Meritor MM-96147 User manual

Copyright Meritor, Inc., 2021
MM-96147 / Revised 03-21
Page 1
(16579)
Printed in USA
DRIVELINE MAINTENANCE MANUA
L
MAINTENANCE MANUAL MM-96147

Copyright Meritor, Inc., 2021
MM-96147 / Revised 03-21
Page 2
(16579)
Printed in USA
Service Notes
Service Notes
About this Manual
This manual provides maintenance and service procedures for
Meritor RPL Series Permalube™, Wing-Style Permalube™,
Full-Round, Easy Service™, Wing-Style and 155R Series drivelines.
How to Obtain Additional Maintenance,
Service and Product Information
Visit Literature on Demand on meritor.com to access and order
additional information.
Contact the Meritor OnTrac™ Customer Service Center at
866-668-7221 (US and Canada) between 7:30 AM and 10:00 PM
ET Monday through Friday, and between 9:00 AM and 6:00 PM ET
on Saturday; 001-800-889-1834 (Mexico); or visit our website:
www.meritor.com/warranty#OnTracSC.
If Tools and Supplies are Specified in
This Manual
Contact Meritor’s Commercial Vehicle Aftermarket at
888-725-9355.
For assistance with parts, you may also contact the Meritor Parts
Center in Florence, KY at 859-525-3500 or
[e-mail].

Copyright Meritor, Inc., 2021
MM-96147 / Revised 03-21
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Table of Contents
Table of Contents
Section 1: Safety Information ..............................................5
Before You Begin Service Procedures ................................... 5
Hazard Alert Messages and Symbols.................................... 5
Section 2: Driveline .............................................................. 6
Standard Driveline............................................................... 6
Two- and Three-Piece Driveline............................................7
Section 3: Introduction......................................................... 9
Description ......................................................................... 9
Section 4: Inspection.......................................................... 11
Driveline........................................................................... 11
End Yokes or Flanges ........................................................11
Universal Joints ................................................................ 12
Center Bearings................................................................ 13
Slip Yoke .......................................................................... 14
Permalube™ Drivelines .................................................... 15
Section 5: RPL Series Permalube ...................................... 18
RPL10 and RPL14 Series Permalube Procedures................ 18
Removal ........................................................................... 18
Disassembly ..................................................................... 19
Assembly ......................................................................... 20
Installation........................................................................ 21
RPL20, RPL25 and RPL25SD Series Permalube Procedures 23
Removal ........................................................................... 24
Disassembly ..................................................................... 26
Assembly ......................................................................... 27
Installation........................................................................ 29
RPL35 and RPL35SD Series Permalube Procedures............ 33
Removal ........................................................................... 34
Assembly ......................................................................... 37
Installation........................................................................ 39
Section 6: Full-Round.........................................................43
Removal ........................................................................... 43
Disassembly ..................................................................... 43
Installation........................................................................ 44
Lubrication ....................................................................... 46
Section 7: Wing-Style Permalube...................................... 48
Removal ........................................................................... 48
Installation........................................................................ 48
Lubrication ....................................................................... 49
Section 8: Easy Service...................................................... 50
Removal ........................................................................... 50
Disassembly ..................................................................... 50
Assembly ......................................................................... 51
Installation........................................................................ 52
Lubrication ....................................................................... 53
Section 9: 155R Series Slip Drive Shaft Assembly............54
Removal ........................................................................... 54
Disassembly ..................................................................... 55
Assembly ......................................................................... 55
Installation........................................................................ 57
Lubrication ....................................................................... 59
Section 10: Center Bearing Removal and Installation ...... 60
Center Bearings on Meritor Drivelines................................. 60
Removal ........................................................................... 61
Disassembly ..................................................................... 61
Installation........................................................................ 64
Coupling Shaft .................................................................. 64
Section 11: Lubrication ...................................................... 66
Maintenance..................................................................... 66
Driveline Inspection ........................................................... 66
Section 12: Torque Specifications ..................................... 69
Section 13: Troubleshooting ..............................................70
Special Tools..................................................................... 70
Troubleshooting ................................................................ 70
Section 14: Meauring and Recording Driveline Angles ....76
Special Tools..................................................................... 76
Overview .......................................................................... 76
Data Gathering Worksheet ................................................. 76
Measure........................................................................... 79
Adjustment....................................................................... 82
Driveline Angle Analysis Program .......................................83
Measuring and Recording Driveline Angles: Plan View ......... 85
Section 15: Driveline Balance Weight................................88
Section 16: Special Tools ................................................... 89
Section 17: Glossary .......................................................... 95
Section 18: Appendix ........................................................ 96

Copyright Meritor, Inc., 2021
MM-96147 / Revised 03-21
Page 4
(16579)
Printed in USA

Copyright Meritor, Inc., 2021
MM-96147 / Revised 03-21
Page 5
(16579)
Printed in USA
1 Safety Information
Safety Information
Before You Begin Service Procedures
1. Read and understand all instructions and procedures before
beginning to service components.
2. Read and observe all hazard alert messages in this
publication.
3. Follow your company’s maintenance and service, installation,
and diagnostics guidelines.
4. Use special tools when required to help avoid serious personal
injury and damage to components.
Hazard Alert Messages
Read and observe all hazard alert messages in this publication.
DANGER
Indicates imminent danger. Failure to follow this instruction will
result in death or serious injury.
WARNING
Indicates a possibly impending danger. Failure to follow this
instruction can result in death or serious injury.
CAUTION
Indicates a hazardous situation or unsafe practice which, if not
avoided, could result in injury or damage to components.

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MM-96147 / Revised 03-21
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2 Drivelines
Driveline
Standard Driveline
The typical driveline system is shown in Figure 2.1. On a standard slip shaft assembly, the splined shaft points forward in the vehicle. For a
typical interaxle driveline, refer to Figure 2.3.
TRANSMISSION
TYPICAL DRIVELINE SYSTEM
NOTE: Series shown are for illustration only.
NON-SLIP
COUPLING
SHAFT
ASSEMBLY
STANDARD
SLIP ASSEMBLY
WELD
YOKE
TUBINGSPLINE
PLUG
SEAL
WITH
SHROUD
SLIP
YOKE
SPLINED
YOKE
CENTER
BEARING
KIT
BEARING
STUB
TUBINGWELD
YOKE
END YOKE
OUTPUT
4003529a
WELCH PLUG
Fig. 2.1

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2 Drivelines
Two- and Three-Piece Driveline
A two- or three-piece driveline is comprised of one or two non-slip coupling shafts followed by a standard slip drive shaft assembly. The non-slip
coupling shafts are always positioned in front of the slip shaft. Figure 2.2.
TRANSMISSION
TYPICAL THREE-SHAFT STANDARD SLIP
STANDARD
SLIP ASSEMBLY
WELD
YOKE
TUBINGSPLINE
PLUG
SEAL
WITH
SHROUD
SLIP
YOKE
SPLINED
YOKE
CENTER
BEARING
KIT
BEARING
STUB
TUBING
WELD
YOKE
END YOKE
OUTPUT
4004043a
WELCH PLUG
NON-SLIP
COUPLING
SHAFT
ASSEMBLIES
Fig. 2.2

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2 Drivelines
4003528a
SHAFT
YOKE
END YOKE
OUTPUT
BEARING
CUPS
TRUNNION
BEARING
CROSS
END YOKE
OUTPUT
END YOKE
OUTPUT REAR
AXLE
FRONT
AXLE SEAL
SLIP
YOKE
SHORT COUPLED
SLIP ASSEMBLY
UNIVERSAL JOINT COMPONENTS
TYPICAL INTERAXLE SYSTEM
NOTE: Series shown are for illustration only.
Fig. 2.3

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3 Introduction
Introduction
Description
RPL Series Permalube™ (Non-Greaseable)
The Meritor RPL Series Permalube non-greaseable driveline is
permanently lubricated and sealed at the factory and does not
require lubricant. RPL10 and RPL14 series drivelines are similar
to the 155R series driveline except they do not require lubrication.
Figure 3.1. RPL20, RPL25 and RPL25SD series drivelines have
arrows on the wing bushings help you to correctly install the
universal joint. Figure 3.2. RPL35 and RPL35SD series drivelines
are the same as RPL20, RPL25 and RPL25SD series drivelines
except they are larger and have coupling flanges instead of yokes.
Figure 3.3.
4018229a
RPL10 AND RPL14
PERMALUBE
Fig. 3.1
RPL20, RPL25 AND RPL25SD
PERMALUBE 4018227a
Fig. 3.2
4018228a
RPL35 AND RPL35SD
PERMALUBE
Fig. 3.3
Wing-Style Permalube™
The Meritor Wing-Style Permalube driveline requires lubrication of
the slip yoke splines only. Figure 3.4.
WING-STYLE PERMALUBE
4001790a
Fig. 3.4
Full-Round, Easy Service™, Wing-Style and 155R
Series (Greaseable)
Full-Round, Easy Service, Wing-Style and 155R greaseable
drivelines require periodic lubrication of the universal joints and slip
yoke splines. Figure 3.5, Figure 3.6, Figure 3.7 and Figure 3.8.
FULL-ROUND 4001788a
Fig. 3.5

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3 Introduction
EASY SERVICE (1/2 ROUND) 4001789a
Fig. 3.6
WING-STYLE
4003527a
Fig. 3.7
4001789b
155R SERIES
Fig. 3.8

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MM-96147 / Revised 03-21
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4 Inspection
Inspection
Hazard Alert Messages
Read and observe all hazard alert messages in this publication.
DANGER
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Support the vehicle with safety stands.
NEVER work under a vehicle supported only by jacks. Jacks can
slip and fall over. Failure to use a jack stand can result in serious
personal injury and damage to components.
DANGER
Check end yoke retaining nuts and bolts for looseness. Tighten
loose fasteners to specification. Check the input and output shaft
splines for wear and damage. Replace worn or damaged splines.
Check for loose, missing or damaged driveline fasteners and
parts. Tighten loose fasteners, and replace damaged and missing
parts. Loose, damaged or missing parts can cause the driveline
to separate from the vehicle. Serious personal injury and damage
to components can result.
DANGER
Only service a driveline when the engine is OFF. A rotating
driveline can cause serious personal injury.
WARNING
To prevent eye injury, always wear eye protection when
performing vehicle maintenance or service.
Driveline
1. Park the vehicle on a level surface. Block the wheels to keep
the vehicle from moving. Raise the vehicle so that the area
you will service is off the ground.
2. Inspect the driveline at regular intervals. Loose end yokes,
excessive radial movement, slip spline radial movement, bent
driveline tubing or missing plugs in the slip yoke can damage
universal joints and bearings.
3. Check the output and input end yokes on both the
transmission and axle for axial looseness. Refer to the axle or
transmission manufacturer’s service instructions.
• If the output and input end yokes or flanges are
loose: Disconnect the driveline. Tighten the retaining nut to
the correct specification. Refer to the axle or transmission
manufacturer’s service instructions.
4. Inspect for worn universal joints. Apply vertical force of about
50 pounds (22.7 kg) to the driveline near the universal joints.
• If movement is greater than 0.006-inch (0.152 mm):
Replace the universal joint.
5. Inspect the slip section to ensure the welch plug and dust seal
(under the shroud) are in the correct position.
6. Inspect the driveline for damaged or bent tubing. Carefully
remove contaminants, such as mud and road debris.
End Yokes or Flanges
Perform the following procedures before you lubricate universal
joints or slip yokes. If you lubricate these components before you
inspect them, lubricant can conceal wear, damage and looseness.
1. Inspect all input and output end yokes or flanges for gaps
between mating surfaces.
• If gaps are present: Refer to the transmission, axle or
transfer case manufacturer’s service instructions.
2. Use the following procedure to check all input and output end
yokes or flanges for looseness.
a. Hold the end yoke or flange with both hands.
b. Move the end yoke UP-AND-DOWN and SIDE-TO-SIDE.
There shouldn’t be any movement where the yoke or flange
connects to the input and output shafts. Figure 4.1 and
Figure 4.2.
4001796a
Fig. 4.1 Yoke-Style Driveline

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4 Inspection
4011842a
Fig. 4.2 Flange-Style Driveline
• If the input and output end yokes or flanges are
loose: Disconnect the driveline. Tighten the retaining
nut or bolt to the correct specification. Refer to the axle
or transmission manufacturer for correct inspection and
replacement procedures.
• If the input and output end yokes or flanges are not
loose, check that the transmission output shaft and
axle input shaft splines aren’t loose at the end yoke
or flange: Hold the yoke or flange with one hand and
rotate it LEFT-TO-RIGHT while you check end play for radial
looseness. Figure 4.1 and Figure 4.2.
• If you find excessive radial looseness: Replace the end
yoke or flange, or input or output shafts, as necessary.
3. Inspect for worn, damaged, missing and loose parts. Replace
as required. Refer to the appropriate sections in this manual
for these procedures.
DANGER
Use a fine-tooth file or an emery cloth to remove raised metal
or fretting from yoke or flange cross hole surfaces. Take care
not to remove an excessive amount of metal. These conditions
can damage the cross and bearing and cause the driveline to
separate from the vehicle. Serious personal injury and damage to
components can result.
4. Inspect all end yoke or flange cross hole surfaces and bolt
hole threads for damage. Remove raised metal or fretting with
a fine-tooth file or emery cloth. Figure 4.3.
• If bolt hole threads are damaged: Replace the yoke or
flange.
4001838a
Fig. 4.3
Universal Joints
DANGER
Excessive looseness across the ends of the universal joint
bearing cup assemblies can cause imbalance or vibration in the
driveline assembly. Imbalance or vibration can cause component
wear, which can result in separation of the driveline from the
vehicle. Serious personal injury and damage to components can
result.
Use the following procedure to check for looseness across the ends
of the universal joint bearing cup assemblies and trunnions.
1. Hold the INBOARD yoke or flange on the driveline with both
hands.
2. Try to move the yoke or flange UP-AND-DOWN and SIDE-TO-
SIDE by applying at least 50 pounds (22.7 kg) of force to the
driveline near the universal joints. Figure 4.4 and Figure 4.5.
• If movement is greater than 0.006-inch (0.152 mm):
Replace the universal joint.
4001794a
Fig. 4.4 Yoke-Style Driveline

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4 Inspection
4011839a
Fig. 4.5 Flange-Style Driveline
Greaseable Universal Joints
1. Check that all grease fittings are installed. Replace missing
or damaged fittings. Tighten them to 6 lb-ft (8 Nm).
Figure 4.6.
2. Check for loose grease fittings. Tighten them to 6 lb-ft (8 Nm).
4001802a
Fig. 4.6
Center Bearings
1. Inspect all center bearing and end yoke or flange midship
nuts for gaps or looseness between the mating surfaces.
Figure 4.7 and Figure 4.8.
• If you can see gaps between the mating surfaces:
Disconnect the driveline. Tighten the coupling yoke or
flange retaining nut to 450-600 lb-ft (612-816 Nm).
4001797a
Fig. 4.7 Yoke-Style Driveline
4011831a
GAP
NUT
Fig. 4.8 Flange-Style Driveline
2. Inspect the center bearing bracket bolts for looseness.
Figure 4.9 and Figure 4.10.
• If the bolts are loose: Verify that the bracket is aligned
correctly before you tighten the bolts. Tighten the center
bearing bracket bolts. Refer to the vehicle manufacturer’s
procedures for the correct torque specification.
4001880a
Fig. 4.9 Yoke-Style Driveline
4011838a
Fig. 4.10 Flange-Style Driveline
3. Inspect the center bearing rubber cushion for damage. If
equipped, check that the deflectors are not rubbing against
the rubber cushion. Verify that the rubber cushion is correctly
seated in the metal bracket.
• If any of these conditions are evident: Replace the
center bearing assembly.

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4 Inspection
Self-Aligning Center Bearings
A self-aligning center bearing accepts ± five degrees of angular
misalignment. This helps to ensure that the hanger bearing is
correctly aligned to the driveline under all operating conditions.
Use the same service procedures for a self-aligning center bearing
as for a standard center bearing. You can identify a self-aligning
center bearing by the bright gold color of the integral deflector.
Deflectors are integral to a self-aligning center bearing, so separate
deflectors are not required.
Most vehicles are equipped with self-aligning center bearings.
Figure 4.11.
• If you replace a self-aligning center bearing: You must
install a new self-aligning center bearing.
CENTER
BEARING
4001915a
Fig. 4.11
Slip Yoke
Check the dust seal to make sure it is in place on the slip yoke.
Inspect for excessive wear on the rubber lip of the seal. If there is
excessive movement and vibration of the slip yoke assembly, refer
to Section 14 for the troubleshooting procedures.

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4 Inspection
Permalube™ Drivelines
Inspection and Maintenance
Table A: RPL Series Permalube and Wing-Style Permalube Driveline Inspection Intervals and Procedures
Mileage Intervals Procedures
At initial inspection, or no more than
2,000 miles (3,200 km)
Verify that all bolts are tightened as follows.
• Universal joint-to-end yoke bolts to 115-135 lb-ft (155-183 Nm)
• Flange-to-flange bolts to 133-163 lb-ft (180-220 Nm)
Every 25,000 miles (40,000 km) If you observe any of the following conditions, remove and replace components as needed.
1. Inspect all universal joints for grease purging.
• If a universal joint shows normal grease purging: Do not replace the universal joint.
2. Check for excessive looseness across the ends of the universal joint bearing cup assemblies and
trunnions.
• Grip driveline near the INBOARD yoke with both hands.
• Try to move the yoke VERTICALLY and HORIZONTALLY. Movement in the universal joint
relative to the INBOARD or OUTBOARD yokes must not exceed 0.006-inch (0.152 mm).
Figure 4.4.
3. Inspect the slip yoke spline seal for grease leakage or seal damage.
4. Inspect for missing balance weights, damaged tubing, or a missing welch plug at the slip yoke.
Every 150,000 miles (240,000 km) In addition to the 25,000-mile (40,000 km) requirements:
Use the following steps to inspect the slip splines for wear (backlash) and for radial looseness between
the slip yoke and the tube shaft.
1. Ensure that the vehicle is on a level surface with its wheels on the ground. For single driveline
systems, check the slip yoke for movement with the driveline installed. For multiple driveline
systems, remove the slip yoke assembly from the vehicle and check for movement.
2. Firmly mount a dial indicator with a magnetic base onto the slip yoke barrel next to the dust
seal. Figure 4.12. You do not want the dial indicator to move when you check the slip yoke for
looseness, or the measurement will not be correct.
3. Extend the dial indicator arm from the base, so that it contacts the neck of the spline plug within
3/4-inch (19.05 mm) from the dust seal. Figure 4.12.
4. With your hands near the center of the driveline, move the slip yoke UP-AND-DOWN. Check the
dial indicator measurement. Movement between the spline plug and slip yoke must not exceed
0.017-inch (0.432 mm). Figure 4.13.
• If movement exceeds 0.017-inch (0.432 mm): Components are worn or damaged. Replace
as required.
5. Use a dial indicator to examine the slip yoke spline for excessive radial movement. Radial
movement betweenthe slip yoke and the tube shaft must not exceed 0.017-inch (0.432 mm).
• If the radial movement exceeds 0.017-inch (0.432 mm): Replace the slip yoke and the
tube shaft.

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4 Inspection
NECK OF
SPLINE PLUG
The base of the
dial indicator must
be next to the dust
seal, as shown.
DUST
SEAL
SLIP YOKE
BARREL
3/4"
(19.05 MM)
MAXIMUM
4001871a
Fig. 4.12
4011840a
Fig. 4.13
Check Universal Joint Capscrews
DANGER
Inspect RPL Series Permalube and Wing-Style Permalube
drivelines for loose or missing capscrews and lock washers.
Loose or missing fasteners can allow the driveline to separate
from the vehicle. Serious personal injury and damage to
components can result. If fasteners are loose or missing:
• RPL Series Permalube drivelines: Install new capscrews with
Dri-Loc patches.
• Wing-Style Permalube drivelines: Install new capscrews with
Dri-Loc patches and secure the capscrews with lock washers.
Meritor recommends that you inspect RPL Series Permalube
bearing cup capscrews and wing-style capscrews and lock
washers at initial inspection, or no more than 2,000 miles
(3200 km).
On RPL Series Permalube Drivelines
1. Check that capscrews are installed on all universal joint
positions. RPL Series Permalube capscrews and Wing-Style
Permalube capscrews are not interchangeable.
• If capscrews are missing: Check for damage to the
universal joint and yoke. Replace damaged parts and
missing capscrews.
• If capscrews are loose: Remove and discard loose
capscrews. Replace them with new capscrews.
2. Use a torque wrench to verify that capscrews are tightened as
follows.
• Universal joint-to-end yoke capscrews to 115-135 lb-ft
(155-183 Nm).
• Flange-to-flange capscrews to 133-163 lb-ft
(180-220 Nm).
On Wing-Style Permalube Drivelines
1. Check that both capscrews and lock washers are installed
on all universal joint positions. RPL Series Permalube
capscrews and Wing-Style Permalube capscrews are not
interchangeable.
• If capscrews and lock washers are missing: Check for
damage to the universal joint and yoke. Replace damaged
parts, capscrews and lock washers. Refer to Section 8.
• If capscrews are loose: Remove and discard loose
capscrews. Replace them with new capscrews and lock
washers.
2. Use a torque wrench to verify that capscrews are tightened to
the correct specification. Refer to Section 13.
Check End Play
Check the universal joint for end play. Apply force in an UP-AND-
DOWN and SIDE-TO-SIDE motion. Figure 4.14 and Figure 4.15.
There should be less than 0.006-inch (0.152 mm) BACK-AND-
FORTH motion of the universal joint. Figure 4.16 and Figure 4.17.
• If movement is greater than 0.006-inch (0.152 mm):
Replace the universal joint.
4001803a
Fig. 4.14 Yoke-Style Driveline

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4 Inspection
4011832a
Fig. 4.15 Flange-Style Driveline
4001806a
Fig. 4.16 Yoke-Style Driveline
4011832b
Fig. 4.17 Flange-Style Driveline

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5 RPL Series Permalube
RPL Series Permalube
Hazard Alert Messages
Read and observe all hazard alert messages in this publication.
RPL10 and RPL14 Series Permalube
Procedures
The following procedures are for RPL10 and RPL14 series
Permalube drivelines. For RPL20, RPL25, RPL25SD, RPL35 and
RPL35SD series Permalube drivelines, refer to the procedures later
in this section.
DANGER
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Support the vehicle with safety stands.
NEVER work under a vehicle supported only by jacks. Jacks can
slip and fall over. Failure to use a jack stand can result in serious
personal injury and damage to components.
DANGER
Only service a driveline when the engine is OFF. A rotating
driveline can cause serious personal injury.
WARNING
To prevent eye injury, always wear eye protection when
performing vehicle maintenance or service.
WARNING
Use a brass or synthetic mallet for assembly and disassembly
procedures. NEVER hit steel parts with a steel hammer. Pieces
of a part can break off. Serious personal injury and damage to
components can result.
WARNING
Only install the correct grade new bearing retainer bolts and
stamped strap bolts. Do not reuse these parts. If the bearing
retainer straps are damaged, install new retainers. Damaged and
reused parts can affect driveline operation, which can cause the
driveline to separate from the vehicle. Serious personal injury
and damage to components can result.
WARNING
A driveline assembly can weigh more than 100 pounds
(46 kilograms). Always use lifting devices and the correct
procedures when you handle drivelines to prevent serious
personal injury and damage to components.
Removal
Driveline
1. Park the vehicle on a level surface. Block the wheels to keep
the vehicle from moving. Raise the vehicle so that the area
you will service is off the ground. Support the vehicle with
safety stands.
2. Loosen and remove the capscrews and bearing straps from
the weld yoke end of the driveline. Support the weld yoke end
and separate it from the end yoke.
3. Loosen and remove the capscrews and bearing straps from
the slip yoke end of the driveline. Support the slip yoke end
and separate it from the vehicle.
Universal Joint
Snap Ring Removal
NOTE: Refer to the Service Notes page on the front inside cover of
this manual for information on how to obtain tools.
1. Use snap ring pliers to remove the snap rings. Figure 5.1.
SNAP RING PLIERS
Fig. 5.1
2. If necessary, use a brass drift and lightly tap the center of the
bushing to assist in snap ring removal. Figure 5.2.

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5 RPL Series Permalube
Fig. 5.2
3. Repeat the previous steps on the other side of the yoke.
Round Bushing Removal Using Press, Bridge and
Bearing Cup Receiver
NOTE: Use only the appropriate tools to remove the round
bushings. Do not use the SPX Kent-Moore yoke bearing cup
installation tool (number J-44516) to remove the round bushings.
Damage to the tool can result.
Use the following procedure to remove and install round bushings.
DANGER
Observe all warnings and cautions provided by the press
manufacturer to avoid damage to components and serious
personal injury.
1. Place the universal joint in a suitable press bridge and bearing
cup bushing receiver. Figure 5.3.
4001812c
PRESS
BEARING CUP
BUSHING
RECEIVER
BRIDGE
Fig. 5.3
2. Press DOWN until the first round bushing loosens. Figure 5.3.
Remove the round bushing. Figure 5.4.
Fig. 5.4
3. Rotate the shaft 180 degrees. Repeat the procedure for the
opposite side of the universal joint. Figure 5.5.
Fig. 5.5
4. Remove the universal joint from the yoke.
Disassembly
Standard Slip Configuration
1. Use a brass or copper hammer and a drift to tap the shroud
off the slip seal.
2. Use a screwdriver to pry the seal out of the groove in the slip
yoke.
3. Mark the slip yoke and slip shaft sections to ensure that you
reassemble them into their original positions. Figure 5.6.
Fig. 5.6

Copyright Meritor, Inc., 2021
MM-96147 / Revised 03-21
Page 20
(16579)
Printed in USA
5 RPL Series Permalube
4. Pull the slip yoke and slip shaft sections apart. Figure 5.7.
Fig. 5.7
5. Remove the seal and shroud from the slip shaft. Figure 5.8
and Figure 5.9.
4001823c
SEAL
Fig. 5.8
4001824a
SHROUD
Fig. 5.9
Assembly
Standard Slip Configuration
1. Remove the grease fittings from the slip yoke before you
assemble the slip yoke and spline shaft sections.
2. Use the grease packet supplied with the slip yoke to apply the
entire amount of grease into the slip yoke. Figure 5.10.
4003525a
Fig. 5.10
3. Use a brush to distribute lubricant on the splines. Figure 5.11.
4003524a
Fig. 5.11
4. Intall the new shroud onto the spline shaft. Figure 5.12.
4001824a
SHROUD
Fig. 5.12