Meritor RS 120 User manual

SINGLE REDUCTION AXLE
RS 120 - Rear Axle (NGIT)
FIELD MAINTENANCE MANUAL
_________________________________________
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Meritor HVS (India) Limited,
Plot No: 36, Hootagalli Industrial Area,
Off Hunsur Road, Mysore-570 018
Ph: [phone] Fax: [phone]
Phone: [phone] fascimile:[phone]

Section 1
Introduction
3

Section 2
Disassembly
I.
REMOVAL OF DIFFERENTIAL CARRIER FROM AXLE HOUSING:
1. Raise the rear end of the vehicle
put on jack stands Figure1.
Jack Stands
Figure 1
2. Disconnect the propeller
Shaft from input flange. Figure 2.
remove drain plug and drain
differential oil.
Disconnect the vehicle
air line from the differential
lock actuator assy.
Figure 2
4

Section 2
Disassembly
3. Use tool (A) to stop rotation of
wheel end assembly and undo screws
(B) fastening axle drive shaft to wheel
hub. Figure 3.
Figure 3
Remove axle shafts
using extraction holes.
Remove all the carrier
mounting fasteners.
Differential
Carrier
Remove the carrier from
the housing.
Mount the carrier on a
repair stand Figure 4.
Driving lugs
Repair
Stand
Figure 4
5

Section 2
Disassembly
II DISASSEMBLY OF DIFFERENTIAL
If the same gear set is to be
reused record the backlash
before disassembly. Figure 5.
Figure 5
Bearing Cap
Carrier Leg
1. Make match marks on one
Carrier leg and bearing cap.
Figure 6
Match Marks
Figure 6
6

Section 2
Disassembly
3. Remove cotter pin using a small
drift and hammer. Figure 7.
Removing
Cotter Key
Figure 7
Remove cap screw, washers and
lock plate. Figure 8.
Figure 8
7

Section 2
Disassembly
4. Remove cap screws and washers of
bearing caps. Figure 9.
• Remove bearing adjusting
rings
Bearing
Cap
Figure 9
Figure 10
5. Lift the differential case
& ring gear assembly Figure 10.
8

Section 2
Disassembly
6. Make match marks on the
diff. case halves. Figure 11.
Match Marks
Match Marks
Figure 11
7. Remove the diff. case bolts.
separate case halves. Remove
spider, pinions, side gears and
thrust washers. Figure 12.
Trust
Washer
Side
Gear
Figure 12
9

Section 2
Disassembly
8. Remove the ring gear
bolts and nuts.
Case Half
• Remove the ring gear from
diff.case using a press
Figure 13.
Press
Plate
Figure 13
Puller
9. Remove the bearings from
diff. cases using bearing
puller/press Figure 14.
Press
Figure 14
10. Fasten a flange bar to the
companion flange
• Remove pinion nut and
washer Figure 15.
Figure 15
Flange
Bar
10

Section 2
Disassembly
11.
Remove the companion flange
using a suitable puller, Figure 16.
• Remove cap screws and
washers of bearing Cage,
SHIMS
DRIVE PINION AND
BEARING CAGE
• Remove bearing Cage and
shims
• Measure and note down
the total thickness of
removed shims.
Figure 16
Drive Pinion
Press
Oil Seal
Bearing.
Cage
Support
Support
12. Remove drive pinion from
bearing Cage
using a press. Figure 17.
Figure 17
11

Section 2
Disassembly
13. Remove the oil seal. figure18
• Take out the outer bearing
cone.
• Remove the bearing cups from
the cage using a small drift and
hammer.
Pinion
Bearing cage
Figure 18
Drive Pinion
Inner Bearing
Cone
14. Remove the inner bearing cone
using the split puller and
press.Figure 19.
Bearing
Support
Figure 19
Bearing Puller
15. Remove the snap ring .
• Remove the spigot bearing
using the puller Figure 20.
Figure 20
12

Section 3
General Information
Use of Dri-Loc Fasteners and
Meritor Liquid Adhesive 2297-
C-3747 or Loctite 277
Install New Dri-Loc Fasteners:
1. Clean the oil and dirt from threaded
holes. There is no special cleaning
required.
2. Assemble parts using the new Dri-
Loc fasteners.
! CAUTION:
Do not apply adhesives or sealants on
new Dri-Loc fasteners or in the
threaded holes. If other adhesives or
sealants are used, the new Dri-Loc
adhesive will not function correctly.
Tighten the Dri-Loc fasteners to the
required torque value for that size
fastener. There is no special procedure
or torque value required. See the torque
chart T
NOTE:
There is no drying time required for
Dri-Loc fasteners.
Install Old Dri-Loc Fasteners Using
Meritor Liquid Adhesive 2297-C-
3747 or Loctite 277:
Figure 21
1. Clean the oil and dirt from threaded
holes. There is no special cleaning
required and it is not necessary to
remove the old Dri-Loc adhesive
from the threads.
2. Apply four or five drops of Meritor
Liquid Adhesive or Loctite 277 to the
threaded holes ONLY. Make sure the
adhesive is on the threads. Figure21.
! CAUTION:
Do not apply adhesive to the fastener
threads. Air pressure in the hole will
push the adhesive out as the fastener
is installed.
3. Tighten the fasteners to the required
torque value for that size fastener.
There is no special procedure or
torque value required. See the
torque chart T
13

Section 3
General Information
NOTE:
There is no drying time required for
Meritor Liquid Adhesive 2297-C-
3747 or Loctite 277.
fastener or hit the fastener with a
hammer.
2. Repeat Step 1 until the fastener can
be removed.
Check Torque Values of Dri-Loc
Fasteners Not Requiring
Removal:
!CAUTION:
Do not exceed 350° F. (+1770 C.)
maximum. Heating must be done
slowly to prevent thermal stresses in
the other components.
!CAUTION:
If Dri-Loc fasteners do not require
removal from the component, check
the component for correct torque
value as follows:
1. Apply the MINIMUM amount of
torque required for that size
fastener. See the torque chart The
fastener MUST NOT rotate. T
2. If the fastener rotates any amount,
remove the fastener from the
component and apply adhesive to
the threaded hole. Follow the
procedure for installing old Dri-Loc
fasteners.
Application of Silicone Gasket
Material
NOTE:
The following silicone gasket
products can be used on Meritor
components.
1. General Electric No. RTV-1473 black.
2. From Meritor Automotive, Inc.:
0.4 kg tube Part No. 1199-Q-2981
Remove Dri-Loc Fasteners:
If it is difficult to remove Dri-Loc
Fasteners from components, the
Strength of Dri-Loc, Meritor adhesive or
Loctite 277 can be decreased by heating.
Use the following procedure:
1. Heat the fastener for three to five
seconds ONLY and try to loosen the
fastener with a wrench.DO NOT
use an impact wrench to loosen the
!WARNING:
Small amounts of acid vapor are
Present when silicone gasket
material is applied. To prevent
possible Injury, be sure there is good
ventilation In the work area. If
silicone gasket material gets in your
eyes, flush your eyes for 15 minutes
with water. Have your eyes checked
by a doctor.
14

Section 3
General Information
1.
2.
Remove all old gasket material
from both surfaces.
Clean the surfaces where silicone
gasket material will be applied.
Remove all oil, grease, dirt and
moisture.
Dry both surfaces.
Apply a 0.125 inch diameter
continuous bead of the silicone
gasket material around one
surface. Also apply the gasket
material around the edge of all
fastener holes in that surface.
Figure 22.
!CAUTION:
The amount of silicone gasket
material applied must not exceed
a.125 Inch diameter bead. Too much
gasket material can block lubrication
passages.
5. Assemble the components
immediately to permit the silicone
gasket material to compress evenly
between the parts. Tighten fasteners
to the required torque value for that
size fastener. There is no special
procedure or torque value required
See Torque Chart .
6. Wait 20 minutes before the
assembly is filled with lubricant.
3.
4.
Figure 22
0.125” (3.2 mm)
DIA. Silicon bead
gasket
Gear Set Information (Drive
Pinion and Ring Gear Marks)
Figure 23
PI=Q=3, 4
1, 2, 3
1,2
1, 2, 3, 4 Option
NI=OI=PI=Q=léíáçå=
1. PART NUMBER3. GEARSET
2. TOOTH COMBINATIONMATCHING
NUMBERNUMBER
4. PINION CONE
VARIATION
NUMBER
15

Section 3
General Information
NOTE:
Before a new gear set is installed in
the carrier, read the following
Information. ALWAYS CHECK THE
GEAR SET FOR CORRECT MARKS TO
MAKE SURE THE GEARS ARE A
MATCHED SET.
The location of the marks are shown in
Figure 23.
1.
A.
Part Number:
Examples of gear set part
numbers: Ring gear –A–2–
C0138 pinion –A–C0138.
Location on Drive Pinion: End
at splines.
Location on Ring Gear: Front
face or outer diameter.
NOTE:
A 5-37 gear set has a 5 tooth drive
pinion and a 37 tooth ring gear.
B.
C.
Location on Drive Pinion: End
at splines.
Location on Ring Gear: Front
face or outer diameter.
3. Gear Set Match Number:
Meritor drive pinions and ring gears are
available only as matched sets. Both
gears of a set have the same match
number.
A.
Example of a gear set match
number: 07 B 1234.
B.
C.
NOTE:
A gear set match number has any
combination of a letter and number.
B.
C.
Location on Drive Pinion: End
of gear head.
Location on Ring Gear: Front
face or outer diameter.
2.
A.
Tooth Combination Number:
Example of a tooth
combination number: 5-37.
16

Section 3
General Information
4. Pinion Cone Variation Number:
NOTE:
The pinion cone variation number is not used when checking for a matched gear
set. The number is used when you adjust the depth of the pinion In the carrier.
See the procedure for adjusting the shim pack thickness under the pinion cage.
A.
B.
Examples of pinion cone variation numbers: PC+3, PC-5, +2, -1, +.01 mm or -
0.02mm
Location on Gear Set: End of pinion gear head or outer diameter of ring gear.
Figure 24.
Figure 24
PINION
CONE
VARIATION
NUMBER
17

Section 4
Prepare Parts for Assembly
Clean
Parts
Ground
and
Polished
Clean Rough Parts
1. Clean rough parts the same as
cleaning ground and polished parts.
2. Rough parts can be cleaned in hot
solution tanks with a weak alkaline
solution.
3. Parts must remain in hot solution
tanks until completely cleaned and
heated.
1. Use a cleaning solvent to clean
ground or polished parts or surfaces.
Kerosene or diesel fuel oil can be
used for this purpose. DO NOT USE
GASOLINE.
!WARNING:
Be careful when using cleaning
solvents.Followthesolvent
manufacturer's Instructions for safe
use to prevent Injury.
2. Use a knife if required, to remove
gasket material from parts. Be
careful not to damage the ground
surfaces.
3. To prevent corrosion, DO NOT clean
ground or polished parts in a hot
solution tank, water, steam or
alkaline solutions.
!WARNING:
Be careful when using hot solution
tanks and alkaline solutions. Follow
thealkalinemanufacturer's
Instructions for safe use to prevent
injury.
4. Parts must be washed with water
until the alkaline solution is
removed.
Dry Parts That Have Been
Cleaned
1. Parts must be dried immediately
after cleaning and washing.
2. Dry the parts using soft clean paper
or cloth rags.
3. Except for bearings, parts can be
dried with compressed air.
Prevent Corrosion and Rust on
Cleaned Parts
1. Apply axle lubricant to cleaned and
dried parts that are not damaged
and are to be immediately
assembled.
2. If parts are to be stored, apply a
special material and paper that
prevents corrosion and rust to all
surfaces.
!CAUTION:
Damage to bearings can be caused if
dried by rotating with compressed
air.
18

Section 4
Prepare Parts for Assembly
Figure 25
Inspect Parts
It is very important to inspect all parts
carefully and completely before the axle
or carrier is assembled. Check all parts
for wear or stress and replace damaged
parts. Replacement of damaged parts
now, will prevent complete failure of the
assembly later.
1. 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, the bearing MUST
be replaced.
Figure 26
CRACK
WEAR
GROOVE
WORN RADIUS
C. A visible roller groove in the cup or
cone inner race surfaces. The groove
can be seen at the small or large
diameter end of both parts.
Figure25.
D. Deep cracks or breaks in the cup,
cone inner race or roller surfaces.
Figure 25.
Figure 27
WORN SURFACE
A. The center of large diameter end of
rollers worn level with or below the
outer surface. Figure 26.
B. The radius at large diameter end of
rollers worn to sharp edge.Figure26.
WEAR MARKS
E. Bright wear marks on the outer
surface of the roller cage. Figure 27.
19