, TOOTH COMBINATION NUMBER, GEAR SET MATCH
NUMBER, PINION CONE VARIATION NUMBER
MOUNTING 2 PART NUMBER, TOOTH COMBINATION NUMBER
SURFACE ON 3 GEAR SET MATCH NUMBER, PINION CONE VARIATION NUMBER
AXLE HOUSING 4 PART NUMBER, TOOTH COMBINATION NUMBER, GEAR SET MATCH
4013557a NUMBER
5 PART NUMBER, TOOTH COMBINATION NUMBER, GEAR SET MATCH
Figure 4.15 NUMBER
Figure 4.16
5. Remove metal filings from the magnets inside the housing.
6. Clean the mounting face of the axle housing using Loctite Examples
ODC Free cleaner, brake cleaner or other suitable solvent that
will air dry. Table A: Gear Set Part Numbers
7. Use Loctite ODC Free cleaner or brake cleaner to clean the Part Number Location
carrier faces. Also, spray brake cleaner on the lower internal Conventional ring gear XXXXX, XXXXXK2, On the front
carrier casting area at the 6 o’clock position near the carrier XXXXXK3, XXXXXK4, face or outer
flange and clean this area in order to prevent an oil drip from XXXXXK5 diameter
leaking down/across the carrier flange during assembly. An oil Conventional drive pinion XXXXX, XXXXXK2, At the end
drip at this position may prevent correct adhesion of sealant XXXXXK3, XXXXXK4, at threads
and may result in a leak. XXXXXK5

Table B: Gear Set Tooth Combination Number To determine if the tandem axle ratios operate within allowable
limits, refer to one of the following procedures. Perform the
Drive Pinion Ring Gear
procedure that will work best for the vehicle you are servicing.
Gear Set Teeth Location Location
5-37 = gear set At the end at On the front face Gear Set Ratios Listed on the Identification
has a five-tooth threads or outer diameter
Tags
drive pinion and a
37-tooth ring gear 1. Locate the identification tags attached to the forward and rear
axle differential carriers. Figure 4.17.
NOTE: Meritor drive pinions and ring gears are only available as
matched sets. Each gear in a set has an alphanumeric match
Figure 4.17
number.
Table C: Gear Set Match Number

CARR
IER PART
CUS NO.
TOM
SERI ER NO.
AL NO.
Drive Pinion Ring Gear

RATI
O
Match Number Location Location

M29 At the end of the On the front face
pinion gear head or outer diameter CARRIER PART NO.
1 CUSTOMER NO. 2
SERIAL NO.
RATIO
NOTE: Don’t use the pinion cone variation number when you check 1003452c
for a matched gear set. Use this number when you adjust the pinion 1 FORWARD
depth of the carrier. Refer to Section 5. 2 REAR
Figure 4.17
Table D: Pinion Cone Variation Number
Pinion Cone (PC) Drive Pinion Ring Gear 2. Compare the axle ratios shown on the tags. To operate
Variation Number Location Location correctly, the axle ratios for both axles must be within one
percent of each other. To calculate the percentage difference
PC+3 At the end of the On the outer
between the axle ratios, refer to the equation in Table E.
+2 pinion gear head diameter
+0.01 mm Table E:
PC–5 Larger Ratio – Smaller

Ratio Percentage Difference
–1 X 100 =
Between Axle Ratios
–0.02 mm Smaller Ratio
Check for Mismatched Ratios on 앫 If the axle ratios shown on the identification tags are
not within one percent of each other: Refer to the vehicle
Tandem Axles manufacturer for further information.
For a tandem axle pair to function correctly, the forward and rear
axles must operate with axle ratios within one percent. A
mismatched tandem axle pair can cause carrier overheating, gear
set wear, metal debris to collect on the magnetic drain plug, carrier
lubricant additive depletion, excessive inter-axle differential wear
and noise.

Rotate the Forward Drive Shaft to Check the Figure 4.19
Gear Set Ratio

WARNING
Park the vehicle on a level surface. Block the wheels to
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result. Rotate two full turns
of forward tire.
1. Park the vehicle on a level surface.
1003454b
2. Engage the inter-axle differential and shift the transmission into
Figure 4.19
NEUTRAL.
3. Block the wheels to prevent the vehicle from moving. 7. Note the positions of the tire marks you previously made. On a
4. Use a jack to raise the vehicle until all the tandem drive axle correctly matched tandem axle gear set, both tire marks will be
wheels clear the ground. Support the vehicle with safety within ± 3.6 degrees of each other. Figure 4.20.
stands. 앫 If the positions of the tire marks are more than 3.6
5. Mark the forward and rear tires at identical relative positions. degrees from each other: Refer to the vehicle
Figure 4.18. manufacturer for further information.
Figure 4.20
Figure 4.18
If the mark appears in

the shaded area, the tandem
gear set is incorrectly matched.
MARKS MARKS 1003453a
Figure 4.18
3.6 3.6
6. Turn the forward drive shaft in one direction by hand until the If the mark appears in
this area, the tandem axle
forward tire completes two rotations. Figure 4.19. The forward gear set is correctly matched.
tire must rotate two times only. If the forward tire rotates more 1003455a
than or less than two rotations, the angle measurements you
make in Step 7 will be inaccurate. Figure 4.20
8. Remove the safety stands and lower the vehicle.
Gear Set Teeth Numbers Stamped on the

Forward and Rear Axle Drive Pinions
When the inter-axle driveline or differential carrier is removed for
service, you can check the gear set teeth numbers stamped on the
forward and rear axle drive pinions.

WARNING Figure 4.22

4
damage to components can result. 10 - 7
1. Park the vehicle on a level surface.

2. Block the wheels to prevent the vehicle from moving. LARGER NUMBER
= GEAR SET RATIO
SMALLER NUMBER 1003457c
To Identify the Gear Teeth Number on the Forward
Axle Drive Pinion Figure 4.22
1. Remove the forward carrier cover. Refer to the procedure in

3. Calculate the gear set ratio by dividing the larger number by
Section 3.
the smaller number. Figure 4.22.
2. Look into the carrier housing. Identify and record the gear set
teeth numbers stamped on the drive pinion end. Figure 4.21. Compare Both Gear Set Ratios
1. Both ratios must be within one percent of each other. To
calculate the percentage difference between the axle ratios,
Figure 4.21
refer to the equation in Table E.
4
10 - 7
앫 If the axle ratios shown on the identification tags are
not within one percent of each other: Refer to the vehicle
manufacturer for further information.
2. Install the inter-axle drive shaft. Refer to the vehicle
manufacturer’s procedures.
3. Install the carrier cover. Refer to the procedure in Section 5.
LARGER NUMBER
= GEAR SET RATIO
SMALLER NUMBER 4. Remove the safety stands and lower the vehicle.
1003456d
Figure 4.21
Verify the Actual Gear Set Ratios
You can check the actual gear set ratios when you remove the
3. Calculate the gear set ratio by dividing the larger number by differential carriers from the axle housings for service or repair.
the smaller number. Figure 4.21. Refer to the following procedure to calculate the actual gear set
ratios.
To Identify the Gear Teeth Number on the Rear Axle
Drive Pinion 1. Count the number of ring gear teeth. Figure 4.23.
1. Remove the inter-axle drive shaft. Refer to the vehicle

manufacturer’s procedures.
2. Identify and record the gear set teeth numbers stamped on the
end of the rear axle drive pinion. Figure 4.22.

Figure 4.23 2. Use a jack to raise the vehicle so that the wheels to be serviced
PINION RING are off the ground. Support the vehicle with safety stands.
GEAR TEETH GEAR
TEETH 3. Remove the driveline.
4. Remove the input, output or 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 GEAR TEETH = ACTUAL 6. Use a correct yoke puller tool to remove the yoke.
PINION GEAR TEETH GEAR SET RATIO
1003458e Check for a Tight-Fit Condition
Figure 4.23
NOTE: You can check for a tight-fit condition when you install any
serviceable yoke.
2. Count the number of pinion gear teeth. Figure 4.23.
3. Divide the number of ring gear teeth by the number of pinion 1. Attempt to install the yoke by hand.
gear teeth to determine the actual gear set ratio for each axle. 앫 If the yoke bottoms out against the adjacent bearing:
Figure 4.23. Replace the yoke.
4. Calculate the percentage difference between the gear set 2. Use a correct yoke installation tool to install the yoke.
ratios using the equation in Table E. All ratios must match
within one percent. 3. As you install the yoke, you should detect resistance between
the yoke and shaft.
앫 If the actual gear set ratios are not within one percent
of each other: Refer to the vehicle manufacturer for further 앫 If you do not detect resistance between the yoke and
information. shaft: Replace the yoke.
4. Install and tighten the input, output or pinion shaft nut to the
Inspection correct torque. Refer to Section 8.
5. Install the driveline.
Yoke
6. Remove the safety stands.
All current Meritor axles feature helical splines at the yoke interface.
This feature provides a tight fit between the yoke and input shaft, 7. Lower the vehicle.
output shaft and pinion shaft. For the axle to operate correctly, the
input shaft, output shaft and pinion shaft must fit tightly to the Tire Matching for Tandem Axles
corresponding yoke.
CAUTION
Check for Yoke Wear Unmatched tires on tandem drive units will cause tire wear
and scuffing and possible damage to the drive units. Meritor
WARNING recommends that the tires be matched to within 0.125-inch
Park the vehicle on a level surface. Block the wheels to (3.18 mm) of the same rolling radius, 0.75-inch (19.05 mm) of
prevent the vehicle from moving. Support the vehicle with the same rolling circumference.
jacks. Jacks can slip and fall over. Serious personal injury and The four largest tires should never be installed onto one driving axle
damage to components can result. or the four smallest tires onto the other driving axle. Such tire
mounting will cause an inter-axle fight, unusually high axle lubricant
1. Park the vehicle on a level surface. Block the wheels to prevent temperatures that result in premature lubricant breakdown and
the vehicle from moving. possible costly axle service.

In addition to matching individual tire rolling radii or rolling

circumference, Meritor recommends matching, as nearly as
possible, the total tire circumference of one driving axle to the total
tire circumference of the other driving axle. This will usually result in
satisfactory tandem axle lubricant temperatures that lengthen drive
unit service with higher tire mileage.
Park the vehicle on a level surface. The vehicle must carry a
correctly distributed rated capacity load. All the tires must be the
same size. Measure new tires to verify that they will be correctly
matched.
1. Inflate all tires to the same pressure.
2. Carefully measure the rolling circumference of each tire with a
steel tape.
3. Mark the size on each tire with chalk and arrange the tires in
order of size, largest to smallest.
4. Mount the two largest tires onto one side of one axle and
mount the two smallest onto the opposite side of the same
axle.
5. Mount the four other tires onto the other axle in the same
manner.
6. Test run the vehicle to gather accurate rear axle lubricant
temperature readings on the two axle lubricant temperature
gauges.
7. Vary tire air pressure within the tire manufacturer’s
recommended range so the lubricant temperatures of both
axles are within 30°F or 17°C of each other and not in excess
of 250°F (121°C). This will usually result in uniform tire loading
and good tire life.

5 Assembly and Installation
Hazard Alert Messages pinion position, remove the ring gear and drive pinion. You must
then install the drive pinion with the helical gear and two spacers as
Read and observe all Warning and Caution hazard alert messages in well as the correct shims. Once you’ve obtained the correct
this publication. They provide information that can help prevent adjustments, continue a “final” installation of the ring gear and
serious personal injury, damage to components, or both. adjust as necessary.
WARNING Drive Pinion Shim Pack Thickness

To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. 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
Take care when you use Loctite adhesive to avoid serious pinion depth shims are misplaced during carrier repair, use
personal injury. Read the manufacturer’s instructions before 0.030-inch (0.76 mm) for the initial pinion position and continue to
using this product. Follow the instructions carefully to prevent the “dry fit” drive pinion assembly procedure in this section. In all
irritation to the eyes and skin. If Loctite adhesive material other cases, continue with the following procedure. Figure 5.1.
procedures. Have your eyes checked by a physician as soon as
possible. Figure 5.1
BEARING
Observe all warnings and cautions provided by the press CUP
manufacturer to avoid damage to components and serious
SHIMS
personal injury.
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
it is not damaged. Do not subject the lifting straps to shocks or
drop-loading.
1002767b
Installation Figure 5.1
“Dry Fit” and “Final” Assembly and 1. Use a micrometer to measure the thickness of the shim pack
Installation Procedures that was removed from the differential carrier. Record the
measurement. Figure 5.2.
Correct assembly of the carrier requires a “dry fit” installation of the
drive pinion and ring gear to determine the correct drive pinion shim Figure 5.2
pack thickness. The carrier is then disassembled and reassembled

using the helical gear, spacers and adjusted shim pack. If the drive
pinion is correctly adjusted, perform the “final” installation steps to
complete the installation.
Installing the Drive Pinion, Adjusting Pinion

Depth and Contact Pattern
The procedure in this manual is to perform a “dry fit” installation of
the pinion, bearings and calculated shim pack into the case
WITHOUT the helical gear and two spacers. You must also install the 1002764a
ring gear and set the backlash to 0.012-inch (0.3 mm). After you
check and adjust the tooth contact patterns to determine the correct Figure 5.2

2. Find the pinion cone (PC) variation number on the drive pinion Table F:
you’ll replace. Record the number. Figure 5.3. Refer to the
Examples Inches mm
following examples of pinion cone numbers.
1. Old Shim Pack Thickness 0.030 0.760
앫 PC +6, PC –6, +6 or –6 = 0.006-inch
Old PC Number, PC +2 + 0.002 + 0.050
앫 PC +.15, PC 0.15 mm, +0.15 mm or –0.15 = 0.15 mm
Standard Shim Pack Thickness = 0.032 = 0.810
Figure 5.3 New PC Number, PC +5 – 0.005 – 0.120
New Shim Pack Thickness = 0.027 = 0.690
Old PC Number, PC –2 – 0.002 – 0.050
New PC Number, PC +5 – 0.005 – 0.120
PINION CONE New Shim Pack Thickness = 0.023 = 0.590
VARIATION
NUMBER 3. Old Shim Pack Thickness 0.030 0.760
1003032d Old PC Number, PC +2 + 0.002 + 0.050

Figure 5.3
New PC Number, PC –5 + 0.005 + 0.120
3. If you can’t find the PC number or it’s unreadable, install a new New Shim Pack Thickness = 0.037 = 0.930
shim pack of the same thickness that you measured in Step 1.
4. If the old pinion cone number is a plus (+), ADD the cone Old PC Number, PC –2 – 0.002 – 0.050
number to the old shim pack thickness that was measured in
Step 1.
New PC Number, PC –5 + 0.005 + 0.120
5. If the old pinion cone number is a minus (–), SUBTRACT the
cone number from the old shim pack thickness that was New Shim Pack Thickness = 0.033 = 0.830
measured in Step 1.
6. Find the pinion cone variation number on the new drive pinion Assembly
that will be installed. Record the number.
“Dry Fit”Assembly of the Drive Pinion to
7. If the new pinion cone number is a plus (+), SUBTRACT the Verify Shim Pack
number from the standard shim pack thickness that was
calculated in Step 4 or Step 5. Use new shims to make a shim NOTE: For initial assembly to verify the shim pack, the helical driven
pack to the determined thickness. Refer to Table F. gear and the spacers are not installed. For final assembly, the
8. If the new pinion cone number is a minus (–), ADD the number spacers and preload must be established and the helical driven gear
to the standard shim pack thickness that was calculated in installed.
Step 4 or Step 5. Use new shims to make a shim pack to the
determined thickness. Refer to Table F. 1. If you are installing a new ring gear and drive pinion, the
correct thickness of the shim pack between the pinion inner
bearing cup and the carrier must be determined. Refer to the
procedure in this section before temporarily assembling and
installing the drive pinion assembly according to this
procedure.

If you are installing the original ring gear and drive pinion, Figure 5.5
temporarily install the drive pinion assembly. BEARING

CUP
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 SHIMS
of the bearing. Apply pressure until the bottom of the cone
touches the shoulder on the pinion. Check to ensure the sleeve
does not contact the bearing roller cage during installation.
Figure 5.4.
Figure 5.4
PRESS
1002767b
AND SLEEVE
Figure 5.5
BEARING
ROLLER
CAGE
Figure 5.6
PRESS
1002766b
Figure 5.4
3. Apply axle lubricant to the bearing cups and cones. BEARING

CUP 1002768b
4. If removed, install the shim pack and the inner bearing cup of
the drive pinion. Figure 5.6
A. Place the carrier into a press so that the legs of the carrier
are toward the TOP of the press. 5. If removed, install the outer bearing cup for the drive pinion.
B. Install the correct amount of shims into the bore for the A. Place the carrier into a press so that the legs of the carrier
inner bearing cup of the drive pinion. Figure 5.5. are toward the BOTTOM of the press. Place supports
under the carrier so that the carrier is level.
C. Place the cup into the bore. Figure 5.5.
B. Place the outer bearing cup for the drive pinion into the
D. Place supports under the differential carrier so that the bore of the carrier.
carrier is level.
C. Use a sleeve or a bearing driver tool and a press to install
E. Place a sleeve or a bearing driver tool onto the cup and the cup. Press the cup into the carrier until the bottom of
press the cup into the bore until the bottom of the cup the cup touches the bottom of the bore. If a press is not
touches the shims. If a press is not available, use a available, use a sleeve, a brass drift or a bearing driver
sleeve, a brass drift or a bearing driver tool and a hammer tool and a hammer to install the cup. Figure 5.7.
to install the cup. Figure 5.6.

Figure 5.7 5. Install the drive pinion nut to contact the bearings while
allowing free movement of the pinion.
PRESS
Assembly
Main Differential and Ring Gear
CAUTION
Heat the ring gear before seating it onto the differential case.
Do not press a cold ring gear on the flange case half. A cold
ring gear will damage the case half because of the tight fit.
1002769d
Figure 5.7 1. Wear safe clothing and gloves. Expand the ring gear by heating
the gear in a tank of water to 160-180°F (71-82°C) for 10 to
15 minutes.
Installation
2. Use a lifting tool to safely lift the ring gear from the tank of
Drive Pinion water.
1. Place the drive pinion into the carrier so that the pinion is 3. Install the ring gear onto the flange case half immediately after
through the inner and the outer bearing cups. the gear is heated.
2. Place the carrier into a press so that the legs of the carrier are 앫 If the ring gear does not fit easily on the case half: Heat
toward the BOTTOM of the press. Place supports under the the gear again.
carrier so that the carrier is level. Place a support under the
4. Align the ring gear and flange case half fastener holes. Rotate
head of the drive pinion so that the inner bearing cone on the
the ring gear as necessary.
pinion shaft touches the inner bearing cup in the carrier.
5. Install the bolts, nuts and washers, if equipped, that hold the
3. Place the outer bearing cone onto the pinion shaft.
ring gear to the flange case half.
4. Use a press and a sleeve to install the bearing cone onto the
앫 For gear set ratios 2.47 and 2.64, install the bolts from the
pinion. Apply no more than two tons (1814 kg) of force to verify
flange half side. Figure 5.9.
that the bearing cone is correctly installed. Figure 5.8.
앫 For all other gear set ratios, install the bolts from the ring
Figure 5.8
gear side and install the washers and nuts on the flange
half side. Figure 5.10.
SLEEVE
Figure 5.9
RING
FLANGE GEAR
CASE
HALF
BOLT HEAD
INSTALLED
FROM FRONT
OF FLANGE
CASE HALF
1002770c
Figure 5.8 4008143a
Figure 5.9

Figure 5.10 앫 If the gaps exceed specification at more than three

FLANGE points: Inspect the flange case half and ring gear for the
RING
CASE GEAR problem that causes the gap. Repair or replace parts as
HALF
necessary. Reassemble the ring gear on the flange case
BOLT HEAD half. Reinspect for gaps.
INSTALLED
FROM FRONT Figure 5.12
OF GEAR
1002780e
Figure 5.10
6. Tighten the bolts or nuts to the correct torque value. Follow the
tightening pattern shown in Figure 5.11. Check for
0.001" (0.025 mm)
gap at four
locations. 1002781e
Torque Plus
Fasteners Torque Angle Figure 5.12
Bolts on Gear Set Ratios 320 ± 20 lb-ft 30 ± 5 lb-ft (40

8. Use a press and the correct size sleeve to install the bearing
2.47 and 2.64 (430 ± ± 5 N폷m) plus
cones onto both of the case halves. Ensure the sleeve contacts
30 N폷m) 90 degrees ± 5
the inner race of the bearing during installation and does not
Nuts on All Other Gear 185 ± 25 lb-ft degrees angle
contact the bearing roller cage. Figure 5.13.
Set Ratios (255 ±
35 N폷m) Figure 5.13
PRESS
Figure 5.11
BEARING
CRISSCROSS TIGHTENING PATTERN ROLLER SLEEVE
CAGE
10 BEARING
4
6 CONE
CASE
8 HALF
2
11 12
SUPPORT SUPPORT
1 7
5
3
9 1002782e
4008146a
Figure 5.13
Figure 5.11
9. Apply axle lubricant on the inside surfaces of both case halves,

7. Inspect for gaps between the back surface of the ring gear and
spider or cross, thrust washers, side gears and differential
the flange of the differential case. Use a 0.001-inch
pinions.
(0.025 mm) feeler gauge to inspect at four points around the
assembly. Figure 5.12.

10. Place the flange case half onto a bench with the ring gear teeth Figure 5.16
toward the TOP.

11. Install one thrust washer and side gear into the flange case THRUST
WASHER
half. Figure 5.14.
NOTE: There are two different design versions of the pinions SIDE GEAR
PLAIN
and side gears: the original design and a new version with CASE
HALF
tooth profile enhancements. If the pinions or side gears must
be replaced, the replacement part must be of the same design
version as the mating part. Do not mix original design pinions
with new design side gears and vice versa. Refer to Section 4
for further information about replacing these parts. 1003068c
Figure 5.14
Figure 5.16
SIDE
GEAR 14. Place the plain half of the differential case over the flange half
THRUST
and gears. Rotate the plain half as needed to align the match
WASHER marks. Figure 5.16 and Figure 5.17.
FLANGE
CASE HALF Figure 5.17
PLAIN
CASE
HALF
1003066c
MATCH
Figure 5.14 MARKS
12. Install the spider or cross, differential pinions and thrust

washers into the flange case half. Figure 5.15.
1003069g
Figure 5.15
SPIDER, PINIONS Figure 5.17

AND THRUST
WASHERS
15. Install Dri-Loc or equivalent fasteners into the case halves
using the following procedure. Refer to Section 4 for more
information about Dri-Loc fasteners. If you are reinstalling
used fasteners instead of new, apply Loctite 680 adhesive,
Meritor specification 2297-K-5523, to the threads in the
tapped holes before you install the fasteners.
1003067e A. Install the capscrews into the case halves.
Figure 5.15 B. Tighten the capscrews in a crisscross pattern to
105 ± 10 lb-ft (140 ± 15 N폷m). You may also use an
13. Install the second side gear and thrust washer over the spider alternate method of tightening the capscrews in a
and differential pinions. Figure 5.16. crisscross pattern to 45 ± 5 lb-ft (60 ± 5 N폷m) then
further tightening them to an angle of 90 degrees ± 5
degrees. Figure 5.18.

Figure 5.18
CRISSCROSS TIGHTENING PATTERN

Figure 5.20
15 1
11 5
9
7
TOOL FOR
13 CHECKING
3 RESISTANCE
14 4
8
10
12
6 1003072i
16
2 4008145a
Figure 5.20
Figure 5.18
3. Install the tool into the differential until the splines of the tool
16. Check the rotating resistance of the differential gears. The are engaged with one side gear. Figure 5.20.
differential assembly must rotate freely.
4. Place a torque wrench onto the nut of the tool and rotate the
differential gears. As the differential gears rotate, read the
Check the Rotating Resistance of the value indicated on the torque wrench. Figure 5.21.
Differential Assembly
앫 If the torque value exceeds 50 lb-ft (68 N폷m):
1. Make an inspection tool using an axle shaft that matches the Disassemble the differential gears from the case halves.
spline size of the differential side gear. Cut the shaft to Inspect the case halves, spider, gears and thrust washers.
approximately 12-inches (304.8 mm). Weld a nut onto the end Repair or replace parts. Assemble the parts and repeat Step
of the shaft. Figure 5.19. 2 through Step 4.
Figure 5.19
Figure 5.21
APPROXIMATELY
12" (304.8 MM)
SIDE Read torque

VIEW value.
END WELD NUT

VIEW TO END
OF SHAFT 1003071c
Figure 5.19
1003073e
2. Place the differential and ring gear assembly flat on a work
bench. Figure 5.20. Figure 5.21

Installation 3. Use a lifting device to safely lift the differential and ring gear
assembly and install it into the carrier. The bearing cups must
“Dry Fit” Installation of the Main Differential be flat against the bores between the carrier legs. Figure 5.23.
Case and Ring Gear Assembly Into the 4. Install the bearing adjusting rings between the carrier legs.
Carrier Figure 5.24.
To carry out preliminary checks for drive pinion adjustments, Figure 5.24
perform a “dry fit” installation of the differential and ring gear ADJUSTING
assembly. Do not lubricate, apply sealant or tighten the fasteners RING
completely. Once adjustments are made, also perform the “final”
installation steps to complete the procedure.
1. If the bearing cones on the main differential case were
removed, install a new cone and cup in a fully-matched set
from the same manufacturer. The bearing cones are not
interchangeable. Use a press and sleeve to install the cones
onto the case. Press only on the inner race of the bearing. LEG
Figure 5.22. 1002789f
Figure 5.22
Figure 5.24
PRESS
CAUTION
Correctly install the bearing caps into their original locations
BEARING SLEEVE
CONE
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.
5. Install the bearing caps over the bearings and adjusting rings in
1002786g
the correct location as marked before removal. Figure 5.25.
2. Install the bearing cups over the bearing cones on the case
halves. Figure 5.23.
BEARING
CAP
Figure 5.23
MATCH
MARKS
BEARING
CUP
BEARING
1002790e
CUP
LEG Figure 5.25
BORE
1002788e
Figure 5.23

After checking the tooth contact patterns for top to root position, the
WARNING
backlash can be adjusted within the specification limits for toe to
Use a brass or synthetic mallet for assembly and disassembly
heel position, if needed. To change the location of the pattern, use
procedures. Do not hit steel parts with a steel hammer. Pieces
the following procedures.
components can result. 1. Attach a dial indicator onto the carrier mounting flange.
Figure 5.26.
CAUTION Figure 5.26

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.
1003086e
앫 If the bearing caps do not correctly fit into position:
Figure 5.26
Check the alignment of the match marks between the caps
and carrier. Remove the caps and repeat Step 4 through
Step 6. 2. Adjust the dial indicator so that the plunger is against the tooth
surface.
7. Hand-tighten the adjusting rings against the bearing cups to
position the ring gear to the pinion with 0.012-inch (0.3 mm) 3. Adjust the dial indicator to ZERO. Hold the drive pinion in
backlash. Refer to the backlash procedure in this section. position.
8. Install the capscrews and washers that secure the bearing 4. After reading the dial indicator, rotate the differential and ring
caps to the carrier. Tighten the capscrews to 25 lb-ft (34 N폷m). gear a small amount in both directions against the drive pinion
@ teeth. Ensure the pinion is held in place to prevent rotation.
Refer to Table G.
Do not install the capscrews and lock plates that secure the
bearing adjusting rings in position. After the ring gear is 앫 If the backlash reading is within the specification:
installed, you must adjust the backlash of the ring gear, inspect Check the tooth contact patterns.
the tooth contact patterns, then adjust the preload of the 앫 If the backlash reading is not within the specification:
differential bearings before the lock plates and capscrews Adjust the backlash as needed.
should be installed.
5. Loosen one bearing adjusting ring one notch. Tighten the
opposite ring by the same amount.
Adjustment of Pinion Shim Pack and
앫 To increase the backlash: Move the ring gear away from
Backlash for Contact Pattern the drive pinion. Figure 5.27.
Ring Gear Backlash 앫 To decrease the backlash: Move the ring gear toward the
drive pinion. Figure 5.28.
Table G: Specifications
Initial Backlash Setting Range of Backlash Setting
0.012-inch (0.30 mm) 0.008-0.018-inch
(0.20-0.46 mm)

Tighten adjusting
HEEL
ring this side.
TOE
Loosen adjusting
Increase backlash. ring this side.
1002795b
1003090h
Figure 5.27
Figure 5.29
Figure 5.28
Loosen adjusting The drive side of the 14X forward is the convex side of the ring gear.
ring this side. The drive side takes precedence over the coast side; but the coast
side should be evaluated as well. Figure 5.30.
Decrease backlash.
Figure 5.30
Tighten adjusting TOE

ring this side.
1002796b
Figure 5.28
HEEL
NOTE: When you adjust the backlash, only move the ring gear. Do
not move the drive pinion. DRIVE SIDE
(CONVEX)
6. Repeat Step 2 through Step 5 until the backlash is within 4008201a

specification. Record the setting for use when you adjust the
Figure 5.30
pinion bearing preload.
Check Gear Set Tooth Contact Patterns

Gear Set Tooth Contact Patterns
1. Apply a marking compound, Multan Gear Mark™ 39SY201
Old Gear Set and Old Shim Pack or equivalent, onto approximately 12 gear teeth of the ring
Adjust ring gear tooth contact patterns and backlash to the setting gear. Rotate the ring gear so that the 12 gear teeth are next to
that was measured before the carrier was disassembled. Refer to the drive pinion. Figure 5.31.
the previous table for the correct specification.
New Gear Set and/or New Shim Pack

Adjust ring gear tooth contact patterns and backlash to the correct
specification from Table G.
In the following procedures, movement of the contact pattern along
the length of the tooth is indicated as toward the heel or toe of the
ring gear. Figure 5.29.

GOOD HAND-ROLLED
TOP PATTERN
ROOT
CONCAVE
1003092d 4008131a
2. Rotate the ring gear forward and backward so that the 12 gear Figure 5.33
teeth go past the drive pinion six times to get the contact GOOD HAND-ROLLED
pattern. Repeat, if needed, to get a more clear pattern. PATTERN
3. Look at the contact patterns on the ring gear teeth. Compare

the patterns to Figure 5.32, Figure 5.33, Figure 5.34,
Figure 5.35, Figure 5.36, Figure 5.37, Figure 5.38 and
Figure 5.39.
The top-to-root pattern position is controlled by the shim pack
and should be adjusted first. The toe-heel pattern position is
CONVEX 4008132a
controlled by backlash and should be adjusted last.
NOTE: When the carrier is in operation under load, a good Figure 5.33
contact pattern will extend approximately the full length of the
gear tooth. The top of the pattern will be near the top of the Figure 5.34
gear tooth. Figure 5.40 and Figure 5.41. HIGH PATTERN (BAD)
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
installed deep enough into the carrier. A low contact pattern
indicates that the drive pinion was installed too deep in the
carrier. CONCAVE
4008133a
앫 If the contact pattern requires adjustment: Continue by
following Step 4 to move the contact patterns between the Figure 5.34
top and bottom of the gear teeth.
앫 If the contact patterns are in the center of the gear
teeth: Continue by following Step 5.

HIGH PATTERN (BAD) SHORT AND EXTREME

TOE PATTERN (BAD)
CONVEX 4008134a CONVEX 4008137b
LOW PATTERN (BAD) SHORT AND EXTREME

HEEL PATTERN (BAD)
CONCAVE
4008135a CONVEX 4008138b
LOW PATTERN (BAD)
CONVEX SATISFACTORY PATTERN IN OPERATION

4008136a
1001095d
Figure 5.37
Figure 5.40

SATISFACTORY PATTERN IN OPERATION
CONVEX Decrease shim pack.

4008139a
1002803b
Figure 5.41
Figure 5.43
4. Change the thickness of the shim pack between the pinion

inner bearing cup and the differential carrier to move the NOTE: It may be necessary to repeat the pattern adjustment
contact patterns between the top and the bottom of the gear procedure several times until the correct pattern is achieved.
teeth.
5. Adjust the ring gear backlash within the specification range to
A. Remove the drive pinion, inner bearing cup and shims move the contact patterns to the correct location along the
from the carrier. Refer to Section 3. length of the gear teeth. Refer to the procedure in this section.
앫 To correct a high-contact pattern: Increase the The toe-to-heel position of the contact pattern on a good
thickness of the shim pack. When you increase the hand-rolled gear set is toe-center to center on the convex side
thickness of the shim pack, the drive pinion will move and center to center-heel on the concave side. Figure 5.32 and
toward the ring gear. Figure 5.42. Figure 5.33.
앫 To correct a low contact pattern: Decrease the A. Decrease the backlash to move the convex pattern toward
thickness of the shim pack. When you decrease the the toe and concave pattern toward the heel. Figure 5.44.
thickness of the shim, the drive pinion will move away
from the ring gear. Figure 5.43. B. Increase the backlash to move the convex pattern toward
the heel and the concave pattern toward the toe.
B. Install the inner bearing cup, the shims and the drive Figure 5.45.
pinion into the carrier. Refer to the procedure in this
section. C. Repeat Step 1 through Step 5 until the contact patterns
are at the correct location along the length of the gear
C. Repeat Step 1 through Step 4 until the contact patterns teeth.
are in the center between the top and bottom of the gear
teeth. Figure 5.44
Move pattern on convex side

Figure 5.42
toward toe, loosen
adjusting ring this side.
Decrease
backlash.
Tighten adjusting
ring this side. 4008764a
Figure 5.44
Increase shim pack.

1002802b
Figure 5.42

Figure 5.45 NOTE: If the depth of the drive pinion was changed, then the
Move pattern on convex side amount of the change must be added or subtracted to the thickness
toward heel, tighten of the spacer between the outer bearing cone and the helical driven
adjusting ring this side. gear.
After you obtain the correct gear tooth contact pattern and the
correct shim pack thickness, you must adjust the bearing preload on
Increase Loosen adjusting the drive pinion. The preload is controlled by the thickness of the
backlash. ring this side. spacer between the helical driven gear and the outer bearing cone.
4008765a
Figure 5.46.
Figure 5.45
Figure 5.46
6. If the backlash and contact patterns are correct, mark the OUTER
SPACER
BEARING
position of the adjusting rings for use during the final CONE
installation procedure. Remove the leg cap capscrews. Use an
appropriate lifting device to remove the ring gear and
differential case assembly. DRIVE
PINION
SUPPORT
Installation SUPPORT
“Final” Installation of the Drive Pinion and 1002779e

Bearing Preload Adjustment Figure 5.46
Use the shim pack and backlash established by the “dry fit”
procedure for final assembly. 1. Place the carrier into a press so that the threaded end of the
pinion is UP. Place supports under the flange of the carrier so
The preload of the bearings on the drive pinion is controlled by a
spacer between the outer bearing cone and the helical driven gear. that the carrier is level. Place a wood block under the head of
the pinion. Figure 5.47.
Adjust the preload by changing the size of the spacer.
2. Press the drive pinion out of the outer bearing cone. Remove
앫 To decrease the preload: Use a thicker spacer. the cone. Figure 5.47.
앫 To increase the preload: Use a thinner spacer.
Figure 5.47
If the depth of the drive pinion is changed, the thickness of the OUTER
spacer must also be changed the same amount. Refer to the PRESS
BEARING
following examples. CONE
앫 If a 0.003-inch (0.076 mm) shim is ADDED to the shim pack WOOD BLOCK
to INCREASE the depth of the drive pinion: A 0.003-inch DRIVE
(0.076 mm) larger spacer must be installed to keep the preload PINION
SUPPORT
on the bearings. SUPPORT
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 1002772c
0.003-inch (0.076 mm) smaller spacer must be installed to keep
Figure 5.47
the preload on the bearings.
3. Turn the carrier on its side.

4. Place the helical driven gear over the pinion bore in the carrier Figure 5.49
so that the splines inside the gear are toward the outer bearing
cone. Place the large spacer on top of the helical driven gear PRESS SLEEVE
so that the spacer is toward the inner bearing cup. WOOD BLOCK
Figure 5.48. AND END OF
DRIVE PINION WOOD
MUST TOUCH BLOCK
Figure 5.48
SUPPORT
SUPPORT
DRIVE
PINION
HELICAL 1002774c
DRIVEN
GEAR Figure 5.49
SPACER
VARIABLE
SUPPORT SPACER 9. Cut two pieces of solder approximately 0.5625-inch (14 mm)
SUPPORT long and 0.625-inch (16 mm) wide. Use the two pieces of
1002773c solder or lead as gauge blocks to determine the correct
thickness of the spacer between the helical driven gear and the
Figure 5.48 outer bearing cone.
5. Install the drive pinion into the helical driven gear. Verify that 10. Place the two pieces of solder so that the pieces are opposite
the splines on the pinion engage the splines inside the gear. each other on top of the helical driven gear.
Figure 5.48. 11. Place the outer bearing cone into the cup over the two pieces
of solder on top of the helical driven gear.
CAUTION
12. Remove the support from the flange of the carrier. Place a
Do not apply pressure after the inner bearing cone touches the
sleeve on top of the outer bearing cone. Use a press to apply
inner bearing cup. If more pressure is applied, the cup, cone
two tons (1814 kg) of force to the outer bearing cone. The
and drive pinion will be damaged.
force of the press compresses the solder pieces to the correct
size. Do not apply more than two tons (1814 kg) of force.
6. Install a nut modified with a lifting loop onto the pinion threads.
Figure 5.50.
Lift the pinion, helical gear and case.
7. Place the carrier into a press so that the threaded end of the Figure 5.50
pinion is toward the TOP of the press. Place supports under the PRESS – DO NOT SLEEVE
flange of the carrier so that the carrier is level. Place a wood APPLY MORE THAN
TWO TONS (1814 KG) OUTER
block under the head of the drive pinion so the inner pinion OF PRESSURE BEARING
bearing cone touches the inner bearing cup. Figure 5.49. CONE
HELICAL
PIECES OF DRIVEN
CAUTION SOLDER GEAR
Do not apply pressure after the helical driven gear touches the
spacer in front of the inner bearing on the drive pinion. If WOOD BLOCK –
pressure is applied after the parts touch each other, the gear MUST SUPPORT
will damage the spacer. HEAD OF PINION 1002775c
Figure 5.50
8. Use a press and a sleeve to completely install the helical driven
gear onto the drive pinion. Use a sleeve on the hub of the gear
13. Release the pressure and remove the wood block from under
that fits inside the outer pinion bearing cup bore in the carrier.
the head of the drive pinion.
Press the gear onto the drive pinion until the gear touches the
spacer. Figure 5.49.

14. Use a press and a sleeve to press the shaft of the drive pinion
CAUTION
out of the outer bearing cone. Do not press the shaft of the
Do not apply pressure after the helical driven gear touches the
drive pinion out of the helical driven gear.
spacer in front of the inner bearing on the drive pinion. If
15. Remove the outer bearing cone and the two pieces of solder pressure is applied after the parts touch each other, the gear
from the outer bearing cone. will damage the spacer.
16. Use a micrometer to measure the thicknesses of the
NOTE: The inner bearing cone on the drive pinion must touch the
compressed pieces of solder. Add the measurements of the
inner bearing cup in the carrier when the helical driven gear is being
two pieces and divide by two (2) to determine the average size
installed.
of the pieces. Add 0.004-inch (0.100 mm) to the average size.
Use this dimension to determine the size of the spacer to install
18. Use a press and a sleeve to completely install the helical driven
between the helical driven gear and the outer bearing cone.
gear onto the drive pinion. Use a sleeve on the hub of the gear
Refer to Table H.
that fits inside the outer pinion bearing cup bore in the carrier.
Table H: Press the gear onto the drive pinion until the gear touches the
spacer. Do not remove the wood block at this time.
Example Inch (mm) Figure 5.50.
Thickness of piece number 1 0.504 (12.800) 19. Install the correct size spacer onto the shaft of the pinion in
Thickness of piece number 2 +0.506 (12.852) front of the helical driven gear.
Total thickness 1.010 (25.652)
NOTE: Verify that the wood block is still under the head of the drive
Divide by two (2) to determine 0.505 (12.826) pinion. The inner bearing cone on the pinion must touch the cup in
the average thickness the carrier.
Add 0.004-inch (0.100 mm) to 0.509 (12.926)
determine the thickness of the 20. Install the outer bearing cone onto the shaft of the drive pinion.
spacer Figure 5.51.
A. Place the outer bearing cone onto the shaft of the drive
17. Place a wood block under the head of the drive pinion so that pinion.
the inner bearing cone on the pinion touches the inner bearing
cup in the carrier. Remove the supports from the carrier. B. Place a sleeve onto the top, inner race, of the outer
Figure 5.51. bearing cone.
C. Use a press to apply two tons (1814 kg) of force on the
Figure 5.51
bearing cone to install the cone onto the shaft of the drive
PRESS – DO NOT pinion. Rotate the carrier in both directions, so that the
APPLY MORE THAN SLEEVE
TWO TONS (1814 KG) carrier pivots on the drive pinion, while the cone is being
OUTER
OF PRESSURE BEARING installed to verify that the bearing cone is correctly
ROTATE/OSCILLATE CONE installed.
THE CARRIER SPACER
ABOUT THE PINION
AXIS AS THE CONE HELICAL 21. Release the pressure and remove the carrier from the press.
IS PRESSED ON THE DRIVEN Place the carrier in a repair stand.
PINION GEAR
WOOD BLOCK – SPACER 22. Install the washer and the nut onto the drive pinion. Prevent the
MUST TOUCH drive pinion assembly from rotating by using a fixture to hold
HEAD OF
DRIVE PINION 1002776d the teeth of the helical driven gear or place wood blocks
between the head of the pinion and the carrier wall. Tighten the
Figure 5.51 nut to the specified torque. Refer to Section 8. Remove the
holding fixture or the wood blocks.

23. Use an inch-pound torque wrench or a spring scale to inspect 1. Prevent the drive pinion assembly from rotating by using a
the preload of the bearings on the drive pinion. fixture to hold the teeth of the helical driven gear or place wood
blocks between the head of the pinion and the carrier wall.
Torque Wrench Method Remove the nut and the washer from the shaft of the drive
1. Place an inch-pound (N폷m) torque wrench and the correct pinion.
socket onto the drive pinion nut. Figure 5.52. 2. Place the carrier into a press so that the threaded end of the
pinion is toward the TOP of the press. Place supports under the
Figure 5.52
flange of the carrier so that the carrier is level. Place a wood

block under the head of the pinion. Verify that the wood block
does not touch the head of the drive pinion. Figure 5.53.
Figure 5.53
OUTER
SPACER
Read BEARING
rotating CONE
torque.
1002777d DRIVE
PINION
Figure 5.52 SUPPORT
SUPPORT
2. Use the torque wrench to rotate the drive pinion assembly.

Inspect and record the torque level. Read while rotating the 1002779e
assembly. Record the dynamic or rotating torque not the Figure 5.53
breakaway torque.
3. The preload of the drive pinion bearings must be within the 3. Press the drive pinion out of the bearing cone. Do not press the
following limits. shaft of the drive pinion out of the helical gear. Remove the
outer bearing cone from the differential carrier.
앫 For new pinion bearings: 10-50 lb-in (1.1-5.6 N폷m)
rotational torque 4. Install the correct size spacer onto the shaft of the pinion over
the helical driven gear.
앫 For used pinion bearings: 10-30 lb-in (1.1-3.3 N폷m)
rotational torque 5. Repeat Step 20 through Step 23 of the drive pinion bearing
preload procedure in this section.
앫 If the preload is not within the specified limits: Remove
and replace the spacer between the outer bearing cone and 6. When the preload is within the specified range, install the main
the helical driven gear. Refer to the procedure below. differential case and ring gear assembly into the carrier. Refer
to “final” installation procedure in this section.
— To decrease the preload: Install a thicker spacer.
— To increase the preload: Install a thinner spacer. “Final” Installation of the Main Differential
Case and Ring Gear Assembly Into the
Spacer Replacement
Carrier
NOTE: Do not grind spacers by hand. The surfaces must be parallel 1. Clean and dry the bearing cups and bores of the carrier legs
within 0.0001-inch (0.0020 mm). You must use the correct and bearing caps.
spacers.
2. Apply axle lubricant to the bearing cones and inside surface of
the bearing cups.

NOTE: Meritor specification 2297-P-3994 adhesive will dry in

CAUTION
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.
3. Apply Meritor specification 2297-P-3994, Loctite 680
adhesive or equivalent 360 degrees around the outside
diameter of the bearing cups. The adhesive must not contact
7. Install the bearing caps over the bearings and adjusting rings in
the adjusting ring threads. Refer to Section 4.
the correct location as marked before removal. Figure 5.56.
4. Install the bearing cups over the bearing cones in the case
halves. Figure 5.54. Figure 5.56
Figure 5.54
BEARING
CAP
BEARING MATCH
CUP MARKS
BEARING
CUP
LEG
BORE
1002790e
Figure 5.56
1002788e
WARNING
Figure 5.54
procedures. Do not hit steel parts with a steel hammer. Pieces
5. Use a lifting device to safely lift the differential and ring gear
assembly and install it into the carrier. The bearing cups must
be flat against the bores between the carrier legs. Figure 5.54.
6. Install the bearing adjusting rings between the carrier legs.
CAUTION
Figure 5.55.
Figure 5.55
ADJUSTING
RING installed correctly, the bores and threads in the cap will not
8. 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:
LEG
1002789f Check the alignment of the match marks between the caps
and carrier. Remove the caps and repeat Step 6 through
Figure 5.55 Step 8.

9. 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)
When you turn the adjusting rings, always use a tool that
backlash. Refer to the backlash setting procedure in this
engages two or more opposite notches in the ring. An
section.
adjusting ring tool can be used for this purpose. If the tool does
10. Install the capscrews and washers that secure the bearing not correctly fit into the notches, damage to the lugs will occur.
caps to the carrier. Tighten the capscrews to 25 lb-ft (34 N폷m).
@ 2. Use an adjusting ring tool to loosen the adjusting ring that is
opposite the ring gear. A small amount of end play will show on
Do not install the capscrews and lock plates that secure the
the dial indicator. Figure 5.58.
bearing adjusting rings in position. After the ring gear is
installed, you must adjust the backlash of the ring gear, inspect Figure 5.58
the tooth contact patterns, then adjust the preload of the ADJUSTING
differential bearings before the lock plates and capscrews RING TOOL
should be installed.
Adjustment
Differential Bearings Preload
Use either the dial indicator or the large micrometer method to ADJUSTING
inspect and adjust the main differential bearing preload. RING OPPOSITE
RING GEAR 1002747d
NOTE: The lock plates and capscrews for the adjusting rings are Figure 5.58
installed after the tooth contact pattern is rechecked.
3. Use one of the following methods to move the differential and
Dial Indicator Method the ring gear carefully to the left and right while you read the
1. Attach a dial indicator onto the carrier mounting flange so that dial indicator.
the plunger or the pointer is against the back surface of the A. Insert two pry bars between the bearing adjusting rings
ring gear. Figure 5.57. and the ends of the differential case. The pry bars must
not touch the differential bearings. Figure 5.59.
Figure 5.57
DIAL
B. Insert two pry bars between the differential case or the
INDICATOR ring gear and the carrier at locations other than described
in Step A. The pry bars must not touch the differential
bearings. Figure 5.60.
Figure 5.59
1003078e
Figure 5.57
Bars must not
touch bearings.
1003080h
Figure 5.59

Bars must not

touch bearings.
1003082d
1003081h
Figure 5.62
Figure 5.60
4. Tighten the bearing adjusting ring until the dial indicator reads
Figure 5.63
LARGE
ZERO end play. Move the differential and ring gear to the left MICROMETER
and right as needed. If necessary, repeat Step A or Step B.
5. Tighten each bearing adjusting ring one notch from ZERO. The
bearings of the differential should have a preload of
15-35 lb-in (1.7-3.9 N폷m). Figure 5.61. @
This procedure should expand the caps 0.002-0.009-inch
(0.05-0.23 mm), and place the correct preload on the bearings
when they are installed into the banjo housing.
1003083h
Figure 5.61
Figure 5.63
ADJUSTING
RING TOOL
CAUTION
When turning 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.
Tighten each
3. Use an adjusting ring tool to tighten each bearing adjusting ring
ring one notch. one notch. Figure 5.58.
1002794d
4. Measure distance X and Y again. Compare the measurements
Figure 5.61
with the distances X and Y measured in Step 2. The difference
between the two distances is the amount the bearing caps
6. Proceed to check ring gear runout. have expanded. Refer to Table I.
Large Micrometer Method Table I: Example
1. Hand-tighten the adjusting rings against the differential
Distances X and Y BEFORE = 13.927-inches (353.75 mm)
bearings.
tightening the adjusting rings
2. Use a large micrometer to measure distance X and Y between Distances X and Y AFTER = 13.932-inches (353.87 mm)
the opposite surfaces of the bearing caps. Record the tightening the adjusting rings
measurement. Figure 5.62 and Figure 5.63.

2. Adjust the dial indicator so that the plunger or pointer is against

13.932-inches – = 0.005-inch difference
13.927-inches the back surface of the ring gear. Figure 5.64. Set the dial
indicator to ZERO.
353.87 mm – 353.75 mm = 0.12 mm difference
3. Rotate the differential and ring gear. Read the dial indicator.
5. If the difference is at or within the specification in Table J: The ring gear runout must not exceed 0.008-inch (0.200 mm).
Continue by checking the runout.
앫 If the ring gear runout is within the specification: Set
If the difference is more or less than the specification: the backlash and contact patterns to the settings
Repeat as needed. determined in the “Check Gear Set Tooth Contact Patterns”
procedure in this section.
NOTE: The maximum legspread between bearing caps for the
140/145/14X series cannot exceed 13.941-inches 앫 If the ring gear runout exceeds the specification:
(354.101 mm). Remove the differential and ring gear assembly from the
carrier. Refer to Section 3.
Table J: Expansion Between Bearing Caps
A. Inspect the differential parts, including the carrier, for
Required Deflection wear and damage. Repair or replace parts as necessary.
Micromet
B. Install the main differential case and ring gear assembly
Axle Series er Size Inches Millimeters
into the carrier. Refer to the procedure in this section.
120/125 12-13″ 0.008-0.01 0.15-0.33
3 C. Repeat the procedure for preload adjustment of the
differential side bearings.
140/145/ 13-14″ 0.002-0.00 0.05-0.23
14X 9 4. Once the adjustments are complete, tighten the bearing cap
capscrews down to a final torque of 360 ± 40 lb-ft (485 ±
160/164 16-17″ 0.002-0.00 0.05-0.23
55 N폷m). You may also use the alternate method of tightening
9
the capscrews to 150 ± 35 lb-ft (200 ± 50 N폷m) then to an
180/185 17-18″ 0.006-0.01 0.15-0.33 angle of 90 degrees ± 5 degrees. @
3
5. Once all adjustments are complete, install the capscrews and
lock plates that hold the two bearing adjusting rings in position.
Ring Gear Runout Use the following procedures.
1. Attach a dial indicator onto the carrier mounting flange.
A. Install the lock plate onto the bearing cap so that the tab
Figure 5.64.
is between the lugs of the adjusting ring. Figure 5.65.
Figure 5.64
Figure 5.65
Rotate ring gear.
LOCK
DIAL PLATE
INDICATOR
THREADED HOLES
IN CAP
1003084g
Figure 5.64
1003105f
Figure 5.65

B. Install the capscrews that hold the lock plate to the Figure 5.67
bearing cap. New capscrews include a locking patch,

10 11
which can only be used once. If you are installing used 9
8
capscrews, apply Loctite 242 threadlocker to the 7
capscrew threads before you install the capscrews.
5
Tighten the capscrews to the correct torque value. Refer 4
16
to Section 8. Figure 5.65.
17
15
14
Installation
Thrust Screw (44,000-Lb Model Only) 6
3
1. Rotate the carrier in the repair stand until the ring gear is 2A
18
toward the TOP. 2 19
1 20
2. Apply sealant, Meritor specification 2297-D-7076, in a 21
continuous 0.60-inch (1.5 mm) bead around the thread 12 13 22
1002732c
circumference.
1 OIL SEAL 12 OIL SCREEN AND PLUG
3. Install the thrust screw with the jam nut into the carrier. 2 BEARING ADJUSTING RING ASSEMBLY
2A ADJUSTING RING O-RING (NEW 13 INPUT SHAFT
4. Use a feeler gauge to verify that the clearance between the DESIGN CARRIERS ONLY) 14 NEEDLE BEARING ASSEMBLIES
thrust screw and the back face of the ring gear is 3 BEARING CUP 15 THRUST BEARING
0.025-0.045-inch (0.64-1.14 mm). Figure 5.66. 4 CAPSCREW 16 HELICAL GEAR
5 LOCK PLATE 17 BEARING CONE
6 BEARING CONE 18 REAR SIDE GEAR
Figure 5.66
7 COVER 19 SNAP RING

JAM NUT 8 OIL PUMP GEARS 20 IAD CASE
9 OIL PUMP PLATE 21 PINION GEAR
10 WASHER 22 SPIDER
11 CAPSCREW
OIL PUMP MODEL
Figure 5.67
THRUST
2. Install the needle bearing assemblies and thrust bearing onto
SCREW RING the input shaft. Figure 5.68.
GEAR
4007402b
Figure 5.68
Figure 5.66
HELICAL
GEAR
5. Once the correct gap is achieved, use a suitable tool to prevent
rotation of the thrust screw and tighten the jam nut to 150 ±
50 lb-ft (200 ± 60 N폷m). @
Assembly
THRUST
Input Shaft and Inter-Axle Differential (Oil BEARING
1002814d
Pump Model)
Figure 5.68
1. Apply axle lubricant, Meritor specification 2297-U-4519, to the
parts as they are being assembled. Figure 5.67.

3. Install the helical gear onto the input shaft. Figure 5.68. Figure 5.70
4. If disassembled, assemble the inter-axle differential. 7

8 9
10
A. Apply axle lubricant, Meritor specification 2297-U-4519, 5
to all of the inter-axle differential parts. 4 14
B. Install the spider into the inter-axle differential case. 13 15

6 12
C. Install the pinion gears onto the spider.
5. Install the inter-axle differential onto the input shaft against the
helical gear. Install the snap ring that fastens the inter-axle 3
differential to the shaft. Figure 5.69. 2A
16
2 17
1
Figure 5.69
18
19
SNAP RING INPUT SHAFT 11 20
1002732d
INTER-AXLE 1 OIL SEAL 11 INPUT SHAFT

DIFFERENTIAL
2 BEARING ADJUSTING RING 12 NEEDLE BEARING ASSEMBLIES
2A ADJUSTING RING O-RING (NEW 13 THRUST BEARING
HELICAL DESIGN CARRIERS ONLY) 14 HELICAL GEAR
GEAR 3 BEARING CUP 15 BEARING CONE
4 CAPSCREW 16 REAR SIDE GEAR
5 LOCK PLATE 17 SNAP RING
6 COVER 18 IAD CASE
1002815c 7 OIL BAFFLE FLANGE 19 PINION GEAR
8 WASHER 20 SPIDER
Figure 5.69 9 CAPSCREW
10 BEARING CONE
NOTE: If you replace either the bearing cup or the cone, replace NON-PUMP MODEL
both parts in a fully-matched set from the same manufacturer. Figure 5.70
6. If removed, use a press and sleeve to drive the bearing cone 2. Use a press and sleeve to install the bearing cone onto the
onto the rear side gear until it is flat against the shoulder. input shaft until it is flat against the shoulder. Figure 5.71.
Input Shaft and Inter-Axle Differential Figure 5.71
(Non-Pump Model)
1. Apply axle lubricant, Meritor specification 2297-U-4519, to the PRESS
parts as they are being assembled. Figure 5.70. SLEEVE
BEARING
CONE
1002543c
Figure 5.71
3. Install the needle bearing assemblies and thrust bearing onto

the input shaft. Figure 5.72.

Figure 5.72
Installation
HELICAL
GEAR Input Shaft Assembly and Cover (Oil Pump
Models)
The carrier must be positioned upright with the pinion shaft in the
vertical position for installation procedures. Refer to Figure 5.76 for
correct carrier position.
THRUST 1. If removed, install the bearing cup for the rear side gear into
BEARING the differential carrier. Use a press and a sleeve to install the
1002814c
cup into the carrier. If a press is not available, use a sleeve or a
Figure 5.72 long, brass drift and a hammer to install the cup. The cup is
correctly installed when the bottom of the cup is seated against
4. Install the helical gear onto the input shaft. Figure 5.72. the bottom of the bore. Figure 5.74.
5. If disassembled, assemble the inter-axle differential. Figure 5.74
A. Apply axle lubricant, Meritor specification 2297-U-4519,

BEARING
to all of the inter-axle differential parts. CUP
B. Install the spider into the inter-axle differential case.

C. Install the pinion gears onto the spider.
6. Install the inter-axle differential onto the input shaft against the
helical gear. Install the snap ring that fastens the inter-axle
differential to the shaft. Figure 5.73.
4008947a
Figure 5.73
Figure 5.74
SNAP RING INPUT SHAFT
INTER-AXLE
DIFFERENTIAL both parts in a fully-matched set from the same manufacturer.
HELICAL 2. Install the rear side gear with the bearing cone into the bearing
GEAR cup in the carrier housing. Figure 5.75.
Figure 5.75
1002815c
REAR SIDE
Figure 5.73 GEAR
both parts in a fully-matched set from the same manufacturer.
7. If removed, use a press and sleeve to drive the bearing cone

onto the rear side gear until it is flat against the shoulder.
4008947b
Figure 5.75

3. Install a nut modified with a lifting loop onto the end of the B. If you are using a new style spring compression tool, part
input shaft. Connect a suitable lifting device to the nut loop. Lift number A-3256V1348, place the IAD adapter plate over
and lower the input shaft assembly into the carrier. Rotate the the IAD bore. Figure 5.78. Secure the IAD adapter plate to
shaft to engage the IAD gears with the rear side gear. the carrier using two M10 capscrews and washers in
Figure 5.76. holes A and C. Figure 5.79.
M12 CAPSCREW IAD SERVICE

AND WASHER
RETAINING
SCREW
NEW STYLE TOOL,
PART NUMBER
A-3256V1348
RETAINING
SCREW
IAD
ADAPTER
PLATE
M12 CAPSCREW
AND WASHER 4013848a
1002727c Figure 5.78
Figure 5.76
Figure 5.79
IAD ADAPTER PLATE

4. Install and test the IAD lock shift unit using the following
procedure. A E D
A. Install the spring in the housing. Figure 5.77.
B
Figure 5.77
8 4013749a
5
3 4 Figure 5.79
2
1
C. Install the spring compression tool over the IAD adapter
plate and into the housing (new tool, part number
7
1002743c
A-3256V1348), Figure 5.78, or the IAD bore (old tool,
part number A-3256L1234), Figure 5.80. Position the
1 HOUSING O-RING spring pins through the recesses in the housing bore and
2 PISTON
3 PISTON O-RING around the fork.
4 SHIFT SHAFT
5 SHIMS
6 CLUTCH COLLAR
7 SHIFT FORK
8 SPRING
Figure 5.77

Figure 5.80 I. Insert a centering tool, screwdriver or other suitable tool

OLD STYLE TOOL, to align the fork with the case shift shaft housing bore.
PART NUMBER Refer to Section 10 for a tool drawing.
A-3256L1234
COLLAR J. Apply grease, Meritor specification 2297-U-4519 or
SPRING 1199-U-1113, to the tapered surface of the shift shaft.
COMPRESSION Insert the shift shaft into the housing bore through the
TOOL
shift fork and spring. Figure 5.81. If necessary, install a
centering tool or other suitable tool to center and seat the
shift shaft. Refer to Section 10 for a tool drawing.
K. Install the same amount of shims as were removed.
SHIFT FORK 4008154c L. Apply grease, Meritor specification 2297-U-4519 or
1199-U-1113, to the O-ring and piston. Install the O-ring
Figure 5.80
onto the piston. Install the piston into the housing with the
stamped ’M’ or solid flat surface facing the front cover.
D. Tighten the retaining screws down into the holes on the Figure 5.82.
IAD adapter plate or the housing.
NOTE: The current piston has an ’M’ stamped on the top
E. Tighten the tool handle down until the spring is surface and is no longer solid flat.
compressed solid.
F. Install the clutch collar onto the fork. Slide clutch collar Figure 5.82
and fork over the input shaft. Insert the end of the fork
above the compressed spring while you install the clutch
collar onto the input shaft. The machined area of the fork
shaft end must be toward the piston bore and the teeth of
the clutch collar must face the helical gear. Ensure the
spring is correctly seated within the raised areas of the
fork. Figure 5.81.
Figure 5.81 1002845d
CLUTCH Figure 5.82

COLLAR
M. Install an O-ring in both the shift tester and housing

SHIFT groove prior to installing the shift tester.
FORK
SPRING N. Install the shift tester over the IAD bore. Tighten the tool
screws in the bolt holes used to fasten the cover to the
SHIFT housing. Apply shop air at the tester fitting. Figure 5.83.
PISTON SHAFT
SHIMS 4007400a
Figure 5.81
G. While holding the fork in position, loosen the tool handle

to release the spring. Loosen the retaining screws and
remove the spring compression tool.
H. If used, remove the capscrews and washers and remove
the IAD adapter plate from the carrier.

Figure 5.83 NOTE: The sealant will dry in approximately two hours. You must
complete the procedure within two hours from the time you apply
SHIFTER
TESTER the sealant. If two hours have passed since the application, clean
the sealant from the parts and apply new sealant.
SHOP
AIR
6. Apply grey sealant, Meritor specification 2297-H-7054, or blue
sealant, Meritor specification 2297-D-7076, in a continuous
1/8-inch (3.175 mm) wide bead to the carrier housing face. Do
not allow the sealant to enter into the IAD piston bore. Be ready
to install the cover within 20 minutes of applying the sealant.
Figure 5.85.
4008155a Figure 5.85
Figure 5.83
O. Ensure the collar moves freely on the input shaft and is

not binding on the fork levers.
P. Check the clearance between the teeth of the clutch collar
and the helical gear to ensure there is a clearance of
0.020-0.040-inch (0.5-1.0 mm). If necessary, remove
the piston and add or remove shims. Reassemble and
retest until correct clearance is achieved. Figure 5.81.
1002816e
Q. Remove the shop air from the shift tester. Loosen the tool
Figure 5.85
screws and remove the shift tester.
R. Grease the IAD front cover-to-housing O-ring and install it NOTE: If you are replacing the cover of an old design carrier,
onto the face of the carrier housing. If you are replacing Meritor recommends using a new design cover as a replacement,
the O-ring with a new O-ring, use a 0.07″ (1.78 mm) size although the old design cover can be used if preferred. Note that the
O-ring for earlier carriers or 0.21″ (5.33 mm) size O-ring adjusting rings in the new and old design covers are not
for later carriers. Use care not to get excess grease on the interchangeable. For more information, refer to New and Old Design
front face of the carrier. Figure 5.84. Carriers in Section 2.
Figure 5.84
7. With the input shaft cup and cone removed, install the cover on
the carrier housing and verify it is fully seated. Rotate the input
shaft and verify the pump teeth are engaged with the shaft
PISTON
splines. Install the washers and capscrews. Replace the two
locating dowels with washers and capscrews. Tighten the
The current
M capscrews using a crisscross pattern to 90 ± 15 lb-ft
piston has an (125 ± 20 N폷m). You may also use an alternate method of
‘M’ stamped
O-RING
tightening the capscrews in a crisscross pattern to 30 ± 5 lb-ft
on it. INSTALLED (40 ± 5 N폷m), then tighten the capscrews an additional 90 ± 5
ON HOUSING degrees using a crisscross pattern. Figure 5.86. @
4008192a
Figure 5.84
5. Install two locating dowels, one on each side, into the carrier
housing face.

SLEEVE DIMENSION
70 MM O.D.
60 MM
I.D.
YOKE
INSTALLATION
TOOL
1002723d
SLEEVE
125.50 MM
Figure 5.86
BEARING
8. Place the bearing cone onto the input shaft. Use an input
bearing installation tool and wrench, or a yoke installation tool 4011955a
and sleeve to press the bearing cone down until it bottoms out Figure 5.88
on the shoulder of the input shaft. Figure 5.87 and
Figure 5.88. NOTE: Do not install the cup more than part way or you may not be
able to adjust the end play correctly. You will then have to remove
Figure 5.87
the cover, bearing and cup again for reinstallation.

TOOL PART NUMBER
3256M1235 9. Install the bearing cup over the bearing cone. Use a hammer
and brass drift, or press and sleeve to install the bearing cup
PART WAY into the cover. The cup will be installed and correctly
INPUT BEARING seated when the adjusting ring is set to the correct end play.
BEARING
INSTALLATION Figure 5.89.
TOOL
Figure 5.89
4008160a HAMMER
Figure 5.87
BRASS
NOTE: The sleeves provided with the yoke installation tool are DRIFT
not long enough to install the bearing cone on an oil pump
model cover. You must use a 125.50 mm-long sleeve (60 mm
I.D, 75 mm O.D) in place of the sleeves provided with the tool
BEARING
to install the bearing cone. CUP
4008157a
Figure 5.89

10. Apply thread sealant, Meritor specification 2297-U-6417, to 2. Install the rear side gear with the bearing cone into the bearing
the oil screen and plug assembly threads. Install the oil screen cup in the carrier housing. Figure 5.92.
and plug assembly into the cover and tighten it to a minimum
of 48 lb-ft (65 N폷m). Figure 5.90. @ Figure 5.92
Figure 5.90 REAR SIDE

GEAR
4008947b
1002817d
Figure 5.92
Figure 5.90
3. Install a nut modified with a lifting loop onto the end of the
input shaft. Connect a suitable lifting device to the nut loop. Lift
Input Shaft Assembly and Cover (Non-Pump and lower the input shaft assembly into the carrier. Rotate the
Models) shaft to engage the IAD gears with the rear side gear.
The carrier must be positioned upright with the pinion shaft in the Figure 5.93.
vertical position for installation procedures. Refer to Figure 5.93 for
correct carrier position. Figure 5.93
1. If removed, install the bearing cup for the rear side gear into
the differential carrier. Use a press and a sleeve to install the
cup into the carrier. If a press is not available, use a sleeve or a
long, brass drift and a hammer to install the cup. The cup is
correctly installed when the bottom of the cup is seated against
the bottom of the bore. Figure 5.91.
Figure 5.91
BEARING
CUP
1002727d
Figure 5.93
4. Install and test the IAD lock shift unit using the following
4008947a procedure.
Figure 5.91 A. Install the spring in the housing. Figure 5.94.
both parts in a fully-matched set from the same manufacturer.

IAD ADAPTER PLATE

6
A E D
8
5
3 4
2 B
1 C
7
1002743c 4013749a
1 HOUSING O-RING Figure 5.96

2 PISTON
3 PISTON O-RING
4 SHIFT SHAFT C. Install the spring compression tool over the IAD adapter
5 SHIMS plate and into the housing (new tool, part number
6 CLUTCH COLLAR
A-3256V1348), Figure 5.95, or the IAD bore (old tool,
7 SHIFT FORK
8 SPRING part number A-3256L1234), Figure 5.97. Position the
Figure 5.94
spring pins through the recesses in the housing bore and
around the fork.
B. If you are using a new style compression tool, part
Figure 5.97
number A-3256V1348, place the IAD adapter plate over

OLD STYLE TOOL,
the IAD bore. Figure 5.95. Secure the IAD adapter plate to PART NUMBER
the carrier using two M10 capscrews and washers in A-3256L1234
holes A and C. Figure 5.96. COLLAR
SPRING
Figure 5.95 COMPRESSION
TOOL
M12 CAPSCREW IAD SERVICE
AND WASHER
RETAINING
SCREW
NEW STYLE TOOL,
PART NUMBER
A-3256V1348
SHIFT FORK 4008154c
Figure 5.97
RETAINING
SCREW
D. Tighten the retaining screws down into the holes on the
IAD
ADAPTER
IAD adapter plate or the housing.
PLATE
E. Tighten the tool handle down until the spring is
M12 CAPSCREW
AND WASHER 4013848a compressed solid.
Figure 5.95

F. Install the clutch collar onto the fork. Slide clutch collar Figure 5.99
and fork over the input shaft. Insert the end of the fork
above the compressed spring while you install the clutch
collar onto the input shaft. The machined area of the fork
shaft end must be toward the piston bore and the teeth of
the clutch collar must face the helical gear. Ensure the
spring is correctly seated within the raised areas of the
fork. Figure 5.98.
Figure 5.98
1002845d
CLUTCH
COLLAR Figure 5.99
M. Install the shift tester over the IAD bore. Tighten the tool
SHIFT
FORK screws in the bolt holes used to fasten the cover to the
SPRING housing. Apply shop air at the tester fitting. Figure 5.100.
Figure 5.100
SHIFT
PISTON SHAFT TOOL PART NUMBER
SHIMS 4007400a 3256P1238
SHIFTER TESTER
Figure 5.98 SHOP
AIR
G. While holding the fork in position, loosen the tool handle

to release the spring. Loosen the retaining screws and
remove the spring compression tool.
H. If used, remove the capscrews and washers and remove
the IAD adapter plate from the carrier.
I. Insert a centering tool, screwdriver or other suitable tool 4008155b
to align the fork with the case shift shaft housing bore.
Figure 5.100
Refer to Section 10 for a tool drawing.
J. Apply grease, Meritor specification 2297-U-4519 or N. Ensure the collar moves freely on the input shaft and is
1199-U-1113, to the tapered surface of the shift shaft. not binding on the fork levers.
Insert the shift shaft into the housing bore through the
O. Check the clearance between the teeth of the clutch collar
shift fork and spring. Figure 5.98. If necessary, install a
and the helical gear to ensure there is a clearance of
centering tool or other suitable tool to center and seat the
0.020-0.040-inch (0.5-1.0 mm). If necessary, remove
shift shaft. Refer to Section 10 for a tool drawing.
the piston and add or remove shims. Reassemble and
K. Install the same amount of shims as were removed. retest until correct clearance is achieved. Figure 5.98.
L. Apply grease, Meritor specification 2297-U-4519 or P. Remove the shop air from the shift tester. Loosen the tool
1199-U-1113, to the O-ring and piston. Install the O-ring screws and remove the shift tester.
onto the piston. Install the piston into the housing with the
Q. Grease the IAD front cover-to-housing O-ring and install it
solid flat surface facing the front cover. Figure 5.99.
onto the face of the carrier housing. If you are replacing
the O-ring with a new O-ring, use a 0.07″ (1.78 mm) size
O-ring for earlier carriers or 0.21″ (5.33 mm) size O-ring
for later carriers. Use care not to get excess grease on the
front face of the carrier. Figure 5.101.

Figure 5.101 NOTE: If you are replacing the cover of an old design carrier,
Meritor recommends using a new design cover as a replacement,
although the old design cover can be used if preferred. Note that the
adjusting rings in the new and old design covers are not
PISTON
interchangeable. For more information, refer to New and Old Design
The current
M Carriers in Section 2.
piston has an
‘M’ stamped 8. Install the cover on the carrier housing. Install the washers and
O-RING
on it. INSTALLED
capscrews. Replace the two locating dowels with washers and
ON HOUSING capscrews. Tighten the capscrews using a crisscross pattern
4008192a to 90 ± 15 lb-ft (125 ± 20 N폷m). You may also use an alternate
method of tightening the capscrews in a crisscross pattern to
Figure 5.101
30 ± 5 lb-ft (40 ± 5 N폷m), then tighten the capscrews an
additional 90 ± 5 degrees using a crisscross pattern.
5. If removed, install the oil baffle, washers and capscrews into
Figure 5.103. @
the housing cover. Tighten the capscrews to 5-7 lb-ft
(7-10 N폷m). @ Figure 5.103
6. Install two locating dowels, one on each side, into the carrier
housing face.
NOTE: The sealant will dry in approximately two hours. You must
complete the procedure within two hours from the time you apply
the sealant. If two hours have passed since the application, clean
the sealant from the parts and apply new sealant.
7. Apply grey sealant, Meritor specification 2297-H-7054, or blue

sealant, Meritor specification 2297-D-7076, in a continuous
1002723c
1/8-inch (3.175 mm) wide bead to the carrier housing face. Do
not allow the sealant to enter into the IAD piston bore. Be ready Figure 5.103
to install the cover within 20 minutes of applying the sealant.
Figure 5.102. NOTE: Do not install the cup more than part way or you may not be
able to adjust the end play correctly. You will then have to remove
Figure 5.102
the cover, bearing and cup again for reinstallation.
9. Install the bearing cup over the bearing cone. Use a hammer
and brass drift, or press and sleeve to install the bearing cup
part way into the cover. The cup will be installed and correctly
seated when the adjusting ring is set to the correct end play.
Figure 5.104.
1002816e
Figure 5.102

HAMMER Clean sealant

from threads.
BRASS
DRIFT
BEARING
CUP
ADJUSTING CARRIER
4008157b RING COVER 4009826a
Inspection NOTE: Suitable tools for cleaning the cover threads are picks, small
wire brushes, cleaning solvents such as brake cleaner and
Adjust the Input Bearing End Play compressed air.
2. Place a rag in the carrier cover opening to prevent debris from

CAUTION
entering the bearing area during the cleaning process. Clean
You must be ready immediately to install the adjusting ring and
the old sealant from the axle carrier mating threads in the
yoke once you apply adhesive sealant. The adhesive sealant
cover.
has a limited time before it dries. You must install and adjust
the end play before it dries or the adhesive sealant will not set 3. For new design covers, apply a small amount of axle oil to the
correctly. O-ring and to the O-ring sealing journal inside the carrier cover.
Use only the amount of oil necessary to lubricate the O-ring
For gauging end play, the preferred method is to have the carrier in and journal to prevent excess oil from spreading to other parts.
the vertical position. Install the O-ring on the adjusting ring. Figure 5.106.
1. Clean the old sealant from the input bearing adjusting ring.
Figure 5.106
Figure 5.105.
ADJUSTING RING
NOTE: For new design carriers, the O-ring should not be
installed on the adjusting ring at this time. Do not allow brake NEW O-RING GROOVE
cleaner to come into contact with the O-ring. DESIGN O-RING
COVER
O-RING SEALING
JOURNAL
4011816a
Figure 5.106

12. Use a dial indicator with a magnetic base or a C-clamp base to

WARNING
inspect the end play of the input bearing. Verify that the pointer
Take care when you use Loctite adhesive to avoid serious
of the dial indicator is against the top of the input shaft. Set the
dial indicator to ZERO. Figure 5.107.
using this product. Follow the instructions carefully to prevent
irritation to the eyes and skin. If Loctite adhesive material Figure 5.107

procedures. Have your eyes checked by a physician as soon as DIAL
possible. INDICATOR
4. Ensure the threads of the adjusting ring are clean and dry.
Apply Loctite 565 thread sealant to the entire circumference
of the input bearing adjusting ring threads.
CAUTION
PLATE
For new design covers, do not allow the O-ring on the
adjusting ring to come into contact with the threaded portion
of the cover. Damage to the O-ring can result.
NOTE: Use care to avoid overtightening the adjusting ring.

1002576c
5. Install the adjusting ring into the cover until it bottoms out and
seats the cup and bearing. Typically, this is two to three Figure 5.107
notches past the original position. If a reference mark was
made during removal, check the mark to determine 13. Use a pry bar and a support to push the yoke or the flange
approximate position of the adjusting ring. Rotate the input away from the carrier. Read the dial indicator. Correct end play
shaft back and forth to further ensure the bearing is seated. is 0.002-0.008-inch (0.05-0.20 mm). Figure 5.108.
Then, back the adjusting ring out two notches.
Figure 5.108
6. For the purpose of gauging end play, install a test 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.
7. Install the nut and washer onto the input shaft.
8. Fasten a yoke or flange bar to the input yoke or flange. The bar
will hold the input shaft in position when the nut is tightened.
9. Tighten the nut on the input shaft to the correct torque value.
Refer to Section 8.
10. Remove the yoke or flange bar.
11. Rotate the input shaft in each direction and push the yoke or 1002577c
flange toward the cover. This ensures that the input shaft
assembly is at the bottom of its travel.
Figure 5.108

14. Use a spanner wrench to tighten or loosen the adjusting ring as Table K: Multiple-Lip Seal (MLS) Seal Drivers and Sleeves Part
necessary and check the input shaft end play until end play is Numbers
0.002-0.008 inch (0.05-0.20 mm). Use care to avoid
Axle Model Seal Service Sleeve
overtightening the adjusting ring.
and Position Part Number Seal Drivers Drivers
앫 If the adjusting ring is tightened to the point that the MT-14X A1-1205X2728 2728T1 2728T2
end play is less than 0.002-inch (0.05 mm): Loosen the Forward-Rear
adjusting ring and pry up on the yoke. Pull the input shaft Unit Input (FUI)
and bearing cup enough to gain more end play. Continue to
MT-14X A1-1205Y2729 2729T1 2729T2
check the end play and adjust the ring until end play is
0.002-0.008 inch (0.05-0.20 mm). Forward-Rear
Unit Output
15. Once the correct end play is achieved, remove the yoke or (FUO)
flange, washer and nut. Install the lock plate and capscrew to
secure the adjusting ring. Tighten the capscrew to Special Tools for Installing Multiple-Lip Seals (MLS)
specification. Install the seal and yoke or flange according to and Yoke Sleeves
the procedures in this section.
There are six installation drivers required for replacement of the
16. Wait two hours after final assembly before you operate the multiple-lip axle yoke seals. To obtain these sleeves, seals and
vehicle. drivers, call Meritor’s Commercial Vehicle Aftermarket at
888-725-9355.
Installation 앫 A sleeve driver and seal driver for the forward-rear input
Multiple-Lip Seal (MLS) and Yoke Sleeve 앫 A sleeve driver and seal driver for the forward-rear output
Meritor multiple-lip seals on the MT-14X forward-rear carrier feature

WARNING
a separable sleeve installed onto the yokes at the tandem
Solvent cleaners can be flammable, poisonous and cause
forward-rear input and forward-rear output positions. The MT-14X
burns. Examples of solvent cleaners are carbon tetrachloride,
rear-rear carrier uses a unitized pinion seal and does not require a
and emulsion-type and petroleum-base cleaners. Read the
yoke sleeve.
manufacturer’s instructions before using a solvent cleaner,
Installation of the new seals requires a set of four seal drivers and then carefully follow the instructions. Also follow the
two sleeve drivers. Refer to Table K for part numbers. procedures below.
Forward input and output seals must be serviced with the seal and 앫 Wear safe eye protection.
sleeve. The service part number provides both when required.
앫 Wear clothing that protects your skin.
Check your application carefully before installing the multiple-lip
seal. 앫 Work in a well-ventilated area.
Gasoline can explode.
1. Clean the ground and polished surface of the yoke journal

using a clean shop towel and a safe cleaning solvent. Do not
use abrasive cleaners, towels or scrubbers to clean the yoke or
flange surface. Do not use gasoline.

2. Inspect the yoke seal area for damage that could cause Figure 5.110
lubricant leaks after you install the seal. Use emery paper or an FORWARD REAR OUTPUT
equivalent product to remove scratches, nicks or burrs only. WITHOUT DEFLECTOR
3. Install the deflector, if equipped, onto the yoke. You must install
the deflector before you install the sleeve onto the yoke.
Figure 5.109.
Figure 5.109
SLEEVE
4004874a
YOKE
Figure 5.110
DEFLECTOR,
IF EQUIPPED Figure 5.111
SLEEVE
DRIVER 4004889a
Figure 5.109
YOKE
WARNING
procedures. Do not hit steel parts with a steel hammer. Pieces SLEEVE
DRIVER
End of the yoke
must bottom out
4. Apply a light coat of axle oil to the yoke seal journal. Position in the sleeve driver. SLEEVE
the sleeve into the forward-rear axle output yoke sleeve driver.
Do not touch the greased areas of the sleeve. The sleeve must
be kept clean prior to assembly into the seal. Use an arbor
press and the appropriate driver to install the sleeve into the INPUT
yoke. Verify that the sleeve is fully-seated on the yoke to POSITION
prevent damage to components. Figure 5.110.
4004990e
The yoke must be fully pressed into the sleeve driver until the
end of the yoke bottoms out in the sleeve driver. This will Figure 5.111
correctly position the sleeve on the yoke. When correctly

seated, the forward-rear output sleeve is positioned
0.200-inch ± 0.030-inch (5 mm ± 0.75 mm) from the end of
the yoke. Figure 5.111.
앫 If you do not have a press: Position the yoke on a
five-inch (127 mm) spacer on a workbench. Use a
dead-blow hammer and the appropriate driver to install the
sleeve into the yoke. Figure 5.112.

Figure 5.112
CAUTION
Hold the sleeve and seal only on the outer diameter. Do not
touch the greased inner diameter of the seal and the greased
area of the sleeve. This can contaminate the seal and cause a
leak between the shaft and the seal. Damage to components
can result.
6. Install the forward-rear axle input seal. Hold the sleeve and
5" (127 MM)
SPACER seal only on the outer diameter. Position the seal into the seal
driver and align it with the adjusting ring on the forward-rear
4004991a axle cover. Do not touch the lips in the inner diameter of the
seal. Use a dead-blow hammer and the appropriate driver to
Figure 5.112
install the seal into the adjusting ring. Figure 5.114.
5. Apply a light coat of axle oil to the yoke seal journal. Position Figure 5.114
the sleeve into the forward-rear axle input yoke sleeve driver.
FORWARD-REAR INPUT
Do not touch the greased areas of the sleeve. The sleeve must
be kept clean prior to assembly into the seal. Use an arbor
press and the appropriate driver to install the sleeve into the
yoke. Verify that the sleeve is fully-seated in the yoke.
Figure 5.113.
The yoke must be fully pressed into the sleeve driver until the
end of the yoke bottoms out in the sleeve driver. This will
correctly position the sleeve on the yoke. When correctly
seated, the forward-rear input sleeve is positioned 0.030-inch
(0.75 mm) from the end of the yoke. Figure 5.111.
앫 If you do not have a press: Position the yoke on a
five-inch (127 mm) spacer on a workbench. Use a
dead-blow hammer and the appropriate driver to install the 4004876c
sleeve into the yoke. Figure 5.112.
Figure 5.114
Figure 5.113
FORWARD-REAR INPUT 7. Install the forward-rear axle output seal. Hold the sleeve and
WITH DEFLECTOR seal only on the outer diameter. Position the seal onto the seal
driver and align it with the forward-rear axle output shaft. Do
not touch the lips in the inner diameter of the seal. Use a
dead-blow hammer and the appropriate driver to install the
seal into the output shaft cage. Figure 5.115.
SLEEVE
4004875a
Figure 5.113

FORWARD-REAR OUTPUT SEAL Measure

the gap.
4008186b
4004878a Figure 5.117
Figure 5.115
Input Yoke
8. Use a feeler gauge to check the seal gap at the input and
output positions. The seal is correctly installed if the gap is less CAUTION
than 0.010-inch (0.25 mm) around the circumference of the Use a press and a sleeve or yoke installation tool to install the
seal flange. Figure 5.116 and Figure 5.117. yoke. Do not use a hammer or mallet. Using a hammer or
mallet can damage the bearings, yoke or flange.
앫 If the gap is more than 0.010-inch (0.25 mm): Use a
dead-blow hammer and the appropriate driver to 1. Use a press and sleeve or special yoke/flange driver tool, SPX
completely install the seal. 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
Figure 5.116
flange must be seated against the outer bearing. If a press and

sleeve are used, verify that the input shaft is well supported.
Figure 5.118.
Figure 5.118
4004877b
4008100b
Figure 5.116
Figure 5.118
2. Install a yoke bar or other suitable tool to hold the yoke in

place. Figure 5.119.

PRESS
SLEEVE
THRU-SHAFT
1002725c 1002825b
3. Apply Loctite 270 or 277 adhesive sealant in a 0.12-inch 3. Use a press and sleeve to install the inner bearing cup into the
(3.1 mm) bead around the inside diameter of the yoke nut. cage. Place the thru-shaft and bearing assembly into the cage.
Install the washer and yoke nut onto the input shaft and tighten
4. Use a press and sleeve to install the outer bearing cup into the
to 800 ± 45 lb-ft (1090 ± 60 N폷m). Figure 5.119. @
cage over the thru-shaft. Figure 5.122.
4. Rotate the input shaft one complete turn to seat the bearings.
Figure 5.122
Output Bearing Cage and Thru-Shaft PRESS

SLEEVE
1. Apply axle lubricant to bearing cups and cones. Figure 5.120.
OUTER
Figure 5.120
BEARING
CUP
BEARING
THRU-SHAFT ASSEMBLIES SNAP OUTER
RING BEARING
CONE
OUTPUT
YOKE
CAGE INNER
BEARING
CUP 1002826d
OIL
SPACER SEAL 1002824b Figure 5.122
Figure 5.120
5. Install the snap ring that fastens the outer cup in the cage. The
snap ring controls the end play of the output bearing.
both parts in a fully-matched set from the same manufacturer. Figure 5.123.
2. If the bearing cones were removed from the thru-shaft, install

new bearing cones. Place both cones back-to-back onto the
thru-shaft. Use a press and sleeve to install both cones. Apply
pressure until the inner cone seats onto the shoulder of the
thru-shaft. Figure 5.121.

BEARING
CAGE
SNAP
RING
THRU-SHAFT
END VIEW
1002828b
1002717b
Figure 5.124
Figure 5.123
6. Place pry bars under the yoke or flange and push the yoke or
6. Install the snap ring or the yoke-to-cone spacer onto the
flange away from the cage. Record the reading on the dial
thru-shaft until the snap ring touches the outer cone.
indicator. The reading must be 0.004-0.008-inch
7. Inspect and adjust the end play of the thru-shaft bearing. (0.10-0.20 mm). The reading is the measurement of the end
play on the output bearing.
Adjustment 앫 If the end play reading is not 0.004-0.008-inch
(0.10-0.20 mm): Remove and replace the snap ring that
Adjust the Output Bearing End Play fastens the bearings in the cage. Install a thinner snap ring
The output bearing end play is controlled by the size of the snap ring to increase the end play. Install a thicker snap ring to
that holds the bearings in the output cage. The snap rings are decrease the end play. Figure 5.125.
available in increments of 0.003-inch (0.076 mm). Install the snap 7. Remove the nut that fastens the yoke or flange to the
ring which results in an end play of 0.004-0.008-inch thru-shaft. Use the correct puller tool to remove the yoke.
(0.10-0.20 mm).
1. Place the thru-shaft and the bearing cage assembly into a vise Figure 5.125
with soft metal covers on the jaws of the vise. OUTPUT BEARING END PLAY
2. Use an installation tool to install the yoke or flange onto the SNAP
RING
thru-shaft. Do not use the nut to draw the yoke onto the shaft.
Do not install the oil seal at this time.
3. Install the nut that fastens the yoke or flange to the thru-shaft.
Place a holding tool on the yoke or flange and tighten the nut to
the specified torque.
4. Push the yoke or flange toward the cage and rotate the shaft in
each direction to verify that the bearings are correctly installed.
5. Install a dial indicator so that the base of the indicator is on the To increase end play, install a thinner snap ring.
mounting flange of the cage. The pointer of the indicator must To decrease end play, install a thicker snap ring.
touch the yoke or flange end of the thru-shaft. Set the dial 1002585c
indicator to ZERO. Figure 5.124.
Figure 5.125

Installation Figure 5.127
SEAL Measure
Output Yoke and Seal for the Output Bearing the gap.
Cage
CAUTION
Hold the seal only on the outer diameter. Do not touch the lips
in the inner diameter of the seal. If you touch the lips on the
inner diameter of the seal, you will contaminate the lips and
cause a leak between the shaft and the seal.
4008186b
Do not apply pressure after the flange of the seal touches the Figure 5.127
top of the cage or you will damage the seal.
1. Install the multiple-lip seal (MLS). Refer to the procedure in this

CAUTION
Use a press and a sleeve or yoke installation tool to install the
section for complete instructions.
yoke. Do not use a hammer or mallet. Using a hammer or
When you install the seal, hold the sleeve and seal only on the mallet can damage the bearings, yoke or flange.
outer diameter. Position the seal onto the seal driver and align
it with the forward-rear axle output shaft. Do not touch the lips 3. Use a press and sleeve or an installation tool to install the yoke
in the inner diameter of the seal. Use a dead-blow hammer and onto the thru-shaft. Verify that the splines inside the yoke or
the appropriate driver to install the seal onto the output shaft. flange are aligned with the splines on the thru-shaft. If a press
Figure 5.126. and sleeve are used, verify that the thru-shaft is supported.
Figure 5.126
4. Install the nut that fastens the output yoke or flange to the
thru-shaft. Place a holding tool on the yoke or flange and
FORWARD-REAR OUTPUT
tighten the nut to 600-700 lb-ft (815-950 N폷m). Figure 5.128.
@
Figure 5.128
4004878a
Figure 5.126
YOKE BAR 1003451c

2. Use a feeler gauge to measure the gap around the complete
flange-to-cage area. The seal is correctly installed if the gap is Figure 5.128
less than 0.010-inch (0.25 mm) around the circumference of
the seal flange. Figure 5.127. 5. Rotate the yoke at least one full turn after the yoke nut is
앫 If the gap is more than 0.010-inch (0.25 mm): Use a tightened to the correct torque specification. This ensures
dead-blow hammer and the appropriate driver to correct seating of the seal.
completely install the seal.

Driver-Controlled Main Differential Lock CAUTION

Refer to Section 6 for installation procedures. Apply RTV sealant in a continuous 0.25-inch (6 mm) bead. If
you use more than this amount, sealant can break off and plug
Differential Carrier into the Axle Housing lubrication passages. Damage to components can result.
WARNING 5. Apply a 0.25-inch (6 mm) bead of Loctite 5699 RTV sealant

Solvent cleaners can be flammable, poisonous and cause to the housing face. ONLY Loctite 5699, which is included in
burns. Examples of solvent cleaners are carbon tetrachloride, the fastener kit, can be used. You must circle each bolt hole for
and emulsion-type and petroleum-base cleaners. Read the correct sealing. Figure 5.129.
manufacturer’s instructions before using a solvent cleaner, NOTE: Applying excessive RTV sealant is NOT BETTER for
then carefully follow the instructions. Also follow the achieving correct sealing. Sealant in excess of a 0.25-inch
procedures below. (6 mm) bead will take longer to cure and will plug lubricant
앫 Wear safe eye protection. passages.
앫 Wear clothing that protects your skin. NOTE: Use care to prevent any lubricant from leaking down on
the cleaned flanges prior to applying the sealant. Oil will
앫 Work in a well-ventilated area. prevent correct sealing and weaken the bond.
Gasoline can explode.
Figure 5.129

1. Clean and prepare the axle housing and carrier for installation
according to the instructions in Section 4.
0.25" (6 MM)
2. Inspect the axle housing for damage. Repair or replace the axle DIAMETER RTV
housing. Refer to Section 4. SEALANT 4013561a
3. Check for loose studs, if equipped, in the mounting surface of Figure 5.129
the housing where the carrier fastens. Remove and clean the
studs that are loose. 6. On an axle with a driver-controlled main differential lock, shift
4. Install the studs into the axle housing. Tighten the studs until the lock into and hold the lock in the locked or engaged
there are no exposed threads. position. The locked position provides enough clearance
between the shift collar and the axle housing for carrier
installation. Refer to Section 6.
WARNING
amount of acid vapor is present. To prevent serious personal CAUTION
injury, ensure that the work area is well-ventilated. Read the Do not allow oil to drip onto the new cleaned flanges. Oil will
manufacturer’s instructions before using a silicone gasket prevent correct bonding of the joint and will result in a leak.
7. Use care to prevent any lubricant from leaking down on the
new applied RTV sealant or cleaned flanges during installation.
emergency procedures. Have your eyes checked by a
physician as soon as possible.

A previously oiled or "wet" carrier will retain oil in the IAD/input

CAUTION
shaft area. To prevent oil from leaking in this area, you may
New capscrew kits have blue Dri-Loc STS threadlocker, an
create a lubricant “dam” at the bottom of the carrier casting
equivalent to Loctite 242 threadlocker, applied to the
using chassis grease. This dam will help capture oil that may
capscrews. Do not remove the blue Dri-Loc STS threadlocker
drip as the "wet" carrier is maneuvered into the housing.
from the capscrews. Damage to components can result.
Leaking lubricant will not be a concern with a new/dry carrier
as the new part has not been oiled and will not be "wet".
NOTE: Use the fasteners provided in the kit for installation. Do NOT
Figure 5.130.
reuse the old fasteners.
Figure 5.130
NOTE: Use the 1/4″ longer, 2″ 10X1595 capscrews at standard

carrier flange thickness tapered dowel locations. The 10X1595 and
10X1594 capscrews are interchangeable at non-tapered dowel
locations.
10. Install the tapered dowels, tapered dowel capscrews and

washers. Use the longest capscrews (2.75″ or 3.5″) in the
high-boss tapered dowel locations and the second longest
capscrews (2.0″) in the standard carrier thickness tapered
dowel locations. Use a crisscross pattern to tighten the tapered
LUBRICANT DAM dowel capscrews to a target torque of 225 lb-ft (range
(CHASSIS GREASE) 4013558b
210-240 lb-ft (285-325 N폷m). Figure 5.132. @
Figure 5.130
NOTE: The fasteners at the tapered dowel locations must be
tighten to specification FIRST before the other fasteners in
8. Install two, 4-inch long studs into the housing to guide the
order to seat the carrier on the housing correctly.
carrier into the housing.
Figure 5.132
CAUTION 14X FORWARD DOWEL LOCATIONS

Do not use a hammer or mallet to install the carrier. A hammer 2.75"
or mallet will damage the mounting flange of the carrier and CAPSCREW
cause oil leaks. AND DOWEL
9. Use a hydraulic roller jack or a lifting tool to install the carrier

into the axle housing. Immediately install the carrier into the
housing to permit the RTV sealant to compress evenly between 2.0"
the faces. Figure 5.131. CAPSCREW
AND DOWEL
Figure 5.131
2.0" 2.75"
CAPSCREW CAPSCREW
AND DOWEL AND DOWEL
4013570a
Figure 5.132
ROLLER
JACK 1002714e
Figure 5.131

11. Install the remaining washers and capscrews (1.75″ length, Take care when you use Loctite adhesive to avoid serious
part number 10X1594, shortest bolts in the kit, unless personal injury. Read the manufacturer’s instructions before
otherwise noted). Using a crisscross pattern, tighten the 1.75″ using this product. Follow the instructions carefully to prevent
capscrews to 100 lb-ft (136 N폷m). Then, angle tighten the irritation to the eyes and skin. If Loctite adhesive material
capscrew 40 degrees. Use a torque wrench for this process. gets into your eyes, follow the manufacturer’s emergency
Use of an impact gun is not recommended. For the other size procedures. Have your eyes checked by a physician as soon as
capscrews, use a crisscross pattern to tighten the fasteners to possible.
a target torque of 225 lb-ft (range 210-240 lb-ft
[285-325 N폷m]). Figure 5.133. @ Tapered Dowel, Hardened Washer and Hardened Nut
1. Clean the mating surfaces of the axle shaft and wheel hub.
Figure 5.133
14X FORWARD NON-DOWEL FASTENERS 2. Install the gasket and axle shaft into the axle housing and
1.75” carrier. The gasket and flange of the axle shafts must fit flat
CAPSCREW STUDS against the wheel hub. Figure 5.134.
앫 If a gasket is not available: Apply a 0.125-inch (3 mm)
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
1.75”
CAPSCREW 1.75” into the axle housing and carrier.
CAPSCREW
2.75” Figure 5.134
CAPSCREW 4013570b
STUD WASHER STUD
Figure 5.133 NUT GASKET
12. Apply Loctite 242 threadlocker to the stud threads.

13. Install the stud nuts and tighten to 190-230 lb-ft
(258-312 N폷m). @ TAPERED
DOWEL,
IF EQUIPPED
14. Connect the vehicle drive shafts to the input and the thru yokes
or flanges. AXLE SHAFT
SHAFT OR HUB
15. Connect the air lines to the inter-axle differential air inlet and, if FLANGE AXLE 1002581c
used, the main differential lock inlet.
Figure 5.134
16. On axles with a main differential lock, connect the electrical
connector of the sensor unit. Verify that the main differential 3. Install solid tapered dowels over each stud and into the flange
lock is disengaged. of the axle shaft. Use a punch or a drift and hammer, if
necessary. Figure 5.134.
Axle Shaft
4. Install the Grade 8 nuts and hardened washers onto the stud.
WARNING Lock washers are an acceptable alternative. Tighten the stud
nuts to the torque specified in Table L.
physician as soon as possible.

Table L: Shaft-to-Hub Torque Fastener Chart Figure 5.135
FILL PLUG LOCATION IN BACK

Torque Value — Grade 8 Nuts lb-ft OF AXLE HOUSING BOWL
Thread (N폷m)
Fastener Size Plain Nut Locknut
FILL
Stud Nut 0.62-18 180-230 (244-312) 150-190 (203-258) PLUG
or Axle 0.75-16 310-400 (420-542) 270-350 (366-475)
Shaft TEMPERATURE
INDICATOR
Studs All Install the coarse thread end of the stud PLUG – DO
into the hub and tighten to the last thread. NOT REMOVE
1002591d
5. Fill the axle with the specified lubricant. Refer to the procedure
Figure 5.135
in this section.
Straight Holes, Nuts and Hardened Washers 3. Fill the axle with lubricant until the lubricant level is to the
bottom of the fill plug hole. Refer to Section 7.
1. Clean the mating surfaces of the axle shaft and wheel hub.
4. Install the fill plug. Tighten the fill plug to 35 lb-ft (47 N폷m).
2. Install the gasket and axle shaft into the axle housing and When correctly installed, one complete thread of the fill plug is
carrier. The gasket and flange of the axle shafts must fit flat visible between the housing and plug head. @
against the wheel hub. Figure 5.134.
5. Road test the vehicle in an unloaded condition for one to two
앫 If a gasket is not available: Apply a 0.125-inch (3 mm) miles (1.6-3.2 km) at speeds not more than 25 mph (40 kmh).
diameter bead of grey sealant, Meritor specification Recheck the lubricant levels and all the fasteners.
around the edge of each fastener hole. Install the axle shaft 6. If used, inspect the operation of the driver-controlled main
into the axle housing and carrier. differential lock. Refer to Section 6.
3. Install the Grade 8 nuts and hardened washers on the stud.

Lock washers are an acceptable alternative. Tighten the stud
nuts to the torque specified in Table L.
4. Fill the axle with the specified lubricant. Refer to procedure in
this section.
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 5.135.

6 Driver-Controlled Main Differential Lock (DCDL)
Hazard Alert Messages

Figure 6.2
FORK PUSH ROD

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. O-RING
WARNING
To prevent serious eye injury, always wear safe eye protection
COVER
when you perform vehicle maintenance or service.
CAGING
BOLT
Description
Some Meritor drive axle models have a driver-controlled main PISTON
differential lock (DCDL). This differential lock is operated by a

SPRING SWITCH
carrier-mounted, air-actuated shift unit. When activated, the shift
4012872a
unit moves a sliding collar which is installed on the splines of the
axle shaft. When engaged, the collar locks the axle shaft to a DCDL WITH SCREW-IN COVER
second set of splines on the differential case. Both driven wheels Figure 6.2
are then simultaneously engaged. Figure 6.1 and Figure 6.2.
Figure 6.1
Removal
SPRING SHIFT FORK DIFFERENTIAL
LOCK COLLAR Differential Carrier from the Axle Housing
Before the differential carrier can be removed or installed, the
differential lock must be shifted into and held in the locked or
engaged position. The locked position gives enough clearance
SHIFT between the shift collar and the axle housing to permit the removal
SHAFT
or installation of the carrier.
The Axle Shafts Were Removed for Towing with the

PISTON 4007399a Differential in the Unlocked or Disengaged Position
DCDL WITH BOLT-ON COVER Install the left-hand axle shaft into the housing before continuing.
Figure 6.1 Perform the following steps for reinstalling the axle shafts into the
axle housing.
1. Remove the protective covers, if used, from the wheel-end
hubs.
2. If the drive axles are equipped with a main differential lock,
shift the differential to the unlocked or disengaged position.
Install the axle shaft with two sets of splines and new gaskets
in the correct location as follows.
A. Push the axle shaft and gasket into the hub and housing
until the shaft stops against the differential lock collar.
B. Push down and in on the axle shaft flange and rotate the
shaft until the splines of the shaft and the shift collar are
engaged.

C. Push the axle shaft further into the housing until the shaft 8. Remove the caging bolt from the side of the housing.
stops against the differential side gear. Figure 6.3.
D. Push down on the axle shaft flange and rotate the shaft Figure 6.3
until the splines of the shaft and the side gear are
engaged.
E. Push the axle shaft completely into the housing until the
axle shaft flange and gasket are flush against the wheel
hub.
Engagement or Lockout of the DCDL

CAGING BOLT
WARNING IN STORAGE
HOLE 4008191a
Do not start the engine and engage the transmission during
disassembly of the driver-controlled main differential lock DCDL WITH BOLT-ON COVER SHOWN
(DCDL), or when the DCDL is in the locked or engaged position, Figure 6.3
and the vehicle’s wheels are raised from the floor. The vehicle
can move and cause serious personal injury and damage to 9. Install the caging bolt into the threaded hole in the center of the
components. DCDL cover. Figure 6.4.
Park the vehicle on a level surface. Block the wheels to Figure 6.4

safety stands. Do not work under a vehicle supported only by LOCK COLLAR
damage to components can result.
Manual Method SHIFT

SHAFT
Use the following manual engaging method to shift the DCDL into
the locked position.
If an auxiliary air supply is not available or if the differential carrier is PISTON CAGING BOLT 4007399b
to be stored for later use, use this manual engaging method for the
DCDL. DCDL WITH BOLT-ON COVER SHOWN
Figure 6.4
1. Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving.
CAUTION
2. Remove the drain plug from the bottom of the housing and
There will be a small amount of spring resistance felt when
drain the lubricant.
you turn in the caging bolt. If a high resistance is felt before
3. Use a jack to raise the left-hand wheel of the drive axle. reaching the locked or engaged position, stop turning the
caging bolt to prevent damage to the cover, fork and bolt
4. Place a jackstand under the left-hand spring seat to hold the
threads.
vehicle in the raised position.
5. Disconnect the driveline from the input yoke. 10. Turn the caging bolt to the right until the head is approximately
0.25-inch (6 mm) from the cylinder cover. Do not turn the
6. Disconnect the wiring harness from the DCDL switch.
caging bolt beyond its normal stop. Figure 6.4.
7. Disconnect the vehicle air line from the inter-axle differential
and main differential lock actuator assemblies.

A high resistance on the caging bolt indicates that the splines 9. Supply 85 psi (586 kPa) regulated air pressure through the air
of the shift collar and the differential case half are not aligned line.
or engaged. To align the splines, use the following procedure.
10. Verify that the DCDL is engaged. Figure 6.5.
A. Rotate the left-hand wheel to align the splines of the shift
collar and case half while you turn in the caging bolt. Figure 6.5

B. When the normal amount of spring resistance is again felt LOCK COLLAR
on the caging bolt, the splines are engaged. Continue to
turn in the caging bolt until the head is approximately
0.25-inch (6 mm) from the cylinder cover. The caging bolt
is now in the service position and the main differential
SHIFT
lock is completely engaged. SHAFT
GEAR
11. Remove the carrier from the axle housing. Refer to Section 3. SHIMS
TEETH
ENGAGED
12. Release the differential lock by removing the caging bolt from PISTON 4007399c
the hole in the center of the DCDL cover. Reinstall the caging
bolt with the washer into its original position on the cover. DCDL WITH BOLT-ON COVER SHOWN
Tighten the caging bolt to 7-9 lb-ft (10-12 N폷m). @ Figure 6.5
Auxiliary Air Supply Method 11. Remove the carrier from the axle housing. Refer to Section 3.
1. Park the vehicle on a level surface. Block the wheels to prevent 12. Shut-off the air supply to the DCDL.
the vehicle from moving.
13. Disconnect the air line from the main differential actuator
2. Remove the drain plug from the bottom of the housing and assembly coupling.
drain the lubricant.
3. Use a jack to raise the left-hand wheel of the drive axle. Place a DCDL Shift Unit with Bolt-On Cover
safety stand under the left-hand axle housing leg to support the 1. Remove the sensor switch. Figure 6.6.
vehicle in the raised position.
4. Disconnect the driveline from the input yoke. Figure 6.6
5. Disconnect the wiring harness from the DCDL switch.

6. Disconnect the vehicle air line from the inter-axle differential
and main differential lock actuator assemblies.
7. Install a suitable air line coupling into the main differential
actuator assembly.
8. Install the air line into the coupling.
CAUTION 4008149a
When you use an auxiliary air supply to engage the
Figure 6.6
driver-controlled main differential lock (DCDL), you must
supply air to the DCDL until you remove the carrier. Do not
disconnect the air line or reduce air pressure to the DCDL 2. Remove the four capscrews and washers that hold the cover.
before you remove the carrier from the housing. Damage to Remove the cover. Figure 6.7 and Figure 6.8.

Figure 6.7 4. Remove the shift shaft from the shift fork. Figure 6.10.
DCDL WITH BOLT-ON COVER
1 2 Figure 6.10
3
4 5 6 7 8 9 10 11 12
4013396a
1 SHIFT FORK 7 PISTON SHIFT
2 CLUTCH COLLAR 8 GASKET SHAFT 1002854d
3 SHIMS 9 COVER
4 SPRING 10 WASHER Figure 6.10
5 SHIFT SHIFT 11 CAPSCREW
6 O-RING 12 CAGING SCREW
5. Remove the shims from the bore.
Figure 6.7
6. Install the spring compression tool over the DCDL bore and
Figure 6.8
hand-tighten the retaining screws. The ends of the tool fit
through recesses in the housing bore and around the fork.
Figure 6.11 and Figure 6.12.
Figure 6.11
BOLT-ON DCDL RETAINING

SCREW
CAPSCREW AND
WASHER, FOUR
CORNERS COVER
1002850d
Figure 6.8
RETAINING
SCREW
3. Use a high-powered magnet or magnetic base of a dial
indicator to remove the piston. Inspect the O-ring for any NEW STYLE TOOL,
PART NUMBER
damage such as cracks, cuts or breaks and replace if A-3256V1348
4013847b
Figure 6.9
Figure 6.11
1002845c
Figure 6.9

Figure 6.12
DCDL Shift Unit with Screw-In Cover
1. Remove the sensor switch. Figure 6.14.
OLD STYLE TOOL,
PART NUMBER
A-3256L1234 Figure 6.14
SENSOR
SWITCH
4008685b
Figure 6.12
7. Tighten the tool handle down until it bottoms to compress the

spring. When the spring is compressed below the fork, pull the
fork out with the shift collar.
8. Loosen the handle on the spring compression tool to release SCREW-IN
COVER
the spring. Loosen the retaining screws and remove the spring 4013415a
compression tool from the carrier.
Figure 6.14
9. Remove the spring. Figure 6.13.
2. Remove the air line from the cover.
Figure 6.13
3. Unscrew and remove the screw-in cover. Inspect the O-ring for
any damage such as cracks, cuts or breaks and replace if
SPRING Figure 6.15
DCDL WITH SCREW-IN COVER

1
2
6 7
8
1002847e
9
3
Figure 6.13 4
5 4013392a
10. Further disassembly of these carriers is the same as axles
without the driver-controlled main differential lock. To continue 1 SHIFT FORK 6 PISTON
2 CLUTCH COLLAR 7 O-RING
disassembly, follow the procedures in Section 3. 3 SPRING 8 COVER
4 SHIFT SHAFT 9 PLUG
5 O-RING
Figure 6.15

4. Use a high-powered magnet or magnetic base of a dial Figure 6.18
indicator to remove the piston. Inspect the O-ring for any

damage such as cracks, cuts or breaks and replace if ADAPTER
Figure 6.16
4013002a
Figure 6.18
Figure 6.19
1002845c
RETAINING
Figure 6.16 SCREW
DCDL
ADAPTER
5. Remove the push rod from the shift fork. Figure 6.17.
Figure 6.17
RETAINING
SCREW
NEW STYLE TOOL,
PART NUMBER
A-3256V1348
SCREW-IN DCDL 4013846b
Figure 6.19
SHIFT
SHAFT 1002854d Figure 6.20
Figure 6.17
14X FORWARD CARRIER WITH SCREW-IN DCDL
DCDL
ADAPTER
6. Remove the shims from the bore.
NOTE: If you are using the old style spring compression tool, part
RETAINING
number A-3256L1234, you will need to obtain and install tool SCREWS
conversion kit A-3256L1234T2 in order to service the screw-in style
DCDL. Contact Meritor’s Commercial Vehicle Aftermarket at OLD STYLE TOOL,
888-725-9355 to obtain the kit and refer to technical publication PART NUMBER
A-3256L1234
TP-1807, Meritor Spring Compression Tool Conversion Kit
Instructions. 4013832b
7. Install the DCDL adapter into the DCDL bore. Install the spring Figure 6.20
compression tool over the DCDL adapter and hand-tighten the

retaining screws. The ends of the tool fit through recesses in 8. Tighten the tool handle down until it bottoms to compress the
the housing bore and around the fork. Figure 6.18, Figure 6.19 spring. When the spring is compressed below the fork, pull the
and Figure 6.20. fork out with the shift collar.

9. Loosen the handle on the spring compression tool to release Install the differential shift assembly after the differential carrier is
the spring. Loosen the retaining screws and remove the spring assembled and the gear and bearing adjustments are made.
compression tool and DCDL adapter from the carrier.
1. If removed, reinstall the main differential and ring gear
10. Remove the spring. Figure 6.21. assembly according to the procedures in Section 5.
Figure 6.21
2. Install the spring into the housing. Figure 6.22.
Figure 6.22
SPRING
SPRING
1002847e
Figure 6.21 1002847e
Figure 6.22
11. Further disassembly of these carriers is the same as axles
without the driver-controlled main differential lock. To continue
3. Install the spring compression tool over the DCDL bore and
disassembly, follow the procedures in Section 3.
hand-tighten the retaining screws. Tighten the tool handle
down until it bottoms to compress the spring. Figure 6.23 and
Installation Figure 6.24.
DCDL Shift Unit with Bolt-On Cover Figure 6.23
BOLT-ON DCDL RETAINING

WARNING SCREW
gasket material gets into your eyes, follow the manufacturer’s RETAINING
emergency procedures. Have your eyes checked by a SCREW
physician as soon as possible. NEW STYLE TOOL,
PART NUMBER
Take care when you use Loctite adhesive to avoid serious A-3256V1348

4013847b
irritation to the eyes and skin. If Loctite adhesive material Figure 6.23
possible.

OLD STYLE TOOL,

PART NUMBER
A-3256L1234
4008685b SHIFT
SHAFT 1002854d
Figure 6.24
Figure 6.26
4. Install the clutch collar onto the fork. Slide the clutch collar and
8. Install the same amount of shims as were removed.
fork into position. Insert the end of the fork above the
compressed spring while you position the clutch collar to the 9. Apply grease, Meritor specification 2297-U-4519 or
main differential. The teeth of the clutch collar must face the 1199-U-1113, to the O-ring and piston. Install the O-ring onto
main differential case teeth. Ensure the spring is correctly the piston. Install the piston into the housing.
seated within the raised areas of the fork.
10. Apply Loctite 242 threadlocker to the capscrew holes. Install
5. While holding the fork in position, loosen the tool handle to the DCDL cover plate with the gasket onto the housing. Install
release the spring. Loosen the retaining screws and remove the washers and capscrews. Tighten the capscrews to 50 ±
the spring compression tool. 10 lb-in (6 ± 1 N폷m). Figure 6.27. @
6. Insert a centering tool, screwdriver or other suitable tool to
Figure 6.27
align the fork with the shift shaft housing bore. Refer to Section
10 for a tool drawing. Figure 6.25.
Figure 6.25
SPRING
FORK
TOOL CAPSCREW AND
WASHER, FOUR
CORNERS COVER
1002850d
Figure 6.27
4008167a
11. Apply shop air to the DCDL assembly to engage the DCDL lock
Figure 6.25 collar into locked position.
12. Ensure the collar moves freely in the engaged position and is
7. Apply grease, Meritor specification 2297-U-4519 or
1199-U-1113, to the tapered surface of the shift shaft. Insert not binding on the fork levers.
the shift shaft into the housing bore through the shift fork and 13. Check the clearance between the teeth of the clutch collar and
spring. Figure 6.26. Use a centering tool to seat the shift shaft the main differential case to ensure there is 0.020-0.040-inch
in the housing bore. Refer to Section 10 for a tool drawing. (0.5-1.0 mm) clearance. If necessary, remove the piston and
add or remove shims. Reassemble and retest until correct
clearance is achieved. Figure 6.28.


LOCK COLLAR
SHIFT
SHAFT
GEAR
SHIMS
TEETH
ENGAGED
PISTON 4007399c
4008149a
DCDL IN LOCKED POSITION
Figure 6.30
Figure 6.28
16. Connect a volt-ohm meter to the sensor switch. Select ohms

CAUTION on the meter. Rotate the switch CLOCKWISE until the meter
When tightening the caging bolt, do not exceed 50 lb-in reading changes from infinity to less than one ohm. Turn in the
(7 N폷m). Damage to components can result. switch fully and tighten to 25-55 lb-ft (35-75 N폷m). @
17. Connect the wiring harness to the DCDL switch.
14. Remove the shop air from the DCDL lock cover and install the
DCDL caging bolt. Check to see that the DCDL teeth are 18. Apply 85 psi (586 kPa) of air and verify the DCDL engages.
engaged with the main differential case teeth while engaging 19. Check the sensor switch operation with the air applied. The
the caging bolt. Do not exceed 50 lb-in (7 N폷m) when differential lock indicator light in the cab of the vehicle should
tightening the caging bolt. When installing the carrier, leave the be ON when the DCDL is engaged, and OFF when disengaged.
caging bolt in until the axle shafts are installed. Also, it is The indicator light will also activate if the DCDL is partially
necessary to cage the DCDL when removing the carrier. engaged.
Figure 6.29.
20. When testing is complete, reinstall the caging bolt into its
Figure 6.29 threaded hole and tighten to 7-11 lb-ft (10-15 N폷m). @
LOCK COLLAR
SHIFT
SHAFT
PISTON CAGING BOLT 4007399b
DCDL LOCKED WITH CAGING BOLT

Figure 6.29
15. Engage the DCDL so the shift collar is in the locked position
and install the sensor switch into its hole but do not tighten.
Figure 6.30.

DCDL Shift Unit with Screw-In Cover Figure 6.32
ADAPTER
WARNING
physician as soon as possible. 4013002a
Figure 6.32
Take care when you use Loctite adhesive to avoid serious
personal injury. Read the manufacturer’s instructions before Figure 6.33

irritation to the eyes and skin. If Loctite adhesive material RETAINING
SCREW
DCDL
gets into your eyes, follow the manufacturer’s emergency ADAPTER
possible.
Install the differential shift assembly after the differential carrier is

assembled and the gear and bearing adjustments are made.
RETAINING
1. If removed, reinstall the main differential and ring gear SCREW
assembly according to the procedures in Section 5. NEW STYLE TOOL,
PART NUMBER
2. Install the spring into the housing. Figure 6.31. A-3256V1348
SCREW-IN DCDL 4013846b
Figure 6.31
Figure 6.33
Figure 6.34
SPRING 14X FORWARD CARRIER WITH SCREW-IN DCDL

DCDL
ADAPTER
RETAINING
SCREWS
1002847e OLD STYLE TOOL,

PART NUMBER
Figure 6.31 A-3256L1234
4013832b
3. Install the DCDL adapter into the DCDL bore. Install the spring
compression tool over the adapter and hand-tighten the Figure 6.34
retaining screws. Tighten the tool handle down until it bottoms
to compress the spring. Figure 6.32, Figure 6.33 and
Figure 6.34.

4. Install the clutch collar onto the fork. Slide the clutch collar and 8. Apply grease, Meritor specification 2297-U-4519 or
fork into position. Insert the end of the fork above the 1199-U-1113, to the O-ring and piston. Install the O-ring onto
compressed spring while you position the clutch collar to the the piston. Install the piston into the housing.
main differential. The teeth of the clutch collar must face the
main differential case teeth. Ensure the spring is correctly
1199-U-1113, to the O-ring groove at the bottom of the cover.
seated within the raised areas of the fork. Figure 6.32.
Install the O-ring on the cover.
5. While holding the fork in position, loosen the tool handle to
10. Install the cover in the carrier threaded bore. Do not apply
release the spring. Loosen the retaining screws and remove
sealant on the cover, the part has pre-applied sealant. Tighten
the spring compression tool and DCDL adapter.
the cover to 85 lb-ft (115 N폷m) (range 88-90 lb-ft
6. Insert a centering tool, screwdriver or other suitable tool to [108-122 N폷m]). @
align the fork with the shift shaft housing bore. Refer to Section
11. Apply a 0.06-inch (1.5 mm) continuous bead of white sealant,
10 for a tool drawing. Figure 6.35.
Loctite 565 PST pipe sealant, around the switch threads.
Figure 6.35
Install and tighten the switch to a torque specification of
40 lb-ft (55 Nm) (range 26-55 lb-ft [35-75 Nm]). Figure 6.37.
SPRING
Figure 6.37
FORK
TOOL
SENSOR
SWITCH
4008167a
Figure 6.35

1199-U-1113, to the tapered surface of the shift shaft. Insert
the shift shaft into the housing bore through the shift fork and SCREW-IN
spring. Figure 6.36. Use a centering tool to seat the shift shaft COVER
4013415a
in the housing bore. Refer to Section 10 for a tool drawing.
Figure 6.37
Figure 6.36
12. Apply approximately 87 psi (600 kPa) of air pressure to the

DCDL assembly to engage the DCDL lock collar into locked
position.
13. Ensure the collar moves freely in the engaged position and is
not binding on the fork levers.
14. Check the sensor switch operation with the air applied. The
differential lock indicator light in the cab of the vehicle should
be ON when the DCDL is engaged, and OFF when disengaged.
SHIFT
SHAFT
The indicator light will also activate if the DCDL is partially
1002854d
engaged.
Figure 6.36

CAUTION WARNING
When tightening the caging bolt, do not exceed 50 lb-in Do not start the engine and engage the transmission during
(7 N폷m). Damage to components can result. disassembly of the driver-controlled main differential lock
(DCDL), or when the DCDL is in the locked or engaged position,
15. Remove the shop air from the DCDL cover and install the DCDL and the vehicle’s wheels are raised from the floor. The vehicle
caging bolt. Check to see that the DCDL teeth are engaged can move and cause serious personal injury and damage to
with the main differential case teeth while engaging the caging components.
bolt. Do not exceed 50 lb-in (7 N폷m) when tightening the
caging bolt. When installing the carrier, leave the caging bolt in 2. Place the differential lock switch in the cab of the vehicle in the
until the axle shafts are installed. Also, it is necessary to cage unlocked or disengaged position.
the DCDL when removing the carrier. Figure 6.38.
3. Drive the vehicle at 5-10 mph (8-16 km/h) and check the
Figure 6.38
differential lock indicator light. The light must be off when the
switch is in the unlocked or disengaged position.
FORK PUSH ROD
4. Continue to drive the vehicle and place the differential lock
switch in the locked or engaged position. A slight left or right
O-RING turn may be required to lock the DCDL. Let up on the
accelerator to remove the driveline torque and permit the shift.
The indicator light must be on when the switch is in the locked
COVER position.
CAGING 앫 If the indicator light remains ON with the switch in the

BOLT unlocked position: The differential is still in the locked
position. A slight left or right turn may be required to unlock
PISTON
the DCDL. If the indicator light remains on after completing
SWITCH a slight left or right turn, check the piston and shift shaft for
SPRING
binding. If necessary, take them apart and check both for
4012872a
burrs, scratches and damage. Replace the parts if
DCDL LOCKED WITH CAGING BOLT necessary. Refer to the procedure in this section.
Figure 6.38
DCDL Driver Caution Alert Label
16. Check the switch operation. Verify that the light is on when
Verify that the driver caution label is installed in the vehicle cab.
engaged and off when disengaged. The light should be on
Figure 6.39. The caution label must be placed in a location that is
when partially disengaged.
easily visible to the driver. The recommended location is on the
17. When testing is complete, reinstall the caging bolt into its instrument panel, next to the differential lock switch and lock
threaded hole and tighten to 7-11 lb-ft (10-15 N폷m). @ indicator light.
18. Install the air line.
Check the Differential Lock

1. Shift the vehicle transmission into neutral. Start the engine to
get the system air pressure to the normal level.

Figure 6.39
This vehicle is equipped with Meritor’s driver-controlled, full-locking

differential (DCDL).
• Engage DCDL only under poor road conditions.
• Do not engage DCDL during downhill operation.
• Do not engage DCDL or operate the vehicle at speeds above 25 mph.
When DCDL is engaged, an “understeer” condition can occur when
making turns, so operate the vehicle carefully. When you disengage
DCDL, normal steering resumes.
Refer to the vehicle manufacturer’s manual or Meritor technical
bulletin TP-9579. To obtain this bulletin, visit Literature on Demand at
meritor.com or call 866-OnTrac1 (668-7221).
TP-9579ALBL (04-06)
4008262a
Figure 6.39
Driver Instruction Information Available

Refer to the Service Notes page on the front inside cover of this
manual to obtain the following publications.
앫 DCDL Caution Alert Label/Order part number TP9579ALBL.
앫 DCDL Driver Instruction Kit/Contains a compilation of technical
bulletins covering DCDL and inter-axle differential (IAD)
operation; the DCDL Caution alert label; and instructions to
prepare an axle for towing or new vehicle drive away
(piggybacking). Order part number TP-9579.
앫 Traction Controls for Drive Axles DVD/Order part number
SP03105.

7 Lubrication
Specifications For complete information on lubricating drive axles and carriers,

7 Lubrication
refer to Maintenance Manual 1, Preventive Maintenance and

Meritor recommends using a lubricant analysis program. Perform Lubrication. To obtain this publication, refer to the Service Notes
lubricant analysis at regularly-scheduled preventive maintenance page on the front inside cover of this manual.
intervals.
Refer to Table M, Table N and Table O for standard information on
lubricants, schedules and capacities.
Table M: 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 N: Oil Change Intervals for All Rear Drive Axles

Construction, Transit Bus,
City Delivery, School Refuse, Yard Tractor, Logging,
Vocation or Bus, Fire Truck, Heavy Haul, Mining, Oil Field,
Vehicle Operation Linehaul Intercity Coach Motorhome Rescue
Initial Oil Change Not required Not required Not required Not required
Check Oil Level Every 25,000 miles Every 25,000 miles Every 10,000 miles Every 5,000 miles (8000 km),
Add the correct type (40 000 km), or the (40 000 km), or the (16 000 km), once a once a month, or the fleet
and amount of oil as fleet maintenance fleet maintenance month, or the fleet maintenance interval, whichever
required. interval, whichever interval, whichever maintenance interval, comes first1
comes first comes first whichever comes first
Petroleum-Based Every 100,000 Every 100,000 miles Every 50,000 miles Every 25,000 miles (40 000 km)
Oil miles (160 000 km) (160 000 km) or (80 000 km) or annually, or annually, whichever comes
Change on axles or annually, annually, whichever whichever comes first first
with or without a whichever comes comes first
pump and filter first
system.
Synthetic Oil Every 500,000 Every 250,000 miles Every 250,000 miles (400 Every 100,000 miles
Change on axles miles (800 000 km), (400 000 km), or every 000 km), or every 3 (160 000 km), or every 2 years,
with or without a or every 4 years, 4 years, whichever years, whichever comes whichever comes first3
pump and filter whichever comes comes first first
system.2 first

7 Lubrication
Construction, Transit Bus,

City Delivery, School Refuse, Yard Tractor, Logging,
Vocation or Bus, Fire Truck, Heavy Haul, Mining, Oil Field,
Vehicle Operation Linehaul Intercity Coach Motorhome Rescue
Filter Change Every 100,000 Every 100,000 miles Every 100,000 miles Every 100,000 miles
Change on axles miles (160 000 km) (160 000 km) (160 000 km) (160 000 km)
with a pump and
filter system.
1
For continuous heavy-duty operation, check the oil level every 1,000 miles (1600 km).
2
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.
3
The change interval for transit bus can be increased to 150,000 miles (241 401 km) or three years, whichever comes first, contingent upon the following three
conditions. 폷 Documentation verifies a 10% fleet oil sampling with results that are below the guidelines specified in 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. 폷 There is a minimum of six
magnets in the housing. Meritor 61163/71163 drive axles come standard with six magnets in the housing. 폷 Approved extended-drain interval lubricants are
used according to TP-9539, Approved Rear Drive Axle Lubricants. (Drive axles excluded are RC-26-633/634 and RC-26/27-720.)
Table O: Tandem Rear Drive Axle Oil Capacities

Oil Capacity*
Axle Model Carrier Pints Liters
MT-40-14X Forward 30 14.2
Rear 32 15.14
*The oil capacities are for standard track axles that have been measured
at various common drive pinion angles. The quantities listed include oil for
both wheel ends. The oil capacities will change if the track or the drive
pinion angle is different.

8 Specifications
Specifications
8 Specifications
Figure 8.1
MT-14X SERIES DIFFERENTIAL CARRIER

2
1
OPTION
8
7
15
9
12
13 10
11
14
4007405a
Figure 8.1
Table P: Torque Specifications

Torque
Item Description Size Lb-Ft N폷m
1 Oil Baffle Capscrew M8 x 1.25-6H 70 ± 10 lb-in 8±2
Class 8.8
2 Oil Pump Cover Capscrew M8 x 1.25 5-7 7-10
3 Lock Plate Capscrew M8 x 1.25 25 ± 1 30 ± 5
Class 8.8
4 Oil Screen and Plug M26 x 1.5 48 65

8 Specifications
Torque
5 Cover Capscrew M12 x 1.75 90 ± 15 125 ± 20
Optional Method: 30 ± 5 (40 ± 5) plus angle tighten to
90 degrees ± 5 degrees
6 Input Shaft Yoke Nut M45 x 1.5 750-850 1020-1150
7 Carrier-to-Axle Housing Capscrew 5/8″ x 1.75″ 100 (136) plus angle tighten to
40 degrees
5/8″ x 2.0″ 210-240 285-325
5/8″ x 2.75″
8 Pinion Nut M45 x 1.5 1100 ± 200 1500 ± 250
9 DCDL Cover Bolts (Bolt-On Type Cover) M6 x 1.0-6g 50 ± 10 lb-in 6±1
Class 8.8
10 DCDL Switch M16 x 1.0 25-55 35-75
11 Carrier-to-Axle Housing Capscrew 5/8″ 210-240 285-325
12 Stud Nut 190-230 258-312
13 Stud 5/8″ Tighten until there are no exposed
threads.
14 DCDL Caging Bolt M10 x 1.25-6g 7-9 10-12
15 DCDL Cover (Screw-In Type Cover) 80-90 108-122
— Pressure Relief Screw M16 x 1.5 20-40 27-54
— Thrust Screw Jam Nut M22 x 1.5 150 ± 50 200 ± 60

8 Specifications
Figure 8.2
1 MAIN DIFFERENTIAL CASE AND

RING GEAR ASSEMBLY
2 (ALL GEAR SET RATIOS
EXCEPT 2.47-2.64)
4
1 (GEAR SET RATIOS 2.47-2.64)
3 4007406a
Figure 8.2
Table Q: Torque Specifications

Torque
1 Lock Plate Capscrew M6 x 1.0-6g Class 8.8 50 ± 10 lb-in 6±1

8 Specifications
Torque
2 Bearing Cap Capscrew* M20 x 2.5-6g Class 10.9 Torque Plus Angle Method: 150 ± 35
(200 ± 50) plus angle tighten to 90 degrees
± 5 degrees
Optional Method:
Initial torque: 20 ± 8 (25 ± 10)
Final torque: 360 ± 40 (485 ± 55)
3 Plain Half-to-Flange Half Capscrew M12 x 1.75 41x-1618 105 ± 10 140 ± 15
Flange Head Class 12.9
Optional Method: 45 ± 5 (60 ± 5) plus angle
tighten to 90 degrees ± 5 degrees
4 Ring Gear-to-Flange Half Nut (for all gear set M16 x 1.5 Class 12 std 185 ± 25 255 ± 35
ratios excluding 2.47 and 2.64) hex head
5 Ring Gear-to-Flange Half Capscrew (for gear set M16 x 1.5-6g Class 12.9 320 ± 20 430 ± 30
ratios 2.47 to 2.64)
*Change to new capscrews after two reassemblies.

8 Specifications
Figure 8.3
AXLE HOUSING WITH OUTPUT SHAFT
4007407a
Figure 8.3
Table R: Torque Specifications

Torque
1 Output Shaft Nut M39 x 1.5 650 ± 50 880 ± 65
2 Output Bearing Cage-to-Carrier Capscrew 0.38″-16 42 ± 8 55 ± 10
3 Breather 0.38″-18 25 ± 5 30 ± 7
4 Drain and Fill Plugs 0.75-14 35 Minimum 47.5 Minimum

9 Adjustment
Adjustment
9 Adjustment
Table S: Drive Pinion Bearings — Preload

Specification New bearings
10-50 lb-in (1.1-5.6 N폷m)
Used bearings in good condition
10-30 lb-in (1.1-3.3 N폷m)
Adjustment Preload is controlled by the thickness of the spacer between bearing cones.
To increase preload, install a thinner spacer.
To decrease preload, install a thicker spacer.
Table T: Drive Pinion — Depth in Carrier

Specification Install the correct amount of shims between the inner pinion bearing cup and the carrier. To
calculate, use the old shim pack thickness and the new and old pinion cone numbers.
Adjustment Change the thickness of the shim pack to get a good gear tooth contact pattern.
Table U: Hypoid Gear Set — Tooth Contact Patterns (Hand Rolled)

Specification Toward the toe of the gear tooth and in the center between the top and bottom of the tooth.
Adjustment Tooth contact patterns are controlled by the thickness of the shim pack between the inner bearing
cone of the drive pinion and the carrier and by ring gear backlash.
To move the contact pattern lower, increase the thickness of the shim pack between the inner
bearing cup of the drive pinion and the carrier.
To move the contact pattern higher, decrease the thickness of the shim pack between the inner
bearing cup of the drive pinion and the carrier.
To move the convex pattern toward the toe and the concave pattern toward the heel, decrease the
backlash of the ring gear.
To move the convex pattern toward the heel and the concave pattern toward the toe, increase the
backlash of the ring gear.
Table V: Main Differential Bearings — Preload

Specification 15-35 lb-in (1.7-3.9 N폷m)
or
Expansion between bearing caps
0.002-0.009-inch (0.05-0.23 mm)
Adjustment Preload is controlled by tightening both adjusting rings after zero end play is reached.
Table W: Main Differential Gears — Rotating Resistance

Specification 50 lb-ft (68 N폷m) maximum torque applied to one side gear

9 Adjustment
Table X: Input Shaft End Play Adjustment

End Play of the Input Shaft 0.002-0.008-inch (0.050-0.200 mm)
Table Y: Output Bearing — End Play and Preload

Specification 0.004-0.008-inch (0.10-0.20 mm) bearing end play
Adjustment End play is controlled by the size of the snap ring in the output bearing cage.
Increase end play by installing a thinner snap ring.
Decrease end play by installing a thicker snap ring.
NOTE: If the end play on the output bearing measures ZERO, a thinner snap ring is required.
Table Z: Ring Gear — Backlash

Specification Range: 0.008-0.018-inch (0.20-0.460 mm)
Backlash setting for new gear sets: 0.012-inch (0.300 mm)
Adjustment Backlash is controlled by the position of the ring gear. Change backlash within specifications to
get a good tooth contact pattern.
To increase backlash, move the ring gear away from the drive pinion.
To decrease backlash, move the ring gear toward the drive pinion.
Table AA: Ring Gear — Runout

Specification 0.008-inch (0.200 mm) maximum
Table AB: Sensor Switch — Installation (Carriers with Differential Lock (DCDL) Only)
Adjustment Shift the differential to the locked position.
Tighten the sensor switch into the carrier until the test light illuminates indicating the circuit is closed.
Tighten to 25-55 lb-ft (35-75 N폷m). @

10 Special Tools
Specifications
10 Special Tools
Carrier Repair Stand

Figure 10.1
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 10.1
To obtain a repair stand, refer to the Service Notes page on the front
inside cover of this manual.

10 Special Tools
How to Make a Yoke Bar 앫 To increase yoke bar rigidity: Weld two angle pieces onto
the handle. Figure 10.3.
1. Measure dimensions A and B of the yoke you are servicing.
Figure 10.2.
How to Make a Drive Flange Retainer Tool
Figure 10.2 1. Obtain a 1/4-inch thick piece of flat steel.
A 2. Cut and drill the plate using the dimensions in Figure 10.4.
YOKE 1003459b
Figure 10.2
2. Calculate dimensions C and D of the yoke bar by adding

0.125-0.250-inch to dimensions A and B of the yoke.
Figure 10.3.
Figure 10.3
YOKE BAR
C
1003460b
Figure 10.3
WARNING
Wear safe clothing and eye protection when you use welding
equipment. Welding equipment can burn you and cause
serious personal injury. Follow the operating instructions and
safety procedures recommended by the welding equipment
manufacturer.
3. To make the box section, cut and weld one-inch x two-inch

mild steel square stock according to dimensions C and D.
Figure 10.3.
4. Cut a four-foot x 1.25-inch piece of mild steel round stock to
make the yoke bar handle. Center weld this piece to the box
section. Figure 10.3.

10 Special Tools
Figure 10.4
180 MM
61.43 MM 61.43 MM
26.99 MM
28.57 MM 28.57 MM
43.01 MM
110 MM
140 MM
43.01 MM
15 MM
26.99 MM
4011995a
Figure 10.4
WARNING
Wear safe clothing and eye protection when you use welding
equipment. Welding equipment can burn you and cause
serious personal injury. Follow the operating instructions and
safety procedures recommended by the welding equipment
manufacturer.
3. Cut a 4-foot x 1.25-inch piece of mild steel round stock to

make the handle. Center weld the handle to the flat plate
section. Weld two angle pieces to the plate to increase the
rigidity as shown in Figure 10.3.

10 Special Tools
Centering Tool
Figure 10.5
10.0
6.75
6.5 0.06 X 45°
1.38 1.5 CHAM
DIA. 0.75 COURSE KNURL
0.12 X 45° CHAM
0.5
0.06 R 0.585
0.976 1.0
DIA. DIA.
0.06 X 45° STAMP TOOL DIA.
CHAM AND DETAIL NO.
NOTE: DCDL use shown as an example.
SPRING
FORK
TOOL
4008166a
Figure 10.5
Service Tools Figure 10.6
To obtain these tools, call Meritor’s Commercial Vehicle Aftermarket

at 888-725-9355. TOOL PART NUMBER
3256N1236
4008161a
COVER REMOVAL TOOL (OIL PUMP MODELS)

Figure 10.6

10 Special Tools
TOOL PART NUMBER

MSTYT114
TOOL PART NUMBER

3256P1238
4008165a 4008164a
YOKE/FLANGE INSTALLATION TOOL IAD SHIFT TESTER

Figure 10.8
TOOL PART NUMBER

3256M1235
4008162a
INPUT BEARING CONE INSTALLATION TOOL

Figure 10.8
Figure 10.9
NEW TOOL PART NUMBER A-3256V1348
IAD ADAPTER PLATE

A E D
B
C
4013812a
IAD/DCDL SPRING COMPRESSION TOOL

Figure 10.9

10 Special Tools
Multiple-Lip Seals, Seal Drivers and Yoke

Sleeve Drivers
Refer to Table AC for information on multiple-lip seals, seal drivers
and yoke sleeve drivers. To obtain these sleeves, seals and drivers,
call Meritor’s Commercial Vehicle Aftermarket at 888-725-9355.
Table AC: Multiple-Lip Seals, Seal Drivers and Yoke Sleeve Drivers
Single and
Tandem
Models Axle Model and Position Seal Service Part Number Seal Drivers Yoke Sleeve Drivers
MT-14X 14X Forward-Rear Unit A1-1205X2728 2728T1 2728T2
Input (FUI)
14X Forward-Rear Unit A1-1205Y2729 2729T1 2729T2
Output (FUO)
14X Rear-Rear Unit Input A1-1205Z2730 2730T1 Not Required — Sleeve
(RUI) is unitized
Forward input and output seals must be serviced with the seal and
sleeve. The service part number provides both when required.

11 Vehicle Towing Instructions
Hazard Alert Messages When transporting a vehicle with the wheels of one or both drive
axles on the road, it is possible to damage the axles if the wrong

Read and observe all Warning and Caution hazard alert messages in procedure is used before transporting begins. Meritor recommends
this publication. They provide information that can help prevent that you use the following procedure.
serious personal injury, damage to components, or both.
WARNING
After Towing or Drive-Away
To prevent serious eye injury, always wear safe eye protection 1. If an auxiliary air supply was used, apply the vehicle parking
when you perform vehicle maintenance or service. brakes using the switch inside the cab of the vehicle. If an
auxiliary air supply was not used, begin with Step 2.
2. Apply the vehicle spring or parking brakes by manually
releasing each spring that was compressed before transporting
started. Refer to the manufacturer’s instructions.
damage to components can result. 3. Disconnect the auxiliary air supply, if used, from the brake
system of the vehicle that was transported. Connect the
Before you service a spring chamber, carefully follow the vehicle’s air supply to the brake system.
manufacturer’s instructions to compress and lock the spring to
4. Remove the covers from the hubs.
completely release the brake. Verify that no air pressure
remains in the service chamber before you proceed. Sudden NOTE: Install only the axle shaft(s) shown in Table AD at this time.
release of compressed air can cause serious personal injury These axle shafts have a double row of splines that engage with
and damage to components. splines of the side gear and shift collar in the main differential.
Figure 11.1.
Engage the parking brake to prevent the vehicle from moving
before you begin maintenance or service procedures that 5. Install the gasket, if used, and axle shaft into the axle housing
require you to be under the vehicle. Serious personal injury and carrier in the same location. The gasket and flange of the
can result. axle shaft must be flat against the hub. Rotate the axle shaft or
the driveline as necessary to align the splines and the holes in
CAUTION the flange with the studs in the hub. Figure 11.1.
If the vehicle is equipped with a front drive axle, tow the
앫 If a gasket is not available: Apply a 0.125-inch (3 mm)
vehicle from the front, with the front wheels off the ground. If
diameter bead of grey sealant, Meritor specification
this is not possible, you must remove the front drive shaft
before towing. Damage to components can result.
around the edge of each fastener hole. Install the axle shaft
into the axle housing and carrier.
Do not use a chisel or wedge to loosen the axle shaft and
tapered dowels. A chisel or wedge can result in damage to the
axle shaft, the gasket and seal, and the axle hub.
NOTE: For complete towing information, refer to Technical Bulletin

TP-9579, Driver Instruction Kit. To obtain this publication, refer to
the Service Notes page on the front inside cover of this manual.
These instructions supersede all other instructions for the purpose

of transporting vehicles for service or new vehicle drive-away dated
before April 1995, including those contained in Meritor maintenance
manuals.

Figure 11.1 Table AE: Shaft-to-Hub Torque Fastener Chart

Torque Value — Grade 8 Nuts lb-ft
DCDL SHIFT ASSEMBLY SHOWN IN THE Thread (N폷m)
LOCKED OR ENGAGED POSITION
Fastener Size Plain Nut Locknut
Stud Nut 0.62-18 180-230 (244-312) 150-190 (203-258)
or Axle 0.75-16 310-400 (420-542) 270-350 (366-475)
2 Shaft
Studs All Install the coarse thread end of the stud
into the hub and tighten to the last thread.
1
3
8. Unlock or disengage the DCDL by removing the manual
4 engaging capscrew from the shift assembly.
9. Install the manual engaging capscrew into the storage hole.
The storage hole is located in the carrier next to the cylinder.
Tighten the capscrew to 40-50 lb-in (5-7 N폷m). @
5
10. Connect the air hose to the shift cylinder. Tighten the air hose
to 22-30 lb-ft (30-40 N폷m). @
6
11. Install the remaining axle shaft into the axle housing and
7 carrier.
8 12. Check the lubricant level in the axles and hubs where the axle
1002609c
shafts were removed. Add the correct type and amount of
1 CURBSIDE, AXLE SHAFT lubricant if necessary. Refer to Section 7.
2 SHIFT ASSEMBLY
3 SHIFT COLLAR
4 ROADSIDE, AXLE SHAFT
5 DOUBLE ROW OF SPLINES
6 SHIFT COLLAR AND DIFFERENTIAL CASE SPLINES ENGAGED OR LOCKED
7 SIDE GEAR
8 DIFFERENTIAL CASE
Figure 11.1
Table AD
Tandem Axles
Forward Axle
Install the roadside, axle shaft
6. Install the dowels, if used, over each stud and into the tapered
holes of the flange.
7. Install the washers and stud nuts. Determine the size of the
fasteners and tighten the nuts to the corresponding torque
value shown in Table AE.

12 Diagnostics
Troubleshooting
12 Diagnostics
Vehicle Will Not Move

Figure 12.1
Visually inspect
the carrier
Check for further carrier
in the axle
damage. If none is found,
housing.
Damaged or Yes repair or replace the oil
contaminated? pump, clean or replace
Remove the the oil screen and install
carrier from the the carrier. Refer to
Yes axle housing. Sections 3 and 5.
Damaged? Repair the carrier No
or install a
remanufactured Inspect the inter-axle differential
No carrier. assembly for damage. Refer to
TP-9955, Failure Analysis for
Drive Axle Components.
Drain and inspect
the lubricant. Check for further carrier
Refer to MM 1. damage. If none is found,
replace the damaged
Yes
Damaged? inter-axle differential
components and install the
carrier. Refer to Sections
No 3 and 5.
Yes Determine the
Contaminated? source of
contamination. Disassemble the
inter-axle
differential case.
No
Remove the
carrier from the Inspect the inter-axle differential
housing. Refer to spider, side gears and bearings.
Section 3. Refer to TP-9955,
Failure Analysis for Drive
Axle Components.
Visually inspect the ring

pinion gear set for
damage. Refer to TP-9955, Yes replace the inter-axle
Failure Analysis for Damaged? differential components
and install the carrier.
Refer to Sections 3 and 5.
No
Repair the carrier
or install a
Yes remanufactured
Damaged? Inspect the main differential
carrier. bearings for damage.
Refer to Sections Refer to TP-9955,
3 and 5. Failure Analysis for
No
Remove and
disassemble the input Repair the carrier
shaft and inter-axle differential Yes or install a
assembly. Refer to Section 3. Damaged? remanufactured
carrier. Refer to
Sections 3 and 5.
No
Check the ring gear backlash

If the carrier is a pump model,
and record the reading.
inspect the input shaft oil Refer to Section 4. Use the
pump for damage and the oil backlash reading when
screen for contamination. Refer you reassemble the carrier.
to TP-9955, Failure Analysis for
This flowchart continues

on the next page.
Figure 12.1

12 Diagnostics
Figure 12.2

from the previous page.
When the carrier is When the carrier is

reassembled later, reassembled later, If damaged, repair the
Yes Backlash No input shaft, inter-axle
set the backlash set the backlash
within spec? differential, side gears or
to the recorded to spec. Refer to
reading. Section 5. bearings. Install the input
shaft. Refer to Sections 3 and 5.
Remove the main
differential and
ring gear from
the carrier. Install a new
Refer to Section 3. multi-lip seal.
Inspect the main differential

bearings for damage. Refer Set the input
to TP-9955, Failure Analysis shaft end play to
for Drive Axle Components. the correct
specification.
Repair the carrier Refer to Section 5.
Yes or install a
Damaged? remanufactured
carrier.
Refer to Sections
No 3 and 5. Install the carrier.
Refer to Section 5.
Test drive the vehicle.
Disassemble the Return the vehicle to service.
main differential.
Refer to Section 3.
Inspect the main

differential case, side gears
and spider for damage.
Refer to TP-9955,
Axle Components.
Repair the carrier

or install a
Yes
carrier.
Refer to Sections
No 3 and 5.
Inspect the drive pinion and

inner drive pinion bearing for
damage. Refer to TP-9955,
Axle Components.
Repair the carrier

Yes or install a
carrier.
Refer to Sections
No 3 and 5.
Reassemble and
install the main
differential.
Refer to Section 5.
Reset the backlash.

Refer to Section 5.
Figure 12.2

12 Diagnostics
Differential Making Noise

Figure 12.3
Visually inspect
the carrier in
the axle housing.
Remove the Damaged or Yes repair or replace the
carrier from the contaminated? oil pump, clean or replace
Yes axle housing. the oil screen and install
Damaged? Repair the carrier the carrier. Refer to
or install a Sections 3 and 5.
remanufactured No
No carrier.
Inspect the inter-axle

Check the input differential assembly for
shaft end play. damage. Refer to TP-9955,
Refer to Section 5. Failure Analysis for Drive
Axle Components.

Set the input
Inspect the damage. If none is found,
End play No shaft end
lubricant. Yes replace the damaged
within spec? play to spec.
Refer to MM 1. Damaged? inter-axle differential
Refer to Section 5.
components and install
Yes the carrier. Refer to
No Sections 3 and 5.
Drain and inspect Yes

the lubricant. Contaminated?
Refer to MM 1. Disassemble
the inter-axle
No
differential case.
Yes Fill the carrier with

Determine
Contaminated? the correct amount
the source of of the specified
contamination. lubricant. Refer to
Inspect the inter-axle
Section 7. Test drive
No differential spider, side gears
the vehicle.
and bearings.
Remove the carrier Refer to TP-9955,
from the housing. Failure Analysis for
Refer to Section 3. Yes Drive Axle Components.
Noisy?

No damage. If none is found, replace
Visually inspect the ring Yes the damaged inter-axle
gear and pinion for Return the Damaged? differential components and
damage. Refer to TP-9955, vehicle to install the carrier. Refer to
Failure Analysis for service. Sections 3 and 5.
Drive Axle Components. No
Inspect the main

differential bearings for damage.
Repair the carrier or Refer to TP-9955, Failure Analysis
Yes for Drive Axle Components.
Damaged? install a remanufactured
carrier. Refer to
Sections 3 and 5.
No Repair the carrier or
Yes install a remanufactured
Damaged?
Remove and carriet. Refer to
disassemble the input Sections 3 and 5.
shaft and inter-axle No
differential assembly.
Refer to Section 3. Check the ring gear
backlash and
record the reading.
Refer to Section 5.
Inspect the input shaft
oil pump for damage
and the oil screen for
contamination. Refer to
TP-9955, Failure This flowchart continues
on the next page.
Analysis for Drive Axle
Components.
Figure 12.3

12 Diagnostics
Figure 12.4

from the previous page.
When the main When the main

differential is differential is Reassemble and install
reassembled later, Yes Backlash No reassembled later, set the main differential.
set the backlash to within spec? the backlash to spec. Refer to Section 5.
the recorded reading. Refer to Section 5.
Remove the main

differential and Reset the backlash.
ring gear from Refer to Section 5.
the carrier.
Refer to Section 3.
If damaged, repair the

input shaft, inter-axle
differential, side gears
Inspect the main differential
or bearings. Install the input
bearings for damage.
shaft. Refer to Sections 3 and 5.
Refer to TP-9955, Failure
Analysis for Drive Axle
Components.
Install a new
multi-lip seal.
Repair the carrier
Yes or install a
carrier. Refer to
Sections 3 and 5. Set the input shaft
No end play to the
correct specification.
Refer to Section 5.
Disassemble the
main differential.
Refer to Section 3.
Install the carrier.
Refer to Section 5.
Test drive the vehicle.
Return the vehicle to service.
Inspect the main
differential case, side
gears and spider for
damage. Refer to TP-9955,
Axle Components.
Repair the carrier

Yes or install a
carrier. Refer to
Sections 3 and 5.
No
Inspect the drive pinion,

inner drive pinion
bearing and spigot bearing
for damage. Refer to
TP-9955, Failure Analysis
for Drive Axle Components.
Repair the carrier

Yes or install a
carrier. Refer to
Sections 3 and 5.
No
Figure 12.4

12 Diagnostics
Oil Leak
Figure 12.5
Visually inspect
the carrier in the
axle housing.
Drain and inspect
Remove the carrier the lubricant.
from the axle housing. Refer to MM 1.
Yes Repair the carrier or
Damaged? install a
remanufactured
carrier. Refer to
No Sections 3 and 5. Remove the carrier
from the axle housing.
Refer to Section 3.
Inspect the
breather.
Clean and prepare

the housing and
carrier flanges.
Apply the correct
Replace the
Yes gasket or silicone.
Breather breather. A clogged
Refer to Section 4.
clogged? breather can cause
a seal leak.
No
Install the carrier.
Refer to Section 5.
Inspect the
input shaft seal
for leaks.
Fill the carrier with

the correct amount
of the specified lubricant.
Seal Yes Replace the input Refer to Section 7.
leaking? shaft seal with
a unitized seal.
No
Test drive the vehicle
Fill the carrier with to confirm that the
the correct amount leak is repaired. Return
Inspect the ouput
of the specified the vehicle to service.
shaft seal for
lubricant.
leakage.
Refer to Section 7.
Clean the seal area.
Replace the output

shaft seal with Yes Seal
a unitized seal. leaking? Test drive the vehicle
to confirm that
the leak is repaired.
No
Return the vehicle
to service.
Fill the carrier with the
correct amount of the Inspect the
specified lubricant. carrier-to-housing
Refer to Section 7. joint for leaks.
Inspect the axle

housing welds for
Test drive the vehicle Joint No cracks or leaks. If you
to confirm that the leaking? find weld cracks, contact
leak is repaired. Return Meritor for repair
the vehicle to service. welding procedures.
Yes
Figure 12.5

12 Diagnostics
Contaminated Lubricant Found During Preventive Maintenance

Figure 12.6
Visually
inspect the
lubricant.
Clean and prepare the

Indicates Milky, Indicates housing and carrier
that water Brownish Silvery flanges. Apply the correct
Lubricant metallic
is entering gasket or silicone.
color? contamination.
the axle. Refer to Section 4.
Send out a lubrication

sample for analysis. Install the carrier.
Inspect the Advise the owner to Refer to Section 5.
breather. return for the results.
If analysis results Fill the carrier with

Replace the
Breather Yes indicate wear or the correct amount
breather. A clogged of the specified lubricant.
clogged? breakdown in the carrier,
breather can cause Refer to Section 7.
refer to the Differential
a seal leak.
Making Noise diagnostic
flowchart in this publication.
No
Test drive the vehicle

Inspect the
to confirm that the
carrier seals
leak is repaired. Return
for leaks.
the vehicle to service.
Seal No Inspect the

leaking? carrier-to-housing
joint for leaks.
Yes
Inspect the axle housing

Replace the leaking Joint No welds for cracks or leaks.
seal with a leaking? If you find weld cracks,
multi-lip seal. contact Meritor for
repair welding procedures.
Yes
Fill the carrier Drain and

with the correct inspect the
amount of the lubricant.
specified lubricant. Refer to MM 1.
Refer to Section 7.
Remove the
carrier from
Test drive the the axle. Refer to
vehicle to confirm Section 3.
that the leak is
repaired. Return the
vehicle to service.
Figure 12.6

Meritor Heavy Vehicle Systems, LLC
2135 West Maple Road Printed in USA
Troy, MI 48084 USA
866-OnTrac1 (668-7221) Copyright 2017 Revised 11-17
meritor.com Meritor, Inc. Maintenance Manual MM-0970 (16579)

MT-14X Series Single-Reduction Forward Differential Carriers On Tandem Axles

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MT-14X Series Single-Reduction Forward Differential Carriers On Tandem Axles

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Maintenance Manual MM-0970

MT-14X Series Single-Reduction Forward

About This Manual How to Obtain Additional Maintenance,

Hazard Alert Messages and Torque

@ This symbol alerts you to tighten fasteners to a specified torque

Meritor Maintenance Manual MM-0970 (Revised 11-17)

pg. 58 Assembly pg. 107 Centering Tool

MT-14X SERIES DIFFERENTIAL CARRIER

Meritor Maintenance Manual MM-0970 (Revised 11-17) 1

Item Description Item Description

2 Meritor Maintenance Manual MM-0970 (Revised 11-17)

DCDL WITH SCREW-IN COVER

Item Description Item Description

Meritor Maintenance Manual MM-0970 (Revised 11-17) 3

AXLE HOUSING WITH THRU-SHAFT

4 Meritor Maintenance Manual MM-0970 (Revised 11-17)

Description Optional Pressurized Lubrication System

The forward axles can be equipped with an optional pressurized

Meritor Maintenance Manual MM-0970 (Revised 11-17) 5

Use of Traction Chains Identifying New Design Carriers

4011800a NEW DESIGN COVER, NON-PUMP VERSION,

6 Meritor Maintenance Manual MM-0970 (Revised 11-17)

Service Recommendations Figure 2.8

Model Number Figure 2.8

AXLE IDENTIFICATION TAG INFORMATION

Serial No. . . . . . . . . Plant . . . . . . . .

LOCATION OF THE IDENTIFICATION TAG, OR STAMP

Meritor Maintenance Manual MM-0970 (Revised 11-17) 7

Axle Type Ratio 1

8 Meritor Maintenance Manual MM-0970 (Revised 11-17)

Hazard Alert Messages

Tool Part Number Manufacturer

Meritor Maintenance Manual MM-0970 (Revised 11-17) 9

Figure 3.2 Figure 3.3

STUD TAPERED DOWEL, ROUND HAMMER

10 Meritor Maintenance Manual MM-0970 (Revised 11-17)

Meritor Maintenance Manual MM-0970 (Revised 11-17) 11

Figure 3.6 Figure 3.8

Figure 3.6 ROLLER

5. Pull the bearing cage, bearings and thru-shaft assembly from

fasteners. The fasteners will hold the carrier in the housing.

NOTE: A carrier stand is available from SPX Kent-Moore. Refer to

12 Meritor Maintenance Manual MM-0970 (Revised 11-17)

or flange and place the assembly in a repair stand. Do not lift

3. Remove the snap ring from the bearing cage assembly.

Meritor Maintenance Manual MM-0970 (Revised 11-17) 13

Removal Figure 3.13

6 1 OIL SEAL 10 BEARING CONE

14 Meritor Maintenance Manual MM-0970 (Revised 11-17)

B. Remove the capscrews and washers that fasten the cover

ADJUSTING SEAL PRY

Meritor Maintenance Manual MM-0970 (Revised 11-17) 15

Figure 3.21 4008158a

16 Meritor Maintenance Manual MM-0970 (Revised 11-17)

NEW STYLE TOOL, PART NUMBER A-3256V1348

IAD ADAPTER PLATE

OLD STYLE TOOL,

SHIFT FORK 4008154c

Meritor Maintenance Manual MM-0970 (Revised 11-17) 17

18 Meritor Maintenance Manual MM-0970 (Revised 11-17)

Figure 3.32 Figure 3.33

SNAP RING INPUT SHAFT

2. Remove the spider assembly from the inter-axle differential