P Series Service

HOIST LIFTRUCK MFG., INC.
6499 W 65TH STREET

BEDFORD PARK, IL 60638
WWW.HOISTLIFT.COM
Introduction
This Service Manual was designed to help the Qualified Service Technician maintain and
service Hoist Industrial Trucks. Inside you will find detailed descriptions of
components and the procedures to repair, replace and service these items.
We hope this Manual assists you with any Repairs or Maintenance needed. If you can
not locate the procedure needed or have any additional questions please contact us.
Hoist Liftruck, Mfg., Inc.
Service Department
Technical Assistance 1-800-367-5600
Monday through Friday 8:00am – 5:00pm Central Time
INDEX
Maintenance And Rebuild Practices
Standard Torque Values
Maintenance Schedule
Chassis
How to Raise the Drive Tires
How to Raise the Steering Tires
How to Move a Disables Liftruck
Tire and Safety

Tire and Wheel Safety
Installing Drive Wheel Assembly to the Truck
Installing Steer Wheel Assembly to the Truck
Drive Axle
Drive Axle Wet Brake
Planetary Axle Wheel Ends
Wet Disc Brake
Dry Disc Park Brake
Engine
Cummins Operation and Maintenance
Transmission
Power Shift Transmission 32000
M04155-2 Controller
Hydraulics
Accumulators
Pump Repair Instructions
Orbitrol
Hydraulic trouble-Shooting
Hydraulic Fitting Tightening Procedure
P Series Hydraulic Pressure Settings
H03353 Hydraulic Schematic
Mast
Cautions and Warnings
Tilt Cylinder Check and Adjustment
Tilt Cylinder Drift Test
Lift Chain
Lubrication
P Series Fluids
P Series Drive Axle Lube Points Wet Brake
P Series Steer Axle Lube Points
P Series Mast Lube Points
Maintenance And Rebuild Practices
Provisions for Maintenance
Powered industrial trucks may become hazardous if maintenance is neglected or repairs,

rebuilds or adjustments are performed contrary to manufacture’s design criteria. Therefore,
maintenance facilities (on or off premises), trained personnel and explicit procedures shall
be provided.
Parts manuals and maintenance manuals may be obtained from the truck manufacturer. In
unusual cases not covered by the manuals, consult the truck manufacturer.
Maintenance and inspection of all powered industrial trucks shall be performed in

accordance with the manufacturer and user’s recommendations and the following
practices:
1. A scheduled planned maintenance, lubrication and inspection system shall be

followed.
2. Only trained and authorized personnel shall be permitted to maintain, repair, adjust
and inspect industrial trucks, in accordance with manufacturers specification.
Caution:
Before starting inspection and repairs of trucks:
1. Raise drive wheels free of floor or disconnect battery and use blocks or other
positive truck positioning devices.
2. Block load engaging means, inner masts, or chassis before working on them.
3. Before disconnecting any part of the engine fuel system of gasoline-powered trucks
with gravity feed fuel systems. Take precautions to eliminate any possibility of
unintentional fuel escape.
4. Before disconnecting any part of the engine fuel system of LP gas powered trucks,
close LP tank valve and run engine until fuel system is depleted and engine stops.
If the engine will not run, close LP truck valve and vent fuel slowly in a non-
hazardous area.
5. On battery powered trucks, disconnect battery before working on the electrical
system.
6. The charger connector shall be plugged only into the battery connector and never
into the truck connector.
7. If the truck has a hydraulic accumulator installed in the hydraulic steering circuit,
discharge the pressure in the hydraulic system by moving the steer handle or wheel
back and forth until any stored oil pressure is depleted. This is essential to prevent
any unintentional movement of the steering mechanism when the power to truck is
disconnected.
Brakes, steering mechanism, control mechanism, warning devices, lights, governors, lift
overload devices, guards and safety devices lift and tilt mechanisms, articulating axle stops
and frame members shall be carefully and regularly inspected and maintained in a safe
operating condition.
Special trucks or devices designed and approved for hazardous area operation shall receive
special attention to ensure that maintenance preserves the original, approved safe operating
features.
Safety Precautions and Truck Maintenance Cautions
The following “precautions” should be followed when working on a forklift.

• Always wear eye protection.
• Do not smoke while working on the vehicle.
• Always turn the key switch to the OFF position, unless a procedure requires the
key switch to be in the ON position.
• Set the parking brake. Place chocks in the front and rear of the tires to prevent
vehicle movement.
• Always use approved safety stands or blocks, when having to work under the
vehicle.
• Always discharge capacitors prior to working with electrical components, to
prevent dangerous electrical shock.
• Always service industrial truck batteries in a well ventilated area, to prevent
danger of explosion for accumulating gases.
• Avoid contact with battery acid the corrosive acid can cause injury.
The following is a list of lift truck maintenance “cautions” for trucks equipped with
solid-state control panels.
CAUTION WELDING ON LIFT TRUCKS
• Make sure the vehicle has no grounds.
• Disconnect the truck battery.
• Protect electrical wiring and components from weld spatter with a shield.
• Ventilate the battery or remove from the vehicle.
Note: Damage to the wiring and electrical components can result if the directions
above are not followed.
CAUTION DO NOT STEAM-CLEAN

Note: Steam cleaning a solid-state lift truck creates excessive moisture that
will interfere with the proper operation of the solid-state components.
The solid-state controls should be cleaned at regular intervals. Blowing dirt off with an
air hose “207 kpa (30psi) max.” periodically. This will help eliminate any serious
cleaning problems.
To do a thorough cleaning with a liquid follow the procedures below.
• Disconnect the battery form the vehicle.
• Use only water and mild detergent “dish washing detergent”
• Air-dry the controls thoroughly before connecting the battery and
putting the vehicle back into service.
CAUTION CHECK BATTERY POLARITY

Note: The battery polarity must be correct or the vehicle will not operate.
CAUTION USE TRUCK BATTERY ONLY

Do not use a motor generator unit or a battery charger to check or move a solid state
controlled vehicle. Doing so can cause serious damage to the electrical components.

TORQUING OF FASTENERS
Objective: Recognize the importance of the proper torquing of fasteners and the required
torquing procedures.
Fastener fatigue failure accounts for the majority of all fastener problems. Fatigue breaks
are caused by insufficient tightening and the lack of proper preload or clamping force.
This results in movement between the parts of the assembly and bending back and forth
or cyclic stressing of the fastener. Eventually, cracks will progress to the point where the
fastener can no longer support its designed load. At this point the fastener fails with
varying consequences.
TORQUING PROCEDURES
For the nut to properly load the bolt and prevent premature failure, a designated amount
of torque must be applied. Proper torque reduces the possibility of the fastener loosening
while in service. The correct torque to apply when you are tightening an assembly is
based on many variables. The fastener is subjected to two stresses when it is tightened.
These stresses are torsion and tension. Tension is the desired stress, while torsion is the
undesirable stress caused by friction. A large percentage of applied torque is used to
overcome this friction, so that only tension remains after tightening. Proper tension
reduces the possibility of fluid leaks.
HOIST TORQUE CHART
class 8.8 (standard) class 10.9 class 12.9 lock nuts
dry treads lubricated treads dry treads lubricated treads dry treads lubricated treads class 8.8 class10.9 class12.9
DIA. [Ft-Ibs] [Ft-Ibs] DIA. [Ft-Ibs] [Ft-Ibs] DIA. [Ft-Ibs] [Ft-Ibs] DIA. [Ft-Ibs] [Ft-Ibs] [Ft-Ibs]
M4 2 1 M4 3 2 M4 4 2 M4 1 1 2
M5 5 3 M5 7 4 M5 8 5 M5 2 3 4
M6 8 5 M6 11 7 M6 14 8 M6 4 5 6
M7 13 8 M7 19 11 M7 23 14 M7 6 8 10
M8 19 11 M8 27 16 M8 34 20 M8 9 12 15
M10 37 22 M10 53 32 M10 66 40 M10 17 24 30
M12 66 39 M12 94 56 M12 116 70 M12 29 42 52
M14 104 62 M14 148 90 M14 184 110 M14 47 66 84
M16 162 98 M16 232 140 M16 290 172 M16 74 104 130
M18 230 138 M18 315 190 M18 395 238 M18 104 144 178
M20 325 196 M20 450 270 M20 560 335 M20 146 202 255
M24 565 340 M24 780 470 M24 972 585 M24 255 350 440
M30 1119 672 M30 1548 929 M30 1930 1158 M30 505 702 864
M36 1955 1173 M36 2705 1623 M36 3372 2023 M36 882 1224 1512
Service Symbols Service Intervals
A‐Adjust C‐Clean CG‐Change 8 50 250 500 750 1000 1250 1500 1750 2000
GR‐Grease X‐Check Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs
ENGINE:
Oil Level ‐ check for evidence of external leakage X X X X X X X X X X
Oil and filter element **Change oil and filter after first 50 hours, then follow schedule CG CG CG CG CG CG CG CG
Tune Up (LPG Engines) CG CG
Crankcase breather C C C C
check engine mounts X X
FUEL SYSTEM:
Fill fuel tank ‐ check for leaks X X X X X X X X X X
Fuel Filters (diesel engine) CG CG CG CG CG CG CG CG
Fuel tank, cap, lines, and clamps X X X X X X X X
Fuel/Water Seperator CG CG CG CG CG CG CG CG
LP Fuel Filter CG CG CG CG
AIR INTAKE SYSTEM:
Check for leaks X X X X X X X X X X
Primary Air Cleaner Element CG CG CG CG
Safety Air Cleaner Element CG
Precleaner C C C C C C C C
EXHAUST SYSTEM:
PTX Purifier ‐ diesel only C C
Exhaust clamps X X X X X X X X
Check for exhaust leaks X X X X X X X X
COOLING SYSTEM
Coolant level X X X X X X X X X X
Belt tensioner and belts X X X X X X X X X X
Hoses, clamps, and radiator ‐ check for leaks X X X X X X X X X X
Radiator (clean externally) as condition warrants X X X X X X X X X X
Drain and flush cooling system CG
ELECTRICAL SYSTEM
Battery ‐ check water level and specific gravity X X X X X X X X
Battery ‐ Clean and inspect terminals C C C C C C C C
Battery ‐ Charge and Load test X X X X X X X X
TRANSMISSION
Maintain fluid level to full mark and check for leaks X X X X X X X X X X
Clean transmission breather C C C C C C C C
Check function, all speeds X X X X X X X X X X
Drain and refill transmission. Clean transmission oil intake filter screen ( use new gasket) CG CG
Transmission filter element. Clean filter housing (use new gaskets) CG CG CG CG CG CG CG CG
STEER AXLE ** Torque Studs after first 10 Hours of Service, weekly thereafter
Lubricate all grease fittings GR GR GR GR GR GR GR GR
Inspect and repack hub bearings GR GR
Adjust wheel bearings A A
Check mounting bolts X X X X X X X X
DRIVE AXLE ** Torque Studs after first 10 Hours of Service, weekly thereafter
Differential and planetary hubs ‐ maintain oil level X X X X X X X X
Differential and planetary hubs ‐ change oil CG
Inspect brake linings (drum and shoe type) X
Adjust slack adjusters A A A A A A A A
Grease s‐cams and slack adjusters GR GR GR GR GR GR GR GR
Check mounting bolts X X X X X X X X
CHASSIS
Lubricate remaining grease fittings and linkages GR GR GR GR GR GR GR GR
Check tires, valve stems and caps, wheels, lugs. And tire pressure X X X X X X X X
HYDRAULIC SYSTEM
Maintain hydraulic level in reservior X X X X X X X X X X
Check hoses and piping for crackes, chafing, leaking, and loose fittings X X X X X X X X
Drain, clean instde tank, and refill system CG
Replace hydraulic tank breather CG CG CG CG CG CG CG CG
Suction strainers CG
Return line filter **Change after the first 50 hours, then follow schedule CG CG CG CG CG CG CG CG
Control valve ‐ check for proper operation X X X X X X X X
Contril valve ‐ check for leaks X X X X X X X X
Hydraulic cylinders ‐ check for leaks and damage X X X X X X X X
Accumulators ‐ check nitrogen precharge X X X X X X X X
MAST AND ATTACHMENT
Lubricate mast hinges GR GR GR GR GR GR GR GR
Lubricate all mast and attachment grease points including, main and side rollers, slides, carriage
rollers, and all other grease fittings on mast. GR GR GR GR GR GR GR GR GR
Check all rollers for smooth motion X X X X X X X X
Check lift chains for rust, streching, and cracking X X X X X X X X
Check lift chains for proper adjustment A A A A A A A A
check chain anchors and pins for wear X X X X X X X X
Lubricate lift chains with chain lube GR GR GR GR GR GR GR GR
Check mast chanels for cracks X X X X X X X X
check carriage for cracks X X X X X X X X
visually inspect forks for cracks and wear X X X X X X X X
Mag particle inspect forks X
P-Series Chassis
Chassis How To Raise The Drive Tires
Contents of this section 1. Put blocks on each side (front and back) of the
This section describes the repair procedures for the steering tires to prevent movement of the lift
chassis and connected parts. truck.
Chassis 2. Put the mast in a vertical position. Put a block

The M-Series chassis is a one-piece weldment and is under each outer mast channel.
designed for the utmost rigidity and reliability. The
chassis incorporates the front axle mount, overhead 3. Tilt the mast fully forward until the drive tires
guard mounting, steer axle mounting, engine and are raised from the surface.
transmission mounts, integral hydraulic and fuel
tanks. 4. Put additional blocks under the frame behind the
drive tires.
WARNING 5. If the hydraulic system will not operate, use a

The removal of the following assemblies will hydraulic jack under the side of the frame near
cause large changes in the center of gravity: the front. Make sure that the jack has a capacity
mast, drive axle, engine and transmission, and equal to at least half the weight of the lift truck.
the counterweight. See the nameplate.
The lift truck must be put on blocks for some
types of maintenance and repair. When the lift How To Raise The Steering Tires
truck is put on blocks put additional blocks in
the following positions to maintain stability: 1. Apply the parking brake. Put blocks on both
sides (front and back) of the drive tires to
1. Before removing the mast and drive axle, put prevent movement of the lift truck.
blocks under the counterweight so that the
lift truck cannot fall backward. 2. Use a hydraulic jack to raise the steering tires.
Make sure that the jack has a capacity of at least
2. Before removing the counterweight, put 2/3 of the total weight of the lift truck as shown
blocks under the mast assembly so that the on the nameplate.
lift truck cannot fall forward.
Put the jack under the steering axle or frame to raise
The surface must be solid, even, and level when the lift truck. Put blocks under the frame to support
the lift truck is put on blocks. Make sure that the lift truck.
any blocks used to support the lift truck are
solid, one piece units.
NOTE: Some lift trucks have lifting eyes. These

lift points can be used to raise the lift truck so that
blocks can be installed.
How to Move a Disabled Lift Truck
WARNING
Use extra caution when towing a lift truck if any of the following conditions exist:
a. Brakes do not operate correctly.

b. Steering does not operate correctly.
c. Tires are damaged.
d. Traction conditions are bad.
e. The lift truck must be towed on a slope.
If the engine cannot run, there is no power available for the hydraulic steering
system and the service brakes. This condition can make the lift truck difficult to
steer and stop. If the lift truck uses power from the engine to help apply the brakes,
the application of the brakes will be more difficult. Poor traction can cause the
disabled lift truck or towing vehicle to slide. A slope will also make the lift truck
more difficult to stop.
Never lift and move a disabled lift truck unless the disabled lift truck MUST be
moved and cannot be towed. A lift truck used to move a disabled lift truck MUST
have a capacity rating equal to or greater than the weight of the disabled lift truck.
The capacity of the lift truck used to move a disabled lift truck must have a load
center equal to half the width of the disabled lift truck. See the nameplate of the
disabled lift truck for the approximate total weight. The forks must extend the full
width of the disabled lift truck. Put the weight center of the disabled lift truck on
load center of the forks. Be careful to not damage the under side of the lift truck.
lift truck. Install approximately

How To tow The Lift Truck ½ of a capacity load on the forks
of the lift truck that is being used
The towed lift truck must have an to tow the disabled lift truck.
operator. This ½ capacity load will
increase the traction of the lift
Tow the lift truck slowly. truck. Keep the load as low as
possible.
1. Raise the carriage and forks
approximately 30 cm (12 inches) 4. Use a towing link made of steel
from the surface. Install a chain that attaches to the tow pins in
to prevent the carriage and mast the counterweights of both lift
channels from moving. trucks.
2. If another lift truck is used to tow

the disabled lift truck, that lift
3. truck must have an equal or

larger capacity than the disabled
MD-3 MAIN DISPLAY PAGE
1) Water temperature gauge – Indicates water temperature of engine

2) Fuel level gauge – Indicates the fuel level of the engine
3) Oil pressure gauge – Indicates the oil pressure level of the engine
4) Tachometer – Indicates the rpm of the engine
5) Filter indicator – Displayed when either the transmission, air or hydraulic filter
element needs replacing
6) Air filter indicator – Displayed in conjunction with the filter indicator to indicate
that the air filter element needs to be replaced.
7) Hydraulic filter indicator – Displayed in conjunction with the filter indicator to
indicate that the hydraulic filter element needs to be replaced.
8) Transmission filter indicator – Displayed in conjunction with the filter indicator to
indicate that the transmission filter element needs to be replaced.
9) Battery indicator – Displayed when the charge of the engine battery is low
10) Parking brake indicator – Displayed when the parking brake is engaged
11) Oil pressure indicator – Displayed when the oil pressure of the engine is low
12) Fuel level indicator – Displayed when the engine fuel level is low
13) Transmission temperature indicator – Displayed when the transmission is at an
unsafe temperature.
14) Water temperature indicator – Displayed when the engine is at an unsafe
temperature.
15) Service indicator – Displayed when preventative maintenance of the vehicle needs
to be performed. (See adjustments section to reset after maintenancing)
16) Hour meter – Displays the number of hours of operation
17) F1 function key – Use to view overload display page if vehicle is equipped with a
shock sensor.
18) Menu key – Use to view the menu display page
19) F2 function key – This function key is inactive in this display page
22) Back function key – This function key is inactive in this display page
23) Up function key – This function key is inactive in this display page
24) Accept function key – This function key is inactive in this display page
25) Down function key – This function key is inactive in this display page
MD-3 MENU DISPLAY PAGE
1) F1 function key – Use to view adjustment menu

2) F2 function key – Use to view measure menu
3) F3 function key – Use to view preferences menu
4) F4 function key – Use to view information menu
5) Back function key – Use to return to main display page
6) Menu function key – This function key can also be used to return to the main display page
MD-3 MAIN ADJUSTMENT DISPLAY PAGE
1) Adjustment group – Listed are all item groups that have adjustable parameters
2) Group security – If the listed adjustment group is password protected then an icon
of a lock will be displayed.
3) F1 Function key – Use to return to menu display page
4) F2 Function key – This function key is inactive in this display page
7) Back function key – Use to return to menu display page
8) Menu function key – Use to view main display page
9) Down function key – Use to scroll down and select between adjustment groups
10) Accept function key – Use to view adjustment group display page
11) Up function key – Use to scroll up and select between adjustment groups
MD-3 SECURITY DISPLAY PAGE
1) Pin code – The proper pin code must be entered in for making adjustments to the
corresponding adjustment group**Pin code 6499 to make adjustments, pin code
4200 to reset service hour meter
2) F1 Function key – This key will tab the cursor to the first digit of the pin code
3) F2 Function key – This key will tab the cursor to the second digit of the pin code
4) F3 Function key – This key will tab the cursor to the third digit of the pin code
5) F4 Function key – This key will tab the cursor to the fourth digit of the pin code
6) Back function key – This key will return the display back to the adjustment page
7) Menu function key – This key will return the display back to the adjustment page
8) Down function key – Use to decrease the highlighted digit of the pin code
9) Accept function key – Use to accept the highlighted digit of the pin code
10) Up function key – Use to increase the highlighted digit of the pin code
ADJUSTMENT GROUP DISPLAY PAGE
(TRANSMISSION ADJUSTMENT)
1) Transmission adjustment group – Listed are all transmission items that can be
adjusted
3) F2 Function key – Use to set highlighted parameter to its default value
6) Back function key – Use to return to main adjustment display page
8) Down function key – Use to scroll down between transmission adjustments
9) Accept function key – Use to view highlighted parameter adjustment page
10) Up function key – Use to scroll up between transmission adjustments
PARAMETER ADJUSTMENT PAGE
(TRANSMISSION UPSHIFT)
1) 2nd to 3rd Upshift value – Listed is the current RPM at which the transmission will
shift from 2nd gear to 3rd gear
3) F2 Function key – Use to set highlighted parameter to its default value
6) Back function key – Use to return to transmission adjustment display page
8) Down function key – Use to decrease 2nd to 3rd upshift value
9) Accept function key – Use to set 2nd to 3rd upshift value
10) Up function key – Use to increase 2nd to 3rd upshift value
MEASURE MENU DISPLAY PAGE
1) Measure group – Listed are all item groups that have parameters that can be
measured
8) Down function key – Use to scroll down and select between measure groups
9) Accept function key – Use to view measure group display page
10) Up function key – Use to scroll up and select between measure groups
MEASURE GROUP DISPLAY PAGE
(ENGINE DATA – SCALED VALUE)
1) Measure parameter – Listed are all parameters and there value/state

3) F2 Function key – Use to change values/states from scaled value to raw value
6) Back function key – Use to return to measure menu display page
8) Down function key – Use to scroll down between measure parameters
10) Up function key – Use to scroll up between measure parameters
MEASURE GROUP DISPLAY PAGE
(ENGINE DATA – RAW VALUE)
1) Measure parameter – Listed are all parameters and there raw value/state
3) F2 Function key – Use to change values/states from raw value to scaled value
6) Back function key – Use to return to measure menu display page
8) Down function key – Use to scroll down between measure parameters
10) Up function key – Use to scroll up between measure parameters
PREFERENCES MENU DISPLAY PAGE
1) F1 Function key – Use to go to display menu

2) F2 Function key – Use to go to date/time menu
3) F3 Function key – Use to go to language menu
DISPLAY MENU DISPLAY PAGE
1) F1 Function key – Use to go to menu display page

2) F2 Function key – Use to select backlight setting
3) F3 Function key – Use to select screen saver setting
5) Back function key – Use to return to preferences display page
7) Down function key – This function key is used to lower backlight and screen
saver settings when item is highlighted
8) Accept function key – Use to accept backlight and screen saver settings
9) Up function key – This function key is used to raise backlight and screen saver
settings when item is highlighted
DATE/TIME MENU DISPLAY PAGE
1) F1 Function key – Use to select date setting

2) F2 Function key – Use to select time setting
5) Back function key – Use to return to preferences display page
7) Down function key – This function key is used to lower date and time settings
when item is highlighted
8) Accept function key – Use to accept date and time settings
9) Up function key – This function key is used to raise date and time settings when
item is highlighted
LANGUAGE MENU DISPLAY PAGE
1) F1 Function key – Use to go to menu display page

5) Back function key – Use to return to preferences menu display page
8) Accept function key – Use to return to preferences menu display page
INFO MENU DISPLAY PAGE
1) F1 Function key – Use to go to modules menu display page

MODULES MENU DISPLAY PAGE
1) F1 Function key – Use to go to the menu display page

5) Back function key – Use to return to info display page
7) Down function key – This function key is used to select module
8) Accept function key – This function key is used to accept module
9) Up function key – This function key is used to select module
6499 West 65th St.
Bedford Park, IL 60638
Date: October 4, 2004

Title: Mounting Procedure for Press-on Tires
Procedure#: A09733
MOUNTING PROCEDURE FOR PRESS-ON TIRES
PROCEDURE:
1) Lubricate inside diameter of tire to be pressed with Tectyl 506

petroleum grease.
2) Verify wheel has a lead-in chamfer or radius containing no sharp
edges. If wheel contains any sharp edges they must be removed
before continuing.
3) Place wheel into press with chamfer/radius side facing up.
4) Place the tire onto the wheel making sure that the tire is sitting squarely
on the wheel.
5) Lower the press slowly and press the tire approx. ½” onto the wheel
such that the tire is beyond the lead-in chamfer or radius.
6) In order to insure the tire is being pressed squarely, release pressure by
raising the press slightly and then re-lower the press onto the tire and
continue pressing.
7) Press the tire fully onto the wheel and verify that the required pressure
does not increase significantly throughout the pressing process. If the
required pressing pressure does increase significantly then see the
precautions section listed below.
8) Release pressure by raising the press fully. If the wheel assembly only
requires a single tire, then this completes the operation. If the wheel
assembly requires dual tires, then proceed with steps 9 thru 14.
9) Place the second tire directly on top of the first tire without changing
the orientation and location of the wheel assembly in the press.
10)Lower the press slowly and press the second tire approx. ½” onto the
wheel such that the tire is beyond the lead-in chamfer or radius.
11)In order to insure the second tire is being pressed squarely, release
pressure by raising the press slightly and then re-lower the press onto
the tire and continue pressing.
12)Press the second tire fully onto the wheel and verify that the required
pressure does not increase significantly throughout the pressing
process. If the required pressing pressure does increase significantly
then see the precautions section listed below.
13)Release pressure by raising the press fully.
14)Remove the new tire and wheel assembly from the press.
PRECAUTIONS:
1) If the pressing pressure is seen to be increasing significantly while
pressing a tire then stop the press and release pressure by raising the
press. If a curl or several curls of steel have formed in front of the tire at
its inside diameter then the tire/wheel assembly must be turned over
and the tire needs to be pressed off. Finally turn the wheel back over
and repress the tire onto the wheel from the opposite end using the
procedure above.
2) If the pressing pressure is seen to be increasing significantly while
pressing the tire but no curls of steel have formed then the tire maybe
slightly undersized. Therefore continue to press the tire onto the wheel
using the procedure above. Keep a close watch that no curls of steel
form in front of the tire.
Press-on Tire
Make sure the lead in
Chamfer or Radius is
facing up and there are
no sharp edges. Make
sure the wheel sits on
a clean flat surface.
Lubricate the inside

diameter of the tire
to pressed with
Tectyl 506
petroleum grease
Place the tire onto
the wheel making
sure that the tire is
sitting squarely on
the wheel.
Look for curl metal in

front of the tire during
pressing, Should
curling occur turn the
tire/wheel over and
press tire off.
Drive –By-Wire
By Wire Accelerator
It is important that the foot pedal
accelerator
l t potentiometer
t ti t sett screw
stops be in place and adjusted
correctly There are two set screws
correctly. screws,
minimum idle set screw and maximum
RPM range set screw. It is important
that minimum idle voltage be @
0.60volt DC minimum to 0.80volt DC
maximum, anything less will result in
an engine stalling condition.
S t
Setup
To set the idle:
Turn the keyy switch
to the on position.
Select the DC range
on the volt meter.
S t
Setup
Attach the positive lead Black “C”
Red “B”
from the volt meter to

the lead wire White “A”
A Whit “A”
White
of connector to the
potentiometer.
Attach the negative lead
from the volt meter to
the wire to the Red “B”
B
of connector to the
potentiometer.
S t
Setup
Potentiometer
Using a wrench loosen the
jam nut on the minimum idle.
Adjust the M8 screw to ½ Jam Nut
volt DC is measured on the
volt meter.
Lock the Jam Nut NOTE: To
prevent the screws from
coming loose apply loctite to Maximum RPM Range
the threads. Set Screw Stop
Minimum Idle Set Screw
Thee Maximum
a u RPM voltage
o tage St
Stop
must also be set not to
exceed 3.25 volts DC. This
will also result in an engine
stalling condition
condition.
P-Series Tire and Steer Axle
Installing Drive Wheel Assembly to the Truck
1
9 4
6 7
Drive Wheel
Assembly
3 2
10 5
8
Install the wheel assembly on the truck axle. Then install the mounting nuts. Tighten the
mounting nuts in 50 ft lb. Increments following the approved torque sequence. Repeat
this sequence till the following torque in reached. Drive Wheel final torque 600 ft lb dry.
This will prevent tire run out, uneven bolt stretch, rim fractures and possible failure.
Installing Steer Wheel Assembly to the Truck
6 4
Steer Wheel
7 Assembly
8
3 2
5
Install the wheel assembly on the truck axle. Then install the mounting lock and nuts.
Tighten the mounting nuts in 50 ft lb. Increments following the approved torque
sequence. Repeat this sequence till the following torque in reached. Steer Wheel final
torque 200 ft lb dry.
This will prevent tire run out, uneven bolt stretch, rim fractures and possible failure.
Steer Axle
The P series axle was designed to service the major steering components
without remove the axle from the truck. In some cases it may become
necessary to change the pivot pin and this would require the steer axle
to be removed.
Shown is the steer axle without the

counterweight attached. NOTE the
counterweight does not need to be
removed to remove the steer axle from
the truck. To remove the steer axle lift up
the truck with a lifting device of adequate
capacity. “Consult your truck’s data plate
for the correct capacity.” Put blocks under
the truck’s frame and remove the steer
Safety Blocks wheels.
Hydraulic Lines Remove the steering hydraulic hoses from

the steel lines make sure to use caps and
plugs to prevent contamination.
Place a hydraulic jack under the steer axle

for support. Remove the four 1”-8 Hex
Head Bolts. The steer axle now can be
lowered and remove from the truck. NOTE
1” – 8 Hex Head there are two caps that hold the steer axle
Steer Axle Cap Cap Bolts. Torque in the truck’s frame “front and back”.
Value 583 Ft Lbs
Dry
To remove the steer cylinder from the steer axle assembly this
procedure assumes the truck is safely blocked up.
Remove the steering hydraulic hoses,

Steel Line Retainers retainers and steel lines to the steering
cylinder. Make sure to use caps and plugs
to prevent contamination.
With a flat blade screw driver remove the

C clip retainer steering the C clip and pin from the steer
and pin cylinder on both sides. Swing the tie rod
and steer knuckle outward for clearance.
M20 Hex Head Bolts. Torque

Value 450 Ft Lbs Dry Remove the four M20 Hex Head Bolts that
retain the steer cylinder. The steer cylinder
now can be removed from the assembly.
Before disassembly the steer cylinder must be cleaned free of dirt,
grease and other contaminations. Servicing the cylinder components,
must be preformed in a clean environment to prevent leaks and
damages. Always work clean, make sure the tools and most important
your hands are keep clean when handling the internal components.
To dissemble the cylinder:
• Remove the two items # 3 Gland by carefully tapping with a soft
hammer from the cylinder tube and side it off the cylinder rod.
• Remove item # 2 cylinder rod piston assembly from the tube.
The seals now can be replaced in the gland and on the cylinder rod.
Before replacing the seals, make sure the surfaces that retain the seals
are clean and are not damaged. Inspected the chrome surface of the
cylinder rod make sure there is no damages. If there are deep scratches
or dents to the chrome surface, it must be repair or replaced before the
cylinder can be put back together. Make sure to inspect the cylinder
tube for damage
• Remove the piston seal ring item # 6 from the cylinder rod.
• Lubricate the new piston seal ring with hydraulic oil and install
the new piston seal ring item # 6 on to the cylinder rod.
• Lubricate both the piston seal ring, cylinder tube and install the
piston rod into the cylinder tube taking care not to damage the
seal ring.
• Remove the seals from the gland take note the order and positions
of the seals.
• Lubricate the new seal with hydraulic and install them in the
gland in the correct order.
• Lubricate the gland nut seals, cylinder rod, and cylinder tube and
install the gland nut on to the cylinder rod taking care not to
damage the seals. Slide the first gland on the rod until it is
connected to the cylinder tube. NOTE do one end first then using
a clean flat surface to line up both glands and install the second
gland on to the cylinder.
• Install the steer cylinder back into the steer axle assembly and
torque the four M20 bolts equally @ 450 Ft Lbs.
The steering knuckle has a stop that is adjustable to prevent the steering
tire from hitting the frame of the truck.
Greasing the wheel bearing is done from the lube fitting located on the
cover of the steer axle hub. When the steer hub must be removed from
the steer axle the following procedure must be preformed:
Lube fitting
3/8-16 SHCS
Wheel Bearing Cones

1st Lock Nut
Star Washer
2nd Lock Nut
Tongue Washer
Bearing Race
Grease Seal
Seal Ring Support
To remove the steering hub:
• Remove the six 3/8-16 SHCS from the cover.

• Remove the cover from the hub.
• With a screw driver or punch lift unlock the tab of the star
washer by lifting it out of the lock nut.
• Remove the 1st lock nut and star washer.
• Remove the 2nd lock nut, tongue washer and cone bearing.
• Remove the steer hub using a lifting device.
The bearing races can be removed using a brass bar and hammer. Line
up the bearing race to the hub and press the race with the correct size
arbor back into the hub. Make sure that the bearing race is seated
squarely into the hub.
While serving the steer hub it is important to replace the grease seal
and ring support seal to prevent contamination:
• Remove cone bearing, grease seal and ring seal support from the
steer knuckle.
• Install the new ring seal support, grease seal on to the steer
knuckle.
• Install the inner wheel bearing cone making sure it is repacked
with a good quality wheel bearing grease. NOTE: use a wheel
bearing grease packing tool. This procedure assumes the wheel
bearings have been cleaned or replaced.
• With a lift device install the steer hub on to the steer axle knuckle.
• Install the outer wheel bearing.
• Install the tongue washer and 2nd lock nut.
• Torque the 2nd lock washer while turning the hub to about 50 Ft
Lbs to seat the cone bearings.
• Back off the lock nut and torque to 5 Ft Lbs.
• Install the star washer and 1st lock nut.
• Torque the 1st lock nut to about 25 Ft Lbs.
• Find the tab on the star washer that lines up with the lock washer
and bend the tab down with a punch.
To remove steer knuckle from the steer axle assembly:
This procedure assumes the steer hub is removed.
M10 H.H.C.S
M10 Lock Washer Grease Seal
Grease Retainer
M5 H.H.C.S
Bearing Race
Bearing Support
Distance Washers
• Remove the six M10 screws and lock washers from the bottom
cap.
• Remove the cap, distance washers and bearing support. NOTE:
The amount of distance washers used.
• Remove the six M10 screws and lock washers from the top cap
and remove the cap.
• Loosen the four M5 screws that retain the grease seal.
• Force the steer knuckle down until the bottom bearing race is out
of the frame.
• Remove the knuckle from the frame.
The bearings and grease seals now can be replaced.

P-Series Drive Axle Service
DRIVE AXLE WET BRAKE
BREAK-IN:
NOTE: Change the fluid in the brake housing and the filter in the wet
brake cooling system after the first month or 200-250 Hours of
operation, which ever comes first.
NORMAL MAINTANENCE:
Change the fluid every 6 months or every 3000 hours of operation,
which ever comes first.
WARNING! ALWAYS USE A CLEAN APPROVED LABELED CONTAINER TO

PREVENT CONTAMINATION.
1826D MM-20195 2/8/01 8:57 AM Page 2
Issued 02-01
$2.50
Wet Disc Brake

with Dowel Pins
Model W3H (360 mm)
Maintenance Manual MM-20195
W3H (360 mm)

1826D MM-20195 2/8/01 8:57 AM Page 3
Service Notes
Before You Begin Access Information on

This manual provides maintenance and service ArvinMeritor’s Web Site
procedures for Meritor’s W3H 360 mm wet disc Additional maintenance and service information
brake with dowel pins. While this manual cannot for ArvinMeritor’s commercial vehicle systems
cover all possible wheel end combinations, it shows component lineup is also available on
two typical wheel ends: ArvinMeritor’s web site at www.arvinmeritor.com.
• A wheel end with the outer bearing assembled To access information, click on Products &
on the ring gear hub journal (such as the PRC Services/Tech Library Icon/HVS Publications.
775 wheel end). The screen will display an index of publications
• A wheel end with the outer bearing assembled by type.
on the spindle journal (such as the PRC 425
wheel end). Additional Information
Before you begin procedures: Call ArvinMeritor’s Customer Service Center at
1. Read and understand all instructions and 800-535-5560 to order the following publications:
procedures before you begin to service components. • Wet Disc Brakes/W3H, W4H, W5H and W4M
2. Read and observe all Caution and Warning (Spring Applied Hydraulic Release)
safety alerts that precede instructions or (Maintenance Manual 4L)
procedures you will perform. These alerts help • Planetary Rigid and Steering Axle Wheel Ends
to avoid damage to components, serious (Cantilever-Mounted Planetary Pinion Shaft
personal injury, or both. Design)
3. Follow your company’s maintenance and (Maintenance Manual 9C)
service, installation, and diagnostics guidelines. • Planetary Wheel Ends/Covered Planetary
4. Use special tools when required to help avoid Spider Design
serious personal injury and damage to components. (Maintenance Manual 9E)
• Planetary Axle Wheel Ends/Coverless Planetary
Safety Alerts, Torque Symbol Spider Design
and Notes (Maintenance Manual 9G)
• Planetary Axle Wheel Ends (Models PRC 425Q,
PRC 775P, PRC 425 W3H and PRC 775 W3H)
! WARNING A Warning alerts you to an (Maintenance Manual 9K)
instruction or procedure
that you must follow • Drivetrain Plus™ by ArvinMeritor Technical
exactly to avoid serious Electronic Library on CD. Features product and
personal injury and service information on most Meritor, ZF
damage to components. Meritor and Meritor WABCO products. $20.
Order TP-9853.
! CAUTION A Caution alerts you to an
that you must follow
exactly to avoid damage
to components and
possible serious personal
injury can also occur.
T The torque symbol alerts

you to tighten fasteners to
a specified torque value.
NOTE: A Note provides

information or
suggestions that help you
correctly service a
component.
1826D MM-20195 2/8/01 8:57 AM Page 4
Table of Contents
! Asbestos and Non-Asbestos Fibers Warnings.................................................................................1
Section 1: Exploded View

W3H – 360mm Wet Disc Brake with Dowel Pins.........................................................................................2
Wheel End with Outer Bearing on Ring Gear Hub Journal .......................................................................3
Wheel End with Outer Bearing on Spindle Journal ...................................................................................4
Section 2: Introduction
Description .....................................................................................................................................................5
Wheel End with Outer Bearing on Ring Gear Hub Journal
Cooling Systems
Wheel End with Outer Bearing on Spindle Journal ..................................................................................6
Cooling Systems
How to Identify the Brake Model..................................................................................................................7
Section 3: Disassembly
Removal – Wet Disc Brake ............................................................................................................................8
Drain Fluids from Wheel Ends
Wheel End with Outer Bearing on Ring Gear Hub Journal .....................................................................10
Wheel End with Outer Bearing on Spindle Journal .................................................................................12
Brake Disc Housing Assembly – Wheel End .............................................................................................13
Brake Piston Housing Assembly ................................................................................................................14
Brake Piston Housing and Wheel Spindle.................................................................................................15
Section 4: Inspection ...................................................................................................................................16
Section 5: Prepare Parts for Assembly

Clean Components Prior to Assembly.......................................................................................................18
1826D MM-20195 2/8/01 8:57 AM Page 5
Table of Contents
Section 6: Assembly
Installation – Wheel Spindle .......................................................................................................................19
Brake Piston Housing ..................................................................................................................................20
Piston Assembly ..........................................................................................................................................21
Brake Disc Housing .....................................................................................................................................22
Duo-Cone Face Seal into Brake Disc Housing and into Hub....................................................................23
Check for Correct Installation of the Duo-Cone Seal ................................................................................25
Wheel Hub to Brake Disc Housing .............................................................................................................26
Adjustment – Wheel Bearing Preload – Wheel End with Outer Bearing on Ring Gear Hub Journal ...27
Wheel Bearing Preload – Wheel End with Outer Bearing on Spindle Journal.......................................28
Fill Wet Brake Assembly with Required Coolant ......................................................................................29
Adjust Brake with New Disc Pack
Remove Air from the System (“Bleed” the Brakes) .................................................................................30
Air/Hydraulic or Mechanical Actuator Systems
Full Hydraulic Systems
Section 7: Maintenance
Coolant Change Intervals............................................................................................................................31
Coolant Draining and Filling
Section 8: Troubleshooting
Brake Does Not Apply .................................................................................................................................33
Brake Does Not Release
Braking Performance
Brake Leaks Actuation Fluid ......................................................................................................................34
Brake Cooling Fluid Leakage
Brake Noise and Vibration
Brake Overheats ..........................................................................................................................................35
Section 9: Specifications
Plug and Screw Torque on Brake Piston Housing....................................................................................36
W3H Wheel End Torque Chart for the PRC 775 ........................................................................................37
W3H Wheel End Torque Chart for the PRC 425 ........................................................................................38
Minimum Brake Disc Thickness .................................................................................................................39
Hydraulic Fluid for Brake Actuation
Brake Coolant Specifications: Sump and Forced Cooling Systems with Hub Seals
Coolant Change Intervals
Hydraulic Fluid Specifications
1826D MM-20195 2/8/01 8:57 AM Page 6
Asbestos and Non-Asbestos Fibers
! ASBESTOS FIBER WARNING ! NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce The following procedures for servicing brakes are recommended to reduce
exposure to asbestos fiber dust, a cancer and lung disease hazard. Material exposure to non-asbestos fiber dust, a potential cancer and lung disease
Safety Data Sheets are available from Meritor. hazard. Material Safety Data Sheets are available from Meritor.
Hazard Summary Hazard Summary

Because some brake linings contain asbestos, workers who service brakes must Most recently manufactured brake linings do not contain asbestos fibers. These brake
understand the potential hazards of asbestos and precautions for reducing risks. Exposure linings may contain one or more of a variety of ingredients, including glass fibers, mineral
to airborne asbestos dust can cause serious and possibly fatal diseases, including wool, aramid fibers, ceramic fibers and silica that can present health risks if inhaled.
asbestosis (a chronic lung disease) and cancer, principally lung cancer and mesothelioma Scientists disagree on the extent of the risks from exposure to these substances.
(a cancer of the lining of the chest or abdominal cavities). Some studies show that the risk Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease.
of lung cancer among persons who smoke and who are exposed to asbestos is much Silicosis gradually reduces lung capacity and efficiency and can result in serious
greater than the risk for non-smokers. Symptoms of these diseases may not become breathing difficulty. Some scientists believe other types of non-asbestos fibers, when
apparent for 15, 20 or more years after the first exposure to asbestos. inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic fiber
Accordingly, workers must use caution to avoid creating and breathing dust when dust are known to the State of California to cause lung cancer. U.S. and international
servicing brakes. Specific recommended work practices for reducing exposure to agencies have also determined that dust from mineral wool, ceramic fibers and silica are
asbestos dust follow. Consult your employer for more details. potential causes of cancer.
Accordingly, workers must use caution to avoid creating and breathing dust when
Recommended Work Practices servicing brakes. Specific recommended work practices for reducing exposure to non-
asbestos dust follow. Consult your employer for more details.
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
from other operations to reduce risks to unprotected persons. OSHA has set a maximum
allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average Recommended Work Practices
and 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to what 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
extent adherence to the maximum allowable exposure levels will eliminate the risk of from other operations to reduce risks to unprotected persons.
disease that can result from inhaling asbestos dust. OSHA requires that the following sign
be posted at the entrance to areas where exposures exceed either of the maximum 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for
allowable levels: silica of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-
asbestos brake linings recommend that exposures to other ingredients found in non-
DANGER: ASBESTOS asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average.
CANCER AND LUNG DISEASE HAZARD Scientists disagree, however, to what extent adherence to these maximum allowable
AUTHORIZED PERSONNEL ONLY exposure levels will eliminate the risk of disease that can result from inhaling non-
RESPIRATORS AND PROTECTIVE CLOTHING asbestos dust.
ARE REQUIRED IN THIS AREA Therefore, wear respiratory protection at all times during brake servicing, beginning with
the removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA)
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter filter approved by NIOSH or MSHA, if the exposures levels may exceed OSHA or
approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, manufacturer’s recommended maximum levels. Even when exposures are expected to
beginning with the removal of the wheels. be within the maximum allowable levels, wearing such a respirator at all times during
3. Procedures for Servicing Brakes. brake servicing will help minimize exposure.
a. Enclose the brake assembly within a negative pressure enclosure. The enclosure 3. Procedures for Servicing Brakes.
should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure a. Enclose the brake assembly within a negative pressure enclosure. The enclosure
in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts. should be equipped with a HEPA vacuum and worker arm sleeves. With the
b. As an alternative procedure, use a catch basin with water and a biodegradable, non- enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the
phosphate, water-based detergent to wash the brake drum or rotor and other brake brake parts.
parts. The solution should be applied with low pressure to prevent dust from becoming b. As an alternative procedure, use a catch basin with water and a biodegradable, non-
airborne. Allow the solution to flow between the brake drum and the brake support or phosphate, water-based detergent to wash the brake drum or rotor and other brake
the brake rotor and caliper. The wheel hub and brake assembly components should be parts. The solution should be applied with low pressure to prevent dust from becoming
thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. airborne. Allow the solution to flow between the brake drum and the brake support or
Wipe the brake parts clean with a cloth. the brake rotor and caliper. The wheel hub and brake assembly components should be
c. If an enclosed vacuum system or brake washing equipment is not available, employers thoroughly wetted to suppress dust before the brake shoes or brake pads are
may adopt their own written procedures for servicing brakes, provided that the removed. Wipe the brake parts clean with a cloth.
exposure levels associated with the employer’s procedures do not exceed the levels c. If an enclosed vacuum system or brake washing equipment is not available, carefully
associated with the enclosed vacuum system or brake washing equipment. Consult clean the brake parts in the open air. Wet the parts with a solution applied with a
OSHA regulations for more details. pump-spray bottle that creates a fine mist. Use a solution containing water, and, if
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use available, a biodegradable, non-phosphate, water-based detergent. The wheel hub
with asbestos when grinding or machining brake linings. In addition, do such work in an and brake assembly components should be thoroughly wetted to suppress dust before
area with a local exhaust ventilation system equipped with a HEPA filter. the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth.
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when
HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic grinding or machining brake linings. In addition, do such work in an area with a local
solvents, flammable solvents, or solvents that can damage brake components as exhaust ventilation system equipped with a HEPA filter.
wetting agents. e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic
by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you solvents, flammable solvents, or solvents that can damage brake components as
empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA wetting agents.
filter approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter
wet the filter with a fine mist of water and dispose of the used filter with care. or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or When you empty vacuum cleaners and handle used rags, wear a respirator equipped
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with with a HEPA filter approved by NIOSH or MSHA, to minimize exposure. When you
a HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter
shake or use compressed air to remove dust from work clothes. with care.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with 5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or
care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped
waste disposal. with a HEPA filter to vacuum work clothes after they are worn. Launder them separately.
Do not shake or use compressed air to remove dust from work clothes.
Regulatory Guidance 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations
States, are made to provide further guidance to employers and workers employed within on waste disposal.
the United States. Employers and workers employed outside of the United States should
consult the regulations that apply to them for further guidance. Regulatory Guidance
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the
United States, are made to provide further guidance to employers and workers employed
within the United States. Employers and workers employed outside of the United States
should consult the regulations that apply to them for further guidance.
1
1826D MM-20195 2/8/01 8:57 AM Page 7
Section 1
Exploded View
W3H – 360mm Wet Disc Brake with Dowel Pins 23

22
21
20
19
18
17
16
14 15
13
5 1
6
11
2
12 3
4
7 5
10 9 8 6
6 5
ITEM DESCRIPTION ITEM DESCRIPTION

1 Housing, Brake Disc 13 Screw, Brake Bleeder
2 Piston 14 Plug Assembly, Forced Cooling Inlet
3 Seal, Piston Outer (large) 15 Housing, Piston
4 Seal, Piston Inner (small) 16 Spring, Piston Return
5 Screw, Brake Adjuster 17 Bolt, Shoulder
6 Jam Nut, Brake Adjuster 18 Washer, Hardened
7 Plug Assembly, Service Brake Inlet 19 Disc, Stationary
8 Capscrew 20 Disc Assembly, Friction
9 Washer, Hardened 21 Dowel Pin, Stationary Disc Locking
10 Plug, Magnetic Drain 22 Toric Seal Ring
11 Plug Assembly, Air Evacuation 23 Duo-Cone Face Seal Half
12 Plug Assembly, Forced Cooling Outlet
2
1826D MM-20195 2/8/01 8:57 AM Page 8
Section 1
Exploded View
Wheel End with Outer Bearing

on Ring Gear Hub Journal 13
(PRC 775 W3H shown as example)
12
11
9 10
8
7
6
5
3 4
2
29
28
1 14
15
16
17
18
30
22
31
27
26
21
25
24
23
20
19
ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION

1 Magnetic Drain Fill Plug 12 Planetary Ring Gear Hub 22 Wheel Stud
2 Planetary Spider 13 O-Ring 23 Hub
3 Thrust Button 14 Snap Ring 24 Face Seal Assembly
4 Thrust Button 15 Inner Thrust Washer 25 Inner Bearing Cup
5 Snap Ring 16 Planetary Pinion Gear 26 Inner Bearing Cone
6 Planetary Sun Gear 17 Outer Thrust Washer 27 Oil Seal Assembly
7 Thrust Washer 18 Pinion Shaft 28 Capscrew
8 Adjusting Nut 18A O-Ring (on pinion shaft) 29 Flat Washer
9 Planetary Ring Gear 19 Outer Bearing Cone 30 Spindle
10 Capscrew 20 Outer Bearing Cup 31 Wet Disc Brake Assembly
11 Lock 21 Wheel Nut
3
1826D MM-20195 2/8/01 8:57 AM Page 9
Section 1
Exploded View
Wheel End with Outer

Bearing on Spindle Journal
(PRC 425 W3H shown as example) 10
8 9
7
6
5
4
3
2
11
12
13
14
15
16
1 17
28
27 29
26
25
24
23
22
20
19 21
18

1 Magnetic Drain/Fill Plug 11 Flat Washer 21 Wheel Nut
2 Setscrew 12 Capscrew 22 Hub
3 Planetary Spider 13 Snap Ring 23 Wheel Stud
4 Thrust Button 14 Inner Thrust Washer 24 Face Seal Assembly
5 Snap Ring 15 Planetary Pinion Gear 25 Inner Bearing Cup
6 Planetary Sun Gear 16 Outer Thrust Washer 26 Inner Bearing Cone
7 Thrust Washer 17 Planetary Pinion Shaft 27 Oil Seal Assembly
9 Pin 19 Outer Bearing Cup 29 Wet Disc Brake Assembly
10 Adjusting Nut 20 O-Ring
4
1826D MM-20195 2/8/01 3:29 PM Page 10
Section 2
Introduction
Cross Section – Wheel End with Outer Bearing on Ring Gear Hub Journal (PRC 775 shown as example)
Figure 2.1
OIL SEAL WHEEL WHEEL
HUB STUD
WHEEL HUB O-RING

SPINDLE
OUTER BEARING
PLANETARY GEAR
O-RING
PLANETARY
PINION SHAFT
ADJUSTING
NUT
THRUST
BUTTON
SUN GEAR
SUN GEAR
AXLE SHAFT THRUST WASHER
LOCK
MAGNETIC
DRAIN PLUG
PLANETARY
RING GEAR HUB
SPIDER
INNER
WET BRAKE WET DISC BRAKE BEARING
PISTON HOUSING HOUSING FACE SEAL
Description Cooling Systems

Wheel End with Outer Bearing on ! CAUTION
Ring Gear Hub Journal The operating temperature of the coolant must
never reach or exceed 250°F (120°C). If the
The W3H – 360 mm Dura-Disc wet disc brake is a operating temperature of the coolant reaches or
hydraulically actuated friction brake. Figure 2.1 exceeds 250°F (120°C), the internal components
shows the wet disc brake installed on the PRC 775 of the brake will be damaged. A forced cooling
axle, which has a wheel end with outer bearing system may be required to assure that the
installed on the ring gear hub journal. coolant temperature remains below 250°F
Four friction discs and four stationary discs are (120°C).
used in the wet disc brake for this type of wheel
end. A forced cooling system is used. The forced
cooling system removes more heat from the discs
• Friction discs rotate with the wheel hub. than a sump cooling system. An external pump
moves hydraulic fluid from a reservoir to the brake
• Stationary discs are locked to the brake housing and back to the reservoir.
housing with dowel pins.
The W3H – 360 mm wet disc brake uses a two- Hub seals on forced cooling systems separate the
piece housing. The outer brake housing contains brake’s coolant from the lubricant in the planetary
the discs, while the inner brake housing contains wheel end.
the piston and the piston seals.
5
1826D MM-20195 2/8/01 8:57 AM Page 11
Section 2
Introduction
Cross Section – Wheel End with Outer Bearing on Spindle Journal (PRC 425 shown as example)
Figure 2.2 INNER WHEEL OUTER

BEARING STUD BEARING
ADJUSTING
NUT
PIN
MAGNETIC
DRAIN PLUG
OIL SEAL
SUN GEAR
SUN GEAR
THRUST
WASHER
THRUST
BUTTON
AXLE SHAFT
PLANETARY
PINION SHAFT
PLANETARY
SPINDLE GEAR
WHEEL HUB PLANETARY

O-RING SPIDER
WET BRAKE WET BRAKE FACE SEAL

PISTON HOUSING DISC HOUSING
Wheel End with Outer Bearing on Cooling Systems

Spindle Journal
! CAUTION
The W3H – 360 mm Dura-Disc wet disc brake is a
hydraulically actuated friction brake. Figure 2.2 The operating temperature of the coolant must
shows the wet disc brake installed on the PRC 425 never reach or exceed 250°F (120°C). If the
axle, which has a wheel end with the outer bearing operating temperature of the coolant reaches or
installed on the spindle journal. exceeds 250°F (120°C), the internal components
of the brake will be damaged. A forced cooling
system may be required to assure that the
Three friction discs and three stationary discs are
coolant temperature remains below 250°F
used in the wet disc brake for this type of wheel
(120°C).
end.
• Friction discs rotate with the wheel hub. A forced cooling system is used. The forced
cooling system removes more heat from the discs
• Stationary discs are locked to the brake than a sump cooling system. An external pump
housing with dowel pins. moves hydraulic fluid from a reservoir to the brake
The W3H – 360 mm wet disc brake uses a two- housing and back to the reservoir.
piece housing. The outer brake housing contains
the discs, while the inner brake housing contains Hub seals on forced cooling systems separate the
the piston and the piston seals. brake’s coolant from the lubricant in the planetary
wheel end.
6
1826D MM-20195 2/8/01 8:57 AM Page 12
Section 2
Introduction
How to Identify
the Brake Model
A tag on the planetary axle housing identifies the
brake model. Figure 2.3.
You can also identify the brake assembly from the
axle’s Bill of Material. The 360 mm (14.17 inch)
wet disc brake has slots and dowel pins that lock
the stationary discs to the brake housing.
Refer to Maintenance Manual 4L, Wet Disc
Brakes/W3H, W4H, W5H and W4M (Spring
Applied Hydraulic Release), for information on a
W3H wet disc brake with splines on the outside
diameter of the stationary discs.
Figure 2.3
Model No. .PRLC-874-W3H-101

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

IDENTIFICATION
TAG .
Ratio . . . . . . . . . . Date . . . . . . . .
PRC 775 W3H 108
AXLE MODEL BRAKE MODEL EXACT

SPECIFICATION
W 3 H
W=WET HOUSING H=HYDRAULIC

DISC BRAKE DIAMETER ACTUATION
M=SPRING
3=320 mm (13 inch) APPLIED
or HYDRAULIC
Axle Identification Tag Location 360 mm (14.17 inch) RELEASE
with Dowel Pins
7
1826D MM-20195 2/8/01 8:57 AM Page 13
Section 3
Disassembly
Drain Fluids from Wheel Ends

! WARNING
To prevent serious eye injury, always wear safe Disassembly of the wet disc brake is required to
eye protection when you perform vehicle replace a leaky seal or worn brake disc pack. Use
maintenance or service. the following procedure:
Removal ! WARNING
Wet Disc Brake Block the wheels to prevent the vehicle from
moving. Support the vehicle with safety stands.
Do not work under a vehicle that is supported
! WARNING only by jacks. Jacks can slip or fall over. Serious
personal injury can result.
Allow the brakes to cool to ambient temperature
(cool to the touch) before draining fluid. Wear 1. Make sure the vehicle is on a level surface.
protective gloves. Personal injury can result.
2. Place blocks under the wheels not being
Use only the type of fluid specified by the serviced to keep the vehicle from moving.
equipment manufacturer. Do not use or mix 3. Raise the vehicle so that the wheels of the axle
different types of fluid. An incorrect fluid can to be serviced are off the ground. Support the
damage the rubber parts of the assemblies, vehicle with safety stands. Refer to the vehicle
which could cause loss of braking and serious manufacturer’s maintenance manual for
personal injury. instructions on raising the vehicle.
Do not reuse hydraulic fluid or coolant. Used fluid 4. Remove the wheel nuts and dual tire/rim
may be contaminated and can cause incorrect assemblies from both wheel ends.
operation, which can result in serious personal 5. Rotate the wheel ends so the magnetic drain
injury and damage to components. plug in the planetary spider is at the bottom.
Remove the wet disc brake assembly from the
typical wheel ends as described below. ! WARNING
Allow the brakes to cool to ambient temperature
(cool to the touch) before draining fluid. Wear
protective gloves. Personal injury can result.
6. Place a suitable container under the wheel end,

remove the magnetic drain/fill plug from the
spider, and drain the lubricant. Dispose of the
lubricant according to state and/or federal
(EPA) recommendations.
7. If necessary, remove the magnetic drain plug
from the bottom of the axle housing. Drain and
dispose of the lubricant from the carrier center
section.
8. If equipped with coolant shutoff valves, close
the shutoff valves to prevent draining the brake
lines and to make sure coolant does not flow
into the brake housing during disassembly.
Remove the forced coolant inlet and outlet
lines from the brake piston housing assembly.
Cap the lines to prevent possible
contamination of the coolant.
8
1826D MM-20195 2/8/01 8:57 AM Page 14
Section 3
Disassembly
9. Place a suitable container under the brake 11. With the adjuster screw matchmarked to the
piston housing to catch the drained fluid. piston housing, place a suitable wrench on
the bottom adjuster screw to keep it from
! CAUTION
rotating. While holding this wrench, use a
second wrench to loosen the jam nut . The
To properly adjust brakes, remove or install the adjuster screw must not turn while the jam
bottom adjuster screw and jam nut as outlined nut is being loosened.
below. Improperly adjusted brakes can lead to
uneven brake disc wear and accelerate brake disc 12. Remove only the bottom adjuster screw to
wearout. permit draining of the coolant from the brake
housing. Do not remove the other two
10. Matchmark the bottom adjuster screw adjuster screws. Remove the bottom adjuster
position to the piston housing. The bottom screw from the housing as follows:
adjuster screw must be repositioned to the A. Rotate the screw COUNTERCLOCKWISE
same depth when reinstalled in order to and count the number of turns required
ensure correct brake adjustment. Figure 3.1. to remove it.
Figure 3.1 PLUG AND SCREW LOCATIONS B. Record this number.
ON BRAKE PISTON HOUSING
13. When you have removed the adjuster screw,
TOP
6
7
remove the recessed Allen-head drain plug
5 8 from the brake housing. Allow the coolant to
2 drain into the container.
14. Dispose of the used fluid in an environ-
4 2 mentally responsible manner, according to
4 state and/or federal (EPA) recommendations.
15. Install the bottom adjuster screw with the
3 same number of turns and lined up with the
matchmark on the piston housing to bring the
3 brake to the original adjustment position.
9
2
1. Plug, Magnetic Drain (1)

2. Adjuster Screw with Jam Nut (3)
3. Plug, Actuation Fluid Inlet (2)
4. Plug, Forced Cooling Outlet (2)
5. Screw, Actuation Fluid Bleeder (1)
6. Plug, Forced Cooling Inlet (1)
7. Plug, Air Evacuation (1)
8. Housing, Brake Piston (1)
9. Capscrew, Brake Piston Housing to Disc Housing (16)
9
1826D MM-20195 2/8/01 8:57 AM Page 15
Section 3
Disassembly
Cross Section – Wheel End with Outer Bearing on Ring Gear Hub Journal (PRC 775 shown as example)
Figure 3.2
HUB STUD
WHEEL HUB O-RING

SPINDLE
OUTER BEARING
PLANETARY GEAR
O-RING
PLANETARY
PINION SHAFT
ADJUSTING
NUT
THRUST
BUTTON
SUN GEAR
SUN GEAR
LOCK
MAGNETIC
DRAIN PLUG
PLANETARY
RING GEAR HUB
SPIDER
INNER
Wheel End with Outer Bearing on

Ring Gear Hub Journal
! WARNING
Observe all warnings and cautions provided by
the press manufacturer to avoid damage to
! WARNING components and serious personal injury.
Support the planetary spider with a lifting strap
before you remove the planetary spider from the Use a brass or leather mallet for assembly and
wheel hub. A planetary spider that is not disassembly procedures. Do not hit steel parts
supported correctly can fall. Serious personal with a steel hammer. Pieces of a part can break
injury and damage to components can result. off and cause serious personal injury.
1. With a lifting device, remove the planetary

spider assembly from the wheel hub and set it ! CAUTION
on a workbench. See Figure 3.2. To avoid damage to the pinion shaft, provide a
2. If the planetary ring gear did not remain with soft cushioned area to receive the pinion shaft
the planetary spider assembly during the when it is removed from the spider.
assembly’s removal, remove the ring gear
from the planetary ring gear hub. If it is necessary to service the planetary spider
assembly, refer to Maintenance Manual 9K.
3. Remove the axle shaft, planetary sun gear and
snap ring assembly.
10
1826D MM-20195 2/8/01 8:57 AM Page 16
Section 3
Disassembly
NOTE: The sun gear thrust washer may come out

with the axle shaft and sun gear assembly.
4. Remove the sun gear thrust washer from the

end of the spindle.
5. Remove the two lock plate capscrews. Remove
the lock plate from the planetary ring gear hub.
6. Matchmark the position of the wheel bearing
adjusting nut to the ring gear hub and spindle.
Remove the wheel bearing adjusting nut.
7. Remove the planetary ring gear hub. The outer
wheel bearing cone will remain on the ring
gear hub. If it is damaged, remove it from the
hub.
8. Remove the wheel hub with brake driver
splines from friction discs. The hub oil seal and
inner bearing assembly will remain in
the hub.
! CAUTION
One-half of the duo-cone face seal comes off with
the hub. The other half will remain in the brake
disc housing. Do not set the hub down onto the
face seal. Damage to the face seal can result.
NOTE: Wrap and label the face seal halves

separately. Store them in a safe place to prevent
damage and reassemble them later in the
same positions.
9. Remove the face seal half from the hub

assembly.
10. Remove the rest of face seal from the brake
housing assembly.
! CAUTION
Do not damage the hub oil seal bore surface in
the wheel hub. Damage to this surface will result
in oil leakage after assembly.
NOTE: If it is necessary to replace the hub oil seal

and bearings, refer to Maintenance Manual 9K.
11. Refer to Brake Piston Housing and Wheel

Spindle for disassembly of brake disc
housing assembly.
11
1826D MM-20195 2/8/01 8:57 AM Page 17
Section 3
Disassembly
Cross Section – Wheel End with Outer Bearing on Spindle Journal (PRC 425 shown as example)
Figure 3.3 INNER WHEEL OUTER

ADJUSTING
NUT
PIN
MAGNETIC
DRAIN PLUG
OIL SEAL
SUN GEAR
SUN GEAR
THRUST
WASHER
THRUST
BUTTON
AXLE SHAFT
PLANETARY
PINION SHAFT
PLANETARY
SPINDLE GEAR
WHEEL HUB PLANETARY

O-RING SPIDER

Wheel End with Outer Bearing on

Spindle Journal ! WARNING
! WARNING components and serious personal injury.
Support the planetary spider with a lifting strap
Use a brass or leather mallet for assembly and
before you remove the planetary spider from the
disassembly procedures. Do not hit steel parts
wheel hub. A planetary spider that is not
with a steel hammer. Pieces of a part can break
supported correctly can fall. Serious personal
off and cause serious personal injury.
injury and damage to components can result.

spider from the wheel hub. Set it on a
! CAUTION
workbench. See Figure 3.3. To avoid damage to the pinion shaft, provide a
soft cushioned area to receive the pinion shaft if
it is removed from the spider.
2. If it is necessary to service the planetary spider

assembly, refer to Maintenance Manual 9K.
12
1826D MM-20195 2/8/01 8:57 AM Page 18
Section 3
Disassembly
NOTE: The sun gear thrust washer may come out Brake Disc Housing Assembly –
Wheel End
snap ring assembly.
! WARNING
4. If necessary, remove the snap ring from the When you remove the 16 capscrews and washers
axle shaft to allow for the removal of the sun from the perimeter of the brake piston housing,
gear and sun gear thrust washer. the brake disc housing can separate from the
5. Remove the planetary ring gear. piston housing. Support the brake housing
assembly with a lifting strap before you install
6. Matchmark the position of the wheel bearing the assembly onto the piston housing assembly.
adjusting nut to the spindle. Remove the wheel The discs in the brake housing assembly are
bearing adjusting nut. loose and can fall. Serious personal injury and
damage to components can result.
! CAUTION Disassemble the brake disc housing assembly
The outer bearing cone will be loose as you pass from the wheel end as follows:
it over the end of the spindle. Hold the cone
securely to avoid dropping it and damaging NOTE: Store the face seal with the O-ring in a
the cone. safe, clean package to prevent damage.
7. Remove the outer bearing cone and wheel hub 1. If not previously removed, carefully remove,
assembly with brake driver splines from the wrap and label the duo-cone face seal with
friction discs. The wheel bearings and oil seal O-ring from the outboard face of the brake
will come off with the wheel hub. disc housing and store in a safe place to
prevent damage.
! CAUTION
One-half of the duo-cone face seal comes off with ! WARNING
the hub. The other half will remain in the brake Use a brass or leather mallet for assembly and
disc housing. Do not set the hub down onto the disassembly procedures. Do not hit steel parts
face seal. Damage to the face seal can result. with a steel hammer. Pieces of a part can break
NOTE: Wrap and label the face seal halves
separately. Store them in a safe place to prevent 2. Loosen the sixteen M16 x 1.5 threaded
damage and reassemble them later in the capscrews on the back of the piston housing.
same positions. Figure 3.1. Hit threaded capscrew heads with a
mallet to separate wet disc brake housing.
8. Remove the face seal half from the hub
3. Remove all but two capscrews at the eleven
assembly.
o'clock and one o'clock positions.
9. Remove the rest of the face seal from the brake
housing assembly.
! CAUTION
NOTE: If it is necessary to replace the hub oil seal

and bearing, refer to Maintenance Manual 9K.
13
1826D MM-20195 2/8/01 8:57 AM Page 19
Section 3
Disassembly
A. Start by marking the top stationary disc as

! WARNING Disc 1 on the left top tang that engages the
dowel pin. Remove the stationary disc, flip
Support the brake disc housing with a lifting
it over and place it on a clean towel.
strap before you remove the capscrews. A brake
disc housing that is not supported correctly can B. Mark the first friction disc at the inner
fall. Serious personal injury and damage to diameter spline as Disc 1, remove it, flip it
components can result. over, and place it on top of the first
stationary disc.
! CAUTION C. Mark the second stationary disc as Disc 2,

remove it, flip it over, and place it on top of
To avoid damaging the spindle seal journal, a the friction disc.
protective pad (such as a clean, folded shop
cloth) should be placed on the spindle seal D. Continue marking, removing, flipping, and
journal before the brake disc housing is removed. stacking until all discs are removed from
the brake housing and stacked in the same
4. With the brake disc housing correctly order as removed.
supported by a lifting strap, remove the
remaining perimeter capscrews holding the Brake Piston Housing Assembly
disc housing to the piston housing.
Disassemble the brake piston housing assembly
as follows:
! CAUTION
1. Remove the four shoulder bolts with washers
The friction discs and stationary discs are loose and springs from the piston and housing
inside the brake housing assembly. Reach assembly. Remove the washers and springs
through the center of the brake housing and keep from the four shoulder bolts.
the discs from falling on the floor. A damaged
disc cannot be reused.
! CAUTION
5. Carefully remove the disc housing from the
piston housing, making sure the discs do not To avoid damaging the spindle seal journal, a
fall out of the housing. A damaged disc cannot protective pad (such as a clean, folded shop
be reused. Place the disc housing open end up cloth) should be placed on the spindle seal
on the workbench. journal before the piston and piston housing
are removed.
! CAUTION 2. Remove the piston by using one of the

following methods:
Do not mix discs and their rubbing surfaces,
because this can result in uneven brake disc wear • Apply low air pressure to the back of the
after parts are reassembled. Component damage piston housing. Do not exceed 20 psi
can result. (1.38 bar or 138 kPa).
• Turn the three brake adjuster screws
NOTE: Stack the stationary discs and friction discs CLOCKWISE and evenly until the piston is
separately outside the brake housing. Do not mix pushed out.
up the mating surfaces while inspecting and
measuring the thickness. Component damage 3. Place the piston on the workbench.
can result.
6. Mark the friction discs at the inner diameter

splines and the stationary discs on the dowel
tabs. Remove only the stationary discs and
friction discs from the brake disc housing
as follows.
14
1826D MM-20195 2/8/01 8:57 AM Page 20
Section 3
Disassembly
Figure 3.3
! CAUTION
Be careful to avoid scratching the piston seal
grooves while removing the “D” seals, since this
can result in actuation fluid leakage past the seals.
4. Carefully remove the “D” seals from the

grooves in the piston and discard. “D” seals
are not reusable and must be replaced with
new seals.
Brake Piston Housing

and Wheel Spindle
! WARNING
Removal of the thirteen 20 mm capscrews from
the inside of the piston housing allows the 2. With the two support studs in place, remove
spindle and piston housing to separate. Support the remaining 11 capscrews and washers that
the piston housing with a lifting strap before you secure the piston housing and spindle to the
remove the capscrews. A piston housing that is not axle housing.
supported correctly can fall. Serious personal injury
and damage to components can result.
! CAUTION
1. To prevent the spindle and brake piston To avoid damaging the spindle seal journal, a
housing from falling after all the mounting protective pad (such as a clean, folded shop
capscrews are removed, perform the following cloth) should be placed on the spindle seal
procedures: journal before the piston housing is removed. Be
careful not to bump the spindle seal journal while
A. Use a lifting strap to support the piston removing the piston housing, since this can
housing and the spindle before damage the seal journal. A spindle with a
disassembly. damaged seal journal will leak and must be
B. Remove only two of the 13 capscrews replaced.
holding the piston housing and spindle
to the axle housing, one from the 3. With the piston housing held by the lifting
eleven o’clock position and one from the strap, remove the piston housing from the
one o’clock position. spindle by sliding it off of the support studs.
Place the piston housing open end up on the
C. Replace the capscrews with temporary workbench.
M20-2.5 threaded support studs 4 inches 4. If necessary, to remove the spindle, support
(102 mm) long. Figure 3.3. the spindle with a lifting strap.
5. Remove the spindle from the axle housing by
sliding it off of the support studs.
! WARNING
6. If required, tap the spindle lightly to loosen the

pilot fit and overcome adhesion from the cured
gasket material in the flange joint. Place the
spindle on the workbench.
15
1826D MM-20195 2/8/01 8:57 AM Page 21
Section 4
Inspection
6. Inspect fasteners and plugs for obvious signs

! WARNING of damage, such as distorted (brinelled)
threads or damaged hex corners. Replace any
To prevent serious eye injury, always wear safe
fastener or plug with thread damage that
eye protection when you perform vehicle
cannot be repaired by running it through the
maintenance or service.
appropriate die.
7. Inspect O-rings on plugs and replace any
Inspection damaged O-ring.
Inspect removed components as follows: 8. Inspect duo-cone face seals and O-rings as
follows:
1. Inspect brake piston bores in the housing for
wear or rough spots. Polish out roughness with
fine crocus cloth. Clean housing to remove ! CAUTION
metal particles.
Install face seal halves in the same positions
2. Inspect “D” seal grooves in the piston for where they were located prior to disassembly.
rough spots. Polish out roughness with fine Mixing up face seal halves can cause component
crocus cloth. Clean the piston to remove metal damage.
particles.
• Look for obvious signs of damage. Replace any
damaged face seal or O-ring. Replace any
! WARNING O-ring that is stuck to the seal or brake housing
Replace all the brake discs at one time to avoid or any that has taken a “set” or cannot be
uneven brake disc wear. Uneven brake disc wear pulled and “snapped” into position on the seal
can result in component damage and serious ring retaining lip.
personal injury. • Duo-cone formed face seals are more flexible
than cast ring seals and, as a result, produce a
Keep used brake discs in the correct order with wear pattern different than cast ring designs.
mating surfaces together. Installing the discs in Typically, formed seals wear in an axial rather
an incorrect order can result in component than radial direction, as depicted below, due to
damage and serious personal injury. their increased flexibility. Figure 4.1.
3. Inspect stationary discs and friction discs for Figure 4.1 LOCATION OF WEAR LIP WHICH
flatness and wear. Measure the thickness of the MUST BE REMOVED
discs. Overall thickness should not be less than
that shown in Table 1. Replace the entire disc
pack if one disc needs replacing.
Table 1. Minimum Brake Disc Thickness

Disc Type Part Number Minimum Thickness
Friction A-3281-Z-1196 0.192 Inch (4.87 mm)
Stationary 3281-F-1203 0.167 Inch (4.25 mm)
4. Inspect brake piston return springs for damage

and replace, if required. DEVELOPMENT OF A WEAR LIP IN
5. Inspect fastener and plug bores for thread THIS AREA MAKES IT NECESSARY
TO INSTALL A NEW SEAL
damage in the piston and disc housings. Use
the appropriate taps lubricated with light oil to
remove minor thread damage.
16
1826D MM-20195 2/8/01 8:57 AM Page 22
Section 4
Inspection
• The total thickness of the flange is the usable

wear material on the formed seal rings, and
good seal performance can generally be
expected until the flange is completely worn
away. Estimate the remaining service life of the
seal ring by measuring the ring flange
thickness and comparing that measurement to
those listed in Table 2. The minimum flange
thickness required for seal ring usability is 1.27
mm (0.050 in.).
• With formed seal rings, the measured
parameter used to check the remaining seal
ring life is the flange thickness at the outer
edge. Measure carefully, since the shoulder is
only 1.52 mm (0.060 in.) from the edge of
the flange.
Table 2. Formed Seal Wear Chart
Flange Thickness Seal Wear
mm (inch) % Worn
1.91 (0.075) 0
1.59 (0.062) 25
1.27 (0.050) 50
0.95 (0.038)* 75
0.64 (0.025)* 100
0.32 (0.012)* 125
0.00 (0.000)* 150
*Seal ring not usable. Replace seal ring.
17
1826D MM-20195 2/8/01 8:57 AM Page 23
Section 5
Prepare Parts for Assembly
! WARNING ! CAUTION
To prevent serious eye injury, always wear safe Keep used brake discs in the correct order with
eye protection when you perform vehicle mating surfaces together. Install discs and face
maintenance or service. seal halves in the same positions where they
were located prior to disassembly. Mixed up face
seals and discs can cause component damage.
Clean Components
Prior to Assembly
! WARNING
! WARNING Wear a faceplate or safety glasses when using
compressed air. Do not exceed 40 psi (276 kPa).
To avoid personal injury when cleaning parts, Serious personal injury can result.
work in a well-ventilated area, wear protective
clothing (face shield or safety glasses and 1. Clean all metal components in pure isopropyl
protective gloves) and follow chemical alcohol or commercial parts cleaner. Make
manufacturer’s recommendations for safe usage. sure all sealing surfaces are free of sealant or
gasket material. Use a soft-bristled brush on
Solvent cleaners can be flammable, poisonous these surfaces, if required. Blow dry with
and cause burns. Examples of solvent cleaners compressed air.
are carbon tetrachloride, emulsion-type cleaners
and petroleum-base cleaners. To avoid serious
personal injury when you use solvent cleaners, ! CAUTION
you must carefully follow the manufacturer’s
Clean friction discs in fresh brake coolant. Wipe
instructions and these procedures:
dry with clean, lint-free cloths or blow dry with
• Wear safe eye protection. compressed air. Do not use solvent. Solvent can
weaken the disc material and damage to
• Wear clothing that protects your skin. components can result.
• Work in a well-ventilated area.
2. Clean friction discs in fresh brake coolant only.
• Do not use gasoline or solvents that contain Wipe dry with clean, lint-free cloths or blow
gasoline. Gasoline can explode. dry with compressed air.
• You must use hot solution tanks or alkaline
solutions correctly. Carefully follow the 3. Inspect the duo-cone face seal tapered ramps
manufacturer’s instructions. in the wheel hub and brake disc housing that
contact the O-rings. To avoid seal damage,
these areas must be free of oil, grease, dirt,
! CAUTION and other contamination before the seals with
O-rings are installed. Clean as necessary.
Use only solvent cleaners to clean ground or
polished metal parts. Hot solution tanks or water 4. Clean the brake disc housings and the metal
and alkaline solutions will damage these parts. face seals for the O-rings using isopropyl
Isopropyl alcohol can be used for this purpose. alcohol and a lint-free wipe. Dry with a clean
If required, use a sharp knife to remove gasket wipe or compressed air.
material from parts. Be careful not to damage the 5. Using a lint-free wipe, clean the O-rings in non-
ground or polished surfaces. petroleum-based solvent. Dry with a clean
wipe or compressed air.
6. Inspect cleaned components thoroughly to
make sure any contaminants are removed.
7. Scrape all bolted joint surfaces to remove
sealant prior to reassembly.
18
1826D MM-20195 2/8/01 8:57 AM Page 24
Section 6
Assembly
! WARNING ! WARNING
To prevent serious eye injury, always wear safe When you apply some silicone gasket materials,
eye protection when you perform vehicle small amounts of acid vapor are present. To
maintenance or service. prevent possible serious injury, the work area
must be well ventilated. If the silicone gasket
material gets into your eyes, flush them with
Installation water for 15 minutes. Have your eyes checked by
a doctor as soon as possible.
Wheel Spindle
3. Apply a 0.125 inch (3.18 mm) diameter
! WARNING continuous bead of silicone gasket material
Solvent cleaners can be flammable, poisonous around the flange mounting face of either the
and cause burns. Examples of solvent cleaners axle housing or the spindle. Also apply the
are carbon tetrachloride, emulsion-type cleaners gasket material around the edge of all the
and petroleum-base cleaners. To avoid serious fastener holes on that surface. Figure 6.2.
personal injury when you use solvent cleaners,
instructions and these procedures: Figure 6.2
• Wear safe eye protection.
• Wear clothing that protects your skin.
• Do not use gasoline, or solvents that contain
gasoline. Gasoline can explode.
solutions correctly. Carefully follow the
manufacturer’s instructions. GASKET
MATERIAL
1. Clean the face of the axle housing and both
sides of the spindle flange with solvent to
remove any remaining gasket material and
blow dry.
2. If previously removed, install two temporary ! WARNING
studs (M20-2.5 threads, approximately four Support the axle spindle with a lifting strap
inches long) into the axle housing flange. before you install the spindle onto the axle
Install the studs at the eleven o’clock and one housing. A spindle that is not supported correctly
o’clock positions. Figure 6.1. can fall. Serious personal injury and damage to
components can result.
Figure 6.1
4. Support the spindle with a lifting strap. Align
the missing hole locations on the spindle and
axle housing. Install the spindle onto the two
support studs and against the axle housing.
Figure 6.2.
5. Remove the lifting strap.
19
1826D MM-20195 2/8/01 8:57 AM Page 25
Section 6
Assembly
Brake Piston Housing

! CAUTION
You must install the adjuster screw and jam nut
! WARNING into the piston housing when you assemble the
When you apply some silicone gasket materials, brakes to ensure correct brake adjustment and
small amounts of acid vapor are present. To avoid damage to components.
prevent possible serious injury, the work area
must be well ventilated. If the silicone gasket NOTE: Brakes with new disc packs require
material gets into your eyes, flush them with adjustment after the wheel end assembly is
water for 15 minutes. Have your eyes checked by complete.
5. If the adjuster screws were used to push the
1. Apply a 0.125 inch (3.18 mm) diameter piston out of the piston housing or if you
continuous bead of silicone gasket material replaced the brake disc pack, perform the
around the flange face of the spindle. Also following operations:
apply a continuous bead of the gasket material A. Clean and install the three disc brake
around the edge of all the fastener holes on adjuster screws in the piston housing.
that surface.
B. Turn the adjuster screws in halfway.
! CAUTION NOTE: Do not install the jam nuts at this time.

Place a protective pad, such as a clean, folded C. Proceed to Step 7.
shop cloth, on the spindle seal journal before you
install the piston housing to prevent damage to 6. Clean the previously removed bottom adjuster
the seal journal. screw, and install the screw in the piston
housing as follows:
A. Install the screw with the same number of
! WARNING turns and lined up with the matchmark on
Support the piston housing with a lifting strap the piston housing to bring the brake to the
before you install the piston housing onto the original adjustment position.
spindle. A piston housing that is not supported B. Insert the bottom adjuster screw into the
correctly can fall. Serious personal injury and piston housing (Figure 6.3).
C. Slowly rotate it CLOCKWISE the same
NOTE: The piston housing has TOP identified by a number or turns used for removal.
raised lug.
2. Support the piston housing with a lifting strap. ! CAUTION

Install the piston housing onto the two support Hold the adjuster screw in place to ensure that
studs and against the spindle. the brakes are adjusted correctly. Do not allow
3. Install the thirteen M20 x 2.5 thread capscrews the adjuster screw to turn. If the adjuster screw
and washers that secure the piston housing turns, damage to components can result.
and spindle to the axle housing and tighten
securely. Remove the lifting strap. D. Apply silicone sealant to the interface
between the base of the adjuster screw and
4. Remove the two temporary support studs and the housing and install the jam nut lightly
install the remaining two capscrews and onto the screw. Do not allow the screw
washers. Tighten the capscrews in two stages: to turn.
A. Using an “X” torquing pattern, tighten to E. Using a suitable wrench to prevent
150 lb-ft (203 N•m) initial torque. T movement of the screw, tighten the jam nut
to 25-35 lb-ft (34-47 N•m).
B. Using an “X” torquing pattern, tighten to T
370-480 lb-ft (500-650 N•m) final torque.
T
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1826D MM-20195 2/8/01 8:57 AM Page 26
Section 6
Assembly
Figure 6.3 PLUG AND SCREW LOCATIONS Piston Assembly

ON BRAKE PISTON HOUSING
1. Clean and inspect the piston for damage.
TOP
6
7 Inspect the piston grooves to ensure no
5 8
2 T contaminants remain in the grooves.
2. Apply an oil lubricant to the “D” seals and
assemble the “D” seals into the appropriate
4 2
grooves in the piston.
4
3. Fabricate four M8 X 1.25 threaded assembly
3 studs like the piston spring shoulder bolts, but
without the heads.
3
NOTE: The piston slightly sticks out of the piston
housing.
4. Install the four fabricated assembly studs into

the piston return spring shoulder bolt holes in
9
the piston housing.
2
1
! CAUTION
2. Adjuster Screw with Jam Nut (3)
Place a protective pad, such as a clean, folded
3. Plug, Actuation Fluid Inlet (2)
install the piston housing to prevent damage to
4. Plug, Forced Cooling Outlet (2)
the seal journal.
5. Screw, Actuation Fluid Bleeder (1)
6. Plug, Forced Cooling Inlet (1) 5. Apply an oil film coating on the piston housing
7. Plug, Air Evacuation (1) bores. Use “C” clamps to assemble the piston
8. Housing, Brake Piston (1) over the assembly studs and push the piston
9. Capscrew, Brake Piston Housing to Disc Housing (16) into the piston housing until it bottoms out.
6. Remove and store the four assembly studs.
7. If the 0.875-14 UNF forced cooling inlet,
forced cooling outlet, and air evacuation O- 7. Install washers and springs on the four
ring plugs were previously removed from the shoulder bolts.
piston housing, clean the plugs, install in the
piston housing, and tighten to 60-75 lb-ft
(81-102 N•m). T
! WARNING
Take care when using Loctite® to avoid serious
8. If the 0.5625-18 UNF actuation fluid O-ring personal injury. Follow the manufacturer’s
plugs in the 3 o’clock or 9 o’clock positions on instructions to prevent irritation to the eyes and
the piston housing were previously removed, skin. If Loctite gets into your eyes, flush them
clean the plugs, install in the housing, and with water for 15 minutes. Have your eyes
tighten to 25-35 lb-ft (34-47 N•m). T checked by a doctor as soon as possible.
9. If the recessed Allen head 3/8-18 NPTF
magnetic drain plug at the 6 o’clock position 8. Apply a small bead of Loctite 518 sealant to the
was previously removed, clean the plug, four shoulder bolt threads and install the four
apply silicone sealant, install in the housing, shoulder bolts into the piston and piston
and tighten to 25-35 lb-ft (34-47 N•m). T housing. Tighten the four shoulder bolts to 22-
30 lb-ft (30-40 N•m). T
10. If the 0.4375-20 UNF bleeder screw between
the 11 o’clock and 12 o’clock positions in the
piston housing was previously removed,
clean the screw and install in the housing.
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1826D MM-20195 2/8/01 8:57 AM Page 27
Section 6
Assembly
Brake Disc Housing 3. Place a friction disc inside the brake housing.
Place a stationary disc into the brake housing
while engaging all the dowels in the disc’s slots.
! WARNING
4. Alternate in this manner (friction disc/stationary
Replace all the brake discs at one time to avoid disc) until all discs are installed. Realign all the
uneven brake disc wear. Uneven brake disc wear friction disc splines and grooves.
can result in component damage and serious
personal injury.
Install used brake discs in the correct order with
! WARNING
mating surfaces together. Installing the discs in an Take care when using Loctite® to avoid serious
incorrect order can result in component damage personal injury. Follow the manufacturer’s
and serious personal injury. instructions to prevent irritation to the eyes and
skin. If Loctite gets into your eyes, flush them
NOTE: The brake housing has TOP identified with a with water for 15 minutes. Have your eyes
raised lug. checked by a doctor as soon as possible.
1. Clean and inspect the brake housing, stationary 5. Apply a continuous, two millimeter diameter
plates and dowels for damage. bead of Loctite® 518 sealant onto the mounting
face of the brake housing. Sealant must be on
• If all of the friction discs and stationary discs can the inner side (inboard) of the bolt holes to
be reused: Reinstall them into the cleaned brake keep fluid from reaching bolts. See Figure 6.4.
disc housing by stacking the discs in the same
order and wear surface orientation as prior to
disassembly. Figure 6.4 Mounting Face of Brake Housing
Showing Location of Sealant Bead
• If all discs are being replaced: Line up all the Inboard of Bolt Holes
friction disc splines and grooves in a stack so that
they can be assembled this way inside the brake
housing.
! WARNING
Support the brake housing assembly with a lifting
strap before you install the assembly onto the
piston housing assembly. The discs in the brake
housing assembly are loose and can fall. Serious
personal injury and damage to components can
result.
! CAUTION
Do not reuse a damaged friction disc or stationary SEALANT BEAD
disc. Damage to components can result.
Do not mix discs and their mating surfaces, which
can result in uneven brake disc wear after parts are
reassembled. Damage to components can result.
Do not lubricate brake discs prior to assembly.
Lubricant can run onto the brake disc housing and
mix with Loctite® sealant, which will cause the
sealing joint to leak. Damage to components can
result.
2. Place the brake housing on an assembly bench. If

previously removed, assemble the eight dowel
pins into the slots in the brake housing.
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1826D MM-20195 2/8/01 8:57 AM Page 28
Section 6
Assembly
Duo-Cone Face Seal into

! CAUTION Brake Disc Housing and into Hub
Place a protective pad, such as a clean, folded
install the disc housing assembly to prevent ! CAUTION
damage to the seal journal. Install face seal halves in the same positions
where they were located prior to disassembly.
Mixing up face seal halves can cause component
! WARNING damage.
The discs in the brake disc housing assembly are
loose. The discs must be correctly supported The duo-cone face seal half with the O-ring must
when the assembly is raised to a vertical position be installed in the brake disc housing and into the
and lifted for installation onto the piston housing hub before the hub can be assembled to the
assembly. A falling disc can result in disc damage housing. Figure 6.5. Install the duo-cone face seal
and serious personal injury. A damaged disc in the brake disc housing and in the hub as
cannot be reused.
Figure 6.5 1
6. Carefully lift the brake housing assembly (lug
on TOP) and install it onto the piston housing
that is already mounted on the axle. 2
3
7. Tighten sixteen M16 x 1.5 threaded capscrews 4
in two stages:
A. Using an “X” tightening pattern, tighten to
150 lb-ft (203 N•m). T
7 6 5
B. Using an “X” tightening pattern, tighten to
200-258 lb-ft (270-350 N•m). T 9
8
1. Seal Ring 6. Seal Ring Face

2. O-Ring 7. Seal Ring Ramp
3. Housing Retainer Lip 8. Seal Ring Retaining Lip
4. Housing Ramp 9. Installation Tool
5. Seal Ring Housing
23
1826D MM-20195 2/8/01 8:57 AM Page 29
Section 6
Assembly
follows:
! WARNING ! CAUTION
Solvent cleaners can be flammable, poisonous Do not use Stanosol® or any other liquid that
and cause burns. Examples of solvent cleaners leaves an oily film and does not evaporate
are carbon tetrachloride, emulsion-type cleaners quickly, since this may result in incorrect seating
and petroleum-base cleaners. To avoid serious of the O-ring in the housing, resulting in seal
personal injury when you use solvent cleaners, leakage.
instructions and these procedures: A. Wet the rubber O-ring with isopropyl
alcohol and install it onto the formed seal
• Wear safe eye protection. ring so that it is seated at the bottom of the
• Wear clothing that protects your skin. seal ring ramp and against the retaining lip.
Figure 6.6.
• Do not use gasoline, or solvents that contain Figure 6.6
solutions correctly. Carefully follow the 1
manufacturer’s instructions. 4
! CAUTION
Check for solvent residue on all seating surfaces. 2
Solvents that leave a residue on the O-ring, metal
face seal or brake disc housing seal seating 3
surface can cause the O-ring to roll into the seal,
rather than slide. Damage to the seal can result.
1. Make sure the formed seal ring, O-ring and

brake disc housing are clean and free of any oil 1. Seal Ring Ramp 3. Seal Ring Retaining Ramp
or other contaminants. If required, use a
2. Rubber O-Ring 4. Seal Ring
solvent that evaporates quickly, leaves no
residue, and is compatible with the O-rings.
B. Make sure the O-ring is not twisted by

! CAUTION rapidly pulling it away from the seal ring
Install the O-ring into the seal ring and make sure and letting it snap back. Do this in a
it is flat. Do not twist the O-ring when installing number of places until the seal is correctly
onto the seal ring. A twisted O-ring will not seal seated. Be careful not to nick or cut the
correctly, allowing leakage of lubricant and O-ring seal, as this will cause leaks.
pumping of debris past the ring. Damage to Figure 6.7.
components can result. Figure 6.7
2. Install the O-ring onto the formed seal ring so
that it rests in the radius of the tail of the seal
ring and is not twisted. Install the O-ring onto
the seal ring as follows:
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1826D MM-20195 2/8/01 8:57 AM Page 30
Section 6
Assembly
Figure 6.9
! CAUTION
Do not use Stanosol® or any other liquid that
leaves an oily film and does not evaporate
quickly, since this may result in incorrect seating
of the O-ring in the housing, resulting in seal
leakage.
3. Coat the O-ring with isopropyl alcohol so that it

slides easily past the retainer lip in the disc
housing and installs correctly on the housing
ramp (see Figure 6.5).
4. Place installation tool 1U6438 15° around the
metal seal ring and O-ring. Installation tools
are available from authorized Caterpillar®
distributors.
5. Wipe the O-ring with a lint-free towel or clean Check for Correct Installation of the
foam brush saturated with isopropyl alcohol. Duo-Cone Seal
6. Shake excess lubricant from the assembly. Check the disc brake housing and wheel hub for
Immediately install (“pop”) the seal into the correct installation of the duo-cone face seal
brake disc housing with a firm push of the before the hub can be installed onto the housing.
installation tool. Figure 6.8.
1. Check assembled height variation (A) in at
7. Remove the installation tool. least four places, 90 degrees apart, using a
caliper, toolmaker’s rule, or other accurately
Figure 6.8 calibrated measuring device. The difference in
height around the ring must not be more than
0.5 mm (0.02 inch). Figure 6.10.
Figure 6.10
8. Follow the same procedure to install the other

half of the face seal assembly onto the wheel
hub. Figure 6.9.
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1826D MM-20195 2/8/01 8:57 AM Page 31
Section 6
Assembly
2. If required, adjust the seal standout height by Wheel Hub to Brake Disc Housing
using the following methods.
NOTE: Complete the assembly of the wheel hub to
• If the standout height cannot be brought into the brake housing. Before installing the wheel hub
specification: Remove the seal and repeat the onto the brake disc housing, however, keep the
installation procedure. following points in mind to ensure correct sealing
between the faces of the duo-cone seals:
! CAUTION 1. Check both sealing faces carefully to make sure
Push or pull the O-ring and face seal only. Do not they are clean and free of any dirt, debris, lint,
push or pull directly on the seal ring. This can and even human hair.
cause component damage.
! CAUTION
A. Use the installation tool to push down on Bring the housings together slowly. High impact
the O-ring and face seal. can result in component damage. Remove
B. With your fingers, pull up uniformly on the protective pad from the spindle's seal journal.
O-ring and face seal.
2. Remove the protective pad from the spindle's
! CAUTION
seal journal.
Apply isopropyl alcohol to the O-ring. Check the • When installing the hub onto the spindle, both
retaining lip of the seal seating area for burrs or seal housings must be aligned correctly.
fins, which can cause a seal to leak. Damage to
components can result. • Slowly bring the two housings together as the
spindle adjustment nut is tightened.
3. Apply isopropyl alcohol as a lubricant to the Figure 6.12.
O-ring and place in the seating area. If
installation does not appear smooth, flat and Figure 6.12
correct, remove the seal from the brake disc
housing and repeat the process.
! CAUTION
FACE SEAL
MATING
SURFACES
To prevent slippage of the O-ring, allow
sufficient evaporation time for the assembly
lubricant before proceeding with further
assembly. Damage to components can result.
4. Seat O-ring correctly. Once correctly in place,

the O-ring must roll on ramp only. See Figure
6.11 for examples of incorrect installation.
Figure 6.11
26
1826D MM-20195 2/8/01 8:57 AM Page 32
Section 6
Assembly
• If the seals are not aligned correctly: The Adjustment

seals will move. Any wobbling motion of
the seals is an indication of incorrectly
positioned (cocked) seals. Dirt can enter Wheel Bearing Preload – Wheel
past the O-ring. End with Outer Bearing
• Shown in Figure 6.13, the O-rings have on Ring Gear Hub Journal
slipped, instead of rolling on the left-hand (PRC 775, for example)
side of the seal. Note how the top O-ring is
to the right and the bottom O-ring is to the NOTE: To adjust the wheel bearing preload, the
left. The same seals are also shown after the bearings must be correctly seated and the rollers
bottom half is rotated 90 degrees. correctly aligned.
• If the O-ring slips at any location, it will
twist, causing the formed seal rings to seat 1. Install the wheel bearing adjusting nut. Tighten
the nut to 400 lb-ft (542 N•m).
incorrectly (cock). T
Figure 6.13 ! WARNING

2. Rotate the hub in both directions. At the same

time, tap the hub several times with a brass or
plastic mallet.
3. Tighten the nut to 400 lb-ft (542 N•m) again. T
4. Back off the nut approximately 1/4 turn to
relieve the preload produced in Step 3.
5. Tighten the nut to 200 lb-ft (271 N•m). T
NOTE: If you move the adjusting nut to align the
! CAUTION
lock plate mounting holes, tighten the nut. Do not
loosen or back off the nut.
Do not apply lubricant to the O-ring. The O-ring
can leak. Damage to components can result. 6. Install the lock plate.
3. Apply a light coating of Dow Corning GN

molybdenum assembly paste lubricant to the ! WARNING
two mating surfaces of the face seal’s steel
rings only. Do not allow this lubricant to Take care when using Loctite® to avoid serious
contact the O-ring. The O-ring can leak. personal injury. Follow the manufacturer’s
Figure 6.12. instructions to prevent irritation to the eyes and
NOTE: If not previously removed, remove the with water for 15 minutes. Have your eyes
protective cloth or pad from the spindle seal checked by a doctor as soon as possible.
journal before installing the hub.
7. Install the lock plate mounting screws.
4. Install the hub with brake driver splines Tighten the mounting screws to 20-30 lb-ft
through the friction discs. (27-41 N•m). T
5. Install the outer bearing cone on the ring gear A. The new lock plate mounting screw threads
hub. Install the spindle nut on the spindle. come equipped with a pre-applied locking
Rotate the hub while tightening the nut agent.
as defined in wheel bearing adjustment
procedure.
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1826D MM-20195 2/8/01 8:57 AM Page 33
Section 6
Assembly
B. If you use the original lock plate mounting

screws, apply two or three drops of Loctite ! WARNING
277 or equivalent to the internal threads of
Carefully align the adjusting nut dowel pin within
the ring gear hub.
a ring gear tooth spline to avoid damage to the
8. Apply axle grease to the inner face of the sun pin. A damaged dowel pin will cause the
gear thrust washer to help secure the washer adjusting nut to back off and loosen the wheel
to the nut. during vehicle operation. Serious personal injury
and damage to components can result.
9. Install the sun gear thrust washer so that the
washer tangs engage the slots in the bearing 6. Carefully align the adjusting nut dowel pin
adjusting nut. within a ring gear tooth spline to avoid
10. Install the planetary sun gear and snap ring damage to the dowel pin. Tighten the
onto the axle shaft. adjusting nut to the correct alignment. Do not
back off the adjusting nut.
11. Install the axle shaft and sun gear assembly.
For correct installation, the following 7. Install the planetary ring gear onto the
situations must occur: spindle. Install the dowel pin in the adjusting
nut into in the hole in the ring gear face to
• The axle shaft contacts the differential side allow the ring gear to seat against the
gear. adjusting nut.
• The sun gear contacts the thrust washer. 8. Apply a thin layer of axle grease to the face of
• The thrust washer tangs are correctly the sun gear thrust washer.
installed in the bearing adjusting nut slots. 9. Install the sun gear thrust washer. The washer
tangs must engage the holes in the ring gear.
Wheel Bearing Preload – Wheel 10. Install the planetary sun gear and snap ring
End with Outer Bearing on Spindle onto the axle shaft.
Journal (PRC 425, for example) 11. Install the axle shaft and sun gear assembly.
For correct installation, the following
NOTE: To adjust the wheel bearing preload, verify situations must occur:
that the bearings are seated and the rollers are
aligned correctly. • The axle shaft fits into the differential side
gear.
1. Install the wheel bearing adjusting nut. Tighten
the nut to 400 lb-ft (542 N•m).
• The sun gear contacts the thrust washer.
T • The thrust washer tangs are correctly
installed in the ring gear hub holes.
! WARNING 12. Install the O-ring on the wheel hub at the base
Use a brass or leather mallet for assembly and of the flange.
2. Rotate the hub in both directions. At the same

plastic mallet.
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1826D MM-20195 2/8/01 8:57 AM Page 34
Section 6
Assembly
Fill Wet Brake Assembly NOTE: Keep brakes applied until all three screws
are adjusted.
with Required Coolant
5. With brake applied, turn the brake adjuster
After completing the wheel end assembly, fill the screws CLOCKWISE until they stop turning.
brakes with the required coolant as follows: The screws are now bottomed on the piston.
1. Fill the brakes with the specified coolant until 6. With the brakes still applied, rotate each
the coolant flows from the outlet plug opening screw COUNTERCLOCKWISE one full turn
(see Figure 6.3) on the piston housing. See (back off the brakes).
Section 9 for required coolant.
7. Matchmark each screw to the housing. Do not
2. Fill planetary wheel end and axle housing with allow the screws to turn after marking.
required lubricants according to vehicle
manufacturer’s recommendations. 8. Release the brakes.
3. Attach forced coolant inlet and forced coolant 9. Apply silicone sealant to the interface
outlet lines to the piston housing. between the piston housing and each adjuster
screw. Do not apply to the jam nuts.
4. Reconnect electrical starting power to the
engine. Place the transmission in neutral and 10. Install the jam nuts onto the adjuster screws.
start the engine. When the level in the Using a suitable wrench to prevent the screws
reservoir goes down, add coolant to adjust the from turning, tighten each jam nut to
level to the specified position. 25-35 lb-ft (34-47 N•m). T
5. Check for leaks, bleed brake lines, and check

for correct brake operation. Refer to “Remove
Air from System (“Bleed” the Brakes).”
Adjust Brake with

New Disc Pack
If adjuster screws were used to push the piston
out of the piston housing, or the disc pack was
replaced by a new disc pack, use the following
procedure to adjust the brakes.
1. Ensure the three adjuster screws are installed
in the piston housing and turn in halfway. Do
not install jam nuts at this time. Figure 6.3.
2. Start the engine and remove the air from the
hydraulic brake system (bleed the brakes).
! CAUTION
Only install the specified petroleum-base brake
actuation fluid. Do not install glycol-base
automotive fluid. Damage to components can
result.
3. If required, add brake actuation hydraulic fluid

to bring it to the required level.
4. With the engine running, apply the brakes to
build up hydraulic pressure in the brakes.
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1826D MM-20195 2/8/01 8:57 AM Page 35
Section 6
Assembly
Remove Air from the System Air/Hydraulic or Mechanical

(“Bleed” the Brakes) Actuator Systems
NOTE: Always start at the point in the system that
! WARNING is farthest from the master cylinder and work back
You must bleed the brakes to remove all air from toward the master cylinder.
the system when you loosen any brake system
hydraulic connection. Air can prevent hydraulic 1. Check that the master cylinder is filled to the
pressure from applying the brakes correctly and correct level with hydraulic fluid specified by
can increase stopping distance. Serious personal the component manufacturer. Keep the master
injury and damage to components can result. cylinder filled when you bleed the brakes, so
air does not enter the system through the
Use only the type of hydraulic fluid specified by master cylinder.
the equipment manufacturer. Do not use or mix 2. Apply the brake pedal.
different types of hydraulic fluid. Using incorrect
hydraulic fluid will damage the rubber parts of 3. Loosen the bleeder screw.
the brake. Loss of braking control, serious 4. Tighten the bleeder screw before you release
personal injury and damage to components the brake pedal so that air does not enter the
can result. system. T
5. Repeat until there are no air bubbles in the
! CAUTION hydraulic fluid when you apply the brake pedal
and loosen the bleeder screw.
Do not reuse hydraulic fluid or coolant. Used fluid
can be contaminated and can cause incorrect 6. Check for fluid leaks.
operation. Damage to components can result.
7. When you have finished bleeding the brakes,
Only install the specified petroleum-base brake check that the master cylinder is filled to the
actuation fluid. Do not install glycol-base correct level.
automotive fluid. Damage to components can
result. Full Hydraulic Systems
NOTE: Always start at the point in the system that NOTE: Always start at the point in the system that
is farthest from the master cylinder and work back is farthest from the master cylinder and work back
toward the master cylinder. toward the master cylinder.
1. Put a clear tube on the bleeder screw. 1. Slowly apply low hydraulic pressure to the
Submerge the opposite end of the tube into a brake. Loosen the bleeder screw.
clear container of the specified hydraulic fluid.
2. Continue to apply pressure until no air bubbles
2. When you complete a wheel, go to the bleeder appear in the container of fluid.
screw on the next closest wheel.
3. Tighten the bleeder screw 15-20 lb-ft
3. Use the following instructions to bleed the (20-27 N•m), then release the pressure to the
brakes. brake. T
4. Check for fluid leaks.
5. When you have finished bleeding the brakes,
check that the master cylinder is filled to the
correct level.
30
1826D MM-20195 2/8/01 8:57 AM Page 36
Section 7
Maintenance
Coolant Draining and Filling

! WARNING
To prevent serious eye injury, always wear safe Hub seals are used in each wheel end assembly to
eye protection when you perform vehicle retain the TOU (tractor oil universal) fluid that
maintenance or service. cools the brake discs. Refer to Section 9 for fluid
recommendations. At the specified intervals,
change the coolant in each brake assembly. Use
Coolant Change Intervals the following procedure:
1. Make sure the axle and brake assembly are in a
! WARNING level position.
To avoid injury from the hydraulic fluid, allow the 2. Place a suitable container under the brake to
brakes to cool to ambient temperature (cool to catch the drained coolant.
the touch) before draining fluid. Wear protective
gloves.
! CAUTION
Use only the type of fluid specified by the Matchmark the brake disc adjuster screw
equipment manufacturer. Do not use or mix position before loosening the jam nut. Hold the
different types of fluid. An incorrect fluid can adjuster screw in place to prevent its movement.
damage the rubber parts of the assemblies, Loosening the jam nut may result in improperly
which could cause loss of braking and serious adjusted brakes when the screw and jam nut are
personal injury. reinstalled. This can lead to uneven brake disc
wear and accelerate brake disc wearout.
Do not reuse hydraulic fluid or coolant. Used fluid
may be contaminated and can cause incorrect 3. Matchmark the bottom adjuster screw to the
operation, which can result in serious personal brake piston housing. Figure 7.1. Reinstall the
injury and damage to components. bottom adjuster screw to the same depth in the
piston housing to ensure correct brake
Hydraulic disc brake assemblies with forced adjustment and even brake disc wear.
cooling systems use a pump to move coolant in
and out of the housings. Coolant is supplied from
a reservoir. The movement of coolant removes ! CAUTION
heat from the discs. At specified times the coolant
must be changed in the complete brake cooling Hold adjuster screw in place. Do not allow
system. adjuster screw to turn. If adjuster screw turns,
Change brake coolant at the following intervals:
4. Place a suitable wrench onto the bottom
• First Coolant Change: Change coolant after adjuster screw. Hold the screw in position to
the first month or after the first 200-250 keep it from moving. With the screw held
hours of operation, whichever comes first. securely, turn the jam nut COUNTER-
CLOCKWISE to loosen.
• Regular Periodic Maintenance: Change
coolant every six months or every 3,000
hours of operation, whichever comes first.
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1826D MM-20195 2/8/01 8:57 AM Page 37
Section 7
Maintenance
Figure 7.1 9. Clean the adjuster screw. Install it in the

PLUG AND SCREW LOCATIONS
ON BRAKE PISTON HOUSING piston housing as follows:
A. Insert the screw in the housing.
TOP
6
7
5 8
2 NOTE: Install the screw with the same number of
turns used to remove it. Line it up with the
matchmark line on the housing to bring the brake
4 2 to the original adjustment position.
4
B. Slowly rotate it CLOCKWISE the same
3 number or turns used for removal.
10. Apply silicone sealant to the interface
3 between the base of the adjuster screw and
the housing. Install the jam nut lightly onto
the screw.
9 ! CAUTION
2
Hold the adjuster screw in place. Do not allow the
1 adjuster screw to turn. If the adjuster screw
turns, damage to components can result.
2. Adjuster Screw with Jam Nut (3) 11 Use a suitable wrench to prevent movement
3. Plug, Actuation Fluid Inlet (2) of the screw. Use a torque wrench to tighten
4. Plug, Forced Cooling Outlet (2) the jam nut to 25-35 lb-ft (34-47 N•m). T
5. Screw, Actuation Fluid Bleeder (1) 12. Remove the hex-head air evacuation plug and
6. Plug, Forced Cooling Inlet (1) the plug from the unused forced cooling
7. Plug, Air Evacuation (1) outlet opening. Figure 7.1.
8. Housing, Brake Piston (1)
13. Fill the brake with the specified coolant until
9. Capscrew, Brake Piston Housing to Disc Housing (16)
the coolant flows from the forced cooling
outlet plug opening. Refer to Section 9.
5. Remove the bottom adjuster screw from the
piston housing. Count the number of rotations 14. Install the air evacuation plug and the forced
required to remove the screw and record cooling outlet plug in the housing, and
this number. tighten to 60-75 lb-ft (81-102 N•m). T
15. Place the transmission in Neutral and start the
NOTE: Install the screw with the same number of
engine. When the level in the reservoir goes
turns used to remove it. Line it up with the
down, add coolant to adjust the level to the
matchmark line on the housing to bring the brake
specified position. Operate the brakes.
to the original adjustment.
16. Check for leaks.
6. Remove the recessed Allen-head magnetic
drain plug directly below the adjusting screw
opening. Allow the coolant to drain from the ! CAUTION
housing into the container. Do not use automotive (glycol-base) brake fluid in
place of required petroleum-base brake actuation
7. Dispose of the used fluid in a manner fluid, since this can result in seal damage
according to state and/or federal (EPA) (swelling).
recommendations.
8. Clean the magnetic drain plug. Apply silicone 17. Bleed the brakes and check for correct brake
sealant to the threads of the plug, install in the operation.
piston housing, and tighten to 25-35 lb-ft
(34-47 N•m).
T
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1826D MM-20195 2/8/01 8:57 AM Page 38
Section 8
Troubleshooting
Brake Does Not Apply

Condition Possible Causes Correction
Low or no pressure 1. Empty fluid reservoir. 1. Fill reservoir to correct level with specified fluid.
to brake. 2. Damaged hydraulic system 2. Repair the hydraulic system.
3. Leakage of brake actuation fluid. 3. Refer to “Brake Leaks Actuation Fluid” in this section.
Brake Does Not Release

Vehicle does not move. Damaged hydraulic system. Repair hydraulic system.
Brakes dragging. 1. More than 1.1 bar (16 psi) pressure 1. Repair hydraulic system so pressure is less than
applied when brakes released. 1.1 bar (16 psi) when brakes released and while
machine is operating in any mode.
2. Damaged piston return spring 2. Repair or replace piston return spring assembly.
assembly.
3. Piston not returning. 3. Check piston seals for swelling or damage. Replace
as necessary.
4. Wrong cooling and/or actuation fluid 4. Check piston seals for swelling or damage. Replace as
used. necessary. Purge system and use specified fluid.
5. Parking brake not adjusted correctly. 5. Adjust parking brake.
Braking Performance
Noticeable change or 1. Inadequate actuation fluid supply to 1. Replenish fluid in brake system. Check for leakage
decrease in stopping brakes. and correct cause.
performance.
2. Inadequate pressure to apply brakes. 2. Check brake apply system. Check for leakage in brake
system or brakes, and correct cause.
3. Worn or damaged discs. 3. Inspect and replace discs if necessary.
NOTE: As disc wear occurs, make sure brake system
can supply adequate fluid to fully apply brakes.
4. Overheated seals and/or discs 4. Inspect and replace discs and seals if necessary.
5. Dirty or contaminated cooling fluid. 5. Drain and flush cooling fluid from brakes and entire
brake system. Replace with approved fluid. In some
cases, it may be necessary to replace discs. Clean or
replace filter.
Brake does not fully 1. Empty fluid reservoir. 1. Fill reservoir to correct level with specified fluid.
apply.
2. Damaged hydraulic system. 2. Repair hydraulic system.
3. Leakage of brake actuation fluid. 3. Refer to “Brake Leaks Actuation Fluid” in this section.
Brakes feel spongy/soft. Brakes or brake system not correctly bled. Bleed brakes and brake system.
33
1826D MM-20195 2/8/01 8:57 AM Page 39
Section 8
Troubleshooting
Brake Leaks Actuation Fluid

Internal leak: Fluid 1. Worn or damaged piston seal. 1. Replace piston seals.
bypasses seals into axle 2. Melted or extruded piston seals. 2. Correct cause of overheating and replace seals.
and fills axle with fluid
and blows out breather or 3. Corrosion, pitting, wear or other 3. Clean, smooth, rework or replace affected parts.
empties brake fluid damage, marks, scratches to piston
reservoir. and/or brake housing bore in area of
seal/sealing lips.
4. Incorrect brake actuation fluid. 4. Check piston seals for swelling or damage. Replace as
necessary. Purge system and use specified fluid.
External leak 1. Loose bleeder screw. 1. Tighten bleeder screw to 20-27 N•m (15-20 lb-ft).
2. Loose inlet fitting or plugs 2. Tighten inlet fitting to 34-47 N•m (25-35 lb-ft).
3. Damaged inlet fitting or plugs or 3. Replace inlet fitting or plug and O-ring if used. Repair
damaged seats or resurface area; or replace as necessary.
Brake Cooling Fluid Leakage

Coolant leaking out 1. Face seal damaged, worn or 1. Reinstall and/or replace face seal.
of brake housing. incorrectly installed.
2. Loose drain plug, fill plug, or forced 2. Tighten plug.
cooling plug.
3. Damaged plug. 3. Replace plug and O-ring, if used.
4. Deteriorated or inadequate sealant 4. Disassemble, clean, re-seal and reassemble joint.
used at joint.
Axle housing filling with 1. Worn or damaged spindle to hub seal. 1. Replace spindle to hub seal and check seal journals.
oil (forced cooling systems 2. Brush hair lodged in grease under 2. Do not use brush to apply grease to seal areas.
only) and may be forced hub-to-spindle seal lip.
out the breather.
Brake Noise and Vibration

Brakes produce noise, Incorrect axle fluid and/or friction 1. Use only Meritor specified or approved materials.
chatter, vibration material used.
2. Drain and flush fluid from axle. Replace with
approved fluid.
3. Replace all friction discs. Thoroughly clean or replace
stationary discs.
34
1826D MM-20195 2/8/01 8:57 AM Page 40
Section 8
Troubleshooting
Brake Overheats
Overheating due to Inadequate coolant flow or heat 1. Install brake cooling system if not already installed on
excessive duty cycle. exchange. vehicle.
2. Re-analyze and re-size brake cooling system if
necessary.
Inadequate coolant flow. Low pump output, blocked filter or Check pump output at different operating modes. Replace
coolant lines. filter and check lines.
Low or no coolant 1. Incorrect fill or leaks 1. Check for correct fill level.
2. Leaking face seal. 2. Replace or reinstall face seal assembly.
3. Loose or damaged plugs. 3. Tighten drain, fill or forced cooling plug. Replace if
damaged.
4. Deteriorated or inadequate sealant 4. Disassemble, clean, re-seal and re-assemble brake
used at joint. housing joint.
Brake drags. 1. More than 1.1 bar (16 psi) pressure 1. Repair hydraulic system so pressure is less than
applies when brakes released. 1.1 bar (16 psi) when brakes released and while
machine is operating in any mode.
2. Damaged piston return spring 2. Repair or replace piston return spring assembly.
assembly.
3. Piston not returning. 3. Check piston seals for swelling or damage. Replace
as required.
4. Wrong cooling and/or actuation fluid 4. Check piston seals for swelling or damage. Replace as
required. Purge system and use correct fluid.
5. Tight or damaged splines (eg., friction 5. Repair or replace parts.
disc-to-hub driver.)
35
1826D MM-20195 2/8/01 8:57 AM Page 41
Section 9
Specifications
Plug and Screw Torque on Brake Piston Housing
6
7
5
2
2
4
4
3
8
2
Item Fastener Torque Value

1 Plug, Magnetic Drain (1) 25-35 lb-ft (34-47 N•m)
2 Adjuster Screw with Jam Nut (3) 25-35 lb-ft (34-47 N•m)
3 Plug, Actuation Fluid Inlet (2) 25-35 lb-ft (34-47 N•m)

4 Plug, Forced Cooling Outlet (2) 60-75 lb-ft (81-102 N•m)
5 Screw, Actuation Fluid Bleeder (1) 15-20 lb-ft (20-27 N•m)
6 Plug, Forced Cooling Inlet 1) 60-75 lb-ft (81-102 N•m)

7 Plug, Air Evacuation (1) 60-75 lb-ft (81-102 N•m)
8 Capscrew, Brake Piston Housing to Disc Housing (16) Initial: 150 lb-ft (203 N•m)
Final: 200-258 lb-ft (270-350 N•m)
36
1826D MM-20195 2/8/01 8:58 AM Page 42
Section 9
Specifications
W3H Wheel End Torque Chart for the PRC 775
8
7

1 Wheel rim nut Per OEM specification
2 Lock plate screw 20-30 lb-ft (27-41 N•m)
3 Wheel bearing adjusting nut Initial = 400 lb-ft (542 N•m)*

Final = 200 lb-ft (271 N•m)*
4 Spindle and wet disc brake mounting 370-480 lb-ft (500-650 N•m)
5 Brake housing capscrews 200-258 lb-ft (270-350 N•m)
6 Oil fill/drain plug 35 lb-ft (47 N•m)

7 Piston return spring shoulder bolts 22-30 lb-ft (30-40 N•m)
8 Actuation fluid inlet fitting 25-35 lb-ft (34-47 N•m)
*Refer to instructions in Section 5 of Maintenance Manual 9K.
37
1826D MM-20195 2/8/01 8:58 AM Page 43
Section 9
Specifications
W3H Wheel End Torque Chart for the PRC 425
1
6
5
8
2 7

2 Spindle and wet disc brake housing mounting 370-480 lb-ft (500-650 N•m)
3 Wheel bearing adjusting nut Initial = 400 lb-ft (542 N•m)*

Final = 200 lb-ft (271 N•m)*
5 Pinion shaft setscrew 35 lb-ft (47 N•m)
6 Oil fill/drain plug (not shown) 35 lb-ft (47 N•m)
8 Actuation fluid inlet fitting 25-35 lb-ft (34-47 N•m)

*Refer to instructions in Section 3 of Maintenance Manual 9K.
38
1826D MM-20195 2/8/01 8:58 AM Page 44
Section 9
Specifications
Minimum Brake Disc Thickness Coolant Change Intervals

Disc Type Part Number Minimum Thickness Break-In Interval: Change the fluid in the brake housing
after the first month or the first 200-
Friction A-3281-Z-1196 0.192 Inch (4.87 mm) 250 hours of operation, whichever
comes first.
Stationary 3281-F-1203 0.167 Inch (4.25 mm)
Normal Change the fluid every 6 months or
Hydraulic Fluid for Brake Actuation* Maintenance every 3000 hours of operation,
Interval: whichever comes first.
! CAUTION Hydraulic Fluid Specifications

Do not use automotive (glycol-base) brake fluid in
Use only the brake hydraulic fluid specified by the
place of required petroleum-base brake actuation manufacturer of the vehicle. Do not use different hydraulic
fluid, since this can result in seal damage fluids. The wrong fluid will damage the seals on the piston.
(swelling).
Component Example
Petroleum Base Hydraulic Meets MIL-H-5606
Fluid (Mineral Oil) specifications
*See fluid and specification recommendations of equipment
manufacturer.
Brake Coolant Specifications: Sump and Forced

Cooling Systems with Hub Seals
Coolant Specification
Petroleum Base See the recommendations of the
SAE 10W, SAE 20W vehicle manufacturer.
or SAE 10W30
! CAUTION
The operating temperature of the coolant must
never reach or exceed 250°F (120°C). If the
operating temperature of the coolant reaches or
exceeds 250°F (120°C), the internal components
system may be required to assure the coolant
temperature remains below 250°F (120°C).
Tractor oil universal fluid, “TOU” types

formulated for wet disc brakes is recommended
for use in the wet disc brake housing. Make sure
that the specifications of the tractor fluid are the
same as the recommended specifications of the
vehicle manufacturer.
39
Revised 02-03
Single-Reduction
Differential Carriers
Single Rear Drive Axles, Rear-Rear Tandem
Drive Axles and Front Drive Steer Axles
Maintenance Manual 5A
RS and RT Series MX and RF Series

Single-Reduction Front Drive Axles
Axles (Single, Rear
of Tandem)
Service Notes
Before
Service Notes
You Begin Access Product and Service Information
on Our Website
This manual provides instructions for the Meritor
MX-, RS-, RT- and RF-Series axles. Before you Visit the DriveTrain PlusTM by ArvinMeritor Tech
begin procedures: Library at arvinmeritor.com to access and order
product and service information.
1. Read and understand all instructions and
procedures before you begin to service
components. To Order Information by Phone
2. Read and observe all Caution and Warning Call ArvinMeritor’s Customer Service Center at
safety alerts that precede instructions or 800-535-5560 to order the following publications.
procedures you will perform. These alerts help O Lubrication (Maintenance Manual 1)
to avoid damage to components, serious
personal injury, or both. O Single-Reduction Differential Carriers
(Maintenance Manual 5)
3. Follow your company’s maintenance and
service, installation, and diagnostics O Single-Reduction Forward Differential Carriers
guidelines. on Tandem and Tridem Axles (Maintenance
Manual 5L)
4. Use special tools when required to help avoid
serious personal injury and damage to O Drive Axle Housings (Maintenance Manual 8)
components. O Approved Rear Drive Axle Lubricants (TP-9539)
Safety Alerts, Torque Symbol and Notes O Driver Instruction Kit (TP-9579)
O Failure Analysis for Drive Axle Components
(TP-9955)
A Warning alerts you to an
WARNING instruction or procedure O Traction Controls package that contains two
that you must follow videos: Splitting the Difference (T-87127V) and
exactly to avoid serious Driver-Controlled, Full-Locking Main Differential
personal injury. (T-9007V). Order T-95125V for this package.
Each video is also available separately.
A Caution alerts you to an
CAUTION instruction or procedure O Drivetrain PlusTM by ArvinMeritor Technical
that you must follow Electronic Library on CD. Features product
exactly to avoid damage to and service information on most Meritor,
components. ZF Meritor and Meritor WABCO products.
$20. Order TP-9853.
A torque symbol alerts you
to tighten fasteners to a
specified torque value.
How to Order Tools and Supplies
Specified in This Manual
NOTE A Note provides
information or suggestions Call ArvinMeritor’s Commercial Vehicle
that help you correctly Aftermarket at 888-725-9355 to order Meritor tools
service a component. and supplies.
SPX Kent-Moore, 28635 Mound Road, Warren,
Michigan, 48092. Call the company’s customer
service center at 800-345-2233, or visit their
website at spxkentmoore.com.
Table of Contents
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Standard Single-Reduction Carriers Without Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Single-Reduction Carriers with DCDL (Driver-Controlled Main Differential Lock) . . . . . . . . . . . . . . . . . .3
Axle Models Covered in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Stall Testing with Automatic Transmissions
Section 2: Removal and Disassembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Differential Carrier from the Axle Housing
Carrier from the Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Differential and Ring Gear from the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Differential and Ring Gear Assembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Drive Pinion and Bearing Cage from the Carrier
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Drive Pinion and Bearing Cage
Clean and Inspect Yokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Clean Ground and Polished Parts
Clean Rough Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Clean Axle Assemblies
Dry Parts After Cleaning
Prevent Corrosion on Cleaned Parts
Inspect Parts
Repair or Replace Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Repair Welding on Axle Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
For Complete Welding Instructions on Meritor Drive Axle Housings
Prepare the Axle
Do Not Bend or Straighten a Damaged Drive Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Fasteners
Removing Fasteners Secured with Adhesive
New Fasteners with Pre-Applied Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Original or Used Fasteners
Applying Adhesive and Silicone Gasket Material
Meritor Specification 2297-T-4180 Adhesive in Differential Bearing Bores
Three Bond 1216, or Equivalent, Silicone Gasket Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Carrier-to-Housing Joint Repair
Installing Tight Fit Yokes and POSE™ Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Installing Any Type Yoke with a Unitized Pinion Seal (UPS)
Clean, Inspect and Install the Yoke After Installing a Unitized Pinion Seal . . . . . . . . . . . . . . . . . . . . . .28
General Yoke and U-Joint Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Gear Sets
Examples
Table of Contents
Section 4: Assembly
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Drive Pinion, Bearings and Bearing Cage
Installation
One-Piece Spigot Bearing on the Drive Pinion with Snap Ring
One-Piece Spigot Bearing on the Drive Pinion Without Snap Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Two-Piece Spigot Bearing on the Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Adjustment
Pinion Bearing Preload
Shim Pack Thickness for a New Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Drive Pinion, Bearing Cage and Shim Pack into the Carrier
Tight Fit Yokes and POSE™ Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Any Type Yoke with a Unitized Pinion Seal (UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Clean, Inspect and Install the Yoke After Installing a Unitized Pinion Seal . . . . . . . . . . . . . . . . . . . . . . 43
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Main Differential and Ring Gear Assembly
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Differential and Ring Gear Assembly
Adjust Differential Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Method 1
Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Check Ring Gear Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Ring Gear Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Check Gear Set Tooth Contact Patterns (Backlash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Adjust the Thrust Screw
Differential Carrier into Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Section 5: Driver-Controlled Main Differential Lock
Driver-Controlled Main Differential Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Differential Carrier from Axle Housing
Axle Setup for DCDL Disassembly
DCDL Assembly Manual Engaging Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Differential and Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
DCDL Assembly into Carrier
Differential Lock Assembly Cover Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Install the Carrier into Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Check the Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Driver Caution Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Traction Control Videos
Section 6: Lubrication
Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Section 7: Fastener Torque Information
Torque Values for Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
General Information
American Standard Fasteners
Metric Fasteners
Table of Contents
Section 8: Adjustments and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Section 9: Special Tools
Carrier Repair Stand Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
How to Make a Yoke Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Unitized Pinion Seals and Seal Drivers
Section 10: Vehicle Towing Instructions
Types of Axles
• Single Axle, with Driver-Controlled Main Differential Lock
(DCDL — Screw-In [threaded] shift assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
• Tandem Axle, with Driver-Controlled Main Differential Lock
(DCDL — Screw-In [threaded] shift assembly) and with Inter-Axle Differential (IAD)
• Single Axle, with Driver-Controlled Main Differential Lock
(DCDL — Bolt-On shift assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
• Tandem Axle, with Driver-Controlled Main Differential Lock
(DCDL — Bolt-On shift assembly) and with Inter-Axle Differential (IAD)
• Single Axle, without Driver-Controlled Main Differential Lock (DCDL) . . . . . . . . . . . . . . . . . . . . . . . 90
• Tandem Axle, without Driver-Controlled Main Differential Lock (DCDL),
with Inter-Axle Differential (IAD)
Exploded Views
Single-Reduction Differential Carrier

Exploded Views
1
2 3
3A
73 4
8
5 9
6
7
72
71
74
70
69 29
68 33
67
66 30
64 31
65
34
62 32
63 59
58
60 57
61 56
1 Nut — Drive Pinion* 32 Capscrews — Differential 65 Spigot Bearing

2 Washer — Drive Pinion* Bearing Cap 66 Drive Pinion
3 Input Yoke* or Flange* 33 Washers 67 Bearing Cone — Pinion Inner
3A Deflector 34 Caps — Differential Bearing 68 Bearing Cup — Pinion Inner
4 POSE™ seal 56 Capscrews — Differential 69 Spacer — Pinion Bearing
5 Triple Lip (Main) Seal Bearing Cup 70 Shims
6 Bearing Cone — Outer 57 Washers 71 Bearing Cage — Drive Pinion
58 Caps — Differential Bearing 72 Capscrew — Bearing Cage
7 Bearing Cup — Inner
59 Carrier 73 Washer
8 Sensor Switch
60 Adjusting Ring 74 Clip and Cable Holder
9 Lock Nut — Sensor Switch
61 Cotter Pin — Adjusting Ring 75 Cover — Bolt-On
29 Capscrews* — Lock Plate* 76 Washer
30 Washers* — Lock Plate* 62 Jam Nut* — Thrust Screw*
77 Bolt
31 Lock Plate — Adjusting Ring 63 Thrust Screw*
78 Cover — Screw-In
64 Snap Ring
* Some Meritor carriers do not have these described parts.

Exploded Views
20 A
19
18 A
18 B
15 17
16
20
14
13 21
12 22
64
78 11 24 23 A
28 26 25
77 23 DL
76 DC 41
AL
ON
OPTI 42
75 40
10
27
28 36 39
38
36
37
43
35
39
45 44
46
54 36
55
36
53
47 37 NO-SPIN
ASSEMBLY
48
49
52
50
51
10 Plug 23A Gasket — Cover Plug 45 Case Assembly — Main

11 Adjusting Ring — R.H. 24 Copper Gasket — Cylinder Cover Differential
12 Shift Fork 25 O-Ring — Piston 46 Spider — Differential
13 Spring — Shift Shaft 26 Piston 47 Bolts* or Rivets* — Ring Gear
14 Shift Shaft 27 Shift Collar and Case Half
15 Pin — Spring Retaining 28 Pins — Shift Fork 48 Ring Gear (Pinion Drive Gear)
16 Washer* or Silastic* — Air 35 Side Gears — Differential 49 Case Half — Flange
Cylinder 36 Thrust Washers — Differential 50 Washers — Case Half
17 Tube — Air Cylinder Pinion 51 Nuts* — Case Half
18A Screw-In Differential Lock 37 Pinions — Differential 52 Bearing Cone — Differential L.H.
Cylinder 38 Differential — Side Gears 53 Bearing Cup — Differential L.H.
18B Cylinder Cover 39 Thrust Washers — Differential 54 Washer for “Thru” Bolt
19 Capscrew — Manual Actuation Side Gear 55 Nut for “Thru” Bolt
20 Plug — Cylinder Cover 40 Cone — Differential Bearing 64 Snap Ring
20A Gasket — Cover Plug 41 Cup — Differential Bearing 75 Cover — Bolt-On
21 Capscrews — Cylinder Cover 42 “Thru” Bolt 76 Washer
22 Washers — Cylinder Cover 43 Bolts* — Differential Case 77 Bolt
23 Plug — Cylinder Cover 44 Washers — Differential Case 78 Cover — Screw-In
* Some Meritor carriers do not have these described parts.
Maintenance Manual 5A Copyright 2003

Revised 02-03 ArvinMeritor, Inc. Page 1
Section 1
Introduction
Standard Single-Reduction Carriers

Section 1
Introduction
Without Differential Lock

Meritor single-reduction standard carriers are
used in most Meritor single axles, rear of tandem
axles and front drive steer axles. Figure 1.1.
The single-reduction carriers are front mounted
into the axle housing. These carriers have a
hypoid drive pinion and ring gear set and bevel
gears in the differential assembly.
A straight roller bearing or spigot is mounted on
the head of the drive pinion. All other bearings
in the carrier are tapered roller bearings.
When the carrier operates, there is normal
differential action between the wheels at all times.
Figure 1.1
8
2
7
3
6 5
1 TAPERED ROLLER BEARINGS 5 BEVEL DIFFERENTIAL GEARS
2 CARRIER 6 HOUSING
3 STRAIGHT ROLLER BEARING 7 TAPERED ROLLER BEARING
4 TAPERED ROLLER BEARING 8 HYPOID DRIVE PINION AND RING GEAR
Copyright 2003 Maintenance Manual 5A

Page 2 ArvinMeritor, Inc. Revised 02-03
Section 1
Introduction
Single-Reduction Carriers with

DCDL (Driver-Controlled Main
Differential Lock)
Meritor single-reduction carriers with
driver-controlled main differential lock (DCDL)
have the same type of gears and bearings as the
standard-type carriers. Figure 1.2. The differential
lock is operated by an air-actuated shift assembly
that is mounted on the carrier.
O When the differential lock is activated, the shift
collar moves along the splines of the axle shaft
toward the differential case.
O When the splines on the collar are engaged
with splines on the differential case, the axle
shafts and differential assembly are locked
together.
O When the carrier operates with the DCDL in the
locked position, there is no differential action
between the wheels.
O When the carrier is operated in the unlocked
position, there is normal differential action
between the wheels at all times.
Figure 1.2
1 BOLT-IN STYLE
2 SCREW-IN STYLE OR THREADED
STANDARD CARRIER WITH DIFFERENTIAL LOCK (DCDL)

Section 1
Introduction
Axle Models Covered in this Manual
Single Drive Axles

RS-13-120 RS-17-145 RS-21-160 RS-23-186
RS-15-120 RS-17-145A RS-21-160A RS-25-160
RS-16-140 RS-19-144 RS-23-160 RS-25-160A
RS-16-141 RS-19-144A RS-23-160A RS-26-160
RS-16-145 RS-19-145 RS-23-161 RS-26-180
RS-17-140 RS-19-145A RS-23-161A RS-26-185
RS-17-141 RS-21-145 RS-23-180 RS-30-180
RS-17-144 RS-21-145A RS-23-185 RS-30-185
RS-17-144A
Rear Axle of Tandem Axles

RT-34-140 RT-40-146 RT-44-145P RT-46-169A For other models (non-MX-,
RT-34-144 RT-40-149 RT-44-149 RT-46-169P RS-, RT- and RF-Series),
RT-34-144A RT-40-149A RT-46-16HEH RT-48-180 refer to Maintenance
RT-34-144P RT-40-149P RT-46-16HP RT-48-185 Manual 5, Single-Reduction
RT-34-145 RT-40-160 RT-46-160 RT-50-160
Differential Carriers.
RT-34-145P RT-40-160A RT-46-160A RT-50-160P To obtain this publication,
RT-34-146 RT-40-160P RT-46-160P RT-52-180 refer to the Service Notes
RT-40-140 RT-40-169 RT-46-164 RT-52-185 page on the front inside
RT-40-145 RT-40-169A RT-46-164EH RT-58-180 cover of this manual.
RT-40-145A RT-40-169P RT-46-164P RT-58-185
RT-40-145P RT-44-145 RT-46-169
Front Drive Steer Axles

MX-10-120 RF-7-120 RF-21-160
MX-12-120 RF-9-120 RF-21-185
MX-14-120 RF-12-120 RF-21-355
MX-16-120 RF-12-125 RF-22-166
MX-21-160 RF-16-145 RF-23-180
MX-21-160R RF-21-155 RF-23-185
MX-23-160 RF-21-156
MX-23-160R
Stall Testing with Automatic Transmissions

Stall testing is an experimental test procedure
sometimes used for automatic transmission
diagnostics, vehicle performance evaluation or to
test service and park brake hold. During stall
testing or a similar procedure, the drive axle input
receives multiplied torque that can greatly exceed
the axle torque rating. This can cause drive axle
damage and result in immediate axle failure or
shortened axle life.
Meritor regards stall testing to be outside the
scope of normal vehicle operation. Axle damage
or failure caused by stall testing or a similar
procedure voids Meritor’s warranty.
For questions related to stall testing, contact
ArvinMeritor’s Customer Service Center at
800-535-5560.

Section 2
Removal and Disassembly
Section 2 and Disassembly

Removal 4. Remove the plug from bottom of axle housing.
WARNING Drain lubricant from the assembly.
To prevent serious eye injury, always wear safe 5. Disconnect the driveline universal joint from
eye protection when you perform vehicle the pinion input yoke or flange on the carrier.
maintenance or service. Figure 2.2.
Park the vehicle on a level surface. Block the

wheels to prevent the vehicle from moving. Figure 2.2
Support the vehicle with safety stands. Do not
work under a vehicle supported only by jacks. EASY SERVICETM 1
Jacks can slip and fall over. Serious personal
injury can result. 2
9
Use a brass or leather mallet for assembly and 3
4
with a steel hammer. Pieces of a part can break 8 5
6
7
Removal
10
WING SERIES
Differential Carrier from the Axle Housing PERMALUBETM
11
12
NOTE: If the vehicle is equipped with a 14
driver-controlled main differential lock, the 13
DCDL collar must be engaged before removing
axle shafts. Refer to complete instructions under
Driver-Controlled Main Differential Lock Assembly 15
and Figure 5.1. FULL-ROUND
16
1. Park the vehicle on a level surface. Block the
wheels to prevent the vehicle from moving.
Figure 2.1.
19 17
2. Use a jack or other lifting tool to raise the
vehicle so that the wheels to be serviced are 18
off the ground. Support the vehicle with safety
stands. Figure 2.1. 20
25
“RPL” SERIES, 21
3. Place a drain pan under the rear axle. PERMALUBETM
24 22
Figure 2.1 23
1 FULL ROUND BEARING 13 SLIP YOKE

CUPS 14 U-JOINT CROSS
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 20 CAPSCREWS
BEARING CUPS 21 END YOKE
8 U-JOINT CROSS 22 SLIP YOKE
9 SLIP YOKE 23 TUBING
10 CAPSCREWS 24 U-JOINT CROSS
1 11 END YOKE 25 WELD YOKE
12 WELD YOKE
1 SAFETY STANDS

Section 2
6. Remove the capscrews and washers or stud Figure 2.4

nuts and washers, if equipped, from the
flanges of both axle shafts. 1
2 3 4 5
7. Loosen the tapered dowels, if equipped, in the
axle flanges of both axle shafts using one of
the following methods.
Brass Drift Method
WARNING
9 8 7
Do not strike the round driving lugs on the flange 6
of an axle shaft. Pieces can break off and cause
serious personal injury. 1 STUD NUT
2 WASHER
3 TAPERED DOWEL
1. Hold a 1-1/2-inch diameter brass drift or brass 4 GASKET
hammer against the center of the axle shaft, 5 STUD
inside the round driving lugs. Figure 2.3. 6 SHAFT HUB AXLE
7 AXLE SHAFT OR FLANGE
8 WASHER
Figure 2.3 9 CAPSCREW
1 Air Hammer Vibration Method
WARNING
2 Wear safe eye protection when using an air
hammer. When using power tools, axle
components can loosen and break off causing
serious personal injury.
CAUTION
1 BRASS HAMMER
2 DRIVING LUGS Do not use a chisel or wedge to loosen the axle
shaft and tapered dowels. Using a chisel or
wedge can result in damage to the axle shaft,
2. Strike the end of the drift with a large hammer, the gasket and seal, and the axle hub.
five to six pounds, and the axle shaft and
tapered dowels will loosen. 1. Use a round hammer bit and an air hammer to
3. Mark each axle shaft before it is removed from loosen tapered dowels and axle shaft.
the axle assembly. 2. Place the round hammer bit against the axle
4. Remove the tapered dowels and separate the shaft or flange between the hub studs.
axle shafts from the main axle hub assembly. Operate the air hammer at alternate locations
Figure 2.4. between the studs to loosen the tapered
dowels and axle shaft from the hub.
5. Install a cover over the open end of each axle Figure 2.5.
assembly hub where an axle shaft was
removed.

Section 2
Figure 2.5 5. After the carrier is loosened, remove the top

two fasteners.
ROUND HAMMER BIT
BETWEEN HUB STUDS
CAUTION
When using a pry bar, be careful not to damage
the carrier or housing flange. Damage to these
surfaces will cause oil leaks.
6. 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.
1 ROUND HAMMER BIT BETWEEN HUB STUDS
NOTE: A carrier stand is available from SPX
Kent-Moore. Refer to the Service Notes page on
3. Mark each axle shaft before it is removed from the front inside cover of this manual to obtain
the axle assembly. the stand.
4. Remove the tapered dowels and separate the 7. Use a lifting tool to lift the differential carrier
axle shaft from the main axle hub assembly. by the input yoke or flange and place the
Figure 2.4. assembly in a repair stand. Figure 2.7. Do not
lift by hand. A carrier stand can be built by
Carrier from the Axle referring to Figure 2.8.
1. Place a hydraulic roller jack under the
differential carrier to support the assembly. Figure 2.7
Figure 2.6.
1
Figure 2.6
1 DIFFERENTIAL CARRIER 2 REPAIR STAND
2
1 WOOD BLOCK
2 ROLLER JACK
2. Remove all but the top two carrier to housing

capscrews or stud nuts and washers.
3. Loosen the top two carrier-to-housing
fasteners and leave attached to the assembly.
The fasteners will hold the carrier in the
housing.
4. Loosen the differential carrier in the axle
housing. Use a leather mallet to hit the
mounting flange of carrier at several points.

Section 2
Figure 2.8
1 2
12
11
3
10
4
9 5
SPX Kent-Moore
8
part number J-3409-D
1 PLATES 8’ LONG x 3/4” THICK x 1-1/4” WIDE WITH A TONGUE TO FIT SLOT IN
BAR WELD PLATES TO BAR
2 HANDLE 7” LONG WITH SLOT IN ONE END TO FIT CLAMP SCREW
3 BAR 2” DIAMETER X 9” LONG WITH ONE END SLOTTED TO FIT PLATE
4 WELD ALL AROUND AFTER PRESSING PLUG IN PIPE
5 WELD
6 SHAPE AND SIZE OF HOLES TO FIT CARRIER
7 23-1/2” CENTER TO CENTER OF PIPE
8 CHAMFER END OF PIPE FOR WELDING
9 4” DIAMETER PIPE
10 PLUG 4” DIAMETER x 7” LONG WITH ONE END TURNED 3” LONG TO FIT PIPE
DRILL 2” HOLE AND MILL 3/16” WIDE SLOT 2” FROM TOP
11 SCREW 3-1/2” LONG x 5/8” DIAMETER WITH FLATS ON END TO FIT HANDLE AND
2-1/2” LENGTH OF THREAD ON OTHER END
12 DRILL 3/8” HOLE THROUGH HANDLE AND SCREW
CARRIER STAND

Section 2
Differential and Ring Gear from the Figure 2.11

Carrier
NOTE: Before working on the differential carrier,
inspect the hypoid gear set for damage. If
inspection shows no damage, the same gear set 1
can be used again. Measure the backlash of the
gear set and make a record of the dimension.
Figure 2.9. Refer to Section 4.
1. Loosen the jam nut on the thrust screw, if
equipped.
2. Remove the thrust screw and jam nut, if
equipped, from the differential carrier. 1 THRUST SCREW AND JAM NUT
Figures 2.10 and 2.11.
3. Rotate the differential carrier in the repair
Figure 2.9 stand until the ring gear is at the top of
the assembly.
1
4. Mark one carrier leg and bearing cap to
correctly match the parts during carrier
assembly. Mark the parts using a center punch
and hammer. Figure 2.12.
Figure 2.12
1
2
1 DIAL INDICATOR
Figure 2.10
3
1 BEARING CAP
2 CARRIER LEG
3 MATCH MARKS

Section 2
5. Remove the cotter keys, pins or lock plates, if Figure 2.15

equipped, that hold the bearing adjusting
rings in position. Use a small drift and 1
hammer to remove pins. Each lock plate is 2
held in position by two capscrews. Figure 2.13.
6. Remove the capscrews and washers that hold
the two bearing caps on the carrier. Each cap
is held in position by two capscrews and
washers. Figure 2.14.
7. Remove the bearing caps and bearing
adjusting rings from the carrier. Figure 2.15.
8. Safely lift the main differential and ring gear
assembly from the carrier. Place the assembly 1 BEARING CAP
2 BEARING ADJUSTING RING
on a work bench. Figure 2.16.
Figure 2.13 Figure 2.16
1 2
1 REMOVING COTTER KEY

2 REMOVING LOCK PLATE
Disassembly
Figure 2.14 Differential and Ring Gear Assembly
WARNING
components and serious personal injury.
1
1. If the match marks on the case halves of the
differential assembly are not visible, mark
each case half with a center punch and
hammer. Figure 2.17.
1 BEARING CAP 2. Remove the capscrews and washers or bolts,
nuts and washers, if equipped, that hold the
case halves together.

Section 2
Figure 2.17
CAUTION
Do not remove the rivets or rivet heads with a
chisel and hammer. Using a flat edge tool can
cause damage to the flange case.
1
6. If rivets hold the ring gear to the flange case

1 1 half, remove the rivets as follows.
A. Carefully center punch each rivet head in
the center, on the ring gear side of the
assembly. Do not use a chisel and
hammer. Figure 2.19.
1 MATCH MARKS B. Drill each rivet head on the ring gear side
of the assembly to a depth equal to the
3. Separate the case halves. If necessary, use thickness of one rivet head. Use a drill bit
a brass, plastic or leather mallet to loosen that is 0.03125-inch (0.79375 mm) smaller
the parts. than the body diameter of the rivets.
Figure 2.19.
4. Remove the differential spider or cross, four
pinion gears, two side gears and six thrust C. Press the rivets through holes in the ring
washers from inside the case halves. gear and flange case half. Press from the
Figure 2.18. drilled rivet head.
5. If the ring gear needs to be replaced, remove

the bolts, nuts, and washers, if equipped, that Figure 2.19
hold the gear to the flange case half.
Figure 2.18
3
2
1 2
1003001a
1 CORRECT DRILLING RIVETS FROM HEAD

2 WRONG CHISELING RIVETS FROM HEAD
1003000a
1 THRUST WASHER
2 SIDE GEAR
3 SPIDER, PINIONS AND THRUST WASHERS

Section 2
7. Use a press to separate the case half and ring Removal

gear. Support the assembly under the ring
gear with metal or wood blocks. Press the case
half through the gear. Figure 2.20.
Drive Pinion and Bearing Cage from the
Carrier
1. Fasten a flange bar to the input yoke or flange.
Figure 2.20
When the nut is removed, the bar will hold the
2 drive pinion in position. Figure 2.22.
3 2. Remove the nut and washer, if equipped, from
1
the drive pinion. Figure 2.22.
3. Remove the yoke or flange bar.
Figure 2.22
1003002b 1
1 CASE HALF
2 PRESS
3 PLATE
4 SUPPORTS
8. If the differential bearings need to be replaced,

use a bearing puller or press to remove the
bearing cones from the case halves.
Figure 2.21.
2
Figure 2.21 1 FLANGE BAR

2 YOKE BAR
PULLER
CAUTION
Do not use a hammer or mallet to loosen and
PRESS
remove the yoke or flange. A hammer or mallet
can damage the parts and cause driveline runout,
or driveline imbalance problems after carrier to
driveline assembly.
4. Remove the yoke or flange from the drive

pinion. Do not use a hammer or mallet.
O If the yoke or flange is tight on the pinion:
Use a puller for removal. Figure 2.23.
5. Remove the capscrews and washers that hold
the bearing cage in the carrier. Figure 2.24.

Section 2

1
YOKE PULLER
1 DRIVE PINION AND BEARING CAGE

2 SHIMS
FLANGE PULLER
7. If the shims are in good condition, keep the

shims together to use when the carrier
is assembled.
8. If shims are to be discarded because of
Figure 2.24 damage, first measure the total thickness of
the pack. Make a note of the dimension.
The dimension will be needed to calculate the
1 depth of the drive pinion in the carrier when
the gear set is installed.
1003350a
1 BEARING CAGE
2 CARRIER
CAUTION
Do not use a pry bar to remove the bearing cage
from the carrier. A pry bar can damage the
bearing case, shims and carrier.
6. Remove the drive pinion, bearing cage and

shims from the carrier. Do not use a pry bar.
O If the bearing cage is tight in the carrier:
Hit the bearing cage at several points
around the flange area with a leather, plastic
or rubber mallet. Figure 2.25.

Section 2
Disassembly 2. Support the bearing cage under the flange

area with metal or wood blocks. Figure 2.27.
Drive Pinion and Bearing Cage 3. Press the drive pinion through the bearing
cage. The inner bearing cone and bearing
spacer will remain on the pinion shaft.
WARNING Figure 2.27.
O If a press is not available: Use a leather,
plastic or rubber mallet to drive the pinion
through the bearing cage.
Figure 2.26
CAUTION
1 2
Be careful when removing the seal. Do not
damage the wall of bore. Damage to the bore
3 wall can result in oil leaks.
4. Use a press and a sleeve to remove the

triple-lip or unitized oil seal from the bearing
7 cage.
O If a press is not available: Place a tool with a
4 flat blade under the flange to remove the oil
seal from the cage. Figure 2.28.
6 5
Figure 2.28
1 DRIVE PINION 5 SPIGOT BEARING
2 OIL SEAL 6 SNAP RING
3 OUTER BEARING, CUP 7 BEARING SPACER
AND CONE
4 INNER BEARING, CUP AND
CONE
1. Place the drive pinion and bearing cage in a

press. The pinion shaft must be toward the top
of the assembly. Figure 2.27.
Figure 2.27 1002437a
3
5. If the pinion bearings need to be replaced,
1
remove the inner and outer bearing cups from
4 the inside of cage. Use a press and sleeve,
bearing puller or a small drift hammer. The
type of tool used depends on the design of the
bearing cage. Figure 2.29.
5
7 6 When a press is used, support the bearing
cage under the flange area with metal or
wood blocks.
1 PRESS 5 SUPPORT
2 DRIVE PINION 6 SPIGOT BEARING
3 OIL SEAL 7 SUPPORT
4 BEARING CAGE

Section 2
BEARING
DRIVER
BEARING 2
PULLER
1 SPIGOT BEARING 2 SNAP RING
9. Remove the spigot bearing from the drive

pinion with a bearing puller. Figure 2.33. Some
spigot bearings are fastened to the drive
pinion with a special peening tool. Figure 2.32.
6. If the pinion bearings need to be replaced, Figure 2.32

remove the inner bearing cone from the drive
pinion with a press or bearing puller. The
1
puller MUST fit under the inner race of the
cone to remove the cone correctly without
damage. Figure 2.30.
Figure 2.30
1
2
5
3 1 PEENING POINTS
Figure 2.33
1
4
1 PRESS 4 SUPPORTS
2 DRIVE PINION 5 INNER BEARING CONE
3 BEARING PULLER
7. If the spigot bearing needs to be replaced,

place the drive pinion in a vise. Install a soft
metal cover over each vise jaw to protect the 2
drive pinion.
1 BEARING PULLER 2 SPIGOT BEARING
8. Remove the snap ring, if equipped, from the
end of drive pinion with snap ring pliers that
expand. Figure 2.31.

Section 2
10. If the spigot bearings are a two-piece

assembly, remove the inner race from the
pinion with a bearing puller. Remove the outer
race and roller assembly from the carrier with
a drift or a press. Figure 2.34.
Figure 2.34
1 Remove outer race and roller assembly from carrier.

2 Remove inner race from pinion.

Section 3
Section 3Parts for Assembly

Prepare 2. Inspect the yoke seal surface for any grooves.
WARNING A. If grooves are present on yoke hubs used
To prevent serious eye injury, always wear safe with single or triple lip seals, the yokes
eye protection when you perform vehicle must be replaced.
B. If grooves are present, use calipers to
measure the groove diameters. If any of
Solvent cleaners can be flammable, poisonous
the yoke grooves measure less than the
and cause burns. Examples of solvent cleaners are
dimensions in Figure 3.1, replace the yoke.
carbon tetrachloride, and emulsion-type and
petroleum-base cleaners. Read the manufacturer’s
instructions before using a solvent cleaner, then Figure 3.1
carefully follow the instructions. Also follow the
procedures below.
O Wear safe eye protection.
O Wear clothing that protects your skin. A B
O Work in a well-ventilated area.

O Do not use gasoline, or solvents that contain
gasoline. Gasoline can explode. Yoke Seal Minimum Yoke Diameter
Diameter at Groove (Inches)
O You must use hot solution tanks or alkaline 3.000/3.005" 2.990"
solutions correctly. Read the manufacturer’s 3.250/3.255" 3.240"
instructions before using hot solution tanks
A MINIMUM GROOVE DEPTH — DIAMETER
and alkaline solutions. Then carefully follow the B YOKE SEAL DIAMETER
instructions.
UNITIZED PINION SEAL (UPS)
®
Take care when you use Loctite adhesive to
avoid serious personal injury. Read the
manufacturer’s instructions before using this
Clean Ground and Polished Parts
product. Follow the instructions carefully to 1. Use a cleaning solvent to clean ground or
prevent irritation to the eyes and skin. polished parts or surfaces. Kerosene or diesel
fuel oil can be used for this purpose. Do not
Clean and Inspect Yokes use gasoline.
2. Use a tool with a flat blade if required, to
remove sealant material from parts. Be
CAUTION careful not to damage the polished or
Do not install a press on shaft excluder or POSE™ smooth surfaces.
seal after installation of a unitized pinion seal. The
use of a POSE™ seal will prevent correct seating
of the unitized pinion seal on the yoke and will CAUTION
result in lubricant leakage at the seal. POSE™ seal Do not use hot solution tanks or water and
installation is recommended only for triple lip and alkaline solutions to clean ground or polished
other previous design seals. parts. Damage to parts can result.
Do not use thin metal wear sleeves to refresh the 3. Do not clean ground or polished parts with
yoke surface. Wear sleeves pressed onto the yoke water or steam. Do not immerse ground or
will prevent correct seating of the pinion seal and polished parts in a hot solution tank or use
damage the pinion seal assembly. Wear sleeve strong alkaline solutions for cleaning, or the
usage will cause the seal to leak. smooth sealing surface may be damaged.
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 yoke or
flange surface. Do not use gasoline.

Section 3
Clean Rough Parts Inspect Parts

1. Clean rough parts with the same method as It is very important to inspect all parts carefully and
cleaning ground and polished parts. completely before the axle or carrier is assembled.
Check all parts for wear and replace damaged parts.
2. Rough parts can be cleaned in hot solution
tanks with a weak or diluted alkaline solution. 1. Inspect the cup, cone, rollers and cage of all
tapered roller bearings in the assembly. If any
3. Parts must remain in hot solution tanks until of the following conditions exist, replace the
heated and completely cleaned. bearing.
4. Parts must be washed with water until all O The center of the large-diameter end of the
traces of the alkaline solution are removed. rollers is worn level with or below the outer
surface. Figure 3.2.
Clean Axle Assemblies O The radius at the large-diameter end of the
1. A complete axle assembly can be steam rollers is worn to a sharp edge. Figure 3.2.
cleaned on the outside to remove dirt.
O There is a visible roller groove in the cup or
2. Before the axle is steam cleaned, close or cone inner race surfaces. The groove can be
place a cover over all openings in the axle seen at the small- or large-diameter end of
assembly. Examples of openings are breathers both parts. Figure 3.3.
or vents in air chambers.
O There are deep cracks or breaks in the cup,
cone inner race or roller surfaces.
Dry Parts After Cleaning Figure 3.3.
1. Parts must be dried immediately after O There are bright wear marks on the outer
cleaning and washing. surface of the roller cage. Figure 3.4.
2. Dry the parts using soft, clean paper or O There is damage on the rollers and on the
cloth rags. surfaces of the cup and cone inner race that
touch the rollers. Figure 3.5.
CAUTION O There is damage on the cup and cone inner
Damage to bearings can result when they are race surfaces that touch the rollers.
rotated and dried with compressed air. Figure 3.6.
3. Except for bearings, parts can be dried with Figure 3.2

compressed air.
1
Prevent Corrosion on Cleaned Parts

1. Apply axle lubricant to cleaned and dried
parts that are not damaged and are to
be assembled.
2. To store parts, apply a special material that
prevents corrosion to all surfaces. Wrap
cleaned parts in a special paper that will
protect the parts from moisture and
prevent corrosion.
2 1003017a
1 WORN RADIUS
2 WORN SURFACE

Section 3
1 2
1 CRACK 1 SPALLING AND FLAKING

2 WEAR GROOVE
CAUTION
Figure 3.4
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.
2. Inspect hypoid pinions and gears for wear and

damage. Replace gears that are worn or
damaged.
WEAR MARKS
1 WEAR MARKS 4000907
Figure 3.5
ETCHING AND PITTING
1003020a
1 ETCHING AND PITTING

Section 3
4. Inspect axle shafts for wear and cracks at the

CAUTION flange, shaft and splines. Replace the axle
shafts, if required.
A thrust washer, differential side gear and
pinion gear are machined as a matched set. 5. Inspect the breather.
When you replace any of these parts, you must
install a new matched set. Do not mix old and A. Remove the breather from the axle
new parts. Damage to components can result. housing.
B. Clean the breather. If the breather remains
3. Inspect the following main differential dirty after cleaning, replace the breather.
assembly parts for wear or stress. Replace C. Apply compressed air to the breather. If
parts that are damaged. Figure 3.7. compressed air does not pass through the
O Inside surfaces of both case halves breather, replace the breather.
O Both surfaces of all thrust washers D. Install the breather in the axle housing.
O The four trunnion ends of the spider or
cross Repair or Replace Parts
O Teeth and splines of both differential
side gears NOTE: Threads must be without damage and
clean so that accurate adjustments and correct
O Teeth and bore of all differential pinions torque values can be applied to fasteners and parts.
1. Replace any fastener if corners of the head

Figure 3.7
are worn.
1
2. Replace washers if damaged.
3. Replace gaskets, oil seals or grease seals at
DIFFERENTIAL the time of axle or carrier repair.
CASE HALVES
4. Clean parts and apply new silicone gasket
material where required when axle or carrier is
assembled. Figure 3.8.
5. Remove nicks, mars and burrs from parts with
3 4
machined or ground surfaces. Use a fine file,
2
india stone, emery cloth or crocus cloth.
6. Clean and repair threads of fasteners and
DIFFERENTIAL holes. Use a die or tap of the correct size or
GEAR NEST a fine file.
ASSEMBLY
5
Figure 3.8
1
6
7
1 Inspect inside surfaces.
2 PINION AND THRUST WASHER
3 SIDE GEAR AND THRUST WASHER
4 Inspect.
5 Inspect.
6 SPIDER OR CROSS
7 Inspect.
1 Remove silicone gasket from parts.

Section 3
Repair Welding on Axle Housings

CAUTION
For Complete Welding Instructions on Remove the differential carrier from the axle
Meritor Drive Axle Housings housing before you weld onto an axle. Do not
weld onto an axle with the differential carrier
installed. Electrical arching and damage to
WARNING components can result.
Wear safe clothing and eye protection when you
use welding equipment. Welding equipment can 2. Remove the differential carrier from the axle
burn you and cause serious personal injury. housing. Refer to the correct Meritor carrier
Follow the operating instructions and safety maintenance manual or the vehicle
procedures recommended by the welding manufacturer’s instructions.
equipment manufacturers.
CAUTION
Axle weld locations and welding procedures must
adhere to Meritor‘s standards. Welding at Remove the brake air chambers before you weld
locations other than those authorized by Meritor onto an axle. Do not expose a brake air chamber
will void the warranty and can reduce axle beam to more than 250°F (121°C). Damage to the air
fatigue life. Serious personal injury and damage chamber can result.
to components can result.
3. Remove the wheel-end components and brake
Refer to Maintenance Manual 8, Drive Axle air chambers from the axle. Refer to the
Housings. To obtain this publication, refer to the correct Meritor brake maintenance manual or
Service Notes page on the front inside cover of the vehicle manufacturer’s instructions.
this manual. 4. For housing-to-cover welds, clean the outside
Meritor permits drive axle housing assembly housing-to-cover weld area 2.00-3.00-inches
repair welding in the following locations only. (50.8-76.2 mm) past each end or side of the
crack. Clean the inside area where the cover
O Housing-to-cover weld joints mates with the housing. Clean the area
O Snorkel welds completely around the cover. Use a wire brush
O Housing seam welds between the suspension and a cleaning solvent that will remove dirt
attaching brackets and grease from these areas. Figure 3.9.
O Bracket welding to the drive axle housing
Figure 3.9
Prepare the Axle
WARNING
The high temperature caused by the open flame
from the cutting torch can ignite the oil in the axle
housing and can cause serious personal injury.
1. Remove the oil drain plug from the bottom of

the axle housing and drain the lubricant from
the assembly. 1
1 Clean this area.

Section 3
5. For suspension bracket welds, clean both 7. Heat the damaged area to approximately
lower and upper suspension brackets and the 300°F (149°C) before you begin welding.
areas of the axle housing around each bracket.
8. Use suitable weld wire electrodes when you
Use a wire brush and a cleaning solvent that
weld. Suitable weld wire electrodes include
will remove dirt and grease from these areas.
Figures 3.10 and 3.11. either BS EN 499 – E 42 2 B 32 H5 or
BS EN 440 – G 42 2 M GSi (American Welding
Society equivalents E7018 and ER70S3,
Figure 3.10 respectively).
1 9. For complete welding instructions, refer to
Maintenance Manual 8. To obtain this
publication, refer to the Service Notes page on
the front inside cover of this manual.
2
Do Not Bend or Straighten a Damaged
Drive Axle Housing
WARNING
Replace damaged or out-of-specification axle
1 Clean these areas. components. Do not bend, repair or recondition
2 LOWER BRACKET
axle components by welding or heat-treating.
A bent axle beam reduces axle strength, affects
vehicle operation and voids Meritor’s warranty.
Figure 3.11 Serious personal injury and damage to
2
Always replace a damaged drive axle housing. Do
not bend or straighten a damaged housing, which
can misalign or weaken it, and void Meritor’s
warranty.
3 Fasteners
1 Removing Fasteners Secured with
1 Clean these areas. Adhesive
2 Clean this area.
3 UPPER BRACKET
If it is difficult to remove fasteners secured with
Dri-Loc®, Meritor adhesive or Loctite® 277
adhesive, use the following procedure.
WARNING When you remove fasteners secured with
adhesive, slowly heat the fastener to 350°F
The axle housing must be 70°F (21°C) or warmer
(177°C). Do not exceed this temperature, or
before you weld onto the axle. Do not weld onto a
heat fasteners quickly. Damage to components
cold axle or weld cold parts onto an axle. Cracks
can result.
in the weld area, damage to components and
serious personal injury can result. 1. Heat the fastener for three to five seconds.
Try to loosen the fastener with a wrench.
6. Ensure that the axle housing temperature Do not use an impact wrench or hit the
measures 70°F (21°C) or warmer. fastener with a hammer.
O If the axle housing temperature measures 2. Repeat Step 1 until you can remove the
less than 70°F (21°C): Store the axle in a fastener.
heated room until the housing reaches the
correct temperature.

Section 3
New Fasteners with Pre-Applied Applying Adhesive and Silicone

Adhesive Gasket Material
NOTE: No drying time is required for fasteners
with pre-applied adhesive. Meritor Specification 2297-T-4180
Adhesive in Differential Bearing Bores
1. Use a wire brush to clean the oil and dirt from
threaded holes. NOTE: Use Meritor specification 2297-T-4180
adhesive for all axles.
2. Install new fasteners with pre-applied
adhesive to assemble parts. Do not apply
1. Clean the oil and dirt from outer diameters of
adhesives or sealants to fasteners with
bearing cups and bearing bores in the carrier
pre-applied adhesive, or to fastener holes.
and bearing caps. There is no special cleaning
3. Tighten the fasteners to the required torque required.
value for that size fastener.
2. Apply axle lubricant to the bearing cones and
the inner diameters of the bearing cups of the
Original or Used Fasteners main differential. Do not get oil on the outer
1. Use a wire brush to clean the oil, dirt and old diameter of the bearing cup and do not permit
adhesive from all threads and threaded holes. oil to drip onto the bearing bores.
NOTE: There is no drying time required for NOTE: Meritor specification 2297-T-4180 adhesive
Meritor liquid adhesive 2297-C-7049, Loctite® 638 will dry in approximately two hours. You must
or 680 liquid adhesive or equivalent. complete the procedure within two hours from the
time you apply the adhesive. If two hours have
2. Apply four or five drops of Meritor liquid passed since application, clean the adhesive from
adhesive, Loctite® 638 or 680 liquid adhesive the parts and apply new adhesive.
or equivalent inside each threaded hole or
bore. Do not apply adhesive directly to the 3. Apply a single continuous bead of the
fastener threads. Figure 3.12. adhesive to the bearing bores in the carrier
and bearing caps. Apply the adhesive
3. Tighten the fasteners to the required torque around the circumference of the smooth,
value for that size fastener. ground surfaces only. Do not place adhesive
on threaded areas. Figure 3.13.
Figure 3.12 4. Install the main differential assembly, bearing
cups and bearing caps into the carrier. Refer to
Section 4.
Figure 3.13
1 2
1 4 TO 5 DROPS ON BORE THREADS
1 ADHESIVE
2 BEARING CAP
3 CARRIER LEG

Section 3
5. Adjust preload of the differential bearings, 3. Dry surfaces.

backlash and tooth contact patterns of the
gear set as required. Refer to Section 4.
CAUTION
Three Bond 1216, or Equivalent, Silicone Apply silicone gasket material in a continuous
Gasket Material 0.125-inch (3 mm) bead. If you use more than this
amount, gasket material can break off and plug
lubrication passages. Damage to components
WARNING can result.
When you apply some silicone gasket materials, a
small amount of acid vapor is present. To prevent 4. Apply 0.125-inch (3 mm) diameter continuous
serious personal injury, ensure that the work area bead of the silicone gasket material around
is well-ventilated. Read the manufacturer’s one surface. Also apply the gasket material
instructions before using a silicone gasket around the edge of all fastener holes on that
material, then carefully follow the instructions. surface. Figure 3.15.
If a silicone gasket material gets into your eyes,
follow the manufacturer’s emergency procedures. Figure 3.15
Have your eyes checked by a physician as soon as
possible.
NOTE: The following silicone gasket products or

equivalent can be used for Meritor components:
O Three Bond Liquid Gasket TB 1216 (Grey)
O Loctite® Grey RTV 5699
O From Meritor: Ten-ounce tubes, part number
2297-F-7052
1
1. Use a tool with a flat blade, if required, to
1 0.125” (3 MM) DIAMETER SILICONE GASKET BEAD
remove all old gasket material from surfaces.
Figure 3.14.
5. Assemble the components immediately to
Figure 3.14 permit the silicone gasket material to
compress evenly between the parts. Tighten
1 fasteners to the required torque value for that
size fastener. Refer to Section 7.
6. Wait 20 minutes before filling the assembly
with lubricant. Refer to Section 6.
Carrier-to-Housing Joint Repair

1. Remove the carrier from the housing. Refer to
Section 2.
2. Remove all debris from inside the housing.
1 Remove old sealant material. 3. Use a rotary tool with a ScotchBriteTM pad to
HOUSING AND CARRIER SHOWN clean all silicone residue from the housing and
carrier faces. Figure 3.16. Surfaces must be
clean, dry and free of foreign matter. The
2. Use a cleaning solvent to clean the surfaces surfaces must not be oily to the touch.
where you will apply silicone gasket material.
Remove all oil, grease, dirt and moisture
without damaging the mating surfaces.
Figure 3.14.

Section 3
12. Immediately install the carrier into the housing

Figure 3.16 to permit the silicone gasket material to
compress evenly between the faces.
CAUTION
Apply silicone gasket material in a continuous
0.125-inch (3 mm) bead. If you use more than this
amount, gasket material can break off and plug
lubrication passages. Damage to components
can result.
13. Apply a 0.125-inch (3 mm) bead of Loctite® 242

CLEANING HOUSING FACE WITH ROTARY TOOL AND threadlocker around the capscrew threads
SCOTCHBRITE™ PAD approximately 0.25-inch (6 mm) from the end.
Apply a 0.125-inch (3 mm) bead of Loctite® 242
threadlocker across the length of the threads.
4. Remove metal filings from the magnets inside Figure 3.17.
the housing.
5. Use solvent to clean the inside of the
housing. Figure 3.17
1
6. Use Loctite® ODC Free cleaner or brake cleaner
to clean the housing and carrier faces.
7. Dry the housing and carrier faces.
8. Use a rotary wire brush to remove any nylon
patch material and clean the carrier-to-housing
capscrew threads. Use a clean cloth to wipe
the threads.
9. Use a tap to clean the internal threads in the
2
housing.
1 360° LOCTITE® BEAD
2 0.25" (6 MM)
WARNING LOCTITE® 242 THREADLOCKER APPLICATION
small amount of acid vapor is present. To prevent
serious personal injury, ensure that the work area 14. Install the capscrews. Use a crossing pattern
is well-ventilated. Read the manufacturer’s to tighten the capscrews evenly. The
instructions before using a silicone gasket capscrews must be tightened within
material, then carefully follow the instructions. If 10 minutes of initial application of Loctite® 242
a silicone gasket material gets into your eyes, threadlocker.
follow the manufacturer’s emergency procedures.
O Tighten 1/2-inch capscrews to 140 lb-ft
Have your eyes checked by a physician as soon as
(190 N•m). T
possible.
O Tighten 5/8-inch capscrews to 225 lb-ft
10. Apply a 0.25-inch (6 mm) bead of Loctite® (306 N•m). T
5699 silicone gasket material to the housing
15. Wait a minimum of 60 minutes before filling
face. Do not use Three Bond 1216E silicone
the assembly with lubricant. Refer to
products.
Section 6.
11. Install two long studs in the carrier to guide
the carrier into the housing.

Section 3
Installing Tight Fit Yokes and Figure 3.19

POSETM Seal 1
Refer to Figure 3.18
Figure 3.18
2 3
1 0.25-0.50” (6.4-12.7 MM)
2 YOKE HUB
3 FACE SEAL ASSEMBLY, POSE™ SEAL ELEMENT
4 3
Installing Any Type Yoke with a
1 Lubricate triple-lip or main seal.
2 INPUT SHAFT OR PINION Unitized Pinion Seal (UPS)
3 POSE™ SEAL, 0.25-0.50” (6.4-12.7 MM) ONTO HUB
4 Inspect yoke hub.
CAUTION
1. Apply the same lubricant used in the axle Once the yoke is partially or fully installed and
housing to the hub of the yoke or flange. then removed for any reason, the unitized pinion
seal will be damaged and unusable. If the yoke
2. Inspect and verify that the lips of the POSE™ and unitized pinion seal are removed after partial
seal and the outer retainer of the triple-lip seal or full installation, remove and discard the
or main seal are clean and free from dirt and original unitized pinion seal and replace it with
particles that may cause lubricant leakage another new unitized pinion seal.
between the seals.
3. Install the POSETM seal on the hub of the yoke If the inner sleeve of the seal is removed, the seal
or flange by hand. The lips of the seal must is not usable. A new seal is required. This will
face toward the end of the hub or the opposite occur if a yoke is installed into the seal and
shoulder. Slide the POSETM seal on the hub until then removed.
the lips are from 0.25-0.50-inch (6.4-12.7 mm)
from the end of the hub. Do not install the 1. Remove the replacement unitized seal from
POSETM seal against the shoulder. Figure 3.19. the package. Figure 3.20.
NOTE: The POSETM seal will position itself Figure 3.20

correctly as the yoke or flange is pressed on
the shaft.
4. Before you install the yoke or flange on the

shaft, apply the same lubricant used in the
axle housing to the hub.
5. Install the yoke or flange using the correct
procedure. The yoke must be completely
seated before tightening the pinion nut to the
input shaft.
UNITIZED SEAL

Section 3
2. Select the correct seal driver from Table A. Figure 3.21

Each seal driver is designed to correctly install
a specific diameter seal. To determine the yoke 1 2
seal diameter, measure the yoke journal. Refer
to Table A on the following page.
3. Position the seal on the driver.
CAUTION
Use a rubber mallet to install the seal. Do not use
a steel, brass or plastic hammer. Damage to the
seal and driver tool can result. 3
4. Use a rubber mallet to drive the seal into or The seal must fully seat
against the bearing cage. The seal must fully into or against the bearing cage.
seat into or against the bearing cage.
Figure 3.21. 1 RUBBER MALLET
2 REFERENCE MARK
5. Use a 0.010-inch shim to check for clearance 3 SEAL DRIVER R4422401
between the entire seal flange circumference
and the bearing cage.
O If the 0.010-inch shim slides between the
seal flange and bearing cage: Correctly
position the seal driver and drive the seal
into the bore until the 0.010-inch shim
cannot slide between the seal flange and
bearing cage at any point around the seal
flange. Figure 3.22.
Table A: Unitized Pinion Seals and Seal Drivers
Yoke Seal
Meritor Unitized Meritor Diameter
Single Models Tandem Models Pinion Seal Seal Installation Location Seal Driver Inches
MX-21-160 RT-34-144 /P A-1205-R-2592 Tandem Forward Input — R4422402 3.250
MX-23-160R RT-34-145 /P 145 models from 11/93 to 3.255
RF-16-145 present
RT-40-145 /A /P
RF-21-160 RT-40-149 /A /P
A-1205-P-2590 Tandem Forward Output — R4422401 3.000
RF-22-166 RT-44-145 /P
Tandem Forward Input 3.005
RF-23-185 RT-40-160 /A /P 145 models before 11/93 with
RS-17-145 RT-40-169 /A /P seal A-1205-F-2424
RS-19-145 RT-46-160 /A /P A-1205-N-2588 Tandem and Single Rear R4422401 3.000
RS-21-145 RT-46-169 /A /P Input — 145 models 3.005
RS-21-160 RT-46-164EH /P
RS-23-160 /A RT-46-16HEH /P
RS-23-161 /A RT-50-160 /P A-1205-Q-2591 Tandem and Single Rear R4422402 3.250
Input — 160/164/185 models 3.255
RS-25-160 /A RT-52-185*
RS-23-186 RT-58-185*
RS-26-185
RS-30-185
To obtain Meritor seal driver KIT 4454, refer to the Service Notes page on the front inside cover of this manual.
* Forward and rear input only.

Section 3
Figure 3.22 NOTE: The unitized seal features a rubber inner

sleeve that is designed to seal and rotate with the
yoke. This feature allows you to reuse a yoke with
1
minor grooves.
2. Inspect the yoke seal surface for grooves.

O If you find grooves on the yoke: Use calipers
to measure the groove diameters.
If any groove diameter measures less than
the dimensions shown in Figure 3.23,
replace the yoke.
MEASURING SEAL GAP Figure 3.23

1 0.010" (0.254 MM)
Clean, Inspect and Install the Yoke A B

After Installing a Unitized Pinion
Seal
Yoke Seal Minimum Yoke Diameter
WARNING Diameter at Groove (Inches)
3.000/3.005" 2.990"
Solvent cleaners can be flammable, poisonous and 3.250/3.255" 3.240"
cause burns. Examples of solvent cleaners are A MINIMUM GROOVE DEPTH — DIAMETER
carbon tetrachloride, and emulsion-type and B YOKE SEAL DIAMETER
instructions before using a solvent cleaner, then
carefully follow the instructions. Also follow the
procedures below. CAUTION
Do not install a POSE™ seal after you install a
unitized pinion seal. The use of a POSE™ seal will
O Wear clothing that protects your skin. prevent correct seating of the unitized pinion seal
on the yoke and can result in lubricant leakage at
O Work in a well-ventilated area. the seal. POSE™ seal installation is recommended
O Do not use gasoline, or solvents that contain only for triple lip and other previous design seals.
Do not use thin metal wear sleeves to refresh the
O You must use hot solution tanks or alkaline yoke surface. Wear sleeves pressed onto the yoke
solutions correctly. Read the manufacturer’s can prevent correct seating of the pinion seal,
instructions before using hot solution tanks and damage the pinion seal assembly and can cause
alkaline solutions. Then carefully follow the the seal to leak.
instructions.
3. Before you install the yoke, lightly lubricate or
1. Use a clean shop towel and a safe cleaning coat the yoke seal journal with axle oil.
solvent to clean the ground and polished
surface of the yoke journal. Do not use 4. Align the yoke splines with the shaft splines.
gasoline, abrasive cleaners, towels, or Slide the yoke over the shaft spline.
scrubbers to clean the yoke. Do not attempt
to polish the yoke.

Section 3
General Yoke and U-Joint Gear Set Tooth Combination Number

Reassembly Drive Pinion Ring Gear
Gear Set Teeth Location Location
Install the end yoke hub capscrews by hand after 5-37 = gear set At the end at On the front face
seating the U-joint. Tighten the capscrews has a five-tooth threads or outer diameter
according to manufacturer’s torque specifications. drive pinion and a
37-tooth ring gear
Gear Sets
Gear Set Match Number
Refer to the following examples for information on
identifying gear sets with matched parts. Always NOTE: Meritor’s drive pinions and ring gears are
check match numbers to verify that the gear set only available as matched sets. Each gear in a set
you will install has matched parts. Figure 3.24. has an alpha-numeric match number.
Figure 3.24 Drive Pinion Ring Gear

Match Number Location Location
1 M29 At the end of the On the front face
gear head or outer diameter
2 3
Pinion Cone Variation Number
4
NOTE: Don’t use the pinion cone variation
5 number when you check for a matched gear set.
Use this number when you adjust the pinion depth
in the carrier. Refer to Section 4.
ALTERNATE LOCATIONS:
1 PART NUMBER, TOOTH COMBINATION NUMBER, Pinion Cone
GEAR SET MATCH NUMBER, PINION CONE (PC) Variation Drive Pinion Ring Gear
VARIATION NUMBER Number Location Location
2 PART NUMBER, TOOTH COMBINATION NUMBER PC+3 At the end of the On the outer
3 GEAR SET MATCH NUMBER, PINION CONE +2 pinon gear head diameter
VARIATION NUMBER +0.01 mm
4 PART NUMBER, TOOTH COMBINATION NUMBER, PC-5
GEAR SET MATCH NUMBER –1
5 PART NUMBER, TOOTH COMBINATION NUMBER –0.02 mm
GEAR SET MATCH NUMBER
Examples
Gear Set
Part Number Location
Conventional ring 36786 On the front face or
gear outer diameter
Conventional 36787 At the end at threads
drive pinion
Generoid ring 36786 K or On the front face or
gear 36786 K2 outer diameter
Generoid drive 36787 K or At the end at threads
pinion 36787 K2

Section 4
Assembly
Section 4
Assembly
Figure 4.2
WARNING
eye protection when you perform vehicle 1

disassembly procedures. Do not hit steel parts 2

components and serious personal injury. 1 SLEEVE 2 INNER BEARING CONE
Assembly 5. Press the inner bearing cone on the shaft of

the drive pinion until the cone is flat against
Drive Pinion, Bearings and Bearing the gear head. Use a sleeve of the correct size
against the bearing inner race.
Cage
1. Place the bearing cage in a press. Figure 4.1. NOTE: Spigot bearings are usually fastened to the
drive pinion with a snap ring. Some are fastened
with a peening tool, and some are a two-piece
Figure 4.1 bearing assembly with the inner race pressed on
the nose of the pinion and the outer race pressed
1 2 into its bore in the carrier.
3 6. Install the spigot bearing using one of the

4 following three procedures.
Installation
One-Piece Spigot Bearing on the Drive
Pinion with Snap Ring
5
1 PRESS 4 CAGE NOTE: The following procedure applies to all
2 SLEEVE 5 SUPPORTS axles except:
3 BEARING CUP
O Some 160 Series single axles may use
snap rings.
2. Support the bearing cage with metal or wood O Some 160 and 180 Series rear-rear tandem
blocks. axles may use snap rings.
3. Press the bearing cup into the bore of bearing
cage until cup is flat against bottom of bore. 1. Place the drive pinion in a press with the gear
Use a sleeve of the correct size to install head or the teeth toward the top. Figure 4.3.
bearing cup. Figure 4.1.
2. Press the spigot bearing on the end of drive
pinion. The bearing must be flat against the
NOTE: Use the same procedure for both gear head. Use a sleeve of the correct size
bearing cups. against the bearing inner race. Figure 4.3.
4. Place the drive pinion in a press with the gear 3. Use snap ring pliers to install the snap ring, if
head or teeth toward the bottom. Figure 4.2. equipped, into the groove in the end of the
drive pinion. Figure 4.4.

Section 4
Assembly

1
2
1
3
1 PUNCH
2 TUBE
1 PRESS
2 SLEEVE 2. When using a staking tool and press, apply
3 SPIGOT BEARING 6,614 lb (3 000 kg) force on a 0.375-inch
(10 mm) ball. Calculate the force required on
the tool as follows.
Figure 4.4 6,614 lb (3 000 kg) x amount of balls in
tool = pounds or kilograms
Example
6,614 lb (3 000 kg) x 3 balls = 19,842 pounds
(9 000 kg)
3. Place the punch of the staking tool over the
2 end of the pinion and spigot bearing. Apply
1 the required amount of force on the punch.
Figure 4.6.
Figure 4.6
1 SNAP RING
2 SPIGOT BEARING
1
One-Piece Spigot Bearing on the Drive 2

Pinion Without Snap Ring
3
NOTE: The following procedure applies to some
180 Series rear-rear tandem axles with existing
snap ring components.
4
For ordering information about the staking tool,
refer to the Service Notes page on the front inside
cover of this manual. Figure 4.5. 1 PRESS
2 Install and center the punch on the end of pinion.
1. Place the drive pinion and the tube of the 3 SPIGOT BEARING
4 Place the shaft of pinion into tube.
staking tool in a press with the spigot bearing
toward the top. Figure 4.6.

Section 4
Assembly
1. Apply two stripes of temperature indicating

CAUTION liquid on the pinion stem from the top to the
bottom. Figure 4.8. Apply a green stripe to
Do not align new points with the grooves in the
indicate 400°F (205°C) and a blue stripe to
end of the drive pinion or in old points. If the
indicate 500°F (260°C).
new staked points are placed in the wrong
areas, the spigot bearing will not be held
correctly on the pinion shaft. Figure 4.8
NOTE: If a three-ball stake tool is used, rotate the

tool 180 degrees.
1
4. Stake the end of the drive pinion at a
minimum of five points. Figure 4.7. Rotate the
punch as many times as required for a
minimum of five points. Repeat Step 3 for
each point.
Figure 4.7
1 1 TEMPERATURE INDICATING LIQUID APPLICATION
CAUTION
You must use the heat shield when you heat the
pinion stem. Do not heat the pinion stem
without the heat shield in place. Damage to
2. Place the heat shield over the pinion stem so

1 STAKING POINTS that you can see the temperature indicating
liquid through the hole in the shield.
Figure 4.9.
Two-Piece Spigot Bearing on the Drive
Pinion Figure 4.9
NOTE: This procedure applies to some 160 Series

single rear axles and rear-rear tandem axles.
These axles may also use a one-piece spigot
bearing with a snap ring retainer.
NOTE: The inner race of two-piece spigot

bearings must be staked in place on RS and
RR-160 series rear axles. Before you stake the
pinion, you must heat the pinion stem to soften it.
NOTE: SPX Kent-Moore kit number J-39039 1003040a

includes the staking tool, temperature indicating
liquid, heat shield and plastigage needed for this
procedure. To obtain this kit, refer to the Service
Notes page on the front inside cover of this
manual.

Section 4
Assembly
WARNING CAUTION
Read the manufacturer’s instructions before Do not press or directly strike the new inner
using a torch. Always wear safe clothing, race. Damage to the bearing will result.
gloves and eye protection when working with a
torch for heating parts to prevent serious 6. Use a press, if available, or a brass hammer to
personal injury during assembly. install the new inner race. Use the old inner
race as a sleeve. The face is completely seated
3. Put on safe clothing, gloves and eye when you cannot fit a 0.002-inch (0.0508 mm)
protection. feeler gauge between the race and the pinion
shoulder.
CAUTION
NOTE: To hold the races in place, use a staking
Do not overheat the pinion stem or you will tool, not the old race, to start the new race
weaken the metal. Damage to components can on the stem. The old race can be used to
result. completely seat the new race.
NOTE: Correct heating will take approximately 7. Place the staking tool over the bearing race.
25-35 seconds, depending on how hot the torch is. Cut a 1-inch (25 mm) piece from the
green plastigage strip and place in between
4. Light and adjust the torch until the white the punch and the staking tool. You do not
part of the flame is approximately 0.25-inch need to use the plastigage for every stake. Use
(6 mm) long. Keep the white part of the flame the plastigage until you are sure you are
approximately 0.125-inch (3 mm) from the top hitting the punch with the correct amount of
of the stem. Figure 4.10. Move the flame force. Figure 4.11.
around the outer diameter of the top of the
pinion stem. The green temperature indicating 8. Strike the punch with a 2-3 pound
liquid will turn black before the blue liquid (0.9-1.4 kg) brass hammer to upset the end of
does. Heat the stem until the blue liquid turns the pinion stem. Remove the strip and
black at a point in the middle of the window. measure its thickness against the gauge on the
strip’s wrapper. The strip must not be less
5. Remove the flame and the heat shield than 0.003-inch (0.0762 mm) thick. This
from the pinion. Let the pinion air cool for thickness indicates that you are using enough
10 minutes. Use a razor blade to remove the force when you hit the punch. If the strip is too
temperature indicating liquid. thin, then you must hit the punch harder so
the stake will hold the race in place. Rotate the
Figure 4.10 tool and repeat this procedure until there are
six evenly spaced stake marks around the
1
stem. Figure 4.11.
9. With a press or a soft mallet and sleeve, install
the outer race and roller assembly into its bore
in the carrier. Use a sleeve that is the same
size as the outer race. Press the bearing until it
is squarely against the shoulder in the bottom
2 3 of its bore.
4
6
5
1 TORCH 4 0.125-INCH (3 MM)
2 WHITE PART OF FLAME 5 PINION
3 0.25-INCH (6 MM) 6 HEAT SHIELD

Section 4
Assembly

1
2
5 1
3
2
4
4
5
1 PUNCH 4 BEARING INNER RACE
2 PLASTIGAGE 5 STAKES
3 STAKING TOOL
1 OUTER BEARING CONE

Drive Pinion 2 BEARING SPACER
3 BEARING CAGE
1. Apply axle lubricant to the bearing cups and 4 INNER BEARING CONE
to the bearing cones in the cage. 5 DRIVE PINION
2. Install the drive pinion into the bearing cage.

3. Install the bearing spacer or spacers onto the Adjustment
pinion shaft against the inner bearing cone.
Figure 4.12. The spacer or spacers control the Pinion Bearing Preload
preload adjustment of the drive pinion
bearings. Press Method
4. Install the outer bearing cone onto the pinion If a press is not available, or the press does not
shaft against the spacer. Do not install the have a pressure gauge, use the yoke or flange
pinion seal in the bearing cage. Figure 4.12. method to adjust pinion bearing preload. Refer
to Yoke or Flange Method.
NOTE: Do not read starting torque. Read only

the torque value after the cage starts to rotate.
Starting torque will give an incorrect reading.
1. Place the drive pinion and cage assembly in a

press, gear head or teeth toward the bottom.
2. Install a sleeve of the correct size against the
inner race of the outer bearing. Figure 4.13.

Section 4
Assembly
Figure 4.13 Table B
Torque Value
1 Press Pressure Needed on Pinion
Thread Needed on Bearings Nut for Correct
2 for Correct Preload Bearing Preload
Size of
Pinion pounds/ (kg/metric
Shaft tons tons) lb-ft (N•m)
7/8"-20 22,000/1 (9979/10) 200-275 (271-373)
1"-20 30,000/15 (13 608/13.6) 300-400 (407-542)
1-1/4"-12 54,000/27 (24 494/24.5) 700-900 (949-1220)
1-1/4"-18 54,000/27 (24 494/24.5) 700-900 (949-1220)
1-1/2"-12 54,000/27 (24 494/24.5) 800-1100 (1085-1491)
1 PRESS 1-1/2"-18 54,000/27 (24 494/24.5) 800-1100 (1085-1491)
2 SLEEVE
1-3/4"-12 50,000/25 (22 680/22.7) 900-1200 (1220-1627)
2"-12 50,000/25 (22 680/22.7) 1200-1500 (1627-2034)
3. Apply and hold the correct amount of pressure
to the pinion bearings. Refer to Table B. As 9. Use the following procedure to calculate the
pressure is applied, rotate the bearing cage bearing preload or torque.
several times so that the bearings make
normal contact. O Pounds Pulled x Radius (inches) =
lb-in Preload
4. While pressure is held against the assembly,
wind a cord around the bearing cage several — Preload x 0.113 = N•m Preload
times. O Kilograms Pulled x Radius (cm) =
5. Attach a spring scale to the end of the cord. kg-cm lb-in Preload
6. Pull the cord on a horizontal line. As the — Preload x 0.098 = N•m Preload
bearing cage rotates, read the value indicated or
on the scale. Record the reading. Figure 4.13.
Examples
7. Measure the diameter of the bearing cage
where the cord was wound. Measure in inches O Reading from spring scale = 7.5 pounds
or centimeters. Figure 4.14. (3.4 kg)
O Diameter of bearing cage = 6.62-inches
(16.8 cm)
Figure 4.14
O Radius of bearing cage = 3.31-inches
(8.4 cm)
7.5 lb x 3.31 in = 24.8 in-lb Preload
Preload x 0.113 = 2.8 N•m Preload
or
3.4 kg x 8.4 cm = 28.6 kg-cm Preload
Preload x 0.098 = 2.8 N•m Preload
1003045b
1
1 Measure diameter of cage.
8. Divide the dimension in half to get the radius.

Record the radius dimension.

Section 4
Assembly
10. If the preload or torque of pinion bearings Figure 4.16

is not within 5-45 lb-in (0.56-5.08 N•m) for
new pinion bearings or 10-30 lb-in
(1.13-3.39 N•m) for used pinion bearings in
good condition, adjust the spacer and repeat
Steps 1 through 9. T
O To increase preload: Install a thinner
bearing spacer.
O To decrease preload: Install a thicker
bearing spacer.
1003355b
11. Check the bearing preload with the drive
pinion and cage assembly installed in the
carrier. Follow the procedures to adjust pinion
bearing preload, yoke or flange method. 4. Fasten a yoke or flange bar to the input yoke
or flange. The bar will hold the drive pinion
Yoke or Flange Method in position when the nut is tightened.
Figure 4.17.
CAUTION
Do not install tight-fitting yokes or flanges on Figure 4.17
shafts using a hammer or mallet. A hammer or
mallet will damage the yoke or flange.
1. Use a press to install the input yoke or flange,

nut and washer, if equipped, onto the drive
pinion. The yoke or flange must be seated
against the outer bearing. Figure 4.15.
1
Figure 4.15
1
1 FLANGE BAR SHOWN
2 5. Tighten the drive pinion nut to the correct

torque value. Figure 4.17. Refer to Table B.
6. Remove the yoke or flange bar.
7. Attach a torque wrench on the drive pinion
nut. Rotate the drive pinion and read the value
indicated on torque wrench. Figure 4.18.
1 PRESS
2 INPUT FLANGE SHOWN
2. Install the drive pinion and cage assembly into

the carrier. Do not install shims under the
bearing cage. Figure 4.16.
3. Install the bearing cage-to-carrier capscrews.
Washers are not required at this time.
Hand-tighten the capscrews.

Section 4
Assembly

3
1
4 2
5
1 Read torque value.
8. If the pinion bearing preload or torque is not 1 Apply grease. 4 BEARING CAGE
within 5-45 lb-in (0.56-5.08 N•m) for new 5 DRIVE PINION
2 TRIPLE-LIP, MAIN SEAL
pinion bearings or 10-30 lb-in (1.13-3.39 N•m) 3 Apply lubricant to seal bore.
for used pinion bearings in good condition,
remove the pinion and cage assembly from
C. Press the seal into the bearing cage. The
the carrier. Adjust the spacer and repeat
seal flange must be flat against the top of
Steps 1 through 7. T
the bearing cage. Use a sleeve or seal
O To increase preload: Install a thinner driver of the correct size that fits against
bearing spacer. the metal seal flange. The diameter of the
sleeve or driver must be larger than the
O To decrease preload: Install a thicker flange diameter. Figure 4.20.
bearing spacer.
O If a press is not available: Use a mallet
9. After adjusting pinion bearing preload, and the sleeve or driver to install the
remove the drive pinion and bearing cage seal. Figure 4.21.
from the carrier. Refer to Section 2.
D. After the triple-lip seal is installed, a gap
10. Install a new triple-lip seal. of approximately 0.015-0.030-inch
(0.38-0.76 mm) between the flange and
CAUTION bearing cage is normal. Figure 4.22.
The seal lips must be clean. Dirt and particles E. Check the gap with a feeler gauge at several
may cause a leak between the yoke and the points around the seal. The gap must be
seal. within 0.015-0.030-inch (0.38-0.76 mm).
The difference between the largest and
A. Apply the same lubricant used in the axle smallest gap measurement must not
housing to the outer surface of the seal exceed 0.010-inch (0.0254 mm).
and the seal bore in the bearing cage.
Figure 4.19.
B. Place the drive pinion and cage assembly
in a press with the seal bore toward the
top.

Section 4
Assembly
Figure 4.20 Shim Pack Thickness for a New Drive

Pinion
1 4
NOTE: Use this procedure if you’ll install a new
2 drive pinion and ring gear set, or if you have to
5 adjust the depth of the drive pinion. Figure 4.23.
3
1. Use a micrometer to measure the thickness of
6 the shim pack that was removed from under
7 the pinion cage. Record the measurement.
Figure 4.24.
1 PRESS 5 SEAL Figure 4.23

2 SLEEVE 6 BEARING CAGE
3 SUPPORTS 7 DRIVE PINION
4 SLEEVE
2
1
Figure 4.21
1 SHIM PACK 2 BEARING CAGE

CONTROLS DEPTH OF 3 CARRIER
PINION
1 SEAL DRIVER
Figure 4.24
Figure 4.22
2. Find the pinion cone (PC) variation number on

1 0.015-0.030” (0.38-0.76 MM) the drive pinion you’ll replace. Figure 4.25.
SHOWN WITHOUT BEARINGS AND PINION Record the number. The pinion cone number
can be one of the following values.
O PC +3, PC –3, +3 or –3 = 0.003-inch
O PC +.03, PC 0.03 mm, +0.03 mm or
–0.03 = 0.03 mm

Section 4
Assembly
Figure 4.25 Table C
Examples Inches mm
1. Old Shim Pack Thickness. 0.030 – 0.002 0.760 – 0.050
1 Old PC Number, PC = 0.028 + 0.005 = 0.710 + 0.130
+2 inches (+0.05 mm) = 0.033 = 0.840
Standard Shim Pack
Thickness. New PC
Number, PC +5 inches
(+0.13 mm)
New Shim Pack
Thickness
2. Old Shim Pack Thickness 0.030 + 0.002 0.760 + 0.050
Old PC Number, PC = 0.032 + 0.005 = 0.810 + 0.130
1 PINION CONE VARIATION NUMBER –2 inches (–0.05 mm) = 0.037 = 0.940
Standard Shim Pack
Thickness. New PC
3. If you can’t find the PC number or it’s Number, PC +5 inches
unreadable, install a new shim pack of the (+0.13 mm)
same thickness that you measured in Step 1. New Shim Pack
Thickness
4. If the old pinion cone number is a plus (+)
number, subtract the number from the old 3. Old Shim Pack Thickness 0.030 – 0.002 0.760 – 0.050
shim pack thickness that was measured in Old PC Number, PC = 0.028 – 0.005 = 0.710 – 0.130
+2 inches (+0.05 mm) = 0.023 = 0.580
Step 2.
Standard Shim Pack
5. If the old pinion cone number is a minus (–) Thickness. New PC
number, add the number to the old shim pack Number, PC –5 inches
(–0.13 mm)
thickness that was measured in Step 2.
New Shim Pack
6. Find the pinion cone (PC) variation number on Thickness
the new drive pinion that will be installed. 4. Old Shim Pack Thickness 0.030 + 0.002 0.760 + 0.050
Record the number. Old PC Number, PC = 0.032– 0.005 = 0.810 – 0.130
–2 inches (–0.05 mm) = 0.027 = 0.680
7. If the new pinion cone number is a plus (+)
Standard Shim Pack
number, add the number to the standard shim Thickness. New PC
pack thickness that was calculated in Step 4 or Number, PC –5 inches
Step 5. Use new shims to make a shim pack to (–0.13 mm)
the correct thickness. Refer to Table C. New Shim Pack
Thickness
8. If the new pinion cone number is a minus (–)
number, subtract the number from the
standard shim pack thickness that was Installation
calculated in Step 4 or Step 5. Use new shims
to make a shim pack to the correct thickness.
Refer to Table C. Drive Pinion, Bearing Cage and Shim
Pack into the Carrier
NOTE: If a new drive pinion and ring gear set is
installed, or if the depth of the drive pinion has to
be adjusted, calculate the thickness of the shim
pack. Refer to the procedure Shim Pack Thickness
for a New Drive Pinion.
1. Select the correct shim pack and install it

between the bearing cage and carrier.
Figure 4.26.

Section 4
Assembly

1
1001059a
2
1 GUIDE STUDS
2 CARRIER
Tight Fit Yokes and POSE™ Seal
®
2. Apply Loctite 518 Gasket Eliminator to the
carrier face. CAUTION
3. Align the oil slots in the shims with oil slots in Do not install tight fit yokes on shafts using a
the bearing cage and carrier. Use guide studs hammer or mallet. Using a hammer or mallet
to help align the shims. Figure 4.26. can damage the yoke.
4. Apply Loctite® 518 Gasket Eliminator to the The seal lips must be clean. Dirt and particles
top of the shim pack. may cause a leak between the yoke and the
5. Install the drive pinion and bearing cage into POSE™ seal.
the carrier. If necessary, use a rubber, plastic
or leather mallet to hit the assembly into NOTE: Do not install POSE™ seal all the way
position. Figure 4.27. against the yoke shoulder. This seal is designed
to position itself as yoke is installed.
Figure 4.27 1. Apply axle lubricant on the yoke seal.
1
2. Check all surfaces of the yoke hub for damage.
3. If the carrier uses a POSE™ seal element, install
a new POSE™ seal.
A. Lightly lubricate the yoke journal with the
2 same lubricant used in the axle housing.
3 B. Partially install the POSE™ seal onto
the yoke 0.25-0.5-inch (6-13 mm).
Figure 4.29.
C. Before installing the yoke onto the drive
1 DRIVE PINION AND BEARING CAGE pinion, lubricate the yoke with the same
2 SHIMS lubricant used in the axle housing.
3 CARRIER
6. Install the bearing cage-to-carrier capscrews

and washers. Tighten the capscrews to the
correct torque value. Figure 4.28. Refer to
Section 7.

Section 4
Assembly
Figure 4.29 Any Type Yoke with a Unitized Pinion

Seal (UPS)
1
NOTE: Once the yoke is partially or fully installed
and then removed for any reason, the unitized
pinion seal will be damaged and unusable. If the
2 yoke and unitized pinion seal are removed after
partial or full installation, remove and discard the
original unitized pinion seal and replace it with
another new unitized pinion seal.
If the inner sleeve of the seal is removed, the seal
4 3 is not usable. A new seal is required. This will
occur if a yoke is installed into the seal and then
1 Lubricate triple-lip or main seal. removed.
2 INPUT SHAFT, PINION
3 POSE™ SEAL, 0.25-0.50” (6-13 MM) ONTO HUB
4 Check yoke hub. 1. Remove the replacement unitized seal from
the package. Figure 4.31.
4. Slide the yoke over the input shaft pinion. 2. Select the correct seal driver from Table D.
Align the yoke splines with the shaft splines. Each seal driver is designed to correctly install
a specific diameter seal. To determine the yoke
seal diameter, measure the yoke journal. Refer
CAUTION to Table D.
Do not use a hammer or mallet to install the 3. Position the seal on the driver.
yoke to the input pinion shaft. Using a hammer
or mallet can damage the yoke or flange.
Figure 4.31
5. Install the input yoke flange onto the drive
pinion shaft. The yoke or flange must be fully
seated against the outer differential bearing
before the nut is tightened to specifications.
6. Install the drive pinion nut and washer on the
input pinion shaft and against the yoke collar.
Tighten the nut against yoke collar to torque
specifications. Figure 4.30. Refer to Section 7.
Figure 4.30
UNITIZED SEAL
1 Use flange or yoke bar.

Section 4
Assembly
Table D: Unitized Pinion Seals and Seal Drivers
Yoke Seal
Meritor Unitized Meritor Diameter
Single Models Tandem Models Pinion Seal Seal Installation Location Seal Driver Inches
MX-21-160 RT-34-144 /P A-1205-R-2592 Tandem Forward Input — 145 R4422402 3.250
models from 11/93 to present
MX-23-160R RT-34-145 /P 3.255
RF-16-145 RT-40-145 /A /P
RF-21-160 RT-40-149 /A /P
A-1205-P-2590 Tandem Forward Output — R4422401 3.000
RF-22-166 RT-44-145 /P Tandem Forward Input 3.005
RF-23-185 RT-40-160 /A /P 145 models before 11/93 with
seal A-1205-F-2424
RS-17-145 RT-40-169 /A /P
A-1205-N-2588 Tandem and Single Rear R4422401 3.000
RS-19-145 RT-46-160 /A /P
Input — 145 models 3.005
RS-21-145 RT-46-169 /A /P
RS-21-160 RT-46-164EH /P
RS-23-160 /A RT-46-16HEH /P A-1205-Q-2591 Tandem and Single Rear R4422402 3.250
Input — 160/164/185 models
RS-23-161 /A RT-50-160 /P 3.255
RS-25-160 /A RT-52-185*
RS-23-186 RT-58-185*
RS-26-185
RS-30-185
5. Use a 0.010-inch (0.25 mm) shim to check for

CAUTION clearance between the entire seal flange
circumference and the bearing cage.
Use a rubber mallet to install the seal. Do not
use a steel, brass or plastic hammer. Damage to O If the 0.010-inch (0.25 mm) shim slides
the seal and driver tool can result. between the seal flange and bearing
cage: Correctly position the seal driver and
4. Use a rubber mallet to drive the seal into or drive the seal into the bore until the 0.010-
against the bearing cage. The seal must fully inch (0.25 mm) shim cannot slide between
seat into or against the bearing cage. the seal flange and bearing cage at any
Figure 4.32. point around the seal flange. Figure 4.33.

1 2
1
The seal must

be fully seated
3 in or against
the bearing cage.
1 RUBBER MALLET MEASURING SEAL GAP

2 REFERENCE MARK 1 0.010" (0.25 MM)
3 SEAL DRIVER R4422401

Section 4
Assembly
Clean, Inspect and Install the Yoke Figure 4.34

After Installing a Unitized Pinion
Seal
A B
WARNING
and cause burns. Examples of solvent cleaners are
carbon tetrachloride, and emulsion-type and Yoke Seal Minimum Yoke Diameter
petroleum-base cleaners. Read the manufacturer’s Diameter at Groove (Inches)
instructions before using a solvent cleaner, then 3.000/3.005" 2.990"
carefully follow the instructions. Also follow the 3.250/3.255" 3.240"
procedures below. 1 MINIMUM GROOVE DEPTH — DIAMETER
2 YOKE SEAL DIAMETER
O Wear clothing that protects your skin.
O Work in a well-ventilated area. CAUTION
O Do not use gasoline, or solvents that contain Do not install a POSE™ seal after you install a
gasoline. Gasoline can explode. unitized pinion seal. The use of a POSE™ seal will
prevent correct seating of the unitized pinion seal
O You must use hot solution tanks or alkaline
on the yoke and can result in lubricant leakage at
solutions correctly. Read the manufacturer’s
the seal. POSE™ seal installation is recommended
only for triple lip and other previous design seals.
and alkaline solutions. Then carefully follow the
Damage to components can result.
instructions.
1. Use a clean shop towel and a safe cleaning Do not use thin metal wear sleeves to refresh the
solvent to clean the ground and polished yoke surface. Wear sleeves pressed onto the yoke
surface of the yoke journal. Do not use can prevent correct seating of the pinion seal,
gasoline, abrasive cleaners, towels, or damage the pinion seal assembly and can cause
scrubbers to clean the yoke. Do not attempt the seal to leak. Damage to components can
to polish the yoke. result.
NOTE: The unitized seal features a rubber inner 3. Before you install the yoke, lightly lubricate or
sleeve that is designed to seal and rotate with the coat the yoke seal journal with axle oil.
yoke. This feature allows you to reuse a yoke with 4. Align the yoke splines with the shaft splines.
minor grooves. Slide the yoke over the shaft spline.
2. Inspect the yoke seal surface for grooves.

CAUTION
O If you find grooves on the yoke: Use
calipers to measure the groove diameters. Do not use a hammer or mallet to install the yoke
If any groove diameter measures less than to the input pinion shaft. Using a hammer or
the dimensions shown in Figure 4.34, mallet can damage the yoke or flange.
replace the yoke.
5. Install the input yoke flange onto the drive
pinion shaft. The yoke or flange must be fully
seated against the outer differential bearing
before the nut is torqued to specifications.
6. Install the drive pinion nut, and washer if
required, on the input pinion shaft and against
the yoke collar. Tighten the nut against yoke
collar to torque specifications. Figure 4.35.
Refer to Section 7.

Section 4
Assembly
Figure 4.35 NOTE: If rivets were used to hold the ring gear to
the flange case half, replace them with bolts, nuts
and washers.
5. Install the bolts, nuts and washers that hold

the ring gear to the flange case half. Install the
bolts from the gear side of the assembly. The
bolt heads must be against the ring gear.
Figure 4.36.
1 Figure 4.36
2
1 Use flange or yoke bar. 1
Assembly
Main Differential and Ring Gear Assembly
CAUTION 3
Heat the ring gear before seating it onto the
differential case. Do not press a cold ring gear on 1 FLANGE CASE HALF
the flange case half. A cold ring gear will damage 2 RING GEAR
3 BOLT HEAD AGAINST GEAR
the case half because of the tight fit.
1. Heat the ring gear in a tank of water to a 6. Tighten the bolts and nuts to the correct
temperature of 160°F-180°F (71°C-82°C) for torque value. Refer to Section 7.
10 to 15 minutes.
7. Use a 0.003-inch (0.08 mm) feeler gauge to
check for gaps between the back surface of
WARNING the ring gear and the case flange. Check for
Wear safe clothing and gloves when working with gaps at four points around the assembly.
the hot ring gear to prevent serious personal Figure 4.37.
injury. O If the gaps exceed specifications: Check
the flange case half and ring gear for the
2. Use a lifting tool to safely lift the ring gear problem that causes the gap. Repair or
from the tank of water. replace parts. Assemble the ring gear on the
3. Install the ring gear on the flange case half flange case half. Repeat the procedure in
immediately after the gear is heated. Tight Fit Yokes and POSE™ Seal.
O If the ring gear does not fit easily on the
case half: Heat the gear again.
4. Align the ring gear and the flange case half
fastener holes. Rotate the ring gear as
necessary.

Section 4
Assembly
1 Check for 0.003” (0.08 mm) gap at four locations. 1 SIDE GEAR
2 THRUST WASHER
3 FLANGE CASE HALF
8. Use a press and the correct size sleeve to
install the bearing cones on both of the case
halves. Figure 4.38.
CAUTION
Figure 4.38 The side gears in some carrier models have
hubs of different lengths. Install the correct
length side gear into the flange case half.
1 Damage to components can result.
2
12. Install the spider or cross, differential pinions
3 and thrust washers into the flange case half.
6 Figure 4.40.
Figure 4.40
5 4 1
1 PRESS 4 SUPPORT
2 SLEEVE 5 SUPPORT
3 BEARING CONE 6 CASE HALF
9. Apply axle lubricant on the inside surfaces of

both case halves, spider or cross, thrust
washers, side gears and differential pinions. 1 SPIDER, PINION AND THRUST WASHERS
10. Place the flange case half on a bench with the
ring gear teeth toward the top.
11. Install one thrust washer and side gear into
the flange case half. Figure 4.39.

Section 4
Assembly
13. Install the second side gear and thrust washer B. Install the other fasteners into the case
over the spider and differential pinions. halves. Tighten the fasteners to the correct
Figure 4.41. torque value. Refer to Section 7.
16. Check the differential gears rotating
Figure 4.41 resistance.
Figure 4.43
1
10 6
2 4 2
13 15
3 8 12
11 7
1 14
1 THRUST WASHER 16 3
2 SIDE GEAR 5 9
3 PLAIN CASE HALF
14. Place the plain half of the differential case over Differential Gears Rotating Resistance Check
the flange half and gears. Rotate the plain
half to align the match marks. Figures 4.41 1. Make an inspection tool using an axle shaft
and 4.42. that matches the spline size of the differential
side gear. Cut the shaft to approximately
12-inches (304.8 mm). Weld a nut onto the end
Figure 4.42 of the shaft. Figure 4.44.
1
Figure 4.44
2
1
2
3
1 PLAIN CASE HALF 4
2 MATCH MARKS
1 APPROXIMATELY 12" (304.8 MM)

15. Install Dri-Loc fasteners into the case halves. 2 SIDE VIEW
Refer to Section 3. 3 Weld nut to end of shaft.
4 END VIEW
A. Install four capscrews and washers or
bolts, nuts and washers, if equipped, into
the case halves. The distance between the 2. Place the differential and ring gear assembly
fasteners must be equal. Tighten the in a vise. Install soft metal covers over vise
fasteners to the correct torque value in a jaws to protect the ring gear. Figure 4.45.
progressive criss-cross pattern opposite
each other. Refer to Section 7. Figure 4.43 3. Install the tool into the differential until the
splines of the tool are engaged with one side
gear. Figure 4.45.

Section 4
Assembly
4. Place a torque wrench onto the nut of the tool 3. Apply adhesive into the bearing bores of the
and rotate the differential gears. As the carrier legs and bearing caps. Adhesive must
differential gears rotate, read the value not contact the adjusting ring threads. Refer to
indicated on the torque wrench. Figure 4.46. Section 3. Figure 4.47.
O If the torque value exceeds 50 lb-ft
(67.8 N•m): Disassemble the differential Figure 4.47
gears from the case halves. Inspect the case
halves, spider, gears and thrust washers. 1 2
Repair or replace parts. Assemble the parts
and repeat Steps 2-4.
3
Figure 4.45
1 ADHESIVE
2 BEARING CAP
3 CARRIER LEG
2 4. Install the bearing cups over the bearing

cones that are assembled on the case halves.
1 TOOL FOR CHECKING RESISTANCE Figure 4.48.
2 SOFT METAL COVER
Figure 4.48
Figure 4.46
1
1 BEARING CUP
2 BEARING CUP
1 Read torque value. 3 LEG BORE
Installation 5. Safely lift the differential and ring gear

assembly and install it into the carrier. The
Differential and Ring Gear Assembly bearing cups must be flat against the bores
between the carrier legs. Figure 4.48.
1. Clean and dry the bearing cups and bores of 6. Install both of the bearing adjusting rings into
the carrier legs and bearing caps. position between the carrier legs. Turn each
2. Apply axle lubricant on the inner diameter of adjusting ring hand-tight against the bearing
the bearing cups and on both bearing cones cup. Figure 4.49.
that are assembled on the case halves.

Section 4
Assembly
Figure 4.49 9. Install the capscrews and washers that hold

bearing caps to the carrier. Hand-tighten the
capscrews four to six turns. Tighten the
1 capscrews to the correct torque value. Refer
to Section 7.
NOTE: Do not install the cotter keys, pins or lock

plates, if equipped, that hold the bearing adjusting
rings in position.
10. Adjust differential bearing preload and hypoid

gear backlash. Check the tooth contact
2 patterns.
1 ADJUSTING RING
2 LEG
Adjust Differential Bearing Preload
7. Install the bearing caps over the bearings and
Differential
adjusting rings. Align the match marks you Bearing All Carrier 15-35 lb-in
made when you removed the caps. Preload Models (1.7-3.9 N•m)
Figure 4.50.
Expansion RS-140, RS-145 0.002-0.009-inch
between bearing and RS-160 (0.05-0.229 mm)
Figure 4.50 caps carrier models
RS-120 and all 0.006-0.013-inch

other carrier (0.15-0.33 mm)
models
1
Method 1
2
1. Attach a dial indicator onto the carrier
mounting flange so that the plunger or
pointer is against the ring gear back surface.
Figure 4.51.
1 BEARING CAP
2 MATCH MARKS Figure 4.51
1
CAUTION
If bearing caps are not installed in correct locations,
the bores and threads in caps will not match the
carrier. You will have problems assembling the
caps on the carrier and damage to parts can occur.
Do not force the bearing caps into position.
8. Seat each bearing cap with a light leather,

plastic or rubber mallet. The caps must fit
easily against the bearings, adjusting rings 1 DIAL INDICATOR
and carrier. Do not force the bearing caps
into position.
O If bearing caps do not correctly fit into
position: Check the alignment of match
marks between caps and carrier. Remove
the caps and repeat Steps 6-8.

Section 4
Assembly
Figure 4.53
CAUTION
When you turn the adjusting rings, always use
a tool that engages two or more opposite
notches in the ring. A T-bar wrench can be used
for this purpose. If the tool does not correctly fit
into
the notches, damage to the lugs will occur.
1
2. Use a T-bar wrench to loosen the bearing
adjusting ring that is opposite the ring gear.
A small amount of end play will show on the
dial indicator. Figure 4.52.
1 Bars must not touch bearings.
Figure 4.52
Figure 4.54
1
1 T-BAR WRENCH
2 ADJUSTING RING OPPOSITE RING GEAR 1 Bars must not touch bearings.
3. Use one of the following methods to move the 4. Tighten the bearing adjusting ring until the
differential and ring gear to the left and right dial indicator reads ZERO end play. Move the
while you read the dial indicator. differential and ring gear to the left and right
A. Insert two pry bars between the bearing as needed. If necessary, repeat Step A or B.
adjusting rings and ends of the differential 5. Tighten each bearing adjusting ring one notch
case. The pry bars must not touch the from ZERO.
differential bearings. Figure 4.53.
6. Proceed to check ring gear runout.
B. Insert two pry bars between the
differential case or ring gear and the
carrier at locations other than described in Method 2
Step A. The pry bars must not touch the 1. Hand-tighten both adjusting rings against the
differential bearings. Figure 4.54. differential bearings.
2. Use a micrometer to measure distance X or Y
between the opposite surfaces of the bearing
caps. Figures 4.55 and 4.56. Record the
measurement.

Section 4
Assembly
Figure 4.55 Check Ring Gear Runout

1. Attach a dial indicator onto the carrier
mounting flange. Figure 4.57.
Figure 4.57
1
Figure 4.56
1
1 Rotate ring gear.

2 DIAL INDICATOR
2. Adjust the dial indicator so that the plunger

or pointer is against the back surface of the
ring gear. Set the dial indicator to ZERO.
3. Rotate the differential and ring gear. Read
1 MICROMETER the dial indicator. Runout must not exceed
0.008-inch (0.20 mm). Figure 4.57.
3. Tighten each bearing adjusting ring one notch. O If runout exceeds specifications: Remove
the differential and ring gear assembly from
4. Measure distance X or Y again. Compare the the carrier. Refer to Differential and Ring
measurement with the one you obtained in Gear from the Carrier in Section 2 and
Step 2. The difference between the two Steps 4 and 5 below.
dimensions is the amount the bearing caps
have expanded. O If runout is within specifications: Proceed
to Ring Gear Backlash Adjustment.
Example
4. Check the differential parts including the
O Measurements of RS-145 carrier carrier for wear and damage. Repair or replace
O Distance X or Y parts.
— before tightening adjusting rings = 5. Install the differential and ring gear into the
13.927-inch (353.74 mm). carrier. Refer to Differential and Ring Gear
O Distance X or Y Assembly in this section. Repeat preload
— after tightening adjusting rings = adjustment of differential bearings.
13.936-inch (353.97 mm)
O 13.936-inch – 13.927-inch = 0.009-inch
(0.23 mm) difference.
O If the dimension is within specifications:
Continue by checking ring gear runout.
O If the dimension is less than specifications:
Repeat Steps 3 and 4 as needed.

Section 4
Assembly
Ring Gear Backlash Adjustment Figure 4.59
Range of Backlash
Ring Gear Backlash Setting for
Pitch Diameter Setting New Gear Sets
Less than 17-inches 0.008-0.018-inch 0.012-inch
(431.8 mm) (0.20-0.46 mm) (0.30 mm)
Greater than 0.010-0.020-inch 0.015-inch

17-inches (0.25-0.51 mm) (0.38 mm)
(431.8 mm)
Measure the outer diameter of ring gear for

approximate pitch diameter. Figure 4.58.
O If the old gear set is installed: Adjust the 2. Adjust the dial indicator so that the plunger
backlash to the setting that was measured or pointer is against the tooth surface.
before the carrier was disassembled. Figure 4.59.
O If a new gear set is installed: Adjust the 3. Adjust the indicator dial to ZERO. Hold the
backlash to the correct specification for new drive pinion in position.
gear sets. 4. After reading the dial indicator, rotate the
differential and ring gear a small amount in
both directions against the drive pinion teeth.
Figure 4.58
O If the backlash reading is within
specifications: Check the tooth contact
patterns.
O If the backlash reading is not within
specifications: Adjust backlash as needed.
5. Loosen one bearing adjusting ring one notch
then tighten the opposite ring the same
1
amount.
O To increase backlash: Move the ring gear
away from the drive pinion. Figure 4.60.
1 Measure outer diameter for approximate pitch O To decrease backlash: Move the ring gear
diameter.
toward the drive pinion. Figure 4.61.
After checking the tooth contact patterns, the Figure 4.60

backlash can be adjusted within specification
limits, if needed. To change the location of the
pattern use the following procedures. 1
1. Attach a dial indicator onto the mounting

flange of the carrier. Figure 4.59.
2 3
1 Tighten adjusting ring this side.

2 Increase backlash.
3 Loosen adjusting ring this side.

Section 4
Assembly
Figure 4.61 Examples

Part numbers for generoid gear sets
1 O 36786-K or 36786-K2 for the ring gear

O 36787-K or 36787-K2 for the drive pinion
2 In the following procedures, movement of the
contact pattern in the length of the tooth is
indicated as toward the heel or toe of the ring
gear. Figure 4.63.
3
Always check tooth contact patterns on the drive
side of the gear teeth. Figure 4.64.
1 Loosen adjusting ring this side.
2 Decrease backlash. Figure 4.63
3 Tighten adjusting ring this side.
NOTE: When you adjust backlash, move the ring

gear only. Do not move the drive pinion.
6. Repeat Steps 2-5 until the backlash is within 2

specifications.
Check Gear Set Tooth Contact 1
Patterns (Backlash)
Some Meritor carriers have a generoid hypoid 1 HEEL
gear set. The tooth contact patterns for each type 2 TOE
of gear set are different. Check the part numbers
to determine what type of gear set is in the carrier.
Refer to Figure 4.62 for the location of part Figure 4.64
numbers.
Figure 4.62
1
2
1
3 1003091b
1 DRIVE SIDE, CONVEX
1. Adjust the backlash of a new gear set to

1 PART NUMBER
2 PART NUMBER
either 0.012-inch (0.305 mm) or 0.015-inch
3 PART NUMBER OPTION (0.380 mm) depending on the size of the ring
gear. Adjust the backlash of an old gear set to
the setting that you measured before the
carrier was disassembled. Refer to Ring Gear
Backlash Adjustment.

Section 4
Assembly
2. Apply a marking compound onto A high contact pattern indicates that the drive
approximately 12 gear teeth of the ring gear. pinion was not installed deep enough into the
Rotate the ring gear so that the 12 gear teeth carrier. A low contact pattern indicates that the
are next to the drive pinion. Figure 4.65. drive pinion was installed too deep in the
carrier.
Figure 4.65 O If the contact patterns require
adjustment: Continue by following Step 5 to
move the contact patterns between the top
and bottom of the gear teeth.
O If the contact patterns are in the center of
the gear teeth: Continue by following
Step 6.
Figure 4.66
3. Rotate the ring gear forward and backward so

that the 12 gear teeth go past the drive pinion
six times to get the contact patterns. Repeat if
needed to get a clearer pattern.
4. Look at the contact patterns on the ring gear
teeth. Compare the patterns to Figures 4.66,
4.67 and 4.68.
GOOD HAND-ROLLED PATTERN, HYPOID GENEROID
The location of good hand-rolled contact GEARS
patterns for new conventional and generoid
gear sets is toward the toe of the gear tooth
and in the center between the top and bottom Figure 4.67
of the tooth. Figure 4.66.
When the carrier is operated, a good pattern
will extend approximately the full length of the
gear tooth. The top of the pattern will be near
the top of the gear tooth. Figure 4.69.
The location of a good hand-rolled contact
pattern for an old gear set must match the
wear pattern in the ring gear. The new contact
pattern will be smaller in area than the old
wear pattern.
HIGH PATTERN
HIGH PATTERN, HYPOID GENEROID GEARS

Section 4
Assembly
Figure 4.68 B. Install the drive pinion, bearing cage and

shims into the carrier. Refer to Shim Pack
Thickness for a New Drive Pinion in this
section.
C. Repeat Steps 2-5 until the contact patterns
are in the center between the top and
bottom of the gear teeth.
Figure 4.70
1001094a
LOW PATTERN, HYPOID GENEROID GEARS
Figure 4.69
1
1003102b
1 Decrease shim pack.
Figure 4.71
1001095
GOOD PATTERN IN OPERATION, GENEROID GEARS
5. Change the thickness of the shim pack under

the bearing cage to move the contact patterns
between the top and bottom of the gear teeth.
Use the following procedure.
1
A. Remove the drive pinion and bearing cage
from the carrier. Refer to Drive Pinion and 1003101b
Bearing Cage from the Carrier in Section 2. 1 Increase shim pack.
O To correct a high contact pattern:
Decrease the thickness of the shim pack
under the bearing cage. When
decreasing the thickness of the shim
pack, the drive pinion will move toward
the ring gear. Figure 4.70.
O To correct a low contact pattern:
Increase the thickness of shim pack
under the bearing cage. When
increasing the thickness of the shim
pack, the drive pinion will move away
from the ring gear. Figure 4.71.

Section 4
Assembly
6. Adjust backlash of the ring gear within the

specification range to move the contact CAUTION
patterns to the correct location in the length
If the carrier has cotter keys, lock the adjusting
of the gear teeth. Refer to Ring Gear Backlash
rings only with cotter keys. If the carrier has roll
Adjustment.
pins, reuse the roll pins or lock the adjusting
A. Decrease backlash to move the contact rings with cotter keys. Do not force a roll pin
patterns toward the toe of the ring gear into a cotter key hole. Damage to components
teeth. Figure 4.72. can result.
B. Increase backlash to move the contact
7. Install the cotter keys, pins, or lock plates, if
patterns toward the heel of the ring gear
equipped, that hold the two bearing adjusting
teeth. Figure 4.73.
rings in position. Use the following
C. Repeat Steps 2-4 and Step 6 until the procedures.
contact patterns are at the correct location
A. Install cotter keys between the lugs of the
in the length of the gear teeth.
adjusting ring and through the boss of the
bearing cap. Bend the two ends of the
Figure 4.72 cotter key around the boss. Figure 4.74.
B. Use a drift and hammer to install the pin
through the boss of the bearing cap until
1 the pin is between the lugs of the
adjusting ring. Figure 4.74.
2
C. Install the lock plate on the bearing cap so
that the tab is between the lugs of the
adjusting ring. Install the two capscrews
that hold the lock plate to the bearing cap.
3 Tighten the capscrews to correct torque
value. Refer to Section 7. Figure 4.74.
1003103b
1 Move pattern toward toe, loosen adjusting ring this Figure 4.74
side.
2 Decrease backlash. 2
3 Tighten adjusting ring.
1 3
Figure 4.73
1
4
2 3 1 COTTER KEY
2 PIN
3 LOCK PLATE
1003104b 4 THREADED HOLES IN CAP WHEN LOCK PLATE IS
1 Move pattern toward toe, loosen adjusting ring this USED
side.
2 Decrease backlash.
3 Loosen adjusting ring.

Section 4
Assembly
Installation Figure 4.77
Adjust the Thrust Screw

2
1. Rotate the carrier in the repair stand until the
back surface of ring gear is toward the top. 1
2. Install the jam nut on the thrust screw, if
equipped, one half the distance between both
ends. Figure 4.75.
Figure 4.75
1 Hold thrust screw in position.
2 Tighten jam nut to correct torque value.
1
1 THRUST SCREW AND JAM NUT
3. Install the thrust screw. Clearance between

the thrust screw and the ring gear must be
0.025-0.045-inch (0.65-1.14 mm).
4. Loosen the thrust screw 1/2 turn, 180 degrees.
Figure 4.76.
Figure 4.76
1 Loosen thrust screw 1/2 turn.
5. Tighten the jam nut, if equipped, to the correct

torque value against the carrier. Refer to
Section 7. Figure 4.77.

Section 4
Assembly
Differential Carrier into Axle Housing 5. Apply silicone gasket material to the mounting
surface of the housing where the carrier
fastens. Refer to Section 3. Figure 4.78.
WARNING
Figure 4.78
small amount of acid vapor is present. To prevent
serious personal injury, ensure that the work area 1
is well-ventilated. Read the manufacturer’s
instructions before using a silicone gasket
material, then carefully follow the instructions.
follow the manufacturer’s emergency procedures.
Have your eyes checked by a physician as soon
as possible.

and cause burns. Examples of solvent cleaners are 1 0.125" (3 MM) DIA. SILICONE GASKET BEAD
carbon tetrachloride, and emulsion-type and
instructions before using a solvent cleaner, then
carefully follow the instructions. Also follow the CAUTION
procedures below.
Do not install the carriers using a hammer or
O Wear safe eye protection. mallet. A hammer or mallet will damage the
O Wear clothing that protects your skin. mounting flange of carrier and cause oil leaks.
O Work in a well-ventilated area. 6. Use a hydraulic roller jack or a lifting tool to

O Do not use gasoline, or solvents that contain install the carrier into the axle housing.
gasoline. Gasoline can explode. 7. Install nuts and washers or capscrews and
O You must use hot solution tanks or alkaline washers, if equipped, in the four corner
solutions correctly. Read the manufacturer’s locations around the carrier and axle housing.
instructions before using hot solution tanks Hand-tighten the fasteners. Figure 4.79.
and alkaline solutions. Then carefully follow the 8. Carefully push the carrier into position. Tighten
instructions. the four fasteners two or three turns each in a
pattern opposite each other. Figure 4.79.
NOTE: To complete the assembly of axles
equipped with driver-controlled main differential
locks, refer to DCDL Assembly into Carrier in Figure 4.79
Section 5.
1. Use a cleaning solvent and rags to clean the

inside of the axle housing and the carrier
mounting surface. Refer to Section 3.
2. Inspect the axle housing for damage. Repair or
replace the axle housing. Refer to Section 3.
3. Check for loose studs, if equipped, in the
mounting surface of the housing where the
carrier fastens. Remove and clean the studs
that are loose.
4. Apply liquid adhesive to the threaded holes. 9. Repeat Step 8 until the four fasteners are
Install the studs into axle housing. Refer to tightened to the correct torque value. Refer
Section 3. Tighten the studs to correct torque to Section 7.
value. Refer to Section 7. T

Section 4
Assembly
10. Install the other fasteners and washers that Table E: Shaft-to-Hub Torque Fastener Chart —
hold the carrier in the axle housing. Tighten Non-Tapered Dowel Applications
fasteners to the correct torque value. Refer
to Section 7. Torque Value — Grade 8 Nuts
Thread lb-ft (N•m)
11. Connect the driveline universal joint to the Fastener Size Plain Nut Lock Nut
pinion input yoke or flange on the carrier. Stud Nut, 0.62-18 150-230 130-190
12. Install the gaskets and axle shafts into the axle Axle Shaft (244-312) (203-258)
housing and carrier. The gasket and flange of 0.75-16 310-400 270-350
(420-542) (366-475)
the axle shafts must fit flat against the wheel
hub. Figure 4.80. Studs All Install the course thread end of stud
into hub and tighten to last thread.
Figure 4.80 Tapered Dowel, Hardened Washer and

Hardened Nut
1
1. Clean the mating surfaces of the axle shaft and
2 3 4 5 6 the wheel hub.
2. If silicone gasket material is used, apply a
0.125-inch (3 mm) diameter bead of the gasket
material around the mating surface of the hub
and around the edge of each fastener hole.
3. Install the gasket and the axle shaft into the
housing. The gasket and the flange of the axle
10 9
8 7 shaft must fit flat against the wheel hub.
Figure 4.80.
11
4. Install solid tapered dowels over each stud
1 TAPERED DOWEL 8 AXLE SHAFT OR
RETENTION FLANGE
and into the flange of the axle shaft. Use a
2 STUD NUT 9 WASHER punch or a drift and hammer, if necessary.
3 WASHER 10 CAPSCREW
4 TAPERED DOWEL 11 NON-TAPERED 5. Install the Grade 8 nuts and hardened washers
5 GASKET DOWEL on the stud. Lock washers are an acceptable
6 STUD RETENTION alternative. Tighten the stud nuts to the torque
7 SHAFT HUB AXLE specified in Table F.
Straight Holes, Nuts and Hardened Washers Table F: Shaft-to-Hub Torque Fastener Chart —
Tapered Dowel Applications
1. Clean the mating surfaces of the axle shaft
Torque Value — Grade 8 Nuts
and the wheel hub.
Thread lb-ft (N•m)
2. If silicone gasket material is used, apply a Fastener Size Plain Nut Lock Nut
0.125-inch (3 mm) diameter bead of the gasket Stud Nut, 0.44-20 50-75 (81-102) 40-65 (67-88)
material around the mating surface of the hub Axle Shaft 0.50-20 75-115 (115-156) 65-100 (102-136)
and around the edge of each fastener hole.
0.56-18 110-165 (176-224) 100-145 (149-197)
3. Install the gasket and the axle shaft into the 0.62-18 150-230 (244-312) 130-190 (203-258)
housing. The gasket and the flange of the axle Studs All Install the course thread end of stud
shaft must fit flat against the wheel hub. into hub and tighten to last thread.
Figure 4.80.
4. 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 E.

Section 5
Driver-Controlled Main Differential Lock
Driver-Controlled Main Differential Lock Assembly

Section 5
Figure 5.1
11
9 10
6 8
7 12
5
4 13
1 2 3
16 15 14
22 20 18 17
19
21
22
1001107a
1 LOCK NUT — SENSOR SWITCH 12 WASHER, OPERATING POSITION

2 SENSOR SWITCH 13 PLUG GASKET, OPERATING POSITION
3 SHIFT FORK 14 COVER CAPSCREWS
4 SHIFT SHAFT SPRING 15 WASHERS
5 SHIFT SHAFT 16 PLUG GASKET, STORAGE POSITION
6 SPRING RETAINING PIN 17 COVER PLUG, STORAGE POSITION
7 FLAT WASHER, OR SILASTIC AS REQUIRED 18 COVER COPPER GASKET
8 AIR CYLINDER TUBE 19 PISTON O-RING
9 SCREW-IN DIFFERENTIAL LOCK 20 PISTON
10 CYLINDER COVER 21 SHIFT COLLAR
11 CAPSCREW — MANUAL ACTUATION, STORAGE POSITION 22 SHIFT FORK ROLL PINS

Section 5
Removal
WARNING
To prevent serious eye injury, always wear safe Differential Carrier from Axle Housing
WARNING
Some Meritor drive axle models have a DCDL or Park the vehicle on a level surface. Block the
a driver-controlled main differential lock. This wheels to prevent the vehicle from moving.
differential lock is operated by a carrier-mounted, Support the vehicle with safety stands. Do not
air-actuated shift unit. When activated, the shift work under a vehicle supported only by jacks.
unit moves a sliding collar which is installed on Jacks can slip and fall over. Serious personal
the splines of the axle shaft. When engaged, the injury and damage to components can result.
collar locks the axle shafts together with a second
set of splines on the differential case. When the Before the differential carrier can be removed or
DCDL is engaged, there is no differential action. installed, the differential lock must be shifted into
Figure 5.1. and held in the locked or engaged position. The
locked position gives enough clearance between
NOTE: The Meritor carrier models with the shift collar and the axle housing to permit the
driver-controlled differential lock equipment are removal or installation of the carrier.
manufactured in metric dimensions and sizes.
When these carriers are serviced, it is important NOTE: If the axle shafts were removed for towing
to use the correct metric size tools on the with the differential in the unlocked or disengaged
fasteners. Refer to Section 7. position, install the right-hand axle shaft into the
housing before removing the differential carrier.
Refer to Section 10.
CAUTION
If the vehicle must be towed to a service facility To shift into the locked position, refer to Manual
with the drive axle wheels on the ground, Engaging Method in this section.
remove the axle shafts before the vehicle is
towed. Damage to components can result. Axle Setup for DCDL Disassembly
1. Remove the axle shafts before the vehicle is wheels to prevent the vehicle from moving.
towed. Refer to Section 10.
2. Remove the drain plug from the bottom of the
2. Install the axle shafts after the vehicle is housing and drain the lubricant.
towed. Refer to Section 10.
3. If the differential carrier must be removed WARNING
from the axle housing, use the following
procedures. During DCDL disassembly, when the DCDL is in
the locked or engaged position and the
vehicle’s wheels are raised from the floor, do
not start the engine and engage the
transmission. The vehicle can move and cause
serious personal injury. Damage to components
can result.
3. Use a jack to raise the vehicle so that the

wheels to be serviced are off the ground. Place
a safety stand under the spring seats to hold
the vehicle in the raised position.
4. Disconnect the driveline from the pinion
input yoke.
5. Disconnect the vehicle air line from the
differential lock actuator assembly.

Section 5
DCDL Assembly Manual Engaging

Methods CAUTION
There will be a small amount of spring
Bolt-On Style Differential Lock Cylinder resistance felt when you turn in the manual
Use the following manual engaging method to engaging capscrew. If a high resistance is felt
lock out the bolt-on DCDL assembly. Figure 5.2. before reaching the locked or engaged position,
stop turning the capscrew, or the cover and
1. Follow Steps 2-5 of Axle Setup for DCDL capscrew threads will be damaged.
Disassembly in this section.
2. Remove the plug and gasket from the hole in 6. Turn the manual adjusting capscrew to the
the center of the cylinder cover. right until the head is approximately
0.25-0.5-inch (6-13 mm) from the cylinder
cover. Do not turn the capscrew beyond its
Figure 5.2 normal stop. If the 0.25-10.5-inch (6-13 mm)
service position of the capscrew is achieved,
1 the main differential lock is completely
2 engaged.
A high resistance on the capscrew indicates
that the splines of the shift collar and the
3 differential case half are not aligned or
engaged. To align the splines, use the
8
following procedure.
4
A. Rotate the drive pinion or right-hand
wheel to align the splines of the shift collar
and case half while you turn in the manual
7 engaging capscrew.
6 5
B. When a normal amount of spring
resistance is felt on the capscrew, the
1 TOP SIDE STORAGE HOLE FOR MANUAL ENGAGING
CAPSCREW splines are engaged. Continue to turn in
2 AIR LINE the manual engaging capscrew until the
3 CYLINDER COVER head is approximately 0.25-inch (6 mm)
4 WIRE from the cylinder cover.
5 SERVICE POSITION CAPSCREW HOLE
6 BOTTOM SIDE STORAGE HOLE FOR PLUG AND 7. Remove the carrier from the axle housing.
GASKET Refer to Section 2.
7 PLUG AND GASKET
8 MANUAL ENGAGING CAPSCREW
Screw-In Style Differential Lock Cylinder
BOLT-ON DCDL ASSEMBLY
Use the following manual engaging method to
lockout the screw-in DCDL assembly.
NOTE: The storage hole for the plug and gasket is
located on the opposite side of the cylinder cover 1. Follow Steps 2-5 of Axle Setup for DCDL
where the storage hole for the manual engaging Disassembly in this section.
capscrew is located. 2. Remove the manual engaging capscrew from
the storage hole in the carrier casting, next to
3. Remove the manual engaging cap screw from the cylinder. Figure 5.3.
the top storage hole in the cylinder cover.
4. Install the plug and gasket into the bottom
storage hole in the cylinder cover.
5. Install the manual engaging capscrew into
the threaded hole in the center of the
cylinder cover.

Section 5
1
4
2
1 STORAGE HOLE 3
MANUAL ENGAGING
2 CYLINDER CAPSCREW 1 SHIFT COLLAR
4 AIR HOSE 2 SHIFT FORK
THREADED SHIFT ASSEMBLY
Bolt-On Style Differential Lock Cylinder

3. Remove air line and fitting. Install the manual
engaging capscrew into the threaded hole in NOTE: On some bolt-on assemblies, a roll pin is
the center of the cylinder cover. installed in the shift shaft and is used as a stop for
4. Turn the manual adjusting capscrew to the the shift shaft spring. It is not necessary to remove
right until the head is approximately 0.25-inch this roll pin during a normal disassembly.
(6 mm) from the cylinder cover. Do not turn the
capscrew beyond its normal stop. The A. Remove the sensor switch and lock nut.
capscrew is now in the service position and the B. Remove the four capscrews and washers
main differential lock is completely engaged. that hold the cylinder cover to carrier.
5. Remove the carrier from the axle housing. Remove the cylinder cover and copper
Refer to Section 2. gasket. Figure 5.5.
C. Remove the shift unit-cylinder and piston.
Differential and Gear Assembly Remove the O-ring from the piston.
Differential Lock Sliding Collar D. Remove the shift shaft from the shift fork.
The shaft may be secured with liquid
1. For carriers with roll pins, tap out the two adhesive or pre-applied adhesive material.
retainer roll pins, if equipped, until they are Refer to Section 3.
level with the inner face of the shift fork.
Release the differential lock if it is manually E. Remove the shift shaft spring and flat
engaged. Figure 5.4. washer. Some models use silastic seal
instead of the flat washer.
2. For carriers without roll pins, snap out collar
from fork. F. Remove the shift fork.
3. If required, remove the DCDL assembly at this
time.

Section 5

1 2
1 CAPSCREW AND WASHER

2 COVER, COPPER GASKET UNDER COVER
BOLT-ON SHIFT ASSEMBLY Installation
Screw-In Style Differential Lock Cylinder DCDL Assembly into Carrier
A. Remove the sensor switch. Bolt-On Style Differential Lock Assembly
B. Remove the cylinder by turning hex nut at Install the differential shift assembly after the
the top of the cylinder with a wrench. The differential carrier is assembled and the gear
cylinder may be secured to the carrier and bearing adjustments are completed.
casting with Loctite® adhesive or Figure 5.7.
equivalent pre-applied liquid adhesive.
Refer to Section 3.
Figure 5.7
C. Remove the shift shaft, spring and shift
2 3
fork. 1
4. Remove the cotter keys, pins or lock plates, if 5 4
equipped, that hold the two bearing adjusting
rings in position. Use a small drift and 6
13
hammer to remove pins. Each lock plate is
held in position by two capscrews. 7
5. Mark one bearing cap and one carrier leg so 8

that these parts will be assembled in the
correct positions. Remove the bearing cap 9
capscrews and washers, the bearing caps and 10
the adjusting rings.
11
6. Lift the differential and gear assembly from 12
the carrier. Tilt the assembly as required to
permit the ring gear to clear the support for 1 FLAT WASHER OR 7 DISENGAGED
SILASTIC AS REQUIRED 8 ENGAGED
the pinion spigot bearing. Figure 5.6. 2 CYLINDER 9 COPPER GASKET
3 ELECTRIC CONNECTION 10 PIN
Further disassembly of these carriers is the 11 SHIFT FORK
FOR SENSOR
same as axles without the driver-controlled 4 AIR LINE 12 COLLAR
main differential lock. To continue 5 O-RING 13 SHIFT SHAFT AND
disassembly, follow the procedures in 6 PISTON SPRING
Section 2. BOLT-ON STYLE

Section 5
1. On carrier models with shift fork roll pins, Figure 5.9

install the two roll pins into the ends of the
shift fork. Tap the pins into position until they
are level with the inner yoke face. Figure 5.8.
Do not install the pins completely at this time.
Figure 5.8
1
2
3
Figure 5.10
1 SHIFT FORK 2
2 ROLL PIN
3 INNER YOKE FACES
2. On models without roll pins, snap the fork into

position. 3
WARNING 2 SPRING
1 Apply Loctite® 222
Take care when you use Loctite® adhesive to threadlocker. 3 SHIFT SHAFT
avoid serious personal injury. Read the
manufacturer’s instructions before using this
product. Follow the instructions carefully to 7. Install the flat washer, when used, or apply
prevent irritation to the eyes and skin. silastic sealant, Meritor part number
1199-Q-2981, to the bottom of the cylinder
3. Apply Loctite® 222 threadlocker, Meritor part bore. Figure 5.11.
number 2297-B-6112, to the threads of the 8. Install the O-ring into its groove on the piston.
shift shaft. Lubricate the O-ring with axle lubricant. Install
4. Install the shift fork into its correct position in the piston into the air cylinder. Figure 5.11.
the carrier case. Figure 5.9.
5. Hold the shift fork in position. Install the shift
shaft spring into the shift shaft opening in the
carrier, through the shift fork bore and into the
bore for the shift shaft spring. Figure 5.10.
6. Slide the shift shaft over the spring. Install the
shaft into the shift fork. Tighten to 20-25 lb-ft
(27-34 N•m). T

Section 5

1 1
2
3
1 CYLINDER AND PISTON
1 AIR CYLINDER 2 PILOT JOURNAL
2 PISTON AND O-RING 3 SHIFT SHAFT
3 Install flat washer or apply silastic sealant. BOLT-ON STYLE
4 SHIFT SHAFT
BOLT-ON STYLE
Figure 5.13
9. Install the cylinder into the housing bore. 1
Verify that the pilot journal on the piston is
against its bore on the shift shaft. Figure 5.12.
10. Install the copper gasket into its bore on the
2
inside of the cylinder cover. Place the cover in
position over the cylinder so that the air intake
port will point up when the carrier is installed
into the housing. Install the cover with the four
attaching capscrews and washers. Tighten the
capscrews to 7.4-8.9 lb-ft (10-12 N•m).
Figures 5.7 and 5.13. T
1 CYLINDER COVER
11. Slide the shift collar into the fork. Engage the 2 CAPSCREW 7.4-8.9 LB-FT (10-12 N•m)
shift collar splines with the splines of the BOLT-ON STYLE
differential case. Use the manual actuation
capscrew to move the shift collar splines into
the differential case splines. Refer to Manual Figure 5.14
Engaging Method in this section.
3
12. Hold the shift collar in the locked or engaged 2
position. If employed, tap the two roll pins into 1
the shift fork ends until they are level with the
outer yoke faces. Figure 5.14.
13. While the shift collar is still in the locked
position, place the sensor switch, with the jam
nut loosely attached into its hole.
14. Connect a battery or bulb tester to the sensor
switch. Rotate the switch into its hole until
contact with the shift fork causes the testing
1 SHIFT FORK
light to go on. Turn the switch one additional 2 SHIFT COLLAR
revolution. Tighten the jam nut to 3 MANUAL ACTUATION CAPSCREW
26-33 lb-ft (34-45 N•m). T BOLT-ON STYLE

Section 5
Screw-In Style Differential Lock Assembly 6. Coat the DCDL cylinder threads with Loctite®
518 Gasket Eliminator.
Install the differential shift assembly after the
differential carrier is assembled and the gear and 7. Screw the DCDL cylinder in place. Tighten
bearing adjustments are completed. Figure 5.15. the cylinder to 80-100 lb-ft (109-136 N•m).
Figure 5.16. T
Figure 5.15
Figure 5.16
2 1
1
3
4
2
7 6
8 1 MANUAL ACTUATION CAPSCREW
2 SCREW-IN CYLINDER 80-100 LB-FT (109-136 N•m)
1 SHIFT SHAFT AND SPRING SCREW-IN STYLE
2 ELECTRIC CONNECTION FOR SENSOR
3 PISTON
4 DISENGAGED 8. Snap the shift collar into the fork. Engage the
5 ENGAGED
6 CYLINDER
shift collar splines with the splines of the
7 O-RING differential case. Use the manual actuation
8 SHIFT FORK capscrew to move the shift collar splines into
9 COLLAR the differential case splines. Refer to Manual
SCREW-IN STYLE Engaging Method in this section.
9. Install the sensor switch into its hole. Tighten
1. Install the shift spring and fork into the correct the switch to 25-35 lb-ft (35-45 N•m). T
position in the carrier case. Compress the
10. Connect a battery or bulb tester to the sensor
spring slightly while installing the fork.
switch. With the DCDL engaged, the tester
2. Install the shift shaft into the shaft bore of the light should go on.
carrier. Slide the shaft through the shift fork
O If the light does not go on: Check the
bore and shift spring inside diameter.
following.
3. Inspect the piston O-ring. Replace the O-ring if
A. Verify that the fork is aligned with the
there is any evidence of cuts, cracks, abrasion
sensor switch when it is in the
or wear.
engaged position.
4. Lightly lubricate the O-ring and DCDL cylinder
B. Check for a loose wiring connection.
bore with the same lubricant used in the axle
The connector must be tightly seated.
housing.
C. Verify that the sensor switch is fully
5. Install the piston and O-ring assembly into the
seated against the carrier spotface.
DCDL cylinder. Slide the piston to the port end
of the cylinder. O If light fails to go on after these checks:
The sensor switch should be replaced.

Section 5
Differential Lock Assembly Cover Plates Figure 5.17

1
WARNING
8
When you apply some silicone gasket 2
materials, a small amount of acid vapor is
present. To prevent serious personal injury, 3
ensure that the work area is well-ventilated. 7
Read the manufacturer’s instructions before
using a silicone gasket material, then carefully
4
follow the instructions.
follow the manufacturer’s emergency 6 5
procedures. Have your eyes checked by a
physician as soon 1 TOP STORAGE HOLE FOR MANUAL ENGAGING
as possible. CAPSCREW
2 AIR LINE
3 CYLINDER COVER
Take care when you use Loctite® adhesive to 4 WIRE
avoid serious personal injury. Read the 5 SERVICE POSITION CAPSCREW HOLE
manufacturer’s instructions before using this 6 BOTTOM STORAGE HOLE FOR PLUG AND GASKET
7 PLUG AND GASKET
product. Follow the instructions carefully to 8 MANUAL ENGAGING CAPSCREW
prevent irritation to the eyes and skin. BOLT-ON DCDL SHIFT ASSEMBLY
NOTE: For carriers without the differential lock or

air shift, assemble the sensor switch plug and
cover plate as follows. Figure 5.18
3
Bolt-On Cover Plate Assemblies
2 4
1. Install the washer and plug into the hole for
the sensor switch. Tighten the plug to
45-55 lb-ft (60-74 N•m). Figure 5.17. T
2. Apply silicone gasket material to the cover 1 6
plate mounting surface on the carrier. Refer
to Section 3. 5
3. Install the four washers and capscrews.

Tighten the capscrews to 7.4-8.9 lb-ft
(10-12 N•m). Figure 5.18. T 1 SENSOR SWITCH PLUG
2 WASHER
Screw-In Cover Plate Assemblies 3 SCREW-IN COVER PLATE (APPLY LOCTITE® 518
LIQUID ADHESIVE TO COVER PLATE THREADS)
1. Apply Loctite® 518 liquid adhesive to the plate 4 WASHER
threads. 5 BOLT-ON COVER PLATE (APPLY SILICONE GASKET
MATERIAL)
2. Install the bolts and washers. Tighten the plate 6 CAPSCREW
into the carrier opening to 7.5-9.0 lb-ft
(10-12 N•m). T

Section 5
Install the Carrier into Axle Housing

CAUTION
WARNING There will be a small amount of spring resistance
when you turn in the manual engaging capscrew.
Solvent cleaners can be flammable, poisonous If a high resistance is felt before reaching the
and cause burns. Examples of solvent cleaners are locked or engaged position, stop turning the
carbon tetrachloride, and emulsion-type and capscrew. Damage to components can result.
instructions before using a solvent cleaner, then 3. Turn the manual adjusting capscrew to the
carefully follow the instructions. Also follow the right until the distance from the head of the
procedures below. capscrew is approximately 0.25-0.50-inch
O Wear safe eye protection. (6-13 mm) from the cylinder cover. Do not turn
the capscrew beyond its normal stop. When
O Wear clothing that protects your skin. the capscrew head is in the service position
O Work in a well-ventilated area. 0.25-0.50-inch (6-13 mm) from top of DCDL,
the main differential lock is manually engaged.
O Do not use gasoline, or solvents that contain
gasoline. Gasoline can explode. A high resistance on the capscrew indicates
that the splines of the shift collar and the
O You must use hot solution tanks or alkaline differential case half are not aligned or
solutions correctly. Read the manufacturer’s engaged.
and alkaline solutions. Then carefully follow the Lift the shift collar as required and rotate to
instructions. align the splines of collar and case half while
turning the manual engaging capscrew
1. Use a cleaning solvent and rags to clean the inward. When the normal amount of spring
inside of the axle housing and the mounting resistance is again felt on the capscrew, the
surface. Blow dry the cleaned areas with splines are engaged. Continue to turn in
compressed air. Refer to Section 3. the manual engaging capscrew until the
0.25-0.50-inch (6-13 mm) service position is
2. Inspect the axle housing for damage. achieved.
If necessary, repair or replace the housing.
Refer to Section 3. 4. Clean both the DCDL actuator and the housing
mounting surfaces.
3. Check for loose studs in the mounting surface
of the housing where the carrier fastens.
Remove and replace any studs where WARNING
required. When you apply some silicone gasket materials, a
4. Install the differential carrier into the housing, small amount of acid vapor is present. To prevent
using the Manual Engaging Method. serious personal injury, ensure that the work area
is well-ventilated. Read the manufacturer’s
Manual Engaging Method instructions before using a silicone gasket
material, then carefully follow the instructions.
1. Align the splines of the shift collar and the If a silicone gasket material gets into your eyes,
differential case half by hand or by installing follow the manufacturer’s emergency procedures.
the right-hand axle shaft through the shift Have your eyes checked by a physician as soon
collar and into the side gear. as possible.
the threaded hole in the center of the 5. Apply silicone gasket material to the cleaned
cylinder cover. housing surface for the DCDL actuator. Refer to
Section 3.
6. Remove the short plug and gasket from the
storage hole of the DCDL.

Section 5
7. Remove the long manual engaging capscrew 11. Connect the vehicle air line to the differential
from the center of the DCDL. lock actuator assembly.
NOTE: When the manual engaging capscrew is 12. Install the electrical connection on the sensor
removed from the service position in the center of switch located in the carrier, below the
the DCDL actuator, the main differential lock is actuator assembly.
disengaged. 13. Install the right and left-hand axle shafts.
Follow the procedures from Before Towing or
8. Clean the plug, gasket, cylinder cover, and Drive-Away in Section 10.
threaded service position hole in the center
of the DCDL cylinder cover. 14. Remove the safety stand from under the drive
axle. Lower the vehicle to the floor.
the DCDL storage hole in the bolt-on or 15. Proceed to Check the Differential Lock.
the screw-in DCDL assembly. Figures 5.17
and 5.19. The sealing gasket must be under Check the Differential Lock
the head of the capscrew.
1. Shift the vehicle transmission to neutral. Start
A. On a bolt-on DCDL shift assembly, remove the engine to get the system air pressure to
the short plug and gasket from the storage the normal level.
hole of the DCDL.
Install the short plug and gasket into the
service position hole in the center of the WARNING
DCDL. Figure 5.17. During DCDL disassembly, when the DCDL is in
the locked or engaged position and one of the
B. On a screw-in DCDL shift assembly, install
vehicle’s wheels is raised from the floor, do not
the short screw or plug into the storage
start the engine and engage the transmission.
hole located in the top of the screw-in
The vehicle can move and cause serious personal
DCDL shift assembly. Figure 5.19.
injury.
Figure 5.19 2. Place the differential lock switch, in the cab of

the vehicle, in the unlocked or disengaged
position.
1
3. Drive the vehicle at 5-10 mph (8-16 km/h) and
2 check the differential lock indicator light. The
light must be off when the switch is in the
unlocked or disengaged position.
4. Continue to drive the vehicle and place the
differential lock switch in the locked or
engaged position. Let up on the accelerator to
3 remove the driveline torque and permit the
4 shift. The light must be on when the switch is
1002870a
1 STORAGE HOLE in the locked position.
2 CYLINDER
O If the indicator light remains ON with the
4 AIR HOSE switch in the unlocked position: The
SCREW-IN DCDL SHIFT ASSEMBLY differential is still in the locked position.
Verify that the manual engaging capscrew
was removed from the cylinder cover of the
10. Tighten the plug, if equipped, to 44-55 lb-ft actuator assembly. Refer to Steps 6-12 of
(60-75 N•m). Tighten the manual engaging Manual Engaging Method.
capscrew to 22-28 lb-ft (30-38 N•m) for bolt-on
style cylinders and to 7-11 lb-ft (10-15 N•m) for
screw-in type reverse shifters. T

Section 5
Driver Caution Label

Verify that the driver caution label is installed in
the vehicle cab. The caution label must be placed
in a location that is easily visible to the driver. The
recommended location is on the instrument panel,
next to the differential lock switch and lock
indicator light. Figure 5.20.
Driver caution labels, TP-86101, are available from
ArvinMeritor’s Commercial Vehicle Aftermarket.
To obtain labels, refer to the Service Notes page
on the front inside cover of this manual.
Figure 5.20
CAUTION
This vehicle is equipped with the
MERITOR DRIVER CONTROLLED FULL LOCKING DIFFERENTIAL.
ENGAGE FULL LOCKING DIFFERENTIAL ONLY

UNDER POOR TRACTION CONDITIONS.
DO NOT USE DURING DOWNHILL OPERATION.
DO NOT USE AT SPEEDS ABOVE 25 M.P.H.
WHEN ENGAGED, YOUR VEHICLE’S STEERING CHARACTERISTICS
WILL BE AFFECTED. THIS “UNDERSTEER” CONDITION REQUIRES
CAREFUL DRIVING PROCEDURES.
WHEN DISENGAGED, NORMAL VEHICLE HANDLING WILL RESUME.
For further information on this system, see your vehicle
operator’s manual or Meritor Driver Instruction Kit TP-9646.
TP-86101
Traction Control Videos

Traction Controls contains two videos —
the all-new Splitting the Difference and
Driver-Controlled, Full-Locking Main Differential.
The videos are also available in CD format.
Driver-Controlled, Full-Locking Main Differential is
one of the industry’s best videos on the operation
of the main differential. The video explains in
full detail how this system works and further
discusses the advantages of Meritor’s unique
traction control device — DCDL. Testimonials from
a large North American fleet support the ease of
use of the DCDL.
Also included are several technical pieces to
supplement the videos by providing detailed
instructions on operating the DCDL and IAD,
driver instructions and the difference between the
two systems.
To obtain these videos, refer to the Service Notes
page on the front inside cover of this manual.

Section 6
Lubrication
NOTE: For complete information on lubricating

Section 6
Lubrication
drive axles and carriers, refer to Maintenance

Manual 1, Lubrication. To obtain this publication,
refer to the Service Notes page on the front inside
cover of this manual.
Refer to Table G, Table H and Table I for standard

information on lubricants, schedules and
capacities.
Table G: 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 H: Oil Change Intervals and Specifications for All Front Drive and Rear Drive Axles a
Vocation or Vehicle Linehaul City Delivery Construction

Operation Motorhome School Bus Transit Bus
Intercity Coach Fire Truck Refuse
Yard Tractor
Logging
Heavy Haul
Mining
Oil Field
Rescue
Initial Oil Change No longer required as of January 1, 1993
Check Oil Level and Breather Every 25,000 miles Every 10,000 miles Every 5,000 miles
(40 000 km) or the fleet (16 000 km), once a month or (8000 km), once a month or
maintenance interval, the fleet maintenance interval, the fleet maintenance interval,
whichever comes first whichever comes first whichever comes first b
Petroleum based oil change Every 100,000 miles Every 50,000 miles Every 25,000 miles
on axle WITH or WITHOUT (160 000 km) or annually, (80 000 km) or annually, (40 000 km) or annually,
pump and filter system whichever comes first whichever comes first whichever comes first
Synthetic oil change on axle Every 250,000 miles Every 100,000 miles Every 50,000 miles
WITHOUT pump and filter (400 000 km) or 3 years, (160 000 km) or annually, (80 000 km) or annually,
system c whichever comes first whichever comes first whichever comes first
Synthetic oil change on Every 500,000 miles Every 250,000 miles Every 100,000 miles
axle WITH pump and filter (800 000 km) (400 000 km) (160 000 km)
system c
Filter change on axle with Every 100,000 miles Every 100,000 miles Every 100,000 miles
pump and filter system (160 000 km) (160 000 km) (160 000 km)
a If a No-Spin differential is installed, change the oil, petroleum or synthetic, at a minimum interval of 40,000 miles (64 000 km)
or a maximum interval of 50,000 miles (80 000 km).
b For continuous heavy-duty operation, check the oil level every 1,000 miles (1600 km). Add the correct type and amount of oil
as required.
c 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.

Section 6
Lubrication
Lubricant Capacities
Use the following lubricant capacities as a guide only. The capacities are measured with the drive pinion
in the horizontal position. When the angle of the drive pinion changes, the lubricant capacity of the axle
will change.
Table I
Capacity Capacity
Axle Model U.S. Pints Liters* Axle Model U.S. Pints Liters*
Single Drive Axles Single Drive Axles
MX-10-120 16.0 7.6 RS-25-160A 37.2 17.6
MX-12-120 16.0 7.6 RS-26-160 51.0 24.2
MX-14-120 16.0 7.6 RS-26-180 38.0 18.3
MX-16-120 16.0 7.6 RS-26-185 38.0 18.3
MX-21-160/160R 43.0 20.0 RS-30-180 38.0 18.3
MX-23-160/160R 43.0 20.0 RS-30-185 38.0 18.3
RF-7-120 15.3 7.2 * Includes 1 pint (0.97 liter) for each wheel end and with
RF-9-120 15.3 7.2 drive pinion angle at 3°.
RF-12-120 15.3 7.2
RF-12-125 15.3 7.2
Capacity
RF-16-145 36.4 17.2
Axle Model U.S. Pints Liters
RF-21-155 27.9 13.2
Rear Axle of Tandems
RF-21-156 27.9 13.2
RT-34-140 (RR-17-140) 35.0 16.9
RF-21-160 43.7 20.7
RT-34-144 25.8 12.2
RF-21-185 39.3 18.6
RT-34-145 (RR-17-145 rear) 36.0 17.1
RF-21-355 28.0 13.2
RT-34-145P 25.4 12.0
RF-22-166 43.7 20.7
RT-34-146 25.4 12.0
RF-23-180 39.3 18.6
RT-40-140 (RR-20-140) 35.0 16.9
RF-23-185 39.3 18.6
RT-40-145/149 (RR-20-145 rear) 36.0 17.3
RS-13-120 15.0 7.2
RT-40-145P 25.8 12.2
RS-15-120 15.0 7.2
RT-40-146 25.8 12.2
RS-16-140 33.6 15.9
RT-40-160 34.4 16.3
RS-16-141 33.6 15.9
RT-40-169 34.4 16.3
RS-16-145 33.6 15.9
RT-44-145 (RR-22-145 rear) 35.0 16.9
RS-17-140 32.0 15.4
RT-44-145P 25.1 11.9
RS-17-141 33.6 15.9
RT-46-160/169 (RR-23-160 rear) 43/41 20.7/19.5
RS-17-144 32.3 15.3
RT-46-160A/160P 34.4 16.3
RS-17-145 33.6 15.9
RT-46-164 33.2 15.7
RS-19-144 32.3 15.3
RT-46-164EH/16HEH 33.2 15.7
RS-19-145 36.0 17.3
RT-48-180 (RR-24-180 rear) 39.0 18.6
RS-21-145 35.0 16.9
RT-50-160/160P 33.2 15.7
RS-21-160 39.5 18.7
RT-52-160 (RR-26-160 rear) 51.0 24.2
RS-23-160 43/41 20.7/19.5
RT-52-180/185 (RR-26-180 rear) 39.0 18.3
RS-23-160A 39.5 18.7
RT-58-180/185 (RR-29-180 rear) 39.0 18.3
RS-23-161/161A 37.2 17.6
RS-23-180 39.0 18.6
RS-23-185 39.0 18.6
RS-23-186 39.0 18.6
RS-25-160 39.0 18.6

Section 7
Fastener Torque Information
Torque Values for Fasteners

Section 7Torque Information
Fastener
Metric Fasteners
A. Measure the diameter of the threads in
General Information millimeters (mm), dimension X. Figure 7.2.
1. The torque values in Table J are for fasteners B. Measure the distance of 10 threads, point
that have a light application of oil on the to point in millimeters (mm), dimension Y.
threads. Make a note of dimension Y. Figure 7.2.
O If the fasteners are dry: Increase the torque C. Divide dimension Y by 10. The result
values by 10%. will be the distance between two threads
O If the fasteners have a heavy application or pitch.
of
oil on the threads: Decrease the torque Figure 7.2
values by 10%.
2. If you do not know the size of the fastener that
1
is being installed, measure the fastener. Use
the following procedure.
American Standard Fasteners

A. Measure the diameter of the threads in
inches, dimension X. Figure 7.1. 2
B. Count the amount of threads in 1-inch.
Figure 7.1. 3
1 PITCH
Figure 7.1 2 X
3 Y
X DIMENSION = EXAMPLE M8 OR 8 MM
1 Y DIMENSION = DISTANCE OF 10 THREADS
2
Example
O Metric size fastener is M8 x 1.25.
3
— M8 is the diameter of the fastener in
millimeters (mm) or dimension X.
— 1.25 is the distance between two threads
or pitch.
1 AMOUNT OF THREADS IN 1"
2 1" 3. Compare the size of fastener measured in
3 X Step 2 to the list of fasteners in Table J
X DIMENSION = EXAMPLE 1/2" to find the correct torque value.
Example
O American Standard size fastener is 0.50-13.
— 0.50 is the diameter of the fastener in inches
or dimension X.
— 13 is the amount of threads in 1-inch.

Section 7
Figure 7.3
5
4
25
1
14 18
6 24
26 19 21
12 22
23
20
7
16
21
17
15
10
11
13
10
8
4000262a

Section 7
Table J: Torque Chart

Fastener Thread Size Torque Value lb-ft (N•m)
1. Capscrew, Axle Shaft .31-24 18-24 (24-33)
.50-13 85-115 (115-156)
2. Nut, Axle Shaft Stud Plain Nut 50-75 (68-102)
.44-20 75-115 (102-156)
.50-20 110-165 (149-224)
.56-18 150-230 (203-312)
.62-18
Lock Nut 40-65 (54-88)
.44-20 65-100 (88-136)
.50-20 100-145 (136-197)
.56-18 130-190 (176-258)
.62-18
3. Breather .38-18 20 minimum (27 minimum)
4. Plug, Oil Fill, Housing .75-14 35 minimum (47.5 minimum)
5. Plug, Heat Indicator .50-14 25 minimum (34 minimum)
6. Plug, Oil Drain .50-14 25 minimum (34 minimum)
7. Capscrew, Differential Case .38-16 35-50 (48-68)
.44-14 60-75 (81-102)
.50-13 85-115 (115-156)
.56-12 130-165 (176-224)
.62-11 180-230 (244-312)
Grade 10.9 Flange Head M12 x 1.75 85-103 (115-140)
Grade 10.9 Standard Hex Head M12 x 1.75 74-96 (100-130)
Grade 12.9 Standard Hex Head M12 x 1.75 105-125 (143-169)
Grade 12.9 Flange Head M16 x 2 203-251 (275-340)
Grade 12.9 Standard Head M16 x 2 220-310 (300-420)
8. Nut, Differential Case Bolt .50-13 75-100 (102-136)
.50-20 85-115 (115-156)
.62-11 150-190 (203-258)
.62-18 180-230 (244-312)
M12 x 1.75 74-96 (100-130)
M16 x 2 220-310 (300-420)
9. Nut, Ring Gear Bolt .50-13 75-100 (102-136)
.50-20 85-115 (115-156)
.62-11 150-190 (203-258)
.62-18 180-230 (244-312)
M12 x 1.25 66-81 (90-110)
M12 x 1.75 77-85 (104-115)
Flange Head M16 x 1.5 192-214 (260-190)
Standard Hex Head M16 x 1.5 196-262 (265-355)
10. Capscrew, Bearing Cap .56-12 110-145 (149-197)
.62-11 150-190 (203-258)
.75-10 270-350 (366-475)
.88-14 360-470 (488-637)
.88-9 425-550 (576-746)
M16 x 2 181-221 (245-300)
M20 x 2.5 347-431 (470-585)
M22 x 2.5 479-597 (650-810)
11. Nut, Housing to Carrier Stud .44-20 50-75 (68-102)
.50-20 75-115 (102-156)
.56-18 110-165 (149-224)
.62-18 150-230 (203-312)
12. Capscrew, Carrier to Housing .44-14 50-75 (68-102)
.50-13 75-115 (102-156)
.56-12 110-165 (149-224)
.62-11 150-230 (203-312)
.75-10 270-400 (366-542)
M12 x 1.75 74-89 (100-120)
M16 x 2 181-221 (245-300)

Section 7
Table J: Torque Chart, Continued

13. Jam Nut, Thrust Screw .75-16 150-190 (203-258)
.88-14 150-300 (203-407)
1.12-16 150-190 (203-258)
M22 x 1.5 148-210 (200-285)
M30 x 1.5 236-295 (320-400)
14. Input Yoke-to-Input Shaft Nut Refer to Table K.
15. Capscrew, Bearing Cage .38-16 30-50 (41-68)
.44-14 50-75 (68-102)
.50-13 75-115 (102-156)
.56-12 110-165 (149-224)
.62-11 150-230 (203-312)
M12 x 1.75 70-110 (90-150)
16. Plug, Oil Fill, Carrier .75-14 25 minimum (34 minimum)
1.5-11.5 120 minimum (163 minimum)
M24 x 1.5 35 minimum (47 minimum)
17. Capscrew, Lock Plate .31-18 20-30 (27-41)
M8 x 1.25 21-26 (28-35)
Torque Values are for Carriers with Bolt-On Style Differential Lock Cylinders
18. Capscrew, Manual Actuation, Storage Position M10 x 1.5 15-25 (20-35)
19. Adapter, Air Cylinder M12 x 1.5 22-30 (30-40)
20. Capscrew, Air Cylinder Cover M6 x 1 7-12 (10-16)
21. Capscrew/Plug, Air Cylinder Cover M10 x 1.5
Operating Position 15-25 (20-35)
Storage Position 15-25 (20-35)
22. Lock Nut, Sensor Switch M16 x 1 25-35 (35-45)
Torque Values are for Carriers with Screw-In Style Differential Lock Cylinders
23. Capscrew, Manual Actuation, Storage Position M10 x 1.25 7-11 (10-15)
24. Air Cylinder M60 x 2.0 80-100 (109-136)
25. Sensor Switch M16 x 1.0 25-35 (35-45)
26. Screw-In DCDL Cylinder Plug or Cap M60 x 2.0 80-100 (109-136)
Table K: Input and Output Yoke Pinion Nut Fastener Torque Specifications
Single and Rear of Tandem Axles
Axle
Model
RF-166, RS-160,
Pinion RS-120, RS-125, RS-161, RS-185, RS-210, RS-220,
Nut Location RS-140 RS-144/145 RS-186 RS-230 RS-240 RS-380
Carrier 740-920 lb-ft 920-1130 lb-ft 1000-1230 lb-ft 740-920 lb-ft 740-920 lb-ft 800-1100 lb-ft
Input Yoke (1000-1245 N•m) (1250-1535 N•m) (1350-1670 N•m) (1000-1245 N•m) (1000-1245 N•m) (1085-1496 N•m)
Fastener Size M32 x 1.5 M39 x 1.5 M45 x 1.5 M32 x 1.5 M39 x 1.5 1-1/2 - 12 UNF

Section 8
Adjustments and Specifications
Drive Pinion Bearings — Preload (Refer to Section 4)

Section 8
Specification New bearings

15-25 lb-in (1.7-2.8 N•m)
Used bearings
5-25 lb-in (1.7-2.8 N•m)
Adjustment Preload is controlled by the thickness of the spacer between bearings.

To increase preload, install a thinner spacer
To decrease preload, install a thicker spacer
Drive Pinion — Depth in Carrier (Refer to Section 4)
Specification Install the correct amount of shims between the bearing cage and carrier. To calculate, use old
shim pack thickness and new and old pinion cone numbers.
Adjustment Change the thickness of the shim pack to get a good gear tooth contact pattern.
Hypoid Gear Set — Tooth Contact Patterns (Hand Rolled) (Refer to Section 4)
Specification Conventional gear set

Toward the toe of the gear tooth and in the center between the top and bottom of the tooth
Generoid gear set
Between the center and toe of the 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 pinion
bearing cage and carrier and by ring gear backlash
To move the contact pattern lower, decrease the thickness of the shim pack under the pinion
bearing cage
To move the contact pattern higher, increase the thickness of the shim pack under the pinion
bearing cage
To move the contact pattern toward the toe of the tooth, decrease backlash of the ring gear
To move the contact pattern toward the heel of the tooth, increase backlash of the ring gear
Main Differential Bearings — Preload (Refer to Section 4)
Specification 15-35 lb-in (1.7-3.9 N•m)

or
Expansion between bearing caps
RS-140, RS-145 and RS-160 carrier models — 0.002-0.009-inch (0.05-0.229 mm)
All other carrier models — 0.006-0.013-inch (0.15-0.33 mm)
Adjustment Preload is controlled by tightening both adjusting rings after zero end play is reached
Main Differential Gears — Rotating Resistance (Refer to Section 4)
Specification 50 lb-ft (68 N•m) torque applied to one side gear

Section 8
Ring Gear — Backlash (Refer to Section 4)
Specification Ring gears that have a pitch diameter of less than 17-inches (431.8 mm)
Range: 0.008-0.018-inch (0.20-0.46 mm)
0.012-inch (0.30 mm) for a new gear set
Ring gears that have a pitch diameter of 17-inches (431.8 mm) or greater
Range: 0.010-0.020-inch (0.25-0.51 mm)
0.015-inch (0.38 mm) for a new gear set
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
Ring Gear — Runout (Refer to Section 4)
Specification 0.008-inch (0.20 mm) maximum
DCDL Sensor Switch — Installation (Refer to Section 4)
Specification Shift the differential to the locked position. Tighten the sensor switch into the carrier until the
test light comes on. Tighten the sensor switch one additional turn and tighten lock nut to
correct torque value.
Spigot Bearing — Peening on the Drive Pinion (Refer to Section 5)
Specification Apply 6,614 lb (3000 kg) load on a 0.375-inch (10 mm) ball. Peen the end of the drive pinion at a
minimum of five points. Softening of the pinion stem end by heating may be required.

Section 9
Special Tools
Carrier Repair Stand Specifications

Section Tools
Special 9
Figure 9.1
2
1
12
11
3
6
10
4
9
5
8 SPX Kent-Moore
part number J-3409-D
1 PLATES 8’ LONG X 3/4” THICK X 1-1/4” WIDE WITH A TONGUE TO FIT SLOT IN BAR WELD PLATES
TO BAR
2 HANDLE 7” LONG WITH SLOT IN ONE END TO FIT CLAMP SCREW
3 BAR 2” DIAMETER X 9” LONG WITH ONE END SLOTTED TO FIT PLATE
4 WELD ALL AROUND AFTER PRESSING PLUG IN PIPE
5 WELD
6 SHAPE AND SIZE OF HOLES TO FIT CARRIER
7 23-1/2” CENTER TO CENTER OF PIPE
8 CHAMFER END OF PIPE FOR WELDING
9 4” DIAMETER PIPE
10 PLUG 4” DIAMETER X 7” LONG WITH ONE END TURNED 3” LONG TO FIT PIPE. DRILL 2” HOLE
AND MILL 3/16” WIDE SLOT 2” FROM TOP
11 SCREW 3-1/2” LONG X 5/8” DIAMETER WITH FLATS ON END TO FIT HANDLE AND 2-1/2” LENGTH
OF THREAD ON OTHER END
12 DRILL 3/8” HOLE THROUGH HANDLE AND SCREW
To obtain a repair stand, refer to the Service Notes

page on the front inside cover of this manual.

Section 9
Special Tools
How to Make a Yoke Bar Figure 9.3

1. Measure dimensions A and B of the yoke you 1
are servicing. Figure 9.2.
D
Figure 9.2
B
1 YOKE BAR
Unitized Pinion Seals and Seal

1
Drivers
1 YOKE
Refer to Table L and Figure 9.4 for information on
unitized pinion seals and seal drivers.
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 9.3. Figure 9.4
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 1
instructions and safety procedures
recommended by the welding equipment Position the seal driver to prevent the
manufacturer. driver spokes from hitting the fastener heads
on the forward tandem output seals.
3. To make the box section, cut and weld
1.0-inch x 2.0-inch mild steel square stock
according to dimensions C and D. Figure 9.3.
2
4. Cut a 4.0-foot x 1.25-inch piece of mild steel 3
round stock to make the yoke bar handle.
Center weld this piece to the box section.
Figure 9.3. 1 SEAL DRIVER
2 FASTENER HEADS
O To increase yoke bar rigidity: Weld two 3 SEAL DRIVER R4422401
angle pieces onto the handle. Figure 9.3.

Section 9
Special Tools
Table L: Unitized Pinion Seals and Seal Drivers
Meritor Yoke Seal

Single Unitized Meritor Diameter
Models Tandem Models Pinion Seal Seal Installation Location Seal Driver Inches
MX-21-160 RT-34-144 /P A-1205-R-2592 Tandem Forward Input — 145 models R4422402 3.250
from 11-93 to present
MX-23-160R RT-34-145 /P 3.255
RF-16-145 RT-40-145 /A /P A-1205-P-2590 Tandem Forward Output — Tandem R4422401 3.000
RF-21-160 RT-40-149 /A /P Forward Input 145 models before 3.005
11/93 with seal A-1205-F-2424
RF-22-166 RT-44-145 /P
A-1205-N-2588 Tandem and Single Rear Input — R4422401 3.000
RF-23-185 RT-40-160 /A /P 145 models 3.005
RS-17-145 RT-40-169 /A /P
A-1205-Q-2591 Tandem and Single Rear Input — R4422402 3.250
RS-19-145 RT-46-160 /A /P 160/164/185 models 3.255
RS-21-145 RT-46-169 /A /P
RS-21-160 RT-46-164EH /P
RS-23-160 /A RT-46-16HEH /P
RS-23-161 /A RT-50-160 /P
RS-25-160 /A RT-52-185*
RS-23-186 RT-58-185*
RS-26-185
RS-30-185

Section 10
Vehicle Towing Instructions
Section 10
Vehicle Towing Instructions When transporting a vehicle with the wheels of one
WARNING or both drive axles on the road, it is possible to
To prevent serious eye injury, always wear safe damage the axles if the wrong procedure is used
eye protection when you perform vehicle before transporting begins. Meritor recommends
maintenance or service. that you use the following procedure.
Park the vehicle on a level surface. Block the Type of Axle

wheels to prevent the vehicle from moving.
Support the vehicle with safety stands. Do not These instructions are for vehicles equipped with
work under a vehicle supported only by jacks. the following Meritor single or tandem rear drive
Jacks can slip and fall over. Serious personal axles.
injury and damage to components can result.
O Single Axle, with Driver-Controlled Main
Differential Lock (DCDL — Screw-In [threaded]
Before you service a spring chamber, carefully shift assembly)
follow the manufacturer’s instructions to
compress and lock the spring to completely O Tandem Axle, with Driver-Controlled Main
release the brake. Verify that no air pressure Differential Lock (DCDL — Screw-In [threaded]
remains in the service chamber before you shift assembly) and with Inter-Axle
proceed. Sudden release of compressed air can Differential (IAD)
cause serious personal injury and damage to
components. Before Towing or Drive-Away
Engage the parking brake to prevent the vehicle 1. Park the vehicle on a level surface. Block the
from moving before you begin maintenance or wheels to prevent the vehicle from moving.
service procedures that require you to be under 2. Apply the vehicle parking brakes using the
the vehicle. Serious personal injury can result. switch inside the cab of the vehicle.
3. Shift the transmission into neutral and start
the vehicle’s engine.
CAUTION
If the vehicle is equipped with a front drive 4. Shift the DCDL and the IAD to the unlocked or
axle, tow the vehicle from the front, with the disengaged positions using the switches
front wheels off the ground. If this is not inside the cab of the vehicle. The indicator
possible, you must remove the front drive shaft lights in the cab will go off.
before towing. Damage to components can 5. Stop the engine.
result.
NOTE: Remove only the axle shaft(s), shown in
Do not use a chisel or wedge to loosen the axle Table M at this time, from the axle(s) that will
shaft and tapered dowels. Using a chisel or remain on the road when the vehicle is
wedge can result in damage to the axle shaft, transported.
the gasket and seal, and the axle hub.
Table M
NOTE: For complete towing information, refer to
Technical Bulletin TP-9579, Driver Instruction Kit. Single Axles
To obtain this publication, refer to the Service Remove the left-hand (road side) axle shaft
Notes page on the front inside cover of this
manual. Tandem Axles
Forward Axle:
Remove the right-hand (curb side) axle shaft
These instructions supersede all other instructions
Rear Axle:
for the purpose of transporting vehicles for service Remove the left-hand (road side) axle shaft
or new vehicle drive-away dated before April
1995, including those contained in Meritor
Maintenance Manuals. 6. Remove the stud nuts or capscrews and the
washers from the flange of the axle shaft.
Figure 10.1.

Section 10

1
2 3 4 5
1
6
3
2
5 4
10 9
8 1 STORAGE HOLE
11 7 2 CYLINDER
3 SHIFT TOWER
7 SHAFT HUB AXLE 4 MANUAL ENGAGING CAPSCREW
1 TAPERED DOWEL 5 AIR HOSE
RETENTION 8 AXLE SHAFT OR FLANGE
2 STUD NUT 9 WASHER THREADED SHIFT ASSEMBLY
3 WASHER 10 CAPSCREW
4 TAPERED DOWEL 11 NON-TAPERED DOWEL
5 GASKET RETENTION
NOTE: If an air supply will be used for the brake
6 STUD
system of the transported vehicle, continue with
Steps 15 and 16, otherwise continue with Step 17.
7. Loosen the tapered dowels, if used, in the
flange of the axle shaft. Figure 10.1. Refer to 15. Connect an auxiliary air supply to the brake
Section 2. system of the vehicle that is being transported.
Before moving the vehicle, charge the brake
8. Identify each axle shaft that is removed from system with the correct amount of air pressure
the axle assembly so they can be installed in to operate the brakes. Refer to the instructions,
the same location after transporting or repair supplied by the manufacturer of the vehicle for
is completed. procedures and specifications. If an auxiliary
9. Remove the tapered dowels, gasket, if used, air supply is not used, continue with Step 17.
and the axle shaft from the axle assembly. 16. When the correct amount of air pressure is in
Figure 10.1. the brake system, release the parking brakes
10. Disconnect the air hose from the shift cylinder. of the vehicle that is being transported.
Figure 10.2. Step 17 is not required.
11. Remove the manual engaging capscrew from 17. If there are spring or parking brakes on the
the storage hole. The storage hole of threaded axle(s) that will remain on the road when the
shift assemblies is located in the shift tower of vehicle is transported, and they cannot be
the carrier, next to the cylinder. Figure 10.2. released by air pressure, manually compress
and lock each spring so that the brakes are
12. Lock or engage the main differential using the released. Refer to the manufacturer’s
Manual Engaging Method. Refer to Section 5. instructions.
13. Remove the remaining axle shaft(s) from the
axle(s) that will remain on the road when the
vehicle is transported.
14. Install a cover over the open end of each hub
where an axle shaft was removed. This will
prevent dirt from entering the bearing cavity
and loss of lubricant.

Section 10
After Towing or Drive-Away Figure 10.3

1. If an auxiliary air supply was used, apply the
vehicle parking 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 2
to the manufacturer’s instructions.
3. Disconnect the auxiliary air supply, if used, 1
from the brake system of the vehicle that was
3
transported. Connect the vehicle’s air supply
to the brake system. 4
4. Remove the covers from the hubs.
NOTE: Install only the axle s haft(s) shown in

Table N at this time. These axle shafts have a 5
double row of splines that engage with splines
of the side gear and shift collar in the main
differential. Figure 10.3. 6
Table N 7
8
Single Axles
1 LEFT-HAND, ROAD SIDE, AXLE SHAFT
Install the right-hand (curb side) axle shaft
2 SHIFT ASSEMBLY
3 SHIFT COLLAR
Tandem Axles
4 RIGHT-HAND, CURB SIDE, AXLE SHAFT
Forward Axle:
5 DOUBLE ROW OF SPLINES
Install the left-hand (road side) axle shaft
6 SHIFT COLLAR AND DIFFERENTIAL CASE SPLINES
Rear Axle: ENGAGED OR LOCKED
Install the right-hand (curb side) axle shaft 7 SIDE GEAR
8 DIFFERENTIAL CASE
SINGLE AXLE OR REAR AXLE OF TANDEM SHOWN WITH
SCREW-IN SHIFT ASSEMBLY AND IN THE LOCKED OR
ENGAGED POSITION
5. Install the gasket, if used, and axle shaft into

the axle housing and carrier in the same
location. The gasket and flange of the 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 the flange with the
studs in the hub. Figure 10.1.
6. Install the dowels, if used, over each stud and
into the tapered holes of the flange.
7. Install the washers and capscrews or stud
nuts. Determine the size of the fasteners
and tighten the capscrews or nuts to the
torque value shown in the following table.

Section 10
Torque Value Before Towing or Drive-Away

Fastener Thread Size lb-ft (N•m)
Capscrews 0.31”-24 18-24 (24-33) wheels to prevent the vehicle from moving.
0.50”-13 85-115 (115-156)
2. Apply the vehicle parking brakes using the
Stud Nuts switch inside the cab of the vehicle.
plain nut 0.44”-20 50-75 (68-102)
0.50”-20 75-115 (102-156) 3. Shift the transmission into neutral and start
0.56”-18 110-165 (149-224) the vehicle’s engine.
0.62”-18 150-230 (203-312)
0.75”-16 310-400 (420-542) 4. Shift the DCDL and the IAD to the unlocked or
disengaged positions using the switches
lock nut 0.44”-20 40-65 (54-88)
0.50”-20 65-100 (88-136)
inside the cab of the vehicle. The indicator
0.56”-18 100-145 (136-197) lights in the cab will go off.
0.62”-18 130-190 (176-258) 5. Stop the engine.
0.75”-16 270-350 (366-475)
NOTE: Remove only the axle shaft(s), shown in

8. Unlock or disengage the DCDL by removing Table O at this time, from the axle(s) that will
the manual engaging capscrew from the shift remain on the road when the vehicle is
assembly. transported.
9. Install the manual engaging capscrew into the Table O
storage hole. The storage hole of threaded
shift assemblies is located in the shift tower of Single Axles
the carrier next to the cylinder. Tighten the Remove the left-hand (road side) axle shaft
capscrew to 15-25 lb-ft (20-35 N•m).
Figure 10.2. T Tandem Axles
Forward Axle:
10. Connect the air hose to the shift cylinder. Remove the right-hand (curb side) axle shaft
Tighten the air hose to 22-30 lb-ft (30-40 N•m). Rear Axle:
Remove the left-hand (road side) axle shaft
T
11. Install the remaining axle shaft into the axle
housing and carrier. 6. Remove the stud nuts or capscrews and the
washers from the flange of the axle shaft.
12. Check the lubricant level in the axles and hubs Figure 10.4.
where the axle shafts were removed. Add the
correct type and amount of lubricant if
necessary. Refer to Section 6.
Type of Axle
These instructions are for vehicles equipped with
the following Meritor single or tandem rear drive
axles.
O Single Axle, with Driver-Controlled Main
Differential Lock (DCDL — Bolt-On shift
assembly)
O Tandem Axle, with Driver-Controlled Main
Differential Lock (DCDL — Bolt-On shift
assembly) and with Inter-Axle Differential (IAD)

Section 10

1
1
2 3 4 5
8
6 2
3
7
10 9
8 6 5
11 7
1 TAPERED DOWEL 6 STUD 1 TOP STORAGE HOLE FOR MANUAL ENGAGING

RETENTION 7 SHAFT HUB AXLE CAPSCREW
2 STUD NUT 8 AXLE SHAFT OR FLANGE 2 AIR LINE
3 WASHER 9 WASHER 3 CYLINDER COVER
4 TAPERED DOWEL 10 CAPSCREW 4 WIRE
5 GASKET 11 NON-TAPERED DOWEL 5 SERVICE POSITION CAPSCREW HOLE
RETENTION 6 BOTTOM STORAGE HOLE FOR PLUG AND GASKET
7 PLUG AND GASKET
7. Loosen the tapered dowels, if used, in the BOLT-ON SHIFT ASSEMBLY
flange of the axle shaft. Figure 10.4. Refer to
Section 2.
11. Remove the plug and gasket from the center
8. Identify each axle shaft that is removed from of the shift cylinder cover. Install the plug and
the axle assembly so they can be installed in gasket into the bottom side storage hole of the
the same location after transporting or repair shift cylinder cover on the opposite end of the
is completed. storage hole for the manual engaging
9. Remove the tapered dowels, gasket, if used, capscrew. Tighten the plug to 15-25 lb-ft
and the axle shaft from the axle assembly. (20-35 N•m). Figure 10.5. T
Figure 10.5.
12. Lock or engage the main differential using one
10. Remove the manual engaging capscrew of the two following methods: Air Pressure
from the storage hole. The storage hole of Method or Manual Engaging Method.
bolted-on shift assemblies is located in the top
side of the shift cylinder cover. Figure 10.5.

Section 10
13. Lock or engage the main differential using the Figure 10.6
air pressure method.
A. Install the manual engaging capscrew into
the threaded hole in the center of the
cylinder cover. Turn the capscrew to the
right three to five turns. Figure 10.7.
B. Shift the transmission into neutral and 2
start the vehicle’s engine. Let the engine
idle to increase the pressure in the air 1
3
system. Do not release the parking brakes.
4
C. Shift the main differential to the locked or
engaged position using the switch inside
the cab of the vehicle. When the
differential is locked, the indicator light in
the cab will go on. If the light does not go
on it will be necessary to rotate the main 5
driveline or the IAD by hand until the main 6
differential is locked and the indicator light
goes on. 7
NOTE: When the shift collar is completely 8

engaged with the splines of the main differential 1 LEFT-HAND, ROAD SIDE, AXLE SHAFT
case, the differential is locked and the driveline 2 SHIFT ASSEMBLY
cannot be rotated. Figure 10.6. 3 SHIFT COLLAR
4 RIGHT-HAND, CURB SIDE, AXLE SHAFT
5 DOUBLE ROW OF SPLINES
D. While the differential is held in the locked 6 SHIFT COLLAR AND DIFFERENTIAL CASE SPLINES
position by air pressure, turn the manual ENGAGED OR LOCKED
engaging capscrew to the right until you 7 SIDE GEAR
feel resistance against the piston. Stop 8 DIFFERENTIAL CASE
turning the capscrew. SINGLE AXLE OR REAR AXLE OF TANDEM SHOWN WITH
BOLTED-ON SHIFT ASSEMBLY AND SHOWN IN THE
E. Place the main differential lock switch in LOCKED OR ENGAGED POSITION
the unlocked or disengaged position.
F. Stop the engine. Proceed to Step 15.

Section 10
14. Lock or engage the main differential using the Figure 10.7
manual engaging method.
CAUTION 1
When you turn the manual engaging capscrew
and you feel a high resistance, stop turning the
capscrew. A high resistance against the capscrew
indicates that the splines of the shift collar and
differential case are not aligned. Damage to the
threads of the cylinder cover and capscrew will
result.
A. Install the manual engaging capscrew into

the threaded hole in the center of the 1 MANUAL ENGAGING CAPSCREW
cylinder cover. Figure 10.7. BOLT-ON SHIFT ASSEMBLY
B. Turn the capscrew to the right until the
head is approximately 0.25-0.50-inch
(6.4-12.7 mm) from the cylinder cover. Figure 10.8
The capscrew is now in the service
position and the main differential is locked
or engaged. Figure 10.8. When you turn
the capscrew you will feel a small amount
of resistance. This is normal.
O If you feel a high resistance before
achieving the 0.25-0.50-inch
(6.4-12.7 mm) distance between the
capscrew head and cylinder: Stop
turning the capscrew and continue with
Steps C, D and E. 1
C. Rotate the main driveline or the IAD a 1 0.25-0.50” (6.4-12.7 MM)
small amount by hand.
D. Turn the manual engaging capscrew again NOTE: If an air supply will be used for the brake
to the right. If you still feel a high system of the transported vehicle, continue
resistance, stop turning the capscrew. with Steps 17 and 18. Otherwise continue with
E. Repeat Steps C and D until you feel a low Step 19.
resistance on the capscrew. Continue with
Step B. 17. Connect an auxiliary air supply to the brake
system of the vehicle that is being transported.
15. Remove the remaining axle shaft(s) from the Before moving the vehicle, charge the brake
axle(s) that will remain on the road when system with the correct amount of air pressure
the vehicle is transported. to operate the brakes. Refer to the instructions
16. Install a cover over the open end of each hub supplied by the manufacturer of the vehicle
where an axle shaft was removed. This will for procedures and specifications. If an
prevent dirt from entering the bearing cavity auxiliary air supply is not used, continue
and loss of lubricant. with Step 19.
18. When the correct amount of air pressure is in
the brake system, release the parking brakes
of the vehicle that is being transported.
Step 19 is not required.

Section 10
19. If there are spring or parking brakes on the 7. Install the washers and capscrews or stud
axle(s) that will remain on the road when the nuts. Determine the size of the fasteners
vehicle is transported, and they cannot be and tighten the capscrews or nuts to the
released by air pressure, manually compress torque value shown in the table below.
released. Refer to the manufacturer’s
instructions. Torque Value
After Towing or Drive-Away Capscrews 0.31”-24

0.50”-13
18-24
85-115
(24-33)
(115-156)
Stud Nuts
plain nut 0.44”-20 50-75 (68-102)
the cab of the vehicle. If an auxiliary air supply 0.50”-20 75-115 (102-156)
was not used, begin with Step 2. 0.56”-18 110-165 (149-224)
2. Apply the vehicle spring or parking brakes by 0.62”-18 150-230 (203-312)
0.75”-16 310-400 (420-542)
compressed before transporting started. Refer lock nut 0.44”-20 40-65 (54-88)
to the manufacturer’s instructions. 0.50”-20 65-100 (88-136)
0.56”-18 100-145 (136-197)
3. Disconnect the auxiliary air supply, if used, 0.62”-18 130-190 (176-258)
from the brake system of the vehicle that was 0.75”-16 270-350 (366-475)
to the brake system.
8. Unlock or disengage the DCDL by removing
4. Remove the covers from the hubs. the manual engaging capscrew from the shift
assembly.
NOTE: Install only the axle shaft(s) shown in
Table P at this time. These axle shafts have a 9. Install the manual engaging capscrew into the
double row of splines that engage with splines storage hole. The storage hole of bolted-on
of the side gear and shift collar in the main shift assemblies is located in the top side of
differential. Figure 10.6. the shift cylinder cover. Tighten the capscrew
to 15-25 lb-ft (20-35 N•m). Figure 10.5. T
Table P 10. Remove the plug and gasket from the storage
hole. Install the plug and gasket into the
Single Axles threaded hole in the center of the shift cylinder
Install the right-hand (curb side) axle shaft cover. Tighten the plug to 15-25 lb-ft
(25-30 N•m). T
Tandem Axles
Forward Axle: 11. Install the remaining axle shaft into the axle
Install the left-hand (road side) axle shaft housing and carrier.
Rear Axle:
Install the right-hand (curb side) axle shaft 12. Check the lubricant level in the axles and hubs
where the axle shafts were removed. Add the
correct type and amount of lubricant if
5. Install the gasket, if used, and axle shaft into necessary. Refer to Section 6.

Section 10
Type of Axle Figure 10.9

These instructions are for vehicles equipped with 1
the following Meritor single or tandem rear drive
axles. 2 3 4 5
6
O Single Axle, without Driver-Controlled Main
Differential Lock (DCDL)
O Tandem Axle, without Driver-Controlled Main
Differential Lock (DCDL), with Inter-Axle
Differential (IAD)
Before Towing or Drive-Away

10 9
1. Park the vehicle on a level surface. Block the 8
wheels to prevent the vehicle from moving. 11 7
2. Apply the vehicle parking brakes using the 1 TAPERED DOWEL 7 SHAFT HUB AXLE
switch inside the cab of the vehicle. RETENTION 8 AXLE SHAFT OR
2 STUD NUT FLANGE
9 WASHER
NOTE: For a single axle, continue with Step 6. For 3 WASHER
10 CAPSCREW
a tandem axle, continue with Step 3. 4 TAPERED DOWEL
5 GASKET 11 NON-TAPERED DOWEL
6 STUD RETENTION
3. Shift the transmission into neutral and start
the vehicle’s engine.
10. Install a cover over the open end of each hub
4. Shift the IAD to the unlocked or disengaged
where an axle shaft was removed. This will
position using the switch inside the cab of
prevent dirt from entering the bearing cavity
the vehicle. The indicator light in the cab will
and loss of lubricant.
go off.
5. Stop the engine. NOTE: If an air supply will be used for the brake
system of the transported vehicle, continue with
NOTE: Remove both axle shafts from the axle(s) Steps 11 and 12, otherwise continue with Step 13.
that will remain on the road when the vehicle is
transported. 11. Connect an auxiliary air supply to the brake
system of the vehicle that is being transported.
6. Remove the stud nuts or capscrews and the Before moving the vehicle, charge the brake
washers from the flange of the axle shaft. system with the correct amount of air pressure
Figure 10.9. to operate the brakes. Refer to the instructions
7. Loosen the tapered dowels, if used, in the supplied by the manufacturer of the vehicle for
flange of the axle shaft. Refer to Section 2. procedures and specifications. If an auxiliary
Figure 10.9. air supply is not used, continue with Step 13.
8. Identify each axle shaft that is removed from 12. When the correct amount of air pressure is in
the axle assembly so they can be installed in the brake system, release the parking brakes
the same location after transporting or repair of the vehicle that is being transported.
is completed. Step 13 is not required.
9. Remove the tapered dowels, gasket, if used,
and the axle shaft from the axle assembly.
Figure 10.9.

Section 10
13. If there are spring or parking brakes on the 8. Check the lubricant level in the axles and hubs
axle(s) that will remain on the road when the where the axle shafts were removed. Add the
vehicle is transported, and they cannot be correct type and amount of lubricant if
released by air pressure, manually compress necessary. Refer to Section 6.
released. Refer to the manufacturer’s
instructions.
After Towing or Drive-Away

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
compressed before transporting started. Refer
to the manufacturer’s instructions.
3. Disconnect the auxiliary air supply, if used,
from the brake system of the vehicle that was
to the brake system.
4. Remove the covers from the hubs.
5. Install the gasket, if used, and axle shaft into
7. Install the washers and capscrews or stud
nuts. Determine the size of the fasteners and
tighten the capscrews or nuts to the torque
value shown in the table below.
Torque Value
Capscrews 0.31”-24 18-24 (24-33)
0.50”-13 85-115 (115-156)
Stud Nuts
plain nut 0.44”-20 50-75 (68-102)
0.50”-20 75-115 (102-156)
0.56”-18 110-165 (149-224)
0.62”-18 150-230 (203-312)
0.75”-16 310-400 (420-542)
lock nut 0.44”-20 40-65 (54-88)
0.50”-20 65-100 (88-136)
0.56”-18 100-145 (136-197)
0.62”-18 130-190 (176-258)
0.75”-16 270-350 (366-475)

Notes
Revised 02-01
$2.50
Planetary Axle Wheel Ends

Maintenance Manual 9K
PRC 775P
PRC 775 W3H
PRC 425Q PRC 475P PRC 775P

(with Q Plus™ Cam Brakes) PRC 475W3H PRC 775 W3H
PRC 425 W3H
2433D MM 9K 2/8/01 2:21 PM Page 3
Service Notes
Before You Begin Access Information on Meritor’s

This manual provides maintenance and service Web Site
procedures for ArvinMeritor’s planetary axle wheel Additional maintenance and service information
ends. Before you begin procedures: for ArvinMeritor’s commercial vehicle systems
1. Read and understand all instructions and component lineup is also available on
procedures before you begin to service ArvinMeritor’s web site at www.arvinmeritor.com.
components. To access information, click on Products &
2. Read and observe all Caution and Warning Services/Tech Library Icon/HVS Publications.
safety alerts that precede instructions or The screen will display an index of publications
procedures you will perform. These alerts help by type.
to avoid damage to components, serious
personal injury, or both. Additional Information
3. Follow your company’s maintenance and Call ArvinMeritor’s Customer Service Center at
service, installation, and diagnostics guidelines. 800-535-5560 to order the following publications.
4. Use special tools when required to help avoid • Cam Brakes
serious personal injury and damage to (Maintenance Manual 4)
components.
• Automatic Slack Adjuster
(Maintenance Manual 4B)
Safety Alerts, Torque Symbol
and Notes • 360 mm Wet Disc Brakes
(Maintenance Manual MM-20195)
• Technical Electronic Library on CD. Features
! WARNING A Warning alerts you to an product and service information on most
instruction or procedure Meritor, ZF Meritor and Meritor WABCO
that you must follow components. $20. Order TP-9853.
exactly to avoid serious
personal injury and
damage to components.
! CAUTION A Caution alerts you to an

that you must follow
exactly to avoid damage
to components and
possible serious personal
injury can also occur.
T The torque symbol alerts

you to tighten fasteners to
a specified torque value.
NOTE: A Note provides

information or
suggestions that help you
correctly service a
component.
2433D MM 9K 2/8/01 2:21 PM Page 4
Table of Contents
! Asbestos and Non-Asbestos Fibers Warnings.................................................................................1

Section 1: Exploded Views
PRC 425Q (with Q Plus™ Cam Brakes) ........................................................................................................2
PRC 425 W3H .................................................................................................................................................3
PRC 775P ........................................................................................................................................................4
PRC 775 W3H .................................................................................................................................................5
Description .....................................................................................................................................................6
Identification ..................................................................................................................................................7
Section 3: Disassembly
PRC 425Q (with Q Plus™ Cam Brakes) Planetary Axle
Removal – PRC 425 Q Plus™ Cam Brake Planetary Axle Wheel End .................................................8
Brake Drum
Planetary Spider Assembly...................................................................................................................10
Cam Brakes.............................................................................................................................................11
Spindle and Brake Spider
PRC 425 W3H Wet Disc Brake

Removal – PRC 425 W3H Wet Disc Brake Wheel End.........................................................................13
Preliminary Disassembly
Wheel End ..............................................................................................................................................15
Spindle and Piston Housing
Wet Disc Brakes .....................................................................................................................................16
PRC 775P Planetary Axle

Removal – PRC 775P Planetary Axle Wheel End.................................................................................17
Brake Drum
Cam Brakes.............................................................................................................................................20

Removal – PRC 775 W3H Wet Disc Brake Wheel End........................................................................21
Preliminary Disassembly
Wheel End ..............................................................................................................................................23
Wet Disc Brakes .....................................................................................................................................24
2433D MM 9K 2/8/01 2:21 PM Page 5
Table of Contents

Clean Ground or Polished Parts .................................................................................................................25
Clean Parts with a Rough Finish
Dry Cleaned Parts
Prevent Corrosion
Inspect Parts.................................................................................................................................................26
Inspect Tapered Roller Bearings
Inspect the Bevel Pinion and Ring Gear Sets............................................................................................27
Inspect the Main Differential Assembly.....................................................................................................28
Inspect the Axle Shafts
Inspect the Yoke
Inspect the Brakes
Repair or Replace Parts
Repair Welding
Apply Silicone Gasket Material ..................................................................................................................29
Section 5: Assembly
PRC 425Q (with Q Plus™ Cam Brakes) Planetary Axle
PRC 425Q (with Q Plus™ Cam Brakes) Planetary Axle Wheel End ..................................................30
Assembly
Spindle, Brake Spider and Brake
Wheel End ..............................................................................................................................................31
Adjust the Wheel Bearing Preload ......................................................................................................32
Planetary Spider and Gearing Assembly
Planetary Spider Assembly ..................................................................................................................33

Assembly – PRC 425 W3H Wet Disc Brake Wheel End ......................................................................34
Spindle and Piston Housing to the Axle Housing
Wet Disc Brakes
Wheel End ..............................................................................................................................................35
Planetary Spider and Gearing Assembly ............................................................................................37
Planetary Spider Assembly ..................................................................................................................38
Fill Wet Disc Brakes with Hydraulic Fluid

Assembly – PRC 775P Planetary Axle Wheel End ..............................................................................39
Wheel End ..............................................................................................................................................40
Planetary Spider Assembly
2433D MM 9K 2/8/01 2:21 PM Page 6
Table of Contents

Assembly – PRC 775 W3H Wet Disc Brake Wheel End ......................................................................43
Spindle and Piston Housing to the Axle Housing
Wet Disc Brakes
Wheel End
Fill Wet Disc Brakes with Hydraulic Fluid
Section 6: Specifications
PRC 425 Q Plus™ Wheel End Torque Chart ..............................................................................................48
PRC 425 W3H Wheel End Torque Chart ....................................................................................................49
PRC 775P Wheel End Torque Chart ..........................................................................................................50
PRC 775 W3H Wheel End Torque Chart ....................................................................................................51
Lubrication Specifications ..........................................................................................................................52
Lubrication Schedule
Wet Disc Brake Coolant Specifications......................................................................................................53
Sump and Forced Cooling Systems With Hub Seals
2433D MM 9K 2/8/01 2:21 PM Page 8
Asbestos and Non-Asbestos Fibers
! ASBESTOS FIBER WARNING ! NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce The following procedures for servicing brakes are recommended to reduce
exposure to asbestos fiber dust, a cancer and lung disease hazard. Material exposure to non-asbestos fiber dust, a potential cancer and lung disease
Safety Data Sheets are available from Meritor. hazard. Material Safety Data Sheets are available from Meritor.
Hazard Summary Hazard Summary

Because some brake linings contain asbestos, workers who service brakes must Most recently manufactured brake linings do not contain asbestos fibers. These brake
understand the potential hazards of asbestos and precautions for reducing risks. Exposure linings may contain one or more of a variety of ingredients, including glass fibers, mineral
to airborne asbestos dust can cause serious and possibly fatal diseases, including wool, aramid fibers, ceramic fibers and silica that can present health risks if inhaled.
asbestosis (a chronic lung disease) and cancer, principally lung cancer and mesothelioma Scientists disagree on the extent of the risks from exposure to these substances.
(a cancer of the lining of the chest or abdominal cavities). Some studies show that the risk Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease.
of lung cancer among persons who smoke and who are exposed to asbestos is much Silicosis gradually reduces lung capacity and efficiency and can result in serious
greater than the risk for non-smokers. Symptoms of these diseases may not become breathing difficulty. Some scientists believe other types of non-asbestos fibers, when
apparent for 15, 20 or more years after the first exposure to asbestos. inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic fiber
Accordingly, workers must use caution to avoid creating and breathing dust when dust are known to the State of California to cause lung cancer. U.S. and international
servicing brakes. Specific recommended work practices for reducing exposure to agencies have also determined that dust from mineral wool, ceramic fibers and silica are
asbestos dust follow. Consult your employer for more details. potential causes of cancer.
Accordingly, workers must use caution to avoid creating and breathing dust when
Recommended Work Practices servicing brakes. Specific recommended work practices for reducing exposure to non-
asbestos dust follow. Consult your employer for more details.
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
from other operations to reduce risks to unprotected persons. OSHA has set a maximum
allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average Recommended Work Practices
and 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to what 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
extent adherence to the maximum allowable exposure levels will eliminate the risk of from other operations to reduce risks to unprotected persons.
disease that can result from inhaling asbestos dust. OSHA requires that the following sign
be posted at the entrance to areas where exposures exceed either of the maximum 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for
allowable levels: silica of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-
asbestos brake linings recommend that exposures to other ingredients found in non-
DANGER: ASBESTOS asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average.
CANCER AND LUNG DISEASE HAZARD Scientists disagree, however, to what extent adherence to these maximum allowable
AUTHORIZED PERSONNEL ONLY exposure levels will eliminate the risk of disease that can result from inhaling non-
RESPIRATORS AND PROTECTIVE CLOTHING asbestos dust.
ARE REQUIRED IN THIS AREA Therefore, wear respiratory protection at all times during brake servicing, beginning with
the removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA)
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter filter approved by NIOSH or MSHA, if the exposures levels may exceed OSHA or
approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, manufacturer’s recommended maximum levels. Even when exposures are expected to
beginning with the removal of the wheels. be within the maximum allowable levels, wearing such a respirator at all times during
3. Procedures for Servicing Brakes. brake servicing will help minimize exposure.
a. Enclose the brake assembly within a negative pressure enclosure. The enclosure 3. Procedures for Servicing Brakes.
should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure a. Enclose the brake assembly within a negative pressure enclosure. The enclosure
in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts. should be equipped with a HEPA vacuum and worker arm sleeves. With the
b. As an alternative procedure, use a catch basin with water and a biodegradable, non- enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the
phosphate, water-based detergent to wash the brake drum or rotor and other brake brake parts.
parts. The solution should be applied with low pressure to prevent dust from becoming b. As an alternative procedure, use a catch basin with water and a biodegradable, non-
airborne. Allow the solution to flow between the brake drum and the brake support or phosphate, water-based detergent to wash the brake drum or rotor and other brake
the brake rotor and caliper. The wheel hub and brake assembly components should be parts. The solution should be applied with low pressure to prevent dust from becoming
thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. airborne. Allow the solution to flow between the brake drum and the brake support or
Wipe the brake parts clean with a cloth. the brake rotor and caliper. The wheel hub and brake assembly components should be
c. If an enclosed vacuum system or brake washing equipment is not available, employers thoroughly wetted to suppress dust before the brake shoes or brake pads are
may adopt their own written procedures for servicing brakes, provided that the removed. Wipe the brake parts clean with a cloth.
exposure levels associated with the employer’s procedures do not exceed the levels c. If an enclosed vacuum system or brake washing equipment is not available, carefully
associated with the enclosed vacuum system or brake washing equipment. Consult clean the brake parts in the open air. Wet the parts with a solution applied with a
OSHA regulations for more details. pump-spray bottle that creates a fine mist. Use a solution containing water, and, if
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use available, a biodegradable, non-phosphate, water-based detergent. The wheel hub
with asbestos when grinding or machining brake linings. In addition, do such work in an and brake assembly components should be thoroughly wetted to suppress dust before
area with a local exhaust ventilation system equipped with a HEPA filter. the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth.
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when
HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic grinding or machining brake linings. In addition, do such work in an area with a local
solvents, flammable solvents, or solvents that can damage brake components as exhaust ventilation system equipped with a HEPA filter.
wetting agents. e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic
by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you solvents, flammable solvents, or solvents that can damage brake components as
empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA wetting agents.
filter approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter
wet the filter with a fine mist of water and dispose of the used filter with care. or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or When you empty vacuum cleaners and handle used rags, wear a respirator equipped
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with with a HEPA filter approved by NIOSH or MSHA, to minimize exposure. When you
a HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter
shake or use compressed air to remove dust from work clothes. with care.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with 5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or
care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped
waste disposal. with a HEPA filter to vacuum work clothes after they are worn. Launder them separately.
Do not shake or use compressed air to remove dust from work clothes.
Regulatory Guidance 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations
States, are made to provide further guidance to employers and workers employed within on waste disposal.
the United States. Employers and workers employed outside of the United States should
consult the regulations that apply to them for further guidance. Regulatory Guidance
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the
United States, are made to provide further guidance to employers and workers employed
within the United States. Employers and workers employed outside of the United States
should consult the regulations that apply to them for further guidance.
1
2433D MM 9K 2/8/01 2:21 PM Page 9
Section 1
Exploded View
PRC 425Q (with Q Plus™ Cam Brakes)

14
8
7
6
5
3 15
13
2
12
1 11
10 26
9 25
24
23
22
27
20
4
18
21
17
16
19

1 Brake Drum 10 Snap Ring 19 Wheel Nut
2 Setscrew 11 Planetary Sun Gear 20 Hub
3 Planetary Spider 12 Thrust Washer 21 Wheel Stud
4 Machine Screw 13 Planetary Ring Gear 22 Inner Bearing Cup
5 Pinion Shaft 14 Adjusting Nut Dowel Pin 23 Inner Bearing Cone
6 Outer Thrust Washer 15 Adjusting Nut 24 Oil Seal Assembly
7 Planetary Pinion Gear 16 Outer Bearing Cone 25 Cap Screw (3/4-10 x 2.75)
8 Inner Thrust Washer 17 Outer Bearing Cup 26 Flat Washer
9 Thrust Button 18 O-Ring 27 Spindle
2
2433D MM 9K 2/8/01 2:21 PM Page 10
Section 1
Exploded View
PRC 425 W3H
10
8 9
7
6
5
4
3
2
11
13 12
14
15
16
1 17
28
27
26
25
24
23
22
20
19 21
18

1 Magnetic Drain/Fill Plug 11 Flat Washer 21 Wheel Nut
2 Setscrew 12 Capscrew 22 Hub
3 Planetary Spider 13 Snap Ring 23 Wheel Stud
4 Thrust Button 14 Inner Thrust Washer 24 Face Seal Assembly
5 Snap Ring 15 Planetary Pinion Gear 25 Inner Bearing Cup
6 Planetary Sun Gear 16 Outer Thrust Washer 26 Inner Bearing Cone
7 Thrust Washer 17 Planetary Pinion Shaft 27 Oil Seal Assembly
9 Pin 19 Outer Bearing Cup
10 Adjusting Nut 20 O-Ring
3
2433D MM 9K 2/8/01 2:21 PM Page 11
Section 1
Exploded View
PRC 775P
13
12
10 11
9
8
7
5 6 14
4
3 15
16
2 17
18
19
1 20 30
29
31
28
27
26
25
24
23
22
21

1 Wheel Nut 13 Planetary Ring Gear Hub 24 Hub
2 Brake Drum 14 Adjusting Nut 25 Wheel Stud
3 Magnetic Drain Fill Plug 15 Lock Ring 26 Inner Bearing Cup
4 Planetary Spider 16 Inner Thrust Washer 27 Inner Bearing Cone
5 Thrust Button 17 Planetary Pinion Gear 28 Oil Seal Assembly
6 Thrust Button 18 Outer Thrust Washer 29 Capscrew
7 Snap Ring 19 Pinion Shaft 30 Flat Washer
8 Planetary Sun Gear 19A O-Ring (on pinion shaft) 31 Spindle
9 Thrust Washer 20 Machine Screw
10 Planetary Ring Gear 21 Outer Bearing Cone
11 Capscrew 22 Outer Bearing Cup
12 Lock 23 O-Ring
4
2433D MM 9K 2/8/01 2:21 PM Page 12
Section 1
Exploded View
PRC 775 W3H

13
12
11
10
9
8
7
6
5
3 4
2
1 14
15
16 29
17 28
18
22
30
27
26
21
25
24
23
20
19

1 Magnetic Drain Fill Plug 13 O-Ring 24 Face Seal Assembly
2 Planetary Spider 14 Lock Ring 25 Inner Bearing Cup
3 Thrust Button 15 Inner Thrust Washer 26 Inner Bearing Cone
4 Thrust Button 16 Planetary Pinion Gear 27 Oil Seal Assembly
5 Snap Ring 17 Outer Thrust Washer 28 Capscrew
6 Planetary Sun Gear 18 Pinion Shaft 29 Flat Washer
7 Thrust Washer 18A O-Ring (on pinion shaft) 30 Spindle
8 Adjusting Nut 19 Outer Bearing Cone
9 Planetary Ring Gear 20 Outer Bearing Cup
10 Capscrew 21 Wheel Nut
11 Lock 22 Wheel Stud
12 Planetary Ring Gear Hub 23 Hub
5
Section 2
Introduction
Description • The teeth of the floating sun gear mesh with

the teeth of the planetary spur gears.
Meritor’s PRC 425Q (with Q Plus™ cam brakes) • The planetary gears rotate on planetary shafts
and PRC 775P planetary axles incorporate a single that are mounted on a spider. The planetary
reduction carrier/differential assembly with gear teeth in turn mesh with the teeth of the
hypoid gearing. They are equipped with the floating ring gear.
RS-145 carrier series. The final reduction is of
planetary spur designed gearing built into the • The hypoid gear set in the carrier transmits
wheel hubs. The axles have only cast housings. power to the axle shafts and the sun gear of
Figure 2.1. the final reduction, through the revolving
planetary gears, and into the planetary spider.
Figure 2.1 • The planetary wheel ends on both the PRC 425
and 775 are serviced almost identically for cam
or wet disc brakes.
• Meritor does not service a carrier-mounted
park brake (if equipped).
• For the PRC 475 axle models, follow the
instructions for the PRC 775 wheel end.
PRC 425Q (with Q PLUS™ CAM BRAKES)
Meritor planetary axles permit the hypoid gearing

of the carrier and the axle shafts to carry only a
nominal torsional load. At the same time, they
provide the highest practical numerical gear
reduction at the wheels.
• The hypoid pinion and differential assembly of
the first reduction supports the roller bearings.
• A hardened precision spacer between the inner
and outer pinion bearings adjusts and
maintains the pinion bearing preload.
• The positioning of the threaded adjusting rings
in the carrier leg and cap bores adjusts and
maintains the differential tapered bearing
preload.
6
2433D MM 9K 2/8/01 2:21 PM Page 14
Section 2
Introduction
Identification
The exact axle model specification is shown on
the identification tag located on the axle housing.
Figure 2.2.
Figure 2.2 SINGLE PLANETARY AXLES
ONLY IF APPLICABLE: HOUSING TYPE

L – MOUNTING OTHER THAN PAD DESIGNATION:
P – PLANETARY R – RIGID WITH DRILLING C – INTEGRAL CAST
P R __ C 7 7 5 P 208
FIRST TWO OR THREE LAST DIGIT: BRAKE TYPE: EXACT

DIGITS: WHEEL END CARRIER N — NONE SPECIFICATION
DESIGNATION DESIGNATION P — CAM-MASTER® “P” SERIES CAM (Q PLUS™
(BASIC MODEL FOR BASE MODEL IN AXLE 425)
NUMBER) NUMBER W3H — DURA-DISC® 14.2 in. (360 mm) WET DISC
7
2433D MM 9K 2/8/01 2:22 PM Page 15
Section 3
Disassembly
PRC 425Q (with Q Plus™ Cam Brakes) Wheel End Cross Section
WHEEL
INNER STUD OUTER
BEARING BEARING
OIL SEAL
ADJUSTING
NUT
PLANETARY
GEAR
SETSCREW
PLANETARY
PINION
SHAFT
PIN
THRUST
BUTTON
SUN
GEAR
SUN GEAR
THRUST
WASHER
MAGNETIC
DRAIN PLUG
PLANETARY RING GEAR
SPIDER
AXLE BRAKE MACHINE
SHAFT SPINDLE O-RING DRUM SCREW
Brake Drum
! WARNING
To prevent serious eye injury, always wear safe 1. Make sure the vehicle is on a level surface.
eye protection when you perform vehicle 2. Place blocks under the wheels not being
maintenance or service. serviced to keep the vehicle from moving.
Removal 3. Raise the vehicle so that the wheels of the axle

to be serviced are off the ground. Support the
vehicle with safety stands. Refer to the vehicle
PRC 425Q (with Q Plus™ Cam maintenance manual for instructions on
raising the vehicle.
Brakes) Planetary Axle
4. Remove the wheel nuts and dual tire/rim
Wheel End assemblies from both wheel ends.
! WARNING 5. Rotate the wheel ends so the magnetic drain

plug in the planetary spider is at the bottom.
Block the wheels to prevent the vehicle from Remove the plug. Drain and discard the
moving. Support the vehicle with safety stands. lubricant from both wheel ends.
Do not work under a vehicle that is supported
only by jacks. Jacks can slip or fall over. Serious
personal injury can result.
8
2433D MM 9K 2/8/01 2:22 PM Page 16
Section 3
Disassembly
6. If necessary, remove the magnetic drain plug
Figure 3.1
from the bottom of the axle housing. Drain and
discard the lubricant from the carrier center
section.
! WARNING
When you work on a spring chamber, carefully
follow the service instructions of the chamber
manufacturer. Sudden release of a compressed
spring can cause serious personal injury.
7. If the brake air chamber assembly has a spring

chamber unit, carefully cage and lock the
spring to prevent the spring from activating
during disassembly.
NOTE: If Meritor automatic slack adjusters are

used, refer to Maintenance Manual 4B, Automatic 10. Install capscrews into the threaded holes
Slack Adjuster for the correct adjustment in the brake drum. Gradually tighten the
procedure. To order this publication, call capscrews in equal amounts to push
ArvinMeritor’s Customer Service Center at the drum off the pilot surface of the
800-535-5560. planetary spider.
8. Adjust the brake slack adjuster to retract the
brake shoes to produce clearance between the
lining and the brake drum.
! WARNING
To prevent serious personal injury and possible
damage to components, be very careful when
using lifting devices during service and
maintenance procedures.
• Inspect to make sure that neither lifting strap
is damaged.
• Do not subject lifting straps to any shock or
drop loading.
9. Use a lifting device to support the brake drum.

Figure 3.1.
9
2433D MM 9K 2/8/01 2:22 PM Page 17
Section 3
Disassembly
11. With the lifting device, carefully remove the

brake drum. Figure 3.2. ! WARNING
Figure 3.2 the press manufacturer to avoid damage to

! CAUTION
To avoid damage to the pinion shaft, provide a
soft cushioned area to receive the pinion shaft
when it is removed from the spider.
4. Use a press to remove the pinion shafts. If a

press is not available, use a brass drift and
mallet to drive out the shaft. Press or drive
the pinion shaft out toward the large flange
end of the planetary spider.
12. Remove the five slotted head machine
screws that attach the planetary spider to the 5. Remove the snap ring, inner thrust washer,
wheel hub. planetary pinion and outer thrust washer
from each pinion shaft.
Planetary Spider Assembly 6. Remove the axle shaft thrust button only if it
is worn. Press it out TOWARD the large end
• If only the planetary pinions are removed for of the planetary spider.
inspection without removing the pinion shaft,
proceed to Step 5. NOTE: The sun gear thrust washer may come out
! WARNING 7. Remove the axle shaft, planetary sun gear
To avoid serious personal injury and possible and snap ring assembly.
damage to components, be very careful when 8. If necessary, remove the snap ring from the
using lifting devices during service and axle shaft to allow for the removal of the sun
maintenance procedures. gear and sun gear thrust washer.
is damaged. 9. If necessary, remove the sun gear thrust
washer from the end of the planetary ring
• Do not subject lifting straps to any shock or gear.
drop loading.
10. Remove the planetary ring gear.
1. With a lifting device, remove the planetary 11. Remove the wheel bearing adjusting nut.
spider from the wheel hub. Set its large
flange side on a workbench.
2. Matchmark the outer ends of the pinion
shafts and the planetary spider to aid in
reassembly if the original pinion shafts are
used.
3. Remove the setscrew from each of the
pinion shafts.
10
2433D MM 9K 2/8/01 2:22 PM Page 18
Section 3
Disassembly

! CAUTION
The outer bearing cone will be loose as you pass
it over the end of the spindle. Hold the cone ! WARNING
securely to avoid dropping it and damaging To prevent serious personal injury and possible
the cone. damage to components, be very careful when
12. Remove the wheel hub assembly. The wheel maintenance procedures.
bearings and oil seal will come off with the
wheel hub. • Inspect to make sure that neither lifting strap
is damaged.
• If replacing the hub oil seal and bearings: • Do not subject lifting loops or lifting straps to
continue with Steps 13 through 16. any shock or drop loading.
! CAUTION Removal of the capscrews allows the spindle and

brake assembly to separate. They can fall from
Do not damage the hub oil seal bore surface in the planetary axle housing and cause damage to
the wheel hub. Damage to this surface will result components and serious personal injury.
1. To prevent the spindle and the brake spider
13. Remove the wheel hub oil seal from the from falling after all the mounting capscrews
wheel hub. are removed, use one of the following
14. Remove the inner bearing cone. procedures:
15. Press out the outer bearing cup and inner A. Use a lifting device to support the spindle
bearing cup from the hub. during disassembly.
16. Remove and discard the O-ring from the B. Remove only two capscrews. Replace them
wheel hub. with two temporary M16 x 2.0 thread studs
four inches (102 mm) before the remaining
capscrews are removed. Figure 3.3.
Cam Brakes
• Install one stud at the eleven o’clock
To disassemble the PRC 425Q (with Q Plus™ cam position.
brakes), refer to Maintenance Manual No. 4, Cam • Install one stud at the one o’clock position.
Brakes. To order this publication, call
800-535-5560. Figure 3.3
If it is necessary to remove the anchor pins,
remove the brake dust shields for convenient
access to the anchor pins.
11
2433D MM 9K 2/8/01 2:22 PM Page 19
Section 3
Disassembly
2. Remove the two capscrews and washers that

mount the clamp around the brake camshaft
housing tube to the axle housing.
3. Remove the capscrews and washers that
mount the brake spider and spindle to the axle
housing.
4. Remove the brake spider and air chamber
assembly from the spindle.
5. Remove the spindle from the axle housing. If
necessary, tap lightly on the spindle to loosen
the pilot fit and to overcome the adhesion due
to the cured gasket material in the flange joint.
12
2433D MM 9K 2/8/01 2:22 PM Page 20
Section 3
Disassembly
PRC 425 W3H Wheel End Cross Section

INNER WHEEL OUTER
ADJUSTING
NUT
PIN
MAGNETIC
DRAIN PLUG
OIL SEAL
SUN GEAR
SUN GEAR
THRUST
WASHER
THRUST
BUTTON
AXLE SHAFT
PLANETARY
PINION SHAFT
PLANETARY
SPINDLE GEAR
WHEEL HUB PLANETARY

O-RING SPIDER

PRC 425 W3H Wet Disc Brake 3. Raise the vehicle so that the wheels of the axle
Wheel End vehicle with safety stands. Refer to the vehicle
maintenance manual for instructions on
! WARNING 4. Remove the wheel nuts and dual tire/rim
Block the wheels to prevent the vehicle from assemblies from both wheel ends.
Do not work under a vehicle that is supported 5. Rotate the wheel ends so the magnetic drain
only by jacks. Jacks can slip or fall over. Serious plug in the planetary spider is at the bottom.
personal injury can result. Remove the plug. Drain and discard the
lubricant from both wheel ends.
Preliminary Disassembly 6. If necessary, remove the magnetic drain plug from
the bottom of the axle housing. Drain and discard
1. Make sure the vehicle is on a level surface. the lubricant from the carrier center section.
serviced to keep the vehicle from moving.
13
2433D MM 9K 2/8/01 2:22 PM Page 21
Section 3
Disassembly
Planetary Spider Assembly 8. If necessary, remove the snap ring from the
axle shaft to allow for the removal of the sun
• If only the planetary pinions are removed for gear and sun gear thrust washer.
inspection without removing the pinion shaft, 9. If necessary, remove the sun gear thrust
proceed to Step 5. washer from the end of the planetary ring
gear.
spider from the wheel hub. Set its large flange 10. Remove the planetary ring gear.
side on a workbench. 11. Mark the position of the wheel bearing
2. Matchmark the outer ends of the pinion shafts adjusting nut. Remove the wheel bearing
and the planetary spider to aid in reassembly adjusting nut.
if the original pinion shafts are used.
3. Remove the setscrew from each of the ! CAUTION
pinion shafts.
The outer bearing cone will be loose as you pass
it over the end of the spindle. Hold the cone
! WARNING securely to avoid dropping it and damaging
the cone.
12. Remove the outer bearing cone and wheel
hub assembly with the brake driver splines
from the friction discs. The wheel bearings
Use a brass or leather mallet for assembly and and oil seal will come off with the wheel hub.
with a steel hammer. Pieces of a part can break • If replacing the hub oil seal and bearing,
off and cause serious personal injury. continue with Steps 13 through 16.
! CAUTION ! CAUTION
To avoid damage to the pinion shaft, provide a Do not damage the hub oil seal bore surface in
soft cushioned area to receive the pinion shaft the wheel hub. Damage to this surface will result
when it is removed from the spider. in oil leakage after assembly.
4. Use a press to remove the pinion shafts. If a 13. Remove the wheel hub oil seal from the
press is not available, use a brass drift and wheel hub.
mallet to drive out the shaft. Press or drive the
pinion shaft out toward the large flange end of 14. Remove the inner bearing cone.
the planetary spider.
15. If replacement of the wheel bearings is
5. Remove the snap ring, inner thrust washer, necessary, press out the outer bearing cup
planetary pinion and outer thrust washer from and inner bearing cup from the hub.
each pinion shaft.
16. Remove and discard the O-ring from the
6. Remove the axle shaft thrust button only if it is wheel hub.
worn. Press it out TOWARD the large end of
NOTE: The sun gear thrust washer may come out


snap ring assembly.
14
2433D MM 9K 2/8/01 2:22 PM Page 22
Section 3
Disassembly
Wheel End
! CAUTION
Refer to Maintenance Manual MM-20195, Wet Disc Do not reuse a damaged friction disc or stationary
Brake with Dowel Pins/Model W3H (360 mm). Call disc. Damage to components can result.
800-535-5560 to order this publication. The friction discs and stationary discs are loose
You can also access maintenance and product inside the brake housing assembly. Reach
information on ArvinMeritor’s web site. Refer to through the center of the brake housing and keep
the Service Notes page on the front inside cover the discs from falling out.
of this manual for instructions on how to access
the site. 5. Support the brake housing assembly. Remove
the remaining capscrews.
! CAUTION
6. Remove the brake housing assembly from the
piston housing and set it on a table with the
The face seal comes off with the hub. Do not set discs facing up to prevent the discs from falling
the hub down on the face seal. Damage to the out.
face seal can result. Remove the face seal from
the hub. 7. Remove the four shoulder bolts from the piston
and piston housing.
1. Remove the face seal half from the hub 8. Remove the washers and springs from the four
assembly. shoulder bolts. Push the piston from the piston
2. Remove the rest of the face seal from the brake housing. Use less than 20 psi (1.38 bar) air
housing assembly. pressure. Insert three adjuster screws. Evenly
turn the screws CLOCKWISE.
! CAUTION
The face seal comes off with the disc housing. Do Spindle and Piston Housing
not set the disc housing on the face seal. Damage
to the face seal can result. Remove the face seal ! WARNING
from the wet disc brake housing. To prevent serious personal injury and possible
NOTE: Place the face seals together and store in a using lifting devices during service and
safe package to prevent damage. maintenance procedures.
! WARNING • Inspect to make sure that neither lifting strap

is damaged.
disassembly procedures. Do not hit steel parts • Do not subject lifting straps to any shock or
with a steel hammer. Pieces of a part can break drop loading.
off and cause serious personal injury. Removal of the capscrews allows the spindle and
piston housing to separate. They can fall from the
3. Loosen sixteen M16 x 1.5 threaded capscrews. planetary axle housing and cause damage to
Hit the threaded capscrew heads with a mallet components and serious personal injury.
to separate the wet disc brake housing.
4. Remove all but two capscrews at the eleven 1. To prevent the spindle and piston housing from
o’clock and one o’clock positions. falling after all the mounting capscrews are
removed, perform the following procedures:
A. Use a lifting device to support the spindle
during disassembly.
15
2433D MM 9K 2/8/01 2:22 PM Page 23
Section 3
Disassembly
B. Remove only two capscrews. Replace them

with two temporary M20 x 2.5 thread studs
capscrews are removed.
position.
• Install one stud at the one o’clock
position.
secure the piston housing and spindle to the
axle housing.
3. Remove the piston housing from the spindle.
Figure 3.4.
Figure 3.4
Wet Disc Brakes

Refer to Maintenance Manual MM-20195, Wet
Disc Brake with Dowel Pins/Model W3H (360 mm).
Call ArvinMeritor’s Customer Service Center at
800-535-5560 to order this publication.
You can also access maintenance and product
information on ArvinMeritor’s web site. Refer to
the Service Notes page on the front inside cover
the site.
16
2433D MM 9K 2/8/01 2:22 PM Page 24
Section 3
Disassembly
PRC 775P Wheel End Cross Section

INNER OUTER
BEARING BEARING
SPINDLE O-RING
ADJUSTING
NUT
PLANETARY
PINION GEAR
SUN GEAR
THRUST
BUTTON
PLANETARY
SPIDER
AXLE SHAFT WHEEL

STUD
WHEEL HUB
O-RING
HUB
BRAKE DRUM
PRC 775P Planetary Axle 3. Raise the vehicle so that the wheels of the axle
! WARNING
Brake Drum
1. Make sure the vehicle is on a level surface.
17
2433D MM 9K 2/8/01 2:22 PM Page 25
Section 3
Disassembly
6. If necessary, remove the magnetic drain plug Figure 3.5

from the bottom of the axle housing. Drain
and discard the lubricant from the carrier
center section.
! WARNING
When you work on a spring chamber, carefully
follow the service instructions of the chamber
manufacturer. Sudden release of a compressed
spring can cause serious personal injury.
7. If the brake air chamber assembly has a spring

chamber unit, carefully cage and lock the
spring to prevent the spring from activating
during disassembly.
NOTE: If Meritor automatic slack adjusters are

used, refer to Maintenance Manual 4B, Automatic 10. Install capscrews into the threaded holes in
Slack Adjuster, for the correct adjustment the brake drum. Gradually tighten the
procedure. To order this publication, call capscrews in equal amounts to push the
ArvinMeritor’s Customer Service Center at drum off the pilot surface of the planetary
800-535-5560. spider.
8. Adjust the brake slack adjuster to retract the 11. With the lifting device, carefully remove the
brake shoes to produce clearance between the brake drum.
lining and the brake drum. 12. Remove the five slotted head machine
screws that attach the planetary spider to the
wheel hub.
! WARNING
is damaged.
drop loading.
9. Use a lifting device to support the brake

drum. Figure 3.5.
18
2433D MM 9K 2/8/01 2:22 PM Page 26
Section 3
Disassembly
Planetary Spider Assembly 6. Remove the planetary pinions and thrust

washers from the planetary spider.
7. If the axle shaft thrust button and/or ring gear
! WARNING support thrust buttons are worn and require
To prevent serious personal injury and possible replacement, place the planetary spider on
damage to components, be very careful when blocks with the large flange end facing
using lifting devices during service and DOWN. Press them out toward the large end
maintenance procedures. of the planetary spider.
• Inspect to make sure that neither lifting strap 8. Remove the axle shaft, planetary sun gear
is damaged. and snap ring assembly.
• Do not subject lifting straps to any shock or NOTE: The sun gear thrust washer may come out
drop loading. with the axle shaft and sun gear assembly.
1. With a lifting device, remove the planetary 9. Remove the snap ring from the axle shaft to
spider assembly from the wheel hub and set it allow for the removal of the sun gear from
on a workbench. Rest the spider on its large the axle shaft.
flange end.
10. If necessary, remove the sun gear thrust
2. If the planetary ring gear did not remain with washer from the axle shaft.
the planetary spider assembly during the
assembly’s removal, remove the ring gear 11. If necessary, remove the sun gear thrust
from the planetary ring gear hub. washer from the end of the spindle.
3. Mark the large ends of the planetary pinion 12. Remove the two lock plate capscrews.
shafts and the planetary spider to aid in Remove the lock plate from the planetary
reassembly if the original pinion shafts are ring gear hub.
used. 13. Remove the wheel bearing adjusting nut.
4. Place the planetary spider assembly on blocks 14. Remove the planetary ring gear hub. The
with the large flange end facing UP. Remove outer wheel bearing cone will remain on the
the snap ring from each pinion shaft. ring gear hub. If it is damaged, remove it
from the hub.
! WARNING 15. Remove the wheel hub. The hub oil seal and
Observe all warnings and cautions provided by inner bearing assembly will remain in the hub.

! CAUTION
To avoid damage to the pinion shaft, provide a
when it is removed from the spider.
5. Use a press to remove the pinion shafts out of

the spider. If a press is not available, use a
brass drift and mallet to drive out the shaft.
Press or drive the pinion shaft out toward the
small end of the spider which faces DOWN.
19
2433D MM 9K 2/8/01 2:22 PM Page 27
Section 3
Disassembly
! CAUTION ! WARNING
Do not damage the hub oil seal bore surface in Removal of the capscrews allows the spindle and
the wheel hub. Damage to this surface will result brake assembly to separate. They can fall from
in oil leakage after assembly. the planetary axle housing and cause damage to
17. Remove the hub oil seal.
1. To prevent the spindle and brake spider from
18. Remove the inner bearing cone. falling after all the mounting capscrews are
19. If replacement of the wheel bearings is removed, use one of the following procedures:
necessary, press out the outer bearing cup A. Use a lifting device to support the spindle
and inner bearing cup. during disassembly.
20. Remove and discard the O-ring from the B. Remove only two capscrews. Replace them
wheel hub. with two temporary M20 x 2.5 UNC thread
studs four inches (102 mm) long before the
Cam Brakes remaining capscrews are removed. Figure 3.6.
To disassemble the P Series brake, refer to Figure 3.6

Maintenance Manual 4, Cam Brakes. To order this
publication, call ArvinMeritor’s Customer Service
Center at 800-535-5560.
If it is necessary to remove the anchor pins,

remove the brake dust shields for convenient
access to the anchor pins.

! WARNING
is damaged. • Install one stud at the eleven o’clock
position.
drop loading. • Install one stud at the one o’clock position.
2. Remove the two capscrews and washers that
mount the clamp around the brake camshaft
housing tube to the axle housing.
3. Remove the capscrews and washers that secure
the brake spider and spindle to the axle housing.
4. Remove the brake spider and air chamber
assembly from the spindle.
20
2433D MM 9K 2/8/01 2:22 PM Page 28
Section 3
Disassembly
PRC 775 W3H Wheel End Cross Section

HUB STUD
WHEEL HUB O-RING

SPINDLE
OUTER BEARING
PLANETARY GEAR
O-RING
PLANETARY
PINION SHAFT
ADJUSTING
NUT
THRUST
BUTTON
SUN GEAR
SUN GEAR
LOCK
MAGNETIC
DRAIN PLUG
PLANETARY
RING GEAR HUB
SPIDER
INNER
PRC 775 W3H Wet Disc Brake 3. Raise the vehicle so that the wheels of the axle
! WARNING
Preliminary Disassembly 6. If necessary, remove the magnetic drain plug

from the bottom of the axle housing. Drain
1. Make sure the vehicle is on a level surface. and discard the lubricant from the carrier
center section.
21
2433D MM 9K 2/8/01 2:22 PM Page 29
Section 3
Disassembly
Planetary Spider Assembly 7. If the axle shaft thrust button and/or ring gear
support thrust buttons are worn and require
replacement, place the planetary spider on
! WARNING blocks with the large flange end facing
DOWN. Press them out toward the large end
of the planetary spider.
using lifting devices during service and 8. Remove the axle shaft, planetary sun gear
maintenance procedures. and snap ring assembly.
is damaged. NOTE: The sun gear thrust washer may come out
• Do not subject lifting straps to any shock or with the axle shaft and sun gear assembly.
drop loading.
9. Remove the snap ring from the axle shaft to
1. With a lifting device, remove the planetary allow for the removal of the sun gear from
spider assembly from the wheel hub and set it the axle shaft.
on a workbench. Rest the spider on its large 10. If necessary, remove the sun gear thrust
flange end. washer from the axle shaft.
2. If the planetary ring gear did not remain with 11. If necessary, remove the sun gear thrust
the planetary spider assembly during the washer from the end of the spindle.
assembly’s removal, remove the ring gear
from the planetary ring gear hub. 12. Remove the two lock plate capscrews.
Remove the lock plate from the planetary
3. Mark the large ends of the planetary pinion ring gear hub.
shafts and the planetary spider to aid in
reassembly if the original pinion shafts are 13. Remove the wheel bearing adjusting nut.
used. 14. Remove the planetary ring gear hub. The
4. Place the planetary spider assembly on blocks outer wheel bearing cone will remain on the
with the large flange end facing UP. Remove ring gear hub. If it is damaged, remove it
the snap ring from each pinion shaft. from the hub.
15. Remove the wheel hub with brake driver
splines from the friction discs. The hub oil seal
! WARNING and inner bearing assembly will remain in
Observe all warnings and cautions provided by the hub.
components and serious personal injury. • If replacing the hub oil seal and bearings,
continue with Steps 17 through 19.
! CAUTION
off and cause serious personal injury. Do not damage the hub oil seal bore surface in
! CAUTION
To avoid damage to the pinion shaft, provide a 17. Remove the hub oil seal.
when it is removed from the spider. 18. Remove the inner bearing cone.
19. If replacement of the wheel bearings is
5. Use a press to remove the pinion shafts out of necessary, press out the outer bearing cup
the spider. If a press is not available, use a and inner bearing cup.
brass drift and mallet to drive out the shaft.
Press or drive the pinion shaft out toward the 20. Remove and discard the O-ring from the
small end of the spider which faces DOWN. wheel hub.
6. Remove the planetary pinions and thrust

washers from the planetary spider.
22
2433D MM 9K 2/8/01 2:22 PM Page 30
Section 3
Disassembly
Wheel End
! CAUTION
Refer to Maintenance Manual MM-20195, Wet Do not reuse a damaged friction disc or stationary
Disc Brake with Dowel Pins/Model W3H (360 mm). disc. Damage to components can result.
800-535-5560 to order this publication. The friction discs and stationary discs are loose
You can also access maintenance and product inside the brake housing assembly. Reach
information on ArvinMeritor’s web site. Refer to through the center of the brake housing and keep
the Service Notes page on the front inside cover the discs from falling out.
the site. 5. Support the brake housing assembly. Remove
the remaining capscrews.
6. Remove the brake housing assembly from
! CAUTION the piston housing and set it on a table with
The face seal comes off with the hub. Do not set the discs facing up to prevent the discs from
the hub down on the face seal. Damage to the falling out.
face seal can result. Remove the face seal from 7. Remove the four shoulder bolts from the
the hub. piston and piston housing.
1. Remove the face seal half from the hub 8. Remove the washers and springs from the four
assembly. shoulder bolts. Push the piston from the piston
2. Remove the rest of face seal from the brake housing. Use less than 20 psi (1.38 bar) air
housing assembly. pressure. Insert three adjuster screws. Evenly
turn the screws CLOCKWISE.
! CAUTION
The face seal comes off with the disc housing. Do
not set the disc housing on the face seal. Damage
to the face seal can result. Remove the face seal ! WARNING
from the disc housing. To prevent serious personal injury and possible
NOTE: Place the face seals together and store in a using lifting devices during service and
safe package to prevent damage. maintenance procedures.
! • Inspect to make sure that neither lifting strap

WARNING is damaged.
disassembly procedures. Do not hit steel parts • Do not subject lifting straps to any shock or
drop loading.
off and cause serious personal injury. Removal of the capscrews allows the spindle and
piston housing to separate. They can fall from the
3. Loosen sixteen M16 x 1.5 threaded capscrews. planetary axle housing and cause damage to
Hit the threaded capscrew heads with a mallet components and serious personal injury.
to separate the wet disc brake housing.
1. To prevent the spindle and piston housing from
4. Remove all but two capscrews at eleven
falling after all the mounting capscrews are
o’clock and one o’clock positions.
removed, perform the following procedures:
A. Use a lifting device to support the spindle
during disassembly.
23
2433D MM 9K 2/8/01 2:22 PM Page 31
Section 3
Disassembly
B. Remove only two capscrews. Replace them

with two temporary M20 x 2.5 thread studs
capscrews are removed.
position.
• Install one stud at the one o’clock
position.
secure the piston housing and spindle to the
axle housing.
3. Remove the piston housing from the spindle.
Figure 3.7.
Figure 3.7
Wet Disc Brakes

Disc Brake with Dowel Pins/Model W3H (360 mm).
800-535-5560 to order this publication.
You can also access maintenance and product
information on ArvinMeritor’s web site. Refer to
the Service Notes page on the front inside cover
the site.
24
2433D MM 9K 2/8/01 2:22 PM Page 32
Section 4
! WARNING
Clean Parts with a
To prevent serious eye injury, always wear safe Rough Finish
maintenance or service. 1. Use a cleaning solvent or a hot solution tank
with a weak alkaline solution to clean parts
with a rough finish.
Clean Ground or Polished Parts 2. Leave parts in the hot solution tank until they
are completely cleaned and heated. When the
! WARNING parts are clean, remove them from the tank.
Solvent cleaners can be flammable, poisonous 3. Wash the parts with water until you
and cause burns. Examples of solvent cleaners completely remove the alkaline solution.
are carbon tetrachloride, emulsion-type cleaners
and petroleum-based cleaners. To avoid serious
personal injury when you use solvent cleaners,
product instructions and these procedures:
• A complete axle assembly can be steam
cleaned on the outside to remove dirt.
• Wear safe eye protection.
• Before the axle is steam cleaned, close or put a
• Wear clothing that protects your skin. cover over all the openings in the axle
assembly. Examples of openings are the
• Work in a well-ventilated area. breathers or vents in air chambers.
• Do not use gasoline or solvents that contain
! CAUTION
solutions correctly. Follow the manufacturer’s Dry bearings with clean paper or rags. Do not
instructions carefully. use compressed air, which can cause abrasive
particles to contaminate the bearings. Damage
to components and reduced lining life can result.
! CAUTION
• Use only solvent cleaners to clean ground or Dry Cleaned Parts
polished metal parts. Hot solution tanks or
water and alkaline solutions will damage these • Immediately after cleaning, use clean paper,
parts. Isopropyl alcohol, kerosene or diesel fuel rags or compressed air to dry parts.
can be used for this purpose.
• If required, use a sharp knife to remove gasket Prevent Corrosion
material from parts. Be careful not to damage
the ground or polished surfaces. NOTE: Parts must be clean and dry before you
lubricate them.
1. Use a cleaning solvent, kerosene or diesel fuel,
to clean ground or polished parts or surfaces. 1. If you assemble the parts immediately after
NEVER USE GASOLINE. you clean them: Lubricate the clean, dry parts
2. Remove gasket material from parts. Take care with grease to prevent corrosion.
not to damage ground surfaces. 2. If you store the parts after you clean them:
3. DO NOT clean ground or polished parts in a Apply a corrosion-preventive material to all
hot solution tank, water, steam or alkaline machined surfaces. Store the parts in a special
solution. paper or other material that prevents
corrosion.
25
2433D MM 9K 2/8/01 2:22 PM Page 33
Section 4
Inspect Parts • A visible roller groove is worn in the cup or

cone inner race surfaces. You can see the
• It is important to carefully inspect all parts for groove at the small or large diameter ends of
wear and damage before you assemble the both parts. Figure 4.2.
axle carrier.
• Replace damaged parts. Figure 4.2
Inspect Tapered Roller Bearings

Inspect the cup, cone, rollers and cage of all
tapered roller bearings in the assembly. If any of
the following conditions exist, replace the
bearing: CRACK WEAR GROOVES
• The centers of the large diameter end of the

rollers are worn level with or below the
surface.
• The centers of the large diameter end of the
rollers are worn to a sharp edge. Figure 4.1.
Figure 4.1
WORN RADIUS
WORN SURFACE
26
2433D MM 9K 2/8/01 2:22 PM Page 34
Section 4
• Deep cracks or breaks are present in the cup, • Spalling or flaking is present on the cup and
cone inner race or roller surfaces. cone inner race surfaces that touch the rollers.
Figure 4.5.
• Bright wear marks are present on the outer
surface of the roller cage. Figure 4.3.
Figure 4.5 SPALLING AND
FLAKING
Figure 4.3
WEAR MARKS
• Etching and pitting is present on the rollers and

on surfaces of the cup and cone inner race that
touches the rollers. Figure 4.4.
Figure 4.4
ETCHING AND
PITTING
Inspect the Bevel Pinion and Ring
Gear Sets
! CAUTION
The bevel drive pinions and ring gears are
machined in matched sets. When a drive pinion
or ring gear of a bevel set needs to be replaced,
both drive gear and pinion must be replaced at
the same time. A higher stress on the original
parts and early failure of the entire assembly will
result if a new part is used in combination with
parts that are older or worn.
1. Inspect the bevel drive pinions and ring gears

for wear and damage. Gears that are worn or
damaged must be replaced.
2. Verify the condition of the bearing cone seats
and spline on the pinion shaft.
27
2433D MM 9K 2/8/01 2:22 PM Page 35
Section 4
Inspect the Main Differential Repair or Replace Parts

Assembly
Replace the worn or damaged parts of an axle
1. Use a cleaning solvent, kerosene or diesel fuel, assembly. The following are some examples to
to clean the interior of the main differential check for repair and possible replacement:
assembly. NEVER USE GASOLINE. • Replace any fastener if corners of the head are
2. Use the left shaft to rotate one side gear. worn.
Replace the differential assembly if you see • Replace washers if damaged.
any binding.
• Replace gaskets, oil seals or grease seals at the
3. Observe the side gear and differential pinions time of axle repair.
during rotation. Replace the differential
assembly if you see chipped or broken teeth, • Clean parts and apply new liquid gasket
or if there are damaged cases. material where required when the axle is
assembled.
• Remove nicks, marks and burrs from parts
Inspect the Axle Shafts having machined or ground surfaces. Use a
fine file, India stone, emery cloth or crocus
If there is any wear or cracks at the flange, shaft cloth for this purpose.
and splines, replace the axle shaft.
• Clean and repair the threads of fasteners and
holes. Use a die or tap of the correct size or a
Inspect the Yoke fine file for this purpose.
• Tighten all fasteners to the correct torque
If there is excessive wear at the seal journal area, values. Refer to chart in Section 6 for fastener
replace the yoke. torque values. T
Inspect the Brakes Repair Welding

Disc Brake with Dowel Pins/Model W3H
(360 mm). Call ArvinMeritor’s Customer Service
! WARNING
Center at 800-535-5560 to order this publication. Do not weld repair, heat, bend or recondition
axle components. This will reduce component
You can also access maintenance and product strength, void Meritor’s warranty, and can result
information on ArvinMeritor’s web site. Refer to in serious personal injury and damage to
the Service Notes page on the front inside cover components. Always replace damaged or
of this manual for instructions on how to access out-of-specification components.
the site.
Inspect the axle components. Replace if damaged
or worn. Do not weld repair or recondition.
28
2433D MM 9K 2/8/01 2:22 PM Page 36
Section 4
Apply Silicone Gasket Material 5. Assemble the components immediately to

permit the gasket material to compress evenly
Meritor Specifications: between parts. Tighten the fasteners to the
required torque value for that size fastener using
• ThreeBond 1216 an “X” torquing pattern. Refer to the Torque
Chart in Section 6.
• Loctite 5699
6. Wait 20 minutes before filling the assembly with
lubricant.
! WARNING
When you apply some silicone gasket materials,
small amounts of acid vapor are present. To
must be well-ventilated. If the silicone gasket
water for 15 minutes. Have your eyes checked by
1. Remove all the old gasket material from the

surfaces of both components.
2. Clean the surfaces where the liquid gasket
material will be applied. Remove all the oil,
grease, dirt and moisture.
3. Thoroughly dry both surfaces.
! CAUTION
The amount of liquid gasket material applied to
component surface must not exceed 0.125 inch
(3.18 mm) diameter bead. Too much gasket
material can block lubrication passages. Damage
to components can result.

continuous bead of silicone gasket material
around one surface. Also apply the gasket
material around the edge of all the fastener holes
on that surface. Figure 4.6.
Figure 4.6
0.125" (3.18 MM)
DIAMETER
SILICONE GASKET
MATERIAL BEAD
29
2433D MM 9K 2/8/01 2:22 PM Page 37
Section 5
Assembly
! WARNING ! WARNING
To prevent serious eye injury, always wear safe When you apply some silicone gasket materials,
eye protection when you perform vehicle small amounts of acid vapor are present. To
maintenance or service. prevent possible serious injury, the work area
must be well-ventilated. If the silicone gasket
PRC 425Q (with Q Plus™ Cam water for 15 minutes. Have your eyes checked by
Brakes) Planetary Axle a doctor as soon as possible.
Wheel End 2. Apply a 0.125 inch (3.18 mm) diameter
Prepare Parts for Assembly around the flange mounting face of either the
axle housing or the spindle. Also apply the
NOTE: Refer to Section 4, “Prepare Parts for gasket material around the edge of all the
Assembly.” fastener holes on that surface. Figure 5.2.
Assembly Figure 5.2

1. Install two temporary studs (M16 - 2.0 threads,
approximately four inches long) into the axle
housing flange. Install the studs at the eleven
o’clock and one o’clock positions. Figure 5.1.
Figure 5.1
GASKET
MATERIAL
3. Install the spindle onto the axle housing.

4. Install the brake spider onto the spindle.
5. Install and hand tighten some of the spindle
mounting capscrews and washers.
6. Remove the two temporary studs.
7. Install the remaining spindle mounting
capscrews and washers. Tighten all capscrews
to 200-260 lb-ft (270-350 N•m). T
30
2433D MM 9K 2/8/01 2:22 PM Page 38
Section 5
Assembly
NOTE: Replace the camshaft bushing and grease

seals before the camshaft bracket is installed
! CAUTION
onto the brake spider. Refer to Maintenance • Do not damage the hub oil seal bore surface in
Manual 4, Cam Brakes. To order this publication, the wheel hub. Damage to this surface will
call ArvinMeritor’s Customer Service Center result in oil leakage after assembly.
at 800-535-5560.
• Apply a light film of non-hardening sealant to
the hub bore surface to eliminate oil leakage
8. Install the brake camshaft bracket with the
from the outer diameter of the seal.
O-ring on the pilot onto the brake spider.
9. Install the four mounting capscrews and
• The hub oil seal is a “unitized” oil seal. The
rotating seal lips are internal. The rubber ribs
washers. Tighten the capscrews to
in the bore of the seal seat onto the spindle
85-115 lb-ft (115-156 N•m). T
journal surface for static sealing. The ribs must
not be cut or damaged to avoid an oil leak path.
NOTE: Refer to Maintenance Manual 4, Cam
Brakes; and Maintenance Manual 4B, Automatic
4. Use the correct oil seal driver to install the
Slack Adjuster, to install the brake camshaft,
wheel hub oil seal. Press the seal into the hub
anchor pin components, brake shoes, brake
until the standout from the hub machined face
springs, slack adjusters and related parts. To
is 0.34 inch (8.64 mm). Figure 5.3.
order this publication, call ArvinMeritor’s
Customer Service Center at 800-535-5560.
Figure 5.3
10. Install the brake camshaft bracket clamp
around the bracket tube. Install the two
capscrews and washers that mount the
clamp to the axle housing. Tighten the
capscrews to 35-50 lb-ft (47-68 N•m). T
11. Install the air chamber-to-bracket mounting
nuts. Tighten the nuts to 100-115 lb-ft 0.34 inch
(136-156 N•m). T (8.64 mm)
12. Attach the chamber push rod yoke to the

slack adjuster. Tighten the yoke jam nut to
25-50 lb-ft (34-68 N•m). T
13. Install the brake dust shield. Tighten the
mounting capscrews and washers to
35-50 lb-ft (47-68 N•m). T
Wheel End
1. Press the new inner and outer bearing cups
NOTE: Use a Permatex coating to seal against
into the wheel hub.
leaks around the hub oil seal. Leaks would result
2. Position the wheel hub with the oil seal bore in requiring disassembly, should leak be noted
facing UP. after the final axle assembly.
3. Apply axle gear lubricant to the bearing 5. Apply a light, uniform coating of Permatex to
rollers and install the inner wheel bearing the wheel hub bore.
cone.
6. Apply a light film of axle lubricant to the hub oil
seal rubber ribs in the oil seal bore.
7. Install the wheel hub, inner bearing and oil seal
assembly onto the spindle. Keep the hub
assembly aligned with the spindle.
31
2433D MM 9K 2/8/01 2:22 PM Page 39
Section 5
Assembly
8. Apply axle lubricant to the outer bearing cone 8. Apply a thin layer of axle grease to the face
rollers. Install the outer bearing cone onto the of the sun gear thrust washer.
spindle.
9. Install the sun gear thrust washer. The
9. Install the wheel bearing adjusting nut. The washer tangs must engage the holes in the
dowel pin in the nut must face OUT. ring gear.
10. Install the planetary sun gear and snap ring
Adjust the Wheel Bearing Preload onto the axle shaft.
NOTE: To adjust the wheel bearing preload, the For correct installation:
bearings must be seated and the rollers in proper
alignment. • The axle shaft must make contact with the
differential side gear.
! • The sun gear must make contact with the

WARNING thrust washer.
disassembly procedures. Do not hit steel parts • The thrust washer tangs must be properly
installed in the ring gear hub holes.
off and cause serious personal injury. 12. Install the O-ring on the wheel hub at the
base of the flange.
1. Install the wheel bearing adjusting nut.
Tighten the nut to 400 lb-ft (542 N•m). T Planetary Spider and
2. Rotate the hub in both directions. At the same Gearing Assembly
plastic mallet.
3. Tighten the nut to 400 lb-ft (542 N•m) again.
! WARNING
T When you apply some silicone gasket materials,
4. Back off the nut approximately 1/4 turn to small amounts of acid vapor are present. To
relieve the preload produced in Step 3. prevent possible serious injury, the work area
5. Tighten the nut to 200 lb-ft (271 N•m). must be well ventilated. If the silicone gasket
T material gets into your eyes, flush them with
! WARNING
Carefully align the adjusting nut dowel pin 1. If thrust button replacement is required, use
within a ring gear tooth spline to avoid damage the procedure below. If the thrust button is not
to the pin. A damaged dowel pin will cause the to be changed, proceed to Step 2.
adjusting nut to back off and loosen the wheel
during vehicle operation. This can result in A. Apply liquid gasket material to the axle
serious personal injury and damage to shaft thrust button shaft before pressing it
components. into the spider.
6. Carefully align the adjusting nut dowel pin B. Press the new axle shaft thrust button into
within a ring gear tooth spline to avoid the planetary spider.
damage to the dowel pin. Tighten the C. Apply a film of non-hardening sealant to
adjusting nut to produce the proper alignment. the spider pinion shaft bores.
Do not back off the adjusting nut.
7. Install the planetary ring gear onto the spindle.
The dowel pin in the adjusting nut must be
installed in the hole in the ring gear face to
allow the ring gear to seat against the
adjusting nut.
32
2433D MM 9K 2/8/01 2:22 PM Page 40
Section 5
Assembly
2. Press the pinion shafts into the bores from the Planetary Spider Assembly
inner cavity end of the spider. Press the non-
coated end of the pinion shaft into the spider NOTE: For correct installation, the planetary
until the end of the shaft is 2.085-2.080 inches pinions must contact both the sun gear and the
(52.96-52.83 mm) from the inside face of the ring gear before installation.
spider. Figure 5.4.
1. Install the planetary spider and gearing
Figure 5.4 ASSEMBLE 3 assembly onto the wheel hub.
SETSCREWS
AS SHOWN
2. Install the five slotted head machine screws
that attach the planetary spider to the wheel
0.3125" hub. Hand tighten the screws. Seat the head of
(7.94 mm) each screw below the surface of the spider
DIAMETER-
0.250 DEEP
flange.
ONE HOLE
EACH SHAFT
3. Install the brake drum over the wheel studs
until the drum seats onto the planetary spider
2.085-2.080" PRESS IN 3 flange.
(52.96-52.83 mm) SHAFTS TO
DIMENSION 4. Mount the inner and outer wheels. Install the
SHOWN wheel nuts and tighten them to the vehicle
manufacturer’s specification. T
NOTE: The PRC 425Q (with Q Plus™ Cam Brakes)

axle has a common oil level between the carrier
and the wheel ends. Three locations must be
filled. The vehicle must be on a level surface
3. Install a setscrew into each pinion shaft. when filling. Fill to the bottom of each fill
Tighten each setscrew to 35 lb-ft (47 N•m). For plughole. Wait and allow the oil to flow through
new pinion shafts (if replaced), machine a hole the axle. Check the oil level again after several
for the setscrew in each shaft. T minutes and fill to the specified level if necessary.
A. Drill a 0.313 inch (8 mm) diameter hole 5. Add the correct axle lubricant into each wheel
0.25 inch (6.4 mm) deep into the pinion end through the fill/level hole in the planetary
shaft. spider at the horizontal position (3 or 9
B. Carefully pass the drill through the o’clock).
0.375 inch-16 tapped hole in the planetary 6. Add the correct lubricant to the axle housing
spider boss. bowl area.
C. Install the setscrew and tighten it to 35 lb-ft 7. Apply sealant to the threads of the fill/level
(47 N•m). T plugs.
4. Apply gear lubricant to the planetary pinion 8. Install the fill/level plugs and tighten to 35 lb-ft
bores and to the pinion shaft journals. (47 N•m). T
5. Install the outer thrust washer with the tang
engaged into the slot in the spider.
NOTE: If the original planetary pinions are used,

verify that the gear bores are smooth and free of
any surface damage.
6. Install the planetary pinion, inner thrust

washer and snap ring.
7. Apply liquid gasket material on the wheel hub
O-ring and the adjacent area.
33
2433D MM 9K 2/8/01 2:22 PM Page 41
Section 5
Assembly
PRC 425 W3H Wet Disc Brake ! WARNING

Wheel End Take care when using Loctite® to avoid serious
personal injury. Follow the manufacturer’s
Prepare Parts for Assembly instructions to prevent irritation to the eyes and
NOTE: Refer to Section 4, “Prepare Parts for with water for 15 minutes. Have your eyes
Assembly.” checked by a doctor as soon as possible.
NOTE: The piston housing has TOP identified by a

Spindle and Piston Housing raised lug.
to the Axle Housing
2. Clean and inspect the spindle and piston
1. Install two temporary studs (M20 x 2.5 housing for damage. Apply a small, two
threads, approximately four inches long) into millimeter bead of Q48 (Loctite 518) near the
the axle housing flange. Install the studs at the OD of the spindle flange, on both sides of the
eleven o’clock and one o’clock positions. spindle flange.
Figure 5.5.
3. Mount the spindle and piston housing (lug on
TOP) onto the axle housing using thirteen
M20 x 2.5 thread capscrews. Tighten the
Figure 5.5
capscrews in an “X” torquing pattern to
achieve 370-480 lb-ft (500-650 N•m) bolt torque.
Install 10 mm x 60 mm long assembly studs
into the four M8 x 1.25 thread holes in the
piston cover.
Wet Disc Brakes

To assemble the PRC 425 W3H wet disc brakes,
refer to Maintenance Manual MM-20195, 360 mm
Wet Disc Brakes. To order this publication, call
800-535-5560.
NOTE: To continue assembling the PRC 425 W3H

wet disc brake wheel end, continue with the
following steps.
34
2433D MM 9K 2/8/01 2:22 PM Page 42
Section 5
Assembly
Wheel End
! CAUTION
! WARNING
Do not reuse a damaged friction disc or
stationary disc. Damage to components can
Take care when using Loctite® to avoid serious result.
instructions to prevent irritation to the eyes and The friction discs and stationary discs are loose
skin. If Loctite gets into your eyes, flush them inside the brake housing assembly. Reach
with water for 15 minutes. Have your eyes through the center of the brake housing and
checked by a doctor as soon as possible. keep the discs from falling out.
1. Clean and inspect the piston for damage, 9. Line up all the friction disc splines and grooves
inspect the piston grooves to ensure no in a stack so that they can be assembled this
contaminants remain in the grooves. way inside the brake housing.
2. Apply an oil lubricant to the “D” seals and 10. Place a friction disc inside the brake housing.
assemble the “D” seals into the appropriate Place a stationary disc into the brake housing
grooves in the piston. while engaging all the dowels in the disc’s
slots.
! WARNING 11. Repeat these steps until completing the
assembly stack of discs. Realign all the friction
Take care when using Loctite to avoid serious
®
discs’ splines and grooves.
instructions to prevent irritation to the eyes and
skin. If Loctite gets into your eyes, flush them ! WARNING
with water for 15 minutes. Have your eyes
checked by a doctor as soon as possible. Take care when using Loctite® to avoid serious
NOTE: The piston slightly sticks out of the piston instructions to prevent irritation to the eyes and
housing. skin. If Loctite gets into your eyes, flush them
3. Apply an oil film coating on the piston housing checked by a doctor as soon as possible.
bores. Use “C” clamps to assemble the piston
over the assembly studs and push the piston 12. Apply a small, continuous two millimeter
into the piston housing until it bottoms out. bead of Loctite 518 onto the mounting face of
the brake housing. Carefully lift the brake
4. Remove and store the four assembly studs. housing assembly (lug on TOP) and install it
5. Install washers and springs on the four onto the piston housing that is already
shoulder bolts. mounted on the axle.
6. Apply a small bead of Loctite 518 to the four 13. Tighten sixteen M16 x 1.5 threaded capscrews
shoulder bolt threads and install the four in an “X” torquing pattern to achieve
shoulder bolts into the piston and piston 200-258 lb-ft (270-350 N•m) bolt torque. T
housing. Tighten the four shoulder bolts to
22-30 lb-ft (30-40 N•m). T
NOTE: The brake housing has TOP identified with

a raised lug.
7. Clean and inspect the brake housing,

stationary plates and dowels for damage.
8. Place the brake housing on an assembly
bench. Assemble the eight dowels into the
slots in the brake housing.
35
2433D MM 9K 2/8/01 2:22 PM Page 43
Section 5
Assembly
NOTE: Use a Permatex coating to seal against Adjust the Wheel Bearing Preload
in requiring disassembly, should the leak be
noted after the final axle assembly. ! WARNING
14. Install half of the face seal into the brake
housing by using a Caterpillar assembly tool
to properly position the O-ring and steel ring
assembly beyond the lip and into the tapered
bore in the brake housing.
NOTE: To adjust the wheel bearing preload, the
15. Measure the height of the metal face above bearings must be seated and the rollers in correct
the housing to ensure the tolerance is within alignment.
1 mm variation.
16. Clean and inspect the hub. Tighten the nut to 400 lb-ft (542 N•m). T
17. Install the inner and outer bearing cups into 2. Rotate the hub in both directions. At the same
the hub. Install the inner bearing cone and time, tap the hub several times with a brass or
spindle seal into the hub. Press the spindle plastic mallet.
seal flush with the shoulder in the hub bore.
NOTE: Use a Permatex coating to seal against
in requiring disassembly, should the leak be
noted after the final axle assembly. 5. Tighten the nut to 200 lb-ft (271 N•m). T
18. Apply a light, uniform coating of Permatex to
the wheel hub bore. ! WARNING
Carefully align the adjusting nut dowel pin within
NOTE: Use isopropyl alcohol to lubricate the a ring gear tooth spline to avoid damage to the
O-ring immediately before this installation. pin. A damaged dowel pin will cause the
adjusting nut to back off and loosen the wheel
19. Install the second half of the face seal into the during vehicle operation. This can result in
hub and cup assembly by using a Caterpillar serious personal injury and damage to
assembly tool to properly position the O-ring components.
and steel ring assembly beyond the lip and
into the tapered bore in the hub. 6. Carefully align the adjusting nut dowel pin
within a ring gear tooth spline to avoid
! CAUTION damage to the dowel pin. Tighten the
Do not apply lubricant to the O-ring. Damage and adjusting nut to produce the proper
leaks will result. alignment. Do not back off the adjusting nut.
7. Install the planetary ring gear onto the
20. Apply a light coating of lubricant to the two spindle. The dowel pin in the adjusting nut
mating surfaces of the face seal’s steel rings must be installed in the hole in the ring gear
only. Do not allow the lubricant to contact the face to allow the ring gear to seat against the
O-ring. Use the same lubricant that was used adjusting nut.
on the coolant side.
8. Apply a thin layer of axle grease to the face of
21. Install the hub with the brake driver splines the sun gear thrust washer.
through the friction discs.
9. Install the sun gear thrust washer. The washer
22. Install the outer bearing cone on the spindle. tangs must engage the holes in the ring gear.
Install the spindle nut on the spindle. Rotate the
hub while tightening the nut as recommended
in the wheel bearing adjustment procedure.
23. Perform the pressure test.
36
2433D MM 9K 2/8/01 2:22 PM Page 44
Section 5
Assembly
10. Install the planetary sun gear and snap ring Figure 5.6 ASSEMBLE 3
onto the axle shaft. SETSCREWS
AS SHOWN
For correct installation: 0.3125"
(7.94 mm)
• The axle shaft must make contact with the DIAMETER-
differential side gear. 0.250 DEEP
ONE HOLE
• The sun gear must make contact with the EACH SHAFT
thrust washer. 2.085-2.080" PRESS IN 3
(52.96-52.83 mm)
• The thrust washer tangs must be properly SHAFTS TO
installed in the ring gear hub holes. DIMENSION
SHOWN
12. Install the O-ring on the wheel hub at the
base of the flange.
Planetary Spider and

Gearing Assembly
1. If thrust button replacement is required, use 3. Install a setscrew into each pinion shaft.
the procedure below. If the thrust button is Tighten each setscrew to 35 lb-ft (47 N•m). For
not to be changed, proceed to Step 2. new pinion shafts (if replaced), machine a hole
for the setscrew in each shaft. T
A. Drill a 0.313 inch (8 mm) diameter hole
! WARNING 0.25 inch (6.4 mm) deep into the pinion
When you apply some silicone gasket materials, shaft.
B. Carefully pass the drill through the
0.375 inch-16 tapped hole in the planetary
spider boss.
water for 15 minutes. Have your eyes checked by C. Install the setscrew and tighten it to 35 lb-ft
a doctor as soon as possible. (47 N•m). T
A. Apply liquid gasket material to the axle 4. Apply gear lubricant to the planetary pinion
shaft thrust button shaft before pressing it bores and to the pinion shaft journals.
into the spider. 5. Install the outer thrust washer with the tang
B. Press the new axle shaft thrust button into engaged into the slot in the spider.
C. Apply a film of non-hardening sealant to verify that the gear bores are smooth and free of
the spider pinion shaft bores. any surface damage.
2. Press the pinion shafts into the bores from the
6. Install the planetary pinion, inner thrust
inner cavity end of the spider. Press the non-
washer and snap ring.
coated end of the pinion shaft into the spider
until the end of the shaft is 2.085-2.080 inches
(52.96-52.83 mm) from the inside face of the
spider. Figure 5.6.
37
2433D MM 9K 2/8/01 2:22 PM Page 45
Section 5
Assembly
Planetary Spider Assembly NOTE: The PRC 425 axle has a common oil level
between the carrier and the wheel ends. The wet
NOTE: For correct installation, the planetary disc brakes must also be filled separately. Five
pinions must contact both the sun gear and the locations must be filled. The vehicle must be on a
ring gear before installation. level surface when filling. Fill to the bottom of
each fill plughole. Wait and allow the oil to flow
1. Install the planetary spider and gearing through the axle. Check the oil level again after
assembly onto the wheel hub. several minutes and fill to the specified level if
necessary.
2. Install the five slotted head machine screws
that attach the planetary spider to the wheel 5. Add the correct axle lubricant into each wheel
hub. Hand tighten the screws. Seat the head of end through the fill/level hole in the planetary
each screw below the surface of the spider spider at the horizontal position (three or nine
flange. Figure 5.7. o’clock).
6. Add the correct lubricant to the axle housing
Figure 5.7 bowl area.
7. Apply sealant to the threads of the fill/level
plugs.
8. Install the fill/level plugs and tighten to 35 lb-ft
(47 N•m). T
Fill Wet Disc Brakes with

Hydraulic Fluid
1. Fill the wet disc brakes with tractor oil universal
(TOU) fluid by using the 0.875"-14 UNF
O-ring plug near the top of the brake and a
0.875"-14 UNF O-ring plug above the three or
nine o’clock position. Fill the brakes until oil
exits the lower plug (above the three or nine
3. Install the brake drum over the wheel studs o’clock position). Install the lower plug and add
until the drum seats onto the planetary spider two more liters of oil through the top plug.
flange. 2. Connect the brake coolant lines and brake
4. Mount the inner and outer wheels. Install the actuation lines at the proper locations.
wheel nuts and tighten them to the vehicle
manufacturer’s specification. T NOTE: Brake coolant inlet is connected to the
0.875"-14 UNF O-ring plug at the top position of
the brake between the mounting bolts. The brake
actuation line is connected at the 0.5625"-18 UNF
plug at either the three or nine o’clock position.
3. Thoroughly bleed all the air from the brake

actuation system.
38
2433D MM 9K 2/8/01 2:22 PM Page 46
Section 5
Assembly

Wheel End ! WARNING
When you apply some silicone gasket materials,
Prepare Parts for Assembly prevent possible serious injury, the work area
NOTE: Refer to Section 4, “Prepare Parts for material gets into your eyes, flush them with
Assembly.” water for 15 minutes. Have your eyes checked by
! WARNING around the flange mounting face of either the
axle housing or the spindle. Also apply the
gasket material around the edge of all the
fastener holes on that surface.
3. Align the flange flats. Install the spindle onto
1. Install two temporary studs (M20 - 2.5 threads,
the axle housing. Figure 5.9.
approximately four inches long) into the axle
housing flange. Install the studs at the
eleven o’clock and one o’clock positions. Figure 5.9
Figure 5.8.
Figure 5.8
GASKET
MATERIAL
4. Install the brake spider onto the spindle.

5. Install and hand tighten some of the spindle
mounting capscrews and washers.
6. Remove the two temporary studs.
7. Install the remaining spindle mounting
capscrews and washers. Tighten all capscrews
and washers to 370-480 lb-ft (500-650 N•m). T
39
2433D MM 9K 2/8/01 2:22 PM Page 47
Section 5
Assembly
NOTE: Replace the camshaft bushing and grease 3. Apply axle gear lubricant to the bearing
seals before the camshaft bracket is installed rollers and install the inner wheel bearing
onto the brake spider. Refer to Maintenance cone.
Manual 4, Cam Brakes. To order this publication,
call ArvinMeritor’s Customer Service Center
at 800-535-5560. ! CAUTION
• Do not damage the hub oil seal bore surface
8. Install the brake camshaft bracket with the in the wheel hub. Damage to this surface will
O-ring on the pilot onto the brake spider. result in oil leakage after assembly.
9. Install the four mounting capscrews and • Apply a light film of non-hardening sealant to
washers. Tighten the capscrews to the hub bore surface to eliminate oil leakage
85-115 lb-ft (115-156 N•m). T from the outer diameter of the seal.
NOTE: Refer to Maintenance Manual 4, Cam • The hub oil seal is a “unitized” oil seal. The
Brakes; and Maintenance Manual 4B, Automatic rotating seal lips are internal. The rubber ribs
Slack Adjuster, to install the brake camshaft, in the bore of the seal seat onto the spindle
anchor pin components, brake shoes, brake journal surface for static sealing. The ribs
springs, slack adjusters and related parts. To must not be cut or damaged to avoid an oil
order this publication, call ArvinMeritor’s leak path.
4. Use the correct oil seal driver to install the
10. Install the brake camshaft bracket clamp wheel hub oil seal. Press the seal into the hub
around the bracket tube and install the two until the standout from the hub machined
capscrews and washers that mount the face is 0.34 inch (8.64 mm). Figure 5.10.
clamp to the axle housing. Tighten the
capscrews to 35-50 lb-ft (47-68 N•m). T
Figure 5.10
11. Install the air chamber-to-bracket mounting
nuts. Tighten the nuts to 100-115 lb-ft
(136-156 N•m). T
12. Attach the push rod yoke to the slack
adjuster. Tighten the yoke jam nut to
25-50 lb-ft (34-68 N•m). T
13. Install the brake dust shield. Tighten the 0.34 inch
(8.64 mm)
mounting capscrews and washers to
35-50 lb-ft (47-68 N•m). T
Wheel End
! CAUTION
1. Press the new inner and outer bearing cups

into the wheel hub.
2. Position the wheel hub with the oil seal bore
facing UP.
40
2433D MM 9K 2/8/01 2:22 PM Page 48
Section 5
Assembly
NOTE: Use a Permatex coating to seal against NOTE: If you move the adjusting nut to align the
leaks around the hub oil seal. Leaks would result lock plate mounting holes, tighten the nut. Do not
in requiring disassembly, should the leak be loosen or back off the nut.
noted after the final axle assembly.
6. Install the lock plate.
5. Apply a light, uniform coating of Permatex to
the wheel hub bore. ! WARNING
6. Apply a light film of axle lubricant to the hub Take care when using Loctite® to avoid serious
oil seal rubber ribs in the oil seal bore. personal injury. Follow the manufacturer’s
7. Install the wheel hub, inner bearing and oil instructions to prevent irritation to the eyes and
seal assembly onto the spindle. Keep the hub skin. If Loctite gets into your eyes, flush them
assembly aligned with the spindle. with water for 15 minutes. Have your eyes
checked by a doctor as soon as possible.
8. Apply axle lubricant to the outer bearing
cone rollers. Install the outer bearing cone 7. Install the lock plate mounting screws. Tighten
onto the planetary ring gear hub. the mounting screws to 20-30 lb-ft
(27-41 N•m). T
9. Install the ring gear hub and bearing
assembly onto the spindle. • The new lock plate mounting screw threads
come equipped with a pre-applied locking
agent.
11. Adjust the wheel bearing preload. Refer to
the following procedure.
• If you use the original lock plate mounting
screws, apply two or three drops of Loctite
Adjust the Wheel Bearing Preload the ring gear hub.
8. Apply axle grease to the inner face of the sun
NOTE: To adjust the wheel bearing preload, the gear thrust washer to help secure the washer
bearings must be properly seated and the rollers to the nut.
properly aligned.
9. Install the sun gear thrust washer so that the
washer tangs must engage the slots in the
! WARNING
bearing adjusting nut.
Use a brass or leather mallet for assembly and 10. Install the planetary sun gear and snap ring
disassembly procedures. Do not hit steel parts onto the axle shaft.
with a steel hammer. Pieces of a part can break 11. Install the axle shaft and sun gear assembly.
off and cause serious personal injury. For correct installation:
1. Install the wheel bearing adjusting nut. • The axle shaft must make contact with the
Tighten the nut to 400 lb-ft (542 N•m). differential side gear.
T
2. Rotate the hub in both directions. At the same • The sun gear must make contact with the
time, tap the hub several times with a brass or thrust washer.
plastic mallet. • The thrust washer tangs must be properly
3. Tighten the nut to 400 lb-ft (542 N•m) again. installed in the ring gear hub holes.
T
5. Tighten the nut to 200 lb-ft (271 N•m).
T
41
2433D MM 9K 2/8/01 2:22 PM Page 49
Section 5
Assembly
Planetary Spider and 9. Press the pinion shafts into the spider until
the pinion shaft inner shoulders contact the
Gearing Assembly thrust washers.
NOTE: If the original planetary pinions are used, 10. Apply a film of sealant to the outside pinion
verify that the gear bores are smooth and free of shaft bores of the planetary spider.
any surface damage.
11. Place the planetary spider on a workbench
with the flange end facing UP.
! WARNING 12. Install the snap rings on each pinion shaft.
When you apply some silicone gasket materials, 13. Install the O-ring at the base of the wheel hub
small amounts of acid vapor are present. To flange.
must be well ventilated. If the silicone gasket 14. Install the planetary ring gear onto the ring
material gets into your eyes, flush them with gear hub.
1. If the axle shaft thrust button and/or ring gear
NOTE: For correct installation, the planetary
thrust buttons are being replaced, apply liquid
pinions must contact both the sun gear and the
gasket material to them before pressing into
ring gear before installation.
the spider.
2. Place the planetary spider on a workbench 1. Install the planetary spider and gearing
with the flange end facing UP. Press the new assembly onto the wheel hub.
buttons into the planetary spider.
2. Install the slotted head machine screws that
3. Inspect the planet pinion bores for damage. temporarily secure the planetary spider to the
Do not reuse pinions with bore surface damage. wheel hub. Hand tighten the screws. Seat the
head of each screw below the surface of the
4. Apply gear lubricant to the planetary pinion spider flange.
bores and to the pinion shaft journals and
shoulder surfaces. 3. Install the brake drum over the wheel studs until
the drum seats onto the planetary spider flange.
with the flange end facing DOWN. 4. Mount the inner and outer wheels. Install the
6. Carefully slide the planetary spider over the manufacturer’s specification.
edge of the workbench just far enough to
reach inside to place a planetary pinion and NOTE: The PRC 775P axle has a common oil level
thrust washer. between the carrier and the wheel ends. Three
7. Install the planetary pinion and the inner and locations must be filled. The vehicle must be on a
outer thrust washers from the large end of the level surface when filling. Fill to the bottom of each
planetary spider. The thrust washer tangs of fill plughole. Wait and allow the oil to flow through
the thrust washer must engage the slots in the the axle. Check the oil level again after a few
planetary spider inner and outer support minutes and fill to the specified level if necessary.
bosses.
5. Add the correct axle lubricant into each wheel
8. Replace the O-ring on each pinion shaft and end through the fill/level hole in the planetary
insert the pinion shafts. Hand tighten them to spider at the horizontal position (three or nine
the support journals. The large end of each o’clock).
pinion shaft must face OUT.
bowl area.
7. Apply sealant to the threads of the fill/level plugs.
8. Install the fill/level plugs and tighten them to
35 lb-ft (47 N•m). T
42
2433D MM 9K 2/8/01 2:22 PM Page 50
Section 5
Assembly

Wheel End
! WARNING
Take care when using Loctite® to avoid serious
Prepare Parts for Assembly instructions to prevent irritation to the eyes and
NOTE: Refer to Section 4, “Prepare Parts for with water for 15 minutes. Have your eyes
Assembly.” checked by a doctor as soon as possible.
Spindle and Piston Housing NOTE: The piston housing has TOP identified by a
raised lug.
to the Axle Housing
1. Install two temporary studs (M20 x 2.5 threads, 2. Clean and inspect the spindle and piston
approximately four inches long) into the axle housing for damage. Apply a small, two
housing flange. Install the studs at the eleven millimeter bead of Loctite 518 near the OD of
o’clock and one o’clock positions. Figure 5.11. the spindle flange, on both sides of the spindle
flange.
Figure 5.11 3. Mount the spindle and piston housing (lug on

TOP) onto the axle housing using thirteen M20
x 2.5 thread capscrews. Tighten the capscrews
in an “X” torquing pattern to achieve
370-480 lb-ft (500-650 N•m) bolt torque. Install
10 mm x 60 mm long assembly studs into the
four M8 x 1.25 thread holes in the piston cover.
Wet Disc Brakes

To assemble the PRC 775 W3H wet disc brakes,
refer to Maintenance Manual MM-20195, 360 mm
Wet Disc Brakes. To order this publication, call
800-535-5560.
NOTE: To continue assembling the PRC 775 W3H

wet disc brake wheel end, continue with the
following steps.
Wheel End
1. Clean and inspect the piston for damage,
inspect the piston grooves to ensure no
contaminants remain in the grooves. Apply oil
lubricant to the “D” seals and assemble the
“D” seals into the appropriate grooves in
the piston.
43
2433D MM 9K 2/8/01 2:22 PM Page 51
Section 5
Assembly
10. Repeat these steps until completing the

! WARNING assembly stack of discs. Realign all the
Take care when using Loctite® to avoid serious friction disc splines and grooves.
! WARNING
with water for 15 minutes. Have your eyes Take care when using Loctite® to avoid serious
checked by a doctor as soon as possible. personal injury. Follow the manufacturer’s
NOTE: The piston slightly sticks out of the piston skin. If Loctite gets into your eyes, flush them
housing. with water for 15 minutes. Have your eyes
checked by a doctor as soon as possible.
2. Apply an oil film coating on the piston
housing bores. Use “C” clamps to assemble 11. Apply a small, continuous two millimeter
the piston over the assembly studs and push bead of Loctite 518 onto the mounting face of
the piston into the piston housing until it the brake housing. Carefully lift the brake
bottoms out. housing assembly (lug on TOP) and install it
3. Remove and store the four assembly studs. onto the piston housing that is already
mounted on the axle.
4. Install washers and springs on the four
shoulder bolts. 12. Tighten sixteen M16 x 1.5 threaded capscrews
in an “X” torquing pattern to achieve 200-258
5. Apply a small bead of Loctite 518 to the four lb-ft (270-350 N•m) bolt torque. T
shoulder bolt threads and install the four
shoulder bolts into the piston and piston NOTE: Use isopropyl alcohol to lubricate O-ring
housing. Tighten the four shoulder bolts to immediately before this installation.
22-30 lb-ft (30-40 N•m). T
13. Install half of the face seal into the brake
6. Clean and inspect the brake housing, housing by using a Caterpillar assembly tool
stationary plates and dowels for damage. to properly position the O-ring and steel ring
assembly beyond the lip and into the tapered
NOTE: The brake housing has TOP identified with bore in the brake housing.
a raised lug. 14. Clean and inspect the hub.
7. Place the brake housing on an assembly 15. Install inner and outer bearing cups into the
bench. Assemble the eight dowels into the hub. Install the inner bearing cone and
slots in the brake housing. spindle seal into the hub. Press the spindle
seal flush with the shoulder in the hub bore.
! CAUTION NOTE: Use a Permatex coating to seal against
Do not reuse a damaged friction disc or stationary leaks around the hub oil seal. Leaks would result
disc. Damage to components can result. in requiring disassembly, should the leak be
noted after the final axle assembly.
The friction discs and stationary discs are loose
inside the brake housing assembly. Reach 16. Apply a light, uniform coating of Permatex to
through the center of the brake housing and keep the wheel hub bore.
the discs from falling out.
NOTE: Use isopropyl alcohol to lubricate O-ring
8. Line up all the friction disc splines and immediately before this installation.
grooves in a stack so that they can be
assembled this way inside the brake housing. 17. Install the second half of the face seal into the
hub and cup assembly by using a Caterpillar
9. Place a friction disc inside the brake housing. assembly tool to properly position the O-ring
Place a stationary disc into the brake housing and steel ring assembly beyond the lip and
while engaging all the dowels in the disc’s into the tapered bore in the hub.
slots.
44
2433D MM 9K 2/8/01 2:22 PM Page 52
Section 5
Assembly
18. Measure height of metal face above housing NOTE: If you move the adjusting nut to align the
to ensure tolerance is within 1 mm variation. lock plate mounting holes, tighten the nut. Do not
loosen or back off the nut.
! CAUTION
6. Install the lock plate.
Do not apply lubricant to the O-ring. Damage and
leaks will result.
! WARNING
19. Apply a light coating of lubricant to the two
mating surfaces of the face seal’s steel rings Take care when using Loctite® to avoid serious
only. Do not allow lubricant to contact the personal injury. Follow the manufacturer’s
O-ring. Use the same lubricant that was used instructions to prevent irritation to the eyes and
on the coolant side. skin. If Loctite gets into your eyes, flush them
20. Install the hub with brake driver splines checked by a doctor as soon as possible.
through the friction discs.
21. Install the outer bearing cone on the ring gear 7. Install the lock plate mounting screws. Tighten
hub. Install the spindle nut on the spindle. the mounting screws to 20-30 lb-ft
Rotate the hub while tightening the nut as (27-41 N•m). T
described in wheel bearing adjustment • The new lock plate mounting screw threads
procedure. come equipped with a pre-applied locking
22. Perform the pressure test. agent.
• If you use the original lock plate mounting
Adjust the Wheel Bearing Preload screws, apply two or three drops of Loctite
NOTE: To adjust the wheel bearing preload, the the ring gear hub.
bearings must be properly seated and the rollers 8. Apply axle grease to the inner face of the sun
properly aligned. gear thrust washer to help secure the washer
to the nut.
! WARNING 9. Install the sun gear thrust washer so that the
washer tangs must engage the slots in the
Use a brass or leather mallet for assembly and bearing adjusting nut.
with a steel hammer. Pieces of a part can break 10. Install the planetary sun gear and snap ring
off and cause serious personal injury. onto the axle shaft.
1. Install the wheel bearing adjusting nut. Tighten 11. Install the axle shaft and sun gear assembly.
the nut to 400 lb-ft (542 N•m). T For correct installation:
2. Rotate the hub in both directions. At the same • The axle shaft must make contact with the
time, tap the hub several times with a brass or differential side gear.
plastic mallet.
• The sun gear must make contact with the
3. Tighten the nut to 400 lb-ft (542 N•m) again. T thrust washer.
4. Back off the nut approximately 1/4 turn to • The thrust washer tangs must be properly
relieve the preload produced in Step 3. installed in the bearing adjusting nut slots.
45
2433D MM 9K 2/8/01 2:22 PM Page 53
Section 5
Assembly
Planetary Spider and 10. Apply a film of sealant to the outside pinion
shaft bores of the planetary spider.
Gearing Assembly
with the flange end facing UP.
verify that the gear bores are smooth and free of 12. Install the snap rings on each pinion shaft.
any surface damage.
1. If the axle shaft thrust button and/or ring gear ! WARNING

thrust buttons are being replaced, apply liquid When you apply some silicone gasket materials,
gasket material to them before pressing into small amounts of acid vapor are present. To
the spider. prevent possible serious injury, the work area
2. Place the planetary spider on a workbench with must be well ventilated. If the silicone gasket
the flange end facing UP. Press the new material gets into your eyes, flush them with
buttons into the planetary spider. water for 15 minutes. Have your eyes checked by
3. Inspect the planet pinion bores for damage. Do
not reuse pinions with bore surface damage. 13. Install the O-ring at the base of the wheel hub
4. Apply gear lubricant to the planetary pinion flange.
bores and to the pinion shaft journals and 14. Install the planetary ring gear onto the ring
shoulder surfaces. gear hub.
5. Place the planetary spider on a workbench with
the flange end facing DOWN.
6. Carefully slide the planetary spider over the
edge of the workbench just far enough to reach NOTE: For correct installation, the planetary
inside to place a planetary pinion and thrust pinions must contact both the sun gear and the
washer. ring gear before installation.
7. Install the planetary pinion and the inner and
outer thrust washers from the large end of the 1. Install the planetary spider and gearing
planetary spider. The thrust washer tangs of assembly onto the wheel hub.
the thrust washer must engage the slots in the 2. Install the slotted head machine screws that
planetary spider inner and outer support temporarily secure the planetary spider to the
bosses. wheel hub. Hand tighten the screws. Seat the
8. Replace the O-ring on each pinion shaft and head of each screw below the surface of the
insert the pinion shafts. Hand tighten them to spider flange.
the support journals. The large end of each
pinion shaft must face OUT.
9. Press the pinion shafts into the spider until the
pinion shaft inner shoulders contact the thrust
washers.
46
2433D MM 9K 2/8/01 2:22 PM Page 54
Section 5
Assembly
3. Mount the inner and outer wheels. Install the
manufacturer’s specification.
NOTE: The PRC 775 axle has a common oil level

between the carrier and the wheel ends. The wet
disc brakes must also be filled separately. Five
locations must be filled. The vehicle must be on a
level surface when filling. Fill to the bottom of
each fill plughole. Wait and allow the oil to flow
through the axle. Check the oil level again after a
few minutes and fill to the specified level if
necessary.
4. Add the correct axle lubricant into each wheel

end through the fill/level hole in the planetary
spider at the horizontal position (three or nine
o’clock).
bowl area.
6. Apply sealant to the threads of the fill/level plugs.
7. Install the fill/level plugs and tighten them to
35 lb-ft (47 N•m). T
Fill Wet Disc Brakes with

Hydraulic Fluid
1. Fill the wet disc brakes with tractor oil universal
(TOU) fluid by using the 0.875"-14 UNF
O-ring plug near the top of the brake and a
0.875"-14 UNF O-ring plug above the three or
nine o’clock position. Fill the brakes until oil
exits the lower plug (above the 3 or 9 o’clock
position).
2. Connect brake coolant lines and brake
actuation lines at the proper locations.
NOTE: Brake coolant inlet is connected to the

0.875"-14 UNF O-ring plug at the top position of
the brake between the mounting bolts. The brake
actuation line is connected at the 0.5625"-18 UNF
plug at either the three or nine o’clock position.
3. Thoroughly bleed all air from brake actuation

system.
47
2433D MM 9K 2/8/01 2:22 PM Page 55
Section 6
Specifications
PRC 425 Q Plus™ Wheel End Torque Chart
8
7 2
6
5 4

2 Pinion shaft set screw 35 lb-ft (47 N•m)
3 Oil fill/level/drain plug 35 lb-ft (47 N•m)
4 Planetary spider-to-wheel hub slotted head screw Hand tighten (no specification)
5 Spindle and brake spider mounting (drum) 200-260 lb-ft (270-350 N•m)
6 Camshaft bracket clamp 35-50 lb-ft (47-68 N•m)
7 Camshaft bracket to spider 85-115 lb-ft (115-156 N•m)
8 Wheel bearing adjusting nut Refer to instructions in Section 3.
48
2433D MM 9K 2/8/01 2:22 PM Page 56
Section 6
Specifications
PRC 425 W3H Wheel End Torque Chart
1
6
2 7

2 Spindle and wet disc brake housing mounting 370-480 lb-ft (500-650 N•m)
5 Pinion shaft setscrew 35 lb-ft (47 N•m)
6 Oil fill/drain plug (not shown) 35 lb-ft (47 N•m)
49
2433D MM 9K 2/8/01 2:22 PM Page 57
Section 6
Specifications
PRC 775P Wheel End Torque Chart

1
4
6
5

4 Planetary spider-to-wheel hub slotted head screw Hand tighten (no specification)
5 Camshaft bracket to spider 85-115 lb-ft (115-156 N•m)
6 Camshaft bracket clamp 35-50 lb-ft (47-68 N•m)
7 Spindle and brake mounting 370-480 lb-ft (500-650 N•m)
50
2433D MM 9K 2/8/01 2:22 PM Page 58
Section 6
Specifications
PRC 775 W3H Wheel End Torque Chart

4 Spindle and wet disc brake mounting 370-480 lb-ft (500-650 N•m)
51
2433D MM 9K 2/8/01 2:22 PM Page 59
Section 6
Specifications
Lubrication Specification
NOTE: Do not fill only through the axle housing
bowl. For axles with a common level, fill the axle
at each wheel end and the axle housing bowl to
the bottom of the fill/level plug hole with the
specified oil. Wait and allow the oil to flow
through the axle. Check the oil level again and fill
to the specified level if necessary.
Lubrication Schedule
Operation Off-Highway➀
Initial Oil Change 250 operating hours➀
Check Oil Level 250 operating hours➀
Petroleum Oil 1,500 operating hours or twice a year

Change (whichever comes first)➀
Synthetic Oil or 3,000 operating hours or once a year

Semi-Synthetic Oil (whichever comes first)
Change
➀ The interval depends on the individual operating conditions, speeds and loads. Severe operating conditions may
require more frequent intervals.
Lubrication Specifications
Outside Temperature
Military °F °C
Meritor Specification Oil
Specifications Approval Description Min. Max. Min. Max.
O-76A, Gear Oil GL-5, SAE 85W/140 10 None -12 None
O-76D, Gear Oil MIL-PRF-2105-E GL-5, SAE 80W/90 -15 None -26 None
O-76E, Gear Oil GL-5, SAE 75W/90 -40 None -40 None
O-76L, Gear Oil GL-5, SAE 75W/140 -40 None -40 None
O-76M, Gear Oil GL-5, SAE 75W/140 -40 None -40 None
O-76N, Gear Oil GL-5, SAE 75W/140 -40 None -40 None
Specification Oil Description

Tractor oil SAE 10W, 20W or 10W30
universal (TOU)
NOTE: Refer to Maintenance Manual 1,

Lubrication, for further lubrication information.
To order this publication, call ArvinMeritor’s
52
2433D MM 9K 2/8/01 2:22 PM Page 60
Section 6
Specifications
Wet Disc Brake Coolant Specifications

Sump and Forced Cooling Systems with Hub Seals
Coolant Specification
Petroleum Base See the recommendations of the vehicle manufacturer.
SAE 10W, SAE 20W or SAE 10W30
• Use tractor oil universal fluid (“TOU” types)

formulated for wet disc brakes in the wet ! CAUTION
disc brake housing. Make sure that the The operating temperature of the coolant must
specifications of the tractor fluid are the never reach or exceed 250°F (120°C). If the
same as the specifications of the vehicle operating temperature of the coolant reaches or
manufacturer. exceeds 250°F (120°C), the internal components
system may be required to assure the coolant
temperature remains below 250°F (120°C).

Break-In Interval: Change the fluid in the brake housing after the first month or the first 200-250 hours of
operation, whichever comes first.
Normal Maintenance Interval: Change the fluid every 6 months or every 3000 hours of operation, whichever comes first.

Use only the brake hydraulic fluid specified by the manufacturer of the vehicle. Do not use different hydraulic fluids. The wrong
fluid will damage the seals on the piston.
53
• Use a bearing puller tool to remove the cone bearing from the
steer knuckle.
• Remove the grease seal and retainer.
• Install the new grease seal and retainer.
• Repack the cone bearing with wheel bearing grease and press the
on to the knuckle. NOTE: this information is for both ends of the
steer knuckle.
To replace the bearing races in the steer axle frame:
• Use a brass punch to knock out the bearing races, both top and
bottom races come out the bottom of the frame.
• Prior to installing new race be sure the seats are free from dirt
and defects.
• Install the races using a press or mandrill make sure the races
press squarely in the frame and seated fully in place.
WARNING!
Lifting or jacking any large piece of equipment such as a fork
truck presents obvious hazards. It must be done with great care and
forethought. Consult the truck weight information that can be found on
the trucks data plate specification, to ensure that your lifting equipment
is of adequate capacity.
WARNING!
Defective equipment can cause accidents! All tools and lifting
equipment must be in good condition. Meet the load requirements and
have OSHA labels when required. Tools with defects can fail and
causing severe injury or death.
POWER SHIFT
TRANSMISSION
32000
MAINTENANCE AND SERVICE
TOWING OR PUSH STARTING
Before towing the vehicle, be sure to lift the drive axle off the ground or
disconnect the driveline to avoid damage to the transmission during
towing.
The engine cannot be started by pushing or towing.
32000 Transmission Control Valve
Forward Solenoid
Inching Valve 1st Speed Solenoid
Reverse Solenoid
2nd Speed Solenoid
Forward Check Port

1st Check Port
Inching Check Port
Reverse Check Port
3rd Check Port
2nd Check Port
Clutch pressure 240-300 PSI with parking brake set, oil temperture180 –200 F and engine
idle 400 to 600 RPM. Shift thru the direction and speed clutches NOTE: all pressure must
be equal within 5 PSI if clutch pressure varies in any one clutch more than 5 PSI repair
the clutch.
M04155-2 FUNCTIONAL DESCRIPTION
Below table shows the connector pin assignments of the M04155-2.

G F
G R
G 1
G 2
O 3
G F HI
O OPTION
O H/S
P-Series Hydraulics
Accumulators
Description
Fluids are practically incompressible and cannot therefore store pressure energy.
The compressibility of a gas (nitrogen) is utilized in hydro-pneumatic accumulators for storing

fluids. Bladder accumulators are designed on this principle, using nitrogen as the compressible
medium.
The bladder accumulator consists of a fluid section and a gas section, with the bladder acting as
a gas-proof screen. The fluid around the bladder is connected with the hydraulic circuit, so that
the bladder accumulator draws in fluid when the pressure increases thus compressing the gas.
When the pressure drops, the compressed gas expands and forces the stored fluid into the
circuit.
Charging and
Gauging Units
for Bladder, Diaphragm,
and Piston Accumulators
1. DESCRIPTION
To maintain system performance
HYDAC recommends a regular
check of the gas precharge
pressure. A loss in the gas
precharge pressure will cause a
drop in the system efficiency
and could cause damage to the
bladder, diaphragm, or piston
accumulator.
By means of a charging and
gauging unit, hydro-pneumatic
accumulators are precharged
with dry nitrogen or their
existing gas precharge pressure
is checked. For these purposes,
a charging and gauging unit is
connected to a commercially
available nitrogen bottle via a
flexible charging hose.
HYDAC offers two types of
charging and gauging units, the
FPS model, used with HYDAC
gas valve version 4, except on
top repairable bladder
accumulators, and the FPK
model used with HYDAC gas
valve version 1. An adapter
FPK/SB can be used with the
FPK model in order to fit
HYDAC gas valve version 4,
including top repairable bladder
accumulators.
The charging and gauging units
incorporate a gauge, check
valve in the charging
connection, manual bleed valve,
and T-handle.
CHARGING AND
GAUGING UNITS
TABLE OF CONTENTS
PAGE
Model Code 3
General 5
Operating and Installation Instructions 6
Dimensions 7
2
2. MODEL CODE FPS 250 F 2.5 - G4 - K
(also order code)
Charging and Gauging Unit

FPK = Gas valve version 1 (M28 x 1.5) for SBO and SK
FPS = Gas valve version 4 (8V1-ISO 4570) for SB1), SBO, and SK
1) For top repairable bladder accumulators with gas valve version 4,
the FPK unit with adapter FPK/SB must be used.
Gauge Pressure Range
10 = 0-145 psi 0-10 bar
25 = 0-350 psi 0-25 bar
100 = 0-1400 psi 0-100 bar
250 = 0-3500 psi 0-250 bar
400 = 0-5800 psi 0-400 bar
Charging Hose
With cap screw G1 (thread W24, 32x1/14 - DIN477)
Charging Hose Length
2.5 = 8 ft. 2.5m (standard)
4.0 = 13 ft. 4.0m (optional)
Adapter (Depends on country of installation)
G1 = Germany
G2 = Australia, Great Britain, India
G3 = France
G4 = USA, Canada, Mexico (standard)
G5 = Italy
G6 = Japan Taiwan
G7 = Japan, South Korea
G8 = Brazil
G9 = China
G10 = Russia
Adapters for other countries: Consult HYDAC
Case (standard)
Accessories (optional)
Adapter FPK/SB (used with FPK unit to charge any HYDAC gas valve version 4 accumulator)
Adapters for other gas valves: consult HYDAC
Allen wrench 6 mm (for HYDAC gas valve version 1)
Open end wrench 14 mm (for HYDAC gauge)
Weight
5.3 lbs. (2.4 kg.)
Dimensions
13” L x 12” W x 4.5” H (33mm L x 30.5mm W x 11.5mm H)
NOTE:
All details subject to change to technical modification
(Not all combinations available)
3
FIG.1: CHARGING AND FIG.2: HYDAC STANDARD GAS VALVES
GAUGING UNITS
FPS
FPK
Version 4 Version 1
H valve protection cap N valve protection cap
(where applicable) (where applicable)
G valve seal cap M O-ring
F O-ring (where applicable)
L socket head cap screw (M8)
K seal ring
A T-handle
B manual bleed valve
C check valve
D cap nut
E charging hose, including cap
screw connections G1 and M
4
3. GENERAL 4. OPERATING AND CHECKING GAS
WARNING! INSTALLATION PRECHARGE PRESSURE
Hydraulic accumulators are INSTRUCTION Connect the appropriate charging
and gauging unit to the accumulator
pressurized vessels and only PREPARATION following the instructions under
qualified technicians should To check the gas precharge pressure “Preparation” (see page 5).
perform maintenance. For in an accumulator, it must first be Note: Temperature affects the gas
additional information refer to isolated from the system shut off, precharge pressure, please refer to
HYDAC Operating and Installation and all hydraulic pressure relieved. “Temperature Effect” (see page 5).
Instructions and HYDAC
Maintenance Instructions. For accumulators with HYDAC gas FPS Unit
valve version 4, unscrew the valve Turn T-handle “A” clockwise a
Read all instructions thoroughly protection cap “H” (where applicable) maximum of 3 full turns from the full
before before beginning any type of and the valve seal cap “G” (see fig. 2). counterclockwise position. The
service or repair.
For accumulator with HYDAC gas gauge needle should indicate the
TOOLS REQUIRED valve version 1, unscrew the valve existing gas precharge pressure. If
protection cap “N” (where there is no gas precharge pressure
1. Gas Valve Core Tool.
applicable). Slightly loosen the indicated or if it is too low or too
2. Torque Wrenches. socket head cap screw “L” with a 6 high, please follow instructions
3. Wrench(es). mm Allen wrench (approx. 1/6 turn, under the appropriate section, either
see fig. 2). “Pressure Release” (see page 5) or
INTERVALS BETWEEN “Charging” (see page 6). If desired
CHECKING GAS FPS Unit
gas precharge pressure registers,
Prior to connecting the charging
PRECHARGE PRESSURE and gauging unit to an accumulator,
please follow the instructions under
The proper gas precharge pressure “Removal of Charging and Gauging
turn T-handle “A” counter clockwise
should be set after each new Unit” (see page 6).
until resistance is felt. Close manual
installation or repair by following the bleed valve “B” by hand tightening. FPK Unit
instructions under the Operating Connect the unit to the accumulator Turn T-handle counter clockwise a
and Installation Instructions below. by screwing cap nut ”D” onto maximum of 3 full turns. The gauge
It should be rechecked at least HYDAC gas valve version4; hand needle should indicate the existing
once during the first week of tighten (see fig.1). gas precharge pressure. If there is
operation. If there is no loss of gas no gas precharge pressure indicated
FPK Unit
precharge pressure, it should be or if it is too low or too high, please
Prior to connecting the charging
rechecked again in 3 to 4 months. follow instructions under the
and gauging unit to an accumulator,
Thereafter, it should be checked at appropriate section, either “Pressure
close manual bleed valve “B” by
least once a year. Recharge Release” (see page 5) or “Charging”
hand tightening. Connect the unit to
accumulator when necessary. (see page 6). If desired gas
the accumulator by screwing cap
precharge pressure registers, please
TEMPERATURE EFFECT nut “D” onto HYDAC gas valve
follow the instructions under
To ensure that the recommended version 1; hand tighten (see fig.1).
“Removal of Charging and Gauging
gas precharge pressure is FPK Unit (with adapter FPK/SB) Unit” (see page 6).
maintained, even at relatively low of Prior to connecting the charging
and gauging unit to an accumulator,
PRESSURE RELEASE
high operating temperatures, the With the appropriate charging and
gas precharge pressure should be take adapter FPK/SB (see fig. 6)
gauging unit attached as previously
adjusted for temperature. The and unscrew the socket head cap
described, gas precharge pressure
formula below relates the precharge screw 3 full turns counter clockwise
can be released by carefully opening
temperature (T0) to the operating using the 6 mm Allen wrench. This
manual bleed valve “B”. Release the
temperature (T). is done to prevent gas valve damage
gas precharge pressure very slowly
and leakage upon installation. Screw
Fahrenheit until the desired gas precharge
the adapter FPK/SB onto HYDAC
2
(
P0,T = P0,T x T0 + 460
0
T2 + 460 ) gas valve version 4, hand tighten.

Close manual bleed valve “B” on
pressure is reached (this insures
that the gas temperature does not
Celsius fluctuate greatly, providing and
the FPK unit hand tight. Connect
2
(
P0,T = P0,T x T0 + 273
0
T2 + 273 ) FPK unit to adapter FPK/SB by

screwing cap nut “D” onto the
accurate gas precharge pressure).
Close the manual bleed valve “B”.
T0 = precharge temperature Allow the gas precharge pressure to
adapter; hand tighten.
stabilize. (5 to 10 minutes) recheck,
T2 = maximum operating adjust if required. Once the desired
temperature gas precharge pressure is reached,
P0,T = gas precharge pressure at
0 please follow the instructions under
precharge temperature “Removal of Charging and Gauging
P0,T = gas precharge pressure at
2
Unit” (see page 6).
maximum operating
temperature
5
CHARGING PRESSURE INCREASE Unit” (see page 6).
When charging an accumulator that REMOVAL OF CHARGING
WARNING! has an existing gas precharge, AND GAUGING UNIT
Never use oxygen or air - this could allow 5 to 10 minutes for the gas
Close the shut-off valve on the
cause an explosion! Use dry nitrogen temperature and thus pressure to
commercially available nitrogen
or other recommended gases. stabilize.
bottle before removing the charging
HYDAC recommends the use of a FPS Unit and gauging unit.
pressure regulator on the Turn T-handle “A” clockwise until the
FPS Unit
commercially available nitrogen gauge needle begins to deflect, then
Turn T-handle “A” counter clockwise
bottle to regulate pressure to the turn it another full turn. Proceed to
until resistance is felt to close the
charging and gauging unit. “Filling”.
gas valve. Open manual bleed valve
Note: Full nitrogen pressure may FPK Unit “B” to relieve pressure in the
damage the gauge. Turn T-handle “A” counter clockwise charging and gauging unit. Proceed
Connect the charging hose to a until the gauge needle begins to to “Disconnecting”.
commercially available nitrogen deflect, then turn it another full turn.
FPK Unit
bottle by means of the G4 adapter Proceed to “Filling”.
Turn T-handle “A” clockwise until
(other adapters are available, check FPK Unit (con adapter FPK/SB) resistance is felt to close the socket
with factory for type); the adapter Turn T-handle “A” clockwise until the head cap screw, hand tighten. Open
connects to the cap screw “G1”. gauge needle begins to deflect, then manual bleed valve “B” to relieve
Connect cap nut “M” of the turn it another full turn. Proceed to pressure in the charging and
charging hose to check valve “C” “Filling”. gauging unit. Proceed to
of the charging and gauging unit “Disconnecting”.
(see fig. 1). Connect the appropriate FILLING FPK Unit (with adapter FPK/SB)
charging and gauging unit to the Open the shut-off valve on the Turn T-handle “A” counter clockwise
accumulator by following the commercially available nitrogen until resistance is felt to close the
instructions previously described bottle and slowly fill the gas valve. Open manual bleed valve
(see page 5). accumulator with dry nitrogen gas. “B” to relieve pressure in the
Precharge very slowly until the charging and gauging unit. Proceed
INITIAL CHARGING pressure in the accumulator to “Disconnecting”.
When charging an accumulator that
reaches 100 psi. Once 100 psi is
has no initial gas precharge, allow
reached, the charging rate can
20 to 30 minutes for the gas DISCONNECTION
increase. Charging too quickly may
temperature and thus pressure to
damage the accumulator. Unscrew the charging and gauging
stabilize. Recheck the gas
Note: The gauge registers the line unit from the gas valve. Note: For
precharge pressure and adjust if
pressure, not necessarily the FPK unit with adapter FPK/SB it
necessary.
accumulator pressure while may be necessary to loosen the
FPS Unit connection between cap nut “D”
charging.
Turn T-handle “A” clockwise 3 full and the adapter to remove the
turns. Proceed to “Filling”. After allowing the appropriate time charging and gauging unit. Check
for the gas temperature and thus for leaks. None are permissable.
FPK Unit
pressure to stabilize, adjust the gas
Turn T-handle “A” counter clockwise 3
precharge pressure as required,
full turns. Proceed to “Filling”.
refer to “Pressure Increase” (see COMPLETION
FPK Unit (with adapter FPK/SB) page 6) or “Pressure Release” (see For HYDAC gas valve version 1,
Turn T-handle “A” clockwise 3 full page 5). tighten socket head screw cap “L”
turns. Proceed to “Filling”. to 20 Nm (15 lb-ft), and screw on
Once the desired gas precharge
pressure is reached close the shut- valve protection cap “N” (where
off valve on the commercially applicable); hand tighten.
available nitrogen bottle. Remove For HYDAC gas valve version 4,
the charging and gauging unit from screw on valve seal cap “G”
the gas valve as described under torquing to 30 Nm (22 lb-ft), and
“Removal of Charging and Gauging valve protection cap “H” (where
applicable); hand tighten.
6
5. DIMENSION OF CHARGING AND GAUGING UNIT
Fig.3: Units FPS and FPK
FPS FPK
6. SPARE PARTS
Charging and Gauging Unit Type:
FPS FPK
Item Description Dimensions Quantity Dimension Quantity
9 O-Ring 6x1 1 6x1 1
10 Seal-Ring A 10 x 13.5 1 A 10 x 13.5 1
11 Gauge Ø 63, conn. G 1/8 1 Ø 63, conn. G 1/8 1
(ISO 228) (ISO 228)
12 Check Valve DN 3 1 DN 3 1
13 Manual Bleed Valve Connection M 10x1 1 Connection M10x1 1
23 O-Ring 7.5 x 2 1 15 x 2 1
32 Seal-Ring Ø 20/11.5 x 2 1 Ø 20/11.5 x 2 1
elastomer ring elastomer ring
Note: Dimensions in mm.

7
ADAPTER DIMENSIONS
Fig.5: Charging Hose
Length 2.5 m (standard)

Length 4.0 m (optional)
Fig.6: Adapter G4
© Copyright 1999 HYDAC TECHNOLOGY CORPORATION - Catalog - Charging and Gauging Units #02071183 / 05.00
Fig.7: Adapter FPK/SB
Note: Dimensions shown in mm
HYDAC CORPORATION
2280 City Line Road • Bethlehem, PA 18017
Phone (610) 264-9503 • Fax (610) 264-7529
www.hydacusa.com • powerup@hydacusa.com
Repair Instructions H01134
CONTENTS
1 Contents
2-3 Seal kits / spare parts kits
4-5 Sealing the drive shaft
6-12 Disassembly and re-assembly of

the complete unit
13 Specification tolerance lists
14 Control valve information
15 Testing and set up instruction
16 Tools and tightening torques
Hoist Liftruck Mfg., Inc.

K1 Sealing kit, existing spare parts:

shaft sealing ring, 6 diff. O-rings
and a circlip (sealing mat.:
perbunan).
K2 Same sealing kit like shown top

(picture K1) only material changed
to sealing material Viton.
K3
Drive shaft
K4
Bearing set / miscellaneous parts
K5
Rotary group complete: 9 pistons,
cylinder sub assembly, valve plate
(cw or ccw corresponding to the
order), retaining plate and retaining
ball.

K6 Swash plate
K7
Parts of the control device: control
piston, piston rod, plug, spring
stopper max flow, hex nut and hex
head nut.
K8 Spare parts kit: DFR pilot valve (in

case of spare parts supply see
packing notes, too)

1
Remove the snap ring.
2 Change the shaft seal and check

its sliding surface (drive shaft),
and housing. Grease the sealing
ring.
Be careful while you seal the

3 drive shaft. Use an adhesive
tape.
4
Assemble the sealing ring. The
fitting tool holds the correct
position of the sealing ring in
the pump housing.
5
Assemble the snap ring.

6 Assemble the snap ring in the

correct position.
NOTE:
This description shows ho to change the drive shaft sealing ring but
it is not the way of serial assembly. The sealing ring is assembled
together with the taper roller bearing from inside the pump housing
to get a secure sealing condition. If you decide to repair the pump
in the shown way, be very careful while handling to ensure that
there is no damage to the drive shaft.

11
Disassemble the pilot valve.
12 Mark the position of the port plate

and remove the socket screw of the
port plate.
13
Remove the port plate together with
the valve plate (hold the valve plate
so that the plate can’t fall down).
14
Remove the O-ring.
15
Disassemble the taper roller bearing
(near by port plate).

16 Remove the adjustment shim.
17 Unscrew the cap nut and remove it.
Loosen the fixing nut of the stopper

18
max flow and disassemble it.
19 Turn in the stopper max flow to get

swivel angle zero.
20 Disassemble the rotary group in

horizontal position.

21
Disassemble the stopper –
maximum flow.
22 Remove the threaded pin

(stopper – maximum flow).
23
Disassemble the plug.
24
Disassemble the control piston
while moving the swash plate.
25 The swash plate must be lifted a

little bit to disassemble the
piston rod.

26
Disassemble the swash plate.
27
Remove the spring.
28
Remove both bearing shells.
29
Remove the drive shaft.
30
Disassemble the snap ring.

31 Disassemble the sealing ring.
32
The external front bearing ring
is pulled out of the pump
housing (tool and surface
information see picture above).
33 Remove the O-ring. Lifting of

the valve plate isn’t shown.
34
A usual commercial bearing
puller is used to disassemble the
external bearing ring of the
taper roller bearing inside the
port plate. Take care of the
surface of the port plate.
35 The spring has additional

pretension while you
disassemble the three pressure
pins inside the cylinder (spare
parts see picture3, page 4).

36 Assemble the variable

displacement pump in reverse
order and note the following:
NOTE! see pictures 37…41.
37 Measurement of the taper roller

bearing pretention (see page 15,
too).
38 Note that there is a correct

connection of the piston rod and
the swash plate.
Pumps driven clockwise must

39 have a position of the valve
plate 4° out of center in the
same direction decentered like
drive direction. (Note spare
parts exist as cw and ccw valve
plates).
40
Pumps anti-clockwise driven
must have a position of the
valve plate 4° decentered in ccw
position.

41
Assembly of the port plate and
the pump housing: Note the
correct position of the drilling
that connects high pressure to
the control valve. Check
control valve drilling position at
the pump housing and fit
together.

Taper roller bearing initial tension
Cast iron pump housing must have initial tension of the bearings: 0…0,05 mm, grind Pos.
12 if necessary.
Mechanical flow limiter
Differential volume if you are rotating the threaded pin – each rotation is approximately
3,1 cm³ (see page 3, too).

All valves shown here have open position of orifice.
Position of the orifice

Ø 0,6
Orifice 0,6mm
________________________________________________________________________
Decompression - orifice X
Pressure compensator and flow control

DFR
Pressure compensator and flow control DFR 1

One X – port is plugged. The plug plugs
Plug decompression orifice X-T.
Adapter without orifice of the

DFR – pilot valve, if you see a
metric pilot pipe connection X.

DR: When pressure line is closed, adjust

the pressure of the controller. If it’s DFR
design, then open the adjustable orifice and
increase force of the spring –FR-
FR: If swivel angle is in the mid position,

adjust differential pressure 14 bar
(adjustable orifice is partly closed).
Mechanical flow limiter: While screwing

in the threaded pin, you will be able to
reduce the flow from Vg maximum to 50%
of Vg maximum. Sets up instructions are
on page 15.
Leakage:
Test-parameters:
Sort of oil: HLP ISO VG 46
Oil temperature: 50° C
Speed: 1500 RPM; test pressure: 250 bar
Max swivel angle: pilot valve doesn’t operate.
Max leakage of a serial fitted new pump
Pressure compensator: DR (1 / min) 3,4
Pressure comp. And flow control DFR: (1 / min) 4,6

Loctite used:
Break off plugs: Nr. 601
All other parts: Nr. 242
Tightening torques
Bolt hardness grade:
Ma (Nm) = maximum tightening torques (screws lubricated µ = 0,125)

HOIST LIFTRUCK
MFG., INC.
ORBITROL REPAIR
MANUAL
H00999 AND H00462
Quality Hydraulic Fluids
Today’s hydraulic fluid has to be tougher, to provide peak pressure and instant
power through many hours of constant operation. It must stand up day after day in all
types of systems. It has to be ready-to-go on cold winter mornings and not let down on
hot summer afternoons. This means more oil punishment and need for built-in quality.
Quality Hydraulic Fluid Needs:
• Anti-wear properties to prevent scuffing and excessive wear at high

speeds, also high-pressure operations.
• High stability to resist oxidation, prevent varnish formation and deposits
that foul systems.
• Rust resistant additives to prevent rust formation from moisture
condensation.
• Anti-foam agents to break up air bubbles in the fluid and prevent
“foaming” that cause sluggish, erratic operations.
• Good viscosity index for easy flow at low temperatures without thinning
out at high temperatures after hours of use.
• Seal conditioner properties to prevent cracking or excessive swelling of
seal that can result in fluid leaks.
The need for good quality hydraulic fluid is very important in today’s hard
working vehicles. In today’s modern systems just any hydraulic fluid won’t do, the
wrong fluid is a sure road to trouble. Always make sure that the hydraulic fluid you use
meets or exceeds vehicle manufacture’s specification.
Oil Storage & Handling

Refiners of hydraulic oils take particular care to prevent contamination of any sort
from entering the oil up to the time of delivery. It is just as important to exercise care in
preventing contamination from entering after its delivery, during storage and handling.
Following these procedure is absolutely necessary to the proper operation of any
hydraulic system or component.
Storage:
• Select a clean, dry spot.
• Store the drums on there sides.
• Cover the drums to prevent dust accumulation.
• Keep water form collecting on the top of the drum. Water can seep
through the plug and into the oil.
• Avoid condensation in storage; drums must be protected from sudden
temperature change.
Handling:
• Before opening a drum, wipe the top carefully to prevent dirt from falling
into the oil. If by chance dirt gets into the oil make sure to strain the oil by
using a 100-mesh screen. If available filter or centrifuge the oil, it is
important to know that active earth type filters remove oil additives.
Consult with your oil manufacturer for the correct filter.
• When drawing oil out of storage make sure to use a clean approved
labeled container. If oil must be transported or stored in the container keep
it tightly covered.
Filling:
• Before removing the filler cap, wipe off plug or cap with a lint-free cloth.
• “Recommend” use a 10-micron filter or filtered nozzle on the container
when pouring oil from a container into a reservoir.
• The reservoir should be tightly covered after filling the system.
• The container should be covered and stored in a clean place.
Dust, water lint or contaminations of any kind can seriously damage the operation
of the hydraulic system. Following the above-mentioned procedures can help
prevent contaminating material from entering hydraulic system.
Hydraulic Fitting Tightening Procedure
1. Tighten fitting finger-tight until it stops turning, while moving the

fitting lightly side to side to prevent cocking or thread damage.
2. Lightly snug fitting with a wrench unit it bottoms out on the seat or
port. Do not over tighten.
P –Series
Lift pump Pressure: 2900 PSI +- 200PSI
Brake & Steering pump: 2450

Compensator: Has two adjustments main pump pressure 2450 PSI and stand by pressure
475 PSI
Main
Pressure
Stand By
Pressure
Test Port Main Test Port Main Lift

Pressure Steer and Pressure line into
Brake Control Valve
Manifold Block
P-Series Mast
Uprights
Service Intervals can be reduced by shimming the rollers to close the

• All upright components should be visually gap between the roller and rails.
checked every day during the Operator’s Forks use a hanger design for mounting on the
Daily Inspection. carriage. Auxiliary attachments may be added to
• A thorough visual inspection should be the upright for specialized handling operations. To
performed by a trained service professional operate the attachment, the hydraulic circuit is
every 50-250 hours. modified with a hose adaptation kit, and an
• Lift chains should be inspected and auxiliary section is added to the main hydraulic
lubricated every 50-250 hours or monthly. valve.
• Lift chain tension should be checked every
50-250 hours or monthly. The free lift and rail lift cylinders on standard
• Upright and carriage roller checks should uprights and triple-stage uprights (TSUs) may be
be performed every 50-250 hours or either piston or ram type cylinder. The free lift
monthly. cylinder on TSUs is a piston type cylinder. See
• Roller patterns should be checked every 6 chart under “specifications” to determine the type
months or after 1000 hours of service. of cylinder used on the upright you are servicing.
• Racking and drift tests should be performed
Piston-type cylinders contain a bypass check valve
every 50-250 hours or monthly.
in the piston that allow any fluid that has
• The complete extended inspection should
accumulated in the rod end of the cylinder to return
be performed at least every year or 2000
to the system. The check valve can be removed and
hours of operation.
cleaned if indicated by troubleshooting. A velocity
fuse in the hydraulic port of the free lift cylinders
prevents the mast from falling rapidly in case of
Description
sudden fluid pressure loss due to line breaks.
The upright assembly includes the lift chains, free
The main pump sends fluid to the main hydraulic
lift cylinders, carriage, forks, and upright or rails
control valve, which contains spools that route
sets. Each of the components can be serviced using
fluid to the lift cylinders and tilt cylinders. The
the tests, checks, adjustments, removal, and
valve assembly also contains counter-balance valve
replacement procedures in the following Sections.
the prevents upright tilt when the truck is not
operating.
The upright uses the hydraulic cylinders and chain
sets to lift the carriage and rail sets. On standard,
Fluid flow rates for lift functions are factory-set
two-stage uprights, the free lift cylinders lift the
and not adjustable. Flow rates for tilt and auxiliary
carriage with the chains and directly lift the inner
functions are controlled by changing the flow
rail sets. On triple stage-uprights, the free lift
cartridges on the main hydraulic valve. A non-
cylinder lifts the carriage by the chains. When the
adjustable “load-lowering” flow valve mounted on
free lift reaches its maximum extension, fluid is
the upright limits upright lowering speed.
diverted to the rail lift cylinders, which lifts the
inner rails using a second set of chain, and lifts the
intermediate rails by direct lift.
Friction and play between the nesting rails is

controlled by roller sets mounted on the rails
carriage. When rails or rollers become worn, the
gap between the rollers and rails becomes larger,
creating more play in lifting and lowering
operations. The rail-web-to-roller-side clearances
P- Series Lubrication
P SERIES FLUIDS
This is a list of recommended lubrications always use a good quality

equivalent type.
WARNING! ALWAYS USE A CLEAN APPROVED LABELED CONTAINER TO

PREVENT CONTAMINATION.
TRANSMISSION FLUID
TYPE CITGO 500SAE30
CAPACITY 5 GAL
HYDRAULIC FLUID
TYPE SHELL DONAX TD UNIVERSAL TRACTOR HYDRAULIC FLUID, WET
DISKS AND HYDRAULIC SYSTEMS
DIFFERENTIAL FLUID
TYPE 80W90 GEAR LUBE CENTER SECTION ONLY ON WET DISK BRAKE
SYSTEM. ON SYSTEM WITHOUT WET BRAKES USE ON BOTH AXLE
PLANETARY WHEEL END AND CENTER SECTION.
5.7 L GM ENGINE
TYPE 10W30
CAPACITY 5QT W/OIL FILTER
5.9 L DIESEL CUMMINS

TYPE 15W 40 CAPACITY 15QT (14.2 LITERS)
ENGINE COOLANT Use a 50% soft water coolant mixture Note: Do not use more
than 50% Antifreeze above –37C (-35F) NEVER: Use more than 68% Antifreeze under
any condition.
CHASSIS
TYPE LITHOPLEX RT2 GREASE
MAST
STEER AXLE
P SERIES DRIVE AXLE LUBE POINTS WET BRAKE
Brake Bleeder
Drive Shaft U-Joint

Fittings Drive and
Motor Ends
Note the drive axle shown is

only use for reference
NOTE: See Planetary Axle Wheel Ends Maintenance

Manual. Before servicing the drive axle. Incorrect fluids
will result in severe damage.
Center Section
P SERIES STEER AXLE LUBE POINTS
It is recommended that the moving parts of the steer axle be lubed with a good quality
grease “LITHOPLEX RT2” every 250hrs
Upper King Pin

Fittings
Steer Cylinder Pins

Fittings
Lower King Pin

Fittings
Steer Axle Hub Fittings
Steer Axle Pivot Fittings “shown without

the counterweight” both lube fittings can
be accessed with a grease gun.
Mast Lube Points

P Series Service

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HOIST LIFTRUCK MFG., INC.

6499 W 65TH STREET

Hoist Liftruck, Mfg., Inc.

Tire and Safety

Provisions for Maintenance

Powered industrial trucks may become hazardous if maintenance is neglected or repairs,

Maintenance and inspection of all powered industrial trucks shall be performed in

1. A scheduled planned maintenance, lubrication and inspection system shall be

The following “precautions” should be followed when working on a forklift.

CAUTION DO NOT STEAM-CLEAN

CAUTION CHECK BATTERY POLARITY

CAUTION USE TRUCK BATTERY ONLY

Chassis 2. Put the mast in a vertical position. Put a block

WARNING 5. If the hydraulic system will not operate, use a

NOTE: Some lift trucks have lifting eyes. These

a. Brakes do not operate correctly.

lift truck. Install approximately

2. If another lift truck is used to tow

3. truck must have an equal or

1) Water temperature gauge – Indicates water temperature of engine

1) F1 function key – Use to view adjustment menu

1) Measure parameter – Listed are all parameters and there value/state

1) F1 Function key – Use to go to display menu

1) F1 Function key – Use to go to menu display page

1) F1 Function key – Use to select date setting

1) F1 Function key – Use to go to menu display page

1) F1 Function key – Use to go to modules menu display page

1) F1 Function key – Use to go to the menu display page

Date: October 4, 2004

MOUNTING PROCEDURE FOR PRESS-ON TIRES

1) Lubricate inside diameter of tire to be pressed with Tectyl 506

Lubricate the inside

Look for curl metal in

from the volt meter to

Shown is the steer axle without the

Hydraulic Lines Remove the steering hydraulic hoses from

Place a hydraulic jack under the steer axle

Remove the steering hydraulic hoses,

With a flat blade screw driver remove the

M20 Hex Head Bolts. Torque

Wheel Bearing Cones

2nd Lock Nut

• Remove the six 3/8-16 SHCS from the cover.

M10 Lock Washer Grease Seal

The bearings and grease seals now can be replaced.

WARNING! ALWAYS USE A CLEAN APPROVED LABELED CONTAINER TO

Wet Disc Brake

W3H (360 mm)

Before You Begin Access Information on

T The torque symbol alerts

NOTE: A Note provides

! Asbestos and Non-Asbestos Fibers Warnings.................................................................................1

Section 1: Exploded View

Section 4: Inspection ...................................................................................................................................16

Section 5: Prepare Parts for Assembly

Asbestos and Non-Asbestos Fibers

! ASBESTOS FIBER WARNING ! NON-ASBESTOS FIBERS WARNING

Hazard Summary Hazard Summary

W3H – 360mm Wet Disc Brake with Dowel Pins 23

ITEM DESCRIPTION ITEM DESCRIPTION

Wheel End with Outer Bearing

ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION

Wheel End with Outer

ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION